Representative Volume Element Model Research Articles

Experimental characterization and numerical prediction for mechanical aging of epoxy and its carbon fiber‐reinforced composite under hydrothermal conditions

AbstractThe Aqueous environment impairs the mechanical performance of carbon fiber‐reinforced polymers (CFRPs) and decreases the durability of engineering structures made of CFRPs primarily by degrading the resin matrix. Hence, the objective of this study is to investigate and accurately predict the influence of hydrothermal aging on the epoxy and its carbon fiber reinforced polymer (CFRP). Particularly, this work developed a modeling method that combined Fick's model, empirical aging model and elastoplastic constitutive model to predict the mechanical behavior of hydrothermally aged epoxy matrix. After the experimental characterization, this epoxy modeling method demonstrated its predictive capability on the mechanical response of the deteriorated epoxy under different hydro‐thermal‐salt conditions, with the mean absolute percent error (MAPE) of approximately 4.61%. Furthermore, the transverse compressive behavior of unidirectional (UD) CFRPs could be predicted by using the representative volume element (RVE) model with the degraded matrix behavior predicted via this epoxy modeling method. Integrated with this CFRP modeling, results from mechanical tests and fracture analysis further demonstrated that the hydrothermal aging effect on the transverse compressive performance of the UD CFRPs was dominated by the deterioration of their resin matrix. Therefore, this study demonstrates the feasibility of the finite element analysis (FEA) for mechanical aging of the epoxy matrix and its CFRP under hydrothermal conditions via employing the proposed integrated modeling method.Highlights Degradation of epoxy polymer under hydro‐thermal‐salt aging conditions. Integrated model to predict mechanical response of hydrothermally aged epoxy. RVE model to predict the mechanical behavior of hydrothermally aged CFRP. Hydrothermal aging on the transverse compressive behavior of UD CFRP.

Multi-scale study on the mechanical properties of concrete based on crack propagation under hygrothermal coupling

During the long-term service of structures, the environmental temperature and humidity fields can lead to the evolution of the pore structure within concrete materials, thereby affecting changes in mechanical properties. However, the mechanisms of their influence still need further clarification and are challenging to correlate for prediction. Addressing this specific issue, the current study focuses on evaluating 78 cubic concrete specimens with C30 and C40 strength grades. These specimens were subjected to a 95 % humidity environment at temperatures of 40 °C, 60 °C, and 80 °C for durations of 30, 60, and 90 days. The research involved conducting both microstructural and macroscopic mechanical tests to quantify the evolution of internal hydrates, pore structures, and pore distribution, as well as to assess the changes in the macroscopic mechanical properties of the specimens. To accurately predict the process, a multiscale finite element model (FEM) based on the bilinear continuum cohesive damage model was established. This model quantifies the changes in mechanical properties of mesoscopic three-phase concrete due to microcrack evolution under hygrothermal coupling. To facilitate multiscale simulations between the Representative Volume Element (RVE) and macroscopic scale models, relevant subroutines were written using Umath, and parallel computing was employed to reduce the computational burden. For the macroscopic model in this study, a homogenized concrete cube model with dimensions identical to the experimental specimens was selected. The effectiveness of the parallel computational model was validated by comparing and analyzing the simulation results under uniaxial compression with the experimental data. The findings indicate that hygrothermal action leads to the initiation and expansion of microcracks within the concrete, thereby impacting the alteration of its mechanical properties. In addition, the parallel computing-based multiscale FEM can more accurately quantify the typical damage process of crack propagation while reducing the computational load and may provide relatively accurate predictions of the mechanical characteristics of concrete under the influence of hygrothermal coupling, ensuring effective modeling of macroscopic structural specimens in various temperature and humidity environments.

Multiscale modeling for the impact behavior of 3D angle-interlock woven composites

In this paper, a multiscale modeling framework predicting the impact response of three-dimensional angle-interlock woven composites (3DAWCs) is presented. Multiscale modeling is performed sequentially at the mirco, meso, and macroscales. A microscopic representative volume element (RVE) model is established to characterize the yarn's nonlinear mechanical properties and damage behavior at different strain rates. At the mesoscale, a novel subcell-based discretization scheme is proposed to discretize 3DAWCs, and developing six representative subcells (RSCs) that bridge the microscale and macroscale effective properties. Based on it, a ballistic impact model involving six kinds of homogeneous material bricks is established. Furthermore, elastic-viscoplastic damage constitutive models are developed for the epoxy matrix and the yarn, respectively, to enhance the predicted accuracy of the multiscale model. Ballistic impact tests of 3DAWCs are conducted, and X-ray micro-computed tomography is employed to evaluate the internal damage of the 3DAWC target after impact. Validation work is conducted by comparing the experimental and numerical results of the ballistic impact of the 3DAWC target, which indicates the effectiveness and efficiency of the developed multiscale framework in the impact damage prediction of 3DAWCs.

