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.     

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.     

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.     

Analytical durability modeling and evaluation—complementary techniques for physical testing of automotive components

As a result of the commercial pressure new methods of durability evaluation have to be explored, automotive suppliers are now being asked to develop new components and subsystems in shorter times and using fewer physical prototypes. The need for the verification of the existing methods for the durability assessment have been increasing and this turns out to be the only way to propose new computational models to validate the final product within these reduced time scales and resources. The paper reviews some of the computational aspects of fatigue damage analysis and life prediction, and a practical fatigue evaluation tool is presented to meet this challenge. The computational methodology based on the local strain approach is described in detail for the fatigue damage assessment of metallic components under general multiaxial fatigue loads. The application of the proposed methodology is illustrated with an industrial example; the numerical simulation of biaxial cornering tests of light-alloy wheels is conducted, and correlations between the cornering test cycles and predicted cycles using different damage models are provided and comparisons in terms test failure locations and estimated crack initiation sites are given.     

Application of inverse first-order reliability method for probabilistic fatigue life prediction

A general probabilistic life prediction methodology for accurate and efficient fatigue prognosis is proposed in this paper. The proposed methodology is based-on an inverse first-order reliability method (IFORM) to evaluate the fatigue life at an arbitrary reliability level. This formulation is different from the forward reliability problem, which aims to calculate the failure probability at a fixed time instant. The variables in the fatigue prognosis problem are separated into two categories, i.e., random variables and index variables. An efficient searching algorithm for fatigue life prediction is developed to find the corresponding index variable at a certain confidence level. Numerical examples using direct Monte Carlo simulation and the proposed IFORM method are compared for algorithm verification. Following this, various experimental data for metallic materials are used for model prediction validation.     

A fatigue damage accumulation model for reliability analysis of engine components under combined cycle loadings

Rotor components of an aircraft engine in service are usually subjected to combined high and low cycle fatigue (CCF) loadings. In this work, combining with the load spectrum of CCF, a modified damage accumulation model for CCF life prediction of turbine blades is first put forward to take into account the effects of load consequence and load interaction caused by high‐cycle fatigue (HCF) loads and low‐cycle fatigue (LCF) loads under CCF loading conditions. The predicted results demonstrate that the proposed model presents a higher prediction accuracy than Miner, Manson‐Halford model does. Moreover, to evaluate the fatigue reliability of rotor components, reliability model with the failure mode of CCF is proposed on the basis of the stress‐strength interference method when considering the strength degeneration, and its results show that the reliability model with CCF is more suitable for aero‐engine components than that with the failure mode of single fatigue.     

Simulation of fatigue crack growth in components with random defects

The paper presents a probabilistic method for the simulation of fatigue crack growth from crack-like defects in the combined operating and residual stress fields of an arbitrary component. The component geometry and stress distribution are taken from a standard finite element stress analysis. Number, size and location of crack-like defects are ‘drawn’ from probability distributions. The presented fatigue assessment methodology has been implemented in a newly developed finite-element post-processor, P • FAT, and is useful for the reliability assessment of fatigue critical components. General features of the finite element post-processor have been presented. Important features, such as (i) the determination of the life-controlling defect, (ii) growth of short and long cracks, (iii) fatigue strength and fatigue life distribution and (iv) probability of component fatigue failure, have been treated and discussed. Short and long crack growth measurements have been presented and used for verification of the crack growth model presented.     

复合材料疲劳可靠性研究

将复合材料疲劳可靠性研究领域划分为载荷／环境谱的编制、疲劳性能、疲劳寿命估算及疲劳可靠性分析与设计四个方面,并分别简述了各自方面的研究进展。     

Finite element simulation of fretting wear and fatigue in thin steel wires

This paper studies the effect of fretting on fatigue life reduction of thin steel wires, using the frictionally-induced multiaxial contact stresses obtained from a finite element wear model, validated in previous work. The fatigue life prediction model uses a critical-plane SWT approach in a 3D crossed cylinder problem. A new damage accumulation methodology for the adaptive mesh simulation, based on the cyclic material removal, has been developed. Four methods (Manson’s universal slope, Muralidharan modified universal slopes, medians and fatigue S–N curves) for estimation of the fatigue coefficients of the wire have been used. Manson’s method and medians method give lives closer to those obtained from fretting wear tests in thin steel wires. The other methods are more conservative. The methodology predicts correctly the life reduction of this component due to the increase of normal load (contact pressure), while it is not clearly predicted that an increase of the stroke reduces the life of these components as shown in the experimental testing. Guidelines for developing a more robust methodology are proposed.     

