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Engineering Failure Analysis 81 (2017) 19

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Engineering Failure Analysis


journal homepage: www.elsevier.com/locate/engfailanal

Fatigue life prediction of wire rope based on stress eld intensity MARK
method
Dan Zhao, Shaogang Liu, Qingtao Xu, Feng Shi, Wenyi Sun, Liqin Chai
College of Mechanical and Electrical Engineering, Harbin Engineering University, Harbin City, Heilongjiang Province 150001, China

AR TI CLE I NF O AB S T R A CT

Keywords: In the paper, on the basis of the stress eld intensity method, the internal complex wingding
Wire rope structure of 6 31SW + FC type wire rope is analyzed and calculated. As a rst step, con-
Fatigue life sidering the weakening speed of weight function in the stress eld intensity method is too fast, a
Stress eld intensity method modication is presented to make it more suitable for the calculation of the fatigue life of wire
Weight function
rope. The load spectrum of the critical locations of wire rope is then established, based on the
Fatigue damage
Costello mechanical model and the actual working conditions. Through the stress eld intensity
method, the time history curve of stress eld is then obtained. Subsequently, the fatigue life of
wire rope is calculated by using the linear cumulative damage theory of fatigue. The wire rope
fatigue test rig is established, and the experimental value of the fatigue life of wire rope is
compared with the theoretical calculation value. The results show that the experimental load of
90 t is the demarcation point of high and low cycle fatigue of wire rope, the theoretical values
and the test results are close to each other in the fatigue cycle, which proves the eectiveness of
the stress eld intensity method in predicting the fatigue life of the wire rope.

1. Introduction

The wire rope has functions of lifting, pulling, tightening and carrying in the process of material handling. It has been widely used
in cranes, aviation equipment parts traction, ship xed cable and other occasions [12] due to its benets including high strength,
light weight, smooth working and Strong ability to bear dynamic load. It can be seen that the wire rope has become an important
component in the eld of engineering. However, it is prone to fatigue, wear and even fracture during use, which leads to engineering
accidents. Therefore, it is necessary to use a reasonable calculation method to predict its fatigue life.
Several studies in the life prediction method of wire rope have been recently conducted such as Kumar and Botsis [3] obtained the
analytical expression at the time of maximum contact pressure by using linear deformation derivative of the multilayered strands
under the action of tension and torsion, respectively. And the eect of a series of connection parameters and material performance on
the contact stress is further studied. Giglio and Manes [4] evaluated the internal and external stress state of single-strand wire rope
using analytical formulas. Zhang et al. [5] tested the fatigue life of the wire rope and found that it is inversely proportional to the
depth of wear.
The proposed studies are all aimed at predicting the high cycle fatigue life of wire rope. In the process of mine hoisting, the
breakage of wire rope occurred frequently due to the overload of wire rope during the strength degradation. Therefore, the low cycle
fatigue life of the wire rope also needs to be analyzed. Dagang Wang [6] studied the eect of end-of-line mass on fatigue parameters
during a working cycle. Dagang Wang [7,8] measured the eect of displacement amplitude on the life of wire rope under low cycle


Corresponding author.
E-mail addresses: zhaodan@hrbeu.edu.cn (D. Zhao), liushaogang@hrbeu.edu.cn (S. Liu), chailiqin@hrbeu.edu.cn (L. Chai).

http://dx.doi.org/10.1016/j.engfailanal.2017.07.019
Received 25 May 2017; Received in revised form 9 July 2017; Accepted 12 July 2017
Available online 13 July 2017
1350-6307/ 2017 Elsevier Ltd. All rights reserved.
D. Zhao et al. Engineering Failure Analysis 81 (2017) 19

