Numerical fatigue life analysis of a high frequency mechanical impact treated industrial component based on damage mechanics models

Abstract

AbstractAfter post weld treatment with high frequency mechanical impact (HFMI) treatment of welds, a significant increase of fatigue life (up to a factor of 10) can be achieved. During the last years numerous experimental tests of welded joints with simple geometry under constant amplitude loading have been performed to quantify the positive effect of high frequency mechanical impact treatment. Due to the lack of methods for the prediction of the high frequency mechanical impact benefits, a widespread use of this process is not the case yet. Furthermore, it is still not clear if the results of these fatigue tests can be transferred to complex geometries and complex loading conditions such as in industrial applications. Therefore, an approach to assess the fatigue life of complex welded structures under variable amplitude loading was developed. For this purpose, high frequency mechanical impact treatment and fatigue load of simple welded specimen made of S690QL steel were simulated with finite element analysis (FEA) firstly. Then, the needed damage parameters for the fatigue life correlation were evaluated from the finite element post‐processing. The calculated life time to crack initiation was in good agreement with the experimental fatigue test results. In the next step, this procedure was implemented on a welded arm of an evacuator of type EW180B of the company Volvo Construction Equipment made of S700MC. The variable amplitude load measured under real service condition was transferred to single constant amplitude load cycles using a rainflow‐counting algorithm. By simulation and damage mechanics evaluation of each load cycle the total damage sum could be calculated and compared with the experimental results from Volvo Construction Equipment.