Gigacycle fatigue behaviors of two SNCM439 steels with different tensile strengthes

Gigacycle fatigue behaviors of two SNCM439 steels with different tensile strengthes were experimentally studied by rotating bending tests,to investigate the effects of the tensile strength obtained by different heat treatment processes on very high cycle fatigue failure mechanisms.The material with higher tensile strength of 1 710 MPa exhibited typical gigacycle fatigue failure characteristics,whereas one with lower tensile strength of 1 010 MPa showed only traditional fatigue limit during the tests and no ...     

Particle flow study on strength and meso-mechanism of Brazilian splitting test for jointed rock mass

A discrete element method （DEM） called particle flow code （PFC2D） was used to construct a model for Brazilian disc splitting test in the present study. Based on the experimental results of intact Brazilian disc of rock-like material, a set of micro-parameters in PFC2D that reflected the macro-mechanical behavior of rock-like materials were obtained. And then PFC2D was used to simulate Brazilian splitting test for jointed rock mass specimens and specimen containing a central straight notch. The effect of joint angle and notch angle on the tensile strength and failure mode of jointed rock specimens was detailed analyzed. In order to reveal the meso-mechanical mechanism of crack coalescence, displacement trend lines were applied to analyze the displacement evolution during the crack initiation and propagation. The investigated conclusions can be described as follows. （1） The tensile strength of jointed rock mass disc specimen is dependent to the joint angle. As the joint angle increases, the tensile strength of jointed rock specimen takes on a nonlinear variance. （2） The tensile strength of jointed rock mass disc specimen containing a central straight notch distributes as a function of both joint angle and notch angle. （3） Three major failure modes, i.e., pure tensile failure, shear failure and mixed tension and shear failure mode are observed in jointed rock mass disc specimens under Brazilian test. （4） The notch angle roles on crack initiation and and joint angle play important propagation characteristics of jointed rock mass disc specimen containing a central straight notch under Brazilian test.     

高强度钢的超高周疲劳裂纹扩展模型研究

当疲劳寿命在106或107周时,Wöhler S-N 曲线被看作渐近于水平轴,107的疲劳强度被看成是疲劳极限。现代应用要求延长零件的工作寿命,实际齿轮部件应用超过107循环的疲劳失效。本文应用压电超声疲劳试验机对经过热处理和渗碳处理后的低铬合金钢材料进行研究,采用红外摄像仪观测试件表面的温度场随疲劳裂纹萌生和扩展的过程。试验条件是室温,应力比为0.1（R=0.1）,频率为20KHz。通过对表面渗碳处理后试件的断口分析,探讨表面渗碳处理、微观结构和与杂质有关的断裂机理,根据Paris公式建立超高周疲劳裂纹扩展模型。对裂纹扩展过程中裂纹尖端的塑性区的分析结果,结合传热学原理,建立热耗散模型,有限元方法的数值解结果较好地符合红外摄像仪的观测的试验结果。     

试样疲劳性能尺度效应的概率控制体积方法

试样尺度、缺口和加载方式通常对材料的疲劳性能具有重要影响. 因此,发展关联试样尺度、缺口和加载方式对疲劳强度影响的方法对于从材料疲劳性能到结构件疲劳性能的预测具有重要意义.首先,采用旋转弯曲加载和轴向加载方式对不同几何形状EA4T车轴钢试样进行了疲劳实验.实验结果表明, 由于试样尺度的增加,轴向加载下狗骨形试样的疲劳强度明显低于沙漏形试样; 相同寿命下,缺口显著降低试样的疲劳强度. 疲劳断口扫描电镜观测结果表明,疲劳裂纹均起源于试样表面.沙漏形试样和狗骨形试样疲劳断口大多只有一个裂纹源,而缺口试样疲劳断口均具有多裂纹源特征. 然后,采用概率控制体积方法研究了试样尺度、缺口和加载方式对疲劳强度的影响,并与临界距离和应变能密度方法进行了比较. 结果表明,概率控制体积方法能够更好地关联试样尺度、缺口和加载方式对EA4T车轴钢疲劳强度的影响.最后, 提出一种基于控制体积的结构件疲劳强度预测方法,并用于具有不连续高应力区域车轴钢试样的疲劳强度预测,预测结果与实验结果 吻合.      

