Fatigue Life Estimation Research Articles

복합하중을 받는 각접촉 볼베어링을 위한 개선된 피로수명식

복합하중을 받는 각접촉 볼베어링을 위한 개선된 피로수명식

Thermomechanical Rotor Fatigue of an Interior Permanent Magnet Synchronous Motor

Interior permanent magnet synchronous motors (IPMSMs) are extensively used as traction motors today because of their exceptional torque, power density, and wide, constant power operating range. Under real-world usage, an IPMSM rotor undergoes varying electromagnetic, thermal, and mechanical loads. Under such conditions, fatigue life-based design criteria should be used over stress-based design criteria to ensure the structural integrity of the rotor. Moreover, the driving dynamics can change the rotor temperature continuously, which affects the electromagnetic, mechanical, and fatigue properties of the rotor material. This paper proposes a robust thermomechanical rotor fatigue simulation workflow considering significant loads acting on an IPMSM rotor and the temperature variation throughout a drive cycle. It discusses an accelerated fatigue life estimation approach based on the peak valley extraction method to reduce the simulation time significantly for the stress and fatigue analysis. Then, it presents a method for a stress-life curve generation for variable loading. It also presents a sensitivity study with a median S-N curve, and a 90% reliability and 95% confidence (R90C95) S-N curve.

Study of the shot peening surface roughness in fretting

Fretting fatigue manifests in mechanical systems exposed to contact forces that vary over time, resulting in premature cracks that can lead to component failure. Shot peening treatment is one of the palliatives to mitigate fretting fatigue problems. Recent studies have noted that the fretting fatigue is also extended by exclusively applying SP to the contact pad surface. This suggests that the improvement in the fatigue live produced by SP comes not only from the compressive residual stresses but also due to the characteristic surface roughness from the SP treatment. For this reason, the main goal of this work is to analyse how the shot peened roughness affects the fretting fatigue life. To do so, a confocal microscope was used to measure various profiles of shot peened pads. Using these profiles, and under fretting loads combination, the contact stress and strain field are calculated, followed by the application of a fatigue model. Finally, the estimated fatigue life is contrasted with empirical data derived from a research published by the authors. The study reveals that the fretting fatigue life is influenced by the surface roughness, although to a lesser extent with respect to residual stresses. Besides, the Smith-Watson-Toper parameter and stress intensity factor were analysed, suggesting that the rough surface primarily affects the initiation phase rather than the propagation phase, as it was expected.

Comparative evaluation of fatigue life estimation under variable amplitude loading through damage models based on entropy

AbstractThree fatigue damage models based on entropy, originally developed for constant amplitude loading, were assessed and compared to each other aimed at stating whether its applicability can be extended towards variable amplitude loading conditions. A variable amplitude loading history, applied on a 2024‐T3 aluminum alloy reported in the literature, was processed using both rainflow cycle counting and spectral techniques to transform it into a distribution of simple processes with constant amplitudes, then the damage models were assessed under the new loading conditions. The results showed that the model by Khonsari, combined with the rainflow technique, exhibited the highest accuracy with regard to the referenced experimental results with a −0.67 standard deviation from the average data and a 16% error from the median. Therefore, it is possible to assess the fatigue damage accumulation in metallic materials under variable amplitude loading through a thermodynamic approach with models developed for constant amplitude loading.

Fatigue life estimation of corroded welded steel joint using probabilistic approach

This study presents a probabilistic model to estimate fatigue life of the corroded welded joint using the concept of the limit state function and Monte Carlo procedure. The basis for the assessment is the long-term experiment in a real corrosive environment. Pit-to-crack transition parameters, after three years of corrosion, are estimated using El Haddad model for small cracks. Calibration of the linear elastic fracture mechanics parameters was performed using S-N analysis for the case when the initial crack size is stochastic and for the case when the crack emanates from a corrosion pit. Results of the failure probability calculation for two approaches after the fourth and fifth year of the service life show that the stochastic initial crack size gives higher failure probability and suggests shorter inspection intervals than the ones obtained with deterministic initial crack size.

