Fatigue Life Prediction for SiC/Al Materials Based on Path Planning Algorithm Considering Residual Stress

To explore the influence of path deflection on crack propagation,a path planning algorithm is presented to calculate the crack growth length.The fatigue crack growth life of metal matrix composites(MMCs)is estimated based on an improved Paris formula.Considering the different expansion coefficient of different materials,the unequal shrinkage will lead to residual stress when the composite is molded and cooled.The crack growth model is improved by the modified stress ratio based on residual stress.The Dijkstra algorithm is introduced to avoid the cracks passing through the strengthening base and the characteristics of crack steps.This model can be extended to predict crack growth length for other similarly-structured composite materials.The shortest path of crack growth is simulated by using path planning algorithm,and the fatigue life of composites is calculated based on the shortest path and improved model.And the residual stress caused by temperature change is considered to improve the fatigue crack growth model in the material.The improved model can well predict the fatigue life curve of composites.By analyzing the fatigue life of composites,it is found that there is a certain regularity based on metal materials,and the new fatigue prediction model can also reflect this regularity.

Residual Fatigue Life Prediction of Ball Bearings Based on Paris Law and RMS

Paris law can reflect the failure mechanism of materials and is usually used to be a method to predict fatigue life or residual fatigue life.But the variable which can represent the health of machine is hardly measured on line.To a degree,the difficulty of on-line application restricts the scope of application of Paris law.The relationship between characteristic values of vibration signals and the variable in the Paris equation which can describe the health of machine is investigated by taking ball bearings as investigative objects.Based on 6205 deep groove ball bearings as a living example,historical lives and vibration signals are analyzed.The feasibility of describing that variable in the Paris equation by the characteristic value of vibration signals is inspected.After that vibration signals decomposed by empirical mode decomposition（EMD）,root mean square（RMS） of intrinsic mode function（IMF） involving fault characteristic frequency has a consistent trend with the diameter of flaws.Based on the trend,two improved Paris models are proposed and the scope of application of them is inspected.These two Paris Models are validated by fatigue residual life data from tests of rolling element bearings and vibration signals monitored in the process of operation of rolling element bearings.It shows that the first improved Paris Model is simple and plain and it can be easily applied in actual conditions.The trend of the fatigue residual life predicted by the second improved Paris model is close to the actual conditions and the result of the prediction is slightly greater than the truth.In conclusion,after the appearance of detectable faults,these improved models based on RMS can predict residual fatigue life on line and a new approach to predict residual fatigue life of ball bearings on line without disturbing the machine running is provided.

Influences of Tool Wear on Residual Stress and Fatigue Life of Workpiece in Hard Cutting Process

Tool wear has an important influence on the residual stress distribution on the machined surface.Also,it will influence the fatigue life of finished workpiece. In this research,the hard turning process of hardened die steel Cr12 MoV was studied by using PCBN tool with considering tool wear. Based on the numerical treatment of residual stress,the dispersion and distribution curves of different tool wear were fitted,and the influence mechanism of tool wear on the residual stress distribution of machined surface was analyzed.Based on the theory of fatigue mechanics and mathematical statistics,the mathematical model for difference of stress dispersion and fatigue life was established. The rotating and bending tests were carried out on the standard parts after cutting process for the workpiece. The influence of tool wear on fatigue life was revealed by fracture surface morphology and fatigue life study. The results provide theoretical support for control of residual stress and the fatigue property of the machined surface under the actual working conditions.

RESIDUAL STRENGTH AND FATIGUE LIFE OF 2-D AND 3-D CARBON FABRIC COMPOSITES

The fatigue behavior and damage mechanisms of 2 D and 3 D carbon/epoxy composites with approximately the same 51% fiber volume fraction were investigated. A test program was conducted on fatigue residual strength and fatigue life under constant amplitude tensile fatigue loading. Equations of predicting the fatigue life for both 2 D and 3 D composites were provided. Comparison of the 2 D and 3 D composites indicated that due to the through thickness reinforcement, the 3 D composite has considerably better fatigue performance. Comparison of experimental data with calculation results shows good agreement, thus confirming the usefulness of the predictions.

Analysis of Fatigue Strain, Fatigue Modulus and Fatigue Damage for the Model Formulation of Concrete Based on Strain Life Approach

Analysis of fatigue strain, fatigue modulus and fatigue damage for the modeling of concrete plays a vital role in the evolution material behaviour which is heterogeneous and anisotropic in nature. The Level-S nonlinear fatigue strain curve, fatigue modulus curve, residual strain curve of concrete in compression, tension, flexure and torsional fatigue loading were proposed using strain life approach. The parameters such as physical meaning, the ranges, and the impact on the shape of the curve were discussed. Then, the evolution model of fatigue modulus was established based on the fatigue strain, fatigue modulus, residual strain and secondary strain evolution model. The hypothesis of fatigue modulus is inversely related with the fatigue strain amplitude. The fatigue evolution of concrete damages the bond between material grains, changed the orientation of structure of molecules and affects the elastic properties resulting in the reduction of material stiffness and modulus by formation of microcracking, macro cracking, cracking and finally damage. This paper presents the fatigue strain life model and analysis of fatigue strain, fatigue modulus and damage parameters of concrete which is capable of predicting stiffness degradation, inelastic deformation, and strength reduction under fatigue loading and experimental results were employed for the validation of the theoretical model.