fatigue by fatigue test rig. A. Cruzado et al. [9] studied the low-cycle fatigue behavior of wire rope using a multi-axis fatigue SWT
critical plane.
There are various prediction methods for fatigue life. A. Cruzado et al. [9] studied the eect of wear on the life of ne steel wire
and introduced four methods of fatigue life prediction: Manson universal slope method, Muralidharan modied universal slope
method, median method and fatigue S-N curve method, and they pointed out that the Manson method and the median method results
were closer to the experimental results, and the modied universal slope method was relatively conservative in predicting the fatigue
parameters, and the calculation of the fatigue life in the low cycle was more accurate. Zhang Chengcheng [10] proposed stress
severity factor method for the fatigue of aircraft fasteners. Guo Jiansheng [11] estimated the fatigue life of welded steel structure
using fracture mechanics, which can be used for the prediction of crack propagation life with crack structure. Shang Deguang [12]
proposed a local stress-strain eld method that can be used for random cyclic loading. Xiong Weigong [13,14] estimated the wire
rope life by using the nominal stress method and the local stress strain method, respectively. The nominal stress method is mainly
used to calculate fatigue life dominated by elastic deformation due to it is based on stress fatigue calculation. The local stress - strain
method is a kind of fatigue life estimation method on the basis of the research of notch strain and low cycle fatigue, so it is more
accurate when the calculation of the fatigue life applied in the low cycle.
Based on the above working conditions and requirements, the stress eld intensity method is a method proposed in the process of
studying the fatigue damage mechanism, applied for multi-axis fatigue life evaluation under complex load, and it is suitable for high
and low cycle fatigue calculation [15,16], and the accuracy of the prediction is relatively high. It has been widely used in the life
prediction of structures such as aviation structure and ange welding parts. Zhou Shangmeng et al. [17] established the model of steel
bridge component to tackle the problem using the stress eld intensity method, and evaluated the fatigue strength of Biaxial or multi-
axis for some special structural details in the bridge structures. Based on the failure mechanism of fatigue damage, Chen Jian [18]
studied the principle and the concrete realization process of the stress eld intensity method to predict the fatigue life of components,
and the signicance of each eld strength parameter in eld intensity method is discussed emphatically. The method presented a
parametereld intensity which reects the severity of the local damage zone and was used to evaluate the fatigue damage of
component [19]. The paper applies the stress eld intensity method to the fatigue damage process of the wire rope under complex
loading, and the high-low cycle fatigue life of wire rope is predicted by the Miner linear fatigue damage accumulation criterion [20].
The fatigue test rig is established to verify the eectiveness of the stress eld intensity method to predict the fatigue life of the wire
rope.

2. The basic theory of stress eld intensity method

2.1. Stress eld intensity method

The denition of stress eld intensity method [21] is:


1
FI =
V
f (ij ) (r ) dv
(1)
where FI is the led intensity of notched, notch failure area, the size of the notched area, f(ij) is the failure stress function, (r) is
the weight function. For the plane problem, Eq. (1) can be written as
1
FI =
S
f (ij ) (r ) ds
D (2)
The S in the formula is the area of the notch failure area D.
Where is usually the size of multiple grains, and it is usually a random variable because of the eects of many variables, such as
material performance, notch parameters. At present, the shape of many fatigue failure zones need to be determined by experiments.
The stress of wire rope obtained at the time of calculation is smaller than its yield stress, therefore, the paper cited the calculation
method of the literature [22], and then take r = 3.55 mm after it is calculated.
The failure stress function f(ij) reects the inuence of stress eld and material properties on the notched strength, and it is
related to the failure mechanism of the material. The application of the strength theory will vary for dierent materials. Now most of
the engineering structural materials are isotropic metal materials, the f(ij) can be obtained by the equivalent stress formula of Von
Mises.
1 1
f (ij ) = [(1 2 )2 + (2 3 )2 + (3 1 )2] 2
2 (3)
The weight function (r) represents the contribution of the stress at the point Q to the peak stress of the | r | in physics. The eect
of surface on fatigue damage is relatively large, while the internal is small. Generally speaking, the stress concentration at the root of
the notch is the most severe. So there exists:
0 (r) 1, and (r) is a generalized monotone decreasing function of | r|;
(r) 1, The maximum stress of the notch root at this moment has the greatest eect on the fatigue damage;
When the stress gradient G = 0, (r) 1, under this condition, smooth specimen or full yield specimen has the same eect on
fatigue damage throughout the failure zone.
For smooth specimens, KT = 1, so (r) = 1; the stress can be considered equal everywhere in the smooth specimen, so the failure

2
D. Zhao et al. Engineering Failure Analysis 81 (2017) 19

stress function is a constant. According to the denition of the eld strength FI = f(ij), the smooth specimen failure while FI = f
(ij) j.
If the specimen is subjected to tensile, torsional and bending combined fatigue loads, the stress in the specimen is z1 = 0,
M r T r
z 2 = J r = max R , z = J r = max R . Meanwhile, the failure stress function is taken as the expression of Von Mises, which is obtained
T
by formula (1)