In-situ deformation inhomogeneity and damage evolution of mixed-grain structure with tempered sorbite/bainite in Fe–Cr–Mo–Mn steel

The inhomogeneous tempered sorbite/bainite (TS/B) with various morphologies and orientations play a significant role in deformation coordination and damage evolution. In this paper, the influence of distinct morphologies and orientations of the mixed-grain structure with TS/B on the deformation heterogeneity were extensively investigated by in-situ tensile testing. Furthermore, a multi-scale model of dislocation density-based crystal plasticity (CP) coupled with the phase field method (PFM) was developed to illustrate the damage nucleation and its evolution via the representative volume element (RVE) modelling. The results shows that mixed-grain structure with TS/B exhibits non-homogeneous deformation during the tensile process, and the coarse grains bear the main plastic deformation, resulting in cross-slip traces and the wrinkling phenomenon at the grain boundary and the interior of coarse grains. Furthermore, the activation of slip systems was determined through slip trace analysis, and the slip transfer behavior between adjacent microstructure was analyzed. According to the critical resolved shear stress (CRSS), the {123}<111> slip system was determined to be the most activated slip system during the in-situ deformation. Hard-orientated lath-shaped B (M1) is more prone to accumulate low angle grain boundaries (LAGBs) than hard-orientated TS (M2) and soft-orientated granular B (M3), resulting in higher orientation rotation degree and geometrically necessary dislocations (GNDs) density of M1 than M2 and M3. The M1 exhibits the nucleation of damage during the initial deformation stage. In addition, compared with the M2 and M3, the Schmid factor (SF) of M1 dominates the transformation from hard orientation to soft orientation and the higher value of damage factor (φ) of M1 results in the more activated slip systems and local damage at high strain levels. This study provides new insights into elucidate the effects of TS/B morphologies and orientations on deformation heterogeneity and damage evolution in large-scale forged spindles for offshore wind power.

Integrating Experimental and Computational Analyses for Mechanical Characterization of Titanium Carbide/Aluminum Metal Matrix Composites.

This study investigates the mechanical properties of titanium carbide/aluminum metal matrix composites (AMMCs) using both experimental and computational methods. Through accumulative roll bonding (ARB) and cryorolling (CR) processes, AA1050 alloy surfaces were reinforced with TiCp particles to create the Al-TiCp composite. The experimental analysis shows significant improvements in tensile strength, yield strength, elastic modulus, and hardness. The finite element analysis (FEA) simulations, particularly the microstructural modeling of RVE-1 (the experimental case model), align closely with the experimental results observed through scanning electron microscopy (SEM). This validation underscores the accuracy of the computational models in predicting the mechanical behavior under identical experimental conditions. The simulated elastic modulus deviates by 5.49% from the experimental value, while the tensile strength shows a 6.81% difference. Additionally, the simulated yield strength indicates a 2.85% deviation. The simulation data provide insights into the microstructural behavior, stress distribution, and particle-matrix interactions, facilitating the design optimization for enhanced performance. The study also explores the influence of particle shapes and sizes through Representative Volume Element (RVE) models, highlighting nuanced effects on stress-strain behavior. The microstructural evolution is examined via transmission electron microscopy (TEM), revealing insights regarding grain refinement. These findings demonstrate the potential of Al-TiCp composites for lightweight applications.

Fracture behavior of composite piezoelectric intelligent structures formed by pasting MFC based on serial multi-scale method

The composite piezoelectric intelligent structures formed by combining piezoelectric materials with composite materials can achieve state perception and deformation control of the structure. Based on the molecular dynamics method, the continuum finite element method and the cohesive force model, the serial multi-scale research on the bonded composite piezoelectric intelligent structure was carried out from the micro, meso and macro scales. Molecular models of adhesive, macro fiber composite (MFC) surface and composite surface were established. The effects of temperature and pressure on the surface interaction energy of adhesive/MFC and adhesive/composite materials were analyzed. The traction-separation (T-S) relationship of cohesive region was obtained by virtual stretching method. Combined with the microscopic observation of the mesoscopic adhesive layer, the representative volume element (RVE) model of the mesoscopic adhesive layer considering the bubble defect was established, and the cohesive relationship curve of the adhesive layer was obtained. A double cantilever beam (DCB) macro finite element model was established to simulate the crack propagation behavior of the adhesive layer, and compared with the experimental results.

