Prediction and evaluation of fatigue life via modified energy method considering surface processing

2021 ◽  
pp. 105678952110451
Author(s):  
Haijie Wang ◽  
Xintian Liu ◽  
Tie Chen ◽  
Shen Xu

To predict fatigue life more accurately, we consider the relationship between static toughness and fatigue toughness in fatigue failure process, the numerical model of total dissipated plastic strain energy (TDPSE) and fatigue life is established. And considering the effect of surface roughness and surface processing coefficient on fatigue life, the life prediction method of TDPSE is modified. In addition, the fatigue life of Non-Masing and Masing materials are predicted by TDPSE and modified TDPSE method, respectively. Compared with TDPSE method, the life estimated by the modified TDPSE method are closer to the test results, and the modified TDPSE method lays a technical foundation for the development of mechanical components.

Author(s):  
Todd Letcher ◽  
M.-H. Herman Shen ◽  
Onome Scott-Emuakpor ◽  
Tommy George ◽  
Charles Cross

The capability of a critical life, energy-based fatigue prediction method is analyzed in this study. The theory behind the prediction method states that the strain energy accumulated during monotonic fracture and fatigue are equal. Therefore, a precise understanding of the strain energy density behavior in each failure process is necessary. The initial understanding of energy behavior shows that the accumulated strain energy density during monotonic fracture is the area underneath the experimental stress-strain curve, whereas the sum of the constant area within every stress-strain hysteresis loop of the cyclic loading process is the total strain energy density accumulated during fatigue; meaning, fatigue life is determined by dividing monotonic strain energy density by the strain energy density in one cycle. Further observation of the energy trend during fatigue shows that strain energy density per cycle is not constant throughout the process as initially assumed. This finding led to the incorporation of a critical life effect into the energy-based fatigue prediction method. The analysis of the method’s capability was conducted on Al 6061-T6 ASTM standard specimens. The results of the analysis provide further improvement to the characterization of strain energy density for both monotonic fracture and fatigue; thus improving the capability of the energy-based fatigue life prediction method.


2011 ◽  
Vol 21 (8) ◽  
pp. 1128-1153 ◽  
Author(s):  
Shun-Peng Zhu ◽  
Hong-Zhong Huang ◽  
Victor Ontiveros ◽  
Li-Ping He ◽  
Mohammad Modarres

Probabilistic methods have been widely used to account for uncertainty of various sources in predicting fatigue life for components or materials. The Bayesian approach can potentially give more complete estimates by combining test data with technological knowledge available from theoretical analyses and/or previous experimental results, and provides for uncertainty quantification and the ability to update predictions based on new data, which can save time and money. The aim of the present article is to develop a probabilistic methodology for low cycle fatigue life prediction using an energy-based damage parameter with Bayes’ theorem and to demonstrate the use of an efficient probabilistic method, moreover, to quantify model uncertainty resulting from creation of different deterministic model parameters. For most high-temperature structures, more than one model was created to represent the complicated behaviors of materials at high temperature. The uncertainty involved in selecting the best model from among all the possible models should not be ignored. Accordingly, a black-box approach is used to quantify the model uncertainty for three damage parameters (the generalized damage parameter, Smith–Watson–Topper and plastic strain energy density) using measured differences between experimental data and model predictions under a Bayesian inference framework. The verification cases were based on experimental data in the literature for the Ni-base superalloy GH4133 tested at various temperatures. Based on the experimentally determined distributions of material properties and model parameters, the predicted distributions of fatigue life agree with the experimental results. The results show that the uncertainty bounds using the generalized damage parameter for life prediction are tighter than that of Smith–Watson–Topper and plastic strain energy density methods based on the same available knowledge.


Author(s):  
Todd Letcher ◽  
Sepehr Nesaei ◽  
Cody Auen ◽  
Matt Nielsen ◽  
Fereidoon Delfanian

Fatigue testing is a time and resource-consuming task. Historically, SN testing was conducted at many stress levels on simple representative specimen in order to determine an SN curve, which could then be used to design a component from the same type of material. Recently, an energy-based fatigue life prediction method has been in development. The goal of this method is to quickly determine a material’s fatigue characteristics using simple test procedures. The main theory behind the energy-based fatigue life prediction method is that the strain energy in a monotonic tensile test is equal to the cumulative hysteresis energy of a cyclic test. This theory has always been tested using a single stress level on each specimen. The hysteresis loop information was then used to make fatigue life predictions at other stress levels. Further testing has been done to learn more about the hysteresis energy behavior throughout the lifetime of a specimen, but only for a single stress value. In this study, several stress levels were tested on a single specimen. This new information will help make fatigue life predictions by completely removing the difficult and inconsistent process of determining experimental curve fit coefficients traditionally used in the energy-based fatigue life prediction method.


2020 ◽  
Vol 142 (3) ◽  
Author(s):  
Dino Celli ◽  
M.-H. Herman Shen ◽  
Onome Scott-Emuakpor ◽  
Casey Holycross ◽  
Tommy George

Abstract The aim of this paper is to provide a novel stochastic life prediction approach capable of predicting the total fatigue life of applied uniaxial stress states from a reduced dataset reliably and efficiently. A previously developed strain energy-based fatigue life prediction method is integrated with the stochastic state space approach for prediction of total cycles to failure. The approach under consideration for this study is the Monte Carlo method (MCM) where input is randomly generated to approximate the output of highly complex systems. The strain energy fatigue life prediction method is used to first approximate SN behavior from a set of two SN data points. This process is repeated with another unique set of SN data points to evaluate and approximate distribution of cycles to failure at a given stress amplitude. Uniform, normal, log-normal, and Weibull distributions are investigated. From the MCM, fatigue data are sampled from the approximated distribution and an SN curve is generated to predict high cycle fatigue (HCF) behavior from low cycle fatigue (LCF) data.


