FEA-Based Fatigue Life Assessment of Cycloidal Displacement Cam and Flat-Faced Follower Mechanism

Cam-followers provide reliable and controlled motions in various mechanical systems. Due to the highly fluctuating load between the cam and follower in operation, the cam-follower may be subjected to a high risk of contact fatigue failure. This paper assesses the fatigue life of a cycloidal displacement cam and a flat-faced follower under the defined loads and constraints. Computer-aided design (CAD) model of the cam-follower is developed in CATIA software and imported to ANSYS software for finite element analysis (FEA) of fatigue life. MATLAB programming is developed for determining the appropriate spring constant and pre-load force to always keep the cam and follower in contact. The fatigue life of the cam-follower has been estimated under the specified operating conditions. The analysis method can be applied to investigate the fatigue life of cams with other profiles, including the modified trapezoidal functions, polynomial functions, etc.

The Effect of Seated Baduanjin Exercise on Psychological State, Fatigue Symptoms, and Quality of Life in Maintenance Hemodialysis Patients

Objective:To evaluate the intervention effects of seated Baduanjin exercise on patients undergoing maintenance hemodialysis(MHD).Methods:A total of 108 MHD patients admitted between July 2022 and July 2023 were selected.They were randomly assigned into two groups:the experimental group,with 55 patients,who received seated Baduanjin exercise combined with leg exercises during dialysis;and the control group,with 53 patients,who only performed leg exercises during dialysis.The psychological state,fatigue symptoms,quality of life,and sleep quality scores were compared between the two groups,and exercise endurance was recorded.Results:After the intervention,the psychological state scores in the experimental group were lower than those in the control group,the fatigue symptom scores were lower,the quality of life scores were higher,the sleep quality scores were lower,and the exercise endurance was higher(P<0.05).Conclusion:Seated Baduanjin exercise can improve the negative psychological state and fatigue symptoms of MHD patients,enhance their quality of life and sleep quality,and effectively increase their exercise endurance.

Fatigue behavior and life prediction of A7N01 aluminium alloy welded joint

Fatigue characteristics of A7N01 aluminium alloy welded joint were investigated and a fatigue crack initiation life-based model was proposed. The difference of fatigue crack initiation life among base metal, weld metal and heat affected zone (HAZ) is slight. Furthermore, the ratio of fatigue crack initiation life (Ni) to fatigue life to failure(Nf) is a material dependent parameter, 26.32%, 40.21% and 60.67% for base metal, HAZ and weld metal, respectively. Total fatigue life predicted using the presented model is in good agreement with the experimental data and that using Basquin’s model. The observation results of fatigue fracture surfaces, using scanning electron microscope (SEM), demonstrate that fatigue crack initiates from smooth surface due to welding process for weld metal, blowhole in HAZ causes fatigue crack initiation, and the crushed second phase particles play an important part in fatigue crack initiation in base metal.

Effect of laser shock processing on fatigue life of fastener hole

The fatigue properties of laser shock processing （LSP） on both side surfaces of fastener hole with diameter of 3 mm in the LY12CZ aluminum alloy specimens were investigated. The superficial residual stress was measured by X-ray diffraction method. Fatigue experiments of specimens with and without LSP were performed, and the microstructural features of fracture of specimens were characterized by scanning electron microscopy （SEM）. The results indicate that the compressive residual stress can be induced into the surface of specimen, and the fatigue life of the specimen with LSP is 3.5 times as long as that of specimen without LSP. The location of fatigue crack initiation is transferred from the top surface to the sub-surface after LSP, and the fatigue striation spacing of the treated specimen during the expanding fatigue crack is narrower than that of the untreated specimen. Furthermore, the diameters of the dimples on the fatigue crack rupture zone of the specimen with LSP are relatively bigger, which is related to the serious plastic deformation in the material with LSP.

A Model of the Fatigue Life Distribution of Composite Laminates Based on Their Static Strength Distribution

The reasons of the static strength dispersion and the fatigue life dispersion of composite laminates are analyzed in this article. It is concluded that the inner original defects, which derived from the manufacturing process of composite laminates, are the common and major reason of causing the random distributions of the static strength and the fatigue life. And there is a correlative relation between the two distributions. With the study of statistical relationship between the fatigue loading and the fatigue life in the uniform confidence level and the same survival rate S-N curves of material, the relationship between the static strength distribution and the fatigue life distribution through a material S-N curve model has been obtained. And then the model which is used to describe the distributions of fatigue life of composites, based on their distributions of static strength, is set up. This model reasonably reflects the effects of the inner original defects on the static strength dispersion and on the fatigue life dispersion of composite laminates. The experimental data of three kinds of composite laminates are employed to verify this model, and the results show that this model can predict the random distributions of fatigue life for composites under any fatigue loads fairly well.

