Cyclic stress-strain data analysis under biaxial tensile stress state

A new device was developed to assess fatigue life under biaxial tensile loading at elevated temperatures. It makes use of an annular disk specimen and can be easily mounted onto a standard push-pull machine so that the axial force is converted into radial forces extending across the disk specimen. Therefore, a positive ratio of the tangential to the radial stress can be imposed at the reduced section of the disk specimen; this ratio depends on the specimen configuration and may be fixed to a value ranging from 0.5 to 0.9 by varying the inner diameter of the disk. The proposed device has performed successfully and was used to study the cyclic behavior of Type-304 stainless steel subjected to various biaxial tensile stress states at room temperature and at 200°C. The data obtained from this experimental procedure have been analyzed to evaluate the effectiveness of some correlations already available for treating the biaxial cyclic stress-strain response in terms of the uniaxial behavior. This analysis shows that a successful correlation should account for all the stress components. The authors discuss the concept used in the modeling of the material cyclic behavior and the formulation of a biaxial fatigue damage parameter necessary for an effective analytical life prediction methodology.     

A new apparatus for studying mechanical behavior under pressure

Using a servohydraulic intensifier, a servohydraulic universal test machine and a novel test chamber, pressures of 750 MPa and axial stresses of almost any magnitude are simultaneously generated and applied to the gage section of a solid, cylindrical specimen. Under combined axial-stress/external-pressure loadings, a solid specimen experiences a truly three-dimensional, homogeneous stress state in which the axial stress equals σ₁ and the radial and circumferential stresses equal the negative of the pressure, —P. Through independent computer control of the pressure and axial stress, amterial behavior under monotonically and cyclically applied multiaxial stresses are investigated. This paper describes the experimental details of the test chamber design, high-pressure fluid production and sealing, load and strain measurement under high pressure, computer control and data acquisition. Experimental results obtained from triaxial monotonic tests on low alloy steel and triaxial cyclic tests on a Ni-Ti alloy using this unique apparatus are presented.     

The evolution of crystalline stresses of a polycrystalline metal during cyclic loading

The presence of a positive average applied stress during cyclic uniaxial loading leads to a reduction in fatigue life of metallic parts. The metals are typically polycrystalline, with stresses varying from crystal to crystal due to differences in lattice orientation and slip system strength. Simulations enable us to better understand how polycrystals behave under cyclic loading and how the changing stress over many cycles influences fatigue life. Specifically, uniaxial cyclic simulations of pre-strained HY100 steel were conducted using an elastic viscoplastic continuum slip model employing a Taylor hypothesis. Stress-controlled loading conditions were employed to mimic fatigue tests on cold-bent bar specimens for three different load levels. The macroscopic axial strains and the crystal axial stresses were monitored during the cycles. The stress–strain response for the first cycle was used to determine the load input for the material point simulations. The peak values of crystal axial stress were found to evolve continuously with the number of loading cycles. It was found that the stress change in a crystal is influenced not only by its own orientation but also by the orientations of the other crystals in the aggregate. Furthermore, the distribution of crystal stresses after thousands of cycles at a lower stress amplitude closely resembled the distribution after tens of cycles at a larger stress amplitude.     

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。     

Finite-element analysis of creep and plasticity tensile-test specimens

Traditionally, mechanical properties as determined from sensile-test specimens are assumed to be truly uniaxial and are used directly in finite-element codes for design purposes. In this paper, the stress and strain distributions in two test geometries, an hourglass specimen and a cylindrical specimen, are critically examined by means of the nonlinear finite-element code CREEP-PLAST. Since some triaxiality of the stress state is inevitable in any region with a transition, it is difficult to have a truly uniaxial test specimen. The determination of the internal stress and strain distributions makes it possible to assess the accuracy of the mechanical properties as indicated by tests on a particular specimen. Furthermore, the data given here guide the choice between the hourglass and the cylindrical specimen for applications in creep, plasticity and fatigue. Extensometry techniques permit measurements to be made only on the surface of the specimen. Thus, trouble can be caused by the nonuniform strain state present in both geometries. With the finite-element analysis, the strain field within the specimens is correlated to that on the surface; extensometry correction factors are given for selected cases.     

Development of a portable shear test fixture for low modulus porous (foam) materials

The shear properties of brittle and highly porous carbon (graphitic) foam cannot be measured reliably with most standard test methods, such as single rail, double rail, Iosipescu shear, etc. A new testing device has been developed to accurately measure the shear stiffness and strength of carbon foam or other porous materials. Specimens of cylindrical cross section are used to reduce the high stress concentration that normally occurs in the vicinity of the grip section. Since strain gages could not be installed on the specimen surface (due to porosity), the shear strain is determined from the specimen end rotation. A high resolution in the rotational measurement is achieved by using a stepper motor with multiple gear reduction. In view of testing low modulus material, the load cell of the fixture was mounted onto an axial roller to relieve the axial constraint while twisting the specimens. The accuracy of the measurement and calibration of the test fixture has been demonstrated by measuring the shear modulus of two plastic (polyvinyl chloride (PVC) and urethane).     

