Abstract: This paper summarizes the work conducted to assess the root cause of the failure of a medium commercial vehicle leaf spring failed in service. Macro- and micro-fractographic analyses by scanning electron microscope as well as material verification tests were conducted in order to understand the failure mechanisms and root cause of the failure. Findings from the fractographic analyses indicated that failure mechanism is fatigue. Crack initiation was identified to have occurred from a point on the top surface near to the front face and to the left side. Two other crack initiation points were also observed, however, these cracks did not propagate. The propagation mode of the fatigue crack revealed that the cyclic loads resulting in crack initiation and propagation were unidirectional bending. Fractographic analyses have also showed that the root cause of the fatigue crack initiation and propagation was loading the part above design stress. Material properties of the part were also verified by chemical composition analysis, microstructural analysis by optical microscopy and hardness tests.
Abstract: Bolted rail joint is one of the most vulnerable areas in railway track. A comprehensive approach was developed for studying the reliability of fatigue crack initiation of railroad bolt hole under random axle loads and random material properties. The operation condition was also considered as stochastic variables. In order to obtain the comprehensive probability model of fatigue crack initiation life prediction in railroad bolt hole, we used FEM, response surface method (RSM), and reliability analysis. Combined energy-density based and critical plane based fatigue concept is used for the fatigue crack prediction. The dynamic loads were calculated according to the axle load, speed, and track properties. The results show that axle load is most sensitive parameter compared to Poisson’s ratio in fatigue crack initiation life. Also, the reliability index decreases slowly due to high cycle fatigue regime in this area.
Abstract: Over the past four decades, the fatigue behavior of
nickel-based alloys has been widely studied. However, in recent
years, significant advances in the fabrication process leading to grain
size reduction have been made in order to improve fatigue properties
of aircraft turbine discs. Indeed, a change in particle size affects the
initiation mode of fatigue cracks as well as the fatigue life of the
material. The present study aims to investigate the fatigue behavior of
a newly developed nickel-based superalloy under biaxial-planar
loading. Low Cycle Fatigue (LCF) tests are performed at different
stress ratios so as to study the influence of the multiaxial stress state
on the fatigue life of the material. Full-field displacement and strain
measurements as well as crack initiation detection are obtained using
Digital Image Correlation (DIC) techniques. The aim of this
presentation is first to provide an in-depth description of both the
experimental set-up and protocol: the multiaxial testing machine, the
specific design of the cruciform specimen and performances of the
DIC code are introduced. Second, results for sixteen specimens
related to different load ratios are presented. Crack detection, strain
amplitude and number of cycles to crack initiation vs. triaxial stress
ratio for each loading case are given. Third, from fractographic
investigations by scanning electron microscopy it is found that the
mechanism of fatigue crack initiation does not depend on the triaxial
stress ratio and that most fatigue cracks initiate from subsurface
carbides.
Abstract: The substantial similarity of fatigue mechanism in a
new test rig for rolling contact fatigue (RCF) has been investigated. A
new reduced-scale test rig is designed to perform controlled RCF
tests in wheel-rail materials. The fatigue mechanism of the rig is
evaluated in this study using a combined finite element-fatigue
prediction approach. The influences of loading conditions on fatigue
crack initiation have been studied. Furthermore, the effects of some
artificial defects (squat-shape) on fatigue lives are examined. To
simulate the vehicle-track interaction by means of the test rig, a threedimensional
finite element (FE) model is built up. The nonlinear
material behaviour of the rail steel is modelled in the contact
interface. The results of FE simulations are combined with the critical
plane concept to determine the material points with the greatest
possibility of fatigue failure. Based on the stress-strain responses, by
employing of previously postulated criteria for fatigue crack initiation
(plastic shakedown and ratchetting), fatigue life analysis is carried
out. The results are reported for various loading conditions and
different defect sizes. Afterward, the cyclic mechanism of the test rig
is evaluated from the operational viewpoint. The results of fatigue
life predictions are compared with the expected number of cycles of
the test rig by its cyclic nature. Finally, the estimative duration of the
experiments until fatigue crack initiation is roughly determined.
Abstract: In this investigation an empirical study was made on fatigue crack initiation on 7075 T6 and 7075 T71 Al-alloys under constant amplitude loading. In initiation stage, local strain approach at the notch was applied. Single Edge Notch Tensile specimen with semi circular notch is used. Based on experimental results, effect of mean stress, is highlights on fatigue initiation life. Results show that fatigue life initiation is affected by notch geometry and mean stress.
Abstract: In this paper fatigue crack initiation and propagation in notched plate under constant amplitude loading through tensile residual stress field of 2024 T351 Al-alloy plate were investigated. Residual stress field was generated by plastic deformation using finite element method (FEM) where isotropic hardening in Von Mises model was applied. Simulation of fatigue behavior was made on AFGROW code. It was shown that the fatigue crack initiation and propagation were affected by level of residual stress filed. In this investigation, the presence of tensile residual stresses at notch (hole) reduces considerably the total fatigue life. It was shown that the decreasing in stress reduces the fatigue crack growth rates.
Abstract: This study reports an empirical investigation of
fatigue crack initiation and propagation in 2024 T351 aluminium
alloy using constant amplitude loading. In initiation stage, local
strain approach at the notch was used and in stable propagation stage
NASGRO model was applied.
In this investigation, the flat plate of double through crack at hole
is used. Based on experimental results (AFGROW Database), effect
of stress ratio, R, is highlights on fatigue initiation life (FIL) and
fatigue crack growth rate (FCGR). The increasing of dimension of
hole characterizing the notch effect decrease the fatigue life.
Abstract: In this paper the fatigue crack initiation location of double shear lap joints, treated by interference fit and bolt clamping, have been investigated both experimentally and numerically. To do so, using the fracture section of available fatigue tested specimens of interference fitted and torque tightened Aluminum 2024-T3 plates, the crack initiation location was determined. The stress distribution attained from the finite element analysis was used to help explain the results observed in the experimental tests. The results showed that the fatigue crack initiation location changes from top and mid plane at the hole edge to somewhere far from the hole edge (stress concentration region) in different combination of clamping force, interference fit size and applied cyclic load ranges. It is worth mentioning that the fatigue crack initiation location affects the fatigue life of the specimens too.