A fatigue life prediction method of rolling bearing under elliptical contact elastohydrodynamic lubrication

In order to more accurately predict the contact fatigue life of rolling bearing, a prediction method of fatigue life of rolling bearing is proposed based on elastohydrodynamic lubrication （EHL）, the 3-paameter Weibull distribution ad fatigue strength. First,the contact stress considering elliptical EHL is obtained by mapping film pressure onto the Hertz zone. Then,the basic strength model of rolling bearing based on the 3-parameter Weibull distribution is deduced by the series connection reliability theory. Considering the effect of the type of stress, variation of shape and fuctuation of load, the mathematical models of the 尸 -tS-TV curve of the minimum life and the characteristic life for rolling bearing are established, respectively, and thus the prediction model of fatigue life of rolling bearing based on the 3-paameter Weibull distribution and fatigue strength is further deduced. Finally, the contact fatigue life obtained by the proposed method ad the latest international standard （IS0281： 2007） about the fatigue life prediction of rolling bearing are compared with those obtained by the statistical method. Results show that the proposed prediction method is effective and its relative error is smaier than that of the latest international standard （IS0281： 2007） with reliability R 〉 0. 93.

A Method in Mixed Frequency-time domain for Fatigue Life Estimation of Steel Girders of Cable-stayed Bridges Due to Buffeting

发展了斜拉桥钢主梁抖振疲劳寿命的混合时－频域方法．在本方法中，首先建立了桥面处的风速风向概率密度函数，导出的应力谱因其包括背景分量而不再是窄带谱．据应力谱模拟出了疲劳应力的时间历程，并用雨流计数法统计了其幅值特性．基于修正的Ｍｉｎｅｒ定理导出了考虑风速风向作用的桥梁主梁抖振疲劳寿命的估算公式，并用此分析了杨浦大桥钢主梁的抖振疲劳寿命．结果表明，风向对抖振疲劳寿命有很大影响；杨浦大桥主梁的疲劳寿命远大于设计寿命．

Computation of the Fatigue Life of Road Wheel with Double-Layer Rubber Flange

In order to increase the fatigue life (FL) of road wheels (RW), a kind of double layer rubber flange (DLRF) is put forward. It consists of two layers of rubber, where metal wires are laid in the inner layer and the outer layer has no inlaid metal wires. Stress, strain and temperature field of DLRF were calculated with ANSYS finite element analysis (FEA) software, FL of DLRF RW was also computed with fracture mechanics fatigue theory. The results of computation indicate that the heat generated in RW's rubber flange (RF) can be reduced by the use of DLRF, and the FL of RW can be increased without affecting the mechanical intensity of RW.

Corrosion Fatigue Life Prediction of Aircraft Structure Based on Fuzzy Reliability Approach

Material performance of LY12CZ aluminum is greatly degraded because of corrosion and corrosion fatigue, which severely affect the integrity and safety of aircraft structure, especially those of lbe navy aircraft structure. The corrosion and corrosion fatigue failure process of aircraft structure are directly concerned with many factors, such as load, material characteristics, corrosive environment and so on. The damage mechanism is very complicated, and there are both randomness and fuzziness in the failure process. With consideration of the limitation of those conventional probabilistic approaches for prediction of corrosion fatigue life of aircraft structure at present, and based on the operational load spectrum obtained through investigating service status of the aircraft in naval aviation force, a fuzzy reliability approach is proposed, which is more reasonable and closer to the fact. The effects of the pit aspect ratio, the crack aspect ratio and all fuzzy factors on corrosion fatigue life of aircraft structure are discussed. The results demonstrate that the approach can be applied to predict the corrosion fatigue life of aircraft structure.

