Fatigue life evaluation of mechanical components using vibration fatigue analysis technique

Unit brackets attached on a cross member and subjected to random loads often fail due to self-vibration. To prevent such failures, it is necessary to understand the fatigue failure mode and to evaluate the fatigue life using test or analysis techniques. The objective of this study is to develop test specifications for components, which are applicable to predict fatigue life at the stage of initial product design, for the unit brackets by using a vibration fatigue technique. For this objective, the necessity of a fatigue analysis considering resonant effect was reviewed. Also, a series of vibration fatigue analyses were carried out by changing the acceleration’s direction and magnitude. Then, a methodology was proposed to determine the optimum vibration fatigue test specification of the component, which gives an equivalent failure mode with the vehicle test condition.     

Thermal postbuckling behavior of shear deformable FGM plates with temperature-dependent properties

Thermal postbuckling analysis is presented for a simply supported, shear deformable functionally graded plate under thermal loading. Two cases of temperature field, i.e. in-plane non-uniform parabolic temperature distribution and heat conduction are considered. The material properties of functionally graded materials (FGMs) are assumed to be graded in the thickness direction according to a simple power-law distribution in terms of the volume fractions of the constituents, and the material properties of FGM layers are assumed to be temperature-dependent. The governing equations are based on a higher-order shear deformation plate theory that includes thermal effects. The initial geometric imperfection of the plate is taken into account. A two-step perturbation technique is employed to determine buckling temperature and postbuckling equilibrium paths. The numerical illustrations concern the thermal postbuckling behavior of perfect and imperfect, geometrically mid-plane symmetric FGM plates under different sets of loading conditions. The results reveal that the temperature dependency has a significant effect on the thermal postbuckling behavior of FGM plates. The results also confirm that for the case of heat conduction, the postbuckling path for geometrically perfect plates is no longer of the bifurcation type.     

含MoSi2热障梯度涂层的抗热震性能研究

对添加MoSi2和未加MoSi2的ZrO2-A1／Ni梯度热障涂层的抗热震性能的比较，并结合微观组织和能谱对此进行了分析。结果表明，，MoSi2在热震过程中发生了反应，添加MoSi2可提高涂层的抗热震性能。     

Thermal buckling analysis of annular FGM plate having variable thickness under thermal load of arbitrary distribution by finite element method

In this paper, a finite element formulation is developed for analyzing the axisymmetric thermal buckling of FGM annular plates of variable thickness subjected to thermal loads generally distributed nonuniformly along the plate radial coordinate. The FGM assumed to be isotropic with material properties graded in the thickness direction according to a simple power-law in terms of the plate thickness coordinate, and has symmetry with respect to the plate midplane. At first, the pre-buckling plane elasticity problem is developed and solved using the finite element method, to determine the distribution of the pre-buckling in-plane forces in terms of the temperature rise distribution. Subsequently, based on Kierchhoff plate theory and using the principle of minimum total potential energy, the weak form of the differential equation governing the plate thermal stability is derived, then by employing the finite element method, the stability equations are solved numerically to evaluate the thermal buckling load factor. Convergence and validation of the presented finite element model are investigated by comparing the numerical results with those available in the literature. Parametric studies are carried out to cover the effects of parameters including thickness-to-radius ratio, taper parameter and boundary conditions on the thermal buckling load factor of the plates.     

TiN涂层刀具的抗热冲击性能

采用激光照射的方法研究了TiN涂层刀具的抗热冲击性能,并用有限元的方法计算了TiN涂层刀具在激光照射过程中产生的应力分布.结果表明:利用激光照射的方法研究涂层刀具的抗热冲击性能是可行的,将激光的临界功率密度作为评价涂层刀具抗热冲击性能的参数;涂层在激光照射过程中产生的压应力作用下发生失稳翘曲,进而导致裂纹的产生.试验结果和有限元计算结果吻合良好.     

Thermal fatigue of cast iron brake disk materials

To develop cast-iron brake disks with high heat resistance to thermal shock loading, three candidate materials were developed. The main components were Fe, C, Si, Mn, Ni, Cr, Mo, Cu and Al. The mechanical and thermal properties of the candidates were measured. Thermal fatigue tests were then carried out using equipment developed by the authors. The possible temperature range of the testing equipment was 20°C ??1500°C. Cylindrical solid specimens ?20 × 80 mm were heated by an induction coil and cooled in water. At an interval of 20??30 thermal cycles, the surfaces of the specimens were examined with a digital microscope to check for thermal cracks. To quantify the total length of the cracks, an image analyzing program capable of measuring the length of cracks on micrographs was developed. It was found the fatigue lifetime of cast iron could be increased by regulating its composition and metallurgical structures.     

