Statistical analysis of HDPE fatigue lifetime

Fatigue lifetime of HDPE structures such as pipes is recognized to show a large scatter. This study aims to compare different statistical methods and distributions, in order to give convenient modeling of tensile and fatigue test results of commercially available polyethylene compression molded sheets. The median rank, the maximum likelihood and the Kolmogorov-Smirnov fitting are compared for the estimation of Weibull parameters. The choice of the best distribution to fit fatigue lifetime is discussed on the basis of the goodness-of-fit results. It is found that whether the three-parameter distributions of Weibull and lognormal types are suitable for lifetime prediction, the two-parameter Weibull is more conservative for probabilistic fatigue design.     

The influence of biaxial stresses on high-cycle fatigue-crack propagation

Arising from a design study, an examination has been made of the problems associated with evaluating the fatigue behavior of an I-beam section joined to a transverse stiffener, loaded in biaxial bending. A laboratory test rig has been designed to study high-frequency (40–230 Hz) fatigue-crack propagation in the tensile flange of a composite aluminum I-section, for a range of stress biaxiality ratios (λ) from 0 to +1 (equibiaxial tension), λ being varied by adjusting the ratios of loading spans in the two orthogonal axes for the same amount of uniaxial deflection. The results obtained are considered in the context of the significantly contradictory information currently available in the literature. Crack geometry and test procedure (as influenced by load/stress measurement) are found to considerably influence the effect of biaxial stresses on fatigue. Thus, the growth rate of corner-initiated cracks increases with increasing stress biaxiality (monitored in terms of nominal applied stresses), but the reverse is true for center-cracked specimens. When tests are conducted in terms of combinations of local stresses, or data reduced using corrections, there is no significant effect of biaxial stresses on fatigue-crack growth.     

Evaluation of the fatigue life of a tractor’s transmission spiral bevel gear

Conventional tractor transmission spiral bevel gears are designed and evaluated based on the engine rated load, which is significantly higher than the load conditions in the field. In this study, the fatigue life of a spiral bevel gear is evaluated to obtain data for design optimization. The equivalent load was calculated using the field load data, and the integrated equivalent load was calculated based on the annual usage of major field operations in Korea. The fatigue life of three spiral bevel gear samples was evaluated using the accelerated life test (ALT) under an engine rated load condition of 120%. It was also evaluated under engine rated, plow equivalent, and integrated equivalent load. Fatigue life was estimated using the ALT results and the fatigue damage exponent based on the ALT equation. We observed that the fatigue life of the spiral bevel gear under the plow equivalent and integrated equivalent loads is higher than that under the rated load by 214 and 9,400 times, respectively. The results of this study can provide useful information for the design optimization of tractor transmission spiral bevel gears considering the field equivalent load.     

Fatigue life enhancement of structures using shape optimisation

The paper proposes a new approach for shape optimisation with fatigue life as the design objective. Conventional designs often incorporate stress optimisation that aims at reducing stress concentrations around a structural boundary by minimising the peak stress. However, this is only an effective and sufficient measure for an ‘ideal’ or ‘flaw-less’ structure. It is a well-known fact that flaws (cracks) are inevitably present in most structures. This emphasises the need to investigate the influence of cracks on optimised shapes. Numerical modelling of cracks using the Finite Element Method requires a fine mesh to model the singularity at crack tips, which makes fracture calculations computationally expensive. Furthermore, for a damage tolerance based optimisation, numerous cracks are to be considered at various arbitrary locations in a structure, and fatigue life evaluation needs to be repeated for each crack at every iteration. This makes the optimisation process extremely computationally inefficient for practical purpose. Moreover, the lack of information concerning crack size, orientation, and location makes the formulation of the optimisation problem difficult. As a result, there has been inadequate research to consider fracture parameters, such as fatigue life, in the optimisation objective. To address this, the paper presents an approach for the shape optimisation of damage tolerant structures with fatigue life as the design constraint.The damage tolerance based optimisation was performed using a number of nonlinear programming algorithms, namely the Broydon-Fletcher-Goldfarb-Shanno (BFGS) method, the Fletcher Reeves (Conjugate Direction) method, and the Sequential Unconstrained Minimisation Technique (SUMT). These methods were extended for optimising the fatigue life in the presence of numerous surface cracks. A significant enhancement in fatigue life was achieved for various crack cases consisting of different initial and final crack sizes. It is shown that the fatigue life optimised shapes can be considerably different from the corresponding stress optimised solution. This emphasises the need to explicitly consider fatigue life as a distinct design objective when optimising damage tolerant structures. A fatigue life optimisation leads to the generation of a ‘near uniform’ fatigue critical surface. The design space near the ‘optimal’ region was found to be relatively flat. This means that the precise identification of the local/global optimum solution is not critical, because a significant structural performance enhancement can be achieved in the ‘near’ optimal region. An additional benefit of fatigue life optimisation is that the resulting optimised shapes may even be lighter than the stress optimised designs. To verify the optimal solutions obtained using the nonlinear programming algorithms, the results were compared with those obtained using a heuristic optimisation method (Biological algorithm). The solutions predicted by both the methods, employing inherently different (gradient-based and gradient-less) algorithms, were found to agree very well.     