LIFE PREDICTION APPROACH FOR RANDOM MULTIAXIAL FATIGUE

According to the concept of critical plane, a life prediction approach forrandom multiaxial fatigue is presented. First, the critical plane under the multiaxial randomloading is determined based on the concept of the weight-averaged maximum shear strain direction.Then the shear and normal strain histories on the determined critical plane are calculated and takenas the subject of multiaxial load simplifying and multiaxial cycle counting. Furthermore, amultiaxial fatigue life prediction model including the parameters resulted from multiaxial cyclecounting is presented and applied to calculating the fatigue damage generated from each cycle.Finally, the cumulative damage is added up using Miner's linear rule, and the fatigue predictionlife is given. The experiments under multiaxial loading blocks are used for the verification of theproposed method. The prediction has a good correction with the experimental results.

Fatigue Life Prediction under Service Load Considering Strengthening Effect of Loads below Fatigue Limit

Lightweight design requires an accurate life prediction for structures and components under service loading histories. However, predicted life with the existing methods seems too conservative in some cases, leading to a heavy structure. Because these methods are established on the basis that load cycles would only cause fatigue damage, ignore the strengthening effect of loads. Based on Palmgren-Miner Rule （PMR）, this paper introduces a new method for fatigue life prediction under service loadings by taking into account the strengthening effect of loads below the fatigue limit. In this method, the service loadings are classified into three categories： damaging load, strengthening load and none-effect load, and the process for fatigue life prediction is divided into two stages： stage I and stage II, according to the best strengthening number of cycles. During stage I, fatigue damage is calculated considering both the strengthening and damaging effect of load cycles. While during stage II, only the damaging effect is considered. To validate this method, fatigue lives of automobile half shaft and torsion beam rear axle are calculated based on the new method and traditional methods, such as PMR and Modified Miner Rule （MMR）, and fatigue tests of the two components are conducted under service loading histories. The tests results show that the percentage errors of the predicted life with the new method to mean life of tests for the two components are –3.78% and –1.76% separately, much lesser than that with PMR and MMR. By considering the strengthening effect of loads below the fatigue limit, the new method can significantly improve the accuracy for fatigue life prediction. Thus lightweight design can be fully realized in the design stage.

A two-parameter model to predict fatigue life of high-strength steels in a very high cycle fatigue regime

In this paper, ultrasonic （20 kHz） fatigue tests were performed on specimens of a high-strength steel in very high cycle fatigue （VHCF） regime. Experimental results showed that for most tested specimens failed in a VHCF regime, a fatigue crack originated from the interior of specimen with a fish-eye pattern, which contained a fine granular area （FGA） centered by an inclusion as the crack origin. Then, a two-parameter model is proposed to predict the fatigue life of high-strength steels with fish-eye mode failure in a VHCF regime, which takes into account the inclusion size and the FGA size. The model was verified by the data of present experiments and those in the literature. Furthermore, an analytic formula was obtained for estimating the equivalent crack growth rate within the FGA. The results also indicated that the stress intensity factor range at the front of the FGA varies within a small range, which is irrespective of stress amplitude and fatigue life.

Effect of Pre-corrosion on Fatigue Life of High Strength Steel 38CrMoAl

The effect of pre-corrosion on fatigue behavior of high strength steel 38CrMoAl was investigated with a fatigue test method using the accelerated pre-corrosion specimen in the neutral salt spray environment. The methods of weight-loss and energy dispersive spectrum （EDS） were adopted. The corrosion weight-loss rate was fitted with the test time using power law, and the relationship between the corrosion weight-loss rate and the time was formulated. Moreover, the fatigue behaviors of the steel for different pre-corrosion time were investigated by the axis-direction tensile fatigue test. The fatigue life distribution characteristics of the pre-corrosion specimens were studied using the statistical probability methods, and the mathematical expectations and the standard tolerances of the material fatigue lives after different pre-corrosion time were obtained. It was found that the crack initiation of the high strength steel was accelerated by the preferential corrosion at the local plastic deform areas. The fatigue life obeys the lognormal distribution perfectly. Furthermore, within the common time range of the engineering, the standard tolerances of the logarithm of the fatigue life were independent of the pre-corrosion time.

