Search Results (113)

Development of forming methods for surface-coated metals is a current concern due to their economic and environmental advantages. For a successful forming operation, it is necessary that both components, the substrate and the coating, are able to withstand stress without damage until the final shape and dimensions are reached. This goal can be achieved through good knowledge of the elastic and plastic properties of the substrate and the coating, the compatibility between them, the appropriate surface treatment, and the rigorous control of technological forming parameters. Our study was carried out with flat specimens of pre-painted Al 99.0 sheet that were electromagnetically formed by bulging. Forming behavior was investigated as depending on the initial thickness of the substrate, on the aluminum sheet pretreatment, as well as on the plastic deformation path of the metal–paint structure. To verify the damage to the paint layer, tests with increasing strains were performed, and the interface between the metal and the coating layer was investigated by scanning electron microscopy. The obtained results indicate that electromagnetic forming of pre-painted sheets can be a feasible method for specific applications if the forming degree of the substrate is tightly correlated with the type of desired coating and with the pretreatment method used for the metal surface. Full article

Circular deep excavations, characterized by their symmetrical geometry, are commonly employed in constructing foundations for large-span suspension bridges and as launching shafts for shield tunneling. However, the mechanical behavior of such excavations under asymmetric surface surcharge remains inadequately understood due to a paucity of relevant investigations. This study addresses this knowledge gap by establishing a three-dimensional finite element model (3D-FEA) based on the anchor deep excavation project of a specific bridge. The model is utilized to investigate the influence of asymmetric surcharge on the forces and deformations within the supporting structure. The results show that both the internal force and displacement cloud diagrams of the support structure exhibit asymmetric characteristics. The distribution of displacement and internal forces has spatial effects, and the maximum values all occur in the areas where asymmetric loads are applied. The maximum values of the displacement, axial force, and shear force of underground continuous walls increase with the increase in the excavation depth. The total displacement curves all show the feature of a “bulging belly”. The maximum displacement is 13.3 mm. The axial force is mainly compression, with a maximum value of −9514 kN/m. The maximum positive and negative values of the shear force are 333 kN/m and −705 kN/m, respectively. The bending moment diagram of different monitoring points shows the characteristics of “bow knot”. The maximum values of the positive bending moment and negative bending moment are 1509.4 kN·m/m and −2394.3 kN·m/m, respectively. The axial force of the ring beam is mainly compression, with a maximum value of −5360 kN, which occurs in ring beams 3, 4, and 5. The displacement cloud diagram of the support structure under symmetrical loads shows symmetrical characteristics. Under different load conditions, the displacement curve of the diaphragm wall shows the characteristics of “bulge belly”. The forms of loads with displacements from largest to smallest at the same position are as follows: asymmetric loads, symmetrical loads, and no loads. These findings provide valuable insights for optimizing the structural design of similar deep excavation projects and contribute to promoting sustainable urban underground development. Full article

This paper, based on the Johnson–Cook damage model, investigates the damage mechanism of high-strength steel tailor welded blanks (TWBs) (Usibor1500P and Ductibor500) during the forming process. Initially, specimens with varying notch sizes were designed and fabricated to perform uniaxial tensile tests to determine their mechanical properties. Then, the deformation process of the notched specimens was simulated using finite element software, revealing the distribution and variation of stress triaxiality at the fracture surface. By combining both experimental and simulation data, the parameters of the Johnson–Cook (J–C) damage model were calibrated, and the effects of temperature, strain rate, and stress triaxiality on material fracture behavior were further analyzed. Based on finite element analysis, the relevant coefficients for stress triaxiality, strain rate, and temperature were systematically calibrated, successfully establishing a J–C fracture criterion for TWB welds, Usibor1500P, and Ductibor500 high-strength steels. Finally, the calibrated damage model was further validated through the Nakajima-type bulge test, and the simulated Forming Limit Diagram (FLD) closely matched the experimental data. The results show that the analysis based on the J–C damage model can effectively predict the fracture behavior of tailor welded blanks (TWB) during the forming process. This study provides reliable numerical predictions for the damage behavior of high-strength steel laser-customized welded sheets and offers a theoretical basis for engineering design and material performance optimization. Full article

