Search Results (313)

The ridged cutter, a highly representative non-planar PDC cutter known for its strong impact resistance and wear durability, has demonstrated significant effectiveness in enhancing the rate of penetration (ROP) in hard, highly abrasive, and interbedded soft–hard formations. Understanding the crack evolution is fundamental to revealing the rock-breaking mechanism of ridged PDC cutters. To date, studies on rock breaking with ridged cutters have largely focused on macroscopic experimental observations, lacking an in-depth understanding of the crack evolution characteristics during the rock fragmentation process. This study employs the Finite–Discrete Element Method (FDEM) to establish a three-dimensional numerical model for simulating the interaction between the ridged cutter and the rock. By analyzing crack propagation paths, stress distribution, and the stiffness degradation factor (SDEG), the initiation, propagation patterns, and sequence of cracks around the cutter are investigated. The results indicate the following outcomes: (1) The ridged cutter breaks rock mainly by tensioning and shearing, while the conventional planar cutter breaks the rock by shearing. (2) The rock-breaking process proceeds in three stages: compaction, micro-failure, and volumetric fragmentation. (3) Crack evolution around the cutter follows the rule of “tension-initiated and shear-propagation”; that is, tensile damage first generates at the front of the crack due to tensile stress concentration, whereas shear damage subsequently occurs at the rear under high shear stress. Finally, mixed tensile–shear macro-cracks are generated. (4) The spatial distribution of cracks exhibits strong regional heterogeneity. The zone ahead of the cutter contains mixed tensile–shear cracks, forming upward-concave cracks, horizontal cracks, and oblique cracks at 45°. The sub-cutter zone is dominated by tensile cracks; the zone on the flank side of the cutter consists of a radial stress field, accompanied by oblique 45° cracks. The synergistic evolution mechanism and distribution law of tensile–shear cracks revealed in this study elucidate the rock-breaking advantages of ridged cutters from a micro-crack perspective and provide a theoretical basis for optimizing non-planar cutter structures to achieve more efficient volumetric fracture. Full article

With the deepening implementation of the coordinated development strategy for energy exploitation and ecological conservation, green coal mining technology has become a critical pathway to achieve balanced resource development and environmental protection. This study investigates the stress field evolution and dynamic fracture propagation mechanisms in overlying strata during shallow coal seam mining in the Shenfu mining area. By employing a multidisciplinary approach combining triaxial compression tests (0–15 MPa confining pressure), scanning electron microscopy (SEM) microstructural characterization, elastoplastic theoretical modeling, and FLAC3D numerical simulations, the synergistic failure mechanisms of overlying strata were systematically revealed. Gradient-controlled triaxial tests demonstrated significant variations in stress-strain responses across lithological types. Notably, Class IV sandstone exhibited exceptional uniaxial compressive strength of 106.7 MPa under zero confining pressure, surpassing the average strength of Class I–III sandstones (86.2 MPa) by 23.6%, attributable to its highly compacted grain structure. A nonlinear regression-derived linear strengthening model quantified that each 1 MPa increase in confining pressure enhanced axial peak stress by 4.2%. SEM microstructural analysis established critical linkages between microcrack networks/grain-boundary slippage at the mesoscale and macroscopic brittle failure patterns. Numerical simulations demonstrated that strata failure manifests as tensile-shear composite fractures, with lateral crack propagation inducing bed separation spaces. The stress field exhibited spatiotemporal heterogeneity, with maximum principal stress concentrating near the initial mining cut during early excavation. Fractures propagated obliquely at angles of 55–65° to the horizontal plane in an ‘inverted V’ pattern from the goaf boundaries, extending vertically 12–18 m before transitioning to the bent zone, ultimately forming a characteristic three-zone structure. Experimental and simulated vertical stress distributions showed minimal deviation (≤2.8%), confirming constitutive model reliability. This research quantitatively characterizes the spatiotemporal synergy of strata failure mechanisms in ecologically vulnerable northwestern China, proposing a confining pressure-effect quantification model for support parameter optimization. The revealed fracture dynamics provide critical insights for determining ecological restoration timelines, while establishing a novel theoretical framework for optimizing green mining systems and mitigating ecological damage in the Shenfu mining area. Full article

