Fatigue Life Extension Research Articles

Probabilistic risk assessment method considering machining-induced random residual stress

The aero-engine disks inevitably have manufacturing-induced anomalies and machining-induced random residual stress (RS) in localized and critical areas, which cause a severe threat to the safety of the aircraft. Traditional structural design of the disks fails to establish a quantitative correlation between the machining process and the failure risk. Therefore, this paper proposes a probabilistic model considering random RS to quantify the influence of machining RS subjected to low-cycle fatigue. The RS dispersion is quantified using a scaling parameter, obtained by X-ray diffraction measurements and orthogonal cutting simulations. The crack life database under varying RSs is established for efficient probability calculations. Results show that the coefficient of variation (COV) of the RS on the same machined surface with the same processing parameters is 7.62 % in the local area and 13.74 % in the whole machined surface. The risk results show that the probability of failure (POF) considering the deterministic RS is 2–4 % lower than the POF without RS, owing to the extension of fatigue life by compressive RS. Furthermore, the POF considering the random RS is almost the same (difference <0.6 %) as the POF considering the deterministic RS because the depth of the machining RS is around 0.2 mm. The proposed method predicts the POF more accurately and is thus valuable for the safety assessment of an aero-engine titanium disk.

An analytical model for predicting fatigue crack arrest and growth behavior in metal plates strengthened with unbonded prestressed reinforcing strips

Fatigue crack arrest and life extension of metallic structures can be achieved by using prestressed strips for fatigue strengthening. However, the popularization of prestressed strengthening techniques has been limited by lack of versatile analytical methods. In this paper, an analytical method is developed for predicting the fatigue behavior of centrally cracked metal plates after being anchored with prestressed reinforcing strips, based on linear elastic fracture mechanics and the superposition method of stress intensity factors. The force transfer between reinforcing strips and metal cracked plates is modeled using the displacement compatibility principle. The finite-width correction factor for centrally cracked metal plates subjected to four-point concentrated forces is derived, allowing the model to analyze the effect of different anchorage locations on the effectiveness of strengthening. The analytical model is validated through experimental data and finite element analysis. The results show that the model is highly accurate and can be used to analyze how different anchorage locations affect fatigue reinforcement.

The Research Effects of Variable Temperature and Early Strength Agent on the Mechanical Properties of Cement-Stabilized Macadam.

In cold regions with high daily temperature gradients (>20 °C), the durability of cement-stabilized macadam (CSM) base materials is poor and prone to cracking. To effectively reduce the cracking of semi-rigid base layers in cold regions with high daily temperature gradients and extend fatigue life, this study focused on cracking and fatigue characteristics of CSM with a 10% commercial early strength agent (ESA) added by the external mixing method under different curing conditions. The ESA was manufactured by Jiangsu Subote New Materials Co., Ltd. (Nanjing, China). The curing conditions were divided into variable temperature (0-20 °C) and standard temperature (20 °C). CSM curing was carried out through a programmable curing box. The research results indicated that the variable temperature curing conditions reduced the strength and fatigue resistance of CSM and accelerated the modulus attenuation rate of CSM. At the same time, the drying shrinkage of CSM was greater. The temperature shrinkage coefficient and strain of CSM under variable temperature conditions were smaller than those under standard temperature conditions. The effect of variable temperature conditions on the cracking and durability of CSM could not be ignored in cold regions. Compared to standard temperature curing conditions, the indirect tensile strength of CSM reduced by 31.04% under variable temperature conditions, the coefficient of variation increased by 2.97 times, and the discrete type significantly increased. Compared with CSM without ESA, the dry and temperature shrinkage strains of CSM with 10% ESA were reduced by 24.65% and 26.10%, respectively. At a stress level of 0.6, compared to standard temperature curing conditions, the fatigue life of CSM decreased by 97.19% under variable temperature conditions. Under variable temperature conditions, the fatigue life of CSM with 10% ESA increased by 196 times compared to 0% ESA. Adding ESA enhanced the anti-shrinkage cracking, strength, and durability of CSM under variable temperatures. ESA incorporation effectively compensated for the weakened characteristics of CSM under variable temperature conditions. The study proposed a practical approach for boosting the durability of CSM in cold environments.

