Bi-variable damage model for fatigue life prediction of metal components

Based on the theory of continuum damage mechanics,a bi-variable damage mechanics model is developed,which,according to thermodynamics,is accessible to derivation of damage driving force,damage evolution equation and damage evolution criteria. Furthermore,damage evolution equations of time rate are established by the generalized Drucker＇s postulate. The damage evolution equation of cycle rate is obtained by integrating the time damage evolution equations,and the fatigue life prediction method for smooth specimens under repeated loading with constant strain amplitude is constructed. Likewise,for notched specimens under the repeated loading with constant strain amplitude,the fatigue life prediction method is obtained on the ground of the theory of conservative integral in damage mechanics. Thus,the material parameters in the damage evolution equation can be obtained by reference to the fatigue test results of standard specimens with stress concentration factor equal to 1,2 and 3.

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.

Fatigue Life Prediction of Rolling Bearings Based on Modified SWT Mean Stress Correction

The existing engineering empirical life analysis models are not capable of considering the constitutive behavior of materials under contact loads;as a consequence,these methods may not be accurate to predict fatigue lives of roll-ing bearings.In addition,the contact stress of bearing in operation is cyclically pulsating,it also means that the bear-ing undergo non-symmetrical fatigue loadings.Since the mean stress has great effects on fatigue life,in this work,a novel fatigue life prediction model based on the modified SWT mean stress correction is proposed as a basis of which to estimate the fatigue life of rolling bearings,in which,takes sensitivity of materials and mean stress into account.A compensation factor is introduced to overcome the inaccurate predictions resulted from the Smith,Watson,and Topper(SWT)model that considers the mean stress effect and sensitivity while assuming the sensitivity coefficient of all materials to be 0.5.Moreover,the validation of the model is finalized by several practical experimental data and the comparison to the conventional SWT model.The results show the better performance of the proposed model,especially in the accuracy than the existing SWT model.This research will shed light on a new direction for predicting the fatigue life of rolling bearings.

A new model for life prediction of GH4133 under TMF conditions

Thermal mechanical cyclic strain tests were carried out under in-phase andout-of-phase conditions on a Nickel-base Superalloy GH4133 in the temperature range of 571-823 degC. Based on analyzing the present models of TMF (thermal mechanical fatigue) life prediction, a newmodel for predicting nickel-base superalloy TMF lifetime was proposed. TMF life of superalloy GH4133was calculated accurately based on the new model. Experimental TMF life has been compared with thecalculated results and all results fall in the scatter band of 1.5. The calculating results showthat the new model is not only simple, but also precise. This model will play great roles as lifeprediction of the metal materials and the engineering components subjected to non-isothermal serviceconditions.

Fatigue Behavior of Plain Concrete Under Biaxial Compression: Experiments and Theoretical Model

The effects of different lateral confinement stress on the fatigue behavior of and cumulative damage to plain concrete are investigated experimentally. Eighty 100 mm x 100 mm x 100 mm specimens of ordinary strength concrete are tested under constant- or variable-amplitude fatigue loading and lateral confinement pressure in two orthogonal directions. A fatigue equation is developed by modifying the classical Aas-Jakobsen S-N equation for taking into account the effect of the confined stress on fatigue strength of plain concrete. The results of variable-amplitude fatigue tests indicate that the linear damage theory proposed by Palmgren and Miner is unreasonable in the biaxial stress state. A nonlinear cumulative damage model that could model the effects of the magnitude and sequence of variable-amplitude fatigue loading and lateral confinement pressure is proposed on the basis of the evolution laws of the residual strains in the longitudinal direction during fatigue tests. The residual fatigue. life predicted by this model is found to be in good agreement with the results of the experimental research.

Microstructural characteristics and low-cycle fatigue properties of AZ91 and AZ91-Ca-Y alloys extruded at different temperatures

