A multi-temporal scale approach to high cycle fatigue simulation

High cycle fatigue (HCF) is a failure mechanism that dominates the life of many engineering components and structures. Time scale associated with HCF loading is a main challenge for developing a simulation based life prediction framework using conventional FEM approach. Motivated by these challenges, the extended space–time method (XTFEM) based on the time discontinuous Galerkin formulation is proposed. For HCF life prediction, XTFEM is coupled with a two-scale continuum damage mechanics model for evaluating the fatigue damage accumulation. Direct numerical simulations of HCF are performed using the proposed methodology on a notched specimen of AISI 304L steel. It is shown the total fatigue life can be accurately predicted using the proposed simulation approach based on XTFEM. The presented computational framework can be extended for predicting the service and the residual life of structural components.     

A hybrid frequency–time domain method for predicting multiaxial fatigue life of 7075‐T6 aluminium alloy under random loading

A hybrid frequency–time domain method for predicting multiaxial fatigue life under random loading is developed on the basis of combination of the frequency domain and time domain analysis. The critical damage point of the structure is determined by the frequency domain equivalent stress method. Then, the fatigue life prediction is made in time domain by generating random load‐time histories from the power spectral density of the critical point. The method is validated with the random vibration fatigue test of 7075‐T6 aluminium alloy. It has been shown that the results of fatigue life calculated by hybrid method are well correlated with the experiment.     

循环荷载作用下粉砂岩疲劳流变损伤模型研究

针对现有流变模型难以有效描述循环荷载作用下岩石变形及疲劳损伤演化特征等问题,开展了粉砂岩循环加卸载试验,分析了不同上限荷载下岩石的流变规律与疲劳特性。基于Kachanov蠕变损伤理论建立损伤变量,引入一个带应变触发和应力阈值的黏塑性元件,与Burgers模型串联构建循环荷载作用下岩石疲劳流变损伤模型;将正弦波应力函数替换流变微分本构方程中的恒定应力,推导岩石在循环荷载下的一维、三维微分型损伤本构方程,再根据叠加原理得到模型的黏弹塑性流变损伤方程。适用性验证表明,新建模型不仅可以精确地反映循环加卸载过程中粉砂岩的衰减、稳态流变阶段,还可以有效地描述上限荷载高于疲劳强度时的加速流变阶段。通过粉砂岩疲劳损伤流变全过程定量化分析,提出加速流变阶段的临界损伤阈值和破坏失稳判据,并给出加速流变阶段的启始时间、持续时间及疲劳寿命预测方法,模型对岩体工程长期稳定性评价具有一定的理论指导意义。     

Damage behaviour of laminated composites during fatigue loading

This study deals with the modelling of damage evolution in the carbon/epoxy laminated composites under static and fatigue loading. A cumulative damage model is developed on the basis of damage evolution due to static and fatigue during cyclic loading. A continuum damage mechanics (CDM)‐based damage model coupling with the micromechanics has been utilized to predict the fatigue behaviour of laminate composites. A multicriterion approach has been introduced to predict the damage behaviour in the longitudinal, transverse, and shear direction at the ply scale. Extensive experimental results on T300/EPL1012 carbon/epoxy laminates are prepared to characterize under static and fatigue loading and to evaluate the proposed model in different conditions. The obtained results show that at the beginning of the cyclic loading, the damage grows suddenly and increases until final failure, which justifies the proposed method is able to predict the evolution of the damage due to static and fatigue loading separately during cyclic loading. The obtained results show that considering damage due to static loading leads to more accurate results, particularly in low‐cycle fatigue.     

Damage mechanics based probabilistic high‐cycle fatigue life prediction for Al 2024‐T3 using non‐intrusive polynomial chaos

This paper proposes a low‐cost method for predicting probabilistic high‐cycle fatigue life for Al 2024‐T3 based on continuum damage mechanics and non‐intrusive polynomial chaos (NIPC). To randomize Lemaitre's two scale fatigue damage model, parameters S and s are regarded as random variables. Based on small sample of test life, inverse analysis is performed to obtain samples of the two parameters. Statistic characteristics of the two parameters are calculated analytically through coefficients of NIPC. Fatigue test of aluminum alloy 2024‐T3 standard coupon and plate with hole under different spectrum loading shows that the proposed method is effective.     