Residual strength model for composite laminates

To research the approach of predicting composites fatigue life,the cumulative fatigue damage of fiber-reinforced plastic laminates(FRP) was investigated,and based on the complex exponential function,the residual strength model was obtained. This model can accurately describe the propagation of cumulative fatigue damage of FRP in three stages,especially in the initial stage and the ceasing stage. Applying this model in the experiment with two loading cycles,it can be found that the prediction result has good coincidence with experimental data. So a reliable residual strength model can be provided for studying the cumulative fatigue damage of FRP.

Finite Element Method Investigation of the Effect of Cold Expansion Process on Fatigue Crack Growth in 6082 Aluminum Alloy

Cold expansion is an efficient way to improve the fatigue life of an open hole. In this paper, three finite element models have been established to crack growth from an expanded hole is simulated. Expansion and its degree influence are studied using a numerical analysis. Stress intensity factors are determined and used to evaluate the fatigue life. The residual stress field is evaluated using a nonlinear analysis and superposed with the applied stress field in order to estimate fatigue crack growth. Experimental test is conducted under constant loading. The results of this investigation indicate expansion and its degree are a benefit of fatigue life and a good agreement was observed between FEM simulations and experimental results.

Effect of residual stress on the vibration failure of dissimilar steels joint

Elasto-plastic finite element method is used for the welding residual stress calculation in butt welded joint of carbon steel and stainless steel, fluctuating pressure on the ship hull induced by a propeller is calculated from the actual measurement data. As the result of the superposition of vibration load and welding residual stress, the stress amplitude is reduced slightly in high stress area near the welding line, while the value of stress reduction becomes larger when the welding current increases. On the contrary, the stress amplitude is increased clearly far from the welding line. The welding residual stress obviously reduced the fatigue life of ship structure with the vibration load. The fatigue lives of ship structures under vibration are - 1.75 × 105 （ 110 000 ton product carrier） and - 2.43 × 105 （52 000 ton all-purpose cargo ship） without welding residual stress, while the residual stress exists, the fatigue life is down to - 3 × 104.

残余应力对GH3230层板焊缝热疲劳寿命影响规律研究

为了探究残余应力对层板冷却结构焊缝服役寿命的影响规律,首先对GH3230层板在常规条件下的激光焊接过程进行有限元模拟与实验验证,然后在此基础上对预拉伸、温差拉伸等焊接残余应力调控方法开展模拟。基于焊后残余应力模拟结果研究了层板服役过程的温度及等效应力变化规律,并将多个模型之间不同残余应力下服役状态进行对比分析,最后利用Morrow修正的Coffin-Manson方程对焊缝后续服役寿命进行评估。研究结果表明,焊接残余应力的存在大幅降低了层板结构焊缝区域热疲劳寿命,通过残余应力调控技术可有效改善焊缝区域服役过程中的应力幅或平均应力,使其分别下降70%与25%,焊接残余应力调控对提高层板结构热疲劳寿命具有重要意义。

激光冲击强化对FV520B钢疲劳寿命的影响

为提高叶轮的使用寿命,对叶片的抗疲劳性能提出了更高的要求,激光冲击强化(LSP)处理是提高材料抗疲劳性能的重要途径。针对FV520B钢棒状试样进行LSP试验和不同应变幅值下的单轴低周疲劳试验,并进行疲劳寿命预测。结果表明,LSP后试样的表面硬度由330 HV提升至490 HV,且LSP后试样表面产生约−90 MPa的残余压应力。相比于未冲击试样,LSP试样的疲劳寿命均有所提高,±0.5%应变幅值下试样的疲劳寿命提高132.2%。SEM结果表明,LSP后试样表面产生的残余压应力抑制了疲劳裂纹的萌生和扩展,裂纹萌生位置由试样表面向次表面转移,且疲劳条纹的间距和韧窝尺寸减小,从而延长了试样的疲劳寿命。采用Manson-Coffin方程针对光滑试样和LSP试样进行疲劳寿命预测,总的来说,对于光滑试样预测结果与试验结果吻合较好;对于LSP试样,预测的疲劳寿命偏保守。考虑残余压应力的影响针对Manson-Coffin方程进行修正,得到了较好的预测结果。研究结果可为FV520B材料LSP处理工艺和疲劳失效研究提供理论依据。

