Fatigue Life Prediction Based on Probabilistic Fracture Mechanics: Case Study of Automotive Parts

2015 ◽  
Vol 2 (1) ◽  
Author(s):  
Mahboubeh Yazdanipour ◽  
Mohammad Pourgol-Mohammad ◽  
Naghd-Ali Choupani ◽  
Mojtaba Yazdani
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Growth ◽  
Probabilistic Models ◽  
Fatigue Loading ◽  
Critical Fields ◽  
Propagation Of Uncertainty ◽  
Automotive Parts ◽  
Crack Growth Model

This paper studies the stochastic behavior of fatigue crack growth analytically and empirically by employing basic models in fracture mechanics. The research estimates the crack growth rate probabilistically, quantifies the uncertainty of probabilistic models under fatigue loading in automotive parts, and applies the simulations on W319 aluminum alloy, which has vast applications in automotive components’ products. Walker and Forman correlations are used in the paper. The deterministic simulations of these models are verified with afgrow code and validated experimentally with fatigue data of W319 aluminum. Then, the models are treated probabilistically by considering the models’ parameters stochastic. Monte Carlo (MC) simulation is employed to investigate the models under stochastic conditions. The paper is quantifies the propagation of uncertainty with calculating the standard deviations of crack lengths via cycles. The proposed procedure is useful for selecting a proper probabilistic fatigue crack growth model in specific applications and can be used in future fatigue studies not only in the automotive industry but also in other critical fields, to obtain more reliable conclusions.

Probabilistic Fatigue Crack Growth Analysis for Life Prediction of Automotive Components

2013 ◽  
Author(s):  
Mahboubeh Yazdanipour ◽  
Mohammad Pourgol-Mohammad ◽  
Naghd-Ali Choupani ◽  
Mojtaba Yazdani
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Probabilistic Models ◽  
Growth Models ◽  
Fatigue Loading ◽  
Deterministic Models ◽  
Propagation Of Uncertainty ◽  
Automotive Parts ◽  
Crack Growth Model

This research focuses on investigating the probabilistic fatigue crack growth models on W319 aluminum alloy which has vast applications in automotive parts products. The aim of this study is to determine the crack growth rate probabilistically and quantification of uncertainty of probabilistic models on estimation of damages (crack length) versus life (number of cycles) under fatigue loading in automotive parts. The models used in this paper include Walker and Forman correlations. The deterministic forms of these models are verified with AFGROW code and validated experimentally with fatigue data of W319 aluminum. After verifying the accuracy of deterministic models, the models are treated probabilistically by considering the models’ parameters stochastic. Monte Carlo simulation is devised to investigate the models under stochastic conditions by drawing samples from these random variables. Finally the propagation of uncertainty is quantified by calculating standard deviations of crack lengths through propagation of the uncertainties via cycles. The results are useful for selecting a proper probabilistic fatigue crack growth model in specific applications and can be used in future studies in automotive industry to obtain more accurate and reliable conclusions.

Fatigue Behavior and Damage Assessment of Stainless Steel/Aluminum Composites

2011 ◽  
Vol 133 (2) ◽  
Author(s):  
Volkan Eskizeybek ◽  
Ahmet Avci ◽  
Ahmet Akdemir ◽  
Ömer Sinan Şahin
Keyword(s):  
Stainless Steel ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Growth ◽  
Fatigue Behavior ◽  
Laminated Composite ◽  
Strain Energy Release ◽  
Fatigue Loading ◽  
304 Stainless Steel

Fatigue crack growth and related damage mechanisms were investigated experimentally in a stainless steel/aluminum laminated composite with middle through thickness crack, and two different fracture mechanics approaches applied to the composite to reveal their differences under fatigue loading. The laminated composite material, which has a unidirectional continuous AISI 304 stainless steel as fibers and Al 1060 as matrix, was produced by using diffusion bonding. Fatigue tests were conducted in accordance with ASTM E 647. The relationships between fatigue crack growth rate (da/dN), stress intensity factor (ΔK), and strain energy release rate (ΔG) were determined; and damage behavior was discussed. Both linear elastic fracture mechanics (LEFM) and compliance method were used, and the results were compared with each other. It is found that as the crack propagates, the LEFM overestimates the ΔG values. Interlaminar and fiber/matrix interface damage were evaluated by fractographic examination.

