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Advances in Fatigue and Fracture Mechanics: June 2 - 6, 2014
Advances in Fatigue and Fracture Mechanics: June 2 - 6, 2014
Stress-Strain
Analysis
Damage Analysis
Fatigue Life
S M S
e peak K
peak e
peak 2 a
a Sn crack
peak Sn
y
y
0 y 0 0
a
dn dn
T T T
a) S
b) c)
© 2008 Grzegorz Glinka. All rights reserved. 6
What stress parameter is needed for the Fracture
Mechanics based (da/dN- K) fatigue analysis?
S
The Stress Intensity Factor K characterizing
the stress field in the crack tip region is
K
x
2 x
needed!
Stress (x)
Load F
peak
0
t
Stress-Strain
Analysis
MATERIAL
n
Damage Analysis A
e D
F
No N
Fatigue Life
F
Q
hs/2
or
n/2
n
Stress amplitude,
K0
K1
K5 K2
K3
K4
K5
0
Number of cycles, N
The Similitude Concept states that if the nominal stress histories in the structure and in the test
specimen are the same, then the fatigue response in each case will also be the same and can be
described by the generic S-N curve. It is assumed that such an approach accounts also for the stress
concentration, loading sequence effects, manufacturing etc.
The S – N method
b) Component
F
e) Standard S-N curves Q
c) Section with welded joint
hs/2
Weld
d) Standard welded joints
or
n/2
R
P
Stress amplitude,
K0 V
K1
K2
K3
K4
K5
Number of cycles, N
5
© 2008 Grzegorz Glinka. All rights reserved. 12
Steps in Fatigue Life Prediction Procedure Based
on the S-N Approach (continued)
f) h) Fatigue damage:
n
Stress,
m5
1 1
D1
K5 N1 C5
m5
t 1 2
n D2
N2 C5
m5
1 3
D3
N3 C5
m5
g) 1 4
D4
N4 C5
Stress
m5
3 4 1 5
D5
N5 C5
i) Total damage:
D D1 D2 D3 D4 D5 ;
1
Ni( m m
i) = A or Ni=A/( i)
Stress range,
N5
N1 N4 N2 N3 N0 Cycles
nR
5
m m
1 1 1 4
D Di D1 D2 D3 D4 D5
D1 ; D4 ; i 1
N1 A N4 A
m m 1 1 1 1 1
1 2 1 1 3
;
D2 ; D5 0; D3 ; N1 N2 N3 N4 N5
N2 A N3 A
if D 1 Failure !!
1 1
LR ; Nf LR nR
D 1 N1 1 N2 1 N3 1 N4 1 N5
© 2008 Grzegorz Glinka. All rights reserved. 14
The FALSN fatigue life estimation software – Typical input and output data
Weldment
a A N
450 P=99%
P=90%
f(S) P=50% 8
P=10% 6
P=1% 48
400
Probability of failure
P(%)
S
S
Rw
PWL
No N
t
fS fK fR
S Smax K Kf R Rw
COMPUTING of Tj
j<L
T
N
L f (T Tr )
Pf
L
Un-satisfactory Most
Over designed
frequent
PSO E
0
t
Stress-Strain
Analysis
MATERIAL
Damage Analysis
2Nf
Fatigue Life
/2)
a) Specimen ' j)
f b
f
x 2N f '
2N f c
log (
f
peak peak 2 E l)
y
z
peak log
0 (2Nf)
b) Notched component
The Similitude Concept states that if
the local notch-tip strain history in the
notch tip and the strain history in the
test specimen are the same, then the
fatigue response in the notch tip region
and in the specimen will also be the
same and can be described by the
material strain-life ( -N) curve.