基于静强度分布参数的复合材料剩余强度及寿命预测

为探讨剩余强度及疲劳寿命与初始静强度分布参数之间的关系,构建基于初始静强度分布参数的剩余强度和疲劳寿命计算模型。在模型构建过程中未涉及复合材料结构的层数、铺层厚度和铺层方向,适应性强。模型参数可通过静力试验和剩余强度试验获得,试验成本相对疲劳试验较低。剩余强度和疲劳寿命与初始静强度变异系数及其分布参数有关,当初始静强度服从威布尔分布时,疲劳寿命亦服从威布尔分布,可为开展疲劳可靠性提供借鉴和参考。算例表明,基于建立的模型,剩余强度计算结果最大误差为-1.58%,疲劳寿命与试验数据吻合较好。

焊接残余应力对高强钢点焊接头裂纹扩展及疲劳性能的影响

点焊接头因高度应力集中,极易于熔核边缘萌生疲劳裂纹,点焊产生的残余应力会影响其扩展。为探究点焊残余应力对疲劳裂纹扩展的影响规律,建立DP600高强钢点焊接头三维裂纹有限元仿真模型。基于热-弹塑性理论求解点焊残余应力场,在此基础上计算有无残余应力时折线裂纹的局部应力强度因子(Stress Intensity Factor,SIF)解,通过分析两种条件下裂纹最深点局部SIF随裂纹深度比变化的曲线,研究点焊残余应力对折线裂纹扩展的影响规律;基于断裂力学理论,采用改进的双参数模型预测有无残余应力时的疲劳寿命。结果表明,点焊残余应力使局部SIF显著提高,且随着裂纹深度比的增加,残余应力对其的影响程度也增加;考虑残余应力后裂纹整体扩展趋势不变但扩展速率显著增加,疲劳寿命由35616次下降至12564次。

Experimental study of surface integrity and fatigue life in the face milling of Inconel 718

The Inconel 718 alloy is widely used in the aerospace and power industries. The machining-induced surface integrity and fatigue life of this material are important factors for consideration due to high reliability and safety requirements. In this work, the milling of Inconel 718 was conducted at different cutting speeds and feed rates. Surface integrity and fatigue life were measured directly. The effects of cutting speed and feed rate on surface integrity and their further influences on fatigue life were analyzed. Within the chosen parameter range, the cutting speed barely affected the surface roughness, whereas the feed rate increased the surface roughness through the ideal residual height. The surface hardness increased as the cutting speed and feed rate increased. Tensile residual stress was observed on the machined surface, which showed improvement with the increasing feed rate. The cutting speed was not an influencing factor on fatigue life, but the feed rate affected fatigue life through the surface roughness. The high surface roughness resulting from the high feed rate could result in a high stress concentration factor and lead to a low fatigue life.

Residual Life Prediction Based on Nonlinear Fatigue Damage Accumulation Model

When a nonlinear fatigue damage accumulation model based on damage curve approach is used to get better residual life prediction results, it is necessary to solve the problem caused by the uncertain exponent of the model. Considering the effects of load interaction, the assumption that there is a linear dependence between the exponent ratio and the loading ratio is established to predict fatigue residual life of materials. Three experimental data sets are used to validate the rightness of the proposition. The comparisons of experimental data and predictions show that the predictions based on the proposed proposition are in good accordance with the experimental results as long as the parameters that represent the linear correlativity are set an appropriate value. Meanwhile, the accuracy of the proposition is approximated to that of an existing model. Therefore, the proposition proposed in this paper is reasonable for residual life prediction.

在役变压吸附器的失效机理分析

变压吸附器是制氢装置中的关键设备,长期服役于交变载荷工况。国内已发生多起变压吸附器开裂和泄漏事故。对变压吸附器的失效机理进行分析后可知:当变压吸附器在大气温度运行时,氢脆的影响可以忽略;采用疲劳裂纹扩展速率曲线的第二阶段对疲劳寿命进行评估时,氢对疲劳裂纹扩展的影响可以忽略。变压吸附器的主要失效机理为机械疲劳,通过有限元法、疲劳损伤累积理论和断裂力学性能测试等方法可以预测变压吸附器的疲劳寿命。

基于改进剩余强度模型的复合材料疲劳寿命预测

复合材料强度退化规律对研究结构疲劳寿命具有重要意义,然而现有剩余强度模型均需利用剩余强度试验数据确认模型参数,模型构建成本较高。通过探究复合材料疲劳寿命和剩余强度的关系,以疲劳寿命累积分布函数为出发点,构建具有明确物理意义的损伤度,进而提出改进剩余强度模型。改进剩余强度模型不需要剩余强度试验数据,仅需初始静强度和疲劳寿命数据。在改进剩余强度模型基础上,构建S-N-φ疲劳寿命预测模型,该模型可以考虑初始静强度对疲劳寿命的影响。算例结果表明,改进剩余强度模型的预测精度是满意的,S-N-φ模型相比经典S-N曲线模型具有更好的预测精度。