Durability Prediction of Cyclically Loaded CP-W800 Fillet Welds

Two methods of durability prediction of fillet welds were researched in this study. Namely, the structural Hot-Spot method and the structural stress method fe-safe Verity were applied to fatigue life estimation of a double plate lap fillet weld made of high-strength complex phase CP-W800 steel. Durability predictions were compared against available high-cycle fatigue experimental data obtained for the same weld detail and material. Both 2D and 3D finite element meshes were considered in the simulations. It was shown that comparable predictions were obtained using either the Hot-Spot method or the fe-safe Verity module in the case of the 3D FE mesh. On the contrary, a less conservative durability prediction was observed using the Hot-Spot method and a more conservative durability prediction was gained using the fe-safe Verity module in the case of the 2D FE mesh due to a different consideration of stress concentration around the weld.

An improved J-integral based adhesive joint fatigue life estimation method for automotive structural durability analysis

ABSTRACT To estimate the fatigue life of lightweight automotive structures in compliance with top-down design principles, there is a need for an accurate adhesive joint fatigue life prediction method that is compatible with industrial finite element modeling practices. This paper proposes a method to split the analytical J-integral solution based on the fracture mode of joints. The split mode I and II J-integrals correspond to the opening mode and sliding mode of the bonded joint, respectively. By splitting the J-integral and introducing the concept of the mixed mode ratio, an improved approach for estimating adhesive joint fatigue life is presented, considering the influence of loading modes. The proposed fatigue life prediction method is validated through fatigue tests on a sub-component level bonded structure. The results of the validation demonstrate that the split J-integral analytical solution method, considering the mixed mode ratio, provides better predictions compared to its predecessor approach.

The Effect of Ply Waviness for the Fatigue Life of Composite Wind Turbine Blades

Wind turbine blade failure is one of the most prominent types of damage occurring in operating wind turbine systems. Glass fibre materials are mainly used for producing wind turbine blades and they consist of large tows, stitched fibres, which are prone to generate imperfections such as ply waviness. The primary objective of this research was to evaluate the effect of ply waviness on fatigue life of typical composites used in wind turbine blades. This study involves two main areas: Finite elements analysis (FEA) and experimental testing. The Finite element analysis was carried out using the commercial code from ESI group. The experimental work was carried out by manufacturing specimens from glass fibre with regular waviness and testing for static and fatigue failure. The tensile static test data was used to identify the effect of ply waviness for failure strength. Cycles to failure (S-N) curves were developed for two different wave profiles based on fatigue testing data. The long term aim of this ongoing research is to improve current fatigue life estimation methods applicable to composite wind turbine blades.

Experimental study on bond durability of GFRP bar/engineered cementitious composite exposed to freeze-thaw environments

Glass fiber reinforced polymer (GFRP) bars and engineered cementitious composites (ECC) present better structural performance as compared to conventional concrete with reinforcing steel bars. However, the bond behavior of the GFRP bar to ECC matrix under freeze-thaw (FT) cycles in cold climates remains underexplored. Therefore, this study aims to investigate the bond durability of GFRP bars and ECC under FT conditions. An experiment was conducted with 33 pullout specimens, categorized according to concrete types (normal concrete and ECC), compressive strengths (30 MPa and 50 MPa) and the number of FT cycles (0, 100, 150, and 200 cycles). Assessment parameters included surface degradation, failure modes, mean bond strength, weight loss, and the relative dynamic modulus of elasticity. Results indicated ECC specimens exhibited greater durability compared to normal concrete specimens, with no significant improvement in durability observed with increased compressive strength. Specifically, the mean bond strengths of N30 (30 MPa normal concrete) specimens, E30 (30 MPa ECC) specimens, and E50 (50 MPa ECC) specimens decreased by 88.41 %, 38.86 %, and 58.21 % after 150 FT cycles, respectively. Failure modes correlated strongly with concrete type and the number of FT cycles. SEM and composition analyses revealed the effects of FT cycles on the concrete matrix, the bond interface, and the GFRP bars. The ascending branches in the bond stress-slip curves of specimens subjected to FT cycles were effectively modeled using Malvar's model. Based on the declining relative dynamic modulus of elasticity and the correlation between laboratory and natural FT cycles, the estimated fatigue lives for GFRP bar/E30 specimens subjected to 250 FT cycles are 35.7, 71.4, and 46.2 years in Beijing, Detroit, and Vancouver, respectively. This research provides insights on GFRP bar/ECC's longevity in practical engineering contexts.