Effect of stress biaxiality on the high-strain fatigue behavior of an aluminum-copper alloy

Although there is now a considerable volume of high-strain (<10⁵ cycles) fatigue data for uniaxial tension-compression and simple-bending conditions, relatively little information is available regarding the effects of stress and strain biaxiality. A method which has been used to study the effects of biaxiality on longlife fatigue strength is to subject thin-walled tubes to repeated internal pressure and an end load which is in phase with, and a linear function of, the pressure. The object of the present research was to use this method to study the influence of stress biaxiality on the high-strain fatigue behavior of a high strength, aluminum-4% copper alloy at room temperature. From a continuum-mechanics point of view, this material is completely elastic after the first few load cycles. Cylinder results for hoop to axial stress ratios of 2:1, 1:1, 1:2 and 2: ?1 suggest that fatigue failure of this material in the life range 10³ to 10⁵ cycles is primarily dependent on the maximum range of tensile stress. This conclusion and a study of fracture surfaces led to the use of linear-elastic fracture mechanics to interpret the fatigue and brittle fracture behavior of these cylinders.     

Evolution of fatigue damage using the fatigue damage map method

Using only readily available material properties and the concept of the fatigue damage map the work attends to develop a methodology able to predict crack tip propagation rates characterising each of the fatigue stages, namely crack arrest, microstructurally and physically short crack (Stage I), long crack growth (Stage II) and Stage III growth. Crack tip propagation rates are predicted through the combination of an Elasto-Plastic crack tip opening displacement model and the crack blunting theory. The methodology provides a theoretical framework for a 3D version of the fatigue damage map for damage tolerance design. In addition, the work attends to explain a number of fundamental problems starting from crack tip propagation discrepancies, found in the short cracking stage, as well as to provide an insight towards the effect of grain size on the fatigue limit/threshold stress intensity factor.     

考虑载荷流泄时盾构机T形焊接结构疲劳可靠性分析

T形焊接结构是盾构机刀盘的关键结构之一,焊接处裂纹在亚临界的扩展是其疲劳失效的关键因素。文章考虑载荷流泄情况下,基于概率断裂力学的一次二阶矩方法提出了一种新的结构疲劳可靠性分析方法。将该方法应用到某盾构机T形焊接结构,给出了考虑与不考虑载荷流泄两种情况下结构疲劳可靠性计算结果,并用Monte Carlo方法验证了文章方法的有效性;利用最小二乘法拟合出了载荷流泄系数对该T形焊接结构疲劳可靠性的影响曲线,将该曲线划分了三个区域：即高、中、低疲劳失效区。结果表明在考虑和不考虑载荷流泄时,T形焊接结构的疲劳失效概率分别是8.2644e-05和3.4314e-04,即载荷流泄能一定程度上提高了结构的疲劳可靠度;实际工程在盾构机T形焊接结构疲劳可靠性设计时,T形焊接结构的厚度作为一个设计变量,而低失效区可以作为一个可靠度约束条件。研究成果为实际工程上盾构机刀盘的维修、检验计划和设计都有一定的理论指导意义。     

超声疲劳试验方法及其应用

超声疲劳是一种加速的疲劳试验方法,它的测试频率(20kHz)远远超过了常规疲劳测试频率(小于200Hz)．超声疲劳试验研究表明50^#车轴钢和40Cr钢直到10^10个应力循环后仍会发生疲劳断裂,并不存在常规疲劳试验曲线所示的“疲劳极限”,因此用10^7周次的疲劳试验数据进行疲劳强度设计并不安全．50^#车轴钢和40Cr钢超声疲劳性能优于常规疲劳性能．扫描电镜分析表明,超长寿命阶段50^#车轴钢裂纹萌生于次表面夹杂．介绍了超声疲劳试验系统、工作原理及超声疲劳试样的设计．     

Stress distributions from interference fits and uniaxial tension

Machine assemblies can be prestressed (1) to eliminate stress gradients and (2) to increase fatigue life. Where prestressing is used to reduce stress gradients, the geometry is usually simple and good mathematical models are available for design purposes. The instances where fatigue life is the prime consideration are difficult to analyze because of asymmetry and variable boundary conditions. However, the interference prestress can be determined from an approximate model. The approximate solution indicates that the normal stress at the interface of a bolt-hole assembly varies almost linearly with diametral interference. When a tensile field is added to an interference prestress, even approximate techniques falter. Quantitative agreement with strain-gage data can be made at a point and for the initial loading cycle only. After several cycles, the experimental value of cycle-stress variation at the interface approximates the average applied tensile stress. The calculated value is twice as great. Stresses due to interference fits can be predicted, and prestressed bolted joints designed with greater confidence.     

