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/2)
a) Specimen '
f f b
x 2N f '
2N f c
log (
f
yy yy 2 E
y
z f/E
yy log (2Nf)
0
b) Notched component
Stress
peak peak
y
x
x x
z
S b)
M
peak
a) smooth specimen
representing the state of affairs
at he notch tip of a notched
body; b) smooth specimen
representing the state of affairs
at the weld toe in a weldment
2
Kt S
Neuber :
S = f(Fi)
1 1' E
3
5
/2)
7 t
f
'
b
0 f '
log (
2N f f 2N f c
2 8 2 E
6 m
4 sf/E 0
Fatigue damages:
se/E
1 1 p e=
D1 ; D2 ;
N1 N2
1 1 1 0
D3 ; D4 ; D5 ; 2N log (2Nf) 2Ne
N3 N4 N5
• Analysis of external forces acting on the structure and the component in question (a),
• Analysis of internal loads in chosen cross section of a component (b),
• Selection of critical locations (stress concentration points) in the structure (c),
• Calculation of the elastic local stress, peak, at the critical point (usually the notch tip, d)
• Assembling of the local stress history in form of the form of peak and valley sequence (f),
• Determination of the elastic-plastic response at the critical location (h),
• Identification (extraction) of cycles represented by closed stress-strain hysteresis loops (h, i),
• Calculation of fatigue damage (k),
• Fatigue damage summation (Miner- Palmgren hypothesis, l),
• Determination of fatigue life (m) in terms of number of stress history repetitions, Nblck, (No. of
blocks) or the number of cycles to fatigue crack initiation, N.
The details concerning many other aspects of that methodology are discussed below.
Stress-Strain
Analysis
Damage Analysis
Fatigue Life
y yy
y
y
x
x
x z
yy
33
xx zz yy 6-8mm
yy
0 0 0 xx 0 0
ij 0 yy 0 ij 0 yy 0
0 0 0 0 0 zz yy
Strain,
Stabilized cyclic
stress-strain curve
0 Time, t
0 0.02
0.01
Strain,
0
Time, t
- 0.01
- 0.02
20 cycles
© 2010 Grzegorz Glinka. All rights reserved. 10
Mathematical Expressions Describing the Stress-Strain Curve and
the Shape of the Hysteresis Lop
1
n'
2 2E 2K '
1
n'
E K'
0 0
E
1
n'
p e
2 2E 2K '
Equation of the cyclic stress-strain curve Equation of the hysteresis loop branch
1 1
n' n'
e p
e p
E K' 2 2 2 2E 2K '
© 2010 Grzegorz Glinka. All rights reserved. 11
The Massing Hypothesis
Massing’s hypothesis states that the stabilised hysteresis loop branch may be
obtained by doubling the basic material stress-strain curve.
1 / n1
a a -cyclic stress – strain curve (amplitudes)
a '
E K
1 / n1
2
E 2K '
© 2010 Grzegorz Glinka. All rights reserved. 12
Monotonic and cyclic stress-strain curves for various
metallic materials
100
[ksi]
100
[ksi]
100
[ksi]
cyclic
cyclic
cyclic
monotonic
Stress,
Stress,
Stress,
50 50 50 monotonic
monotonic
monotonic
cyclic
150 150 150 cyclic
[ksi]
cyclic monotonic
[ksi]
[ksi]
monotonic
Stress,
Stress,
50 SAE 4340 50 50
350 BHn Ti - 811 Waspalloy A
If ult
1.2 the material will cyclically soften
y
f’=938 MPa ea
2 E
RQC-100 Steel
uts=758 MPa
10-4
10 102 103 104 105 106
Number of cycles, Nf
0
ap
Plastic strain amplitude
10-2
f ’=1.38 p c
'
pa f 2N f
2 E
Plastic
10-3
10-4
10 102 103 104 105 106
Number of cycles, Nf
© 2010 Grzegorz Glinka. All rights reserved. 16
Fatigue Strain – Life Properties
In 1910, Basquin observed that stress-life (S-N) data could be plotted linearly on a log-log scale.
'
f (2 N f )b
2
where: / 2 - true stress amplitude; 2 N f - reversals to failure (1 rev = ½ cycle);
'
f - fatigue strength coefficient, b - fatigue strength exponent (Basquin’s exponent)
Parameters f’ and b are fatigue properties of the material. The fatigue strength coefficient, f’, is
approximately equal to the true fracture strength at fracture f. The fatigue strength exponent, b,
varies in the range of 0.05 and –0.12.