陶瓷/金属非保守FGM斜板的颤振分析

研究了陶瓷/金属非保守功能梯度材料（FGM）斜板的颤振问题。以薄板理论为基础,假定材料的等效物性参数为沿厚度方向体积分数的幂律变化,在斜坐标系下建立了非保守FGM斜板的运动微分方程。运用微分求积法,对四边固支边界条件下陶瓷/金属非保守FGM斜板的量纲一复频率进行了数值计算,分析了FGM斜板的梯度指标、夹角和长宽比的变化对非保守FGM斜板稳定性的影响。结果表明,非保守FGM斜板的临界颤振荷载随梯度指标和夹角的增大而减小,随长宽比的增大而增大。     

激光冲击处理对曲轴疲劳强度的影响

利用激光冲击波对曲轴连杆轴颈圆角进行了强化处理,通过液压伺服疲劳试验研究激光冲击处理工艺对曲轴扭转疲劳强度的影响,利用X射线衍射法分析激光冲击处理后轴颈圆角处残余应力的分布规律,利用扫描电镜观察激光冲击处理表面微结构,分析激光冲击处理提高曲轴疲劳强度的微观机理。结果表明,激光冲击处理在曲轴圆角表面产生了残余压应力场,曲轴疲劳寿命显著提高,疲劳裂纹扩展速率大大降低;残余压应力场提高是激光冲击处理改善曲轴疲劳性能的主要机制。     

Thermal characteristic evaluation of functionally graded composites for PSZ/metal

The functionally graded material (FGM) is the new concept for a heat resisting material. FGM consists of ceramics on one side and metal on the other. A composition and microstructure of an intermediate layer change continuously from ceramics to metal at the micron level. This study is carried out to analyze the thermal shock characteristics of functionally graded PSZ/metal composites. Heat-resistant property was evaluated by gas burner heating test using C₂H₂/O₂ combustion flame. The ceramic surface was heated with burner flame and the bottom surface cooled with water flow. Also, the composition profile and the thickness of the graded layer were varied to study the thermomechanical response. Furthermore, this study carried out the thermal stress analysis to investigate the thermal characteristics by the finite element method. Acoustic emission (AE) monitoring was performed to detect the microfracture process in a thermal shock test.     

A study on the evaluation of the micro grooving using the AE technology

This study describes evaluation and monitoring methods of machining characteristics for developed micro grooving machines. Experiments were conducted under various process conditions such as spindle revolution speed, feed rates, and depth of groove. V and U shape of blades and STD11 were used in this experiment. The status of grooving was evaluated through analysis of the acoustic emission (AE) signal resulted in each process condition. Based on the analysis, this paper examines the possibility of monitoring adapting fuzzy logic. In conclusion, this paper presents the possibility of monitoring in process adapting AE technology and appropriate micro grooving conditions.     

Thermal expansion of solids at high temperatures by the gamma attenuation technique

A new technique is described for the measurement of the thermal expansion of isotropic solid materials at high temperatures. The method utilizes gamma attenuation to measure thermal expansion with a noncontacting probe. The experimental apparatus and analytical method are described, and results are presented for aluminum to 900 K and type 303 stainless steel to 1660 K to illustrate the use and precision of the technique. These results agree with published values measured by other techniques, and in the case of the stainless steel alloy, some new results are presented in the temperature range 1400-1660 K.     

Fretting fatigue of laser shock peened Ti-6Al-4V

The objective of this paper is to examine fretting fatigue of laser shock peened (LSP) titanium to quantify the influence of LSP on fretting fatigue life. Contact conditions such as loads and pad geometry are chosen to generate fretting fatigue stresses similar to those occurring in blade/disk contacts in gas turbine engines. LSP treated specimens attained 5-, 10- and 25-fold increase in lives compared to untreated specimens. Metallography of the contact area and fractographic analysis of worn pads detail the fretting behavior of LSP treated specimens.     

Reliability and fatigue life evaluation of railway axles

The axle is one of the most important components of a rail vehicle which transmits the weight of the vehicle to the wheels, meets the vertical and horizontal loads formed during static and dynamic moving, and carries the driving moment and braking moment. The prediction of fatigue failure of axles plays an important role in preventing fatigue fractures. Varying loads on components lead to cumulative failure in the mechanism. In this study, failures in axles of rail vehicles serving the Istanbul Transportation Co. have been investigated. Statistical evaluation of real life values has been performed by taking into account the kilometer and load cycle. Equivalent stresses have been used to derive life equations and diagrams by using one of the cumulative life theories known as the Palmgren-Miner method. Finally, theoretical and practical Wohler diagrams S-N (σ-N: stress-life) have been plotted to reveal error calculation.     