1 r 2 2 r
2
FI =
S
z21 + z22 + 3z
R R
(r ) dxdy
(4)

2.2. Modication of weight function

For the problem of fatigue damage weaken too fast by the weight function is studied in detail. If the weight function (r) is not
only related to the distance | r |, but also related to the stress and stress gradient | |, it is desirable to [23]:
(r ) = 1 || r (5)
According to the previous experience of [24], the stress gradient | | is desirable
ie
|| = 1
max (6)
where ieis the stress of equivalent for the unit; max is the maximum equivalent stress for the failure zone. Since the equivalent stress
ie of the element is changed under non-static load, the weight function is changed in real time. In the Eq. (5), where r is the distance
between arbitrary points and the peak in the damaged area, so it can be taken the distance between the center of mass and the peak
point in the processing. Although the value of r is usually small, it will cause a large result error when it is unreasonable. On the basis
of the physical meaning of the weight function, redene the weight function as follows:
1
2
(r ) = i r

max (7)
In the new weight function, i
and max show the eect of dierent stress amplitude on the contribution of the peak stress around
the peak point, respectively. In the original weight function, the value of r is usually much smaller than 1, which has the eect of
weakening the fatigue damage and the farther the distance, the stranger the weakening eect. The study found that the weakening
speed of the weight function is too fast, and the improved weight function is more suitable for the life calculation of wire rope due to
its decreased weakening speed.

2.3. p-S-N curve of the material

The p-S-N curve is the key parameter to calculate the fatigue life, which is the S-N curve set of dierent materials under the
dierent survival rate p. The p-S-N curve is almost a straight line in the logarithmic coordinate system in the stage of the high cycle
fatigue.
lg Np = ap + bp lg S (8)
where Np is the fatigue life when the survival rate is p. Where S is the stress corresponding to the stress amplitude Sa or maximum
stress value Smax of a certain stress ratio; Where ap and bp are the material constants associated with the survival rate.
According to the material requirements of the wire rope, the wire rope is the most important part of the lifting situation. Let the
survival rate p is 90%, which is the probability of fatigue failure at the stress level is 10%. According to the p-S-N curve of the
literature [25], the tensile strength of the 6 31SW + FC type wire rope is1932 MPa, and the material constant under the curve is:
ap = 18.0 , bp = 4.4.

3. Determination of hazardous parts and establishment of load spectrum

3.1. Determination of hazardous parts

The fatigue fracture of wire rope often occurs in the stress concentration zone of wire rope. The wire rope is usually subjected to
tensile fatigue damage - bending fatigue damage - tensile fatigue damage in the actual working conditions, the stress changes
periodically during the whole work, the fatigue damage is accumulated gradually with the change of the period until the occurrence
of fracture. The fatigue damage of wire rope is the interaction result of the tensile load and the bending load. Therefore, the position
of the stress concentration of wire rope is estimated to introduce the life of the entire wire rope. The force of wire rope in the bending
section is obviously larger than that of the straight line after analysis, so a small part of the bending section is intercepted for analysis,
and where the meshing situation of the whole wire rope in the bending section is shown as the following gure (Fig. 1).
The position of the dangerous point of wire rope is determined through the nite element analysis (Fig. 2). The gure shows the
results of nite element analysis of bending section. In order to see the position of stress concentration zone of wire rope more clearly,

3
D. Zhao et al. Engineering Failure Analysis 81 (2017) 19

Fig. 1. Wire mesh of bending section.

Fig. 2. Stress condition of wire rope section.

the right side of the pulley hidden from the gure. It can be clearly seen from the gure that the maximum stress is concentrated on
the contact position of outer and outer strands, and the position contacted with the pulley the stress concentration is also obvious.
Therefore, the contribution of the cross section on the life of wire rope is further studied by taking the external strand force of the
cross section contacted with the pulley as the research object.
Fig. 3 shows a schematic conguration of the dangerous section, which is simplied by nite element structure analysis. In the

Fig. 3. Schematic conguration of dangerous section. (For interpretation of the references to color in this gure, the reader is referred to the web version of this
article.)