Tensile and Tensile-Mode Fatigue Testing of Microscale Specimens in Constant Humidity Environment

A tensile and tensile-mode-fatigue tester has been developed for testing microscale specimens in high humidity environments in order to investigate the fracture mechanisms of microelectromechanical materials. A humidity control system was installed on a tensile-mode fatigue tester equipped with an electrostatic force grip. A specimen and a griping device were inserted into a small chamber and the humidity was controlled by air flow from a temperature and humidity chamber. The humidity stability was within ±2%RH for humidities in the range 25–90%RH for eight hours of testing. Fatigue tests were performed on single-crystal silicon (SCS) specimens in constant humidity environments and laboratory air for up to 10⁶ cycles. The gauge length, width, and thickness of the SCS specimens were 100 or 500 μm, 13.0 μm, and 3.3 μm, respectively. The average tensile strength was 3.68 GPa in laboratory air; this value decreased in high humidity environments. Fatigue failure was observed during cyclic loading at stresses lower than the average strength. A reduction in the fatigue strength was observed at high relative humidities. Different fracture origins and fracture behaviors were observed in tensile tests and fatigue tests, which indicates that the water vapor in air affects the fatigue properties of SCS specimens.     

交变载荷下含两孔洞的铝合金长条的五种疲劳破坏型式

通过试验发现交变载荷下含两孔洞的铝合金长条,由于两孔洞的方位不同,至少有五种疲劳裂纹引起的破坏型式.在五种不同的破坏情况下,疲劳裂纹初始寿命和疲劳裂纹扩展寿命均不同,必须分阶段评估,这也直接影响到整体疲劳寿命的预计;此时常规的、经典的疲劳裂纹扩展理论难以直接应用.     

考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测研究

微动疲劳是矿井提升钢丝绳主要失效形式之一,在钢丝微动疲劳过程中,微动磨损严重影响钢丝微动疲劳裂纹扩展特性,进而制约钢丝微动疲劳断裂机制,故开展考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测研究至关重要. 运用自制钢丝微动疲劳试验机开展钢丝微动疲劳试验和拉伸断裂试验,通过高速度数码显微系统揭示微动疲劳过程中钢丝微动磨损演化、裂纹萌生和扩展及断裂特性,基于摩擦学和断裂力学理论,运用有限元法、循环迭代法和虚拟裂纹闭合技术建立了考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测模型,并进行试验验证. 结果表明:采用微动疲劳过程稳定阶段磨损系数预测钢丝微动磨损演化可保证预测正确性,微动疲劳过程中钢丝主要为I型裂纹扩展模式,考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测值和试验值吻合较好,验证了预测模型正确性.      

Flexural fatigue behavior of threaded connections for large diameter pipes

Full-scale flexural fatigue tests were conducted to investigate the fatigue behavior of a patented threaded connection for large diameter (0.61 m (24 in) outside diameter, 25.4 mm (1 in) wall thickness) offshore pipes. Fifteen fatigue tests were performed by subjecting the threaded connection to constant amplitude stress ranges (between 69 MPa (10 ksi) and 151.8 MPa (22 ksi) on gross cross section) with zero mean stress. The corresponding measured fatigue lives varied from 45000 to 4852200 cycles. Fatigue failures were in the form of cracks through the thickness of the wall and located at the root of the first full contact thread. The failure surfaces were ‘typical’ with identifiable zones of crack initiation, propagation and fracture. Linear regression analysis of the experimental results, namely the applied stress range (S _r ) and the measured number of cycles to failure (N) data, in the log-log domain gave anR ² value of 0.88 and the least-squares best fit equation asS _r (MPa)=1573.2N ^−0.212. The 90% probable fatigue strength prediction equation was estimated asS _r =1393.8N ^−0.212. This equation is recommended for design purposes.     