Fatigue performance simulation of reinforced concrete beams externally strengthened with side bonded CFRP sheets

Damaged Reinforced Concrete (RC) beams are commonly strengthened by bonding Carbon Fiber Reinforced Polymer (CFRP) strips to their soffits. However, inaccessible or narrow soffits limit the use of bottom-bonded CFRP strips. The Side Bonded (SB) CFRP technique overcomes this, yet studies on SB-CFRP-reinforced beams' fatigue behavior are limited. This paper presents a Finite Element (FE) model for simulating the fatigue behavior of RC beams externally strengthened with SB-CFRP sheets. The model incorporates cyclic-dependent CFRP-concrete interface degradation. Existing experimental results are utilized to validate its accuracy. Computational analyses are undertaken to explore the effects of CFRP dimensions, load and prestress levels, and end-U-shaped wrapping on fatigue performance. A simple model is proposed to predict fatigue life considering load and prestress levels. The FE model effectively predicts fatigue performance. Parametric studies indicate that narrow CFRP strips are unable to prevent concrete failure under high loads. Fatigue failure modes include rebar ruptures and CFRP delamination. Besides, the end-U-shaped wrapping reduces interface damage, extending fatigue life. The study emphasizes the sensitivity of vibration excitation method to CFRP debonding. The proposed equation efficiently predicts the fatigue life of RC beams with externally bonded CFRP strips on their sides.

ВПЛИВ КІЛЬЦЕВИХ КАНАВОК ХОЛОДНОГО ОБТИСКУ НА ДОВГОВІЧНІСТЬ ПАНЕЛЕЙ КРИЛА З ФУНКЦІОНАЛЬНИМИ ОТВОРАМИ

This article studies in detail the method of cold extrusion annular grooves to solve the problem of aircraft fatigue life extension that reduces the fatigue life of aircraft wing panels due to functional holes. This method is a very simple and effective anti-fatigue manufacturing technology. In order to simulate the different wing panels with functional holes, the experiment is designed to extrude the specimen with different extrusion forces to obtain annular grooves of different depths. Fatigue tests are conducted on specimens with annular grooves. The test results show that: 1) Cold extrusion annular grooves can extend the fatigue life of wing panels with functional holes; 2) The fatigue life of wing panels with functional holes is affected by the depth of the cold extrusion annular groove. The fatigue life changes in an inverted "V" shape as the depth of the cold extrusion annular groove increases; 3) When cold extrusion annular groove depth is 0.26mm, the fatigue life of specimen with holes is maximum, and the fatigue life is increased by 2.35~32.9 times when specimen thickness is 5 mm

Very high cycle fatigue of fiber‐reinforced polymer composites: Uniaxial ultrasonic fatigue

AbstractThis review explores uniaxial ultrasonic fatigue (USF) testing as a common and dependable method for quantifying the extended fatigue life of fiber‐reinforced polymer (FRP) composites. The objective is to explain the complexities governing the fatigue life behavior of FRPs, particularly in the realm of very high cycle fatigue (VHCF) where the number of loading cycles exceeds 107. To this end, this review encompasses the analysis of VHCF behavior, including the derivation and interpretation of stress–life (S–N) data, the evaluation of various fatigue damage mechanisms (i.e., controlling mechanisms of crack initiation and propagation) exhibited in FRP composites, and a thorough investigation of the frequency‐dependent effects on fatigue responses. Furthermore, this review tries to analyze the microscopic intricacies intrinsic to the VHCF failure of FRP composites, encompassing aspects such as fiber‐matrix de‐bonding, matrix cracking, and delamination, unveiling their modes and effects in a detailed manner. This review also underscores the pivotal integration of simulations, machine learning, and modeling techniques, emphasizing their crucial role in explaining both macroscopic and microscopic interactions governing the VHCF of FRPs.

High-performance hybrid glass fibre epoxy composites reinforced with amine functionalised graphene oxide for structural applications