High‐Temperature Thermal Conductivity of Fiber Hybrid Ceramic Matrix Composites with Different Modes

Thermal conductivity (TC) is one of the important thermal property evaluation parameters for high‐temperature‐resistant fiber‐reinforced composites. Herein, based on the flexible‐oriented three‐dimensional (3D) woven technology, fiber hybrid ceramic matrix composites (FH‐CMCs) with different hybrid modes are designed and fabricated by using carbon fiber and silicon carbide fiber. The representative volume element (RVE) models of fiber bundle and matrix with mesoscopic characteristics and the macroscopic RVE models with hybrid structure characteristics are established. The heat flux distribution and effective TCs of FH‐CMCs in the thickness and in‐plane directions at different temperatures are obtained by finite element analysis (FEA) and experimental tests. The results show that the FEA and experimental results of the TCs of different FH‐CMCs are in good agreement. In the range of 25–1000 °C, the effective TCs of FH‐CMC gradually decrease with the increase in temperature. The TCs in the thickness direction of different FH‐CMCs are directly proportional to the hybrid ratio, and the TCs in the in‐plane direction are inversely proportional to the hybrid ratio. The heat flux and temperature field distributions of the FH‐CMCs are mainly affected by the TCs of the components, fiber hybrid ratio, and orientation, and the distribution along different directions are obviously different. The research results are helpful to provide theoretical and experimental reference for the structural design and performance improvement of hybrid composites.

A Multi-Scale Analysis of Unidirectional Carbon Fiber-Reinforced Polymer Composite

In this paper, a multi-scale computational analysis is conducted based on representative volume element (RVE) modeling and molecular dynamics (MD) simulation of a carbon fiber-reinforced polymer composite micropillar. The fiber distribution in the micropillar was obtained from a specimen manufactured for real micropillar mechanical testing. Based on the failure modes directly observed from the micropillar testing, the RVE model aims to capture the major failure mechanism, which is the fiber/matrix interface failure of the composite. In the finite element model, the properties of each individual phase, namely, the fiber and the matrix are first identified. Then, cohesive elements are incorporated into the interphase region between the fiber and matrix to capture the interphase debonding. Finally, the global stress–strain relation of the composites is obtained and compared to experimental results. A good correlation was found. Due to convergence difficulties associated with stiffness degradation, the simulation was performed in the commercial software ABAQUS/Explicit. A Molecular dynamics simulation is performed to investigate the stress–strain relation and shear strength of carbon fiber-reinforced polymer composites at nanoscale. The compressive strength and stiffness obtained from MD simulation were lower than that observed from experiments. Interface debonding is a critical failure mode, of which the failure strength is determined from fiber pull-out simulation. The results can be used in RVE simulation to deduce the interphase properties. The modeling method allows the detailed failure mechanisms of the composite microstructure to be captured and a correlation between the micro-properties and macro-properties of the material to be established.

Crystal plasticity modeling fatigue behavior in bimodal Ti–6Al–4V: Effects of microdefect and lamellar orientation

AbstractInvestigating fatigue failure in titanium alloys is crucial for material design and engineering. Fatigue behavior in dual‐phase titanium alloys is strongly correlated with microstructural features and microdefects. This work formulates an improved modeling method to investigate fatigue behavior of bimodal Ti–6Al–4V, emphasizing the effects of lamellar orientation and microdefects. Using an improved Voronoi tessellation method, we establish representative volume element (RVE) models with various grain size distributions. Crystal plasticity finite element modeling (CPFEM) is used to analyze fatigue deformation in bimodal Ti–6Al–4V, considering microdefects and lamellar orientation. Fatigue indicator parameters are then incorporated into CPFEM to predict fatigue life and verified with experimental data. Numerical results highlight the significant influence of lamellar orientation and microdefects on fatigue behavior, with predicted life within the 3‐error band. This method efficiently overcomes challenges in quantitatively characterizing microstructural lamellae that experiments are short of, paving the way for designing fatigue‐resistant alloy materials with similar microstructures.

