Assessment of Fatigue Lifetime and

Characterization of Fatigue Crack

Behavior of Aluminium Scroll
Compressor Using C-Specimen

Rafael Setiawan (2006608421) & Dede Santoso (1906432490)

Magister Teknik Metalurgi & Material
Mekanika Material - Reguler
Outline

 Introduction
 Experiments
 Finite Element Modelling Information
 Results
 Conclusion
Scroll Compressor

 Widely used in automobile industry

 Operation under axial and radial loading
 Rotation →pressure and temperature changes
 Previous studies only calculated regular operations
 Unexpected loading condition → contact with counterparts (fixed scroll)
 For proper parameter, fatigue life is divided into initiation and propagation region
 Crack initiation → Miner’s rule “accumulation of repeating stress can lead to failure”
cycle determination: S-N curve
σa=amplitude stress
σ’f=fatigue strength coefficient
b=fatigue strength exponent
 Mean stress effect → correcting non-uniform loading conditions
Goodman method

Gerber method

 For severe loading → plastic deformation → ε-N curve

 Crack initiation cycle: Altair Optistruct Software
 Crack propagation → Paris Law:
a=crack length
G=energy release rate
G1c=critical energy release rate
 If plastic deformation occurs → adds Darveaux coefficient:

N0=cycle no for damage initiation

Δw=inelastic hysteresis strain criteria
DN=damage variable for degradation stiffness assumption
 Degradation can be calculated as:

 Crack propagation cycle: ABAQUS 6.14 Software

Experiments
 Material: Si-Mn Al Alloy (Al 4007 A)
 The scroll shape is altered into C-specimen→accommodating stress distribution and
deformation profile during operation
Removed part of the wrap to accurately apply
vertical load at point A
 S-N curve was evaluated on bulk material
→rotary bending test
Advantage: speed is 50 Hz, 5x tensile test
 Fatigue testing using MTS 810 multipurpose
testing machine
 Additional guide structure→preventing unexpecting loading types
 Testing parameters:

Testing Parameters
Operational Freq 10
(Hz)
R-Ratio 0.05
1900
1662.5
Load Amplitude
1444
Applied (N)
1140
948
Finite Element Modelling
(FEM) Informations
 Material Information: Al 4007 A

 Si-Mn Aluminium Alloy

 High yield strength & Low elongation
 

 For Optistruct analysis: using stress-life & strain-life curve

Fatigue strength coefficient () & exponent (b) are identical
in S-N and ε-N curve, obtained from S-N Curve
 Parameters used in optistruct:
 
 Two methods used: Paris Law & Darveaux
 Paris Law: only is used
 Darveaux method: added c1-c4 parameters
 Parameter used:
FEM Modelling: Loading & Boundary
Condition

 Identical for simulations in Optistruct and ABAQUS

 Element type is hexagon, size 0.5 mm
 Total amount of load = summary of load given at each node
 Red area: fixed, adapting the actual structure
 FEM Modelling: Crack Initiation

 Testing used: Altair Optistruct 2018

 Occurred crack contour is represented as 1 based on Milner’s rule
 Testing based on one static step
 The study recommends proper parameter by
comparing experiment results and FEM
 FEM Modelling: Crack Propagation

 Examined using ABAQUS XFEM

 Crack is already initiated with accurate location (assumed)
 Advantage: conserves the stiffness of the structure
 XFEM enrichment function:
 Direction parameter (r,θ)→location which satisfy damage initiation criterion
 No criterion (Paris Law) →crack will extend without a path (∆G>G1c)
 With damage criterion (Darveaux) → ∆G changes due to element degradation
→changes stress distribution near crack tip → changes crack path

 Cycle count: direct cycling step in ABAQUS based on the results of the static steps
Results
Conclusion