Manson and Coffin, working independently (1950), found that plastic strain-life data ( p-N) could be
linearized in log-log co-ordinates.
p '
f (2 N f ) c
2
p ’
where: 2
- plastic strain amplitude; 2Nf - reversals to failure; f - fatigue ductility coefficient
c - fatigue ductility exponent
Parameters f’ and c are fatigue properties of the material. The fatigue ductility coefficient, f’, is
approximately equal to true fracture ductility (true strain at fracture), f’. The fatigue ductility exponent,
c, varies in the range of –0.5 and –0.7.
f’=1.38
/2
Total
10-4
/2 (log scale)
= a
f’
Strain amplitude,
f’=938 MPa
Elastic 0.0648 c
a/E
= a
10-4 f’/E
Total
Plastic
10-4
10 102 103 104 105 106 1 2Nt (log scale)
Number of cycles to failure, Nf Number of reversals to failure, 2Nf
c
f/E
b
e/E
1/ n
Stress
Stress
max,2 m,3 m,3> 0
min,3
max,
1
m,2 Time m,2 =0
Strain
m,1 m,1< 0
’
f
min,
/2)
2
min,1
Strain amplitude, log(
m,1 < 0;
m,2 = 0;
m,3 > 0;
Morrow
'
f m b c
'
2Nf f 2Nf
2 E
Manson-Halford
c/ b
' '
f m b f m c
'
2Nf f '
2Nf
2 E f
Smith-Watson-Topper (SWT)
2
'
f 2b b c
' '
max 2N f f f 2N f
2 E
© 2010 Grzegorz Glinka. All rights reserved. 22
Comparison of Constant Life a - m Curves According to Morrow’s
and the SWT Mean Stress Correction Model;
SAE 8620 Alloy Steel; at Nf =106 cycles
SAE 8620 Alloy Steel
a - m diagrams for N=106 cycles
140
120
Morrow
100
SWT
(ksi)
80
a
Stress Amplitude
60
40
20
0
-350 -300 -250 -200 -150 -100 -50 0 50 100 150 200 250 300 350
Mean Stress m
(ksi)
• This equation tends to predict too much mean stress effect at short lives or
where plastic strains dominate. At high plastic strains, mean stress
relaxation occurs.
max f Nf 0
it becomes undefined when max is negative ( max < 0). The physical
interpretation of this approach assumes that no fatigue damage occurs
when the maximum stress is compressive.
F
C 12
2 C
peak
C
22
22 33 n 22
A, B 11 A, B 23
A
D 0 B 1
33
3 33
22 22
D
11 F D 11
T
M
33 33
e
e
e
e, e
ij ij
E
E
a, a
ij ij a
a a
E
f( )
E
a
© 2010 Grzegorz Glinka. All rights reserved. 27
The Neuber Rule and material stress-strain curve
1
n'
for 0
E K' E
P ? for 0
e
0
22
2 E
a
22 0 0
n
1
2
Kt n a a e e a a
22 22 or 22 22 22 22
E
2L
a
a 22 a
22 f 22
E
P
e B
22
e
22 B
a a
22
22
A AA
0 22
a 0 a
e 22 e 22
22
2 2 e e
a
n Kt e e a a n Kt 22 22
22
a a
22 22 22 22 22 d 22
E 2E 2 0
a
a
a 22 a
22 f 22
a 22
f a
E 22
E
22
e B
22
e
22 B
a a
22
22
A AA
0 22
a 0 a
e 22 e 22
22
2 1
2 a 2
nKt
e e a a
e e a a Kt n 22 22 22 22 22
n
22 22 22 22
E 1 2E 2 2E n 1 K
1
a a n a a n
a 22 22 a 22 22
22
E K 22
E K
© 2010 Grzegorz Glinka. All rights reserved. 30
Graphical solution to the Neuber rule and the equation
of the Stress-Strain curve
Elastic behavior
a
22
Neuber’s rule
2
Kt n e e a a
22 22 22 22
E
0 a Strain
22
a
a e
max max
2
Notched Body
P
0 Notch tip strain, a
e
2
Hysteresis stress-strain curve
a
S S
P1 2
1 K t Smax
Neuber’s hyperpola, a a
2
2L
Material Response at the Notch Tip
Due to Loading and Unloading
P
Reversals of Load P
© 2010 Grzegorz Glinka. All rights reserved. 32
- curve Simulation of Stress-Strain Response at the Notch
Tip (Neuber’s Rule) Induced by Cyclic Loading
2
Kt n2
1
1 1
n' 1 E
E K' 2
3
01, 03
peak
Nominal stress,
n
n1 n3
1
0
0 y
dn
T 3
0 n2 n4
time 02
2 1
1 n' 2
1
1 1 1 ' 2
E K Kt
1 n2
2
n' 2 2
2
2 2 E
2 2 2 '
E 2K
© 2010 Grzegorz Glinka. All rights reserved. 33
