Durability analysis using Markov chain modeling under random loading for automobile crankshaft

2019 ◽  
Vol 10 (4) ◽  
pp. 454-468 ◽  
Author(s):  
Salvinder Singh ◽  
Shahrum Abdullah
Keyword(s):  
Life Cycle Assessment ◽  
Life Cycle ◽  
Fatigue Life ◽  
Automotive Industry ◽  
Life Prediction ◽  
Fatigue Life Prediction ◽  
Fatigue Reliability ◽  
Load History ◽  
Content Type ◽  
Durability Analysis

Purpose The purpose of this paper is to present the durability analysis in predicting the reliability life cycle for an automobile crankshaft under random stress load using the stochastic process. Due to the limitations associated with the actual loading history obtained from the experimental analysis or due to the sensitivity of the strain gauge, the fatigue reliability life cycle assessment has lower accuracy and efficiency for fatigue life prediction. Design/methodology/approach The proposed Markov process embeds the actual maximum and minimum stresses by a continuous updating process for stress load history data. This is to reduce the large credible intervals and missing loading points used for fatigue life prediction. With the reduction and missing loading intervals, the accuracy of fatigue life prediction for the crankshaft was validated using the statistical correlation properties. Findings It was observed that fatigue reliability corresponded well by reporting the accuracy of 95–98 per cent with a mean squared error of 1.5–3 per cent for durability and mean cycle to failure. Hence, the proposed fatigue reliability assessment provides an accurate, efficient, fast and cost-effective durability analysis in contrast to costly and lengthy experimental techniques. Research limitations/implications An important implication of this study is durability-based life cycle assessment by developing the reliability and hazard rate index under random stress loading using the stochastic technique in modeling for improving the sensitivity of the strain gauge. Practical implications The durability analysis is one of the fundamental attributes for the safe operation of any component, especially in the automotive industry. Focusing on safety, structural health monitoring aims at the quantification of the probability of failure under mixed mode loading. In practice, diverse types of protective barriers are placed as safeguards from the hazard posed by the system operation. Social implications Durability analysis has the ability to deal with the longevity and dependability of parts, products and systems in any industry. More poignantly, it is about controlling risk whereby engineering incorporates a wide variety of analytical techniques designed to help engineers understand the failure modes and patterns of these parts, products and systems. This would enable the automotive industry to improve design and increase the life cycle with the durability assessment field focussing on product reliability and sustainability assurance. Originality/value The accuracy of the simulated fatigue life was statistically correlated with a 95 per cent boundary condition towards the actual fatigue through the validation process using finite element analysis. Furthermore, the embedded Markov process has high accuracy in generating synthetic load history for the fatigue life cycle assessment. More importantly, the fatigue reliability life cycle assessment can be performed with high accuracy and efficiency in assessing the integrity of the component regarding structural integrity.

Reliability-based fatigue life of vehicle spring under random loading

2019 ◽  
Vol 10 (5) ◽  
pp. 737-748 ◽  
Author(s):  
Reza Manouchehry Nya ◽  
Shahrum Abdullah ◽  
Salvinder Singh Karam Singh
Keyword(s):  
Fatigue Life ◽  
Life Prediction ◽  
Reliability Assessment ◽  
Fatigue Life Prediction ◽  
Coil Spring ◽  
Fatigue Reliability ◽  
Random Loading ◽  
Content Type ◽  
Road Surfaces ◽  
Road Data

Purpose The purpose of this paper is to analyse fatigue-life prediction based on a reliability assessment for coil springs of vehicle suspension systems using different road excitations under random loading. Design/methodology/approach In this study, a reliability assessment was conducted to predict the fatigue life of an automobile coil spring during different road data surfaces. Campus, urban and highway road surfaces were considered to capture fatigue load strain histories using a data acquisition system. Random loadings are applied on top of a coil spring where coil is fixed from down. Fatigue reliability was established as a system of correlated events during the service life to predict the probability of fatigue life using Coffin–Manson, Morrow and Smith–Watson–Topper (SWT) models. Findings Fatigue-life prediction based on a reliability assessment revealed that the Morrow model can predict a safe region of a life data point for the three road surfaces. Highway road data indicated the highest rate of reliability at 0.8 for approximately 1.69 × 105 cycles for the SWT model. Originality/value Reliability assessment of the fatigue life of vehicle coil springs is vital for safe operation. The reliability analysis of a coil spring under random loading excitations can be used for fatigue-life prediction.