Grey cast iron brake discs with lamellar graphite (GJL) offer excellent strength and thermal conductivity but are prone to wear and dust emissions. To mitigate these issues, a multilayer coating was applied via Laser Metal Deposition (LMD), comprising a 316L stainless steel base layer and a WC-reinforced top layer. This study examines the microstructural evolution of the coatings under simulated thermomechanical and corrosive conditions using a brake shock corrosion test. Microstructural characterization was performed via Scanning Electron Microscopy (SEM) and Electron Backscatter Diffraction (EBSD), focusing on grain size, orientation, and texture before and after testing. EBSD analysis revealed significant grain coarsening, with sizes increasing from below 20 µm to 30–60 µm, and a shift toward <101> texture. Hardness measurements showed a reduction in the WC-reinforced layer from 478 HV to 432 HV and in the 316L base layer from 232 HV to 223 HV, confirming the influence of thermomechanical stress. SEM analysis revealed a transition from horizontal cracks—caused by residual stress during LMD—to vertical microcracks propagating from the substrate, activated by braking-induced loads. These findings provide insights into the microstructural response of LMD coatings under realistic service conditions and underscore the importance of grain boundary control in designing durable brake disc systems. Full article

With global sustainable construction growth, fully recycled coarse aggregate concrete (RCAC)—eco-friendly for cutting construction waste and reducing natural aggregate over-exploitation—has poor durability in seasonally freezing saline-soil regions (e.g., Tumushuke, Xinjiang): freeze-thaw and salt ions (NaCl, Na₂SO₄) cause microcracking, faster performance decline, and shorter service life, limiting its use and requiring better salt freeze resistance. To address this, a field survey of Tumushuke’s saline soil was first conducted to determine local salt type and concentration, based on which a matching 12% NaCl + 4% Na₂SO₄ mixed salt solution was prepared. RCAC specimens modified with fly ash (FA), silica fume (SF), and polypropylene fiber (PPF) were then fabricated, cured under standard conditions (20 ± 2 °C, ≥95% relative humidity), and subjected to rapid freeze-thaw cycling in the salt solution. Multiple macro-performance and microstructural indicators (appearance, mass loss, relative dynamic elastic modulus (RDEM), porosity, microcracks, and corrosion products) were measured post-cycling. Results showed the mixed salt solution significantly exacerbated RCAC’s freeze-thaw damage, with degradation severity linked to cycle count and admixture dosage. The RCAC modified with 20% FA and 0.9% PPF exhibited optimal salt freeze resistance: after 125 cycles, its RDEM retention reached 75.98% (6.60% higher than the control), mass loss was only 0.28% (67.80% lower than the control), and its durability threshold (RDEM > 60%) extended to 200 cycles. Mechanistic analysis revealed two synergistic effects for improved performance: (1) FA optimized pore structure by filling capillaries, reducing space for pore water freezing and salt penetration; (2) PPF enhanced crack resistance by bridging microcracks, suppressing crack initiation/propagation from freeze-thaw expansion and salt crystallization. A “pore optimization–ion blocking–fiber crack resistance” triple synergistic protection model was proposed, which clarifies admixture-modified RCAC’s salt freeze damage mechanism and provides theoretical/technical guidance for its application in extreme seasonally freezing saline-soil environments. Full article

Natural cracks are prone to form in toppling deformed rock masses during the toppling process, and these cracks are likely to undergo hydraulic fracturing failure under the action of high water head. This paper leverages the advantage of the extended finite element method (XFEM) in simulating crack propagation, considers the effect of water pressure on the crack surface, conducts numerical simulation and analysis on the hydraulic fracturing of cracks in toppling deformed rock masses, and studies the influences of different crack lengths, rock formation dip angles and crack surface water pressures on crack propagation. The main conclusions are as follows: (1) After hydraulic fracturing occurs in the rock mass, with the continuous rise in the water level, the crack propagation rate is slow first and then fast. When the water pressure is low, microcracks extend slowly; when the water pressure reaches a certain level, the rock formation cracks expand rapidly and eventually fracture. (2) Under the same water pressure, rock formations with longer initial crack lengths are more prone to hydraulic fracturing, and their cracks expand faster; rock formations with a dip angle of 45° are more likely to undergo hydraulic fracturing than those with other dip angles, while rock formations with a dip angle close to 90° are hardly susceptible to hydraulic fracturing. (3) The instability failure mechanism of hydraulic fracturing in toppling deformed rock masses is tension shear action. As the fissure water pressure rises, the tensile stress at the crack tip will increase sharply. Once new microcracks appear in the initial crack, it will be in an unstable expansion state. Full article