The commercial AZ91 alloy and nonflammable SEN9(AZ91-0.3Ca-0.2Y,wt%)alloy are extruded at 300°C and 400°C.Their microstructure,tensile and compressive properties,and low-cycle fatigue(LCF)properties are investigated,with particular focus on the influence of the extrusion temperature.In the AZ91 and SEN9 materials extruded at 300°C(300-materials),numerous fine Mg_(17)Al_(12)particles are inhomogeneously distributed owing to localized dynamic precipitation during extrusion,unlike those extruded at 400°C(400-materials).These fine particles suppress the coarsening of recrystallized grains,decreasing the average grain size of 300-materials.Although the four extruded materials have considerably different microstructures,the difference in their tensile yield strengths is insignificant because strong grain-boundary hardening and precipitation hardening effects in 300-materials are offset almost completely by a strong texture hardening effect in 400-materials.However,owing to their finer grains and weaker texture,300-materials have higher compressive yield strengths than400-materials.During the LCF tests,{10-12}twinning is activated at lower stresses in 400-materials than in 300-materials.Because the fatigue damage accumulated per cycle is smaller in 400-materials,they have longer fatigue lives than those of 300-materials.A fatigue life prediction model for the investigated materials is established on the basis of the relationship between the total strain energy density(ΔW_(t))and the number of cycles to fatigue failure(N_(f)),and it is expressed through a simple equation(ΔW_(t)=10·N_(f)-0.59).This model enables fatigue life prediction of both the investigated alloys regardless of the extrusion temperature and strain amplitude.

Modeling Boundary and Edge Effect of Chloride Diffusion for Durability Design of Concrete Structures Exposed in Marine Environment

According to the Fick＇s second law of diffusion, six analytical solutions of chloride profile in concrete were studied and discussed with regard to different boundary and initial conditions. In those analytical solutions, the most prevailing error-function solution which is based on semi-infinite assumption is the simple one, but may under-estimate the chloride content in concrete and over-rate the life time prediction of concrete structures. The experimental results show that compared with other solutions, the chloride content in concrete predicted by error-function model is the minimum, and the calculation difference produced by different analytical models should not be ignored. The influence of models on chloride content prediction is more than other environment and material coefficients in some time. In order to get a more realistic prediction model, modification to error-function model is suggested based on analysis and calculation examples concerning the boundary and edge effect.

QUICK ASSESSMENT METHODOLOGY FOR RELIABILITY OF SOLDER JOINTS IN BALL GRID ARRAY (BGA) ASSEMBLY——PART Ⅰ: CREEP CONSTITUTIVE RELATION AND FATIGUE MODEL

In this study, a new unified creep constitutive relation and a mod- ified energy-based fatigue model have been established respectively to describe the creep flow and predict the fatigue life of Sn-Pb solders. It is found that the relation successfully elucidates the creep mechanism related to current constitutive relations. The model can be used to describe the temperature and frequency dependent low cycle fatigue behavior of the solder. The relation and the model are further employed in part Ⅱ to develop the numerical simulation approach for the long-term reliability assessment of the plastic ball grid array (BGA) assembly.

Fatigue behavior and cumulative damage rule of concrete under cycli ccompression with constant confined stress

The effects of different lateral confinement stress on the fatigue behavior and cumulative damage of plain concrete were investigated experimentally. Eighty 100mm×100mm×100mm specimens of ordinary strength concrete were tested with constant-or variable-amplitude cyclic compression and lateral confinement pressure in two orthogonal directions. A fatigue equation was gained by modifying the classical Aas-Jakobsen S-N equation and used for taking into account the effect of the confined stress on fatigue strength of plain concrete. The present study indicates that the fatigue failure is greatly influenced by the sequence of applied variable-amplitude fatigue loading, and Miner’s rule is inapplicable to predict the residual fatigue life, especially in the sequence of low to high. The present research also shows that the exponent d of the Corten-Dolan’s damage formula is a constant depending on the materials and the levels of load spectrum, and d can be determined through the two-stage fatigue tests. The residual fatigue lives predicted by Corten-Dolan’s damage formula are found to be in good agreement with the results of the experiments.

Effect of Loading Frequency on the High Cycle Fatigue Strength of Flax Fiber Reinforced Polymer Matrix Composites

Among natural fibers,flax fiber reinforced polymer matrix composites show excellent dynamic/fatigue properties due to its excellent damping properties.Knowledge about fatigue limit and effect of loading frequency on fatigue limit is very crucial to know before being used a member as a structural component.Fatigue limit of fiber reinforced composite is measured through high cycle fatigue strength(HCFS).The effect of loading frequency on the HCFS of flax fiber reinforced polymer matrix composites was investigated using stabilized specimen surface temperature based thermographic and dissipated energy per cycle-based approaches.Specimens of unidirectional flax fiber reinforced thermoset composites were tested under cyclic loading at different percentages of applied stresses for the loading frequencies of 5,7,10,and 15 Hz in order to determine the stabilized surface temperature of the specimen and dissipated energy per fatigue cycle.Both approaches predicted similar fatigue limits(HCFS)which showed a good agreement with experimental results from Literature.HCFS of flax fiber reinforced composites decrease little with increasing loading frequency.Furthermore,effect of loading frequency on stabilized specimen temperature and dissipated energy per fatigue cycle was also investigated.Although specimen surface temperature increases with loading frequency,dissipated energy per-cycle does not change with loading frequency.Thermal degradation at higher loading frequencies may play a significant role in decreasing HCFS with increasing loading frequency.

