一种新的铝合金应变疲劳计算方法

提出了一种在铝合金构件应变疲劳分析中,计算局部应力和应变变程的新方法。这种方法称作应力功恒等法。采用这种新方法,计算了2024-T42铝合金试件在恒幅循环载荷作用下的疲劳寿命,并将疲劳寿命计算结果与试验结果进行了对比分析。对比分析结果表明,采用这种新方法计算构件应力集中处的局部应力和应变变程,具有较高的计算精度。     

弹塑性随机有限元在低周疲劳分析中的应用

推导了交变载荷下弹塑性随机有限元的迭代格式,计算了局部多轴应力应变的随机响应。迭代格式中,针对复杂的交变载荷,采用运动强化模型反映塑性变形引起的各向异性和包辛格效应,运用Jhansale模型描述材料的瞬态应力应变关系。弹塑性有限元分析,克服了以往近似方法只能计算单轴局部应力应变响应的缺陷,为多轴疲劳分析奠定了基础。考虑零构件的随机因素,将随机有限元方法引入到交变载荷下弹塑性有限元的迭代格式中,得到局部应力应变的随机响应,为低周疲劳可靠性分析提供了更精确的依据。MontCarlo模拟结果证实了提出的弹塑性随机有限元方法是可靠的。     

基于自适应响应面法的输电塔线体系腐蚀疲劳可靠度研究

环境腐蚀和风振疲劳耦合作用下输电塔体的结构性能逐渐退化,满足预定设计功能的概率减小。然而,传统响应面法计算结构可靠度时均不能兼顾"效率"和"精度"。为此,首先通过严格的数学推导给出了交叉项是否存在的判断准则,将该判断准则与传统二次响应面法相结合建立了考虑部分交叉项的自适应响应面法。然后,通过Q345等边角钢腐蚀疲劳试验结果给出了构件腐蚀疲劳t-P-S-N曲线方程,再与概率论相结合建立了随机疲劳曲线方程。最后,通过工程算例采用建议自适应响应面法以风速、腐蚀时间和随机腐蚀疲劳S-N曲线方程为随机变量对输电塔线体系进行了腐蚀疲劳可靠度研究,结果表明:①交叉项判断准则能有效地保留相互影响随机变量之间的交叉项;②建议自适应响应面法在满足精度的同时能有效减少计算量;③构件随机腐蚀疲劳S-N曲线模型在结构可靠性分析中简单易行。     

基于背应力功的疲劳能量模型及其在轮槽构件寿命预测中的应用

基于局部应力-应变法与疲劳损伤能耗结构,以疲劳过程中背应力塑性功累积为基础,建立了一种新的缺口构件疲劳寿命预测能量模型,并将其应用于某型汽轮机轮槽结构件的疲劳寿命预测.通过与试验结果相比较,初步验证了模型的预测精度(预测寿命与试验寿命误差小于20％).此外,还进一步将上述能量模型与传统疲劳寿命预测能量方法进行了比较.结...     

基于概率断裂力学的老龄钢桥使用安全评估

我国交通线上存在大量老龄钢桥,这些老龄钢桥承受着日益繁重的交通荷载,其疲劳剩余寿命已受到桥梁管理部门的高度重视。为确保老龄钢桥的使用安全,避免不必要的维护与更换,建立老龄钢桥疲劳剩余寿命与使用安全评估方法十分必要。建立了反映老龄铆接钢桥疲劳破坏机理的脆断和韧断概率失效模型,给出了用于疲劳可靠性分析的极限状态方程,合理确定了随机变量的参数取值。建立了铆接钢桥构件单角钢概率疲劳破坏模型,基于MonteCarlo算法实现了铆接钢桥构件单角钢疲劳断裂失效概率的计算,编制了相应的概率断裂分析程序SAPFF。进而将铆接构件概率断裂模型应用于上海市浙江路桥的时变疲劳可靠度分析,并给出了浙江路桥概率疲劳剩余寿命评估结果与维护对策。     

基于车桥耦合随机振动分析的钢桥疲劳可靠度评估

发展了一种基于车桥耦合系统随机振动分析的铁路钢桥疲劳可靠度评估方法,建立车桥耦合系统模型,选取车速和轨道不平顺作为基本随机变量进行随机振动分析,以此确定桥梁构件等效疲劳应力幅及其循环次数的概率模型。在此基础上,建立基于S-N曲线法的疲劳极限状态函数并进行疲劳可靠度分析。以一座铁路下承式钢桁梁桥为例进行了疲劳可靠度评估,并讨论了车速及轨道平顺性对构件疲劳可靠性的影响。结果表明:该文方法可有效用于铁路钢桥疲劳可靠度评估;受车速及轨道不平顺随机性的影响,列车引起的桥梁构件等效疲劳应力幅及其循环次数均具有一定的不确定性,应视为随机变量,二者可采用对数正态分布表示;车速和轨道不平顺可显著影响桥梁构件的疲劳可靠性,疲劳关键构件的可靠度指标随着轨道平顺性增强而提高。     

