Numerical Simulation of Fretting Fatigue Damage Evolution of Cable Wires Considering Corrosion and Wear Effects

In this paper,a numerical model of fretting fatigue analysis of cablewire and the fretting fatigue damage constitutive model considering the multi-axis effect were established,and the user material subroutine UMAT was written.Then,the constitutive model of wear morphology evolution of cable wire and the constitutive model of pitting evolution considering the mechanical-electrochemical effect were established,respectively.The corresponding subroutines UMESHMOTION_Wear and UMESHMOTION_Wear_Corrosion were written,and the fretting fatigue lifewas further predicted.The results showthat the numerical simulation life obtained by the programin this paper has the same trend as the tested one;the error is only about 0.7%in the medium life area;When the normal contact force increases from 120 to 240 N,the fretting life of cable wire decreases by 25%;When the evolution of wear morphology and corrosion effect are considered simultaneously,the depth of the wear zone exceeds 0.08mm after 600,000 loads,which ismuch larger than 0.04 mmwhen only the evolution of wear morphology is considered.When the evolution of wear morphology and corrosion morphology is considered simultaneously,the damage covers the whole contact surface after 300,000 loads,and the penetrating damage zone forms after 450,000 loads,which is obviously faster than that when only the wearmorphology evolution is considered.Themethod proposed in this paper can provide a feasible numerical simulation scheme for the visualization of the damage process and accurate life prediction of cable-supported bridges.

Analysis of Temperature Rise Characteristics and Fatigue Damage Degree of ACSR Broken Strand

In this paper,the research on ACSR temperature of broken strand and fatigue damage after broken strand is carried out.Conduct modeling and Analysis on the conductor through AnsoftMaxwell software.The distribution of magnetic force lines in the cross section of the conductor after strand breaking and the temperature change law of the conductor with the number of broken strands are analyzed.A model based on electromagnetic theory is established to analyze the distribution of magnetic lines of force in the cross section of the conductor after strand breaking and the temperature variation law of the conductor with the number of broken strands.The finite element analysis results show that with the increase in the number of broken strands,the cross-sectional area of the conductor decreases,the magnetic line of force of the inner conductor at the broken strand becomes denser and denser,and the electromagnetic loss of the conductor becomes larger and larger.Therefore,the temperature of the conductor at the broken strand becomes higher and higher.Then,the current carrying experiment of conductor is carried out for LGJ-240/30 conductor.It is found that the temperature rise at the junction of inner and outer layers at the broken strand is particularly obvious,and the temperature of inner aluminumconductor at the broken strand also increases with the increase of broken strand.According to the analysis of experimental data,with the increase of broken strands,the antivibration ability and service life of the conductor decrease.At the same time,under certain conditions of broken strand,the fatigue life of conductor increases with the increase of temperature.

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.

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.

A DAMAGE FUNCTION USED FOR PREDICTION OF LOW CYCLIC FATIGUE LIFE

In this paper, the cyclic plastic strain energy is acted as damage variable and its mathematical model of transient response is established. The nonlinear fatigue damage function is given by means of the damage mechanical method. The formula used for prediction of low cyclic fatigue life is obtained from this damage function which takes into account the cyclic relativity of cyclic plastic strain energy. The low cyclic fatigue life predicted by this formula is in correspondence with the experimental result.

Probabilistic Life Calculation Method of NdFeB Based on Brittle Fatigue Damage Model

This paper proposes a probabilistic life calculation method of NdFeB based on brittle fatigue damage model.Firstly,Zhu-Wang-Tang(ZWT)constitutive model considering strain rate is established,and based on this,a numerical co-simulation model for NdFeB life calculation is constructed.The life distribution diagram of NdFeB under different stress levels is obtained after simulation.Secondly,a new model of brittle fatigue damage based on brittle damage mechanism is proposed.Then the parameters in the model are identified according to the life distribution diagram of NdFeB and the parameter distribution of the damage evolution model when applied to NdFeB is obtained.Finally,the probability density evolution equation of NdFeB life calculation is established and solved using the probability density evolution method.Probability density function(PDF)of NdFeB life under different stress levels is obtained and provides theoretical basis for the reliability of NdFeB in engineering applications.