2019 ◽  
Vol 28 (9) ◽  
pp. 1438-1454 ◽  
Author(s):  
Long Pan ◽  
Jian Chao Pang ◽  
Yu Jun Xie ◽  
Meng Xiao Zhang ◽  
Liang Liang Nie ◽  
...  

Due to the higher reliability needs of the large moving component motor-generator rotor, the assessment of the service life has drawn more and more attention. After finite element analysis of the rotor, the simulation part which can represent the magnetic pole with the most dangerous position of the rotor was designed to investigate the S–N curves. Compared with the conventional specimen, considering the main influencing factors of fatigue life for simulation part, the comprehensive factor was proposed to establish the fatigue life relationship between magnetic pole material and simulation part. It was found that the calculation method of fatigue notch factor based on the notch sensitivity factor is relatively simple and practical, and there is no significant effect of surface roughness on high and low cycle fatigues for low roughness ( R a is about 1 µm), and the dimension factor changes linearly with the scale factor. Based on those results, a fatigue life prediction method was proposed and validated, and the predicted results were in good agreement with the experimental data. This study will provide a reasonable reference to determine the fatigue life prediction of large moving components.


Author(s):  
John N. Wertz ◽  
M.-H. Herman Shen ◽  
Tommy George ◽  
Charles Cross ◽  
Onome Scott-Emuakpor

An energy-based fatigue life prediction framework for calculation of torsional fatigue life and remaining life has been developed. The framework for this fatigue prediction method is developed in accordance with our previously developed energy-based axial and bending fatigue life prediction approaches, which state: the total strain energy dissipated during a monotonic fracture and cyclic processes is the same material property, where each can be determined by measuring the area underneath the monotonic true stress-strain curve and the area within a hysteresis loop, respectively. The energy-based fatigue life prediction framework is composed of the following entities: (1) development of a shear fatigue testing procedure capable of assessing strain energy density per cycle in a pure shear stress state and (2) incorporation of an energy-based fatigue life calculation scheme to determine the remaining fatigue life of in-service gas turbine materials subjected to pure shear fatigue.


2014 ◽  
Vol 684 ◽  
pp. 291-296
Author(s):  
Yan Feng ◽  
Shou Xu Song ◽  
Qing Di Ke

Combining the method of finite element analysis with fatigue life prediction, fatigue cracks on the shaft parts is analyzed with cyclic loading. Analyzing the shafts with different sizes of cracks in different locations, a simulation modal is established. Informed by analytical and numerical simulation method, the crack formation and propagation life could be calculated. With considering the relationship of "Frequency - crack - fatigue life - remanufacturing ", the remanufacturability of the shaft parts might be evaluated based on service condition. And in this paper, a more convenient way to detecting and predicting the fatigue cracks on shaft parts is given.


Author(s):  
Dino Celli ◽  
M.-H. Herman Shen ◽  
Onome E. Scott-Emuakpor ◽  
Casey M. Holycross ◽  
Tommy J. George

Abstract The aim of this paper is to provide a novel stochastic life prediction approach capable of predicting the total fatigue life of applied uniaxial stress states from a reduced data set reliably and efficiently. A previously developed strain energy-based fatigue life prediction method is integrated with the stochastic state space approach for prediction of total cycles to failure. The approach under consideration for this study is the Monte Carlo method where input is randomly generated to approximate the output of highly complex systems. The strain energy fatigue life prediction method is used to first approximate SN behavior from a set of two SN data points. This process is repeated with another unique set of SN data points to evaluate and approximate distribution of cycles to failure at a given stress amplitude. Uniform, normal, log-normal, and Weibull distributions are investigated. From the Monte Carlo Method, fatigue data is sampled from the approximated distribution and an SN curve is generated to predict HCF behavior from LCF data.


Author(s):  
Onome Scott-Emuakpor ◽  
Tommy George ◽  
Charles Cross ◽  
Todd Letcher ◽  
John Wertz ◽  
...  

An energy-based life prediction method is used in this study to determine the fatigue life of tension-compression loaded components in the very low cycle regime between 102 and 104. The theoretical model for the energy-based prediction method was developed from the concept that the strain energy accumulated during both monotonic failure and an entire fatigue process are equal; In other words, the scalar quantity of strain energy accumulated during monotonic failure is a physical damage quantity that correlates to fatigue as well. The energy-based method has been successfully applied to fatigue life prediction of components failing in the fatigue regime between 104 and 107 cycles. To assess Low Cycle Fatigue (LCF) with the prediction method, a clearer understanding of energy dissipation through heat, system vibration, damping, surface defects and acoustics were necessary. The first of these topics analyzed is heat. The analysis conducted studies the effect of heat generated during cyclic loading and heat loss from slipping at the interface of the grip wedges of the servo-hydraulic load frame and the test specimen. The reason for the latter is to address the notion that slippage in the experimental setup may be the cause of the reduction in the accuracy of the energy-based prediction method for LCF, which was seen in previous research. These analyses were conducted on Titanium 6Al-4V, where LCF experimental data for stress ratios R = −1 and R = −0.813 were compared with the energy-based life prediction method. The results show negligible effect on both total and cyclic energy from heat generation at the interface of the grip wedges and heat generation in the fatigue zone of the specimen.


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