Master of Science / Industrial & Manufacturing Systems Engineering / Shuting Lei / Transparent brittle materials such as glass and silicon dioxide have begun to replace the conventional materials due to the advantageous properties including high strength and hardness, resistance to corrosion, wear, chemicals and heat, high electrical isolation, low optical absorption, large optical transmission range and biocompatibility. However because these materials are extremely hard and brittle, development of an ideal machining process has been a challenge for researchers. Non-traditional machining processes such as abrasive jet and ultrasonic machining have improved machining quality but these processes typically results with issues of poor surface integrity, high tool wear and low productivity. Therefore a machining technique that overcomes the disadvantages of existing methods must be developed. This study focused primarily on improving the machinability and attaining crack-free machined surfaces on transparent brittle materials by inducing micro cracks or seed damages on the subsurface of the materials. The hypothesis was that micro-cracks induced by femtosecond laser would synergistically assist the material removal process by a cutting tool by weakening or softening the material, followed by conventional machining process. Laser induced damages due to varying laser intensities and at different depths in bulk BK7 glass was studied in order to select the optimal laser machining conditions for the experiments. Dimensional and structural profiles of laser cracks are observed using an optical microscope. A comparative study of machined untreated BK7 samples and damage induced BK7 samples was conducted. Due to its simple process kinematics and tool geometry, orthogonal machining is used for the study. Results showed that machining laser-treated samples caused an average 75% force reduction on comparison to machining of untreated samples. Laser treated machined samples were produced without subsurface damages, and reduced tool wear was noted. Overall improved machinability of BK7 glass samples was achieved.

A formação e propagação de fissuras é um fenômeno observado em diversos materiais utilizados na engenharia, como concreto, metais, cerâmicas e rochas. Tendo em vista a grande influência que fissuras têm no comportamento global da estrutura o objetivo deste trabalho consiste na implementação de um modelo de fissura com descontinuidades fortes incorporadas a fim de analisar o processo de fratura em materiais quase-frágeis. A descontinuidade no campo de deslocamentos (descontinuidade forte) é representada através da introdução de graus de liberdade adicionais no interior do elemento finito, sendo esta abordagem denominada enriquecimento elementar (E-FEM). Nestes modelos a fissura pode se propagar em qualquer direção dentro do elemento finito, evitando a necessidade de redefinição da malha em cada etapa, além de fornecer resultados relativamente independentes da malha de elementos finitos utilizada. Por serem internos a cada elemento finito, os graus de liberdade adicionais podem ser eliminados da solução global por condensação estática. Desta forma as descontinuidades são definidas em nível de elemento e o modelo pode ser facilmente implementado em códigos computacionais existentes. O modelo implementado foi proposto por Dvorkin, Cuitiño e Gioia (1990), o qual pertence à classe de modelos com formulação assimétrica estaticamente e cinematicamente consistente (SKON). Esta formulação é caracterizada por garantir o movimento de corpo rígido entre as partes do elemento além de assegurar a continuidade de tensões na linha de fissura, resultando numa matriz de rigidez assimétrica. Diferentes relações constitutivas podem ser utilizadas para descrever o comportamento das regiões com e sem fissura. Portanto, para a região não fissurada, utilizouse um modelo constitutivo elástico linear e para a região fissurada foi analisada a performance de dois modelos constitutivos distintos: linear e exponencial. A capacidade de representar o comportamento de elementos estruturais fissurados foi ilustrada através de exemplos de tração e flexão comparados com outros modelos de fissura existentes e com resultados experimentais. Em relação aos modelos constitutivos para a linha da fissura, o modelo linear não se mostrou adequado por superestimar as tensões de pico além de apresentar um ramo de amolecimento mais frágil. Já o modelo exponencial mostrou-se bastante eficiente representando de forma correta o comportamento de materiais quase-frágeis. / The formation and propagation of cracks is a phenomenon observed in many materials used in engineering, such as concrete, metals, ceramics and rocks. In view of the influence of cracks in the global behavior of the structure, the aim of this work is the implementation of an embedded strong discontinuity model in order to analyze the fracture process in quasi-brittle materials. The discontinuity in the displacement field (strong discontinuity) is represented by the introduction of additional degrees of freedom within the finite element. This approach is called elemental enrichment (E-FEM). The embedded models allow the propagation of crack in any direction within the finite element, avoiding the need of remeshing and providing objective results (mesh independent). The additional degrees of freedom are introduced into the finite element, then these degrees can be eliminated from the global solution by static condensation and the model can be easily implemented in existent computational codes. The model used here was proposed by Dvorkin, Cuitiño and Gioia (1990), which belongs to the statically and kinematically optimal non-symmetric (SKON) formulation. In this formulation, the kinematics that allows for relative rigid body motion and the enforcement of the traction continuity are introduced at element level, resulting a non-symmetric formulation. Different constitutive relations can be used to describe the behavior of the zones with and without cracks. For the zone without cracks it was used a linear elastic model and for the cracked zone it was analyzed the behavior of two different constitutive models: linear and exponential. The ability of the model to represent the behavior of cracked structural elements was illustrated by bending and tensile tests and the results were compared with numerical and experimental data. Regarding the constitutive models for the fracture zone, it was concluded that the linear model was not suitable because it overestimated the maximum stress and promoted a britller softening. In contrast, the exponential model proved to be very efficient to represent the behavior of quasi-brittle materials.