Influence Law of Axis Deflection on the Mechanical Properties of Steel Stranded Short Slings in Arch Bridges

Most cable arch bridge damage accidents are caused by bridge collapse due to fracture of the short sling of the arch bridge. The service life of the short sling is much lower than the design life, mainly resulting from the action of vehicles and temperature, and the arch rib and the bridge floor will have relative displacement along the bridge direction, which leads to the emergence of bending stress due to the different axes at both ends of the short sling, forming local stress concentration. The stress concentration is coupled with corrosion to accelerate the damage to the sling. To study the influence of shaft deflection on the mechanical properties of short slings of steel strands in arch bridges, this study analyzes the distribution law of the shaft deflection angle of arch bridge slings under the action of vehicle and temperature loads for a medium-bearing arch bridge with a main span of 560 m. The results show that under different vehicle and temperature loads, the axial deflection angle of the short sling is the largest, and the closer it is to the center of the span, the smaller the axial deflection angle. The static and fatigue properties of 1, 3, 7, 9, 12, 19, and 27 strands of whole bunch extruded strand slings were simulated and analyzed under a 0.45σb force when the axial deflection angle of the strand slings was 0 mrad, 10 mrad, 20 mrad, and 30 mrad. The results show that the ultimate tensile properties, breaking strength, and fatigue life of the strand slings decreased to a certain extent with increasing shaft deflection angle. The accuracy of the finite element models is verified by the ultimate tensile test and the fatigue test. This study explores the bending deflection results of the short slings of arch bridges due to the different axes of the upper and lower anchorages and provides the necessary theoretical support for the design and fatigue life estimation of the short slings of arch bridges.

Framework for a finite element method-based simulation approach to fatigue assessment of welded joints using the 4R method

The increased tensile strength capacity of high-strength steels (HSS) can be utilized fully in static loads, for fluctuating loads, however, more detailed analysis of design and manufacturing is needed. This study presents a framework for investigating utilization of the finite element method (FEM) in multiparametric 4R method-based fatigue evaluation. More specifically, the aim of the current study is to produce a concept for determining the parameters of the 4R method using FEM, thus providing a tool for evaluating fatigue strength related factors numerically. The study examines gas metal arc welded (GMAW) longitudinal gusset joints made of HSS S700MC Plus. The simulation is carried out as a sequentially coupled welding analysis that includes material condition changes in the HAZ and the fluctuating response as a restart analysis. Experimental measurement is performed for comparison with the results of the numerical model in the intermediate stages of the analysis process, and in the final stage as regards fatigue life. The experimental and simulated sub-results are consistent, and the estimated fatigue lives are in relatively good agreement with the experimental fatigue results. The numerical method thus provides a tool to predict fatigue related factors considered in 4R to evaluate fatigue life of welded joints.

Statistical modeling of microstructurally short crack growth in high cycle fatigue

Capturing the behavior of short cracks under fatigue conditions has become a challenge for researchers. The early stage of crack propagation is influenced by microstructural features, such as grain boundaries and orientations, which leads to significant statistical variations. Models such as the ones developed by Navarro and De Los Rios have been able to describe the process by considering the average properties of the material and estimating the number of cycles related to the short crack stage. However, fatigue should be seen as an extreme value process. In the present work, a more realistic model was developed to consider the statistical nature related to grain orientations to estimate fatigue life dispersion. Eleven crack propagation criteria have been used to compute the number of cycles spent in the short crack stage. Parameters such as the Schmid factor, the potential crack length, and the various angles describing the misorientation between adjacent grains were considered. One thousand random scenarios for short crack growth were studied for each propagation criterion and some statistical analyzes were run to estimate the worst-case scenario out of one million. Results can be well described using the generalized extreme value distribution, capturing the stochastic nature of the fatigue life.