Fabrication, mechanical, finite element and In vitro evaluation of 3D printed polylactide/biphasic calcium phosphate composite blends

Polylactic acid (PLA) reinforced with biphasic calcium phosphate mixtures were extruded as filaments and subsequently 3D printed into definite shapes in accordance with the ASTM standards. The optimum combination of PLA and BCP to attain a stable 3D printed component has been respectively determined as 80 and 20 wt %. BCP inclusions in the range of 2.5 and 5 wt % in PLA led to a respective upsurge ∼11 % in tensile strength and ∼15 % upsurge in compressive strength than pure PLA. While excess BCP additions led to a decline in the material strength. Further, representative volume element models were developed using the properties of BCP and PLA to build ASTM models for performing Finite element analysis (FEA) under both static and dynamic loading conditions. FEA results specified good uniformity with the experimental mechanical data. In vitro tests ensured the biocompatibility of 3D printed PLA-BCP composites.

Machine learning in solid mechanics: Application to acoustic metamaterial design

AbstractMachine learning (ML) and Deep learning (DL) are increasingly pivotal in the design of advanced metamaterials, seamlessly integrated with material or topology optimization. Their intrinsic capability to predict and interconnect material properties across vast design spaces, often computationally prohibitive for conventional methods, has led to groundbreaking possibilities. This paper introduces an innovative machine learning approach for the optimization of acoustic metamaterials, focusing on Multiresonant Layered Acoustic Metamaterial (MLAM), designed for targeted noise attenuation at low frequencies (below 1000 Hz). This method leverages ML to create a continuous model of the Representative Volume Element (RVE) effective properties essential for evaluating sound transmission loss (STL), and subsequently used to optimize the overall topology configuration for maximum sound attenuation using a Genetic Algorithm (GA). The significance of this methodology lies in its ability to deliver rapid results without compromising accuracy, significantly reducing the computational overhead of complete topology optimization by several orders of magnitude. To demonstrate the versatility and scalability of this approach, it is extended to a more intricate RVE model, characterized by a higher number of parameters, and is optimized using the same strategy. In addition, to underscore the potential of ML techniques in synergy with traditional topology optimization, a comparative analysis is conducted, comparing the outcomes of the proposed method with those obtained through direct numerical simulation (DNS) of the corresponding full 3D MLAM model. This comparative analysis highlights the transformative potential of this combination, particularly when addressing complex topological challenges with significant computational demands, ushering in a new era of metamaterial and component design.

Micromechanical modeling for longitudinal tensile property of unidirectional CFRP considering dispersion of fiber properties

Longitudinal tensile failure prediction has always been the focus of research on unidirectional (UD) Carbon Fiber Reinforced Polymer (CFRP). In this paper, the longitudinal tensile tests of unidirectional T800 grade carbon fiber reinforced epoxy resin composite were carried out first. The experimental stress–strain curves show that there are obvious progressive damages before the final failures of the specimens. However, this phenomenon is usually neglected in most of the existing investigations and tests to only obtain elastic modulus and ultimate strength. Thus, a Representative Volume Element (RVE) model based on micromechanics was established using finite element method, considering the randomness of fiber spatial distribution and fiber strength. The tensile strength of fiber monofilaments was assumed to follow a statistical two-parameter Weibull distribution. The failure process of UD composite under longitudinal tensile load was simulated by explicit finite element method. The stress–strain curves obtained by simulation are in good agreement with the experimental results. Finally, the influence of different boundary conditions on the calculation of the RVE was studied. It is found that the final failure strengths of the RVE with uniform displacement boundary conditions are similar to the case of periodic boundary conditions, while the former has higher computational efficiency.

Experimental study and crystal plasticity modeling of additive manufacturing IN718 superalloy considering negative strain rate sensitivity behavior