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D. Zhao et al. Engineering Failure Analysis 81 (2017) 19

Fig. 4. Tension load spectrum of wire rope on both sides of pulley.

gure, the red part is the stress concentration point, and the dangerous section established is the dangerous strand shown below,
under this situation, the bearable stress of the dangerous strand is slightly larger than other strands, moreover, contacted with the
pulley leads to friction for a long time and wear more serious.

3.2. The establishment of the load spectrum

The wire rope mainly bears tensile and bending loads during the working process. In theory, the tensile and bending loads should
be constant when the external force is constant, while these loads are dynamic in actual working process. The total tension on both
sides of the pulley is chosen as 90 t of the experimental data in order to obtain the dynamic load of working process of wire rope. The
load spectrum of the internal tension of a single wire rope in the working process is shown in Fig. 4. From the gure, it is observed
that the tension within the wire rope uctuates in a certain range and the experimental period is 15 s, the wire rope perform a
movement in the reverse direction after bypassing the pulley at about 7.5 s. In the meantime, the tension within wire rope reaches the
maximum value in a period, which is 4.413 105 N, and then the tension within the wire rope gradually reduced and tends to be
stable.
It is assumed that the acceleration and deceleration process is neglected during the movement of wire rope, and the whole process
is almost at uniform speed. From the previous analysis, the dangerous section of wire rope need to experience four processes that is
straight line segment - bending segment - reverse bending segment straight line segment. The axial tension of straight and curved
segment and the load spectrum of the moment and torque are obtained respectively by using the Costello [26] wire rope mechanical
model and the data of tension shown in the Fig. 4. The load spectrum of the straight line and the bending segment is combined to
obtain the load spectrum of the actual working condition. As shown in Fig. 5.

4. Wire rope fatigue test

4.1. Experimental scheme

The wire rope fatigue test stand is shown in Fig. 6. The wire rope is wound on the movable and xed pulley block through a wire
rope joint, the xed pulley block is xed on the test bench, while the movable pulley along the guide rail on the platform for linear
movement under the action of tension of the hydraulic system to make wire rope tension and keep the tension constant. After the
tensioning in the wire rope, the hydraulic drive system drive the wire rope joint which is xedly connected with it for straight
reciprocating motion, so as to realize the fatigue performance test requirements of wire rope and pulley. The wire rope is counted as a
test every time of reciprocating motion and the number of tests for wire rope is recorded when it is broken.

4.2. Test wire rope

The cross-section of wire rope utilized in the test is shown in Fig. 7. The model 6 31SW + FC with a diameter that is 36 mm,
and the middle of wire rope is the wire rope core which is mixed by natural ber and synthetic ber, and the outer layer is a wire rope
of 6 strands. The wire rope suitable for large load operation due to its benets of round strand, albert lay, small structure, high
strength, good abrasion resistance and strong impact resistance.

5. The analysis of theoretical life compared with experimental result

According to the load spectrum of actual working conditions that have been established, and using MATLAB software on the Eq.

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D. Zhao et al. Engineering Failure Analysis 81 (2017) 19

Fig. 5. Actual stress state of dangerous section of wire rope.

Fig. 6. Fatigue test rig for wire rope.

(4) for programming calculation, the eld intensity time history curve is established as shown in Fig. 8, where the curve is the
variation of stress eld intensity within a period. The period is that the initial timing from straight segment of wire rope, and then
enters bending segment of pulley after 0.6 s, after the bending process of 6.9 s, and then reverse movement back to original point. It
can be seen from the gure that stress eld intensity of wire rope increases obviously from straight segment to bending segment, but
stress eld intensity increases slightly when wire rope carrying on reverse movement after completing half cycle, and the value of
stress at this time reaches maximum of the entire time course. Calculating the life of wire rope based on the curve of stress eld
intensity. The value of eld intensity is assumed a constant and the fatigue damage of wire rope is also a constant in each second. So
that, the simplied time history curve is shown in Fig. 9.
According to the eld intensity value and time of dangerous segment under the amplitude of eld intensity, the fatigue life Ni and
1 t 1 t
the fatigue damage Di = N . T Di = N . T can be obtained by using the material constants and the Eq. (8) under the p-S-N curve. The
i i
result is shown in Table 1.
As shown in Table 1, the critical damage value of DCR is in the vicinity of 1 [27], and the fatigue damage can be obtained
corresponding to eld intensity amplitude by using the theory of linear fatigue damage. Therefore, the fatigue cumulative damage of
wire rope in the entire period is obtained:

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D. Zhao et al. Engineering Failure Analysis 81 (2017) 19

Fig. 7. Section structure of wire rope.

