Experimental and Numerical Investigation of Torsion Fatigue of Bearing Steel

2013 ◽  
Vol 135 (3) ◽  
Author(s):  
John A. R. Bomidi ◽  
Nick Weinzapfel ◽  
Trevor Slack ◽  
Sina Mobasher Moghaddam ◽  
Farshid Sadeghi ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Crack Initiation ◽  
Normal Stress ◽  
Failure Mechanism ◽  
Fatigue Damage ◽  
Fatigue Failure ◽  
Damage Mechanics ◽  
Damage Model ◽  
Bearing Steel ◽  
Fatigue Damage Accumulation

This paper presents the results of torsion fatigue of widely used bearing steels (through hardening with bainite, martensite heat treatments, and case hardened). An MTS torsion fatigue test rig (TFTR) was modified with custom mechanical grips and used to evaluate torsional fatigue life and failure mechanism of bearing steel specimen. Tests were conducted on the TFTR to determine the ultimate strength in shear (Sus) and stress cycle (S-N) results. Evaluation of the fatigue specimens in the high cycle regime indicates shear driven crack initiation followed by normal stress driven propagation, resulting in a helical crack pattern. A 3D finite element model was then developed to investigate fatigue damage in torsion specimen and replicate the observed fatigue failure mechanism for crack initiation and propagation. In the numerical model, continuum damage mechanics (CDM) were employed in a randomly generated 3D Voronoi tessellated mesh of the specimen to provide unstructured, nonplanar, interelement, and inter/transgranular paths for fatigue damage accumulation and crack evolution as observed in micrographs of specimen. Additionally, a new damage evolution procedure was implemented to capture the change in fatigue failure mechanism from shear to normal stress assisted crack growth. The progression of fatigue failure and the stress-life results obtained from the fatigue damage model are in good agreement with the experimental results. The fatigue damage model was also used to assess the influence of topological microstructure randomness accompanied by material inhomogeneity and defects on fatigue life dispersion.

Damage Mechanics Based Fatigue Life Prediction for 63Sn-37Pb Solder Material

2000 ◽  
Author(s):  
Y. Wei ◽  
C. L. Chow ◽  
M. K. Neilsen ◽  
H. E. Fang
Keyword(s):  
Fatigue Life ◽  
Fatigue Damage ◽  
Damage Accumulation ◽  
Damage Mechanics ◽  
Damage Model ◽  
Hysteresis Loops ◽  
Cyclic Softening ◽  
Softening Behavior ◽  
Fatigue Damage Accumulation ◽  
Theory Of Damage

Abstract This paper presents a method of TMF analysis based on the theory of damage mechanics to examine the fatigue damage accumulation in 63Sn-37Pb solder. The method is developed by extending a viscoplastic damage model proposed earlier by the authors (Wei, et al 1999, 2000). A computer simulation is carried out to calculate hysteresis loops at three different strain ranges. The damage-coupled fatigue damage model is applied to predict the cyclic softening behavior of the material and the prediction is found to agree well with the experiment. With a proposed failure criterion based on the concept of damage accumulation, the TMF model is also found to predict successfully the fatigue life of 63Sn-37Pb solder.

Contact fatigue life prediction of rolling bearing considering machined surface integrity

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Li Cui ◽  
Yin Su
Keyword(s):  
Fatigue Life ◽  
Fatigue Damage ◽  
Fatigue Failure ◽  
Surface Integrity ◽  
Damage Accumulation ◽  
Rolling Bearing ◽  
Content Type ◽  
Accumulation Model ◽  
Fatigue Damage Accumulation ◽  
Damage Accumulation Model

Purpose Rolling bearings often cause engineering accidents due to early fatigue failure. The study of early fatigue failure mechanism and fatigue life prediction does not consider the integrity of the bearing surface. The purpose of this paper is to find new rolling contact fatigue (RCF) life model of rolling bearing. Design/methodology/approach An elastic-plastic finite element (FE) fatigue damage accumulation model based on continuous damage mechanics is established. Surface roughness, surface residual stress and surface hardness of bearing rollers are considered. The fatigue damage and cumulative plastic strain during RCF process are obtained. Mechanism of early fatigue failure of the bearing is studied. RCF life of the bearing under different surface roughness, hardness and residual stress is predicted. Findings To obtain a more accurate calculation result of bearing fatigue life, the bearing surface integrity parameters should be considered and the elastic-plastic FE fatigue damage accumulation model should be used. There exist the optimal surface parameters corresponding to the maximum RCF life. Originality/value The elastic-plastic FE fatigue damage accumulation model can be used to obtain the optimized surface integrity parameters in the design stage of bearing and is helpful for promote the development of RCF theory of rolling bearing.