CrMoV合金钢的微动疲劳实验研究

本文利用一种自行设计的微动疲劳实验装置研究CrMoV合金钢的微动疲劳特性。作者研究了接触压力对材料微动疲劳寿命的影响规律,得到了研究条件下CrMoV合金钢的接触压力阈值。当接触压力较小时,微动桥压块与试件表面间有相对滑动,微动疲劳寿命随接触压力的增加快速下降;当接触压力达到或超过阈值62.5MPa时,微动疲劳寿命达到最低值并不再随接触压力的增加而下降。本文给出了CrMoV合金钢在接触压力为225MPa的微动疲劳曲线和零接触压力(纯)疲劳曲线,并给出微动疲劳强度与常规疲劳强度的关系,分析了微动疲劳破坏的微观机理。     

不均匀组织ER8车轮滚动接触疲劳性能研究

针对含不均匀组织ER8车轮服役过程中过早出现滚动接触疲劳(RCF)损伤这一实际问题,通过RCF试验,获得了车轮不均匀组织和正常组织的RCF极限;利用光学显微镜(OM)和透射电镜(TEM)重点表征了RCF裂纹萌生处的微观组织. 借助扫描电镜(SEM)和原位拉伸试验台测试了两种组织的弹、塑性能并原位观察了裂纹的扩展行为. 结果表明:车轮踏面不均匀组织的RCF极限低于轮辋正常组织,不均匀组织中除车轮正常组织应有的珠光体和先共析铁素体组织外,还存在大量的上贝氏体,上贝氏体的存在破坏了车轮正常组织的连续均匀性. RCF裂纹的萌生和扩展主要发生在上贝和正常组织的边界处,上贝氏体的硬度、弹性高于正常组织,但塑性小于正常组织,在相同接触应力作用下,两者弹-塑性变形的不协调是导致其组织边界处产生应力集中,进而诱发并促进疲劳裂纹的萌生和扩展,加速车轮RCF损伤出现的主要原因.      

含缺口试件疲劳全寿命预测一种建议的方法

传统的研究含缺口构件的疲劳的方法是将疲劳启裂和疲劳裂纹扩展两个过程完全独立起来,用不同的方法来模拟,相互间并没有定量的关系。本文是基于最新发展的多轴疲劳损伤理论,建立了一种适用于各种载荷条件下的疲劳启裂和裂纹扩展的普适方法。根据从弹塑性分析中得到的应力应变,确定疲劳损伤模型,建立能够预测疲劳启裂、裂纹扩展速率和扩展方向的新方法。整个模拟可以分为两步:弹-塑性应力分析得到材料的应力应变分布;再运用一个通用的疲劳准则预测疲劳裂纹启裂和裂纹扩展。通过对1070号钢含缺口试件的疲劳全寿命预测,得到了与实验非常吻合的模拟结果。     

Fatigue life assessment of a high strength steel 300 M in the gigacycle regime

The fatigue behavior of a high strength steel 300 M in the gigacycle regime was investigated. Fully reversed tension — compression fatigue tests at ambient temperature were performed using an ultrasonic fatigue system operating at 20 kHz. The staircase test method was employed to obtain accurate values of the mean fatigue strength corresponding to fixed numbers of cycles up to 10⁹. These results were compared to the curve which is estimated by the data tested in the mid-long life regime on conventional servo hydraulic test machine at 20 Hz. Results indicate that the fatigue strength determined from ultrasonic fatigue testing is lightly higher than conventional testing in the range of 10⁶–10⁷ cycles. It is obvious that nucleations of fractures tend to occur below the surface, if fractures happen after more than 10⁷ cycles. All the fractured specimens fails from internal SiO₂ inclusions or smaller carbides and carbide clusters.     