Glass fibre-reinforced epoxy (GFRE) composites have had limited use as structural components in industrial applications (e.g., oil and gas, aerospace and civil infrastructure). The use of nanomaterials, such as graphene, has been explored recently to enhance the mechanical and long-term properties of GFRE to realise their full potential and increase their usage. This study evaluated the tensile, creep, and fatigue behaviour of amine-functionalised graphene oxide (fGO) modified glass fibre/epoxy laminate composites. A spray coating technique was used to coat the fGO particles onto the glass fibre surface, and epoxy composite laminates were manufactured using the vacuum resin infusion method. Creep and fatigue testing was performed under a load-controlled mode in tension. Adding fGO within the composites significantly improves the static, creep, and fatigue properties of the fGO-GFRE composites at both room and elevated temperatures. It is shown that fGO acts as a barrier to microcrack initiation and restrains the macrocrack propagation during cyclic loading under elevated temperatures in the GFRE composites. These factors, therefore, prevent the early delamination of the matrix and fibre interface during cyclic loading, which explains the fatigue life extension observed in the fGO-modified composites. With 0.05 wt% fGO, the fatigue life of the fGO-GFRE composites was extended by 8× and 30× at a maximum stress of 124 and 151 MPa respectively, in a 90 °C environment compared to the control GFRE composites. While the creep life compared to the control increased by 63×, 103× and 159× with 0.25 wt%, 0.5 wt% and 1 wt% fGO, respectively. These enhancements are attributed to the large surface area, high stiffness, and functional groups present, which provide a stronger bond between the composite phases. These features help restrict the mobility of the polymer chain during the creeping load and act as barriers to fatigue crack propagation, enhancing the composite’s durability. The nanocomposites produced display attractive properties for many possible industrial applications where improved performance is needed while maintaining a minimum cost.

Optimization of cutout characteristics in AISI 1045 steel plates for high-cycle fatigue life extension

Crack growth is a pivotal concern in structural engineering, directly impacting structures’ stability, quality, and overall lifespan. This study addresses this challenge by investigating structural optimization strategies to mitigate fatigue crack growth (FCG) by strategically incorporating stop-drilled cutouts near the crack tip. The research introduces three optimization problems, focusing on determining the optimal cutout position with a fixed radius, the optimal cutout radius with a fixed position, and the optimal cutout shape with a constant position for the cutout’s center. Experimental assessments are conducted on an edge-cracked AISI 1045 steel plate to evaluate the effectiveness of these optimization strategies in enhancing fatigue life. Employing the Extended Finite Element Method (XFEM) for numerical simulations and Particle Swarm Optimization (PSO) for the optimization process, the findings reveal that strategically positioned cutouts substantially reduce the crack growth rate. Optimal cutout placement significantly improves fatigue life, demonstrating an approximate 287% increase. The analysis affirms the accuracy of the numerical model in predicting fatigue life and crack growth paths, validated through comparison with experimental data. In summary, this research underscores the effectiveness of optimization techniques in mitigating fatigue crack growth, providing valuable insights for structural integrity enhancement in structural mechanics.

Effects of hot extrusion texture on anisotropy in microstructure and mechanical properties of spray formed Al–Zn–Mg–Cu 7055 aluminum alloy

The Al–Zn–Mg–Cu 7055 aluminum alloy was meticulously fabricated through spray forming (SF) technology, followed by hot extrusion and T76 treatment. This comprehensive process allowed for a thorough investigation of its microstructural characteristics, mechanical properties, and fatigue behavior. Post-treatment analysis revealed that the SF-7055 aluminum alloy exhibited no notable segregation or porosity defects, ensuring its exceptional quality and reliability. The microstructural analysis revealed a uniform distribution of refined grains and dispersed precipitates, contributing to the material's strength. Mechanical testing demonstrated that the hot extruded SF-7055 aluminum alloy exhibits superior tensile strength and elongation, with significant anisotropy in mechanical properties favoring the extrusion direction (ED) over the transverse direction (TD). Fatigue testing under varying cyclic stresses revealed an extended fatigue life in the ED-oriented specimens, attributed to the texture-induced resistance to crack initiation and propagation. The study underscores the effectiveness of SF and hot extrusion in enhancing the SF-7055 aluminum alloy's performance, making it a viable candidate for critical aerospace applications. The findings provide valuable insights into the relationship between processing, microstructure, and properties, offering a pathway to the design and fabrication of high-performance aluminum alloys.

Experimental analysis of S–N curves of welded joints with different fatigue life extension approaches

Abstract The fatigue life extension approaches played an important role in ensuring the safety of marine engineering structures. This study conducted an in-depth analysis of the S–N curves of welded structures under different service environments and different fatigue life extension approaches, and found that the comprehensive life extension process of welding toe polishing and coating (the fatigue life was extended by 15–33 times compared to untreated samples) was the most significant approach under dry air medium environment. The comprehensive life extension process of welding toe polishing and coating (the fatigue life was extended by 10–25 times compared to untreated samples) was the most significant approach under salt spray corrosive medium environment. Moreover, the S–N curve and related parameters of welded joints of semi-submersible platform under different environmental media conditions and different combinations of fatigue life extension approaches were studied in depth, which had important guiding significance for practical life extension tools of jacket platform T-joints in practice.