The stability of open-pit mines under low-temperature conditions is critical for safe and efficient coal extraction. However, the mechanisms of rock damage and fracture under combined temperature and stress effects remain unclear, particularly regarding the evolution of mechanical properties under repeated freeze–thaw cycles and varying peripheral pressures. This study investigates the damage and rupture behavior of coal-bearing sandstone in cold-region open-pit mines through experimental testing and theoretical modeling. The research was conducted in three stages: (1) freeze–thaw and peripheral pressure experiments to evaluate mechanical property evolution; (2) acoustic emission monitoring to analyze internal fracture initiation, propagation, and coalescence under temperature–stress coupling; (3) development of a local deterioration model to quantify post-damage strength decay considering low-temperature erosion and freeze–thaw effects. Results show that increasing freeze–thaw cycles leads to a transition from brittle to ductile behavior, while higher peripheral pressures significantly enhance ductility. Mechanical parameters are highly sensitive to peripheral pressure but largely independent of freeze–thaw cycle count. Acoustic emission signals respond strongly to temperature, and temperature–stress coupling governs the three-stage evolution of fracture germination, extension, and penetration. The local deterioration model effectively captures post-peak residual strength and damage evolution. These findings indicate that in regions with higher microcrack density, fault propagation is driven by rapid coalescence under stress concentration, whereas in lower-density regions, it is dominated by gradual fracture growth and temperature-induced expansion. The results provide theoretical guidance for stability assessment and support design in open-pit coal mines in cold environments. Full article

Dynamic fatigue of rocks under repeated cyclic impact is a nonconservative property, as surrounding rocks in real environments subjects them to variable impact disturbances, and the degree of damage varies under different energy level loads. To evaluate the dynamic response and fatigue damage characteristics of rocks under multi-level cyclic impacts, uniaxial cyclic impact tests were carried out on granite with various stress paths and energy levels using a modified split Hopkinson pressure bar. Dynamic deformation characteristics of specimens under different loading modes were investigated by introducing the deformation modulus of the loading stage. Evolution of macroscopic cracks during the impact process was investigated based on high-speed camera images, and the microscopic structure of damaged specimens was examined using SEM. In addition, cumulative energy dissipation was used to assess the damage of rocks. Results show that the deformation modulus of the loading stage, dynamic peak stress and strain of specimens increase with the impact energy, and the deformation modulus of the loading stage decreases as the damage level increases. Propagation rate of tensile cracks in rock was correlated with participation time of the higher energy level, which observed the following sequence: linearly decreasing > same > linearly increasing energy level, and cyclic loading of nonlinear energy level produced more tensile cracks and rock spalling than the same energy level. Compared with cyclic impacts of the same energy level, multi-level impacts form more microcracks and fatigue striations. The cumulative rate of specimen damage under the same energy change rate is as follows: linear decreasing > same > linear increasing loading. This provides a new case study for evaluating the dynamic damage, crushing efficiency and load-bearing capacity of rocks in real engineering environments. Full article

The combined effect of sulfate-reducing bacteria (SRB) and a microstructure on the stress corrosion behavior of heat-affected zones (HAZs) in pipeline steel for shale gas field applications was investigated. The results show that when the peak heating temperature reached 1020 °C, a coarse microstructure formed during multiple thermal cycles (MTCs), and Widmanstätten structures appeared in the HAZ. In the simulated environment, SRB intensified localized pitting corrosion of both the base metal and the HAZ. The welding HAZ was softened by the MTCs, and significant microcrack growth was observed in the presence of SRB. Among all subzones, the coarse-grained HAZ (CGHAZ) was the most susceptible to stress corrosion cracking (SCC) under shale gas service conditions. Cracks initiated at the metal surface and propagated vertically into the material. SRB activity further increased the SCC sensitivity of the CGHAZ. Full article

To investigate the failure mechanisms of surrounding rock in deep mine tunnels and its spatio-temporal evolution patterns, a true triaxial disturbance unloading rock testing system, the acoustic emission (AE) system, and the miniature camera monitoring system were employed to conduct true triaxial graded loading tests on sandstone containing circular holes at burial depths of 800 m, 1000 m, 1200 m, 1400 m, and 1600 m. The study investigated the patterns of mechanical properties and failure characteristics of porous sandstone at different burial depths. The results showed that the peak strength of the specimens increased quadratically with increasing burial depth; the failure process of porous sandstone could be divided into four stages: the calm period, the particle ejection period, the stable failure period, and the complete collapse period; as burial depth increases, the failure mode transitions from a composite tensile–shear crack type to a shear crack-dominated type, with the ratio of shear cracks to tensile cracks exhibiting quadratic growth and reduction, respectively; the particle ejection stage is characterised by low-frequency, low-amplitude signals, corresponding to the microcrack initiation stage, while the stable failure stage exhibits a sharp increase in low-frequency, high-amplitude signals, reflecting macrocrack propagation characteristics, with the spatial evolution of their locations ultimately forming a penetrating oblique shear failure zone; and peak stress analysis indicates that as burial depth increases, peak stress during the particle ejection phase first increases and then decreases, while peak stress during the stable failure phase first decreases and then stabilises. The duration of the pre-instability calm phase shows a significant negative correlation with burial depth. The research findings provide a theoretical basis for controlling tunnel rock mass stability and disaster warning. Full article