End-grip configurations for axial loading of composite tubes

Testing of high-strength, tubular, composite specimens in uniaxial and biaxial tension require end-grip fixturing to transfer large axial loads into the specimen. Two gripping configurations were analytically and experimentally evaluated to determine their affect on stress distribution within the specimen test section. The first was a bonded grip in which the tubular specimen is adhesively bonded in a deep-slotted aluminum end tab. The second was a threaded grip with glass cloth/epoxy overwrap on the specimen ends that thread into an aluminum, split-collar end tab. Large axial loads can be transmitted to the specimen with either design; however, each introduces axial-stress concentrations into the composite sample. The magnitude and distribution of stresses (strains) with axial position, which are a function of biaxial-stress ratio, were computed by finite-element analyses and verified experimentally with surface-strain measurements. This study illustrates the importance of utilizing analytical tools to examine the effect of end grip/specimen interaction on stress distribution within the gage section and on test data.     

Failure properties of a PBAN propellant in multiaxial stress fields

Experimental data have been obtained which duplicate the stress and strain field in a solid-propellant rocket-motor grain under pressurization. Development of a hollow ellipsoidal specimen has made possible the acquisition of these data. This test also allows a more thorough evaluation of the failure mechanism in multiaxial stress and strain fields. Failure data were obtained in the tensile-tensile-compressive (++?) stress and biaxial tensile-compressive (+?) strain octants by applying pressure to the internal surface of an ellipsoidal specimen. Data were obtained in the triaxial compressive (???) stress and biaxial tensile-compressive (+?) strain octants by simultaneous application of pressure to both internal and external surfaces of the ellipsoidal specimen and a gradual reduction of external pressure until failure. A stress analysis of the specimen is presented and data-reduction techniques are discussed. Data obtained with a hollow spherical specimen and with the newly developed hollow ellipsoidal specimen are compared. These data are obtained in the same stress and strain octants; however, the relative magnitudes of the parameters and, therefore, the positions within the stress and strain octants are different. This results in a change in the magnitudes of the failure parameter. Data from uniaxial specimens of the same propellant also are presented.     

An investigation about interference fit effect on improving fatigue life of a holed single plate in joints

In this article, the effect of interference fit on fatigue life of holed plate of mechanical joints was investigated both experimentally and numerically. In the experimental part, fatigue tests were carried out on the holed specimens of Al 7075-T6 alloy in which oversized steel pins were force fitted to them. These fatigue tests were conducted on open hole specimen and specimens with 1, 1.5, 2 and 4% nominal interference fit sizes at different cyclic longitudinal loads. From these tests the stress-life (S–N) data for different interference fit sizes were obtained. The results show that interference fit increases fatigue life compared to open hole specimens. In the numerical part of the investigation, 3D finite element simulations have been performed to obtain stress (or strain) histories and distributions around the hole due to interference fit and subsequent cyclic longitudinal loading using FEM package. The stress history from finite element (FE) simulation was used to explain the reason for fatigue life improvement in the interference fitted specimens.     

Comparison of low-cycle fatigue results with axial and diametral extensometers

Low-cycle fatigue tests at room temperature have been carried out on a stainless steel and an aluminum alloy utilizing an axial extensometer with cylindrical specimens and a diametral extensometer with hour-glass specimens. In all cases, the axial strain was the controlled parameter. The results obtained with both extensometers are compared. For the materials studied, it is found that the data obtained with a diametral extensometer correspond to a somewhat longer life (by a factor of the order of 1.6 for the parameters used). Furthermore, two tests have been carried out on cylindrical specimens with both extensometers where the axial-strain computed through the diametral strain was controlled throughout the material life and the measured axial strain was simultaneously recorded. Results indicate that geometry of specimen is the predominant factor influencing fatigue life.     