Enhancing fatigue performance of AZ31 magnesium alloy components fabricated by cold metal transfer-based wire arc directed energy deposition through LPB

Cold Metal Transfer-Based Wire Arc Directed Energy Deposition (CMT-WA-DED) presents a promising avenue for the rapid fabrication of components crucial to automotive, shipbuilding, and aerospace industries. However, the susceptibility to fatigue of CMT-WA-DED-produced AZ31 Mg alloy components has impeded their widespread adoption for critical load-bearing applications. In this study, a comprehensive investigation into the fatigue behaviour of WA-DED-fabricated AZ31 Mg alloy has been carried out and compared to commercially available wrought AZ31 alloy. Our findings indicate that the as-deposited parts exhibit a lower fatigue life than wrought Mg alloy, primarily due to poor surface finish, tensile residual stress, porosity, and coarse grain microstructure inherent in the WA-DED process. Low Plasticity Burnishing (LPB) treatment is applied to mitigate these issues, which induce significant plastic deformation on the surface. This treatment resulted in a remarkable improvement of fatigue life by 42%, accompanied by a reduction in surface roughness, grain refinement and enhancement of compressive residual stress levels. Furthermore, during cyclic deformation, WA-DED specimens exhibited higher plasticity and dislocation density compared to both wrought and WA-DED + LPB specimens. A higher fraction of Low Angle Grain Boundaries (LAGBs) in WA-DED specimens contributed to multiple crack initiation sites and convoluted crack paths, ultimately leading to premature failure. In contrast, wrought and WA-DED + LPB specimens displayed a higher percentage of High Angle Grain Boundaries (HAGBs), which hindered dislocation movement and resulted in fewer crack initiation sites and less complex crack paths, thereby extending fatigue life. These findings underscore the effectiveness of LPB as a post-processing technique to enhance the fatigue performance of WA-DED-fabricated AZ31 Mg alloy components. Our study highlights the importance of LPB surface treatment on AZ31 Mg components produced by CMT-WA-DED to remove surface defects, enabling their widespread use in load-bearing applications.

Waste cooking oil based capsules for sustainable self-healing asphalt pavement: Encapsulation, characterization and fatigue-healing performance

Waste cooking oil has surfaced as a hazardous waste that induces severe environmental contamination. Encapsulation technology presents a viable solution to regenerate the waste oil and augment the self-healing ability of asphalt materials. This study characterized capsules synthesized with selected waste oil for self-healing asphalt mixture, and evaluated the self-healing and environmental impact. The wetting ability, capillary, anti-aging, and self-healing performance of three potential healing agents were analyzed, and the optimal healing agent was obtained by evaluating the comprehensive behavior with the radar chart method. Capsules were synthesized using the ionic gelation method, and their thermal stability, chemical structure, mechanical performance, and morphology were characterized. Fatigue-healing performance asphalt mixture with capsules were investigated by indirect tensile fatigue test with intermittent time. Leakage of waste oil core were measure to verify it environmental impact to surroundings. Results showed that all healing agents could restore the aged asphalt, and waste rapeseed oil had superior overall performance with comprehensive fi value of 0.993 in radar chart evaluation. The compression characteristic of the capsules could transform from brittleness to plasticity as the water-to-oil(WO) ratio decreases from 15 to 5. SEM observation implied when the WO ratio varied from 10 to 15, the multi-pore structure of capsules could be appropriately filled. The addition of capsules in the mixture increased the fatigue life extension rate (HDf) of aged mixtures (with intermittent time 0.1 s∼0.8 s) by 10∼30%. Leakage of waste oil from the mixture was inhibited, substantially reducing 38% release of waste oil. This can serve as a means for the sustainable utilization of waste oil, thereby mitigating environmental pollution and negative effects caused by waste oil.

Determining the Gear Design Parameters Which Have Strong Correlation with Gear Volume and Contact Ratio for Helical Gear Design Optimization

The market has a significant demand for low-cost, compact size, extended fatigue life and high load-carrying capacity helical gears. One way to manufacture such gears is by minimizing gear volume and maximizing contact ratio. Most researchers focus on gear design optimization, but minimal study has been conducted to identify design variables that significantly impact gear volume and contact ratio. Hence, it is crucial to determine gear design parameters that strongly correlate with gear volume and contact ratio beforehand. A single-stage helical gear train of local electric multiple units (EMU) is used as the gear model, and the calculations are done based on ISO 6336. Seven parameters have been chosen as independent variables; module, number of teeth of pinion, gear ratio, helix angle, tooth thickness factor, normal pressure angle and addendum factor. Graphs of total gear volume and contact ratio against independent variables are plotted to examine their relationship. The results indicate that normal module, number of teeth of the pinion, and gear ratio strongly correlate with the total gear volume. Meanwhile, the number of teeth of pinion, helix angle, tooth thickness factor, normal pressure angle and addendum factor strongly correlate with contact ratio. Therefore, these design parameters must be considered to improve the accuracy of the gear design optimization model, which aims to optimize gear volume and contact ratio.