Fatigue and fretting fatigue life prediction of double-lap bolted joints using continuum damage mechanics-based approach

2016 ◽  
Vol 26 (1) ◽  
pp. 162-188 ◽  
Author(s):  
Ying Sun ◽  
George Z Voyiadjis ◽  
Weiping Hu ◽  
Fei Shen ◽  
Qingchun Meng
Keyword(s):  
Fatigue Life ◽  
Fatigue Damage ◽  
Damage Mechanics ◽  
Failure Modes ◽  
Damage Model ◽  
Continuum Damage Mechanics ◽  
Fretting Fatigue ◽  
Bolted Joints ◽  
Continuum Damage ◽  
Bolted Joint

Fatigue and fretting fatigue are the main failure mode in bolted joints when subjected to cyclic load. Based on continuum damage mechanics, an elastic–plastic fatigue damage model and a fretting fatigue damage model are combined to evaluate the fatigue property of bolted joints to cover the two different failure modes arisen at two possible critical sites. The predicted fatigue lives agree well with the experimental results available in the literature. The beneficial effects of clamping force on fatigue life improvement of the bolted joint are revealed: part of the load is transmitted by friction force in the contact interface, and the stress amplitude at the critical position is decreased due to the reduction in the force transmitted by the bolt. The negative effect of fretting damage on the bolted joint is also captured in the simulation.

scholarly journals New Nonlinear Cumulative Fatigue Damage Model Based on Ecological Quality Dissipation of Materials

2021 ◽  
Vol 2021 ◽  
pp. 1-11
Author(s):  
Hongsong Li ◽  
Yongbao Liu ◽  
Xing He ◽  
Wangtian Yin
Keyword(s):  
Fatigue Life ◽  
Cyclic Loading ◽  
Fatigue Damage ◽  
Damage Model ◽  
Fatigue Loading ◽  
Ecological Quality ◽  
Aircraft Structures ◽  
Variable Amplitude ◽  
Fatigue Damage Accumulation ◽  
Cumulative Fatigue Damage

The failure of many aircraft structures and materials is caused by the accumulation of fatigue damage under variable-amplitude cyclic loading wherein the damage evolution of materials is complicated. Therefore, to study the cumulative fatigue damage of materials under variable-amplitude cyclic loading, a new nonlinear fatigue damage accumulation model is proposed based on the ecological quality dissipation of materials by considering the effects of load interaction and sequence. The proposed new model is validated by the test data obtained for three kinds of material under multilevel fatigue loading. Compared with the Miner model and Kwofie model, the proposed model can more effectively analyse the accumulative damage and predict fatigue life of different materials under variable-amplitude cyclic loading than others. The study provides a basis for predicting fatigue life accurately and determining reasonable maintenance periods of aircraft structures.

scholarly journals Continuum damage mechanics based approach to the fatigue life prediction of cast aluminium alloy with considering the effect of porosity

2018 ◽  
Vol 165 ◽  
pp. 14011
Author(s):  
Xiaojia Wang ◽  
Weiping Hu ◽  
Qingchun Meng
Keyword(s):  
Fatigue Life ◽  
Aluminium Alloy ◽  
Fatigue Damage ◽  
Damage Mechanics ◽  
Damage Model ◽  
Continuum Damage Mechanics ◽  
Fatigue Behaviour ◽  
Continuum Damage ◽  
Die Cast ◽  
Elastoplastic Constitutive Model

A damage mechanics based approach is applied for the study of fatigue behaviour of high pressure die cast ADC12 aluminium alloy. A damage coupled elastoplastic constitutive model is presented according to the concept of effective stress and the hypothesis of strain equivalence. An elastic fatigue damage model taking into account the pore-induced stress concentration is developed to investigate fatigue damage evolution of the specimens subjected to cyclic loading. The predicted lives for the specimens with different sizes of pores are consistent with the experimental data. The pore-induced fatigue damage and the variation of fatigue life along with the size of pores are also investigated.

scholarly journals A Modified Model for Nonlinear Fatigue Damage Accumulation of Turbine Disc Considering the Load Interaction Effect

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 919 ◽  
Author(s):  
Huang ◽  
Ding ◽  
Li ◽  
Zhou ◽  
Huang
Keyword(s):  
Fatigue Life ◽  
Fatigue Damage ◽  
Damage Accumulation ◽  
Damage Model ◽  
Modified Model ◽  
Damage Models ◽  
Fatigue Damage Accumulation ◽  
Turbine Disc ◽  
Damage Accumulation Model ◽  
Nonlinear Damage Model

Fatigue damage accumulation theory is one of the core contents in structure fatigue strength design and life prediction. Among them, the nonlinear damage model can overcome the shortcomings of the linear damage model, which takes the loading sequence effect into account. Besides, the loading interaction cannot be ignored for its profound influence in damage accumulation behavior. In the paper, some commonly-used methods of the linear and nonlinear fatigue damage accumulation theory are investigated. In particular, a modified nonlinear fatigue damage accumulation model which considers the effects of loading sequences as well as loading interactions on fatigue life is developed, and a load interaction parameter is obtained by analyzing damage models which assumes that the load logarithm ratio between adjacent stress levels can characterize this phenomenon. Finally, the modified model is employed to predict the fatigue life of high pressure turbine disc. Moreover, comparison is made between the experimental data as well as the predicted lives using the Miner’s rule, the Ye’s model, and the modified model.