Multiaxial notch fatigue life prediction based on pseudo stress correction and finite element analysis under variable amplitude loading

A new computational methodology is proposed for fatigue life prediction of notched components subjected to variable amplitude multiaxial loading. In the proposed methodology, an estimation method of non‐proportionality factor (F) proposed by authors in the case of constant amplitude multiaxial loading is extended and applied to variable amplitude multiaxial loading by using Wang‐Brown's reversal counting approach. The pseudo stress correction method integrated with linear elastic finite element analysis is utilized to calculate the local elastic‐plastic stress and strain responses at the notch root. For whole local strain history, the plane with weight‐averaged maximum shear strain range is defined as the critical plane in this study. Based on the defined critical plane, a multiaxial fatigue damage model combined with Miner's linear cumulative damage law is used to predict fatigue life. The experimentally obtained fatigue data for 7050‐T7451 aluminium alloy notched shaft specimens under constant and variable amplitude multiaxial loadings are used to verify the proposed methodology and equivalent strain‐based methodology. The results show that the proposed methodology is superior to equivalent strain‐based methodology.     

The needs of understanding stochastic fatigue failure for the automobile crankshaft: A review

This paper reviews the fatigue failure mechanisms for the automobile crankshaft under service loading through the stochastic point of view. Fatigue failure of crankshafts are reviewed in general, as it is a major concern due to the uncertainties that arise i.e. randomness in structural materials, the geometric shape of the component and randomness of service loads. There has been very little research carried out in assessing the fatigue failure using the stochastic process in predicting the fatigue life of crankshafts. This review paper discusses the durability aspects of the component and is followed by a review of the characteristics of loading and the stochastic fatigue failure effect on the components. In addition, the stochastic approach from empirical model aspect using a safe-life approach from the more recent advances in computational methods to assess stochastic fatigue failure was discussed and reviewed in the context of this paper. The integration between the empirical and probabilistic methods can be quantified using statistical models, which evaluate the damage that leads to fatigue and eventually fatigue failure. Hence, this review provides a platform for understanding the stochastic fatigue failure for an accurate predictive prediction on the structural integrity of components, especially in the automobile industry.     

Application of continuum damage mechanics to vibration fatigue life prediction

It is pivotal to predict the multiaxial vibration fatigue life during mechanical structural dynamics design. An algorithm of the finite element method implementation for multiaxial high cycle fatigue life evaluation is proposed, on the basis of elastic evolution model of continuum damage mechanics. By considering structural dynamic characteristics, namely, resonant frequencies and mode shapes, this algorithm includes a modal analysis and harmonic analysis, which makes this different from existing fatigue life prediction methods. A 10% decrease in the resonant frequency is regarded as the failure criterion. A critical damage value was obtained, which indicates mesocrack initiation fulfilment. To validate the effectiveness of the algorithm, auto‐phase sine resonance track‐and‐dwell experiments were conducted on notched cantilever beams made of Ti‐6Al‐4V alloy. The life predictions are conservative and in good agreements with the experimental results, which are mainly distributed within a scatter band of 2. This investigation could provide technical support for structural dynamics design and the analysis of reusable spacecraft.     

An improved damage model using the construction technology of virtual load spectrum and its statistical analysis

In this work, an improved damage model based on construction technology of virtual load spectrum is developed. A predetermined reliability index is used as the termination criterion to calculate the fatigue life, and the results of statistical analysis have shown that the accuracy of fatigue life prediction result has been greatly improved. The model is targeting cyclic loading applications. The main advantage of the model is the use of construction technology of virtual load spectrum for expanding load spectrum and the Monte Carlo method for correcting fatigue damage. Another advantage concerns the link between predetermined reliability criterion and the fatigue life, which puts forward a new method of calculating fatigue life. The convergence proof of the model is presented, and physical experiment data are shown for validation. Several illustrative examples are presented to confirm the accuracy and efficiency of the proposed damage model.     

Health Monitoring and Prognostics of Electronics Subject to Vibration Load Conditions

This paper discusses a health monitoring and prognostics methodology for assessing the reliability of a group of electronic components mounted on a printed circuit board by using strain gauges and an accelerometer to monitor the life-cycle vibration loads. These loads were converted into the component interconnects' stress values, which were then used in a vibration failure fatigue model for damage assessment. Damage estimates were accumulated using Miner's rule and then used to predict the life consumed and remaining life. The results were verified by experimentally measuring component lives through real-time daisy-chain resistance measurements.     

An improved neural computing method for describing the scatter of S–N curves

The reliability evaluation of structural components under random loading is affected by several uncertainties. Proper statistical tools should be used to manage the large amount of causalities and the lack of knowledge on the actual reliability-affecting parameters. For fatigue reliability prediction of a structural component, the probability distribution of material fatigue resistance should be determined, given that the scatter of loading spectra is known and a suitable damage cumulating model is chosen. In the randomness of fatigue resistance of a material, constant amplitude fatigue test results show that at any stress level the fatigue life is a random variable. In this instance fatigue life is affected by a variety of influential factors, such as stress amplitude, mean stress, notch factor, temperature, etc. Therefore a hybrid neural computing method was proposed for describing the fatigue data trends and the statistical scatter of fatigue life under constant loading conditions for an arbitrary set of influential factors. To support the main idea, two examples are presented. It can be concluded that the improved neural computing method is suitable for describing the fatigue data trends and the scatter of fatigue life under constant loading conditions for an arbitrary set of influential factors, once the optimal neural network is designed and trained.     