A pragmatic approach for the fatigue life estimation of hybrid joints

The need for more environmentally sustainable ways of transportation and for a reduction in emissions and fuel consumption make lightweight structures essential. Together with the use of lightweight materials and design optimisation, the use of hybrid joints represents one way to reduce the weight of components and it is becoming increasingly popular in the transportation industry. The name ‘hybrid joint’ refers to a connection where adhesive bonding is used in conjunction with traditional joining techniques, such as spot welds and rivets with the aim of combining and exploiting the advantages of the individual joining techniques. To optimise the design of hybrid joints and minimise the risk of in-service fatigue failures, the transportation industry needs efficient, robust, and easy-to-use approaches for the modelling and fatigue life estimation of hybrid joints.This work presents two practical methodologies for estimating the fatigue life of hybrid joints that can be easily adopted by companies in the transportation industry. The first methodology neglects the life given by the mechanical joints after failure of the adhesive (the joint is considered failed when the adhesive fails), while the second methodology considers the life of both the adhesive and the mechanical joints. In the first methodology, just one configuration would need to be analysed (‘hybrid’ joint or ‘purely bonded’ joint, if this simplification is considered reasonable). In the second methodology, instead, the analysis of two configurations would be required (the previous configuration followed by a configuration where only the mechanical fasteners are considered). The second methodology would produce more realistic fatigue life estimations compared to the first methodology, but it would be more onerous both in terms of modelling and computationally. For both methodologies, FE modelling guidelines to recover the required stresses are suggested. These guidelines require limited changes to the typical FE modelling strategies currently used, especially in the automotive industry. Furthermore, the proposed modelling guidelines provide FE models that are not computationally too onerous, reasonably mesh insensitive and that do not require congruent meshes. The relevant stresses recovered from the FE model are then used as an input into nCode DesignLife to estimate the fatigue life of the hybrid joints in the analysed structure. The fatigue life estimation is carried out using standard Stress-Life (SN) based nCode DesignLife analysis engines and bespoke SN curves obtained through testing of hybrid joint specimens, representative of the joints in the production parts.

A practical methodology for the fatigue life estimation of adhesive joints

The use of adhesives in structural joints as an alternative to traditional joining techniques, such as welding and rivets, is becoming increasingly popular in the transportation industry, including (but not limited to) automotive and aerospace. This trend is driven especially by the increasing need and focus on greener ways of transportation and the consequent light weighting requirements. Furthermore, adhesives have the significant advantage, over traditional joining techniques, of allowing joining of dissimilar materials, including composites. Therefore, to optimise the design of adhesively bonded structures and reduce the risk of in-service fatigue failures, the transportation industry needs efficient, robust, and easy-to-use approaches for the modelling and fatigue life estimation of adhesively bonded joints.This work presents a practical methodology for estimating the fatigue life of adhesively bonded joints that can be easily adopted by companies in the transportation industry. The proposed methodology includes Finite Element (FE) modelling guidelines to recover the required stresses along the bond lines, with limited changes to the typical FE modelling strategies currently used, especially in the automotive industry. It is proposed to model the adherends using shell elements and the adhesive layer with solid elements. The exposed edges of the adhesive are then wrapped with membrane shell elements used to extract the peel stresses. The solid elements and the shell elements are connected using ‘bonded contacts’ (or similar tools, depending on the FE software used). The proposed modelling guidelines provide FE models that are not computationally too onerous, with a good level of mesh insensitivity and that do not require congruent meshes. The peel stresses recovered from the FE model along the bond lines are then used as an input into nCode DesignLife to estimate the fatigue life of the bonded joints in the analysed structure. The fatigue life estimation is carried out using the standard nCode DesignLife SN analysis engine and bespoke SN curves obtained through testing of adhesively bonded specimens, representative of the joints in the production parts.