Stepped‐isothermal fatigue analysis of engine piston

Stepped‐isothermal fatigue failure is the main failure mechanism of modern engine pistons under bench reliability test condition. This paper presents a methodology for stepped‐isothermal fatigue analysis of engine pistons, which consists of a fatigue criterion, evaluation of temperature and stress distribution by finite element analysis and the final life prediction. The major character of the methodology is the fatigue definition of engine pistons with respect to engine load change cycle and a damage‐based fatigue criterion accounting for the nonlinear creep–fatigue damage. Taking as an example, the fatigue life of an engine piston was predicted by the proposed analysis procedures. The analysis results showed that the most critical area was located in the throat edge. Moreover, the proposed methodology can give a relatively accurate and reasonable life prediction for an engine piston under the loading condition of bench reliability test, with a benefit of decreasing the needed component's reliability tests and design time.     

Modelling of load interaction and overload effect on fatigue damage of steel bridges

This paper studies the effects of load sequence and interaction, and overloading effect on the fatigue damage of bridges on the basis of a non-linear fatigue damage model. The model is derived from the theory of continuum damage mechanics for high-cycle fatigue. Fatigue behaviour at two levels of constant stress range is first discussed in detail. The formulation for the effective fatigue strength of the predamaged members is then derived, and the results predicted by the model are compared with the experimental data for two stress level tests and other results obtained from linear and double linear fatigue damage models. The variation of cycle ratio and fatigue life due to overloading is secondly investigated; the equations for evaluating the effect of overloading on fatigue damage accumulation on bridges at normal traffic loading are then derived. It has been demonstrated that the developed model can well describe the effect of load sequence and interaction and has also been verified by comparing the predicted results obtained by the model with the experimental data based on two levels of stress tests. The effect of accidental overloading on the fatigue damage of existing bridges can also be evaluated using the model. The model is applied to evaluate the fatigue damage and service life of the Tsing Ma Bridge, an essential portion of the transport network for the Hong Kong airport, under normal traffic loading and possible accidental overloading.     

局部高密度钢纤维混凝土弯曲疲劳损伤演变规律

在混凝土弯曲构件底部用高密度钢纤维局部增强称为局部高密度钢纤维混凝土(PHPFRC)与同样纤维掺量的传统钢纤维混凝土(SFRC)比较它可以用相近的价格获得高得多的刚度﹑承载力和抗疲劳断裂性能为了能够预测PHPFRC在循环荷载作用下的疲劳寿命需要确定其疲劳损伤演变规律本文通过试验发现局部高密度钢纤维混凝土的弯曲疲劳损伤表现出韧性材料所具有的性质基本上接近韧性损伤这与素混凝土及传统钢纤维混凝土有本质的不同根据其疲劳特性的实验结果探讨了PHPFRC弯曲疲劳损伤阈值结合损伤理论建立了适合于纤维体积掺量为1.2%的局部高密度钢纤维混凝土试件的弯曲疲劳损伤演变方程     

Multiaxial fatigue and life prediction of elastomeric components

Elastomeric components have wide usage in many industries. The typical service loading for most of these components is variable amplitude and multiaxial. In this study a general methodology for life prediction of elastomeric components under these typical loading conditions was developed and illustrated for a passenger vehicle cradle mount. Crack initiation life prediction was performed using different damage criteria. The methodology was validated with component testing under different loading conditions including constant and variable amplitude in-phase and out-of-phase axial–torsion experiments. The optimum method for crack initiation life prediction for complex multiaxial variable amplitude loading was found to be a critical plane approach based on maximum normal strain plane and damage quantification by cracking energy density on that plane. Rainflow cycle counting method and Miner’s linear damage rule were used for predicting fatigue life under variable amplitude loadings. The fracture mechanics approach was used for total fatigue life prediction of the component based on specimen crack growth data and FE simulation results. Total fatigue life prediction results showed good agreement with experiments for all of the loading conditions considered.     