On Normalized Fatigue Crack Growth Modeling

2020 ◽  
Author(s):  
Sebastian T. Glavind ◽  
Henning Brüske ◽  
Michael H. Faber
Keyword(s):  
Fatigue Crack ◽  
Fatigue Life ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Model ◽  
Probabilistic Models ◽  
Maintenance Planning ◽  
Mechanical Models ◽  
Inspection And Maintenance ◽  
Crack Growth Model

Abstract Modeling of fatigue crack growth plays a key role in risk informed inspection and maintenance planning for fatigue sensitive structural details. Probabilistic models must be available for observable fatigue performances such as crack length and depth, as a function of time. To this end, probabilistic fracture mechanical models are generally formulated and calibrated to provide the same probabilistic characteristics of the fatigue life as the relevant SN fatigue life model. Despite this calibration, it is recognized that the rather complex fracture mechanical models suffer from the fact that several of their parameters are assessed experimentally on an individual basis. Thus, the probabilistic models derived for these parameters in general omit possible mutual dependencies, and this in turn is likely to increase the uncertainty associated with modeled fatigue lives. Motivated by the possibility to reduce the uncertainty associated with complex multi-parameter probabilistic fracture mechanical models, a so-called normalized fatigue crack growth model was suggested by Tychsen (2017). In this model, the main uncertainty associated with the fatigue crack growth is captured in only one parameter. In the present contribution, we address this new approach for the modeling of fatigue crack growth from the perspective of how to best estimate its parameters based on experimental evidence. To this end, parametric Bayesian hierarchical models are formulated taking basis in modern big data analysis techniques. The proposed probabilistic modeling scheme is presented and discussed through an example considering fatigue crack growth of welds in K-joints. Finally, it is shown how the developed probabilistic crack growth model may be applied as basis for risk-based inspection and maintenance planning.

Effect of Bi-Linear S-N Curve and Crack Growth Law on the Safety Analyses of Welded Joints of an Offshore Structure

2008 ◽  
Author(s):  
Rizwan A. Khan ◽  
Suhail Ahmad
Keyword(s):  
Fatigue Crack ◽  
Fatigue Life ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Growth ◽  
Limit State ◽  
Published Data ◽  
Offshore Structure ◽  
Structure Degradation ◽  
Crack Growth Model

Design of welded structures for fatigue limit state is normally carried out by means of either linear or bilinear S-N curves which have been found adequate to predict crack initiation only. To properly assess the effects of design, fabrication, inspection and repair strategy for structure degradation due to crack growth, Fracture mechanics (FM) models need to be applied. In this paper, alternative S-N and FM formulations of fatigue are investigated. Probabilistic fracture mechanics approach predicts the fatigue life of welded steel structure in the presence of cracks under random spectrum loading. It is based on a recently proposed bi-linear relationship to model fatigue crack growth and incorporates a failure criterion to describe the interaction between fracture and plastic collapse. Uncertainty modeling, especially on fatigue crack growth parameters, is undertaken with the aid of recently published data in support of the bilinear crack growth relationship. Results pertaining to fatigue reliability and fatigue crack size evolution are presented using the Monte Carlo Simulation Technique, and emphasis is placed on a comparison between linear and bi-linear crack growth models. The bi-linear S-N curve and crack growth model are found to lead to higher fatigue life estimates and shows sensitivity to many other parameters in addition to the stress state of the component. These findings implicate inspection schemes for components of the marine structures to ensure minimization of the surprises due to wide scatter of the fatigue phenomenon in marine environment. Variations in system configuration, service life and coefficients of crack growth laws have been studied on the parametric basis.

scholarly journals Probabilistic Fatigue Damage Assessment for Small Crack Growth

2000 ◽  
Author(s):  
Zhengwei Jack Zhao ◽  
Irewole Wally Orisamolu
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Growth ◽  
Fatigue Damage ◽  
Probabilistic Analysis ◽  
Damage Assessment ◽  
Small Crack ◽  
Assessment Methodology ◽  
Crack Growth Model

Abstract Fatigue and fracture are typical random phenomena due to various uncertainty sources, including material property, initial flaw and crack shape, structural configuration and geometry around crack tip, load fluctuation, and other environmental factors. As contrast to the most commonly used probabilistic fatigue growth models, which are built based on simplified fatigue crack growth law, a framework of probabilistic fracture mechanics based fatigue damage assessment methodology for small crack propagation is presented here. The proposed modeling is developed based on a comprehensive fatigue crack growth model, which accounts the effect of crack aspect ratio, stress ratio, and crack closure and retardation. Due to the complicated nature of the fatigue damage modeling adopted, a high non-linear limit state function with discontinuity resulted from physical domain jumping and overlapping are encountered. The advanced fast probability integration techniques in conjunction with response surface methodology and Monte Carlo simulation are used and the accuracy of the analysis is verified. The interface between probabilistic analysis package and the deterministic fracture mechanics analysis program is developed for the purpose of uncertainty propagation. The probability of failure of fatigue damage is computed first. The statistical characteristics of estimated fatigue life and critical crack size are obtained and presented through CDF/PDF curves. The sensitivity analysis is also performed, which provides an indication of the order of importance for the random variables considered. The results of the study have shown robustness and efficiency of the probabilistic analysis to deal with the real world challenge of uncertainty modelling, propagation, and quantification. Currently, possibility to combine the subject probabilistic damage assessment methodology with reliability updating techniques is under the investigation. The successfulness of the presented research activity will address an important issue of quantitative risk analysis for aging structures subjected to accumulative material damage.

