Failure, mechanical Fracture

Of the various tool failure mechanisms, fracture is least desirable because it is unpredictable. Most tool material development work is focused on minimizing flank wear and retarding unwanted tool failure modes such as catastrophic fracture, gross plastic deformation, BUE, crater wear, and DOCN. 

Ghassemieli, E. and Nassehi, V., 2001b. rediction of failure and fracture mechanisms of polymeric composites using finite clement analysis. Part 1 particulate filled composites. Poly- Compos. 22, 528-541. 

Any test (several such tests are used) in which time to failure of smooth specimens is determined is an overall measure of the incubation period to initiate a crack, the ability to resist the propagation of a stress corrosion crack and the ability to resist final mechanical fracture. Since this test does not indicate the relative merits of an alloy in each individual aspect of the... 

In many cases, a product fails when the material begins to yield plastically. In a few cases, one may tolerate a small dimensional change and permit a static load that exceeds the yield strength. Actual fracture at the ultimate strength of the material would then constitute failure. The criterion for failure may be based on normal or shear stress in either case. Impact, creep and fatigue failures are the most common mode of failures. Other modes of failure include excessive elastic deflection or buckling. The actual failure mechanism may be quite complicated each failure theory is only an attempt to explain the failure mechanism for a given class of materials. In each case a safety factor is employed to eliminate failure. 

Possible causes—blockage, valve failure (mechanical or power), failure of steam supply (fracture of main, boiler shut-down). 

Clear-liquor advance, 5 124 CLEAR process, 23 576 Clear Skies Legislation, 26 45 Cleavage fracture, as failure mechanism, 26 983... 

Dual nickel, 9 820—821 Dual-pressure processes, in nitric acid production, 17 175, 177, 179 Dual-solvent fractional extraction, 10 760 Dual Ziegler catalysts, for LLDPE production, 20 191 Dubinin-Radushkevich adsorption isotherm, 1 626, 627 Dubnium (Db), l 492t Ductile (nodular) iron, 14 522 Ductile brittle transition temperature (DBTT), 13 487 Ductile cast iron, 22 518—519 Ductile fracture, as failure mechanism, 26 983 Ductile iron... 

The possible fatigue failure mechanisms of SWCNT in the composite were also reported (Ren et al., 2004). Possible failure modes mainly include three stages, that is, splitting of SWCNT bundles, kink formation, and subsequent failure in SWCNTs, and the fracture of SWCNT bundles. As shown in Fig. 9.12, for zigzag SWCNT, failure of defect-free tube and tubes with Stone-Wales defect of either A or B mode all resulted in brittle-like, flat fracture surface. A kinetic model for time-dependent fracture of CNTs is also reported (Satapathy et al., 2005). These simulation results are almost consistent with the observed fracture surfaces, which can be reproduced reasonably well, suggesting the possible mechanism should exist in CNT-polymer composites. 

The term fracture toughness or toughness with a symbol, R or Gc, used throughout this chapter refers to the work dissipated in creating new fracture surfaces of a unit nominal cross-sectional area, or the critical potential energy release rate, of a composite specimen with a unit kJ/m. Fracture toughness is also often measured in terms of the critical stress intensity factor, with a unit MPay/m, based on linear elastic fracture mechanics (LEFM) principle. The various micro-failure mechanisms that make up the total specific work of fracture or fracture toughness are discussed in this section. 

Fig. 6.12. Toughness maps depicting contours of predicted fracture toughness (solid lines in kJ/m ) for (a) glass-epoxy composites as a function of fiber strength, Uf, and frictional shear stress, tf and (b) Kevlar-cpoxy composites as a function of at and clastic modulus of fiber, Ef. The dashed line and arrows in (a) indicate a change in dominant failure mechanisms from post-debonding friction, Rif, to interfacial debonding, Sj, and the effect of moisture on the changes of Of and Tf, respectively. Bundle debond length...

Low, I.M. and Mai, Y.W. (1990). Fracture properties and failure mechanisms of pure and toughened epoxy resins. In Handbook of Ceramics (N.P. Cheremisinoff ed.), Marcel Dekker, New York, pp. 105-160. 

Various NDE techniques are used to locate defects and flaws in the failed or similar equipment that may not be apparent during the macro visual inspection. An analysis of cracks and other damage during the initiation or progressive phases often provides more information regarding the failure mechanism(s) than the same analysis would at locations where complete failure occurred. Considerable secondary damage to a worn, fractured, or corroded surface may occur after failure. The most common methods of NDE are given below. 

Acoustic emission (AE) is a technique that has been successfully employed to study fracture events in composites, where potentially, each failure mechanism has a unique acoustic signature (17-191. FE is another technique, which can be used in parallel with AE, and offers better sensitivity to the various microfracture processes. We have shown that interfacial failure between fiber and matrix in a composite produces significantly more intense emission and longer lasting decay... 

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