hs
peak
hs n
b) Component
d)
peak
1 1'
3 5 1
7 n'
tt
E K'
0
2 8 0
6
4 ,
1,1'
5,5'
7,7' '
3
2 f ' , '
f f
peak
Neuber : '
E f ' , '
f f
8 N f ?,?
6 2,2'
4
/2)
Fatigue damage:
'
f b c
f '
2N f 2N f 1 1 1 1
log (
2 E f D1 ; D2 ; D3 ; D4 ;
N1 N2 N3 N4
Total damage:
f/E
D D1 D2 D3 D4 ;
e/E
p e=
E p
2
t 2N 1
f(k) f(Kt)
fM1 fM3
e ’f M K’
Scaling factor k SCF Kt
fM2
SAMPLING: k , Kt , f , f' , K’ s ’f
LIFE CALCULATION: T i
i <L
Y
T T
© 2008 Grzegorz Glinka. All rights reserved. 26
Probability of failure
0
t
Stress-Strain
Analysis
MATERIAL
da n
dN
Damage Analysis
Kth K
Fatigue Life
F 10-8
Q
10-9
b) Weld detail
a
10-10
10-11
10-12
K 1 10 100
K,MPa m
a c) Specimen
e)
Stress, S
S3 S4
b) Component
S1
t
S2
F
S5
Q
Weld
R
P
V d)
af
f)
Stress intensity factor, K
(indirect method)
Crack depth, a
Weight function, m(x,y)
(x, y)
K x, y m x, y dxdy Fatigue Life
A
K
Y
n a
ai
Stress intensity factor, K
Number of cycles , N
(direct method)
g)
KI yFE 2 xFE h) Integration of Paris’ equation
a
or
m
K E
dU
EG
ai C Ki Ni
da
N
K af a0 ai
Y
n a i 1
N Ni
da n
S dN
PWL
Kth K
t
fS fa fK
fC
S Smax a a Kt C C
K
fKth
SAMPLING RANDOM VARIABLES
Kth Kth
CALCULATION of Tj fKc
Kc KIc
j<L
Yes
No
L f (T Tr )
Pf
L
The FALPR statistical simulation flow chart for the analysis of fatigue crack growth
© 2008 Grzegorz Glinka. All rights reserved. 35
Irregular geometrical shape of a real fatigue crack
300000
100000
50000
0
0 0.5 1 1.5 2 2.5
Crack Length 2c (in)
a a=
23 21
0 a= 0
12
a=0
2 32
a
11
a a= 0
31 13
a
33
1
3
a
11 0 0
a a
ij 0 22 0
a
0 0 33
a a=
23 21
0 a= 0
12
2 a
a
11 = 0
32
1 a 13
a= 0
31
a
33
3
a
11 0 0
a a a
ij 0 22 23
a a
0 32 33
22 F
C 2
peak C
F
22
n
22
n Anet
33
A, B
11
and
A D B
1
peak Kt n
22 3
22
D
11
F
33
© 2010 Grzegorz Glinka. All rights reserved. 41
Stresses concentration in a prismatic notched body
22
F
A, B, C
2
peak C
F
n
22
D 22
Anet
11
11
n
and
A
E
peak Kt n
D B 1
22 33
E
3
F
33
0 t
Fi-1
Fi+1
peak, i
f Fi ; f F ?
n, i
g Fi ; g F ?
n
pea
k
F
n ;
Anet
Stress
peak
n
n kF F ; peak hF F ;
y Analytical, FEM Hndbk
0
kF 1 ; hF peak
; hF kF K t ;
dn Anet F
T
n, i kF Fi ; peak , i hF Fi ;
F
M cnet
Stress
peak n ;
Inet
n
y n kM M ;
0
cnet
dn kM ; n,i
kM M i ;
T I net
peak ,i hM M i or peak ,i k M M i K tb
b) M
Stress
M cnet M c gross
Stress
peak peak
n or S
n I net I gross
n
peak peak
r y r y Kt or K t
0 n S
0
net Kt gross Kt
dn dn
T T Kt – stress concentration factor
(net or gross, net Kt gross Kt !! )
3.0
n
2.8
peak/
2.6
Stress concentration factor Kt=
2.4
2.2
2.0
1.8 P d b P
1.6
h
1.4 peak
1.2 n =P/[(b-d)h]
1.0
0 0.1 0.2 0.3 0.4 0.5 0.6
r
3.0
2.8
n
M M
peak/
2.6 H h
Stress concentration factor Kt=
b
2.4
2.2
Mc 6M
peak n
2.0 I bh2
1.8
1.6 H/h=6
H/h=2
1.4 H/h=1.2
H/h=1.05
1.2
H/h=1.01
1.0
0 0.05 0.10 0.15 0.20 0.25 0.30
Radius-to-height ratio r/h
(B.J. Hamrock et. al.
