RELIABILITY OF ELASTO-PLASTIC STRUCTURE USING FINITE ELEMENT METHOD

A solution of probabilistic FEM for elastic-plastic materials is presented based on the incremental theory of plasticity and a modified initial stress method. The formulations are deduced through a direct differentiation scheme. Partial differentiation of displacement, stress and the performance function can be iteratively performed with the computation of the mean values of displacement and stress. The presented method enjoys the efficiency of both the perturbation method and the finite difference method, but avoids the approximation during the partial differentiation calculation. In order to improve the efficiency, the adjoint vector method is introduced to calculate the differentiation of stress and displacement with respect to random variables. In addition, a time-saving computational method for reliability index of elastic-plastic materials is suggested based upon the advanced First Order Second Moment (FOSM) and by the usage of Taylor expansion for displacement. The suggested method is also applicable to 3-D cases.

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.

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.

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 Reliability Assessment of Correlated Welded Web-frame Joints

The objective of this work is to analyze the fatigue reliability of complex welded structures composed of multiple web-frame joints, accounting for correlation effects. A three-dimensional finite element model using the 20-node solid elements is generated. A linear elastic finite element analysis was performed, hotspot stresses in a web-frame joint were analyzed and fatigue damage was quantified employing the S-N approach. The statistical descriptors of the fatigue life of a non-correlated web-frame joint containing several critical hotspots were estimated. The fatigue reliability of a web-frame joint wasmodeled as a series system of correlated components using the Ditlevsen bounds. The fatigue reliability of the entire welded structure with multiple web-frame joints, modeled as a parallel system of non-correlated web-frame joints was also calculated.

Thermo-mechanical fatigue reliability optimization of PBGA solder joints based on ANN-PSO

Based on a method combined artificial neural network (ANN) with particle swarm optimization (PSO) algorithm, the thermo-mechanical fatigue reliability of plastic ball grid array (PBGA) solder joints was studied. The simulation experiments of accelerated thermal cycling test were performed by ANSYS software. Based on orthogonal array experiments, a back-propagation artificial neural network (BPNN) was used to establish the nonlinear multivariate relationship between thermo-mechanical fatigue reliability and control factors. Then, PSO was applied to obtaining the optimal levels of control factors by using the output of BPNN as the affinity measure. The results show that the control factors, such as print circuit board (PCB) size, PCB thickness, substrate size, substrate thickness, PCB coefficient of thermal expansion (CTE), substrate CTE, silicon die CTE, and solder joint CTE, have a great influence on thermo-mechanical fatigue reliability of PBGA solder joints. The ratio of signal to noise of ANN-PSO method is 51.77 dB and its error is 33.3% less than that of Taguchi method. Moreover, the running time of ANN-PSO method is only 2% of that of the BPNN. These conclusions are verified by the confirmative experiments.

Fuzzy stochastic generalized reliability studies on embankment systems based on first-order approximation theorem

In order to address the complex uncertainties caused by interfacing between the fuzziness and randomness of the safety problem for embankment engineering projects, and to evaluate the safety of embankment engineering projects more scientifically and reasonably, this study presents the fuzzy logic modeling of the stochastic finite element method （SFEM） based on the harmonious finite element （HFE） technique using a first-order approximation theorem. Fuzzy mathematical models of safety repertories were introduced into the SFEM to analyze the stability of embankments and foundations in order to describe the fuzzy failure procedure for the random safety performance function. The fuzzy models were developed with membership functions with half depressed gamma distribution, half depressed normal distribution, and half depressed echelon distribution. The fuzzy stochastic mathematical algorithm was used to comprehensively study the local failure mechanism of the main embankment section near Jingnan in the Yangtze River in terms of numerical analysis for the probability integration of reliability on the random field affected by three fuzzy factors. The result shows that the middle region of the embankment is the principal zone of concentrated failure due to local fractures. There is also some local shear failure on the embankment crust. This study provides a referential method for solving complex multi-uncertainty problems in engineering safety analysis.

Calculation of Thermal Stress and Fatigue Life of 1000 MW Steam Turbine Rotor

The paper calculated the temperature and stress fields of 1000 MW ultra-supercritical steam turbine rotors which start in cold condition using the finite element calculation program (ANSYS). After getting rotor stress field, the paper use the general slope method to estimate the low cycle fatigue life loss, the rest of the conditions can be calculated in this method.

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.

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.

FATIGUE DAMAGE AND LIFETIME PREDICTION OF AERONAUTIC WELDED STRUCTURES UNDER HIGH TEMPERATURE

The fatigue damage evolution equations and the relation of fatigue damage parameter with maximum cyclic stress of superalloy GH150 and its welded structures are established. The fatigue damage evolution equations in a multiaxial stress state are also given. By use of cyclic thermal elastoplastic damage constitutive relations, the fatigue damage and lifetime predictions are carried out for the welded combustion chamber of aeroengine.

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.

基于MSC.Fatigue的链条疲劳寿命分析与优化

针对链条疲劳寿命可靠性设计求解复杂、试验周期长、试验成本高等问题,在ABAQUS有限元分析的基础上,提出了一种基于MSC.Fatigue的链条疲劳寿命分析方法,能够快速确定链条的最小疲劳寿命及其分布,找出链条设计薄弱环节。同时提出了一种优化设计方案,并且对优化方案分别进行了MSC.Fatigue疲劳寿命分析和疲劳试验验证。疲劳寿命结果不仅满足了疲劳设计要求,而且更进一步验证了仿真分析与实际试验验证结果的一致性和有效性,为后续链系统的可靠性设计提供了依据。

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.

