Improved effective notch strain approach for fatigue reliability assessment of load-carrying fillet welded cruciform joints in low and high cycle fatigue

AbstractDemands on modern gearboxes are constantly increasing, for example to comply with lightweight design goals or new CO2 thresholds. Normally, to increase performance requires making gearboxes and powertrains more robust. However, this increases the weight of a standard gearbox. The two trends therefore seem contradictory. To satisfy both of these goals, gears in gearboxes can be shot-peened to introduce high compressive residual stresses and improve their bending fatigue strength. To determine a gear’s tooth root bending fatigue strength, experiments are conducted up to a defined number of load cycles in the high cycle fatigue range. However, investigations of shot-peened gears have revealed tooth root fracture damage initiated at non-metallic inclusions in and above the very high cycle fatigue range. This means that a further reduction in bending load carrying capacity has to be expected at higher load cycles, something which is not covered under current standard testing conditions. The question is whether there is a significant decrease in the bending load carrying capacity and, also, if pulsating tests conducted at higher load cycles—or even tests on the FZG back-to-back test rig—are necessary to determine a proper endurance fatigue limit for shot-peened gears. This paper examines these questions.

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High Cycle Fatigue Resistance and Reliability Assessment of Flexible Printed Circuitry

Journal of Electronic Packaging ◽

10.1115/1.1462628 ◽

2002 ◽

Vol 124 (3) ◽

pp. 254-259 ◽

Cited By ~ 9

Author(s):

Elena Martynenko ◽

Wen Zhou ◽

Alexander Chudnovsky ◽

Ron S. Li ◽

Larry Poglitsch

Keyword(s):

Fatigue Resistance ◽

High Cycle Fatigue ◽

Failure Mechanisms ◽

Three Dimensional ◽

Reliability Assessment ◽

Core Layer ◽

High Strength ◽

Multiple Cracks ◽

Material System ◽

Cycle Fatigue

Flexible printed circuitry (FPC) is a patterned array of conductors supported by a flexible dielectric film made of high strength polymer material such as polyimide. The flexibility of FPC provides an opportunity for three dimensional packaging, easy interconnections and dynamic applications. The polymeric core layer is the primary load bearing structure when the substrate is not supported by a rigid plate. In its composite structure, the conductive layers are more vulnerable to failure due to their lower flexibility compared to the core layer. Fatigue data on FPCs are not commonly available in published literature. Presented in this paper is the fatigue resistance and reliability assessment of polyimide based FPCs. Fatigue resistance of a specific material system was analyzed as a function of temperature and frequency through experiments that utilized a specially designed experimental setup consisting of sine servo controller, electrodynamic shaker, continuity monitor and temperature chamber. The fatigue characteristics of the selected material system are summarized in the form of S-N diagrams. Significant decrease in fatigue lifetime has been observed due to higher displacements in high cycle fatigue. Observed temperature effect was however counter-intuitive. Failure mechanisms are discussed and complete fracture analysis is presented. In various FPC systems, it has been found that the changes take place in FPC failure mechanisms from well-developed and aligned single cracks through the width at low temperature to an array of multiple cracks with random sizes and locations at high temperature.

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