SHAPE OPTIMIZATION FOR FATIGUE PROBLEMS IN MECHANICAL ENGINEERING

High Cycle Fatigue (HCF) is a very important topic in mechanical engineering problems. Almost any machine part contains some changes in cross section or boreholes connected with stress concentration. It is the task of shape optimization to improve the strength of machine parts by changing the design at free boundaries. In the past, some work was done with the so-called classical stress concentration factors just to minimize the mentioned stress concentration, also for fatigue. This paper represents a more sophisticated view by including modern Continuum Damage Mechanics (CDM) to model material behavior in HCF. The central question is to design machinery parts so that maximum lifetime is obtained. The whole context for this is developed in this paper, including non-linear finite element algorithms. The paper concludes with numerical and experimental tests for the shape optimization of a notched tension bar in HCF.     

Efficient development of cycle time response surfaces using progressive simulation metamodeling

In semiconductor manufacturing, hot lots are to provide marketing and engineering with extra flexibility regarding delivery lead times, and in turn enhance its competitive advantages against other companies. On the other hand, hot lots are among major sources of disruption of the smoothness of the manufacturing flow. They can lead to a significant increase of cycle time of normal lots, and in turn result in delayed delivery times and serious service deteriorations. Due to the complex nature of semiconductor manufacturing, evaluating the impact of hot lots on the cycle time of normal lots presents major challenges. In this paper, we propose a methodology, called progressive simulation metamodelling (PSM), that allows for an efficient development of the response surface between the cycle time of normal lots and the percentage of hot lots in semiconductor manufacturing. The response surface generated by the proposed PSM is like an easy-to-use analytical model, but with the fidelity of simulation that takes into account all important manufacturing details. The specially-designed mechanisms, including identifying the critical region and sequentially adding design points in the critical region, further grants PSM computational advantages compared to the traditional response surface method. An empirical study conducted in collaboration with a semiconductor company validates the viability of PSM in real settings.     

连续管现场快速修复技术

连续管作业时会出现压扁、折弯和局部破损等问题,在现场需要安全快速切断连续管损坏部位,并实施管-管对接焊修复工程。为此,研制了便携式和全位置连续管校直机、旋转锥套式胀圆器、管口开坡口机以及6个自由度对中机构等成套修复设备。在采油井口连续管作业现场,运用这些修复设备和试验制定的修复工艺,在很短时间内就可以高质量地修复损坏的连续管。修复后连续管接头的疲劳循环次数达到母材管的61%。应用连续管快速修复技术可大大提高连续管井下作业效率,保证作业的安全性。     

Tensile flow behavior of ultra low carbon,low carbon and micro alloyed steel sheets for auto application under low to intermediate strain rate

This paper is concerned with tensile characteristics of auto grade low carbon, ultra low carbon and micro alloyed steel sheets under low to intermediate strain rates ranging from 0.0007 to 250 s⁻¹. Experimental investigation reveals two important aspects of these steels under intermediate strain rate deformation. Firstly, the yield stress increases with strain rate in all these steels. Of course yield stress increment is higher for low carbon and ultra low carbon steel sheets. Secondly, the strain hardening rate drastically decreases with strain rate for low carbon and ultra low carbon steel sheets, whereas it remains steady for micro alloyed steel sheets. Based on these observations, a constitutive model has been proposed which predicts the strain rate sensitive flow behavior of all these grades within the strain rate range of automotive crash event.     

Visualization of Fatigue Cracks at Structural Members Using a Pulsed Laser Scanning System

In this research, a noncontact nondestructive testing (NDT) method is proposed to detect the fatigue crack and to identify the location of the damage. To achieve this goal, Lamb wave propagation of a plate-like structure, which is induced by scanning laser source actuation system, is analyzed. A ND:YAG pulsed laser system is used to generate Lamb wave exerted at the multiple points of a steel coupon, and a piezoelectric sensor is installed to measure the structural responses. Multiple time signals measured by the piezoelectric sensor are aligned along the vertical and horizontal axes corresponding to laser impinging points so that 3-dimensional data can be constructed. Then, the 3-dimensional data is sliced along the time axis to visualize the wave propagation. The scattering of Lamb wave due to the damage can be described in the wave propagation image, and hence the damage can be localized and quantified. Damage-sensitive features, which are reflected wave from the damage, are clearly extracted by wave-number filtering based on the 3-dimensional Fourier transform of the visualized data. Structural members with fatigue cracks are investigated to verify the effectiveness and the robustness of the proposed NDT approach.     