Simulation of Stress-Strain Response at the Notch
- curve Tip (ESED Method) Induced by Cyclic Loading
2
Kt n2
2
2 d 2
1 1 2E 0
n'
3
' 2
E K 01, 03
2
Kt n1
1
1 d 1
2E 0
Nominal stress history
n
Stress
peak
Nominal stress,
n 1
n1 n3 0
0 y
dn 3
T
02
0 n2
time
n4 2
1 1
1 2 2
' 1
1 1
n 2 2 2 2
n'
1 d 1
1
' ' 2 d 2
0
2E n 1 K 0
2E n' 1 2K '
0
t
a a
max, max 0
a
a
min
1
a a n'
0 a max max
a
max '
E K
1
1
a a n' a a n'
a
2 a
E 2K ' 2
a
min , E 2K '
a
min
a a a
a
min max
a a a
min max
© 2010 Grzegorz Glinka. All rights reserved. 35
Cyclic loading and cyclic stress-strain response
notched component, non-linear elastic-plastic stress-strain curve
n
1
a a n' n,max
a max max
max '
E K
n
0 n,min
a
max,
0 t
a
max
F a F
0 n
a
2 2
1
Kt n ,max a a
Kt n a a
a a n' max max
a
2 E E
a
min, E 2K ' 1 1
a a a n' a a n'
min a max max a
max
2
a E K '
E 2K '
a a a a a a
min max ; min max
S Smax
Sa Material curve
S S
Sm ys
Smin
0 E
Kt
0
ys max
ys max ys
max
min
0 0 0
min
No yielding Yielding on the 1st cycle Reversed yielding
ys
min
max
Smax
max Sa
K tSmax S
max
a Sm
a K t Sa
Kt Sm 0 t
m
min ys min
© 2010 Grzegorz Glinka. All rights reserved. 38
Strain,
Material Stress-Strain Response
Applied strain 2
1
b) Due to Variable Amplitude
history
Cyclic Loading
3
4 2’
5
6 7
7 1’
Resulting
Resulting stress history
stress-strain
path
Stress,
Stress history
a '
b c
f '
2N f 2N f
a
a f
Strain amplitude,
a
2 E
a
' b c 5
i f ' D Di D1 D2 D3 D4 D5
a ,i
2 N fi f
2 N fi N fi
2 E i 1
1 1 1 1 1 1 1 1
D1 ; D2 ; D3 ; ;
Nf1 Nf2 Nf3 N f1 Nf2 Nf3 Nf4 Nf5
1 1 if D 1Failure !!
D4 ; D5 ;
Nf4 Nf5 1 1
LR
D 1 N f1 1 Nf2 1 Nf3 1 Nf4 1 Nf5
© 2010 Grzegorz Glinka. All rights reserved. 42
The Loading Sequence Effect
P
S A e B
S
2
C E a D
t t
S S
0 0
D 1 C E
B 2L A
a A
P a B
C, E
S, a D
m
a
200 MPa
0 0
m
a
D
a
0.005
C, E
B A
© 2010 Grzegorz Glinka. All rights reserved. 43
Modeling the residual stress effect
2 2 E
Kt S r
Kt S r
22
E E
N
22
N
22
- Neuber’s 22 d 22
- ESED method
E rule 2E 0
e e
2
Kt S r
22 22 2
E Kt S r
2E
2
Kt S 2
22 22 r Kt S
r E
2E
E
e e
Kt S Kt S
E E
Kt S r Kt S r
E E
© 2010 Grzegorz Glinka. All rights reserved. 44
Nominal stress S
B
S Residual Stress Effect on
y peak the Stress-Strain Response
Stress
at the Notch Tip
C
Case 1 r> 0!
A Time x
B
Case 2 r< 0!
B max
r
A
r= 0!
S
B B r> 0!
max
m m
m
A A
m
0 0
r< 0! C min
C r= 0! C
min C
r A
© 2010 Grzegorz Glinka. All rights reserved. 45
Summary of the Local Strain-Life ( -N) Approach
Advantages:
• The method takes into account the actual stress-strain response of the material due
to cyclic loading.
• Plastic strain, and the mechanism that leads to crack initiation, is accurately
modeled.
• This method can model the effect of the residual mean stresses resulting from the
sequence effect in load histories and the manufacturing residual stresses. This
allows for more accurate damage accumulation under variable amplitude cyclic
loading.
• The -N method can be more easily extrapolated to situations involving complicated
geometries.
• This method can be used in high temperature applications where fatigue-creep
interaction is critical.
• In situations where it is important, this method can incorporate transient material
behavior.
• This method can be used for both low cycle (high strains) and high cycle fatigue (low
strains)
• There is only one essential empirical element in the method, i.e. the correction for
the mean stress effect.