Force Controlled Low Cycle Fatigue (LCF) Life Evaluation Methodology Based on Unstabilized Material Properties

Low Cycle Fatigue (LCF) is a prominent failure mechanism in many design components; therefore, an evaluation of cycles to failure in this regime is of high importance. Most international standards recommend a closed loop strain-controlled mode specimen testing in this regime. However, the ꜪN data obtained from this test is not suitable for life evaluation of parts enduring force-controlled history during actual service without correction for control mode. Many existing procedures, which accounts for cyclic strain stabilization during force-controlled loading may significantly complicate the finite elements analysis (FEA) at solving or post processing stages and are often an inherent source of uncertainty. A heuristic, cost effective and sufficiently accurate approach for LCF life estimation is advocated. The method involves only two force loading FEA simulations, one of the actual parts and the other of the test specimen, using initial unstabilized stress strain curve, followed by a limited number of force-controlled specimens testing. Actual part and specimen life correlation performed using first loading unstabilized equivalent plastic strain value Ꜫp1 under locality and similitude assumptions. Unstabilized strain vs. number of cycles to failure curve Ꜫp1N is constructed and discussion regarding specimen geometry considerations for providing sufficient accuracy is included. Method validation and crack propagation study are provided.