L’objectif de cette thèse est d’étudier le comportement à la rupture des matériaux fragiles avec une approche capable de relier l’amorçage de fissures à leurs propagations. On adopte la méthode des éléments discrets (DEM), avec le matériau composé d'un ensemble bidimensionnel régulier de particules en contact. Ceci qui nous permet de dériver une expression pour le facteur d'intensité de contraintes en fonction des forces et des déplacements relatifs des deux contacts adjacents à la pointe d’une fissure. Un critère de rupture classique, basé sur la ténacité du matériau, est ensuite adopté pour l'analyse de la propagation des fissures, représenté par la perte des forces de contact entre les particules. La vérification de la formulation est faite par la comparaison des simulations numériques à des solutions classiques de la mécanique de la rupture en mode I, mode II et mode mixte. Ensuite, on étend l’application du critère discret au comportement d’un matériau sain (non pré-fissuré), soumis à des contraintes homogènes, pour lequel on retrouve un critère de rupture du type Rankine. Le résultat final est un modèle discret simple totalement compatible avec les approches continues usuelles, et qui ne demande pas d’essais de calibration, typiques des approches discrètes conventionnelles. / The objective of this thesis is to study the fracture behavior of brittle materials by an approach which relates crack initiation to crack growth. We adopt the discrete element method (DEM) and we represent the material by a 2D regular set of particles in contact. This allows us to derive an expression for the stress intensity factor as a function of the forces and relative displacements of two adjacent contacts at the crack tip. A classical failure criterion, based on the material’s toughness, is then adopted for the analysis of crack propagation, represented by the loss of contacts forces between particles. The formulation is verified by the comparison of numerical simulations to classical solutions of fracture mechanics in mode I, mode II and mixed mode. Afterwards, we apply our discrete criterion to uncracked materials under homogenous stress conditions, obtaining a Rankine like behavior.. The work results in a simple discrete model which is totally compatible to continuum mechanics, where no calibration tests are required, in contrast to most of discrete approaches.

No description available.

This work is focused on the evaluation of the selected fracture parameters of quasi-brittle material, especially concrete, and an assessment of their dependence on the size and shape of the fracture process zone developing at the tip of the macroscopic crack during fracture. For this purpose, experimentally obtained loading diagrams published in the scientific literature have been utilized. These diagrams have been processed into a form enabling creation and calibration of numerical models of these tests in the ATENA FEM program. The results obtained from simulations of the three-point bending tests on beams of four sizes, with three notches lengths, using the created numerical models were used for determination of fracture parameters of concrete. Results of the work consist of the determined values of the specific energy dissipated for creation of new surfaces of the effective crack and an estimation of the specific energy dissipated in the volume of the fracture process zone, which exhibits specific parameters for each beam size and notch length.

The purpose of dissertation is the analysis of the calculation of fracture parameters using Double-K fracture model for quasi-brittle specimens with the stress concentrator loaded by three-point bending or wedge splitting. To calculation of these parameters was used the developed DKFM_BUT software in Microsoft Excel application with using of Visual Basic programming language. Furthermore, the adequate shape functions and compliance functions were introduced for the selected wedge splitting test configurations. Main part of this dissertation is the series of comprehensively implemented and evaluated fracture experiments on specimens from advanced building materials, while the attention was paid to the analysis of experimental data. Finally, the selected results obtained using mentioned software support were presented and discussed.

The aim of the thesis is the investigation of fracture-mechanics parameters on specimens made of quasi-brittle materials. The principles of two-parameter fracture mechanics are used. Couple of numerical simulations were done and their outputs are used for two main analysed specimen geometries. For simulations the finite element method software ANSYS is used. In the first part, the thesis focuses on bended specimens. The influence of different geometric parameters on fracture mechanics behaviour of cracked specimen is investigated. For model calibration the outputs of other authors are used. In the second part the specimens for modified compact-tension test (CT test) are analysed. Similar to the first part, the influence of geometric parameters of the specimen (in this case, the specimen size) on fracture mechanics parameters were investigated. The modified CT test was derived from CT test which is commonly used for metal materials testing as the suitable geometry for cement-based composite materials testing. The outputs of both parts are calibration polynomials, which are expressions obtained for different specimen geometries, giving the value of fracture mechanics parameter as the function of specimen geometry. As the example, calibration curves are used to obtain fracture toughness of tested material using the outputs from recent experiment.