海上平台结构疲劳与疲劳可靠性分析程序设计

本文介绍了作者开发的适用于固定式导管架海上平台结构系统疲劳与疲劳可靠性分析程序系统的设计原理、结构及功能特点。最后，以一固定式导管架平台作为算例验证了程序系统的可靠性与实用性。     

大型汽轮机部件低周疲劳安全寿命的设计和评定

文中提出了汽轮机部件低周疲劳安全寿命的设计和评定方法。介绍了汽轮机部件低周疲劳安全寿命的含义和计算方法。该方法以概率论和统计学为基础，把汽轮机部件的低周疲劳寿命处理为随机变量，对低周疲劳试验数据进行统计分析来确定材料低周疲劳寿命的分布参数，使用可靠性理论来确定汽轮机部件的低周疲劳安全寿命。文中给出了低周疲劳寿命服从正态分布和对数正态分布时汽轮机部件低周疲劳安全寿命的计算方法和应用实例。该方法考虑了汽轮机运行参数随机性和材料低周疲劳特性离散性的影响，为汽轮机部件低周疲劳寿命的设计、评定和诊断提供了科学的依据。     

Definition of a new predictor for multiaxial fatigue crack nucleation in rubber

From an engineering point of view, prediction of fatigue crack nucleation in automotive rubber parts is an essential prerequisite for the design of new components. We have derived a new predictor for fatigue crack nucleation in rubber. It is motivated by microscopic mechanisms induced by fatigue and developed in the framework of Configurational Mechanics. As the occurrence of macroscopic fatigue cracks is the consequence of the growth of pre-existing microscopic defects, the energy release rate of these flaws need to be quantified. It is shown that this microstructural evolution is governed by the smallest eigenvalue of the configurational (Eshelby) stress tensor. Indeed, this quantity appears to be a relevant multiaxial fatigue predictor under proportional loading conditions. Then, its generalization to non-proportional multiaxial fatigue problems is derived. Results show that the present predictor, which is related to the previously published predictors, is capable to unify multiaxial fatigue data.     

疲劳设计方法的进展

本文对早期疲劳设计方法,包括无限寿命设计、安全寿命设计、破损-安全寿命设计、损伤容限设计作了简单的回顾,对可靠性设计新方法作了详尽描述,同时还对疲劳寿命估算中的名义应力法与局部应力应变法进行了比较,最后对今后这课题的研究提出了一些建议。      

Fatigue design of bolted joints taking into account reliability concepts

A method is presented for fatigue design by comparing the load on the bolt in joints with the fatigue strength of the bolt-nut joints. Two types of bolted joints, cylindrical and T-flange joints, are treated as examples. Reliability concepts are introduced to the design. Fatigue tests of the above-mentioned bolted joints were also carried out to verify the applicability of the method. As a result, it appears that the fatigue behavior of threaded fasteners can be estimated to some extent by comparing the load on the bolt with the fatigue strength. Paper was presented at the 1986 SEM Spring Conference on Experimental Mechanics held in New Orleans, LA on June 8–13.     

透平转子的可靠性设计

介绍透平转子的可靠性设计方法。该方法以传统的转子强度和振动的设计方法为基础,把透平转子的静应力、材料静强度、应力幅、尺寸系数、表面加工系数、应力集中系数、材料疲劳极限、热疲劳累积损伤程度、材料低周疲劳程度、蠕变寿命、固有频率、激振力频率、不平衡响应等处理为随机变量,使用机械概率设计法确定转子设计的可靠度。文中给出了透平转子静强度、疲劳强度、热疲劳、蠕变寿命、避开弯曲共振、避开扭转共振和限制不平稳响     

