Fatigue Analysis Techniques

Fatigue Analysis Techniques
Darrell Socie Mechanical Engineering University of Illinois
Fatigue Analysis Techniques

Load-Life ! Stress-Life ! BS 5400 ( Eurocode 3 ) ! Strain-Life ! Crack Growth
!
Common Features
Constant amplitude test data ! Rainflow ! Linear damage
!
Load-Life Data
1000
Lateral Force, kN
100
10 1E+0
1E+1
1E+2
1E+3
1E+4
1E+5
1E+6
1E+7
Cycles
Stress-Life Data
10000
Stress Amplitude, MPa
1000
100 1E+0
1E+1
1E+2
1E+3
1E+4
1E+5
1E+6
1E+7
Cycles
BS 5400 ( Eurocode 3 ) Data
400
Stress Range, MPa
Steel
C D
300 200 100 0
F2
105
106
107
108
BS 5400 ( Eurocode 3 ) Data
125
Stress Range, MPa
Aluminum
B C
100 75 50 25 0
D E
105
106
107
108
Cycles
BS 5400 ( Eurocode 3 ) Weld Class F
Strain-Life Data - 2Nf

1
Strain Amplitude
0.1 0.01 0.001 0.0001 0.00001 1E+0
1E+1
1E+2
1E+3
1E+4
1E+5
1E+6
1E+7
Reversals
Strain-Life Data
600
Stress Amplitude
500 400 300 200 100 0 0 0.002 0.004 0.006 0.008 0.01 0.012 0.014
Strain Amplitude
Crack Growth Data

Crack Growth Rate, m/cycle
1E-6 1E-7 1E-8 1E-9 1E-10 1E-11 1E-12 1.00E+00
1.00E+01
1.00E+02
Cyclic Stress Intensity, MPa m
Rainflow Counting
G I
H E B D F
Hysteresis Loops
A C G I
H E B D F C G A, I
E H
D, F
Damage Accumulation
!
Miners Linear Damage Rule " Ni / Nf = 1
Load-Life
!
Major Assumption
" Loads
used to generate baseline data are the same as service loading
Load-Life
!
Advantages
" Actual
test of structure " Manufacturing and local stress concentration effects automatically included " Stress analysis is not needed
Load-Life
!
Limitations
" Actual
test of structure " New tests required for each change in material, loading or geometry " Mean stress effects can not be included
Stress-Life
!
Major Assumptions
" Nominal
stresses and material strength control fatigue life " Accurate determination of Kf for each geometry and material
Notched S-N Curve

