Fatigue Analysis and Life Prediction of Dumpers with Cumulative Fatigue Damage Approach

A fatigue damage model is developed for evaluating accumulative fatigue damage of dumpers. The loading spectrums acted on dumpers are created according to measured strain data in field. The finite element analysis is carried out for assessing stress distribution and strength characteristics of dumpers. Fatigue damage indexes and service life are calculated by a modified Palmgren-Miner rule. The investigation shows that fatigue notch factor has a significant influence on the calculation of fatigue damage of dumpers.

RELIABILITY ANALYSIS FOR AN AERO ENGINE TURBINE DISK UNDER LOW CYCLE FATIGUE CONDITION

Reliability analysis methods based on the linear damage accumulation law (LDAL) and load-life interference model are studied in this paper. According to the equal probability rule, the equivalent loads are derived, and the reliability analysis method based on load-life interference model and recurrence formula is constructed. In conjunction with finite element analysis (FEA) program, the reliability of an aero engine turbine disk under low cycle fatigue (LCF) condition has been analyzed. The results show the turbine disk is safety and the above reliability analysis methods are feasible.

The Effects of Fatigue Cracks on Fastener Loads during Cyclic Loading and on the Stresses Used for Crack Growth Analysis in Classical Linear Elastic Fracture Mechanics Approaches

High strength threaded fasteners are widely used in the aircraft industry, and service experience shows that for structures where shear loading of the joints is significant, like skin splices, fuselage joints or spar caps-web attachments, more cracks are initiated and grow from the edges of the fastener holes than from features like fillets radii and corners or from large access holes. The main causes of this cracking are the stress concentrations introduced by the fastener holes and by the threaded fasteners themselves, with the most common damage site being at the edge of the fastener holes. Intuitively, it is easy to visualize that after the crack initiation, during the growth stages, some of the load transferred initially by the fastener at the cracked hole will decrease, and it will be shed to the adjacent fasteners that will carry higher loads than in uncracked condition. Using currently available computer software, the method presented in this paper provides a relatively quick and quantitatively defined solution to account for the effects of crack length on the fastener loads transfer, and on the far field and bypass loads at each fastener adjacent to the crack. At each location, these variations are determined from the 3-dimensional distribution of stresses in the joint, and accounting for secondary bending effects and fastener tilt. Two cases of a typical skins lap splice with eight fasteners in a two rows configuration loaded in tension are presented and discussed, one representative for wing or fuselage skins configurations, and the second case representative for cost effective laboratory testing. Each case presents five cracking scenarios, with the cracks growing from approx. 0.03 inch to either the free edge, next hole or both simultaneously.

New approach based on continuum damage mechanics with simple parameter identification to fretting fatigue life prediction

A new continuum damage mechanics model for fretting fatigue life prediction is established. In this model, the damage evolution rate is described by two kinds of quantities. One is associated with the cyclic stress characteristics obtained by the finite element （FE） analysis, and the other is associated with the material fatigue property identified from the fatigue test data of standard specimens. The wear is modeled by the energy wear law to simulate the contact geometry evolution. A two-dimensional （2D） plane strain FE implementation of the damage mechanics model and the energy wear model is presented in the platform of ABAQUS to simulate the evolutions of the fatigue damage and the wear scar. The effect of the specimen thickness is also investigated. The predicted results of the crack initiation site and the fretting fatigue life agree well with available experimental data. Comparisons are made with the critical plane Smith- Watson-Topper （SWT） method.

Fatigue Life Estimation of an Elastomeric Pad by ε-N Curve and FEA

Failure analysis and fatigue life prediction are very important in the design procedure to assure the safety and reliability of rubber components. The fatigue life of a railway elastomeric pad is predicted by combining the test of material properties and finite element analysis (FEA). The specially developed chloroprene rubber material’s fatigue life equation is acquired based on uniaxial tensile test and fatigue life tests performed on the dumbbell specimens of the chloroprene rubber. The same chloroprene rubber was developed at Indian Rubber Manufacturer’s Research Association, Thane. The strain distribution contours and the maximum total principal strains of the elastomeric pad at different compressive loads are obtained using finite element analysis method. The software used for the FEA was ANSYS. The three parameter nonlinear hyperelastic Mooney-Rivlin Model and plane 182 elements were used for finite element analysis. The critical region cracks prone to arise are obtained and analysed. Then the maximum first principal elastic strain was used as the fatigue damage parameter, which is substituted in the chloroprene rubber’s fatigue life equation, to predict the fatigue life of an elastomeric pad in the number of cycles at different compressive loads. The results were compared with the technical requirements given by Indian Railway’s Research Designs and Standards Organization. These requirements were achieved up to certain extents. The results were also compared with the data available in the literature and a similarity was observed between the results acquired and literature data. In short, the proposed fatigue life prediction method can shorten the product design cycle, decrease the design and product cost remarkably and improve the quality of an elastomeric pad.