Fractured rock masses in cold regions are subject to long-term seasonal freeze–thaw cycles. To investigate the fatigue damage characteristics of sandstone with different fracture inclinations under freeze–thaw cycling conditions, samples containing fractures of varying inclinations were prepared using sandstone from Altay, Xinjiang. After vacuum saturation and freeze–thaw cycling treatment (−30 °C to 30 °C), uniaxial cyclic loading tests were conducted to analyze strain, elastic modulus, Poisson’s ratio, and damage variables. The results showed that under cyclic loading, the strain of the sandstone exhibited a “stepwise accumulation” characteristic, with peak and residual strain increasing with the progression of the cycle. Among them, the specimen with a fracture angle of 45° exhibited the fastest strain increase before failure. The peak elastic modulus showed a “continuous decrease within each stage and an initial increase followed by a decrease between stages,” while the residual elastic modulus continued to decrease, with both experiencing a sudden, sharp drop at the end of the cycle. The peak Poisson’s ratio decreases with the number of cycles in the early stage, then transitions to logarithmic growth in the later stage, rapidly increases near failure, and finally, the residual Poisson’s ratio in the final cycle exceeds the peak Poisson’s ratio; the evolution of damage variables exhibits an S-shaped three-stage characteristic, with the initial stage showing an irreversible deformation growth rate exceeding 10% due to compaction. In the middle stage, it grows steadily due to microcrack propagation, and in the final stage, it approaches 1. Samples with steep inclination angles exhibit earlier damage initiation and faster growth rates. The study reveals that crack inclination angle influences the evolution rhythm by regulating the proportion of compaction and shear damage, providing a theoretical basis for assessing the engineering stability of fractured rocks in cold regions. Full article

Hybrid fiber-reinforced concrete (HFRC), renowned for its significantly enhanced mechanical properties and structural integrity, is widely used in infrastructure construction and has become a key avenue of modern high-performance concrete development. The hybrid application of basalt fiber (BF) and polypropylene fiber (PPF) at optimized ratios generates synergistic effects, improving both mechanical performance and material service reliability. To explore and evaluate the synergistic mechanism of BF-PPF hybrid fibers on concrete’s mechanical properties and performance, this study employs an orthogonal experimental design and mechanical testing methods, measuring the materials’ static compressive strength (loading rate: 0.6 mm/min), splitting tensile strength (loading rate: 0.12–0.14 MPa/s), dynamic elastic modulus (measured by the ultrasonic method), and dynamic compressive strength (loading rates: 0.6 mm/min, 6 mm/min, and 60 mm/min). For these tests, we prepared 100 mm × 100 mm × 100 mm cubic specimens (for static compressive, dynamic compressive, and splitting tensile tests) and 400 mm × 100 mm × 100 mm prismatic specimens (for dynamic elastic modulus tests), with three parallel specimens in each test group. In addition, the microstructure was characterized by scanning electron microscopy (SEM) to observe the fiber-matrix interaction. The results show that when the BF/PPF volume ratio is 1:2 (BF0.05PPF0.1), the concrete’s compressive strength, splitting tensile strength, and elastic modulus increase by 13.7%, 76.3%, and 116.0%, respectively, with corresponding synergistic effect indices (Q) of 0.057, 0.213, and 0.241, indicating obvious positive synergy. Under dynamic loading, hybrid combinations with higher PPF content (e.g., BF0.05PPF0.1) exhibit strain-rate-dependent enhancements in compressive strength and better impact resistance. SEM analysis reveals that fibers inhibit microcrack propagation through fiber bridging, network distribution, and pull-out resistance, while also improving the interfacial transition zone’s structure. These findings provide theoretical support for the engineering application of composite fiber-reinforced concrete materials. Full article