t1
pea
k
E
r D
hs
n
M A
t B
C
P
F
C
Various stress distributions in a T-butt weldment with transverse fillet welds;
g=h
P P
t
0.65
W
1 exp 0.9
2h 1 h
K tten 1 2
W W r
1 exp 0.45 2.8 2
2h t
where : W t 2h 0.6 hp
Range of application - reasonably designed weldments, (K.Iida and T. Uemura, ref. 14)
t1= tp h
Validated for : 0.02 r/t 0.16 and p
30o 60o, source [14]
h
x
P P
t
y
0.65
W
1 exp 0.9
2h 1 h
K tt 1
W W r
1 exp 0.45 2.8 2
2h t
where : W t 2h 0.3 t p 2hp
© 2010 Grzegorz Glinka. All rights reserved. 52
Cyclic Loads and Cyclic Stress Patterns
(histories) in Engineering Objects
M
n,i kF Fi kM M i ;
Stress
peak
peak ,i
kF Fi Ktt kM M i Ktb;
n
or
y
peak ,i
hF Fi hM M i ;
0
b) M
F hF , hM ; From detail FEM analysis
d N.A.
y 2
W/2
W/2 W/2
B A x 3
RB RA
Moment Mb 32 M b
n ,min c)
d3 1 cycle
l 1
L n,max
Stress
M bc 32 M b n,a
S n peak ;
I d3 2 time
W d d3 n,min
Mb L l ; c ; I ; 3
4 2 64
Note! In the case of smooth components,
such as the railway axle, the nominal stress and the local peak stress are the same!
© 2008 Grzegorz Glinka. All rights reserved. 55
Fluctuations and complexity of the stress state at the
notch tip
x3 x3
33
T
F F
x2 22 22 x2
2R
t
23
33
23
ABC ABC
23
23
A 23
A
0 t 0 t
2
B 22
0 2
B
22 22 0
C
0 t C 0 t
P
n, i kP Pi M
n, i kM Mb,i ; T
n, i kT Ti
c) In the case of proportional loading the normal peak and valley stresses can be added and the
resultant nominal normal stress history can be established. Because all load modes in proportional
loading have the same number of simultaneous reversals the resultant history has also the same
number of resultant reversals as any of the single mode stress history.
n,i
kP Pi kM Mb,i ;
d) In the case of non-proportional loading the normal stress histories (and separately the shear
stresses) have to be added as time dependent processes. Because each individual stress history
has different number of reversals the number of reversals in the resultant stress history can be
established after the final superposition of all histories.
n ti k P P ti k M M b t i
Mode a Mode a
n,a
n,a
Stress
Stress
time
0 0
Mode b
n,b
n,b
Mode b
Stress
Stress
time
0 0
n
Stress
Stress
0 0
10 10
8 - 28
5
- 30
0
0
- 40
-5
- 50
605 610 615 620 600 605 610 615 620
600
Time [s] Time [s]
Source [43]
Note! One reversal of the wind speed results in several stress reversals
a)
b)
0
Flying
Stress
c)
time
0
Taxiing Landing Source [9]
a) Ground loads on the wings, b) Distribution of the wing bending moment induced by the ground
load, c) Stress in the lower wing skin induced by the ground and flight loads
0 t
Fi-1
Fi+1
peak, i
f Fi ; f F ?
n, i
g Fi ; g F ?
n
pea
k
peak
peak,max
n,max
n
Fmax
Stress
Stress
Load F
peak,
n,i i
Fi
n,i+1 peak,i+1
Fi+1
0 Time Time Time
0 0
Fi-1
n,i-1
peak,i-1
+1
n,i kF Fi
i+1
peak , i Kt n, i K t kF Fi
0
i-1
Fi n,i peak , i
n,i
Fmax n ,max peak ,max
1 n,i 1
-1
© 2008 Grzegorz Glinka. All rights reserved. 62
How to get the nominal stress n from the
Finite Element method stress data?