To improve the traction performance of mobile mechanisms on soft ground, such as paddy fields, tidal flats, and swamps, a mallard (Anas platyrhynchos) foot was adopted as a bionic prototype to explore the influence and contribution of the plantar morphology of the toes and webbing on the anti-subsidence function during its locomotion on wet and soft substrates and to apply this to the bionic design of high-traction wheel grousers. A handheld three-dimensional laser scanner was used to scan the main locomotion postures of a mallard foot during ground contact, and the Geomagic Studio software was utilized to repair the scanned model. As a result, the main three-dimensional geometric models of a mallard foot during the process of touching the ground were obtained. The plantar morphology of a mallard foot was divided into three typical parts: the plantar irregular edge curve, the lateral webbing surface, and the medial webbing surface. The main morphological feature curves/surfaces were extracted through computer-aided design software for the fitting and construction of a mathematical model to obtain the fitting equations of the three typical parts, and the mathematical model construction of the plantar irregular morphology of the mallard foot was completed. In order to verify the sand-fixing and flow-limiting characteristics of this morphological feature, based on the discrete element method (DEM), the numerical simulation of the interaction between the plantar surface of the mallard foot and sand particles was carried out. The simulation results show that during the process of the mallard foot penetration into the loose medium, the lateral and medial webbing surfaces cause the particles under the foot to mainly move downward, effectively preventing the particles from spreading around and significantly enhancing the solidification effect of the particles under the sole. Based on the principle and technology of engineering bionics, the plantar morphology and movement attitude characteristics of the mallard were extracted, and the characteristics of concave middle and edge bulge were applied to the wheel grouser design of paddy field wheels. Two types of bionic wheel grousers with different curved surfaces were designed and compared with the traditional wheel grousers of the paddy field wheel. Through pressure-bearing simulation and experiments, the resistance of different wheel grousers during the process of penetrating into sand particles was compared, and the macro–micro behaviors of particle disturbance during the pressure-bearing process were analyzed. The results show that a bionic wheel grouser with unique curved surfaces can well encapsulate sand particles at the bottom of the wheel grouser, and it also has a greater penetration resistance, which plays a crucial role in improving the traction performance of the paddy field wheel and reducing the disturbance to the surrounding sand particles. This paper realizes the transformation from the biological model to the mathematical model of the plantar morphology of the mallard foot and applies it to the bionic design of the wheel grousers of the paddy field wheels, providing a new solution for improving the traction performance of mobile mechanisms on soft ground. Full article

Space-borne gravitational wave detection missions demand ultra-precise inertial sensors with acceleration noise below $3\times {10}^{-15} \mathrm{m}/{\mathrm{s}}^2/\sqrt{\mathrm{H}\mathrm{z}}$. Patch field effects, arising from surface contaminants and nonuniform distribution of potential on the test mass (TM) and housing surfaces, pose critical challenges to sensor performance. Existing studies predominantly focus on nonuniform potential distributions while neglecting bulge effects (surface deformation caused by the adhesion of pollutants or oxides, production and processing defects, and other factors) and rely on commercial software with limited flexibility for customized simulations. This paper presents a novel boundary element partitioning and octree-based simulation algorithm to address these limitations, enabling efficient simulation of both electrostatic and geometric impacts of patch fields with low spatiotemporal complexity ($O\left(n\right)$). Leveraging this framework, we systematically investigate the influence of single patches on the TM electrostatic force ($\Delta F_x$) and stiffness ($\Delta K_{xx}$) through parametric studies. Key findings reveal that $\Delta F_x$ and $\Delta K_{xx}$ exhibit linear dependence on patch potential variation ($\Delta u$) and can be fitted by a quartic polynomial (which can be simplified in some cases, such as only a cubic term) about patch radius ($rₘ$). The proposed method’s capability to concurrently model geometric bulges and potential nonuniformity offers significant advantages over conventional approaches, providing critical insights for gravitational wave data analysis. These results establish a foundation for optimizing mitigation strategies against patch-induced noise in future space missions. Full article