Fatigue Life Prediction under Variable Loading Based a Non-Linear Energy Model

2016 ◽  
Vol 22 ◽  
pp. 14-21
Author(s):  
Abdelkader Djebli ◽  
Mostefa Bendouba ◽  
Aid Abdelkarim
Keyword(s):  
Fatigue Life ◽  
Aluminium Alloy ◽  
Fatigue Damage ◽  
Damage Model ◽  
Experimental Results ◽  
Random Loading ◽  
Random Load ◽  
Complex Load ◽  
Proposed Model ◽  
Fatigue Damage Accumulation

A method of fatigue damage accumulation based upon application of energy parameters of the fatigue process is proposed in the paper. Using this model is simple, it has no parameter to be determined, it requires only the knowledge of the curve W–N (W: strain energy density N: number of cycles at failure) determined from the experimental Wöhler curve. To examine the performance of nonlinear models proposed in the estimation of fatigue damage and fatigue life of components under random loading, a batch of specimens made of 6082 T6 aluminium alloy has been studied and some of the results are reported in the present paper. The paper describes an algorithm and suggests a fatigue cumulative damage model, especially when random loading is considered. This work contains the results of uni-axial random load fatigue tests with different mean and amplitude values performed on 6082 T6 aluminium alloy specimens. The proposed model has been formulated to take into account the damage evolution at different load levels and it allows the effect of the loading sequence to be included by means of a recurrence formula derived for multilevel loading, considering complex load sequences. It is concluded that a ‘damaged stress interaction damage rule’ proposed here allows a better fatigue damage prediction than the widely used Palmgren–Miner rule, and a formula derived in random fatigue could be used to predict the fatigue damage and fatigue lifetime very easily. The results obtained by the model are compared with the experimental results and those calculated by the most fatigue damage model used in fatigue (Miner’s model). The comparison shows that the proposed model, presents a good estimation of the experimental results. Moreover, the error is minimized in comparison to the Miner’s model.

scholarly journals A Revised Approach for the Life Prediction of Metal Materials Fabricated by Additive Manufacturing

Mechanika ◽  
2021 ◽  
Vol 27 (3) ◽  
pp. 187-192
Author(s):  
Haiming HONG ◽  
Jiaying WANG ◽  
Peng LI
Keyword(s):  
Fatigue Life ◽  
Additive Manufacturing ◽  
Theoretical Model ◽  
Energy Density ◽  
Fatigue Damage ◽  
Damage Mechanics ◽  
Damage Model ◽  
Density Ratio ◽  
Volume Energy ◽  
Metal Materials

In this work, a new fatigue damage model considering the additive manufacturing (AM) effects is established. We first present the elastoplastic constitutive model with the newly established fatigue damage model considering AM effects. The method to calibrate the material parameters is put forward, and the numerical solution of the theoretical model is implemented. Second, the fatigue lives of two AM metal materials are predicted, and the applicability of the theoretical model is verified by the test results. Finally, the influence of the volume energy density ratio on the fatigue life of AM metal materials is analyzed, and the results show that the volume energy density ratio has a great influence on the fatigue behavior of AM metal materials. When the ratio is less than 1.0, the fatigue life increases rapidly with the increase of the ratio. The fatigue life increases with the stress ratio when the volume density ratio keeps as a constant. The research work in this paper provides a feasible method to predict the fatigue life of AM metal materials by continuum damage mechanics in engineering.

A Multi-Level Low Cycle Fatigue Damage Model for Forging Die Material

2006 ◽  
Vol 514-516 ◽  
pp. 804-809
Author(s):  
S. Gao ◽  
Ewald Werner
Keyword(s):  
Fatigue Life ◽  
Fatigue Damage ◽  
Low Cycle Fatigue ◽  
Damage Model ◽  
Fatigue Loading ◽  
Cycle Fatigue ◽  
Die Material ◽  
Multi Level ◽  
Loading Sequence ◽  
Forging Die

The forging die material, a high strength steel designated W513 is considered in this paper. A fatigue damage model, based on thermodynamics and continuum damage mechanics, is constructed in which both the previous damage and the loading sequence are considered. The unknown material parameters in the model are identified from low cycle fatigue tests. Damage evolution under multi-level fatigue loading is investigated. The results show that the fatigue life is closely related to the loading sequence. The fatigue life of the materials with low fatigue loading first followed by high fatigue loading is longer than that for the reversed loading sequence.

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