10000
Stress Amplitude
1000
100
Kt or Kf
10 1E+00
1E+01
1E+02
1E+03
1E+04
1E+05
1E+06
1E+07
Cycles
Stress-Life
!
Advantages
" Changes
in material and geometry can easily be evaluated " Large emperical database for steel with standard notch shapes
Stress-Life
!
Limitations
" Does
not account for notch root plasticity " Mean stress effects are often in error " Requires emperical Kf for good results
BS 5400 ( Eurocode 3 )
!
Major Assumptions
" Complex
weld geometries can be described by a standard classification " Crack growth dominates fatigue life " Results independant of material and mean stress for structural steels
Stress Range, MPa
1000
100
Fatigue Limit
No Fatigue Limit
10 1E+05 1E+06 1E+07 1E+08
Cycles
!
Advantages
" Manufacturing
effects are directly included " Large emperical database exists
!
Limitations
" Difficult
to determine weld class for complex shapes " No benifit for improving manufacturing process
Welded Structure
Strain-Life
!
Major Assumptions
" Local
stresses and strains control fatigue behavior " Accurate determination of Kf
Strain-Life
!
Advantages
" Plasticity
effects " Mean stress effects
Mean Strain Example
Tensile Mean Stress
Compressive Mean Stress
Neubers Rule
1000 800 Stress 600 400 200 0 0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 Strain
2 Kf
S e =
Strain-Life
!
Limitations
" Requires
emperical Kf " Long life situations where surface finish and processing variables are important
Crack Growth
!
Major Assumptions
" Nominal
stress and crack size control fatigue life " Accurate determination of initial crack size
Crack Growth
!
Advantage
" Only
method to directly deal with cracks
Crack Growth
!
Limitations " Sequence effects
Keff = f ( K ) " K = E e Y( a ) a " Accurate determination of ai
Crack Closure
Crack Opened
Crack Closed
Crack Opening Load
Damaging portion of loading history
Opening load
Nondamaging portion of loading history
Applications
Material Selection / Improvement ! Fillet Weld ! Scaling / Editing Load Histories ! Crack Size / Shape
!
Transmission History
1000 800 600
Nominal Strain
400 200 0 -200 -400 -600
Material Properties
BHN
'f ,MPa
187 1668 -0.149 0.556 -0.522 1460 0.234 206
277 2978 -0.158 0.700 -0.578 1743 0.189 206
336 3902 -0.159 0.563 -0.595 2051 0.163 208
410 4593 -0.167 0.381 -0.589 2381 0.172 206
545 5666 -0.170 0.068 -0.603 4438 0.169 205
b
'f
c K, MPa n E, GPa
Strength Variation
600 500
Hardness, BHN
400 300 200 100 0 1E+03
1E+04
1E+05
1E+06
1E+07
Blocks
Kf Variation
4.5 4
Fatigue Notch Factor
3.5 3 2.5 2 1.5 1E+03
1E+04
1E+05
1E+06
1E+07
Blocks
Scale Factor Variation

2
1.5
Scale Factor
0.5
0 1E+03
1E+04
1E+05
1E+06
1E+07
Blocks
Cycle Histogram
25
counts 0 0
ran ge (uE ) a me E) u ( n
-1000
1500
1000
-N Damage
10 % damage 0 0
ran ge (uE ) a me s res t s n
-50
1500
50
Weld Geometry
Crack Depth
Geometry Factor
3.0
2.5
2.0
Y ( a/W )
1.5
1.0
0.5
0.0 0.0 0.2 0.4 0.6 0.8 1.0
a/W
Crack Length
0.005
0.004
Crack Length, m
0.003
0.002
0.001
0 0 200 400 600 800 1000
Blocks

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Fatigue Analysis Techniques

Darrell Socie Mechanical Engineering University of Illinois

Fatigue Analysis Techniques

Stress Amplitude, MPa

BS 5400 ( Eurocode 3 ) Data

Stress Range, MPa

300 200 100 0

BS 5400 ( Eurocode 3 ) Data

Stress Range, MPa

BS 5400 ( Eurocode 3 ) Weld Class F

Strain-Life Data - 2Nf

0.1 0.01 0.001 0.0001 0.00001 1E+0

Crack Growth Data

Cyclic Stress Intensity, MPa m

Miners Linear Damage Rule " Ni / Nf = 1

used to generate baseline data are the same as service loading

Notched S-N Curve

Stress Range, MPa

effects are directly included " Large emperical database exists

stresses and strains control fatigue behavior " Accurate determination of Kf

effects " Mean stress effects

Mean Strain Example

Tensile Mean Stress

Compressive Mean Stress

method to directly deal with cracks

Limitations " Sequence effects

Keff = f ( K ) " K = E e Y( a ) a " Accurate determination of ai

Crack Opening Load

Damaging portion of loading history

Nondamaging portion of loading history

400 200 0 -200 -400 -600

187 1668 -0.149 0.556 -0.522 1460 0.234 206

277 2978 -0.158 0.700 -0.578 1743 0.189 206

336 3902 -0.159 0.563 -0.595 2051 0.163 208

410 4593 -0.167 0.381 -0.589 2381 0.172 206

545 5666 -0.170 0.068 -0.603 4438 0.169 205

400 300 200 100 0 1E+03

Fatigue Notch Factor

3.5 3 2.5 2 1.5 1E+03

Scale Factor Variation

0.0 0.0 0.2 0.4 0.6 0.8 1.0

0 0 200 400 600 800 1000

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