传统局部应力应变法在高周疲劳寿命估算中的应用

本文指出了传统的局部应力应变法不适应于高周疲劳的原因，由此提出解决这一问题的方法：用等效应变－寿命曲线或四参数应变－寿命曲线替换Ｍａｎｓｏｎ－Ｃｏｆｆｉｎ公式，用更合适的缺口疲劳系数或缺口场强度来描述缺口受载的严重程度。     

不同环境对2D70铝合金低周疲劳性能的影响研究

循环应力和低周疲劳寿命都是材料疲劳损伤的关键指标.循环应力表征的是材料在循环载荷下抵抗变形的能力.大多数飞机构件由于拐角、圆孔、沟槽等的存在都会存在应力集中现象,当构件承受循环应力载荷时,虽然构件总体处于弹性范围内,但局部已进入弹塑性状态,即已处于循环应变的疲劳过程中.这类服役条件下的构件疲劳寿命一般小于105周次,称为低周疲劳,又由于低周疲劳断裂时应力水平往往较高,低周疲劳也称高应力疲劳或者应变疲劳.衡量材料抗低周疲劳特性的指标主要有低周疲劳极限和低周疲劳寿命,二者统称材料的低周疲劳性能.低周疲劳极限,是指材料所承受应力低于该应力极限值时其理论循环次数可为无限次;低周疲劳寿命,即构件破坏前能承受应力循环的次数.     

一种基于混合硬化本构模型的汽轮机轮盘榫槽疲劳寿命预测方法

针对汽轮机转子轮盘的受力特点,以非对称载荷下材料的瞬态应力应变响应为基础,在内变量理论框架下,建立起某型汽轮机轮盘材料的率无关循环塑性本构模型;并结合局部应力应变法,进一步建立了基于混合硬化本构模型(N-5L1)描述平均应力松弛行为的汽轮机轮盘榫槽疲劳寿命预测方法。通过与实验结果相比较,表明混合硬化本构模型能够较好地模拟脉动加载下转子轮盘材料的循环应力应变响应及平均应力松弛行为,由此建立的寿命预测方法可对轮盘榫槽进行较为准确的疲劳寿命预测(与试验寿命误差总体落在1.5倍分散带以内),明显优于基于平均应力松弛经验公式的疲劳寿命预测值。     

钢箱梁桥海量应变监测数据分析与 疲劳评估方法研究

海量监测数据的分析与应用是桥梁结构健康监测研究中的重要问题之一,以润扬大桥钢箱梁的长期应变监测数据为研究对象,研究了海量应变监测数据分析与疲劳评估方法。首先,基于Eurocode3规范的S-N曲线和Palmgren-Miner准则建立了焊缝疲劳损伤分析及寿命预测方法。其次,研究了应力循环的快速提取及应变数据中随机干扰成分的剔除方法。在此基础上,讨论了对公路钢箱梁桥开展长期持续疲劳监测的必要性,并给出了润扬大桥钢箱梁焊缝的疲劳寿命预测值。研究发现,采用MATLAB与C语言联合编程的雨流计数法可快速处理海量应变监测数据;根据对焊缝疲劳损伤的贡献可确定有效应力循环阀值,从而剔除由随机干扰引起的数量极多但幅值较小的应力循环;焊缝疲劳损伤在一年内会发生大幅度的变化,短期应变监测数据可能导致焊缝疲劳寿命评估值出现较大的偏差。     

Strain-life approach in thermo-mechanical fatigue evaluation of complex structures

This paper is a contribution to strain‐life approach evaluation of thermo‐mechanically loaded structures. It takes into consideration the uncoupling of stress and damage evaluation and has the option of importing non‐linear or linear stress results from finite element analysis (FEA). The multiaxiality is considered with the signed von Mises method. In the developed Damage Calculation Program (DCP) local temperature‐stress‐strain behaviour is modelled with an operator of the Prandtl type and damage is estimated by use of the strain‐life approach and Skelton's energy criterion. Material data were obtained from standard isothermal strain‐controlled low cycle fatigue (LCF) tests, with linear parameter interpolation or piecewise cubic Hermite interpolation being used to estimate values at unmeasured temperature points. The model is shown with examples of constant temperature loading and random force‐temperature history. Additional research was done regarding the temperature dependency of the K_p used in the Neuber approximate formula for stress‐strain estimation from linear FEA results. The proposed model enables computationally fast thermo‐mechanical fatigue (TMF) damage estimations for random load and temperature histories.     