多尺度聚丙烯纤维混凝土弯曲疲劳寿命试验及数值模拟

为研究多尺度聚丙烯纤维混凝土的弯曲疲劳性能,开展基准混凝土、聚丙烯粗纤维混凝土及多尺度聚丙烯纤维混凝土的静载试验及不同应力水平(0.75、0.80、0.85)下的弯曲疲劳试验,建立弯曲疲劳寿命方程,并结合ABAQUS与FE-SAFE软件建立纤维混凝土梁的三点弯曲疲劳有限元模型。结果表明:聚丙烯纤维的掺入,尤其是多尺度聚丙烯纤维混掺显著增强了混凝土基体的抗折、抗疲劳性能。双对数lgS-lgN疲劳方程能够较好地描述多尺度聚丙烯纤维混凝土的应力水平与疲劳寿命的相关性,使用lgS-lgN疲劳方程计算得到200万次循环荷载作用下多尺度聚丙烯纤维混凝土的疲劳强度最高,为3.91 MPa。三组试件疲劳寿命的数值模型预测值均介于实测疲劳寿命的最大值与最小值之间,并接近于疲劳寿命平均值,该模型为多尺度聚丙烯纤维混凝土的疲劳寿命预测提供了理论依据。

锈蚀及疲劳损伤后钢筋混凝土梁寿命预测及敏感性分析

为了探究锈蚀和疲劳作用后钢筋混凝土梁的长期性能,基于试验建立了钢筋混凝土梁含初始损伤的长期性能计算模型.基于该模型建立了锈蚀及疲劳损伤后钢筋混凝土梁的极限状态方程,采用蒙特卡洛模拟研究了梁长期性能的时变可靠度并进行了寿命预测,分析了设计参数和初始损伤对梁使用寿命的影响,研究了试验梁满足100 a使用寿命的临界服役条件.结果表明,锈蚀和疲劳作用会严重削弱钢筋混凝土梁的长期性能,仅含4%锈蚀率和15%疲劳损伤梁的长期性能难以满足服役要求.增加梁的截面高度和钢筋截面面积可以有效地提高梁的长期性能,增大梁的截面宽度只能改善初始损伤小的梁的长期性能.

Fatigue life prediction model of 2.5D woven composites at various temperatures

As one of the new structural layout in the family of woven composites, 2.5D Woven Composites（2.5D-WC） have recently attracted an increasing interest owing to its excellent properties, i.e. high specific strength and fatigue resistance, in the aerospace and automobile industry. Indepth understanding of the fatigue behavior of this material at un-ambient temperatures is critical for the engineering applications, especially in aero-engine field. Here, fatigue behavior of 2.5D-WC at different temperatures was numerically investigated based on the unit cell approach. Firstly, the unit cell model of 2.5D-WC was established using ANSYS software. Subsequently, the temperature-dependent fatigue life prediction model was built up. Finally, the fatigue lives alongside the damage evolution processes of 2.5D-WC at ambient temperature（20 ℃） and unambient temperature（180 ℃） were analyzed. The results show that numerical results are in good agreement with the relevant experimental results at 20 and 180 ℃. Fatigue behavior of 2.5D-WC is also sensitive to temperature, which is partially attributed to the mechanical properties of resin and the change of inclination angle of warp yarns. We hope that the proposed fatigue life prediction model and the findings could further promote the engineering application of 2.5D-WC, especially in aero-engine field.

Review on fatigue life prediction models of welded joint

Fatigue assessment of welded joint is still far from being completely solved now,since many influencing factors coexist and some important ones should be considered in the developed life prediction models reasonably.Thus,such influencing factors of welded joint fatigue are firstly summarized in this work;and then,the existing life prediction models are reviewed from two aspects,i.e.,uniaxial and multiaxial ones;finally,significant conclusions of existing experimental and theoretical researches and some suggestions on improving the fatigue assessment of welded joints,especially for the low-cycle fatigue with the occurrence of ratchetting,are provided.

Research on Service Life Prediction Model of Concrete Structure of Sea-crossing Bridge

According to the chloride corrosion environment,service life prediction model of concrete structure of sea-crossing bridge was built using modified Fick's second law and the whole probability calculation method,which was suitable for China. Furthermore,a visual service life prediction program of concrete structure was developed by optimized Monte Carlo method. Meanwhile,Life 365 program was compared,indicating reliability of the prediction program. Finally,the validity of prediction model was verified in JinTang Bridge of Zhoushan Island Mainland Linkage Project.

