A new distortion energy-based equivalent stress for multiaxial fatigue life prediction

A new equivalent stress amplitude expression has been developed for the assessment of fatigue life in components under multiaxial loading. The expression was generated by incorporating non-linear/plastic stress–strain relation into a mechanical energy calculation, and then applying the calculation to the distortion energy theory for a cyclic loading case. Therefore, the new uniaxial equivalent stress expression determines an appropriate stress amplitude value for multiaxial cyclic loading. The purpose of the equivalent stress value is to determine multiaxial fatigue failure using an energy-based fatigue life prediction criterion. The governing understanding behind the criterion states that the physical damage quantity for failure is equal to the accumulated strain energy in a monotonic fracture, which is also equal to the accumulated strain energy during fatigue failure. Using the new equivalent stress amplitude expression and the energy-based life prediction method, a comparison is made between prediction results and multiaxial empirical data. The multiaxial data was acquired by a vibration-based biaxial bending fatigue test and a torsion fatigue test with an assumed axial misalignment. The results of the comparison provide encouragement regarding the capability of the newly developed equivalent stress amplitude expression for fatigue life prediction.     

重型车驾驶室结构特性仿真分析与研究

针对某重型车驾驶室结构特性分析与优化的问题进行研究,采用CATIA软件对驾驶室进行几何建模,利用HYPERMESH软件建立有限元模型,并进行自由模态仿真分析;利用试验模态和计算模态分析对比的方法,验证了有限元模型的有效性;结合此款驾驶室的承载特点,利用MSC.Patran/Nastran对驾驶室的弯曲和扭转工况进行刚度和强度仿真计算,利用Fatigue对扭转工况下驾驶室的疲劳强度进行仿真计算,给出了驾驶室的易疲劳破坏位置。研究结果表明:驾驶室固有频率为37.826Hz,避开了激振频率,避免了共振现象;在扭转、弯曲两种工况下,驾驶室产生的最大应力分别为108MPa、38.8MPa,均小于材料许用应力,弯曲、扭转刚度满足要求,驾驶室抵抗变形的能力较好,结构设计合理。     

扭转预应变对35CrMo钢低周疲劳性能的影响

自行设计了疲劳和扭转两用的试样,通过对试件预扭转不同的角度,系统研究35CrMo钢在不同扭转预应变下的低周疲劳性能,分析了扭转预应变后35CrMo钢的循环硬化软化特性、滞后回线、塑性应变能及循环弹性模量的变化规律,并对疲劳断口进行扫描电镜分析。结果表明:4种预扭转处理过的试件均表现出明显的循环软化行为,且循环软化规律及衰减的程度基本相同;循环应力范围及疲劳寿命随着预扭转角的增大而降低;应力应变滞后回线中加卸载曲线间的宽度随着预扭转角的增大而减小;塑性应变能都随着循环次数的增大而增加,且随着预扭转角的增大其增大速率下降;循环弹性模量都随着循环次数的增加而逐渐降低,且随着预扭转角的增大其衰减趋势减缓。     

Optimization of a metal honeycomb sandwich beam-bar subjected to torsion and bending

In this paper, we analyze a metal honeycomb sandwich beam/torsion bar subjected to combined loading conditions. The cell wall arrangement of the honeycomb core is addressed in the context of maximizing resistance to either bending, torsion, or combined bending and torsion for given dimensions, face sheet thicknesses and core relative density. It is found that the relative contributions of the honeycomb core to torsion and bending resistances are sensitive to the configuration of cell walls and the optimal properties significantly exceed those of stochastic metallic foams as sandwich beam core materials for this configuration.     

A criterion for high-cycle fatigue life and fatigue limit prediction in biaxial loading conditions

This paper presents a criterion for high-cycle fatigue life and fatigue strength estimation under periodic proportional and non-proportional cyclic loading. The criterion is based on the mean and maximum values of the second invariant of the stress deviator. Important elements of the criterion are: function of the non-proportionality of fatigue loading and the materials parameter that expresses the materials sensitivity to non-proportional loading. The methods for the materials parameters determination uses three S–N curves: tension–compression, torsion, and any non-proportional loading proposed. The criterion has been verified using experimental data, and the results are included in the paper. These results should be considered as promising. The paper also includes a proposal for multiaxial fatigue models classification due to the approach for the nonproportionality of loading.     