The Study of Contact Pressure Analyses and Prediction of Dynamic Fatigue Life for Linear Guideways System

The application of the linear guideways is very extensive, such as automation equipment, heavy-duty carry equipment, heavy-cut machining tool, CNC grinding machine, large-scale planning machine and machining center with the demand of high rigidity and heavy load. By means of the study of contact behavior between the roller/guideway and roller/slider, roller type linear guideways can improve the machining accuracy. The goal of this paper is to construct the fatigue life model of the linear guideway, with the help of the contact mechanics of rollers. In beginning, the analyses of the rigidity of a single roller compressed between guideway and slider was conducted. Then, the normal contact pressure of linear guideways was obtained by using the superposition method, and verified by the FEM software (ANSYS workbench). Finally, the bearing life theory proposed by Lundberg and Palmgren was used to describe the contact fatigue life.

Stress distribution and fatigue life of built-up sleeved backup roll

The advantage of built-up sleeved backup roll was described. Based on the stress distribution analysis and simulation for the built-up sleeved backup roll by using finite element method, the effects of roll sleeve thickness and shrink range on the stress-strain field were studied. Finally, based on the methodology and strategy of the fatigue analysis, fatigue life of backup roll was estimated by using the stress-strain data obtained through finite element simulation. The results show that roll sleeve thickness and shrink range have a great influence on sleeve stress distribution of built-up sleeved roll. Under the circumstance of ensuring transferring enough torque, the shrink range should be kept small. However, thicker roll sleeve has longer roll service life when the shrink range is constant.

Influence of Long-term Climate on Fatigue Life of Bridge Pier Concrete and a Reinforcement Method

This paper quantitatively evaluated the fatigue life of concrete around the air-water boundary layer of bridge piers located in inland rivers,considering the long-term climate.The paper suggests a method to predict the low-cycle fatigue life by demonstrating a thermal-fluid-structural analysis of bridge pier concrete according to long-term climate such as temperature,velocity and pressure of air and water in the process of freezing and thawing in winter.In addition,it proposes a reinforcing method to increase the life of damaged piers and proves the feasibility of the proposed method with numerical comparison experiment.

Influences of fine pitch solder joint shape parameters on fatigue life under thermal cycle

The solder joint reliability of a 0.5mm lead pitch, 240-pin quad flat package(QFP) was studied by nonlinear finite element analysis(FEA). The stress/strain distributions within the solder joints and the maximum plastic strain range of the solder joints were determined. Based on the calculated maximum plastic strain range the thermal fatigue life of the solder joints was calculated using Coffin-Manson equation. The influences of shape parameters including volume of solder joint, pad size and stand-off on the thermal fatigue life of the solder joints were also studied. The results show that the stress and strain distribution in the solder joint are not uniform; the interface between the lead and the solder joint is the high stress and strain region; the maximum stress and stain occur at the topmost point where the solder joint intersects with the inner side of the lead. The solder joint cracks should occur firstly at this point and propagate along the interface between the solder and the lead. The solder joint with the pad size of 1.25mm×0.35mm, the stand-off of 0.02mm and the solder volume of 0.026mm^3 has longer fatigue life than that of any others. These optimal parameters have been applied in practice to assemble the 240-pin, 0.5mm pitch QFP.

基于ANSYS/Fatigue的泵用压电振子疲劳分析

为预测压电泵驱动部件压电振子的疲劳寿命,建立了双晶片压电振子的有限元模型,并应用ANSYS软件对模型进行静力学分析,得到双晶片压电振子的等效应力图和危险区域最大应力节点.利用ANSYS/Fatigue模块对这些危险点进行疲劳分析,并和其他区域应力集中的点进行比较,得到双晶片压电振子的疲劳耗用系数.利用M iner法则判断压电振子是否满足设计要求,并预测其疲劳寿命.研究了不同基底材料以及结构参数对双晶片压电振子疲劳寿命的影响,并和单晶片压电振子进行了对应比较.结果表明,基底最优材料为Cu,半径变化不影响其疲劳寿命,而厚度变化对疲劳寿命的影响要比电压变化的影响要大,双晶片压电振子的疲劳寿命总要比单晶片的稍长些,这为选择和优化压电振子结构提供了理论依据.

基于MSC.Fatigue的汽车驱动桥壳疲劳寿命预估

运用三维造型软件Pro/Engineer Wildfire2.0建立某型商用车驱动桥后桥壳的实体模型.依据有限元基本理论,进一步建立该桥壳的有限元模型,并在通用有限元分析系统MSC.Nastran中进行有限元应力分析.基于应力分析结果,采用有效的疲劳寿命预估方法,利用专业耐久性疲劳寿命分析系统MSC.Fatigue对该桥壳进行全寿命分析,得到桥壳整体的疲劳寿命分布和危险点的寿命值.通过与台架疲劳试验的桥壳失效情况相对比,预估结果与试验结果一致.而后对在试验中发生破坏的桥壳进行疲劳断口的微观分析.最终在试验与仿真分析结果的基础上提出对该型桥壳生产的改进方案.