Bonded and prestressed fatigue crack retarders based on Fe-SMA

A bonded and prestressed retarder concept is proposed in this work. The shape memory effect of an iron-based shape memory alloy (Fe-SMA) has been exploited to realize a desirable self-prestressing mechanism, resulting in compressive stresses in the parent structure. The synergistic prestressing and added fail-safe features of bonded and prestressed Fe-SMA retarders desirably restrain the fatigue crack growth. The fatigue crack growth behaviour in metallic plates reinforced with bonded and prestressed retarders is experimentally studied in this work. A test campaign has been implemented to investigate the effects of prestressing, as well as the influence of the relative location between the Fe-SMA retarders and the initial crack tip on the crack growth behaviour and fatigue crack life extension. The experimental results show that the prestressing of retarders desirably extends the fatigue crack growth life. More extension in fatigue life can be achieved by positioning the bonded prestressed retarders from 40 to 20 mm before the initial crack tip, the desirable retardation due to beneficial compressive prestressing and added load path on the small crack is significant. The findings in this work imply that it is beneficial to proactively reinforce the fatigue-prone locations in metallic structures with bonded and prestressed Fe-SMA retarders in order to extend the service life.

Very high cycle fatigue of laser powder bed fused Al-Cu-Mg-Ag-TiB2 (A20X) Alloy: Stress relief and aging treatments

This study presents a comprehensive exploration of the fatigue response in the very high cycle fatigue (VHCF) regime for an additively manufactured (i.e., laser powder bed fused) A20X aluminum alloy. Although the need for high-performance materials with exceptional fatigue qualities has increased dramatically, the VHCF behavior of Al-Cu-Mg-Ag-TiB2 (A20X) structures remains largely unknown. A series of ultrasonic fatigue tests were performed to assess the prolonged fatigue life of the A20X alloy (in the VHCF domain where the number of cycles to failure is beyond 10 million cycles). The VHCF response, assessed through ultrasonic fatigue testing, was investigated by examining the stress-life (S-N) curves in a statistical framework, the fatigue crack initiation and propagation behavior, and the fracture surfaces. An asymptotic trend was experimentally found at 109 cycles, with a stress amplitude of 110 MPa for stress-relieved (SR) and 125 MPa for artificially aged (T7) materials, indicating the presence of an endurance limit. Furthermore, fracture surfaces showed the typical fisheye morphology, with a fine granular area (FGA) containing an internal crack-initiating site. The findings of this paper can assist in optimizing fatigue and durability design allowable for applications for extended fatigue life in the VHCF domains.

Fatigue performance and alternate coupling mechanism of ZL114A aluminum alloy under corrosion-fatigue alternating

This paper investigates the fatigue performance of ZL114A cast aluminum alloy through laboratory corrosion-fatigue alternating test conducted under simulated tropical marine humid-hot atmosphere. The study examines the impact of different alternating frequency on the fatigue properties of the aluminum alloy. At the same time, the micro morphology of the specimen surface and fatigue fracture were observed, and the damage mechanism under the alternating action of corrosion-fatigue was analyzed. The concept of ‘fatigue impact factor’ in alternating test was proposed to reflect the effect of fatigue on corrosion in alternating process. The results show that the increase of alternating frequency leads to an extended fatigue life for the alloy, following a power function relationship. Pitting is identified as the primary form of corrosion damage on specimen surfaces, with multi-crack initiation observed in fatigue fractures. It is found that the fatigue impact factor exponentially increases with each alternating cycle during testing. In early alternating cycles of test, the presence of fatigue inhibits corrosion by promoting passivation of corrosion pits; however, in later alternating cycles, propagation of fatigue cracks accelerates growth in size for these corrosion pits which subsequently promotes further corrosion.