To enhance the mechanical properties of 6063-T4 aluminum alloy tubes, surface mechanical grinding treatment was conducted under graphene-assisted lubrication. The effects of rotational speed and cooling conditions on the mechanical properties of aluminum alloy tubes under biaxial stress were systematically explored. It was found that increasing the rotational speed and cooling rate facilitates the formation of finer lamellar grains, higher-density nano-precipitates, and a reduced dislocation density on the tube surface. These microstructural characteristics significantly contribute to an increased yield strength and sustained strain hardening capacity during bulging deformation. This study proposes an innovative approach for improving the strength and toughness of light alloy components during integral forming, providing meaningful insights for future engineering applications. Full article

The tubercles on the flipper of humpback whales are beneficial for improving their locomotion performance. Based on biomimetic design, the bulge model was developed to mimic this function through cubic B-spline curve fitting, aiming to improve the stall performance of the two-element wingsail. The numerical calculation method was validated against experiments to ensure the reliability of the numerical results. Five models of the bulges of the main wing were developed, and the influence of different bulges on the stall performance of the two-element wingsail under logarithmic gradient wind conditions was examined. By analyzing its lift and drag characteristics, pressure load distribution, and flow field near the stall angle, the mechanism by which the bulges improved the stall characteristics of the two-element wingsail was revealed. The result indicated that the two-element wingsail in the Case 5 scheme has a maximum lift coefficient of 1.25, and that the lift reduction in the early stage of stall is only 8.8%, which is 43.6% less than the original wingsail lift reduction. As the bulge size increases the strength of the forward vortex created by the middle larger bulge increases, resulting in the absence of a symmetrical vortex structure on the suction surface of the wingsail, causing high fluid momentum band deflection. The energy of the boundary layer is supplemented by vorticity transport, promoting the formation of attached flow on the side of the smaller bulge and improving the lift coefficient. Full article

Choosing the appropriate yield function is essential to precisely predicting the anisotropic hardening behavior of steel metals considering general loading directions. This research investigates the anisotropic hardening behavior of HC420 steel sheet by combining experimental and analytical modeling. Experiments are conducted for uniaxial tensile tests according to the three different directions and bulging tests to obtain hardening data. The experimental findings show that the loading direction affects the anisotropic behavior of HC420 steel’s strength and plastic deformation. The Chen-coupled quadratic and non-quadratic (Chen-CQN) approach is used to ensure the convexity of the HC420 steel. By comparing the Chen-CQN approach with the Yld2000-2d and Stoughton-Yoon’2009 yield functions, the Chen-CQN approach shows superiority in predicting the hardening behavior of the HC420 sheet, exhibiting a more straightforward numerical implementation and enhanced accuracy in yield stress predictions under different loading directions. Results from experimental hardening tests reveal that the Chen-CQN function precisely and flexibly characterizes the yield surface of HC420 steel, with a constant variation of within 2% from its predictions. Full article

This study conducted numerical simulations of three-dimensional vortex-induced vibrations (VIV) on cylindrical bodies with various surface protrusion coverage rates, systematically investigating the impact of coverage and protrusion height on the vibrational response of flexible cylinders. The fluid forces on the surface of the riser were resolved using the finite volume method, while the structural forces were solved with the finite element method. A strongly coupled approach was employed for iterative updates between the flow field and structural field data, achieving a bidirectional flow–structure coupling simulation of VIV in a marine environment. The study further explored the performance of surface protrusions in suppressing VIV and considered protrusion heights of 0.1 times the cylinder diameter (0.1D) under coverage rates (CR) of 0%, 10%, 20%, 30%, and 40%, as well as seven different protrusion heights of 0.05D, 0.1D, and 0.15D at a 20% coverage rate. The mechanism of VIV suppression by surface protrusions was identified as altering the separation point of the shear layer and the frequency of vortex shedding through the vortices formed between the surface protrusions. It was found that a 20% coverage rate with a protrusion height of 0.01D (CR20) effectively suppressed the VIV of the cylinder, showing the best performance in VIV suppression, with an efficiency of 30.04%. These results provide a theoretical basis for designing more efficient VIV suppression devices and contribute to enhancing the resistance of marine structures against vortex-induced vibrations. Full article