Revealing underlying mechanisms of IN718 superalloy's negative strain rate sensitivity behavior at elevated temperatures is significantly important for its further applications in extreme conditions. This work investigates the microstructural mechanisms of the temperature-dependent strain rate sensitivity using experimental methods and crystal plasticity characterization model. Firstly, Electron backscatter diffraction (EBSD) and scanning electron microscopy (SEM) techniques are utilized to observe microstructural characteristics of additively manufactured IN718 alloy at different temperatures. The influence of solute precipitation and dislocation slip interaction on the mechanical properties is discussed. Subsequently, the representative volume element (RVE) model is constructed by using acquired orientation, grain size, and dislocation density data. Finally, the crystal plasticity model incorporating dynamic strain aging and dislocation density evolution is developed to characterize the relationship between strain rate sensitivity and temperature. The model can effectively simulate the transition of strain rate sensitivity of additive manufacturing materials. The results indicate that the increase in dislocation pinning caused by intensified carbon element precipitation at high temperatures is the primary reason of the strain rate sensitivity change observed in IN718 metal materials. The carbon precipitated at the dislocation nucleus induces serration flow in IN718 superalloy under high strain. This study contributes to understanding and characterizing the microscopic mechanisms of deformation in metal materials subjected to thermal environments.

Prediction of Thermo-Mechanical Properties of 8-Harness Satin-Woven C/C Composites by Asymptotic Homogenization.

The elasticity matrix and the coefficients of thermal expansion (CTEs) of 8-harness satin-woven (8HS) carbon-fiber-reinforced carbon matrix (C/C) composites at high temperatures were obtained by the asymptotic homogenization method (AHM) and finite element method (FEM). By analyzing the microstructure of the 8HS C/C composites, a representative volume element (RVE) model considering a braided structure was established. The effects of the temperature and component volume fraction on the elasticity matrix and CTEs of the composites were investigated. The sensitivity of model parameters, including the size of RVE model and mesh sensitivity, were studied. The optimal calculation model was employed. In addition, the effects of the 4HS methods and 8HS methods on the elastic constants of the composites were compared. The temperature and variation in the carbon fiber volume fraction were found to have a significant impact on the elasticity matrix and CTEs of composite materials. At the same volume fraction of carbon fibers, some elastic coefficients of the 4HS composite material were slightly lower than those of 8HS composite material. This research affords a computational strategy for the accurate prediction of the themo-mechanical properties of satin-woven C/C composites.

NEPE Propellant Mesoscopic Modeling and Damage Mechanism Study Based on Inversion Algorithm.

To accurately characterize the mesoscopic properties of NEPE (Nitrate Ester Plasticized Polyether) propellant, the mechanical contraction method was used to construct a representative volume element (RVE) model. Based on this model, the macroscopic mechanical response of NEPE propellant at a strain rate of 0.0047575 s-1 was simulated and calculated, and the parameters of the cohesive zone model (CZM) were inversely optimized using the Hooke-Jeeves algorithm by comparing the simulation results with the results of the uniaxial tensile test of NEPE propellants. Additionally, the macroscopic mechanical behavior of NEPE composite solid propellants at strain rates of 0.00023776 s-1 and 0.023776 s-1 was also predicted. The mesoscopic damage evolution process of NEPE propellants was investigated by the established model. The study results indicate that the predicted curves are relatively consistent with the basic features and change trends of the test curves. Therefore, the established model can effectively simulate the mesoscopic damage process of NEPE composite solid propellants and their macroscopic mechanical properties.

Experimental study and numerical simulation of transverse tensile behavior for thermoplastic glass fiber reinforced plastics

In order to predict the mechanical behavior of thermoplastic composites, the phases of glass fiber reinforced plastics (GFRP) were discretized within the computational micromechanics framework. This approach incorporated the random distribution of fibers, nonlinear matrix behavior, and interface damage behavior in a synergistic manner. Subsequently, a three-dimensional representative volume element (RVE) model was established. To verify the accuracy of the numerical model, macroscopic transverse tensile experiments on GFRP were designed. Building upon this foundation, a detailed study on the damage failure of GFRP under transverse tensile loads was conducted to reveal the damage evolution mechanisms. Furthermore, the influence of the random distribution of fibers, nonlinear characteristics of the matrix, and interfacial parameters on the transverse damage mechanical behavior of GFRP was elucidated. The results demonstrate that the random distribution of fibers significantly affects the damage initiation point and crack evolution path. Moreover, GFRP with higher interfacial performance exhibits substantially improved transverse tensile strength compared to those with lower interfacial performance.