Experimental investigation on strength and failure behavior of pre-cracked marble under conventional triaxial compression

Fractures in natural rocks have an important effect on the strength and failure behavior of rock mass, which are often evaluated in rock engineering practice. The theoretical evaluation of mechanical behavior of fractured rock mass has no satisfactory answer due to the role of confining pressure and crack geometry. Therefore, in this paper, conventional triaxial compression experiments were carried out to study the strength and failure behavior of marble samples with two pre-existing closed cracks in non-overlapping geometry. Based on the experimental results of a number of triaxial compression tests, the effect of crack coalescence on the axial supporting capacity and deformation property were investigated with different confining pressures. The results show that intact samples and flawed samples (marble with pre-existing cracks) have different deformation properties after peak stress, which change from brittleness to plasticity and ductility with the increase of confining pressure. The peak strength and failure mode are found depending not only on the geometry of flaw, but also on the confining pressure. The strength of flawed samples shows distinct non-linear behavior, which is in a better agreement with non-linear Hoek–Brown criterion than linear Mohr–Coulomb criterion. For a kind of rock that has been evaluated as a Hoek–Brown material, a new evaluation criterion is put forward by adopting optimal approximation polynomial theory, which can be used to confirm more precisely the strength parameters (cohesion and internal friction angle) of flawed samples. For intact samples, the marble leads to typical shear failure mode with a single fracture surface under different confining pressures, while for flawed samples, under uniaxial compression and a lower confining pressure (σ₃ = 10 MPa), tests for coarse and medium marble (the coarse and medium refer to the grain size) exhibit three basic failure modes, i.e., tensile mode, shear mode, and mixed mode (tensile and shear). Shear mode is associated with lower strength behavior. However, under higher confining pressures (σ₃ = 30 MPa), for coarse marble, the axial supporting capacity is not related to the geometry of flaw. The friction among crystal grains determines the strength behavior of coarse marble. For medium marble, the failure mode and deformation behavior are dependent on the crack coalescence in the sample. The present research provides increased understanding of the fundamental nature of rock failure under conventional triaxial compression.     

An experimental and numerical study of fracture coalescence in pre-cracked specimens under uniaxial compression

This study presents crack initiation, propagation and coalescence at or near pre-existing open cracks or flaws in a specimen under uniaxial compression. The flaw geometry in the specimen was a combination of a horizontal flaw and an inclined flaw underneath. This flaw geometry is different from those reported in the previous studies, where a pair of parallel flaws was used. Three materials were used, PMMA (Poly Methyl MethAcrylate), Diastone (types of molded gypsum), and Hwangdeung granite. Crack initiation and propagation showed similar and different patterns depending on the material. In PMMA, tensile cracks initiated at the flaw tips and propagated to the tip of the other flaw in the bridge area. The cracks then coalesced at a point of the inclined flaw, which is affected by the flaw inclination angle. For Diastone and Hwangdeung granite, tensile cracks were observed followed by the initiation of shear cracks. Coalescence occurred mainly through the tensile cracks or tensile and shear cracks. Crack coalescence was classified according to the crack coalescence types of parallel flaws for overlapping flaw geometry in the past works. In addition, crack initiation and coalescence stresses in the double-flawed specimens were analyzed and compared with those in the single-flawed specimen. Numerical simulations using PFC^2D (Particle Flow Code in two dimensions) based on the DEM (Discrete Element Method) were carried out and showed a good agreement with the experimental results in the coalescence characteristics in Hwangdeung granite. These experimental and numerical results are expected to improve the understanding of the characteristics of cracking and crack coalescence and can be used to analyze the stability of rock and rock structures, such as the excavated underground openings or slopes, tunneling construction, where pre-existing cracks or fractures play a crucial role in the overall integrity of such structures.     

缺口件疲劳寿命分布预测的有效应力法

本文提出了一种由光滑件疲劳寿命试验数据预测缺口件疲劳寿命分布的有效应力法。该方法中缺口件的裂纹可能萌生表面被分解成一个个微元,整个表面可看成是这些微元组成的一个串联模型,按照串联概率失效模型,缺口件的疲劳强度失效概率就可以由各微元的疲劳强度失效概率计算得到,其中微元的疲劳强度失效概率是由光滑件的疲劳强度失效概率通过最弱环节理论计算得到的。在缺口件的疲劳强度失效概率表达式中,引入了有效应力的概念,用它查取光滑件的疲劳寿命试验数据就可以直接得到缺口件的疲劳寿命分布。该方法可以同时考虑到应力梯度和试件尺寸对缺口件疲劳寿命分布的影响。进行了材料LY12CZ的带中心孔缺口件的寿命算例分析,预测结果和试验结果吻合良好,表明该方法是有效的。     