Fatigue Life Estimation Model of Repaired Components with the Expanded Stop-Hole Technique

Fatigue crack growth tests are conducted to assess the efficacy of the stop-hole crack repair method. This straightforward and widely adopted technique involves drilling a hole at the crack tip and subsequently enlarging it using a pin inserted into the hole. A fracture mechanics-based model is proposed to estimate the extension of fatigue life achieved through the implementation of the stop-hole technique. The model’s predictions are validated using data obtained from fatigue crack growth tests conducted on both unrepaired and repaired M(T) specimens, following the guidelines outlined in the ASTM E647 standard. The error of the fracture mechanics-based model was 1.4% in comparison with the fatigue tests.

Comparative study of failure analysis in glass fiber reinforced laminated pin joints under cyclic and static loading conditions

Glass Fiber Reinforce Polymer (GFRP) composite Joints were studied under monotonic loads for aerospace and marine applications, but cyclic loading is also a common and serious concern in these applications. In this current study, GFRP composite pin joints were analyzed under cyclic loading, at various geometric factors experimentally and numerically using finite element analysis (FEA) and also compared with monotonic loading. Fatigue tests were carried out using sinusoidal tension-tension loading and covering a range of stress levels from 50% to 90% of effective failure strength (EFS). Weibull distribution was utilized to predict the reliable fatigue life of joints at various joint configurations. Under cyclic loading rapid degradation of dynamic modulus indicated catastrophic failure with shorter fatigue life, while gradual degradation implied slow micro-crack growth and extended fatigue life with progressive failure while in monotonic loading, a sudden fall in the stress-strain curve represented catastrophic failure, and a zigzag curve indicated bearing failure mode before fracture. The damage rate was also determined from the hysteresis loop cycles which indicate greater loop expansion due to the stiffness degradation and higher energy dissipation shows rapid damage accumulation and shorter fatigue life at higher stress level. On the other hand at lower stress level, moderate enlargement of the hysteresis loop demonstrates extended fatigue life with slower damage propagation.

Design Analysis and Optimization of Coil Spring for Three-Wheeler Vehicles Using Composite Materials

The quest for lightweight, efficient, and corrosion-resistant coil springs for vehicle suspension systems has led to the exploration of alternative materials beyond traditional steel. This study delves into the potential of composite materials, particularly carbon/epoxy and carbon/carbon nanotube/epoxy, as replacements for conventional steel coil springs in light vehicles. Through a comprehensive analysis of mechanical properties under static and dynamic loading conditions, the study demonstrates the superior performance of composite springs compared to their steel counterparts. After optimization, the deflection of the carbon/carbon nanotube/epoxy and carbon/epoxy springs decreased to 15.003 mm and 18.703 mm, respectively, and the maximum shear stress decreased by 64.63% and 62.2%, respectively. Likewise, strain energies increased to 2.3644 and 3.5616, respectively. The springs were also studied under dynamic conditions, and the result showed these springs have the ability to perform in dynamic conditions. The carbon/carbon nanotube/epoxy composite emerged as the frontrunner, exhibiting remarkable improvements in shear stress, fatigue life, strain energy, and deformation properties. The study highlights the ability of carbon/carbon nanotube/epoxy composite springs to significantly reduce weight, enhance efficiency, and extend fatigue life, making them a promising alternative for next-generation vehicle suspension systems.

Rock bolts under cyclic loading: Mechanical performance and damage assessment by acoustic emissions

Rock bolt support is one of the key methods to maintain the stability of underground space. The durability of the rock bolt can be weakened by cyclic loading, resulting in premature failure of the underground structures. A comprehensive understanding of the performance of the bolting system under cyclic loading is essential to assess the safety of the bolting system and underground structures. In this context, this study investigated the mechanical performance of rock bolts installed in simulated soft and medium hard rock and subjected to cyclic loading. The Acoustic Emission (AE) technique was used to monitor internal damage to the bolt system under different loading conditions. A cumulative AE energy slope method has been proposed to determine the onset of the macro crack formation stage. The rock bolt demonstrated an extended fatigue life in soft rock, but its condition worsened when implanted in medium hard rock. The cyclic loading resulted in a slight improvement in the load bearing capacity of the soft rock bolt system and a significant deterioration in the medium hard rock bolt counterpart. The main fatigue failure modes of the rock bolt systems were splitting and shear failure of the surrounding rock, and debonding of the interface. Increasing the amplitude of the cyclic loading reduced the macro crack initiation cycle for both rock bolt systems, whereas increasing the frequency had different effects. The damage variable increased with frequency and amplitude for both rock bolt systems. The toughness of the soft rock bolt degraded during cyclic loading, while the high frequency cyclic loading did not modify the toughness of the medium hard rock bolt.