During petroleum drilling, the reciprocating motion in the seal device leads to piston and sleeve wear, which may cause leakage of the sealing medium. Selecting appropriate materials for the piston and sleeve, along with surface modifications, can effectively prolong the seal service life of the seal. The friction and wear properties of piston and sleeve pairs of different materials in a metal sealing device were simulated by the laboratory “pin-on-block” reciprocating friction test. Pins made of 45# steel, 35CrMo, and 20Cr13 were used to simulate piston bulges, while 35CrMo samples were used to simulate sleeves. Additionally, the influence of DLC (diamond-like carbon) coating and QPQ (Quench–Polish–Quench) nitriding on the wear resistance of the materials was studied. Based on this, the friction and wear properties, along with the wear mechanism of different material pairs, were analyzed. The results show that the friction coefficient curves of the three piston base materials and the 35CrMo sleeve are similar, and the friction coefficient of 45# steel is lower than that of 35CrMo and 20Cr13 at the initial stage. The DLC surface coating exhibited the best anti-wear performance, with the lowest friction coefficient, minimal wear, and the most stable friction coefficient. Surface QPQ nitriding treatment can also improve the wear resistance of the base material. However, due to the oxide formed during nitriding being prone to flaking, the friction coefficient fluctuates significantly at the initial stage of testing, and its anti-wear performance was inferior to that of the DLC coating. This study on material pairing and surface modification provides theoretical support for material selection and surface modification design of pistons and sleeves in oil drilling sealing devices. Full article

Objectives: This study aimed to identify radiologic features that differentiate lymphoma from metastasis manifesting as a solid enhancing mass lacking necrosis in the cerebellum. Methods: Pathologically confirmed 24 primary central nervous system lymphoma (PCNSL) and 32 metastasis patients with solid enhancing cerebellar masses without necrotic or hemorrhagic components were retrospectively analyzed. We evaluated the imaging characteristics using contrast-enhanced magnetic resonance imaging (MRI). The serrate sign was defined as a tumor spreading along white matter with branch-like enhancement or outward spikes. Results: The serrate sign was exclusively identified in the PCNSL group, showing a significant difference compared to the metastasis group (75.0% vs. 0%, p < 0.001). Homogeneous enhancement occurred more frequently in PCNSL than in metastasis (91.7% vs. 21.9%, p < 0.001). Conversely, bulging contour (62.5% vs. 4.2%, p < 0.001) and surface involvement (71.9% vs. 29.2%, p = 0.003) were more prevalent in metastasis than PCNSL. For predicting PCNSL, the serrate sign demonstrated 75.0% sensitivity, 100% specificity, 100% positive predictive value, 84.2% negative predictive value, and 89.3% accuracy. Conclusions: This study found that the serrate sign and homogeneous enhancement are reliable MRI features for differentiating cerebellar PCNSL from metastasis, whereas a bulging contour and surface involvement suggest metastasis. The serrate sign demonstrated diagnostic significance in differentiating PCNSL from metastasis. Full article

Massively carbon-supersaturated (MCSed) tool steel dies were developed to make galling-free forging products from titanium bar feedstocks in dry conditions without lubricating oils. Two types of tool steel dies were used, SKD11 and ACD56, following the Japanese Industrial Standard (JIS). The plasma-immersion carburizing process was employed to induce massive carbon supersaturation in two kinds of tool steel dies at 673 K for 14.4 ks. A pure titanium bar was upset in a single stroke up to the reduction of thickness of 70% using the MCSed SKD11 die. Very few bulging displacements of the upset bar proved that μ = 0.05 on the contact surface of the MCSed SKD11 die to pure titanium work. Two continuous forging experiments were performed to demonstrate that an in situ lubrication mechanism played a role to prevent the contact surface from galling to titanium works in both laboratory- and industry-scaled forging processes. After precise microstructure analyses of the contact surface, the free-carbon film formed in situ acted as a lubricating tribofilm to reduce friction and adhesive wear in continuous forging processes. The MCSed ACD56 dies were also used to describe the galling-free forging behavior of manufacturing eyeglass frames and to evaluate the surface quality of the finished temples. The applied load was reduced by 30% when using the MCSed ACD56 dies. The average surface roughness of the forged product was also greatly reduced, from 4.12 μm to 0.99 μm, together with a reduction in roughness deviations. High qualification of forged products was preserved together with die life prolongation even in dry manufacturing conditions of the titanium and titanium alloys. Full article