Auto‐adaptive multiblock cycle jump algorithm for fatigue damage simulation of long‐span steel bridges

An algorithm is developed for fatigue damage evolution simulation of long‐span steel bridges based on continuum damage mechanics (CDM) in this study. The progressive fatigue damage from local component damage evolution to entire structural failure is simulated with nonstandard varying block cycle length, which is automatically obtained during computation to speed up fatigue evolution simulation without user intervention. In this paper, progressive fatigue damage evolution of the Stonecutters cable‐stayed bridge due to vehicle loading is simulated by using the proposed algorithm and the bridge model. It shows that the algorithm is effective, and it can improve the computational efficiency of fatigue damage simulation of a large‐scale steel bridge.     

The fatigue life prediction for structure with surface scratch considering cutting residual stress,initial plasticity damage and fatigue damage

In this paper, a continuum damage mechanics based fatigue model is used to evaluate the effect of surface scratches resulting from accidental scrapes on the fatigue life of structures. First, a dynamic analysis is conducted to simulate scratch generation. Second, the initial damage field caused by plastic deformation in the scraping process is calculated. Third, for structures with scratches under fatigue loading, Chaudonneret’s damage model for multiaxial fatigue is applied and the finite element implementation is presented. At last, this method is applied to life calculation for scratched specimens and for a scratched fixed plate. The theoretical calculation tallies with the experimental results.     

A model for predicting the creep-fatigue life under stepped-isothermal fatigue loading

A model is developed herein for predicting the fatigue life of creep-fatigue damage interaction, which is induced by combined high frequency mechanical loading and low frequency temperature variation, i.e. stepped-isothermal fatigue loading. The model is derived from continuum damage mechanics. In the model, the interaction between creep and fatigue damage is considered to be nonlinear. To validate the proposed model, a cast aluminum alloy is fatigue tested at 200–350 °C and 350–400 °C. The results show that good agreement can be achieved between predicted life and experimental data.     

Effects of intermittent loading time and stress ratio on dwell fatigue behavior of titanium alloy Ti-6Al-4V ELI used in deep-sea submersibles

Different components of deep-sea submersibles,such as the pressure hull,are usually subjected to inter-mittent loading,dwell loading,and unloading during service.Therefore,for the design and reliability assessment of structural parts under dwell fatigue loading,understanding the effects of intermittent loading time on dwell fatigue behavior of the alloys is essential.In this study,the effects of the inter-mittent loading time and stress ratio on dwell fatigue behavior of the titanium alloy Ti-6Al-4V ELI were investigated.Results suggest that the dwell fatigue failure modes of Ti-6Al-4V ELI can be classified into three types,i.e.,fatigue failure mode,ductile failure mode,and mixed failure mode.The intermittent loading time does not affect the dwell fatigue behavior,whereas the stress ratio significantly affects the dwell fatigue life and dwell fatigue mechanism.The dwell fatigue life increases with an increase in the stress ratio for the same maximum stress,and specimens with a negative stress ratio tend to undergo ductile failure.The mechanism of dwell fatigue of titanium alloys is attribute to an increase in the plastic strain caused by the part of the dwell loading,thereby resulting in an increase in the actual stress of the specimens during the subsequent loading cycles and aiding the growth of the formed crack or damage,along with the local plastic strain or damage induced by the part of the fatigue load promoting the cumu-lative plastic strain during the dwell fatigue process.The interaction between dwell loading and fatigue loading accelerates specimen failure,in contrast to the case for individual creep or fatigue loading alone.The dwell fatigue life and cumulative maximum strain during the first loading cycle could be correlated by a linear relationship on the log-log scale.This relationship can be used to evaluate the dwell fatigue life of Ti alloys with the maximum stress dwell.     