Adaptive Neural Network Modelling in Fatigue life Prediction under Load History effects

2011 ◽  
Vol 284-286 ◽  
pp. 1266-1270
Author(s):  
M. Abdul Razzaq ◽  
Kamal A. Ariffin ◽  
Ahmed El Shafie ◽  
Shahrum Abdullah ◽  
Z. Sajuri ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Crack Growth ◽  
Life Prediction ◽  
Experimental Tests ◽  
Fatigue Life Prediction ◽  
Load History ◽  
Adaptive Neural Network ◽  
Network Modelling ◽  
History Effects ◽  
Point Bend

Artificial intelligence (AI) techniques and in particular, adaptive neural networks (ANN) have been commonly used in order to Fatigue life prediction. The aim of this paper is to consider a new crack propagation principle based on simulating experimental tests on three point-bend (TPB) specimens, which allow predicting the fatigue life and fatigue crack growth rate (FCGR). An important part of this paper is estimation of FCG rate related to different load histories. The effects of different load histories on the crack growth life are obtained in different representative simulation and experiments.

Fatigue Reliability Analysis Including Super Long Life Regime

2010 ◽  
Vol 118-120 ◽  
pp. 17-26 ◽  
Author(s):  
Yong Xiang Zhao
Keyword(s):  
Fatigue Life ◽  
Reliability Analysis ◽  
Life Prediction ◽  
Reliability Assessment ◽  
Cyclic Stress ◽  
Fatigue Life Prediction ◽  
Fatigue Reliability ◽  
Stress Strain ◽  
Structural Fatigue ◽  
Long Life

For an engineering structure with an actual fatigue life over that corresponding to a so-called fatigue limit, appropriate reliability assessment and fatigue life prediction are essential for developing the structure and sustaining its high quality in service. Basic clues are explored. A competition fatigue initial mechanism is shown to provide a requirement of material primary quality management. Affordable deduced material and structural probabilistic S-N curves are presented by fitting into material mid-and-long life S-N data and fatigue limits and, then, comparing to structural fatigue limits. Random cyclic stress-strain relations are depicted for constructing random stressing history of structures. Reliability assessment and fatigue life prediction are established to synthetically consider the interference of applied stresses deduced from the random cyclic stress-strain relations and capacity strengths derived from the structural S-N relations with an expected life. Affordable and appropriate method has been then developed to realize the reliability assessment and fatigue life prediction including the super long life regime. Availability of the present method has been indicated through a reliability analysis to the velocity related reliabilities and fatigue lives of a railway axle.

Fatigue life prediction for automobile stabilizer bar

2019 ◽  
Vol 11 (2) ◽  
pp. 303-323
Author(s):  
Shuangshuang Li ◽  
Xintian Liu ◽  
Xiaolan Wang ◽  
Yansong Wang
Keyword(s):  
Fatigue Life ◽  
Life Prediction ◽  
Test Sample ◽  
Fatigue Life Prediction ◽  
Bench Test ◽  
Load Spectrum ◽  
Content Type ◽  
Life Model ◽  
On The Road ◽  
The Impact

Purpose During the running of automobile, the stabilizer bar is frequently subjected to the impact of complex random loads, which is prone to fatigue failure and accident. In regard to this, the purpose of this paper is to study and discuss fatigue life of automobile stabilizer bar. Design/methodology/approach Durability bench test shows that failure is located at the joint of sleeve and stabilizer bar body. Based on the collection and compilation of micro-strain load spectrum of the stabilizer bar, the strain-life model is studied considering the influence of average stress and maximum stress at failure area. Seven-grade strain-life curves of the stabilizer bar are established. According to the principle of linear damage accumulation, the relationship between fatigue life and damage is discussed, then the fatigue life of stabilizer bar is predicted. Fatigue life evaluation is carried out from three aspects: reliability analysis, static analysis and fatigue life simulation. Findings The results show that the reliability of the test sample is 99.9 percent when the confidence is 90 percent and the durability is 1,073 load spectrum cycles; the ratios of predicted and simulated life to design life are 2.77 and 2.30, respectively. Originality/value Based on the road load characteristics of automobile stabilizer bar, the method of fatigue life prediction and evaluation is discussed, which provides a basis for the design and development of automobile chassis components.