Assessment of fatigue response of thermally aged reduced activation ferritic-martensitic steel based on finite element analysis

Abstract

In the present investigation, effect of thermal ageing on low cycle fatigue (LCF) behaviour of Reduced Activation Ferritic Martensitic steel has been assessed by finite element analysis. The steel was thermally aged at 873 K for 3000 hour. Low cycle fatigue tests were carried out on both the as-received and thermally aged material at strain rate of 3×10^?3 s^?1 at 823 K, over strain amplitudes in the range of ± 0.25 to ± 0.8%. Continuous cyclic softening till final failure, except for initial few cycles especially at relatively lower strain amplitudes, was observed in both the material conditions. Thermal ageing resulted in marginally higher cyclic stress response accompanied by lower fatigue life. The differences in fatigue responses have been attributed to the coarsening of precipitates on thermal ageing. Finite element analysis has been carried out considering combined isotropic and kinematic hardening as material model to estimate the effect of thermal ageing on the response of material under LCF loading. Thermal ageing was found to decrease both the isotropic and kinematic hardening with appreciable effect on isotropic hardening. The predicted cyclic stress response and hysteresis loops were found to be in good agreement with the experimental data. The LCF life of the steel has been estimated based on the hysteresis energy approach.     

Thermal-mechanical fatigue simulation of a P91 steel in a temperature range of 400–600°C

Abstract

This paper deals with the identification of material constants to simulate the effect of cyclic mechanical loading and temperatures. A Chaboche viscoplasticity model was used in this study to model the thermal-mechanical behaviour of a P91 martensitic steel. A fully-reversed cyclic mechanical testing programme was conducted isothermally between 400 and 600°C with a strain amplitude of 0.5%, to identify the model constants using a thermo-mechanical fatigue (TMF) test machine. Thermo-mechanical tests of P91 steel were conducted for two temperature ranges of 400 – 500°C and 400 – 600°C. From the test results, it can be seen that the P91 steel exhibits cyclic softening throughout the life of the specimens, for both isothermal and thermal-mechanical loading and this effect can be modelled by the set of viscoplasticity constants obtained. Finite element simulations of the test specimens show good comparison to isothermal and TMF experimental data.     

Grain-level statistical plasticity analysis on strain cycle fatigue of a FCC metal

The micromechanical strain cycle fatigue-life is systematically investigated by the micro-level numerical simulation, compared with symmetrical strain cycle experiments of copper, focusing on the characteristics of polycrystalline aggregation and the mechanism of microscale plastic deformation. A methodology to predict the low-cycle fatigue life by micro-level simulation along with statistical analysis is proposed through the following steps: (1) A crystal plasticity model is developed based on the nonlinear kinematic hardening mechanism of crystal slipping system. This model is applied to the calculations of crystal grain interior stresses and plastic strains. (2) A statistical representative volume element (SRVE) is constructed for a pure copper as a material model which features a polycrystalline Voronoi aggregation consisting of a number of crystal grains. This SRVE can be used for statistical analysis of the material inhomogeneous stresses and strains during cycle loading. (3) The simulations are performed to model the experimental cycle evolution of strain fatigue by using the SRVE under the symmetrical tensile–compressive loading. (4) Statistical and micromechanical analyses are carried out for the inhomogeneous interior stresses and strains of the SRVE of the polycrystalline copper in the low cycle regime. The resulting analysis can render the microscale interpretation and numerical simulation for the low-cycle fatigue evolution accordingly.