A fatigue-testing machine for combined bending and torsion

A testing machine is designed and developed in such a way as to be capable of exerting simultaneous cyclic bending and twisting moments, such moments being uniformly distributed along the entire gage length of the test specimen. The ratio of bending to twisting moments can be adjusted within the range 0 to 0.5, the angular deflection of specimen being controlled in the machine. Experimental results first obtained for reversed torsion show that the fatigue life is best expressed in terms of the shearstrain range or the shear-stress amplitude in potential form. Further wark on the subject is proceeding.     

Stress redistribution during bending fatigue

One of the effects of the application of cyclic stress, in most metals, is a change in stiffness. Some materials become harder while others initially soften as increasing numbers of cyclic stress are imposed. The effect of this changing stiffness on the distribution of stress during bending fatigue is examined. In general, the maximum stress, strain and bending moment are all observed to vary throughout the fatigue life. The manner of variation is dependent on the type of material as well as the loading conditions imposed. Experimental results are compared with calculated values based on cyclic stress-strain curves obtained in axial stress tests.     

基于结构应力的焊接接头多轴高周疲劳寿命估算

本文对承受弯扭组合载荷下的焊接接头危险点焊趾处进行了疲劳应力分析。结合结构应力考察了在比例载荷和非比例载荷下焊趾处临界面上的应力分量;建立了基于结构应力和修改的Wohler曲线法的临界面上多轴疲劳寿命估算方法;采用该方法对某管板焊接接头进行了多轴估算,将评定结果与文献中的疲劳试验数据做了比较,同包括欧洲钢结构规范3在内的其他的多轴疲劳评定方法相比,本文提出的多轴寿命估算结果最好,而且该方法具有网格划分不敏感性。     

短碳纤维局部增强混凝土疲劳性能实验研究

对局部增强短碳纤维混凝土进行三点弯曲疲劳试验,发现相同试件在不同应力水平下的疲劳寿命符合两参数威布尔分布,并由此建立考虑失效概率和高低应力比的局部增强短碳纤维混凝土双对数疲劳方程.在工程应用中可以根据实际情况确定失效概率,运用线性插值得到相应回归系数,求得双对数疲劳方程.通过比较相同应力水平下短碳纤维局部增强试件和素混凝土试件的试验结果,发现仅对混凝土进行低掺量的局部增强就可以成倍地提高混凝土的疲劳寿命.上述结果对混凝土路面工程或一些有特殊要求工程的设计有参考意义.     

STUDY ON THE SURFACE CRACK GROWTH BEHAVIOR IN 14MnNbq BRIDGE STEEL

Three-dimensional crack closure correction methods are investigated in this paper.The fatigue crack growth tests of surface cracks in 14MnNbq steel for bridge plate subjected to tensile and bending loadings are systematically conducted.The experimentally measured fatigue crack growth rates of surface cracks are compared with those of through-thickness cracks in detail.It is found that the crack growth rates of surface cracks are lower than those of through-thickness cracks.In order to correct their differences in fatigue crack growth rates, a dimensionless crack closure correction model is proposed.Although this correction model is determined only by the experimental data of surface cracks under tensile loading with a constant ratio R=0.05, it can correlate the surface crack growth rates with reasonable accuracy under tensile and bending loadings with various stress ratios ranging from 0 to 0.5.Furthermore, predictions of fatigue life and crack aspect ratio for surface cracks are discussed, and the predicted results are also compared with those obtained from other prediction approaches.Comparison results show that the proposed crack closure correction model gives better prediction of fatigue life than other models.     

镍基单晶合金多轴非比例加载低周疲劳研究

基于正交设计, 分别在680℃和850℃下进行DD3镍基单晶合金薄壁圆管试样([001]取向)拉/扭非比例加载低周疲劳试验, 研究等效应变范围、应变路径角、拉/扭载荷相位角、循环特性和温度诸因素对镍基单晶合金多轴低周疲劳寿命的影响作用. 疲劳试验数据的极差分析表明, 应变路径角、拉/扭载荷相位角和等效应变范围是影响疲劳寿命的主要因素. 将菱形应变加载路径区分为比例加载段和非比例加载段, 提出了表征非比例加载效应的等效应变参量, 并通过引入单晶应变三轴性因子反映拉/扭应变路径角对多轴疲劳寿命的影响. 用考虑非比例加载效应的等效应变范围和单晶应变三轴性因子构造循环塑性应变能损伤参量, 进行多元线性回归分析, 疲劳寿命回归模型与试验寿命具有很好的相关性, 所有试验数据都落在2.0倍的偏差分布带之内.      