喷丸强化对车辆传动齿轮裂纹扩展影响的研究综述

疲劳断裂是重载车辆传动齿轮的主要失效形式之一,齿轮底部疲劳裂纹的扩展将缩短车辆传动系统的服役寿命,严重时会导致车辆发生安全事故。延缓裂纹扩展的主要方法是在传动齿轮的表面引入一定大小的残余压应力。喷丸技术是一种冷加工表面强化处理工艺,该技术利用高速弹丸冲击材料表面,使零件表层产生塑性应变的同时,在表面和内部引入残余压应力,从而使裂纹闭合的能力得到强化,达到延缓裂纹扩展的强化效果。为了更好地揭示喷丸引入的残余压应力对疲劳裂纹扩展的影响,首先综述了传动齿轮表面疲劳裂纹产生的原因以及疲劳裂纹的扩展行为对重载车辆服役的影响。从强度因子、J积分以及裂纹闭合效应出发,介绍了传动齿轮表面疲劳裂纹扩展的理论以及残余压应力与疲劳裂纹扩展速率之间的关系。其次概述了目前国内外常用的新型有益于将残余拉应力转化为残余压应力的微粒子喷丸、激光喷丸、超声喷丸方法,并与传统机械喷丸技术相比较,阐述了新型喷丸表面强化技术的优缺点。此外,从数值模拟和试验结果两方面,论述了喷丸速度、喷丸角度、弹丸直径、弹丸材质和覆盖率5个工艺参数对在传动齿轮表面引入残余压应力的改善影响。最后对喷丸强化技术在传动齿轮上的多目标参数优化以及多尺度残余压应力与疲劳性能进行了展望,并结合重载车辆的使用需求,强调需要创新设计一种效率高、价格低、适用性广的喷丸技术,以进一步推动喷丸强化在延缓疲劳裂纹扩展方面的持续发展。

Effect of Welded Residual Stresses on the Fatigue Life of Structural Components in Two-dimensional State

The problem of low cycle fatigue is investigated by using the local stress strain approach. The modified rainflow counting method is adopted to obtain the loading and unloading paths as well as rainflow counting. The local stress strain approach is extended successfully to the two dimensional cases by using the first principal stress and strain and the Mises equivalent stress and strain. Three models are established to investigate the effect of residual stresses on the fatigue life in two dimensional conditions.The effect of residual stresses is treated as that of the mean stress. The fatigue life of a large scale digging machine is predicted by using the method proposed, and the results agree well with the real fatigue life.

喷丸强度对船舶典型Q345钢十字型焊接接头残余应力分布的影响

对船舶典型Q345钢十字型焊接接头进行了不同喷丸强度(0.167,0.183,0.198 mm)下的喷丸处理,研究了喷丸后接头残余应力表面和沿深度方向的分布以及疲劳寿命,确定了最优喷丸强度。结果表明:喷丸处理消除了焊接接头表面残余拉应力,引入了较高水平残余压应力,改善了表面残余应力分布均匀性,增加了残余应力影响层深度,延长了疲劳寿命;随着喷丸强度增加,引入的残余压应力增大,分布均匀性先提升后减小,残余应力影响层深度增加,疲劳寿命先延长再缩短;最优喷丸强度为0.183 mm,此时焊接接头表面残余压应力较大,分布均匀性最好,残余应力影响层深度较大,疲劳寿命最长。

孔挤压强化技术研究进展

概述了直接、间接和复合孔挤压强化的研究现状,从残余应力与微观组织的角度总结了孔挤压强化的抗疲劳强化机理,基于孔结构的疲劳寿命和断口形貌详细分析了孔挤压强化的疲劳性能。研究结果表明,孔挤压强化的孔结构孔壁形成残余压应力,孔结构受到外加交变载荷时孔壁残余压应力能够抵消部分外加交变载荷产生的拉应力,降低了受载孔结构孔壁的应力峰值和平均应力;孔挤压强化的孔结构孔壁发生剧烈的塑性变形,孔壁微观组织发生细化,形成位错胞状结构,能够抑制晶粒的位错滑移,延缓了疲劳裂纹萌生,增大了疲劳裂纹萌生的门槛值,降低了疲劳裂纹扩展速率;在残余应力和微观组织的共同作用下,提高了孔挤压强化孔结构的疲劳寿命。最后,展望了孔挤压强化的发展趋势和研究问题。