Papers by Keyword: Subsurface Cracks

Abstract: In this paper, fatigue crack growth simulation of interacting subsurface cracks using the s-version finite element method (SFEM) is presented. In order to evaluate the accuracy and reliability of the proximity rules published by the ASME, during the fatigue crack growth simulations, the subsurface cracks are approximated to either a single elliptical crack or semi-elliptical surface crack in accordance with the proximity rules. Then, the proximity rules are slightly modified for improving the accuracy and reliability. The results of crack depth evolution calculated by the SFEM with the use of the new proximity rules suggest that the approximation to deep cracks drastically improves the accuracy of the fatigue crack growth evaluation. Thus, the approximation to deep cracks must be a promising approach for having better evaluation of fatigue crack growth of subsurface cracks.

Abstract: Silicon carbide ceramics with its excellent physical and mechanical properties have become the preferred material for space large diameter mirror. Diamond wheel grinding is the main way of SiC ceramics forming processing. Subsurface cracks is generated due to the high hardness and brittleness of the material after grinding. In order to remove the impact of cracks, poishing processing with very low efficiency is applied, so it is significant to control the depth of silicon carbide ceramic grinding subsurface cracks and shorten the processing cycle.In this paper grinding experiment of SiC ceramic is conducted. The method of cross-section polishing combined with scanning electron microscope observation is used to research grinding subsurface cracks. The depth of broken surface layer and the maximum depth of sub-surface cracks were proposed to evaluate the grinding subsurface cracks. The result show broken surface layer depth and the maximum depth of sub-surface cracks increase with the decreasement of spindle speed, and increasement of feed rate and grinding depth.

Abstract: An engine bearing was failed during service. During inspection, ball and races of rear bearing were found with wear marks. The bearing was subjected to metallurgical failure analysis. Inclusion level in the balls of bearing was observed higher; these inclusions were rich in Mo and V. The inclusions being the potential sites of the stress concentration caused the subsurface fatigue cracks in the bearing balls. The bearing was failed due to the severe spalling produced under subsurface fatigue leading to the subsequent wear of the raceways.

Abstract: The wear behaviour of Ca a-sialon ceramics of two distinct microstructures, fine equiaxed grains (EQ) and large elongated grains (EL), with the same chemical composition was investigated as a function of apparent contact pressure and sliding speed, using ball-on-disc type tribometers at room temperature and at 600°C. For room temperature tests, the EL microstructure exhibited a lower wear rate than EQ in the severe wear regime due to a greater resistance to large crack-induced material removal. As the apparent contact pressure decreased, mild wear appeared for both microstructures. The mechanism that dominated the material removal in EQ was grain pullout. In contrast, the controlling mechanism for EL was transgranular fracture. Therefore, EL had a lower wear rate than EQ in the mild wear regime. For wear tests at 600°C, crack-induced severe wear occurs in both EQ and EL samples for all contact pressures. EL had a slightly lower wear rate than EQ. Wear particles were generated on the wear track, but no tribofilm was observed and no oxidation products were detected. Wear models revealed that the grain aspect ratio plays a more important role than grain diameter in influencing the crack propagation during severe wear and grain pull-out during mild wear.

Abstract: In the present paper, an integral transform-based method is presented for calculating the stress intensity factors of subsurface cracks. Due to the interaction between the crack and the free surface, the crack tip fields are generally of I-II mixed mode. The solutions for two typical configurations, a Griffith crack and a circular crack beneath the free surface of a semi-infinite solid, are derived.