Fatigue Analysis of Steering Knuckles Using the Local Strain Approach

The study investigates the mechanical properties and fatigue behavior of steering knuckles used on commercial vehicles. The steering knuckle is made of hot forged bainitic steel (18MnCrMoV6-4-8), which is known to demonstrate high levels of fatigue strength, toughness, and hardness. The local strain concept was adopted to assess the durability of the steering knuckle based on the stabilized cyclic material behavior. For this purpose, experimental investigations have been conducted on both the steering knuckle as well as fatigue specimens under constant and variable amplitude loadings. The fatigue specimens were removed from the area next to the crack initiation location, to represent the microstructure in the critical area of the component. Fatigue life estimations were performed under different load ratios using the FKM guideline nonlinear, employing damage parameters PRAM and PRAJ. The assessment enables a fatigue strength assessment for the steering knuckle by considering the local non-linear material behavior. The estimations of the material's fatigue lifetime using the FKM guideline nonlinear approach were unsatisfactory.

Local relaxation of residual stress in HFMI-treated high-strength steel welded joints subjected to high-peak loads

This study investigates the effect of high-peak loads on local relaxation of residual stress and fatigue damage in HFMI-treated high-strength steel welded joints. The finite element simulations are applied to consider the combined effect of geometry, material, and residual stress. This simulation model specifically contains the actual treated surface profile with material imperfections. As a result, the material imperfections highly influence the local elastic-plastic behavior under load conditions, including a high tensile and compressive peak load, thus the local relaxation of residual stress and fatigue damage. The results provide further understanding towards a robust modeling approach to the fatigue life estimation of HFMI-treated welds subjected to high-peak loads.

Numerical and experimental fatigue strength evaluation of thin-walled aluminum components for aerospace application manufactured by roll forming

The design of structural components for use in commercial aircraft places high demands on the safety under static and cyclic loading conditions during the total operating time. With immerging innovative developments in the production of thin-walled sheet metal components, savings in energy consumption and material are achievable by switching from metal-cutting production to forming operations. As the forming process has an impact the local material properties due to resulting residual stress state, cold working and surface finish, the fatigue life estimation requires the consideration of the forming history.The structural component under consideration from aluminum alloy EN AW-7475 T761 is manufactured by automated, robot-assisted roll forming. Potentially existing residual stresses are determined via process simulation of the angled profile utilizing commercial finite element solver LS-Dyna®. The fatigue life assessment is carried out using the Local Strain Approach for different loading conditions.

Study on fatigue life estimation method of welded structure of lifting machinery

The fatigue strength of lifting machinery structure has always been an important issue in ensuring safety. In order to effectively and accurately evaluate the fatigue life of lifting machinery structure, this paper based on Miner linear cumulative damage theory and S-N curve in British BS 7608 standard, the fatigue life calculation of metal welded structure is carried out. Taking the large-scale bridge crane of hydropower station as an example, the nominal stress of the corresponding key parts is obtained by applying the actual load in the finite element model, and the stress time history is calculated, and then the safe service life of the structure is estimated, which provides an effective and feasible method for evaluating the fatigue residual life of the crane. The example analysis shows that the calculation method is convenient and reliable, which provides a scientific basis for accurately estimating the fatigue life of welded structure of lifting machinery.

Impact of daily and seasonal temperature variation on rolling contact fatigue damage in the rail

Rolling contact fatigue is the most frequent degradation mode observed on the rail. Many mechanical studies have revealed the main physical parameters that generate the crack initiation, which are all linked with the track geometry, the dynamic of the wheel and contact conditions. Except for extreme climate, exogenous phenomena such as ambient temperature have not been analysed. The main reason is that temperature variations induce stress cycles in the rail that are under the endurance limit of the material. Therefore, most fatigue life estimation methods do not consider these cycles. In this paper, 6 years of daily temperature measurement over all the French railway network are used and integrated in a machine learning model developed for computing residual lifespan of each rail segment before crack initiation by rolling contact fatigue. Temperature data are aggregated using the continuum damage mechanics model developed by Lemaitre and Chaboche that gives the possibility to let low amplitude cycles to contribute to fatigue damage. Classification models are then implemented, and importance variables are finally quantifed. Results show that daily temperature variations have more impact than seasonal variations and that its contribution to fatigue is significant.

Fatigue life estimation of metal materials based on finite element analysis

Fatigue life estimation of metal materials based on finite element analysis