基于MSC.Fatigue的安全带固定支架焊缝的疲劳强度分析及优化

以某型号座椅为例,基于材料力学、断裂力学和局部应力应变法给出了汽车座椅安全带固定支架焊缝的静强度和疲劳强度的计算模型。通过MSC.patran建立其有限元模型,并进行了静力学分析,分析结果揭示了焊缝的应力集中部位。在静力学分析的基础上通过MSC.Fatigue进行了疲劳强度分析,结果表明应力集中部位的疲劳寿命最低,构件的疲劳寿命主要受薄弱环节的疲劳状况影响。根据有限元仿真分析结果,提出了"安全区域"的概念,基于"安全区域"对焊缝进行了优化设计,结果表明断续段焊缝相对于连续全焊缝更加符合工程实际要求。

基于MSC.Fatigue的捡膜弹齿疲劳寿命分析与优化

应用MSC.Fatigue疲劳分析软件,对捡膜弹齿进行强度和疲劳寿命分析,得到捡膜弹齿的应力云图和疲劳寿命云图,通过仿真分析,找出捡膜弹齿折断的原因,并进行优化,为捡膜弹齿的设计提供理论依据。

基于MSC.Fatigue的捡膜弹齿疲劳寿命分析与优化

应用MSC.Fatigue疲劳分析软件,对捡膜弹齿进行强度和疲劳寿命分析,得到捡膜弹齿的应力云图和疲劳寿命云图,通过仿真分析,找出捡膜弹齿折断的原因,并进行优化,为捡膜弹齿的设计提供理论依据。

Fatigue Damage Mechanism of Oil Film Bearing Sleeve

With the rapid development of the steel industry, to keep pace with the current trend of high speed, continuous, and large-scale production that focuses on automation and high levels of efficiency, many state-owned steel companies are being equipped with oil film bearings. Through long-term on-spot inspection and research on the fatigue failure of oil film bearing, three segments of annulated fatigue breakage were found axially along the inner surface of the bearing sleeve. In order to elucidate the reason for the three-segment annulated damage under rolling load, numerical boundary element method was adopted to analyze the contact behaviors between the sleeve and rollneck. Failure mechanism was discussed in detail, the distributions of contact stress were analyzed, and the service lives of the sleeve for different positions on the inner surface were quantitatively described, which provided an effective means to decrease wear and adhesive damage of the sleeve and to increase the load capacity of oil film bearing and its service life as well.

Computational Multiaxial Fatigue Modelling for Notched Components

Fatigue failures of driveline and suspension notched components for ground vehicles under multiaxial loading conditions are common, since most of those components are subjected to complex multiaxial loadings in service. A computational fatigue analysis methodology has been proposed here for performing multiaxial fatigue life prediction for notched components using analytical and numerical methods. The proposed multiaxial fatigue analysis methodology consists of an elastic-plastic stress/strain model and a multiaxial fatigue damage parameter. Results of the proposed multiaxial fatigue analysis methodology are compared to sets of experimental data published in the literature to verify the prediction capability of the elastic-plastic stress/strain model and the multiaxial fatigue damage parameter. Based on the comparison between calculated results and experimental data, it is found that the multiaxial elastic-plastic stress/strain model correlates well with experimental strain data for SAE 1070 steel notched shafts subjected to several non-proportional load paths. In addition, the proposed fatigue damage parameter is found to correlate reasonably well with experimental fatigue data of SAE 1045 steel notched shafts subjected to proportional and non-proportional loadings.

Fatigue Performance of Orthotropic Steel Decks in Super-Wide Steel Box Girder Considering Transverse Distribution of Vehicle Load

This study presents an investigation on the fatigue analysis of four types of details on orthotropic steel decks(OSDs)for a cable-stayed super-wide steel box girder bridge based on finite-element analysis(FEA)with vehicle transverse distribution model(VTDM).A high-fidelity 3D FE model verified by the static load test is established to satisfy the fatigue analysis accuracy.The stress behavior of super-wide steel box girders under the vehicle load at different lane locations is investigated.Then,considering the effect of VTDM,the fatigue life analysis of four typical details is performed using the Miner cumulative damage rule.The results show that the vehicle transverse location has a great influence on the stress behavior of details with sharp influence surface,and the stress ranges in the outermost lane are larger than those in other lanes,indicating that the details of OSD in the outermost lane are prone to fatigue.The fatigue life analysis indicates that the diaphragm cutout is more prone to fatigue than other details,which should be carefully treated in bridge maintenance.

A NEW FATIGUE CUMULATIVE DAMAGE DYNAMIC INTERFERENCE MODEL

On the basis of the statistical characteristics of fatigue cumulative damageand its critical value, a new dynamic interference model for reliability analysis is presented. Because the nonlinearity of fatigue damage accumulation is taken into account,this model is able to predict the fatigue reliability for random spectrum loadingconveniently. To verify the predicted results, a special fatigue expenment, in which thenumber of specimen is up to 101, is conducted using a fighter spectrum loading. It isshown that the new model is reliable, practicable and better than existing models.