CALCULATIONS TO ITS FATIGUE DAMAGE FRACTURE AND TOTAL LIFE UNDER MANY－STAGE LOADING FOR A CRANK SHAFT

Suggests some calculating formulas and methods with respect to the damage evolvingrate da / dN|i and the fatigue life and in varied history from uncrack to microcrackinitiation until fracture for a crankshaft, which are suitable to stress concentration positionsabout its journal fillets and oil holes on a crankshaft, that it is undergone to bending, twistingand shearing loading and subjected to unsymmetric cyclic many-stage loading. Last the total lifein whole process is estimated by

Low Cycle Fatigue Life Estimation and Tracking for Industrial Gas Turbine Blades Using Fatigue Factor Approach

Low cycle fatigue life consumption analysis was carried out in this work. Fatigue cycles accumulation method suitable even if engine is not often shut down was applied together with the modified universal sloped method for estimating fatigue cycles to failure. Damage summation rule was applied to estimate the fatigue damage accumulated over a given period of engine operation. The concept of fatigue factor which indicates how well engine is operated was introduced to make engine life tracking feasible. The developed fatigue life tracking method was incorporated in PYTHIA, Cranfield University in-house software and applied to 8 months of engine operation. The results obtained are similar to those of real engine operation. At a set power level, fatigue life decreases with increase in ambient temperature with the magnitude of decrease greater at higher power levels. The fatigue life tracking methodology developed could serve as a useful tool to engine operators.

Energetical Theories on Fatigue Life Prediction

Current developments on fatigue life prediction methods have been systematically reviewed.In con- sideration of the irreversibility of energy dissipation during fatigue damage process,the main contents for fatigue damage estimation and localized equivalence as well as simulation models have been established.A frame of energy-based fatigue life prediction method has been proposed,meanwhile, the procedure in application to a practical structure component has been described.

An improved fatigue life prediction model based on loading sequence

Purpose–In view of the difficulty in determining the key parameters d in the Corten-Dolan model,based on the introduction of small loads,damage degrees and stress states to the Corten-Dolan model and the existing improved model,the sequential effects of the adjacent two-stage load were further considered.Design/methodology/approach–Two improved Corten-Dolan models were established on the basis of modifying the parameter d by two different methods,namely,increasing stress ratio coefficient as well as considering the effects of loading sequence and damage degree as independent influencing factors respectively.According to the test data of the welded joints of common materials(standard 45 steel),alloy materials(standard 16Mn steel)and Q235B steel,the validity and feasibility of the above two improved models for fatigue life prediction were verified.Findings–Results show that,compared with the traditional Miner model and the existing Corten-Dolan improved model,the two improved models have higher prediction accuracy in the fatigue life prediction of welding materials whether under two-stage load or multi-stage load.Originality/value–Because the mathematical expressions of the models are relatively simple and need no multi-layer iterative calculation,it is convenient to predict the fatigue life of welded structure in practical engineering.

The probability distribution of fatigue damage and the statistical moment of fatigue life

The randomization of deterministic fatigue damage equation leads to the stochastic differential equation and the Fokker-Planck equation affected by random fluctuation. By means of the solution of equation, the probability distribution of fatigue damage with the change of time is obtained. Then the statistical moment of fatigue life in consideration of the stationary random fluctuation is derived. Finally, the damage probability distributions during the fatigue crack initiation and fatigue crack growth are

Hole surface strengthening mechanism and riveting fatigue life of CFRP/aluminum stacks in robotic rotary ultrasonic drilling

Carbon fiber reinforced plastic(CFRP)and aluminum stacks are widely used in aviation industry due to light weight and high performance.Millions of rivet holes need to be drilled on body materials,and more than 80%of fatigue cracks occur at the connection holes,so the damage and residual stress of hole surface have crucial effect on the riveting fatigue life of CFRP/aluminum stacks and the flight performance.Recently,robotic rotary ultrasonic drilling(RRUD)technology is a promising method to machine the stacks.However,the hole surface strengthening mechanism in RRUD and the service performance of the riveting joint are not verified.Thus,in this paper,the hole surface strengthening mechanism of RRUD for CFRP/aluminum stacks is investigated,a theoretical residual stress model is established,and the fatigue life experiment of riveted joints is conducted.Firstly,analysis on residual stress in RRUD is carried out with consideration of strengthening force and cutting temperature.Residual stress model is established based on the calculation of elastic stress,plastic stress and stress release.Validation experiment results show that ultrasonic vibration changes residual stress from tensile stress to compressive stress.At the same time,comparative damage analysis of CFRP hole exit and hole surface in robotic conventional drilling(RCD)and RRUD is presented.Finally,fatigue strength experiments of riveted joints are conducted for performance verification.Experimental results indicate that fatigue life of single-hole riveted joints is increased by 68%with ultrasonic vibration,and four-hole riveted joint arranged according to aerospace design standards is increased by more than 86%.