An improved fatigue life prediction model for shock absorber cylinder with surface roughness correction

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Haijie Wang ◽  
Xintian Liu ◽  
Que Wu ◽  
Xiaolan Wang ◽  
Yansong Wang
Keyword(s):  
Surface Roughness ◽  
Fatigue Life ◽  
Prediction Model ◽  
Life Prediction ◽  
Shock Absorber ◽  
Fatigue Life Prediction ◽  
Improved Method ◽  
Content Type ◽  
Lateral Forces ◽  
Life Prediction Model

Purpose The purpose of this paper is to obtain a more accurate fatigue life of structures by introducing the surface roughness into fatigue life prediction model. Design/methodology/approach Based on the fatigue life prediction model with surface roughness correction, the shock absorber cylinder is taken as an example to verify the feasibility of the improved method. Based on the load of the shock absorber cylinder during driving, fatigue experiments are performed under longitudinal and lateral forces, respectively. Then, the fatigue life predicted by the modified model is compared with that predicted by the traditional model. Findings By comparing with the test results, considering the influence of mean stress, the Manson method is more accurate in life prediction. Then, the modified Manson-Coffin and Manson method with surface roughness is more accurate in life prediction under longitudinal force and lateral forces, respectively. This verifies the feasibility of the improved method with the surface roughness. Originality/value The research on the influence of surface roughness on fatigue life can lay the technical foundation for the life prediction of products and have great significance to the quality evaluation of products.

Fatigue life-based reliability assessment of a heavy vehicle leaf spring

2019 ◽  
Vol 10 (5) ◽  
pp. 726-736
Author(s):  
Lennie Abdullah ◽  
Salvinder Singh Karam Singh ◽  
Abdul Hadi Azman ◽  
Shahrum Abdullah ◽  
Ahmad Kamal Ariffin Mohd Ihsan ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Life Prediction ◽  
Reliability Assessment ◽  
Gumbel Distribution ◽  
High Amplitude ◽  
Fatigue Life Prediction ◽  
Leaf Spring ◽  
Heavy Vehicle ◽  
Random Loading ◽  
Content Type

Purpose This study aims to determine the reliability assessment based on the predicted fatigue life of leaf spring under random strain loading. Design/methodology/approach Random loading data were extracted from three various road conditions at 200 Hz using a strain gauge for a duration of 100 s. The fatigue life was predicted using strain-life approaches of Coffin–Manson, Morrow and Smith–Watson–Topper (SWT) models. Findings The leaf spring had the highest fatigue life of 1,544 cycle/block under highway data compared uphill (1,299 cycle/block) and downhill (1,008 cycle/block) data. Besides that, the statistical properties of kurtosis showed that uphill data were the highest at 3.81 resulted in the presence of high amplitude in the strain loading data. For fatigue life-based reliability assessment, the SWT model provided a narrower shape compared to the Coffin–Manson and Morrow models using the Gumbel distribution. The SWT model had the lowest mean cycle to failure of 1,250 cycle/block followed by Morrow model (1,317 cycle/block) and the Coffin–Manson model (1,429 cycle/block). The SWT model considers the mean stress effects by interpreting the strain energy density that will influence the reliability assessment. Research limitations/implications The reliability assessment based on fatigue life prediction is conducted using the Gumbel distribution to investigate the behaviour of fatigue random loading, where most previous studies had concentrated on a Weibull distribution on random data. Originality/value Thus, this study proposes that the Gumbel distribution is suitable for analysing the reliability of random loading data in assessing with the fatigue life prediction of a heavy vehicle leaf spring.