Notched shaft under axial, bending and torsion load
x3
M T M
F
F x2
d
D
T
Discrete cross section stress distribution
t obtained from the FE analysis
r x3
n pea
k
y y yi 6 y yi yi
1 1
(y1)
t t2
(yi)
n peak x
yi
Determination of
yi
t yn nominal stresses
from discrete FE data
by the linearization
yn method
(yn)
0 0 n
y 1 dy y dy y yi
m P t t 1
n ;
1 t 1 t t 0
t 0 n
t
y 1 y dy 6 y y dy 6 y yi yi
b c M 2 t t 1
n 3 2
;
I 1 t t t2
12
© 2010 Grzegorz Glinka. All rights reserved. 64
How to get the resultant stress distribution from the
Finite Element stress data? (Notched shaft under axial, bending load)
x3 b x3
n
Bending M M
23 P
P x
d
22 22
d
2
0
D
33
t
r
x3 m x3
n pea
k
Axial Resultant
(x3)
22 0 22
d
d
n, max n
Stress
n, 0 time
n, min
x3
Resultant
22
0
d
• Multiaxial state of
stress at weld toe
• One shear and two
zz
normal stresses xx
• Due to stress
concentration, xx is
the largest component
– Predominantly responsible
for fatigue damage
xz
zx
xx
zz
x L L
P x
P P P
(x,y)
t t
peak
(x,y)
L /2 0 hs
x , y dxdy
L /2 t P - depends on L and is constant along the weld toe line
n
t L t L
0 0
x 0, y dy 6 x 0, y ydy Independent of L but it changes
m b t t along the weld toe line
hs hs hs
t t2
a) Stress distribution in the critical cross section near the cover plate ending and the nominal or the
hot spot stress n (independent of length L ) and hs (independent of length L),
b) Stress distribution in the critical plane near the ending of a vertical attachment (gusset) and the
nominal or the hot spot stress n (dependent on length L ) or hs (independent of length L)
© 2008 Grzegorz Glinka. All rights reserved. 68
The Nominal Stress n versus the local Hot Spot Stress hs
m b m b
hs , A hs , A hs , A ; hs , B hs , B hs , B ;
P
n, A ;
t L
n, B ??; A hs,A y
P
P
B
hs,B (x,y)
y L
x x
max min
stress range max
max Stress a
min
a stress amplitude m
2 time
max 0
min mean stress
m
2 min
Unfortunately, the cycle definition is not simple in the case of a variable amplitude signal. The only non-
dubious quantity, which can easily be defined, is a reversal, example of which is marked with the thick line in
the Figures below.
15
10
Bending moment [10 kNm]
0
1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81
-5
-10
-15
-20
-25
-30
-35
10
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
-5
-10
-15
-20
-25
-30
-35
max min ;
Stress
mean
max min
One cycle min a
2 2
0 Time
Variable amplitude stress history max min
b)
m ;
2
Stress
min
R
max
One
reversal Time
0
0
© 2008 Grzegorz Glinka. All rights reserved. 76
Stress Reversals and Stress Cycles in a Variable
Amplitude Stress History
In recent years the rainflow cycle counting method has been accepted
world-wide as the most appropriate for extracting stress/load cycles for
fatigue analyses. The rainflow cycle is defined as a stress excursion,
which when applied to a deformable material, will generate a closed
stress-strain hysteresis loop. It is believed that the surface area of the
stress-strain hysteresis loop represents the amount of damage induced
by given cycle. An example of a short stress history and its rainflow
counted cycles content is shown in the following Figure.
i+1
i-1
i-2
i+2
Time
A rainflow counted cycle is identified when any two adjacent reversals in the
stress history satisfy the following relation:
ABS i 1 i ABS i i 1
ABS i 1 i ABS i i 1
The stress amplitude of such a cycle is: The stress range of such a cycle is:
ABS i 1 i ABS i 1 i
a
2
The mean stress of such a cycle is:
i 1 i
m
2
© 2008 Grzegorz Glinka. All rights reserved. 79
The rainflow cycle counting procedure - example
Determine stress ranges, Si, and corresponding mean stresses, Smi for the stress history
given below. Use the ‘rainflow’ counting procedure.
