Abstract
Car body and chassis components made of aluminum or steel sheets are produced with varying cutting processes in the different development stages. Whereas the series components are mainly manufactured by shear cutting, the prototype components are often produced with laser cutting. Each cutting process results in specific properties for the cut-edge like surface finish, hardness distribution and residual stresses in the near surface region. The fatigue crack in such components usually starts from a cut-edge, making the fatigue lifetime dependent on different cut-edge conditions. In literature the influence of the cut-edge conditions on the fatigue behaviour so far mainly focuses on constant amplitude loading. Therefore the influence of variable amplitude loading on the cut-edge effect is the objective of this paper. The results of stress-controlled fatigue tests with constant and variable amplitude loading, using a random Gaussian amplitude distribution, are compared for aluminum sheets with different cut-edge conditions. These results show an influence of the load-time-history on the cut-edge effect. The decrease of the fatigue strength under variable amplitude loading is significantly less than for constant amplitude loading. However since the Gassner-lines are shallower than the Woehler-lines the decrease of the fatigue life is higher under variable amplitude loading compared to constant amplitude loading.
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