Impact evaluation of rolling contact fatigue life models

Since the accurate prediction of fatigue life has a significant value, many researchers have attempted to develop a reliable fatigue life model. Recently, rolling contact fatigue life models incorporating machining impact were developed. These models have contributed to a significant improvement in prediction accuracy as compared with earlier models, thus representing a major step forward in the modeling effort. This paper compares the prediction accuracy of these models with that of the prediction method in International Standards. When α is set to 0.25, the observed improvement of prediction accuracy as measured by variance of prediction errors due to these models over that due to prediction method in International Standards is statistically significant. Impact analyses of such improvement are conducted to illustrate its value. It is further noted that while difference was observed between the variance of prediction errors due to the crack initiation life model based on a dislocation model and that due to the crack initiation life model based on a local stress-life curve, the observed difference is not statistically significant.

     

Calibration and uncertainty evaluation of single pitch deviation by multiple-measurement technique

Gears are key elements of power transmission systems, and the inspection of their pitch deviation is one of the most important tests on gears. The specifications of gears are assessed using gear measuring instruments (GMIs) or coordinate measuring machines (CMMs), and the results of the measurements must be validated under an appropriate traceability system. In the traceability system, calibrated gauges whose measuring uncertainties are estimated are necessary. In the case of pitch deviation measurement, special artefacts or gears manufactured with high dimensional accuracy are used as reference gauges. In this paper, authors propose calibration and uncertainty evaluation methods for the single pitch deviation of gears measured using CMMs. First, the evaluation of single pitch deviation using a multiple-measurement technique and the estimation of its uncertainty based on the analysis of variance are formulated. Second, a technique for reducing the measurement trials based on the symmetry of the measurement is discussed. Finally, the proposed calibration method is validated through experiments.     

滚动轴承疲劳寿命数值仿真技术的研究

建立了滚动轴承疲劳寿命计算的数学模型,运用Monte-Carlo方法对其实验数据进行模拟,编制出相应的计算程序并建立了滚动轴承疲劳寿命预测系统.在计算机上完成滚动轴承寿命计算、数值模拟和滚动轴承的疲劳寿命的预测.     

借助振动和声发射诊断滚动轴承的失效

借助振动和声发射(ＡｃｏｕｓｔｉｃＥｍｉｓｓｉｏｎ,简称ＡＥ)来检测和诊断轴承的滚动接触疲劳失效,已经做了大量的研究工作(ＤａｒｌｏｗａｎｄＢａｄｇｌｅｙ,1975;Ｂｅｒｒｙ,1991;Ｃａｒｔｅｒ,1996;Ｂａｒｋｏｖ等,1996;Ｊａｍｅｓ等,1973;Ｅｎｓｏｒ等,1975及Ｉｎｏｕｅ等,1987)。在通过振动和ＡＥ检测轴承的失效中,快速傅里叶变换(ＦＦＴ)分析被广泛采用。然而ＦＦＴ分析需要许多步骤才能得到轴承中有缺陷的零件的频谱。为了在轴承应用中推广现代诊断技术(ＣＤＴ),有必要研究更简便的分析方法。本文所述方法是通过ＡＥ声源定位和测…     

Thermal diffusivity measurement of Au nanofluids of very low concentration by using photoflash technique

In this paper, the application of photoflash technique to measuring the thermal diffusivity of gold nanofluids of very low concentration at room temperature was presented. The nanofluid samples were prepared from the pulse laser ablation procedure. The thermal diffusivity was obtained by fitting the theoretical temperature signal to the experimental data, and it was found to increase linearly from 1.47 × 10⁻³ cm² s⁻¹ to 1.68 × 10⁻³ cm² s⁻¹ as the concentration increased from 1.11 mg/L to 3.18 mg/L. The increase in thermal diffusivity in these multidispersed nanofluids was attributed to the higher nanoparticle concentration as well as to the increasing presence of the smaller size nanoparticles.     

Dynamic test and fatigue life evaluation of compressor blades

High-cycle fatigue (HCF) has been identified as one of the primary causes of gas turbine engine failure. To verify the reliability of the high cycle fatigue fracture of the 5 MW gas turbine engine blade being developed by Doosan Heavy Industries & Construction Co., Ltd., dynamic tests were conducted using real size compressor rigs according to previous studies. The dynamic safety margin of the 5MW gas turbine engine blade was calculated on the basis of the ratio between the dynamic stress and endurance limit stress respectively determined through the compressor rig and fatigue tests. The HCF characteristics and the fatigue life stability of the DGT-5 compressor blades were verified through these processes. A fatigue life design procedure for the gas turbine compressor blade was established on the basis of the design, analysis, and test processes implemented in a previous study. In sum, the 5 MW class gas turbine compressor blades were found to be well designed in terms of resonance stability and fatigue life.