Fig. 8. Time history curve of eld intensity.

Fig. 9. Simplied time history curve of eld intensity.

n
D= Di = 9.378 105
i=1 (8)

And then obtain its fatigue life:

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D. Zhao et al. Engineering Failure Analysis 81 (2017) 19

Table 1
Fatigue damage of wire rope.

Field intensity amplitude (MPa) Time (s) Life Ni Fatigue damage Di

494.62 1.2 1.396 106


5.727 10 8
1510.75 3 1.027 104 1.948 10 5
1516.13 1 1.011 104 6.594 10 6
1521.5 2 9.954 103 1.339 10 5
1529.03 1.4 9.74 103 9.582 10 6
1530.1 1 9.71 103 6.866 10 6
1531.1 0.4 9.68 103 2.755 10 6
1532.3 3 9.65 103 2.072 10 5
1545.2 2 9.3 103 1.433 10 5

1
N= n = 1.066 10 4
Di
i=1 (9)
The calculated fatigue life of wire rope is 10,660 cycles when the constant load is 90 t, besides the fatigue life value of wire rope
are obtained when load value change during 50 t120 t by this way said above, and the theoretical calculating value of wire rope
fatigue life is shown in Fig. 10.
As shown in Fig. 10, the tendency of wire rope theoretical fatigue life is roughly conform to its S-N curve. The fatigue life of wire
rope is 121,826 cycles when the constant load is 50 t, which has exceeded 105 cycles and reach sub fatigue region. Besides, the
theoretical fatigue life of wire rope is 10,660 cycles when the load is 90 t, and it is near the boundary between high and low cycle
fatigue region. Wire rope reach bearing limit when the load is more than 130 t. The test platform designed in the paper only test the
type of 6 31SW + FC wire rope in the 70120 t load range due to the large number of sub fatigue region life cycles and the test will
take a long time. The comparison results between theoretical and experimental of the fatigue life are obtained by using the fatigue
test data of wire rope fatigue test rig, which are shown in Table 2.
As can be seen from the Table 2, the fatigue life of wire rope is at the critical point of high and low cycle fatigue region when the
load is 90 t. Besides, the fatigue form is low cycle fatigue when the load is in the range of 90 t120 t, but the fatigue form is high cycle
fatigue when the load is in the range of 60 t90 t. The results of high and low cycle fatigue test are close to the theoretical results.
Although there is a certain deviation between the theoretical estimated life and the test life of wire rope, the error is small and within
the allowable range. Therefore, the method of stress eld intensity is suitable for the calculation of the high and low cycle fatigue life
of wire rope.

6. Conclusion

(1) For the problem of fatigue damage weaken too fast by the weight function, and the weight function is modied to make it more
suitable for the calculation of the fatigue life of wire rope.
(2) The dangerous section of wire rope is established by the nite element analysis, besides the load spectrum of axial tension,

Fig. 10. Theoretical fatigue life of wire rope.

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D. Zhao et al. Engineering Failure Analysis 81 (2017) 19

Table 2
Comparison results between theoretical and experimental.

Loads (t) Theoretical fatigue life (times) Experimental fatigue life (times)

70 27,718 25,681
80 15,402 16,105
90 10,660 9822
100 5770 6231
110 3793 3665
120 2587 2318

bending moment and torque of dangerous section are established by using the Costello mechanical model and the wire rope
tension load data.
(3) Based on the theory of stress eld intensity and linear fatigue cumulative damage theory, the fatigue life of wire rope is predicted
and the theoretical value is compared with the experimental value. The results show that: the fatigue life of wire rope is at the
critical point of high and low cycle fatigue region when the load is 90 t for the type of 6 31SW + FC wire rope. Besides, the
fatigue form is low cycle fatigue when the load is in the range of 90 t120 t, but the fatigue form is high cycle fatigue when the
load is in the range of 60 t90 t. The results of high and low cycle fatigue test are close to the theoretical results. Furthermore, the
feasibility of estimating the fatigue life of the cable based on the stress eld intensity method is proved.

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