Fatigue Life Analysis of Coiled Tubing in Deep Well Jet Plugging Removal

The coiled tubing plugging has become the main means of plugging in gas Wells in Xinjiang. These Wells are deep and have high pressure, which can easily affect the fatigue life of the operating coiled tubing. In order to improve the life of coiled tubing in high-pressure gas Wells, this paper studies the plugging conditions of coiled tubing in high-pressure ultra-deep Wells. Firstly, the cross section deformation of coiled tubing under high internal pressure is analyzed. Secondly, the factors influencing the fatigue life of coiled tubing and the influence of surface damage on the fatigue life of coiled tubing were studied. Finally, the mechanism of furrow damage caused by coiled tubing and the main measures to reduce furrow damage are analyzed. The following suggestions are made to improve the life of coiled tubing: select the right material and the right size coiled tubing;Use appropriate measures to prevent premature coiled tubing failure and reduce operating costs.

A NEW DAMAGE MECHANICS BASED APPROACH TO FATIGUE LIFE PREDICTION AND ITS ENGINEERING APPLICATION

An approach based on continuum damage mechanics to fatigue life prediction for structures is proposed. A new fatigue damage evolution equation is developed, in which the pa- rameters are obtained in a simple way with reference to the experimental results of fatigue tests on standard specimens. With the utilization of APDL language on the ANSYS platform, a finite element implementation is presented to perform coupling operation on damage evolution of mate- rial and stress redistribution. The fatigue lives of some notched specimens and a Pitch-change-link are predicted by using the above approach. The calculated results are validated with experimental data.

A DAMAGE MECHANICS MODEL FOR FATIGUE LIFE PREDICTION OF FIBER REINFORCED POLYMER COMPOSITE LAMINA

A damage mechanics fatigue life prediction model for the fiber reinforced polymer lamina is established. The stiffness matrix of the lamina is derived by elastic constants of fiber and matrix. Two independent damage degrees of fiber and matrix are introduced to establish constitutive relations with damage. The damage driving forces and damage evolution equations for fiber and matrix are derived respectively. Fatigue tests on 0° and 90° unidirectional laminates are conducted respectively to identify parameters in damage evolution equations of fiber and matrix. The failure criterion of the lamina is presented. Finally, the life prediction model for lamina is proposed.

Mechanical and magnetic hysteresis as indicators of the origin and inception of fatigue damage in steel

N2 and N3 are known as the transition points of the three principal stages of fatigue: initial accommodation, accretion of damage and terminal fatigue. Many experiments show that the ratios of N2/Nf and N3/Nf tend to be stable even though the specific N2 and N3 values may fluctuate widely. The primary goal of this research is to study the piezomagnetic field surrounding AISI 1018 steel specimen under repeated loads and to find the ratio values of N2/Nf and N3/Nf by analyzing 11 sets of low-cycle fatigue data. An MTS-810 testing system with a peak capacity of 222 kN was used to obtain the data which consisted of stress, strain, and piezomagnetic field. A computer program was constructed to track the evolution of the piezomagnetic field and re- gression analysis was carried out to determine N2 and N3 values. It was observed that there exists a consistent relationship between N2 and Nf. The apparent invariance of the ratio N2/Nf implies that N2 may be identified as an index of performance in the early loading response of a specimen that forecasts its fatigue life, Nf. It has been demonstrated that measurements of the magnetic and mechanical hysteresis can yield significant insights into the various stages of the development of a fatigue critical microstructure which culminates in complete rupture of the material.

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.

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.

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.