D6

FATIGUE LIFE PREDICTION OF NOTCHED

COMPONENTS USING FINITE ELEMENT METHOD
15MEC499. Phase-II
Review Number 2 , 04.04.2022
Batch Members
AJAY KUMAR.T CB.EN.U4MEE18004
BALASUBRAMANIYAM.S.A CB.EN.U4MEE18015
KARTHICK.K.A CB.EN.U4MEE18028
MADHAN.S CB.EN.U4MEE18036

Project Advisor : Dr.Padmanaban R

Department of Mechanical Engineering
 Outline
• Introduction

• Literature survey

• Gap analysis
• Objective & Problem statement

• Methodology

• Deliverables

• Time plan

• References
FATIGUE LIFE PREDICTION OF NOTCHED
COMPONENTS USING FINITE ELEMENT
METHOD
FATIGUE
• LIFE
• STAGES
• PREDICTION
 APPROACHES/METHODOLOGIES

• Stress based approach

• Strain based approach
• Fracture mechanics based approach
 ADVANTAGES: DISADVANTAGES:

•Modelling • MATERIAL DATA

•Adaptability • HARDWARE
• TIME
•Accuracy
•Boundaries
•Visualization
APPLICATIONS
 Literature Survey
• J.Toribio et.al [1] studied the Effect of the presence of
notches on the stress intensity factor in circumferentially
cracked bars under tension were analyzed
• Finite element method (FEM) together with the computation
of the J-integral were used to predict the notch effect.
• Stress intensity factor for a circumferentially cracked round
bar was calculated to analyse it with the notch
• The presence of the cylindrical hole inside the specimen is
irrelevant from the point of view of the characteristic relative
crack depth from which the notch effect is negligible
 Literature Survey
• Branco et al.[2] investigated the effects of lateral notched round
bars made of DIN 34CrNiMo6 subjected to in-phase and out-
phase bending–torsion for different loading histories.
• fatigue life prediction was model based on local equivalent von
Mises stresses.
• The notch effect was analysed using the equivalent strain energy
density concept
• fatigue life predictions were obtained from linear elastic finite
element analyses using the Coffin–Manson model.
• Both the experimental and predicted results were well correlated
for higher lives(>104 cycles) and average for lower lives
 Literature Survey
• Liu et al.[3] proposed a model for multiaxial high-cycle fatigue
life evaluation of smooth and notched specimens of Al–Si alloy,
• The Volume Method (VM) of Theory of Critical Distances (TCD)
and Finite Element Method (FEM) used under proportional and
non-proportional loadings.
• The results shows that the fatigue life under non-proportional
loading is much lower than that under proportional loading.
• The evaluated life and experimental life keep good agreement
within a scatter band of factor 2.
• The factor that leads to the decrease of the material fatigue life.
 Literature Survey
• Bayram et al.,[4] investigated the accuracy and reliability of
the testing method
• Three different types of circumferentially notched round bars
specimen materials - a dual-phase steel with three different
morphologies, an Al-Zn-Mg-Cu wrought alloy and Al-Si-cast
alloys.
• By finding stress concentration factors-->bluntness of the
notch--> correction factors for the fracture toughness
calculations
• Fracture toughness measurement of metallic is observed to
be an accurate and reliable procedure.
 Literature Survey
• Zappalorto.,et al [5] proposed an analytical expressions for the
mode III NSIFs for a sharp notch - the theoretical stress
concentration factor of corresponding problem.
• Circumferentially-sharply-notched rounded bars - torsion
loading conditions.
• Then analytical solutions for the notch stress intensity factors -
deep sharp V-notches, shallow sharp and finite sharp V-notches.
• Closed-form solutions of stress distributions for hyperbolic and
parabolic notches.
• Results obtained were compared.
 Objective and Problem Statement
• The objective of this work is to apply finite element method to
analyze the stress in notched component and to predict the fatigue
life of notched component.
• Study the effect of specimen geometry, and notch dimensions on
the Fatigue life .
• Explore the FCG behavior considering CCRNB specimen.
 Gap Analysis

• Experimental and numerical

• Finite element analysis

• Different loading conditions

• Different Parameters
 Methodology

MATERIAL FATIGUE
DATA ANALYSIS

GEOMETRY FATIGUE
RESULTS

LOADING REDESIG
CONDITION N
S
 DELIVERABLES
• Stress life

LOADING TYPE •Constant amplitude,proportional loading

MEAN STRESS • Goodman

EFFECTS • Soderberg
• X,Y,Z Component
MULTIAXIAL STRESS • Von mises
CONDITIONS • Maximum shear,
• maximum principal

FATIGUE • Value of Infinite Life

MODIFICATIONS • Fatigue Strength factor
• Load Scale Factor
 DELIVERABLES
• Strain life

LOADING TYPE •Constant amplitude,proportional loading

MEAN STRESS • Morrow

EFFECTS •Smith-watson-topper
• Component X,Y, Z
MULTIAXIAL STRESS • Von Mises
CONDITIONS

FATIGUE • Value of Infinite Life

MODIFICATIONS • Fatigue Strength factor
• Load Scale Factor
 DELIVERABLES
ANSYS CRACK
ANALYSIS
SOLUTIONS

STRESS PROVIDE INITIAL

ANALYSIS OF CRACK(Fracture
UNCRACKED Mechanics Approach)
STRUCTUE Stress analysis of
cracked
structure
Identify crack
initial location
and direction
Evaluate crack Grow crack

PREDEFINED ARBITARY
Fracture PATH PATH
parameters

XFEM SMART
VCCT CZM
SIF,Energy
release rate,J- FATIGUE
integral STATIC CRACK
GROWTH CRACK
GROWTH
 SMART METHOD
Geometry

Material
Properties Pre meshed
crack
Mesh
Smart crack Fatigue
Fracture
MODEL

growth
static
Static Force
structural
Fixed
supported
displacement
Stress
Solution Strain

Deformation

Fracture tool SOLVE--->Results

 TIMELINE
Feb-22 Mar-22 Apr-22 May-22
w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4

Project finalization
Literature Review
Gap Analysis
Problem statement
Methodology
Modelling and Analysis
Documentation
 REFERENCES
[1]Toribio, J., Matos, J.C. and Gonzalez, B., 2018. Notch effect on the stress
intensity factor in tension-loaded circumferentially cracked bars. Engineering
Fracture Mechanics, 202, pp.436-444.
[2]Branco, R., J. D. Costa, and F. V. Antunes. "Fatigue behaviour and life prediction
of lateral notched round bars under bending–torsion loading." Engineering
Fracture Mechanics 119 (2014): 66-84.
[3]Liu, Xiao-Yong, Tie-Xiong Su, Yi Zhang, and Mei-Ni Yuan. "A multiaxial high-
cycle fatigue life evaluation model for notched structural components."
International Journal of Fatigue 80 (2015): 443-448.
[4]Zappalorto, M., Lazzarin, P. and Berto, F., 2009. Elastic notch stress intensity
factors for sharply V-notched rounded bars under torsion. Engineering Fracture
Mechanics, 76(3), pp.439-453.
[5]Bayram, A., Uguz, A. and Durmus, A., 2002. Rapid determination of the
fracture toughness of metallic materials using circumferentially notched
bars. Journal of Materials Engineering and performance, 11(5), pp.571-576.
Thank You