Transient reliability of ceramic structures

Present capabilities of the NASA Ceramic Analysis and Reliability Evaluation of Structures/Life (CARES/Life) code include probabilistic life prediction of ceramic components subjected to fast fracture, slow crack growth (SCG) (stress corrosion), and cyclic fatigue failure modes. Currently, this code has the capability to compute the time-dependent reliability of ceramic structures subjected to simple time-dependent loading. For example, in SCG type failure conditions CARES/Life can handle the cases of sustained and linearly increasing time-dependent loads, whereas for cyclic fatigue applications, it can account for various types of repetitive constant amplitude loads. In real applications applied loads are rarely that simple, but rather vary with time in more complex ways such as engine start up and shut down and dynamic and vibrational loads. In addition, when a given component is subjected to transient environmental and/or thermal conditions, the material properties also vary with time. The objective of this paper is to demonstrate a methodology capable of predicting the time-dependent reliability of components subjected to transient thermomechanical loads that take into account the change in material response with time. In this article, the dominant delayed failure mechanism is assumed to be SCG. This capability has been added to the NASA CARES/Life code, which has also been modified to have the ability of interfacing with commercially available finite element analysis codes executed for transient load histories. An example involving a ceramic exhaust valve subjected to combustion cycle loads is presented to demonstrate the viability of this methodology and the CARES/Life program.     

Application of Kriging and radial basis function in power electronic module wire bond structure reliability under various amplitude loading

This paper discusses life time prediction of wire bond structure in a power electronic module based on computational approach that integrates methods for high fidelity analysis, reduced order modelling, and life time prediction using reduced order model. This methodology is demonstrated for the design of a wire bond structure in a power electronic module with aim of reducing the chance of failure due to the wire bond lift off in power electronic module when a random load is applied to the aluminium wire. In particular, wire bond reliability of the power module related to the thermal fatigue material degradation of aluminium wire is one of the main concerns. In the power electronic module reliability, understanding the performance, reliability and robustness of wire bond is a key factor for the future development and success of the power electronic module technology, because wire bond lift off failure ignites other catastrophic failures.The main focus in this study is on the application of reduced order modelling techniques and the development of the associated models for fast evaluation and analysis. The discussion is on methods for approximate response surface modelling based on interpolation techniques using Kriging and radial basis functions. The reduced order modelling approach uses prediction data for the electro-thermo-mechanical behaviour of the power module wirebond design obtained through non-linear transient finite element simulations, in particular for the fatigue life-time of the aluminium wire attached to the silicon chip of the wire in the module. The reduced order models are used for the analysis of predicting the life time of the wire bond structure under random load. One of the widely used cycle counting algorithm, so called rainflow counting algorithm is utilised to count the cycles of temperature profile at the a specific point of the wire bond structure in a power electronic module. Using the cycle results from rainflow algorithm mean life time of the wire bond structure is predicted by a linear cumulative damage model such as Palmgren–Miner rule. This model is utilised to predict the mean fatigue life of the wire bond structure.     

Fatigue reliability evaluation using probability density evolution method

Probability density evolution method is extended to analysis of fatigue reliability. The joint probability density evolution equation of random parameters and fatigue damage is derived based on the principle of preservation of probability, and a finite difference algorithm in terms of TVD theory is presented. For a given damage threshold, cycle-dependent fatigue reliability can be calculated by the proposed method without assuming the probabilistic distribution of fatigue damage in advance. Two validation examples indicate that the proposed method is able to give reasonable results for constant-amplitude loading and variable-amplitude loading. The predicted fatigue reliability under constant-amplitude loading shows a considerable accuracy. In addition, reliability isolines of fatigue damage can be used to predict the fatigue life with a specified failure probability.     

A semi-analytical Monte Carlo simulation method for system's reliability with load sharing and damage accumulation

A novel approach for assessing a systems' reliability with dependency structures, load sharing, and damage accumulation and reversal is proposed in this paper. It is a blend of analytical reliability analysis performed at the component level, and is based on understanding the failure mechanism of the components, and a Monte Carlo simulation for the entire system to assess the reliability at the system level incorporating the dynamics of the system behavior as the components interact, share loads, and age over time. Model reduction is deployed to reduce the complexity and accelerate the simulation and convergence of the analytical methods such as FORM and SORM performed at the component level. Numerical examples are provided to illustrate the usability and performance of the method.     

SHAPE DESIGN SENSITIVITY ANALYSIS AND OPTIMIZATION FOR STRUCTURAL DURABILITY

In this paper, a design sensitivity analysis (DSA) method for fatigue life of 3-D solid structural components of mechanical systems with respect to shape design parameters is presented. The DSA method uses dynamic stress DSA obtained using an analytical approach to predict dynamic stress increment due to design changes; computes fatigue life of the component, including crack initiation and crack propagation, using the predicted dynamic stress; and uses the difference of the new life and the original life at the same critical point to approximate the sensitivity of fatigue life. A tracked vehicle roadarm is presented in this paper to demonstrate accuracy and efficiency of the DSA method. Also, this method is applied to support design optimization of the tracked vehicle roadarm considering crack initiation lives as design constraints. © 1997 by John Wiley & Sons, Ltd.