Method to calculate fatigue fracture life of control fissure in perilous rock

Rupture and safety of perilous rock are dominated by control fissure behind perilous rock block. Based on model-Ⅰ and model-Ⅱ stress strength factors of control fissure under acting of weight of perilous rock, water pressure in control fissure and earth- quake forces, method to calculate critical linking length of control fissure is established. Take water pressure in control fissure as a variable periodic load, and abide by P-M criterion, when control fissure is filled with water, establish the method to calculate fatigue fracture life of control fissure in critical status by contributing value of stress strength factor stemming from water pressure of control fissure in Paris＇s fatigue equation. Further, parameters （C and m） of sandstone with quartz and feldspar in the area of the Three Gorges Reservoir of China are obtained by fatigue fracture testing.

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.

Revised damage evolution equation for high cycle fatigue life prediction of aluminum alloy LC4 under uniaxial loading

The fatigue life prediction for components is a difficult task since many factors can affect the final fatigue life. Based on the damage evolution equation of Lemaitre and Desmorat, a revised two-scale damage evolution equation for high cycle fatigue is presented according to the experimental data, in which factors such as the stress amplitude and mean stress are taken into account. Then, a method is proposed to obtain the material parameters of the revised equation from the present fatigue experimental data. Finally, with the utilization of the ANSYS parametric design language （APDL） on the ANSYS platform, the coupling effect between the fatigue damage of materials and the stress distribution in structures is taken into account, and the fatigue life of specimens is predicted. The outcome shows that the numerical prediction is in accord with the experimental results, indicating that the revised two-scale damage evolution model can be well applied for the high cycle fatigue life prediction under uniaxial loading.

Grain size based low cycle fatigue life prediction model for nickel-based superalloy

Nickel-based superalloys are easy to produce low cycle fatigue(LCF)damage when they are subjected to high temperature and mechanical stresses.Fatigue life prediction of nickel-based superalloys is of great importance for their reliable practical application.To investigate the effects of total strain and grain size on LCF behavior,the high temperature LCF tests were carried out for a nickel-based superalloy.The results show that the fatigue lives decreased with the increase of strain amplitude and grain size.A new LCF life prediction model was established considering the effect of grain size on fatigue life.Error analyses indicate that the prediction accuracy of the new LCF life model is higher than those of Manson-Coffin relationship and Ostergren energy method.

Fatigue life analysis of SMA490BW steel welded butt joint for train bogie based on ABAQUS/FE-SAFE

Stress concentration has a significant effect on fatigue properties of welded butt joint of bogie.The influences of joint geometric parameters {weld edge transition arc radius r,weld toe inclination angle θ） on stress concentration coefficient Kt at weld toe and fatigue life N were studied based on the finite element software ABAQUS/FE-SAFE,and the parametric equations were founded based on regression analysis of Origin software.The results show that weld edge transition arc radius r plays the most important role in stress concentration coefficient Kt as well as weld toe inclination angle 0.For the same inclination angle θ,stress concentration coefficient Kt decreases gradually with transition arc radius r increasing.With inclination angle θ increases,the effect of transition arc radius r on stress concentration factor Kt is increasing continuously,also the effect of change in stress concentration coefficient Kt caused by r on fatigue life N is increasing continuously.While in the case of same weld edge transition arc radius r,stress concentration coefficient Kt increases with inclination angle θincreasing.With transition arc radius r increases,the effect of inclination angle θ on stress concentration factor Kt is decreasing constantly,the effect of change in stress concentration coefficient Kt caused by θ on fatigue life N is decreasing constantly.The associated parametric equations have important instructive significance for the improvement of stress concentration degree and fatigue life of welded butt joint for train bogie.

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.

MULTIAXIAL CREEP-FATIGUE LIFE EVALUATION UNDER PROPORTIONAL LOADING

A new method was proposed for the multiaxial creep-fatigue life evaluation under proportional loadings. Because this method was derived from the strain range partitioning method with a multiaxiality factor, it was possible to consider the influence of both creep-fatigue interaction and multiaxial stress state on fatigue life. In order to predict the combined axial-torsional fatigue life the damage under combined loading was defined as linear summation of the damages under axial loading and torsional loading. Axial-torsional creep-fatigue tests were carried out using tubular specimens of 316LC austenitic stainless steel and the ferritic rotor steel. This rotor steel was developed for the permanent magnet type eddy current retarder in heavy trucks. Experimentally obtained lives of both steels were well corresponded with the lives predicted by the proposed method. It was found that the proposed method was effective in multiaxial fatigue life evaluation under proportional creep-fatigue loadings.