Tunnel linings play a vital role in underground infrastructure, yet their performance can be severely affected by pre-existing cracks. This study investigates the mechanical behavior and failure mechanisms of C30 concrete with artificial cracks under uniaxial compression, simulating various crack conditions observed in tunnel linings. Specimens were designed with varying crack lengths and orientations. Acoustic emission (AE) monitoring was employed to capture the evolution of internal damage and micro-cracking activity during loading. Fractal dimension analysis was performed on post-test crack patterns to quantitatively evaluate the complexity and branching characteristics of crack propagation. The AE results showed clear correlations between amplitude characteristics and macroscopic crack growth, while fractal analysis provided an effective metric for assessing the extent of damage. To complement the experiments, discrete element modeling (DEM) using PFC3D was applied to simulate crack initiation and propagation, with results compared against experimental data for validation. The study demonstrates the effectiveness of DEM in modeling cracked concrete and highlights the critical role of crack orientation and size in strength degradation. These findings provide a theoretical and numerical foundation for assessing tunnel lining defects and support the development of preventive and reinforcement strategies in tunnel engineering. Full article

Accurate estimation of multiaxial fatigue life plays a critical role in maintaining the structural integrity and operational reliability of mechanical components subjected to complex loading conditions. Under non-proportional loading, fatigue life tends to decrease significantly due to the emergence of additional damage mechanisms, such as dislocation accumulation, cyclic hardening, and accelerated propagation of micro-cracks. This study conducts a systematic investigation into the primary factors that influence fatigue behavior under non-proportional loading conditions. A novel damage factor is proposed, which quantifies the additional strengthening effects caused by complex stress and strain interactions. Based on this factor, a new prediction model is developed through the combination of critical plane theory and an energy-based framework. This model captures the influence of non-proportional strengthening on fatigue strength with improved accuracy. Experimental validation is carried out using En8, TC4, and Al7050-T7451 materials under tension and torsion loading conditions. Comparative analysis with three conventional models shows that the proposed method improves the accuracy of predictions and offers a dependable approach for practical engineering applications. Full article

Due to the shortage of construction aggregates, carbonate rock aggregates—including mainly limestone aggregates—have long been used in structural concrete in many countries worldwide. On the other hand, earlier tests on the shear fracture toughness of concretes with limestone aggregates were very limited and were even abandoned for many years. For the above reasons, in this paper, completely new fracture toughness tests were performed according to the mode II fracture for limestone concretes with different grain size distributions. Two types of aggregate grain were used, i.e., two with maximum grain sizes of 8 mm (M1 series concrete) and 16 mm (M2 series concrete). During the experiments, the critical stress-intensity factor (K_IIc) and critical unit work of failure (J_IIc) were determined. Based on the conducted studies, it was found that higher values of fracture mechanics parameters were noted as the grain sizes of the aggregate used increased. The increases in the analyzed fracture mechanics parameters were noticeably greater in the M2 series concrete compared to the results for the M1 series concrete, specifically by 27% for K_IIc and 35% for J_IIc. In addition to macroscopic tests, detailed microstructural analyses of the ITZ area between the coarse aggregate grains and the cement matrix were conducted. Based on the captured images, it was determined that, in the M1 series concrete, the contacts between the aggregate grains and the cement paste exhibit a loose structure with visible microcracks. In contrast, the M2 series concrete showed no visible damages within the ITZ area itself nor at their displacement at a distance of approximately a few μm away from this area. This microstructure of both materials resulted in the M1 series concrete being more prone to rapid and sudden fracture propagation, leading to its brittle behavior during the fracture process. In contrast, the large, well-developed limestone aggregate grains in the M2 series concrete facilitated improved stress transfer beyond the ITZ area into the cement matrix, preserving the continuity of the material structure and consequently leading to quasi-plastic behavior of the concrete during the fracture process. The novelty and utilitarianism of the research undertaken result from the fact that exploring the properties of concretes with limestone aggregates using mode II fracture is an important aspect of evaluating the durability and safety of concrete structures subjected mainly to shear forces. Full article

As austempered ductile iron (ADI) is a key gear material for meeting the lightweight and cost-effective demands of new energy vehicles, its bending fatigue performance has a direct impact on vehicle transmission efficiency. In the present work, QTD 800 gears were subjected to bending fatigue testing using a combination of the conventional group method and the staircase method, with considerations given to fatigue life and fatigue limit at different reliability levels. Subsequently, the gears were characterized using optical microscopy and a microhardness tester to examine their metallographic structure and determine their hardness. The results indicate that the bending fatigue limits corresponding to gear reliability levels of 50%, 90%, and 99% are 390.00 MPa, 372.55 MPa, and 358.32 MPa, respectively. It was also observed that higher gear life stability corresponds to a lower sustainable fatigue limit stress. The analyses further reveal that under low loads, the main crack exhibits a relatively straight and smooth propagation trajectory, formed through the slow extension of an existing crack, whereas under high loads, the main crack displays a rough and serrated appearance, arising from the coalescence of microcracks initiated around graphite nodules. Full article