The TC4 titanium alloy is widely used in medical, aerospace, automotive, shipbuilding, and other fields due to its excellent comprehensive properties. As an advanced processing technology, laser processing can be used to improve the surface quality of TC4 titanium alloy. In the present research, a new type of rotational laser processing method was adopted, by using a beam shaper to modulate the Gaussian spot into a line spot, with uniform energy distribution. The effects of the laser power and rotational speed on the laser ablation surface of the TC4 titanium alloy were analyzed. The results reveal that the melting mechanism of the material surface gradually changes from surface over melt to surface shallow melt with the increase in the measurement radius and the surface roughness increases first, then decreases and, finally, tends to be stable. By changing the laser power, the surface roughness changes significantly with the variation in the measurement radius. Because low laser power cannot provide sufficient laser energy, the measurement radius corresponding to the surface roughness peak of the microcrack area is reduced. Under a laser power of 11 W, the surface roughness reaches its peak when the measurement radius is 600 μm, which is 200 μm lower than that of a laser power of 12 W, 13 W, and 14 W. By changing the rotational speed, the centrifugal force generated by the rotation of the specimen affects the distribution and re-condensation of the molten pool of the surface. As the rotational speed increases, the shallow pit around the pit is made shallower by the filling of the pit with molten material and the height of the bulge decreases, until it disappears. The surface oxygen content of the material increases first and then decreases with the increase in the measurement radius and gradually approaches the initial surface state. Compared with a traditional laser processing spot, the rotational line spot covers a larger processing area of 22.05 mm². This work can be used as the research basis for rotational modulation laser polishing and has significance for guiding the innovative development of high-quality and high-efficiency laser processing technology. Full article

Amorphous/crystalline high-entropy-alloy (HEA) composites show great promise as structural materials due to their exceptional mechanical properties. However, there is still a lack of understanding of the dynamic nanoindentation response of HEA composites at the atomic scale. Here, the mechanical behavior of amorphous/crystalline HEA composites under nanoindentation is investigated through a large-scale molecular dynamics simulation and a dislocation-based strength model, in terms of the indentation force, microstructural evolution, stress distribution, shear strain distribution, and surface topography. The results show that the uneven distribution of elements within the crystal leads to a strong heterogeneity of the surface tension during elastic deformation. The severe mismatch of the amorphous/crystalline interface combined with the rapid accumulation of elastic deformation energy causes a significant number of dislocation-based plastic deformation behaviors. The presence of surrounding dislocations inhibits the free slip of dislocations below the indenter, while the amorphous layer prevents the movement or disappearance of dislocations towards the substrate. A thin amorphous layer leads to great indentation force, and causes inconsistent stacking and movement patterns of surface atoms, resulting in local bulges and depressions at the macroscopic level. The increasing thickness of the amorphous layer hinders the extension of shear bands towards the lower part of the substrate. These findings shed light on the mechanical properties of amorphous/crystalline HEA composites and offer insights for the design of high-performance materials. Full article

With the rapid development of China’s transportation network, the demand for bridge construction is increasing, the traffic volume is increasing yearly, and the average vehicle speed and the frequency of overloaded vehicles crossing bridges are soaring. When a vehicle passes over a highway bridge, it can easily form a coupling vibration between the vehicle and bridge due to the excitation of the expansion joint, the unevenness of the bridge deck, and the existing coating-hole. The impact effect is significant, which seriously affects the operation safety of both the vehicle and bridge, seriously damaging the service life of the bridge. Due to the influence of construction technology, it is common for the vibration to meet transverse and longitudinal expansion joints of a prefabricated girder bridge, where an aging bridge deck frequently results in bulges and potholes in asphalt pavement. The bridge vibration amplification effect under the dynamic load of heavy, high-speed vehicles is significant, and research about the large impact coefficient of bridges with local pavement deterioration is urgently needed. This study used SIMULINK simulation software and involved conducting several bridge model tests. Dynamic simulation analyses and running vehicle tests on scaled and real bridge models were carried out to study the coupling vibration response of bridge decks in the presence of different pothole sizes. The results show that the impact effect of low-speed vehicles passing through a larger-sized pothole is relatively significant, and the impact coefficient can be amplified to 214% of the original value under good road surfaces in extreme cases. The vehicle–bridge coupling impact effect of potholes is similar to bulges. This relevant work could provide suggestions for the operational performance evaluation and maintenance of bridges with local pavement deterioration. Full article