Probabilistic Fracture Mechanics Assessment of Welded Joints of Offshore Structure Using a Bilinear Crack Growth Law

2008 ◽  
Author(s):  
Rizwan A. Khan ◽  
Suhail Ahmad
Keyword(s):  
Fatigue Crack ◽  
Fatigue Life ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Growth ◽  
Limit State ◽  
Published Data ◽  
Offshore Structure ◽  
Probabilistic Fracture Mechanics ◽  
Crack Growth Model

Design of welded structures for fatigue limit state is normally carried out by means of either linear or bilinear S-N curves approaches. To properly assess the effects of design, fabrication, inspection and repair strategy for structures degradation due to crack growth, Fracture mechanics (FM) models need to be applied. This paper deals with the application of a probabilistic fracture mechanics approach to predict the fatigue life of welded steel structure in the presence of cracks under random spectral loading. It is based on a BS7910 [1] proposed bi-linear relationship to model fatigue crack growth and incorporates a failure criterion to describe the interaction between fracture and plastic collapse. Uncertainty modeling, especially of fatigue crack growth parameters, is undertaken with the aid of recently published data in support of the bi-linear crack growth relationship. Results pertaining to fatigue reliability and fatigue crack size evolution are presented using the Monte Carlo Simulation technique, and emphasis is placed on a comparison between linear and bi-linear crack growth models. The bi-linear crack growth model is found to lead to higher fatigue life estimates and shows sensitivity to many other parameters in addition to the state of stress of the component. This leads to implications on inspection schemes for components of the marine structures and to ensure minimization of the surprises due to wide scatter of the fatigue phenomenon in marine environment. Variations in the system configuration, service life and coefficients of crack growth laws have been studied on the parametric basis.

Effective Modeling of Fatigue Crack Growth in Pipelines

2012 ◽  
Author(s):  
Steven J. Polasik ◽  
Carl E. Jaske
Keyword(s):  
Fatigue Crack ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Fracture Mechanics ◽  
Crack Growth ◽  
Growth Models ◽  
Critical Parameters ◽  
Operating Pressure ◽  
Mechanics Model ◽  
Key Variables

Pipeline operators must rely on fatigue crack growth models to evaluate the effects of operating pressure acting on flaws within the longitudinal seam to set re-assessment intervals. In most cases, many of the critical parameters in these models are unknown and must be assumed. As such, estimated remaining lives can be overly conservative, potentially leading to unrealistic and short reassessment intervals. This paper describes the fatigue crack growth methodology utilized by Det Norske Veritas (USA), Inc. (DNV), which is based on established fracture mechanics principles. DNV uses the fracture mechanics model in CorLAS™ to calculate stress intensity factors using the elastic portion of the J-integral for either an elliptically or rectangularly shaped surface crack profile. Various correction factors are used to account for key variables, such as strain hardening rate and bulging. The validity of the stress intensity factor calculations utilized and the effect of modifying some key parameters are discussed and demonstrated against available data from the published literature.

Evaluation of Fatigue Crack Growth Curves in Existing Codes and a Proposed Modification Based on Experimental Data of Cr-Ni-Mo-V Steel Welded Joints

2016 ◽  
Author(s):  
Yan-Nan Du ◽  
Ming-Liang Zhu ◽  
Fu-Zhen Xuan ◽  
Shan-Tung Tu
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Welded Joints ◽  
Growth Curves ◽  
Crack Growth Behavior ◽  
Fatigue Assessment ◽  
Crack Growth Model ◽  
Threshold Regime ◽  
Near Threshold

A comparison of currently available codes for assessment of fatigue crack growth, including ASME (America Society of Mechanical Engineers) SEC. XI, FKM (Forchungskuratorium Maschinenbau) guideline, WES (Japan Welding Engineering Society) 2805, BS7910 and JSME (The Japan Society of Mechanical Engineers), was carried out by paying attention to the suitability of application and the easiness to obtain the parameters, based on fatigue crack growth data of Cr-Ni-Mo-V steel welded joints. Results showed that fatigue crack growth curves provided by the FKM or WES were good choice when few inputs were at hand while the curves in the BS7910, JSME and ASME were recommended for precise estimation. It was indicated that the assessment of welded joints solely by fatigue crack growth behavior at base metal part and the assessment of fatigue crack growth for the aged condition by as-received one both resulted in non-conservativeness, albeit dependent on the range of stress ratios, R. A new bilinear form of fatigue crack growth model independent of R was developed based on transition point occurred in the near-threshold regime. This constituted the bilinear approach to fatigue assessment, and thus contributed to the optimization of fatigue assessment in the near-threshold regime.

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