3D modeling of subsurface fatigue crack nucleation potency of primary inclusions in heat treated and shot peened martensitic gear steels |
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| Authors: | Rajesh Prasannavenkatesan Jixi Zhang David L McDowell Gregory B Olson Herng-Jeng Jou |
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| Affiliation: | 1. George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405, USA;2. School of Materials Science and Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0245, USA;3. Department of Mechanical Engineering, University of Nevada, Reno, NV 89557, USA;4. Department of Materials Science and Engineering, Robert R. McCormick School of Engineering and Applied Science, Northwestern University, Evanston, IL 60208-3108, USA;5. Questek Innovations LLC, Evanston, IL 60201, USA;1. School of Materials Science and Engineering, Tsinghua University, Beijing 100084, PR China;2. Institute of Special Steel, Central Iron and Steel Research Institute, No.76 XueYuanNanLu, Beijing 100081, PR China;3. NCS Testing Technology Co., Ltd., No.13 GaoLiangQiao XieJie, Beijing 100081, PR China;1. Iron and Steel Development Team, R & D Division of Hyundai Motor Company, 150, HyundaiYeonguso-ro, Namyang-eup, Hwaseong-si, Gyunggi-do, Republic of Korea;2. Mechanical, Industrial and Manufacturing Engineering Department, The University of Toledo, 2801 W. Bancroft Street, Toledo, OH 43606, USA;1. Department of Mechanical Engineering, The University of Sheffield, United Kingdom;2. Design Unit, Gear Technology Centre, The University of Newcastle, United Kingdom;1. School of Materials Science and Engineering, Dalian University of Technology, Dalian 116085, China;2. Beijing Aeronautical Manufacturing Technology Research Institute, Beijing 100024, China;1. Materials Engineering Division, CSIR-National Metallurgical Laboratory, Jamshedpur 831007, India;2. CSIR-National Metallurgical Laboratory Madras Centre, CSIR Madras Complex, Taramani, Chennai 600113, India |
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| Abstract: | A computational strategy is developed to characterize the driving force for fatigue crack nucleation at subsurface primary inclusions in carburized and shot peened C61® martensitic gear steels. Experimental investigation revealed minimum fatigue strength to be controlled by subsurface fatigue crack nucleation at inclusion clusters under cyclic bending. An algorithm is presented to simulate residual stress distribution induced through the shot peening process following carburization and tempering. A methodology is developed to analyze potency of fatigue crack nucleation at subsurface inclusions. Rate-independent 3D finite element analyses are performed to evaluate plastic deformation during processing and service. The specimen is subjected to reversed bending stress cycles with R = 0.05, representative of loading on a gear tooth. The matrix is modeled as an elastic–plastic material with pure nonlinear kinematic hardening. The inclusions are modeled as isotropic, linear elastic. Idealized inclusion geometries (ellipsoidal) are considered to study the fatigue crack nucleation potency at various subsurface depths. Three distinct types of second-phase particles (perfectly bonded, partially debonded, and cracked) are analyzed. Parametric studies quantify the effects of inclusion size, orientation and clustering on subsurface crack nucleation in the high cycle fatigue (HCF) or very high cycle fatigue (VHCF) regimes. The nonlocal average values of maximum plastic shear strain amplitude and Fatemi–Socie (FS) parameter calculated in the proximity of the inclusions are considered as the primary driving force parameters for fatigue crack nucleation and microstructurally small crack growth. The simulations indicate a strong propensity for crack nucleation at subsurface depths in agreement with experiments in which fatigue cracks nucleated at inclusion clusters, still in the compressive residual stress field. It is observed that the gradient from the surface of residual stress distribution, bending stress, and carburized material properties play a pivotal role in fatigue crack nucleation and small crack growth at subsurface primary inclusions. The fatigue potency of inclusion clusters is greatly increased by prior interfacial damage during processing. |
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