Thermal performance and fatigue life prediction of POP stacked chip assembly under thermal cycling load

2020 ◽  
Vol 37 (4) ◽  
pp. 165-171
Author(s):  
Dongbo Li ◽  
Jianpei Wang ◽  
Bing Yang ◽  
Yongle Hu ◽  
Ping Yang
Keyword(s):  
Fatigue Life ◽  
Thermal Cycling ◽  
Life Prediction ◽  
Solder Joints ◽  
Fatigue Life Prediction ◽  
Load Spectrum ◽  
Thermal Reliability ◽  
Joint Stress ◽  
Content Type ◽  
Fatigue Characteristics

Purpose This paper aims to perform experimental test on fatigue characteristics of package on package (POP) stacked chip assembly under thermal cycling load. Some suggestions for design to prolong fatigue life of POP stacked chip assembly are provided. Design/methodology/approach The POP stacked chip assembly which contains different package structure mode and chip position was manufactured. The fatigue characteristics of POP stacked chip assembly under thermal cycling load were tested. The fatigue load spectrum of POP stacked chip assembly under thermal cycling load was given. The fatigue life of chips can be estimated by using the creep–fatigue life prediction model based on different stress conditions. Findings The solder joint stress of top package is significantly less than that of bottom solder joints, and the maximum value occurs in the middle part of the solder joints inner ring. Originality/value This paper fulfils useful information about the thermal reliability of POP stacked chip assembly with different structure characteristics and materials parameters.

An improved energy prediction method to predict the fatigue life of laminated rubber-alloy spherical thrust elastomeric bearing under multiaxial loads

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jianlei Yi ◽  
Kunjian Jin ◽  
Haiying Qin ◽  
Yuhong Cui
Keyword(s):  
Fatigue Life ◽  
Life Prediction ◽  
Multiaxial Fatigue ◽  
Fatigue Life Prediction ◽  
Torsional Stiffness ◽  
Axial Stiffness ◽  
Elastomeric Bearings ◽  
Content Type ◽  
Energy Prediction ◽  
Elastomeric Bearing

Purpose An ideal method for predicting the fatigue life of spherical thrust elastomeric bearings has not been reported, thus far. This paper aims to present a method for predicting the fatigue life of laminated rubber spherical thrust elastomeric bearings. Design/methodology/approach First, the mechanical properties of standard rubber samples were tested; the axial stiffness, cocking stiffness, torsional stiffness and fatigue life of several full-size spherical thrust elastomeric bearings were tested. Then, the stiffness results were calculated using the neo-Hookean, Mooney–Rivlin and Yoeh models. Using a modified Mooney–Rivlin constitutive model, this paper proposes an improved method for fatigue life prediction, which considers the laminated characteristics of a spherical thrust elastomeric bearing and loads of multiple multi-axle conditions. Findings The Mooney–Rivlin model could accurately describe the stiffness characteristics of the spherical thrust elastomeric bearings. A comparative analysis of experimental results shows that the model can effectively predict the life of a spherical thrust elastomeric bearing within its range of use and the prediction error is within 20%. Originality/value The fatigue parameters of elastomeric bearings under multiaxial loads were fitted and corrected using experimental data and an accurate and effective multiaxial fatigue-life prediction expression was obtained. Finally, the software was redeveloped to improve the flexibility and efficiency of modeling and calculation.

scholarly journals Fatigue Life Prediction of Half-Shaft Using the Strain-Life Method

2020 ◽  
Vol 2020 ◽  
pp. 1-8
Author(s):  
Xipei Ma ◽  
Xintian Liu ◽  
Haijie Wang ◽  
Jiachi Tong ◽  
Xiaobing Yang
Keyword(s):  
Fatigue Life ◽  
Fatigue Damage ◽  
Life Prediction ◽  
Prediction Method ◽  
Local Stress ◽  
Damage Parameter ◽  
Fatigue Life Prediction ◽  
Maximum Shear Strain ◽  
Durability Analysis ◽  
Fatigue Damage Parameter

Fatigue life prediction is an important part of the reliability and durability analysis of automobile components. Based on Wang and Brown’s framework, multiaxial random fatigue damage was adopted to predict the fatigue life of half-shaft. The stress analysis of half-shaft was resolved analytically to determine the local stress tensor in the potential area of fracture. The maximum shear strain fatigue damage parameter and the normal stress fatigue damage parameter were evaluated to predict the fatigue life of half-shaft. The results show that the prediction method is reliable and meets the service life and safety requirements.

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