Tension-Torsion High-Cycle Fatigue Life Prediction of 2A12-T4 Aluminium Alloy by Considering the Anisotropic Damage:Model, Parameter Identification, and Numerical Implementation

To consider the anisotropic damage in fatigue, an improved boom-panel model is presented to simulate a representative volume element (RVE) in the framework of continuum damage mechanics. The anisotropic damage state of the RVE is described by the continuity extents of booms and panels, whose damage evolutions are assumed to be isotropic. The numerical implementation is proposed on the basis of damage mechanics and the finite element method. Finally, the approach is applied to the fatigue life prediction of 2A12-T4 aluminium alloy specimen under cyclic loading of tension-torsion. The results indicate a good agreement with the experimental data.

环境和疲劳荷载作用下开裂混凝土寿命预测研究进展

混凝土是一种准脆性材料,大量混凝土结构在设计使用寿命期间会不可避免地出现裂缝并带着裂缝工作。裂缝的存在会直接影响到混凝土结构使用寿命,特别是在侵蚀性环境因素或疲劳荷载作用下。本文对钢筋混凝土裂缝扩展过程进行了分析,对不同侵蚀环境作用下开裂混凝土结构劣化机制、寿命预测研究方法及预测模型等进行了系统的梳理和对比。阐述了疲劳裂纹扩展理论在开裂混凝土结构疲劳寿命预测中的应用现状与优势,并归纳了基于该理论的部分寿命预测方法及预测模型。此外,还对侵蚀环境与疲劳荷载耦合作用下开裂混凝土结构寿命预测方法进行了总结与讨论,指出了现有开裂混凝土结构寿命预测研究尚存在的问题,并对今后的研究方向提出了建议。

改性橡胶透水混凝土老化寿命精准预测模型构建

为了提高改性橡胶透水混凝土老化寿命预测效果,构建改性橡胶透水混凝土老化寿命精准预测模型,制备不同改性剂含量的橡胶混凝土试件,并进行老化温度循环实验。引入威布尔分布,建立混凝土的密度函数与分布函数,并构建改性橡胶透水混凝土修正Coffin-Manson老化寿命模型,实现改性橡胶透水混凝土寿命预测。结果表明:不含改性剂混凝土的质量损失最大,而改性橡胶透水混凝土可以保持较高的有效孔隙率与相对动弹模量。通过该模型预测可知,不含改性剂的混凝土老化寿命更短,而4%改性剂的试件在冻融循环2267.2次后失效,即该试件的老化寿命为2267.2,其老化寿命最高,且该预测模型的预测可靠度高于0.8,可以精准预测老化寿命。

冻融作用下高速铁路路基沥青混凝土防水封闭结构疲劳寿命预测模型

以高速铁路路基沥青混凝土防水封闭结构为研究对象,考虑季节性冻土地区的气象条件设计了疲劳试验和冻融循环试验,研究冻融循环作用对其疲劳特性参数演变规律的影响。结合平稳值与冻融循环周期的作用规律,提出了高速铁路路基沥青混凝土防水封闭结构在冻融循环作用下的疲劳寿命预测模型,并利用疲劳极限临界点的平均值对此疲劳寿命预测模型进行了可靠性验证。结果表明:沥青混凝土耗散能变化率与加载次数曲线在冻融前后呈现三个阶段;沥青混凝土防水封闭结构的疲劳寿命随冻融循环次数的增多而降低,且降低幅度越来越大,其抗疲劳性能受到显著损伤;经验证,高速铁路路基沥青混凝土防水封闭结构疲劳寿命预测模型准确、可靠。

考虑平均应力影响的7075-T651铝合金疲劳性能研究

研究了平均应力效应对7075-T651铝合金疲劳性能的影响,选取了R=0.5、0.3、0.1和-0.1四组应力比进行疲劳试验。结果表明,同一应力比下,随着峰值应力水平的增加,疲劳寿命逐渐降低;而同一峰值应力水平下,随着应力比的提高,疲劳寿命则呈现出逐渐升高的趋势。同时,使用扫描电子显微镜(Scanning Electron Microscopy,SEM)观察疲劳断口形貌发现,在峰值应力相同的情况下,裂纹萌生及扩展区的扇形面积随平均应力的增大而增大。最后,基于7075-T651铝合金疲劳实验结果,提出了一种考虑S-N-R的改进型预测模型,结果对比显示相较于其他模型,此模型在一定程度上对7075-T651铝合金具有更好的疲劳寿命预测效果。