定侧压混凝土双压疲劳损伤模型

基于边界面概念和损伤力学理论,建立了一向定侧压混凝土双轴压各向异性损伤模型。加载面、边界面方程均以损伤能量释放率表示。在能量释放率空间内,由加载面与初始损伤面、边界面之间的位置描述损伤状态。通过建立累积损伤与相应循环损伤能量释放率阈值之间的关系,确定了疲劳加载中极限断裂面尺寸的变化规律,由此模拟混凝土在循环荷载作用下的刚度退化过程。结合已有的试验结果,确定了理论模型中的计算参数。经比较,理论模型预测的应力-应变数值、疲劳寿命和试验结果吻合较好。     

Systematic fatigue spectrum editing by fast wavelet transform and genetic algorithm

Fatigue testing is critical in order to establish the service life of load-bearing components and structures. The extensive time associated with full fatigue spectrum testing can lead to prohibitive costs. A significant need exists for a fatigue load spectrum editing methodology, based on the mechanics of fatigue, that produces load spectra that can replicate service damage in laboratory testing and can lead to compressed testing times and reduced costs. In this work, a wavelet genetic (WAVEGEN) algorithm is developed to edit fatigue loading spectra using wavelet analysis to greatly reduce the length of a spectrum while retaining the same damage accumulation characteristics. In addition, an optimization protocol using a genetic algorithm is included within this process to automatically select the best wavelet editing parameters. The algorithm is designed to identify the most suitable wavelet type, filter, and level to optimally edit a given fatigue spectrum and ensure equivalence between edited and unedited spectra from a damage perspective. The algorithm was applied to two well-known aircraft fatigue spectra: Fighter Aircraft Loading Standard for Fatigue evaluation (FALSTAFF) and Transport Wing Standard (TWIST). The proposed approach has demonstrated that both spectra can be compressed significantly even while ensuring equivalence from a damage perspective.     

High temperature strength and multiaxial fatigue life assessment of a tubesheet structure

A continuum damage mechanics (CDM) model was adopted to calculate the multiaxial fatigue damage of perforated structure (also called ‘tubesheet’) of a heat exchanger. In achieving this goal, the structure strength was numerically investigated in terms of steady and transient state prior to perform fatigue life prediction. Due to the complexity of geometry and loading pattern, the three dimensional (3D) finite element (FE) model was established for the tubesheet, and the changes of the multiaxial factor were explored in the spatial and temporal perspective respectively. Furthermore, the fatigue damage evolution was analyzed by taking multiaxial factor into account. Finally, the results showed that the fatigue damage evolution was significantly accelerated by multiaxial factor, and the life prediction by multiaxial CDM was in good agreement with observed data for the tubesheet.     

混凝土拉-压疲劳损伤模型及其验证

基于连续损伤力学理论,提出了混凝土单轴拉-压疲劳损伤模型。模型中采用了拉和压两个边界面。加载面、边界面方程均以损伤能量释放率表示。在能量释放率空间内,由加载面与初始损伤面、边界面之间的位置描述损伤状态。通过建立累积损伤与相应循环损伤能量释放率阈值之间的关系,确定了疲劳加载中极限断裂面尺寸的变化规律,由此模拟混凝土在循环荷载作用下的刚度退化过程。结合作者完成的疲劳试验结果,确定了理论模型中的计算参数。经比较,理论模型预测的应力-应变数值、疲劳寿命和试验结果吻合较好。     

Multiaxial fatigue reliability analysis of railroad wheels

A general methodology for fatigue reliability degradation of railroad wheels is proposed in this paper. Both fatigue crack initiation and crack propagation life are included in the proposed methodology using previously developed multiaxial fatigue models by the same authors. A response surface method in conjunction with design of experiments is used to develop a closed form approximation of the fatigue damage accumulation with respect to the input random variables. The total fatigue life of railroad wheels under stochastic loading is simulated, accounting for the spatial and temporal randomness of the fatigue damage. The field observations of railroad wheel fatigue failures are compared with the numerical predictions using the proposed methodology.