Notched fatigue behavior including load sequence effects under axial and torsional loadings

Notch effects on axial and torsion fatigue behaviors of low carbon steel were investigated. Fully-reversed tests were conducted on thin-walled tubular specimens with or without a transverse circular hole. A shear failure mechanism was observed for both smooth and notched specimens and under both axial and torsion loadings. The notch effect was more pronounced under axial loading, in spite of higher stress concentration factor in torsion. The commonly used nominal S–N approach with fatigue notch factor in conjunction with von Mises effective stress resulted in overly conservative life predictions of both smooth and notched torsion fatigue lives. Neuber’s rule yielded notch root stress and strain amplitudes close to the FEA results for both axial and torsion loadings. The local strain approach based on effective strain obtained from Neuber’s rule or FEA resulted in poor correlation of the fatigue life data of smooth and notched specimens. The Fatemi–Socie critical plane parameter represented the observed failure mechanism and resulted in very good correlations of smooth and notched specimens fatigue data under both axial and torsion loadings. In block loading tests with equal number of alternating axial and torsion cycles at the same stress level, beneficial effect of axial loading was observed. Possible potential reasons for this unexpected behavior are discussed.     

The J-integral applied to cyclic loading

The influence of notch geometry on the life to fatigue crack initiation is determined using a modified two-dimensional J-integral analysis. A notched plate that is subjected to fully reversed cyclic nominal strain control is analyzed in order to determine the strain history at the notch root. The expression for strain concentration has the same form as that obtained from the Neuber approach. After the local stress-strain history has been determined, a life prediction for fatigue crack initiation could be made. The modified J-integral and Neuber approaches are compared. Justification for the use of the modified J-integral may be found in the appendices.     

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.     

Multiaxial fatigue life prediction method in the ground vehicle industry

The extensive progress which has been made in the multiaxial fatigue area over the past 5 to 10 years has allowed wider application of the multiaxial fatigue method in component durability design in the ground vehicle industry. The method adopts the long established local strain–life approach and includes several new features. (1) A three-dimensional cyclic stress–strain model, used to simulate the elastic–plastic material behavior under complicated loadings. (2) The critical plane approach, which requires the fatigue analysis to be performed on various potential failure planes before determining the lowest fatigue life. (3) A biaxial damage criterion, to better quantify fatigue damage under various loading conditions. (4) A multiaxial Neuber equivalencing technique, used to estimate, from the elastic finite element stress results, the multiaxial stress and strain history of plastically deformed notch areas. This paper examines the application of the above features to the fatigue analyses of three generic service/test histories: a constant amplitude (baseline) test history, a history directly recorded by strain gages mounted on the critical location of a structural component, and a loading history recorded in multichannels for a complex structure.     

Damage tolerance reliability analysis of automotive spot-welded joints

This paper develops a damage tolerance reliability analysis methodology for automotive spot-welded joints under multi-axial and variable amplitude loading history. The total fatigue life of a spot weld is divided into two parts, crack initiation and crack propagation. The multi-axial loading history is obtained from transient response finite element analysis of a vehicle model. A three-dimensional finite element model of a simplified joint with four spot welds is developed for static stress/strain analysis. A probabilistic Miner's rule is combined with a randomized strain-life curve family and the stress/strain analysis result to develop a strain-based probabilistic fatigue crack initiation life prediction for spot welds. Afterwards, the fatigue crack inside the base material sheet is modeled as a surface crack. Then a probabilistic crack growth model is combined with the stress analysis result to develop a probabilistic fatigue crack growth life prediction for spot welds. Both methods are implemented with MSC/NASTRAN and MSC/FATIGUE software, and are useful for reliability assessment of automotive spot-welded joints against fatigue and fracture.     