基础激励下裂纹梁结构疲劳寿命预测模型

为了发展基于模型的裂纹梁结构疲劳寿命预测方法,提出了一种新的三维裂纹梁单元刚度矩阵。基于该刚度矩阵,建立基础激励下裂纹梁结构的三维有限元模型。推导三维裂纹梁单元的应力强度因子,建立三维裂纹梁单元的疲劳裂纹扩展模型。采用振动响应与裂纹扩展增量交互计算方法,计算循环载荷作用下裂纹梁结构的疲劳寿命。研究结果表明:裂纹梁结构寿命预测模型较好地体现了疲劳裂纹扩展寿命与基础激励参数、结构参数和裂纹参数之间的内在关系,反映了基础激励对裂纹梁结构疲劳寿命的影响。最后通过实验对模型进行了验证。

弹上电子产品加固防护可靠性分析研究

提出一种弹上电子产品球栅阵列封装元器件的新型加固防护工艺方法,对使用不同加固防护方法的电子产品进行了随机振动试验与有限元仿真分析,研究对球栅阵列封装(BGA)元器件焊点可靠性的影响;采用Steinberg疲劳寿命模型分析焊点的疲劳寿命。研究表明,纳米疏水剂、四角点胶配合3D打印壳体封装的组合新型弹上电子产品加固防护方法能有效提升产品可靠性。

波纹管最大压缩位移及疲劳寿命分析

为解决某GIS母线中波纹管的最大压缩位移和疲劳寿命究竟能否同时满足工程指标的难题,应用工程计算和有限元分析分别加以计算,然后通过两种计算结果和实验验证进行比较,以期获得哪种方法更精确可靠。为达此目的,文中给出了工程计算和有限元建模的详细过程。按工程计算方法得到的最大压缩位移结果无法满足工程指标,而有限元分析计算方法,却可以达到工程指标,且有较大的安全裕度。有限元分析还揭示了满足大压缩位移的机理,计算结果符合某GIS工程同时需要的压缩位移和疲劳寿命。经型式试验也验证了模拟的正确性。充分证明了有限元分析方法是比按工程计算方法更为先进和准确的设计手段。

岸桥起重机前大梁疲劳寿命的数值模拟分析

为了保证岸桥起重机的安全作业,评估岸桥起重机前大梁的疲劳寿命是非常必要的.首先在ANSYS中建立前大梁模型进行静力分析,采用实际工况进行加载,求得起重机主要构件在荷载组合下的应力状态和变形量,与行业规范进行比较,校验在荷载作用下的强度和刚度.针对结构的危险部位,如出现较大应力及变形量的部位,使用ANSYS APDL导出其周边的柔性体,耦合多体动力学软件ADAMS进行动力学仿真.采取不同的连接方式添加运动副及驱动,还原岸桥起重机构件间的连接状态,并导出在给定工况下岸桥起重机前大梁载荷谱.利用Ncode design life的“疲劳五框图”结合线性损伤理论、材料的S-N曲线,对岸桥起重机前大梁进行了疲劳分析.结果表明,前大梁与前拉杆的连接处为寿命最短部位,基于修正模型Godman获得的最小循环次数为7.145E+05次.该文的研究结果可为预测岸桥起重机的疲劳寿命提供重要参考.

倾覆力耦合的大兆瓦风机主轴-齿轮箱法兰结构疲劳寿命研究

大兆瓦风机主轴-齿轮箱法兰连接受倾覆力及其他交变载荷的作用,极易产生疲劳破坏。文中建立了考虑倾覆力耦合作用的法兰连接有限元数值模型,分析了特定工况下法兰连接各部件应力场分布规律;通过GH-Bladed获得主轴实际转矩变化数据,根据雨流计数法计算得到了主轴和螺栓多种工况下载荷-时间历程曲线,基于Brown-Miller准则并结合材料的S-N曲线,使用FE-SAFE给出了不同预紧力条件下主轴和螺栓的疲劳寿命,疲劳分析结果表明:随着预紧力的减小,主轴的疲劳寿命大于螺栓的,螺栓在风机运行过程中更容易发生疲劳破坏。基于VDI2230规范,结合法兰界面涂层增摩工艺,得到了法兰界面摩擦因数、螺栓预紧力与法兰结构疲劳寿命的理论模型。该研究对于大兆瓦风机主轴-齿轮箱法兰连接结构设计和疲劳寿命提升具有一定的指导意义。

超临界锅炉再热热段管道裂纹分析及寿命评估

某型超临界锅炉再热热段管道内壁出现网状裂纹,裂纹分布于该处疏水管沿蒸汽流动方向约200 mm范围内。经宏观检查,无损检测以及扫描电镜形貌检查,判断其为热疲劳裂纹。通过查询该锅炉的运行记录,分析原因为再热蒸汽压力波动,导致疏水管道产生的冷凝水反复涌入再热热段管道,使其管道内壁产生热疲劳裂纹。运用有限元软件模拟出了疏水管内冷凝水产生的液面位置,即距离再热热段管道外壁超过30 cm的疏水管内再热蒸汽会全部冷凝为液态水。提出了避免产生此种热疲劳裂纹的解决方法,如调整疏水一次阀门的位置以及控制再热蒸汽压力的大幅度波动。最后对该段无裂纹的热段管道进行了寿命评估,得出剩余寿命约为61 722 h。