Computational and Experimental Analysis of Surface Residual Stresses in Polymers via Micro-Milling

This research conducts an in-depth investigation into the residual stresses in resin micro-milling processes. Considering that resin is the most crucial matrix material in composites, the construction of a precise machining theory for it is not only key to achieving high-quality- and efficient processing of composite materials but also fundamental to enhancing the overall performance of the materials. This paper meticulously examines the surface integrity and accuracy of epoxy polymers following precision machining, primarily revealing the significance of residual stresses and size effects in extending the lifespan of precision components and promoting their miniaturization. We have adopted an innovative finite element (FE) simulation method, integrated with the Mulliken-Boyce constitutive model, to profoundly analyze the impacts of residual stresses on the surfaces and sub-surfaces of thermosetting polymers. This research further explores the influence of critical machining parameters such as chip thickness, cutting edge radius, feed per tooth, and axial depth on cutting forces, as well as the inherent size effects in polymers. Utilizing X-ray diffraction (XRD) technology, we accurately measured the residual stresses generated during the micro-milling process. The close correlation between FE simulations and experimental results validates the accuracy and effectiveness of our method. This study represents a substantial breakthrough in finite element simulation techniques for high-precision machining of polymer materials, injecting valuable theoretical and practical knowledge into the field.

Numerical Simulation and Comparison of the Mechanical Behavior of Toughened Epoxy Resin by Different Nanoparticles

Adding nanoparticles as the second phase to epoxy can achieve a good toughening effect. The aim of this paper is to simulate the toughening behavior of epoxy resin by different nanoparticles using a convenient and effective finite element method. The mechanical behaviors of epoxy resins toughened by nano core-shell polymers, liquid rubber, and nanosilica were compared by numerical simulations using the representative volume element (RVE). It is indicated that the addition of a nano core-shell polymer and liquid rubber can reduce the tensile properties of epoxy resin, while nanosilica is on the contrary. With the increase of nanoparticle content, the length of crack propagation decreases, and the toughening effect of the nano core-shell polymer is the best. The failure mode is determined by the particle/matrix interface when the modulus of the nanoparticle is much larger than that of epoxy resin. However, it is determined by the interface properties of the particle/matrix and the modulus of nanoparticles in other cases. The results provide a theoretical basis for toughening nanoparticle selection of nanoparticle-toughened epoxy resin and other similar simulations in the future.

Early crack detection using modified spectral clustering method assisted with FE analysis for distress anticipation in cement-based composites

The present work reports an efficient way of capturing real-time crack propagation in concrete structures. The modified spectral analysis based algorithm and finite element modeling (FEM) were utilised for crack detection and quantitative analysis of crack propagation. Crack propagation was captured in cement-based composite (CBC) containing saw dust and M20 grade concrete under compressive loading using a simple and inexpensive 8-megapixel mobile phone camera. The randomly selected images showing crack initiation and propagation in CBCs demonstrated the crack capturing capability of developed algorithm. A measure of oriented energy was provided at crack edges to develop a similarity spatial relationship among the pairwise pixels. FE modelling was used for distress anticipation, by analysing stresses during the compressive test in constituents of CBCs. FE modeling jointly with the developed algorithm, can provide real-time inputs from the crack-prone areas and useful in early crack detection of concrete structures for preventive support and management.

Impact of a nanomixture of carbon black and clay on the mechanical properties of a series of irradiated natural rubber/butyl rubber blend

A series of natural rubber/butyl rubber NR/IIR blend loaded with N660 carbon black (CB) and triethoxy vinyl silane treated clay nanoparticles (TCNPs) were prepared using gamma irradiation in the presence of a polyfunctional monomer, trimethylolpropane triacrylate (TMPTA). The effect of incorporating different contents of N660 CB and five parts per hundred of rubber (phr) of treated clay on the mechanical properties of the prepared nanocomposites has been investigated. The addition of TCNP to CB/rubber composites markedly increase their tensile strength due to the increase of the cross-link density. These results indicated that the TCNP may be enclosed or trapped in the occluded structure of CB. The effect of CB and the TCNP content on the tensile strength (σ), elongation at break (ε b, %), and modulus of elasticity (E, MPa) of natural rubber/butyl rubber NR/IIR blend have been investigated. The incorporation of 5 phr of TCNP into 30 phr CB-loaded NR/IIR composites results in the increased tensile strength value by about 60%. Finally, theoretical models were used to interpret the experimental results.

Synergistical Performance Modification of Epoxy Resin by Nanofillers and Carboxyl-Terminated Liquid Nitrile-Butadiene Rubber

Epoxy composite materials are widely used in power equipment. As the voltage level increases, the requirement of material properties, including electrical, thermal, and mechanical, has also increased. Introducing thermally conductive nanofiller to the epoxy/liquid rubber composites system is an effective approach to improve heat performance, but the effects of thermally conductive nanofillers on relaxation characteristics remain unclarified. In this paper, nano-alumina (nano-Al₂O₃) and nano-boron nitride (nano-BN) have been employed to modify the epoxy/carboxyl-terminated liquid nitrile–butadiene rubber (epoxy/CTBN) composites system. The thermal conductivity and glass transition temperature of different formula systems have been measured. The effect of the nanofillers on the relaxation behaviors of the resin matrix has been investigated. Results show that the different kinds of nanofillers will introduce different relaxation processes into the matrix and increase the conductivity at the same time. This study can provide a theoretical basis for the synergistic improvement of multiple properties of epoxy resin composites.