Hybrid reinforcing effect of multi-scale short carbon fibers on the wear resistance of PTFE composites: Self-reconstruction and stress transmission

This study investigates the mechanical properties and tribological behavior of multi-scale hybrid short carbon fibers (SCFs)-reinforced polytetrafluoroethylene (PTFE) composites. The optimization of 0.5 mm SCFs (SSCFs) and 400 mesh SCFs (LSCFs) ratios was studied based on the representative volume element (RVE) model. The experimental results show that the specific wear rate of the composite is reduced by 91.1% and 93.3% respectively compared to the addition of SSCFs and LSCFs alone. Electron microscopy and surface SCFs cross-sectional area characterizations reveal that the internal LSCFs effectively transfer stress to improve the mechanical properties of the composites, and the self-orientation and enrichment (self-reconstruction) of SSCFs on the friction surface together lead to outstanding wear resistance of the composites.

Multiscale modelling of damage occurrence of eutectic phase in Al–Ni–Mn alloy

Aluminum-nickel binary alloys exhibit good thermal stability. However, by adding Mn microstructures of the alloy are largely changed and resulting mechanical properties could be significantly affected. A microstructure based approach coupled with damage criteria was proposed for investigating local stress, strain developments and damage mechanisms on the micro-scale of Al–4Ni–1Mn with Sc and Zr alloy. For the model, flow curves of each constituent phase were determined using both experiments and dislocation theory. Tensile test results of the alloy showed that damage mostly initiated within α-Al matrix and afterwards propagated to eutectic phase region. Therefore, the Hosford-Coulomb ductile damage model was employed for describing failure evolution of the Al matrix. The representative volume element (RVE) model fairly demonstrated microstructure deformation of a mini-tensile sample. Then, effects of different phase morphologies on local damage onset of the examined alloy were analyzed. It was found that eutectic particles with aspect ratio higher than 7 and oriented in parallel to loading direction were the most critical sites of cracking. This result was in accordance with experimental fracture analyses.

Effect of void defects on mechanical behavior and failure features of C/C honeycomb structure

The combination of honeycomb structure and carbon/carbon (C/C) composites offers unique high load-bearing and light-weight advantages in satellite-bearing platforms. However, the defects generated by the imperfect preparation process are inevitable. This paper employs the chemical vapor infiltration (CVI) technique to fabricate novel C/C honeycomb structures and considers the presence of internal void defects. Based on micro-computerized tomography (μ-CT) images, the void distribution and porosity as well as the micro-structure characteristics are acquired. Meso-scale representative volume element (RVE) models is established to predict the performance of honeycomb wall material. A secondary development of ABAQUS is performed to establish a model of honeycomb structure containing void defects. Multi-scale models are developed for investigating the mechanical performance of the C/C honeycomb structure. Experimental methods and finite element simulations are utilized to examine the effects of porosity and different weave structures on the compression and shear properties, as well as damage modes of C/C honeycomb structures in detail. The results demonstrate that the presence of low porosity ρ = 1 % severely diminishes the load-bearing capacity of the honeycomb and affects its damage pattern. Twill-2 weave C/C honeycomb inherits the advanced performance of the composites and exhibits superior comprehensive properties compared to plain weave and twill-1 weave honeycomb structures.

Correlation between Surface Integrity and Low Cycle Fatigue Life of Machined Inconel 718

This work aims to improve the surface integrity and LCF life of machined Inconel 718. The correlation between the LCF life of Inconel 718 and various states of machined surface integrity is explored. In this paper, the surface integrity of Inconel 718 specimens is enhanced by low-plasticity burnishing (LPB). The LCF life of specimens with different surface integrity is predicted using a micro–macro finite element method (FEM). Firstly, the LCF specimens with different surface integrity are machined by turning (turned specimen), polishing (matrix specimen), and LPB process (LPBed specimen). Secondly, the LCF experiment is carried out to reveal the effect of surface integrity on LCF life. Finally, the LCF micro–macro FEM model is proposed to predict the LCF of machined Inconel 718 specimens. The representative volume element (RVE) model is established based on the measured surface integrity and microstructure of Inconel 718 specimens. The effect of surface integrity on LCF life is transformed to equivalent load. The micro–macro FEM model combined with Tanaka–Mura dislocation crack initiation theory and extended finite element method (XFEM) is applied to predict the LCF life of the machined specimens. The study results show that the LCF life of LPBed specimens can be improved by 90.5% and 36.1% compared with that of turned specimens and polished matrix specimens, respectively. The errors between FEM prediction results and experimental results are 13.1%, 9.2%, and 12.2%, respectively. The proposed micro–macro FEM model could be utilized to predict the LCF life of Inconel 718 with different surface integrities, and to apply the LCF life prediction further in industry.