An experimental study of inhomogeneous cyclic plastic deformation of 1045 steel under multiaxial cyclic loading

An experimental study was conducted on the inhomogeneous cyclic plastic deformation of 1045 steel under multiaxial cyclic loading. Thin-walled tubular specimens were used and small strain gages were bonded on the specimen surface to characterize the local deformation. The controlled loading paths included cyclic tension–compression, cyclic torsion, proportional axial-torsion, 90°-out-of-phase axial-torsion, and fully reversed torsion with a constant axial stress. The maximum stress in each experiment was lower than the lower yield stress of the material. It was found that the cyclic plastic deformation within the gage section of the specimen under multiaxial stress state followed the three-stage process that was observed from uniaxial loading, namely, incubation, propagation, and saturation. The plastic deformation was significantly inhomogeneous during the propagation stage, and the inhomogeneity continued through the saturation stage. The duration of each stage and the saturated strains were dependent on the cyclic stress amplitude and the loading path. Multiaxial stress state reduced the incubation stage. With identical equivalent stress magnitude, the nonproportional loading path resulted in the shortest incubation and propagation stages, and the saturated equivalent plastic strain magnitude was the smallest. Although the deformation over the gage section was inhomogeneous, the plastic deformation in a given local area was found to be practically isotropic.     

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.     

高韧性合金钢断裂韧性及疲劳裂纹扩展门槛值的联合试验方法

在柴油机曲轴、连杆等关键零部件的可靠性设计和失效评估中,断裂韧性及疲劳裂纹扩展门槛值分别是衡量材料抵抗裂纹失稳扩展和裂纹开始扩展的重要指标．但是,对于高韧性合金材料,难以通过常规试验所推荐的厚度确定平面应变断裂韧性,而门槛值的测定通常不但非常耗时,且难以直接应用于不同循环特性的实际结构．本文针对高韧性合金钢34CrNi3MoA,提出一种将断裂韧性和疲劳裂纹扩展门槛值试验合二为一的试验方法,即用同一个试件可以同时测定门槛值和断裂韧性．利用断裂韧性关于试件厚度的渐近特性,以几种较薄试件的试验,确定平面应变状态下的断裂韧性．试验结果还表明,裂纹扩展门槛值的试件厚度依存性可以忽略,并给出了任意循环特性（应力比）下的门槛值计算公式．     

Transient stresses in axisymmetric bodies of varying area

The purpose of this paper is to report on an experimental and theoretical investigation of one-dimensional stress-wave propagation in axisymmetric bodies of varying area. An experimental investigation of elastic waves produced by the axial collision of strikers with truncated 7075 aluminum cones and conical shells with a half angle of 5 deg was performed using an air gun. Strain distributions along the 5-deg conical specimens were obtained by strain gages mounted on the specimen. The method of characteristics was utilized in the theoretical analysis of the propagation of elastic stress waves. Procedures of numerical integration along the characteristic directions are established and carried out for all the experimentally tested cases on a digital computer. Good agreement between the data and the results of calculations based on the analysis was obtained.     

海洋平台K型管节点的疲劳裂纹扩展分析Ⅰ:试验测试

对承受疲劳载荷的海洋平台K型管节点首先进行了静力测试,确定了沿着焊缝的热应力区的应力分布及热应力区最大应力点的位置,从而判断裂纹产生的位置;然后通过专用测试设备提供循环疲劳载荷,用ACPD(Alternating Current Potential Drop,即交流电流势能落差法)技术检测裂纹的产生和增长过程,得到裂纹最深点,用S-N曲线估算其疲劳寿命。对已有裂纹的K型管节点,用应力强度因子估计其剩余寿命。同时用测试的结果验证了S-N的准确性和可靠性。     

微拉曼光谱研究M55JB碳纤维/微滴的拉伸变形行为

使用评价纤维/基体界面力学性能的新方法纤维微滴拉伸测试,来研究M55JB碳纤维/环氧树脂基体之间的界面应力传递性能。使用自制的微加载装置对碳纤维/环氧树脂微滴试样进行对称式拉伸测试,用微拉曼光谱仪记录下不同应变下的嵌入微滴内纤维上的拉曼频移信号,经过应力/频移关系转换成纤维轴向应力。实验结果显示,微滴内纤维轴向应力随载荷而明显增加。根据界面力平衡模型得到相应的界面剪切应力呈反对称式分布,在纤维嵌入端存在剪应力集中。新测试方法能保证嵌入微滴内纤维上的应力呈对称式分布,而且能降低纤维嵌入端附近的应力奇异性。     

High-temperature fatigue-life estimation: Extension of a unified theory

A procedure is presented for predicting the fatigue behavior at elevated temperature by extending the unified theory of fatigue damage previously proposed for room temperature. The method predicts the experimental results of high-temperature push-pull tests under isothermal conditions, using the total strain range. The analysis is based on parameters obtained from short-term tensile tests in which the temperature and the strain rate are the same as for the fatigue test. The procedure is applied for fatigue of a stainless steel at 650°C under cyclic axial strain. It has also been applied to published data for three austenitic stainless steels. In general, the present procedure gives estimates closer to experimental results than those obtained from other known methods.