随机不确定性下Kriging辅助的谐波减速器柔轮疲劳寿命预测

柔轮作为谐波减速器核心传动件,在循环交变载荷作用下容易发生疲劳失效,其疲劳寿命直接影响谐波减速器的工作寿命。为揭示随机不确定性因素对谐波减速器柔轮疲劳寿命的影响规律,本文考虑材料属性和载荷等不确定因素对谐波减速器柔轮开展疲劳寿命预测研究,以期实现更客观地评估柔轮疲劳寿命。首先,建立柔轮的三维模型和有限元模型,通过有限元分析及寿命计算获得确定性条件下的柔轮寿命。然后,将材料属性及载荷考虑为随机变量,采用拉丁超立方抽样方法对柔轮进行试验设计。最后,基于主动学习Kriging模型和柔轮材料P-S-N曲线,通过逐一加点的方式对柔轮进行疲劳寿命分析,获得疲劳寿命统计结果,并与确定性条件下的柔轮疲劳寿命结果进行对比。结果表明,随机不确定因素影响下柔轮疲劳寿命预测结果与确定性条件下相比有所降低,对柔轮抗疲劳设计具有一定指导意义。     

Revised damage evolution equation for high cycle fatigue life prediction of aluminum alloy LC4 under uniaxial loading

The fatigue life prediction for components is a difficult task since many factors can affect the final fatigue life. Based on the damage evolution equation of Lemaitre and Desmorat, a revised two-scale damage evolution equation for high cycle fatigue is presented according to the experimental data, in which factors such as the stress amplitude and mean stress are taken into account. Then, a method is proposed to obtain the material parameters of the revised equation from the present fatigue experimental data. Finally, with the utilization of the ANSYS parametric design language (APDL) on the ANSYS platform, the coupling effect between the fatigue damage of materials and the stress distribution in structures is taken into account, and the fatigue life of specimens is predicted. The outcome shows that the numerical prediction is in accord with the experimental results, indicating that the revised two-scale damage evolution model can be well applied for the high cycle fatigue life prediction under uniaxial loading.     

热端部件低温热腐蚀疲劳损伤机理、寿命模型和抗腐蚀设计方法

对于沿海地区或海洋环境中使用的航空发动机来说,由于高温、机械载荷和盐雾环境的共同作用,热腐蚀疲劳破坏是影响其热端部件服役寿命的主要因素.本文对热端部件低温热腐蚀疲劳损伤机理、寿命模型和防腐蚀设计方法进行了总结、归纳及评述,提出了未来的研究趋势与发展方向.首先介绍航空发动机热端部件的热腐蚀疲劳故障案例、损伤演化机理;其次,重点分析了低温腐蚀疲劳寿命的唯象模型、损伤力学模型、断裂力学模型以及机器学习模型;再次,对几种代表性的考虑腐蚀演化不同阶段的分段式腐蚀疲劳全寿命模型进行综述,还分析指出了腐蚀疲劳全寿命模型的发展趋势;从次,对航空发动机材料选择、零件制造、结构强度设计和外场运行维护不同阶段的抗腐蚀方法进行了综述.最后,对增材制造零部件的热腐蚀疲劳问题以及无损检测技术、人工智能等与热腐蚀疲劳研究的结合进行了展望.     

基于疲劳传感器的桥梁载荷谱检测研究

设计了一种结构独特的应变增幅器,使疲劳计的响应灵敏度大大提高,从而使疲劳计较高响应门槛值能与结构高周疲劳情况相匹配,扩展了疲劳计的应用范围,满足了桥梁工程结构疲劳检测要求.由恒幅标定数据和等效原理用插值方法得到复杂加载下疲劳响应计算方法,并根据桥梁载荷谱的瑞利分布特点,得到该分布下的疲劳响应计算方法.采用增幅器的双疲劳计结构设计,利用疲劳计响应的非线性特性,得到疲劳传感器电阻变化与桥梁瑞利载荷谱的对应关系.该传感器的检测原理提供了一种新的工程疲劳检测方法,它较目前采用的其它方法效率高、精度好,适用于长期疲劳监测.疲劳实验表明,实验载荷谱与预测载荷谱相当吻合,所设计的疲劳传感器性能良好、满足桥梁疲劳载荷检测要求.     

机翼主梁钛合金模拟件谱载疲劳寿命实验研究

确定某型飞机机翼主梁结构的使用寿命是保证该机使用安全的关键。本文对全机第一关键危险部位--机翼钛合金主梁下缘螺栓孔模拟件进行随机谱和程序块谱载荷下的疲劳寿命试验,获得了模拟件的疲劳裂纹形成寿命和疲劳全寿命,并对其寿命进行了统计处理和对比分析。结果表明,程序块谱较随机谱有更长的疲劳寿命。这说明随机谱比程序块谱要严重,对钛合金主梁模拟件的疲劳寿命有显著的影响。该结论可为机翼钛合金主梁构件疲劳寿命预测及疲劳设计提供试验依据。