The main objective of this paper was to propose a computational scheme for anti-fatigue design of structural components made of typical engineering metals. The proposed fatigue life prediction methodology was based on the local strain-life approach, and used available models for multiaxial cyclic plasticity, notch analysis, multiaxial damage estimation. A cyclic plasticity model using nonlinear kinematic hardening rule is integrated with an approximation method for notch stress-strain analysis, and the four multiaxial damage parameters are employed for fatigue damage assessment analyses along with linear accumulation rule. Following the mathematical description of computational methodology, the fatigue damage simulation of an industrial application is conducted. Fatigue cycles and crack initiation locations of an aluminum alloy wheel in biaxial cornering tests are estimated. In global analyses, first the critical locations are determined using the computed damage per cycle, and various points on the wheel hub-arms connection are identified as the fatigue critical locations, and best correlations are obtained with critical plane parameters, while effective parameters performed relatively poor. Fatigue test cycles predicted using Fatemi-Socie damage parameter based on critical plane concepts are considerably close to test cycles for all wheel loads, and falls in to a band within a factor of 3-5. In order to investigate the trends predicted with increasing number of cycles, the numerical simulation for the wheel failure location is conducted up to a test cycle of 100 000 using Fatemi-Socie parameter, and the variation of damage per cycle is determined to be monotonically decreasing function, indicating that the estimation of fatigue life using the damage predicted with the first cycle after monotonic loading is an appropriate strategy resulting in an conservative results for this particular case. The reduction in damage per cycle is determined to be approximately 13%, increasing from 390 000 to 440 000. Finally, it is worth to note that the critical plane parameters involving mean stress terms perform equally similar predictions under nonproportional unbalanced loading case considered here, and Fatemi-Socie and Smith-Watson-Topper models based on critical plane concept constitute a pair of damage parameters applicable in both cases within the margin of acceptable accuracy from engineering point of view in the design of wheels with conformance to anti-fatigue requirements in biaxial cornering tests. Furthermore, a decrease in the computed damage per cycle is investigated with reference to notch stress-strain analysis approach capable of modeling 'stress relaxation like' behavior and cyclic strain accumulation.
Analytical durability modeling and evaluation complementary techniques for physical testing of automotive components
Engineering Failure Analysis ; 11 , 4 ; 655-674
2004
20 Seiten, 11 Bilder, 2 Tabellen, 56 Quellen
Article (Journal)
English
Physical testing and analytical modeling - complementary techniques for durability
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