氧化腐蚀对HRB400EⅢ级建筑抗震钢筋低周疲劳性能的影响

工程实际中,建筑用钢不可避免地会接触空气而遭受氧化腐蚀。本文开展了地震区域大力推广应用的HRB400EIII级钢筋氧化前、后的低周疲劳行为研究。采用轴向应变控制方法,在MTS809拉扭复合疲劳试验机上开展了大量的低周疲劳试验,获得了氧化前、后HRB400EIII级钢筋低周疲劳性能,如循环应力响应特征、循环应力-应变关系以及寿命预测公式等。通过断口电镜扫描发现,氧化后HRB400EIII级钢筋的裂纹均萌生于试件表面,且存在多处裂纹源。研究结果表明,氧化腐蚀对低周疲劳寿命及微观断裂机理方面均存在明显影响,并从力学性能变化的角度对引起差异的原因进行了解释。     

钢质蜂窝夹芯梁的高温疲劳模型

针对钎焊钢质蜂窝夹芯梁开展高温三点弯曲疲劳实验研究. 结果表明芯子排列方向显著影响结构疲劳性能, 高温下W向试件易于承受循环载荷. 提出基于疲劳模量退化的寿命预测经验函数方法, 其参数与材料性质、载荷环境等因素有关. 该方法可以预测结构疲劳寿命而避免大量重复性实验. 结果表明: 对于L向试件, 剩余模量退化规律可用二阶多项式拟合; 而W向试件则倾向于用指数型函数描述. 从刚度退化方程中得到非线性累积损伤模型, 并与线性Miner准则和试验结果进行了比较, 合理解释了蜂窝夹芯梁的高温损伤问题.      

Estimation of Fatigue Limits from Temperature Data Measured by IR Thermography

To determine the fatigue limits of materials, fatigue testing, which is time-consuming and very expensive, is required. In order to overcome these shortcomings, estimating methods for fatigue limits based on temperature changes measured by IR camera have been proposed, and research and development of such methods have been widely conducted. In the current paper, a non-lock-in type, inexpensive IR camera was used for rotational bending fatigue testing to estimate the fatigue limit from temperature changes independent from loading signals. The results indicated that it is possible to estimate the fatigue limit from the time-temperature change curves measured under various stress conditions and converted stress amplitude-temperature change curves. The estimated results were sufficiently accurate and thus we confirmed that it is promising to estimate the fatigue limit by a non-lock-in type, inexpensive IR camera. The inflection point of a stress amplitude-temperature change curve can be determined by approximating a curve by two straight lines and finding the combination of the lines for which the sum of the residuals between the curve and the lines is the smallest. Although the temperature changes depended on the loading history (the number of loading cycles), the results of fatigue limit estimation changed little. Therefore, the proposed method is practically accurate as a simple estimation method. We also measured the behavior of stress-stroke for each loading history (the number of loading cycles) in tension-compression fatigue testing and confirmed that temperature changes during fatigue testing are associated with plastic strain energy.     

SGBEM modeling of fatigue crack growth in particulate composites

The symmetric-Galerkin boundary element method (SGBEM) has previously been employed to model 2-D crack growth in particulate composites under quasi-static loading conditions. In this paper, an initial attempt is made in extending the simulation technique to analyze the interaction between a growing crack and clusters of perfectly bonded particles in a brittle matrix under cyclic loading conditions. To this end, linear elastic fracture mechanics and no hysteresis are assumed. Of particular interest is the role clusters of inclusions play on the fatigue life of particulate composites. The simulations employ a fatigue crack growth prediction tool based upon the SGBEM for multiregions, a modified quarter-point crack-tip element, the displacement correlation technique for evaluating stress intensity factors, a Paris law for fatigue crack growth rates, and the maximum principal stress criterion for crack-growth direction. The numerical results suggest that this fatigue crack growth prediction tool is as robust as the quasi-static crack growth prediction tool previously developed. The simulations also show a complex interplay between a propagating crack and an inclusion cluster of different densities when it comes to predicting the fatigue life of particulate composites with various volume fractions.     