Scaling of size/time/temperature — Part 2: Progressive damage in uniaxial compressive specimen

This work is concerned with predicting the fatigue failure initiation of a wing/fuselage bolt assembly. Accounted for in the analysis are both the influence of energy dissipation and damage accumulation as the structure is subjected to repeated cyclic loading. Results involving the location and number of cycles to initiate a fatigue crack 10⁻² in. are obtained. They agreed both qualitatively and quantitatively with the experimental findings. Also discussed is the influence of pre-torque in the bolt which tends to decrease the number of cycles to fatique crack initiation. Fatigue life may be extended by altering the load path so as to decrease the accumulation of energy near the site of failure initiation. This can be accomplished without major modification of the design. The methodology that makes use of the strain energy density criterion can be used to optimize the fatigue strength of other structural sub-assemblies by appropriate combination of material and geometry for specified load conditions.     

A Study on the Evaluation of the Fracture Process Zone in CCNBD Rock Samples

The safety of many civil and mining concrete and rock structures including pre-existing crack networks is fundamentally affected by the mechanical behaviour of the material under static and cyclic loading. In cyclic loading case, cracks can grow at a lower load level compared to the monotonic case. This phenomenon is called fatigue due to subcritical crack propagation and depends on the behaviour of the fracture process zone (FPZ). This study presents the results of laboratory diametrical compression tests performed on Brisbane tuff disc specimens to investigate their mode-I (tensile) fracture toughness response to static and cyclic loading and relevant FPZ. The FPZ and fracture toughness response to cyclic loading was found to be different from that under static loading in terms of the ultimate load and the damage mechanisms in front of the chevron crack. A maximum reduction of the static fracture toughness (K _IC ) of 42 % was obtained for the highest amplitude increasing cyclic loading test. Detailed scanning electron microscope (SEM) examinations were performed on the surfaces of the tips of the chevron notch cracks, revealing that both loading methods cause FPZ development in the CCNBD specimens. When compared with monotonic FPZ development, the main difference with the cyclically loaded specimens was that intergranular cracks were formed due to particle breakage under cyclic loading, while smooth and bright cracks along cleavage planes were formed under static loading. Further, the SEM images showed that fatigue damage in Brisbane tuff is strongly influenced by the failure of the matrix because of both intergranular and transgranular subcritical fracturing.     

Design of an Impact Loading Machine Based on a Flywheel Device: Application to the Fatigue Resistance of the High Rate Pre-straining Sensitivity of Aluminium Alloys

This paper presents a device that has been designed for tensile loading at medium impact rates (up to 10³ s^–1) and for performing either interrupted or failure tests. This machine allows us to apply prescribed pre-straining to the specimen, and then apply subsequent loading histories such as impact fatigue. Two specimen loading systems are considered, which make it possible to carry out tests with various ranges of force and various durations of time. A multi-CCD camera system is triggered by a chosen threshold from the force signal. The system is dedicated to the displacement measurement and gives both qualitative and quantitative information about the stretching mechanism leading to fracture. To illustrate the performance of the device, experimental results concerning impact tensile tests at a strain rate of about 300 s^–1 are presented, as well as consecutive impact-fatigue tests on two aluminium alloys.     

Resonant fatigue testing of riveted joints

A special test facility was constructed for evaluating the fatigue strength of turbine-blade components under steady pullout and vibratory bending loadings. The use of mechanical resonance for these applications was particularly attractive in that failure in inaccessible areas could be detected by the change in natural frequency of the specimen. The sensitivity of the method allowed determination of a fatigue crack as early in life as possible. The application of this facility to the determination of the fatigue strength of a type of riveted connection employed on certain types of blades is described in this paper. A steady load representing the centrifugal force was applied hydraulically through a long flexible pullrod which in combination with the test specimen was excited laterally at its resonant frequency by an electromagnetic shaker. An accelerometer provided closed-loop control on both vibration amplitude and resonant frequency through special circuitry. Fatigue-strength reduction factors at 10⁷ cycles were determined for three types of riveted test specimens in air at room temperature. These values exceeded the elastic stress-concentration factors estimated from earlier photoelastic tests for all three cases.