Concurrent ratcheting and stress relaxation at the notch root of steel samples undergoing asymmetric tensile loading cycles

The current study intends to develop a framework model to assess ratcheting and stress relaxation at the notch root of 1045 steel samples over asymmetric loading cycles. The framework involves the Ahmadzadeh‐Varvani (A‐V) kinematic hardening rule to control ratcheting progress and Neuber rule to accommodate for local stress and strain components at the vicinity of notch root. Plastic strain at notch root was first coupled with its counterpart in the A‐V model to establish a relation between local stress and backstress components. Calculated local stress and strain values at turning points enabled the A‐V model to assess ratcheting strain over each loading cycle. The stepwise drop in stresses at peak‐valley tips of hysteresis loops at the notch root was associated to coupled framework of the A‐V model and Neuber rule through constancy in local strain while ratcheting progressed over each cycle. This relaxed out the local stresses at tips of hysteresis loops to position on Neuber hyperbolic curve. Predicted ratcheting values at notch root of various diameters closely agreed with those of measured in steel samples over stress cycles.     

Fatigue life assessment of a low pressure steam turbine blade during transient resonant conditions using a probabilistic approach

This paper presents a sequential approach used in fatigue life prediction of a low pressure steam turbine blade during resonance conditions encountered during a turbine start-up by incorporating probabilistic principles. Material fatigue properties are determined through experimental testing of used blade material X22CrMoV12-1 along with statistical modelling using regression analysis to interpret the stress-life diagram. A finite element model of a free-standing LP blade is developed using the principle of sub-structuring which enables the vibration characteristics and transient stress response of the blade to be determined for variations in blade damping. Random curve fitting routines are performed on the fatigue and FEM stress data to ensure that the selection of the random variables used in fatigue life calculations is stochastic in nature. The random vectors are selected from a multivariate normal distribution. The use of confidence intervals in the probabilistic fatigue life model works effectively in being able to account for uncertainty in the material fatigue strength parameters and varying stress in the blade root. The predicted fatigue life of the blade is shown to be in good agreement with discrete life modelling results.     

Variation mode and effect analysis: an application to fatigue life prediction

We present an application of the probabilistic branch of variation mode and effect analysis (VMEA) implemented as a first‐order, second‐moment reliability method. First order means that the failure function is approximated to be linear around the nominal values with respect to the main influencing variables, while second moment means that only means and variances are taken into account in the statistical procedure. We study the fatigue life of a jet engine component and aim at a safety margin that takes all sources of prediction uncertainties into account. Scatter is defined as random variation due to natural causes, such as non‐homogeneous material, geometry variation within tolerances, load variation in usage, and other uncontrolled variations. Other uncertainties are unknown systematic errors, such as model errors in the numerical calculation of fatigue life, statistical errors in estimates of parameters, and unknown usage profile. By treating also systematic errors as random variables, the whole safety margin problem is put into a common framework of second‐order statistics. The final estimated prediction variance of the logarithmic life is obtained by summing the variance contributions of all sources of scatter and other uncertainties, and it represents the total uncertainty in the life prediction. Motivated by the central limit theorem, this logarithmic life random variable may be regarded as normally distributed, which gives possibilities to calculate relevant safety margins. Copyright © 2008 John Wiley & Sons, Ltd.     

Simulation of cyclic stress/strain evolutions for multiaxial fatigue life prediction

This study deals with simulation for cyclic stress/strain evolutions and redistributions, and evaluation of fatigue parameters suitable for estimating fatigue lives under multiaxial loadings. The local cyclic elastic–plastic stress–strain responses were analyzed using the incremental plasticity procedures of ABAQUS finite element code for both smooth and notched specimens made of three materials: a medium carbon steel in the normalized condition, an alloy steel quenched and tempered and a stainless steel, respectively. Emphasis is on the studying of ‘intelligent’ material behaviors to resist fracture, such as stress redistribution and relaxation through plastic deformations, etc. For experimental verifications, a series of tests of biaxial low cycle fatigue composed of tension/compression with static and cyclic torsion were carried out on a biaxial servo-hydraulic testing machine (Instron 8800). Different multiaxial loading paths were used to verify their effects on the additional cyclic hardening. The comparisons between numerical simulations and experimental observations show that the FEM simulations allow better understanding on the evolutions of the local cyclic stress–strain and it is shown that strong interactions exist between the most stressed material element and its neighboring material elements in the plastic deformations and stress redistributions. Based on the local cyclic elastic–plastic stress–strain responses, the energy-based multiaxial fatigue damage parameters are applied to correlating the experimentally obtained lives. Improved correlations between the predicted and the experimental results are shown. It is concluded that the improvement of fatigue life prediction depends not only on the fatigue damage models, but also on the accurate evaluations of the cyclic elasto-plastic stress/strain responses.