Experimental Investigation and Finite Element Analysis of Fatigue Crack Growth in Pipes Containing a Circumferential Semi-elliptical Crack Subjected to Bending

In this paper, a circumferential external surface flaw in a metallic round pipe under cyclic bending loading is considered. Because of very rapid changes in the geometrical parameters around the crack front region, the mesh generation of this region must be done with great care. This may lead to an increase in the run time which makes it difficult to reach valid results and conclusions. Because of the advantages of the sub-modeling technique in problems which need very high mesh density, this method is used. Stress intensity factors in mode I condition are determined using three-dimensional finite element modeling with 20 node iso-parametric brick elements in the ANSYS 9.0 standard code and the singular form of these finite elements at the crack front. In order to estimate the analysis error, the structural parameter error in energy norm criterion was used. Because of the advantages of non-dimensional analysis, this method is employed, and the stress intensity factors are normalized. For the analysis of the fatigue crack growth, the Paris law is used. The propagation path of the surface flaw is obtained from the diagram of aspect ratio versus relative crack depth. The fatigue crack growth analysis (the relative crack depth against loading cycles diagram) of different initial crack aspect ratio under cyclic loading is also considered. Fatigue shape development of initially semi-elliptical external surface defects is illustrated. The effect of the Paris exponent (material constant) on fatigue crack propagation is shown as well. Moreover, the fatigue crack growth of several specimens is assessed experimentally using a manually-constructed experimental set up. Finally, the experimental results obtained by cyclic bending loading tests are compared with the numerical results. The experimental results show good conformity with the finite element results.     

Evaluating the limiting state of materials with asymmetric cyclic loading and a complex stress state

Conclusion In order to construct models of the limiting state in asymmetric cyclic loading, it is best to use the representation of a unique limit curve that is invariant to the time to failure and type of stress state. Isotropic metallic materials were used as an example to show that such a curve does exist and is described satisfactorily by an exponential cosine function.The models constructed above were used to calculate the limiting state for several steels and alloys acted upon by the combinations of cyclic bending and cyclic torsion, static bending and cyclic torsion, and static torsion and cyclic bending. Results were also calculated for materials with stress raisers. The calculated data were compared with experimental findings and were shown to agree satisfactorily with the latter.S. P. Timoshenko Institute of Mechanics, National Academy of Sciences of Ukraine, Kiev. Translated from Prikladnaya Mekhanika, Vol. 31, No. 2, pp. 67–79, February, 1995.     

Fatigue life predictions by integrating EVICD fatigue damage model and an advanced cyclic plasticity theory

An event independent cumulative damage (EVICD) fatigue prediction model was previously developed for the fatigue damage prediction under general multiaxial stress state and loading conditions. The model takes the plastic strain energy as the major contributor to the fatigue damage. The application of the EVICD model does not require a cycle counting method for general random loading. In the current effort, derivations were made to explicitly and directly relate the material constants in the fatigue model to the parameters in the Manson–Coffin equations and the cyclic stress–strain curve of the material. In addition, an advanced cyclic plasticity theory was implemented for the determination of the detailed stress–strain response that was required as the input for the EVICD fatigue model. Three metallic materials were used to demonstrate the capability of the modified fatigue model for the predictions of fatigue lives under different loading conditions. The results show that the fatigue model can provide fatigue life predictions in close agreement with the experimental observations.     

超声弯曲疲劳试验方法及其应用

在三点弯曲超声疲劳试验方法的基础上开发了对称弯曲超声疲劳试验系 统. 介绍了对称弯曲超声疲劳试样的设计及其加工误差的影响,并利用对称弯曲超声疲劳系 统(20\,KHz)测定了50$^{\#}$车轴钢的$S$-$N$曲线. 结果表明,50$^{\#}$车轴 钢的$S$-$N$曲线是一条连续下降型曲线. 与对称拉压加载下50$^{\# }$车轴钢的$S$-$N$曲线对比结果表明,在高周阶段,加载方式对疲劳性能有明显 影响,而在超高周阶段,加载方式无明显影响.