6
5
Stress Si (MPa 102)
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
-1
-2
-3
Reversing point number, i
Absolute maximum !
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5
Absolute maximum
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5
6
5
4
The modified 3
stress history 2
1
0
4 6 7 9 10 11 12 13 14 15
-1 1 2 3 5 8
-2
-3
6
5
Stress (MPa)x10 2
4
3
2
1
0
-1 1 2 3 4 5 6 6 8 9 11 12 13 14 15
-2
-3
-2
-3
starting point
© 2008 Grzegorz Glinka. All rights reserved. 83
Start counting from the point No. 2 !!
6
5
4
3
2
1
0
-1 1 2 3 4 5 6 7 8 9 11 12 13 14 15
-2
-3
3 2 1; 6 7 3 2 2.5;
6 7 6 7 m,6 7 2 2
6
5
4
3
2
1
0
-1 1 2 3 4 5 6 7 8 9 11 12 13 14 15
-2
-3
1 4 3; 4 5 1 4 2.5;
4 5 4 5 m,4 5 2 2
-2
-3
2 (5) 7; 2 3 2 5 1.5;
2 3 2 3 m,6 7 2 2
6
5
4
3
2
1
0
-1 1 2 3 4 5 6 7 8 9 11 12 13 14 15
-2
-3
1 ( 2) 3; 9 10 1 2 0.5;
9 10 9 10 m,9 10 2 2
-2
-3
3 2 1; 13 14 3 2 2.5;
13 14 13 14 m,13 14 2 2
6
5
4
3
2
1
0
-1 1 2 3 4 5 6 7 8 9 11 12 13 14 15
-2
-3
4 1 3; 11 12 4 1 2.5;
11 12 11 12 m ,11 12 2 2
© 2008 Grzegorz Glinka. All rights reserved. 86
6
5
4
3
2
1
0
-1 1 2 3 4 5 6 7 8 9 11 12 13 14 15
-2
-3
6 ( 3) 9; 1 8 6 3 1.5;
1 8 1 8 m,1 8 2 2
m -32 -22 -13 -3.2 6.44 16.1 25.7 35.3 45 54 64.1 73.7 83.3 92.9 103 112 122 131 141 151
298.8 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1
283.9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
268.9 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 1
254 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1
239 0 0 0 0 0 0 0 1 2 2 0 0 0 0 0 0 0 0 0 0 5
224.1 0 0 0 0 0 0 0 0 2 2 1 0 0 0 0 0 0 0 0 0 5
209.2 0 0 0 0 0 0 0 3 4 5 2 0 0 0 0 0 0 0 0 0 14
Stress range,
194.2 0 0 0 0 0 1 0 1 7 2 0 0 0 0 0 0 0 0 0 0 11
179.3 0 0 0 0 0 0 1 0 4 4 0 0 0 0 0 0 0 0 0 0 9
164.3 0 0 0 0 1 0 0 0 3 1 0 0 0 0 0 0 0 0 0 0 5
149.4 0 0 0 0 0 0 1 0 0 0 0 2 1 0 0 0 0 0 0 0 4
134.5 0 0 0 0 0 0 0 0 0 0 0 4 1 1 0 0 0 0 0 0 6
119.5 0 1 1 0 0 0 0 0 0 0 3 1 5 1 2 0 0 0 0 0 14
104.6 0 0 1 2 1 0 0 0 0 2 4 3 7 3 2 1 2 1 0 0 29
89.64 0 1 2 3 7 2 0 0 0 1 2 8 10 7 5 6 2 1 0 0 57
74.7 1 1 3 4 3 5 0 1 2 2 10 18 23 20 17 11 4 1 0 0 126
59.76 2 1 5 7 4 1 4 5 1 2 11 20 34 31 31 28 9 7 1 1 205
44.82 1 6 9 7 9 7 10 3 3 8 15 37 49 64 62 41 16 11 2 1 361
29.88 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
14.94 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
854
Total number of cycles, N=854
(stress spectrum)
j
nj=6 - number of cycles j=6
in the class j=6
Stress range
1 max/ max
max
j=4/
j/
max 0
Number cycles N
Relative stress range
nj=6/NT
0.5
The End