Metal Fatigue Testing and Analysis

Theory and Practice

1st Edition - January 29, 2025
Imprint: Elsevier
Author: Yung-Li Lee
Language: English
Paperback ISBN:
9 7 8 - 0 - 4 4 3 - 2 6 6 6 5 - 2
eBook ISBN:
9 7 8 - 0 - 4 4 3 - 2 6 6 6 6 - 9

Metal Fatigue Testing and Analysis: Theory and Practice provides the theoretical knowledge and practical skills required to design durable metallic structures and compon… Read more

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Metal Fatigue Testing and Analysis: Theory and Practice provides the theoretical knowledge and practical skills required to design durable metallic structures and components. The book thoroughly reviews fatigue and reliability theories for product durability designs, analyses, and validations, highlighting the latest advances and identifying key challenges. It is structured to guide readers in how to design targets from mission profile data, which is crucial in ensuring that structures (vehicle, systems, and components) meet the specific requirements of their applications. Insight is provided on how to analyze and design structures based on established targets, with practical insights and methodologies for structure designs provided.

Readers are guided through the development of validation tests to assess the durability of their designs, with emphasis placed on the importance of implementing reliability demonstration tests to ensure that test structures meet the design targets.

Metal Fatigue Testing and Analysis
Cover image
Title page
Table of Contents
Copyright
Dedication
About the author
Preface
1 Cumulative damage assessment models
Abstract
Keywords
1 Introduction
2 Damage curve approach
2.1 Fatigue behavior under high-low sequence loading
2.2 Comparison of linear and nonlinear damage rules
2.3 Equivalent damage cycles
3 Linear damage model
4 Double-linear damage model
4.1 Two life extremes in block loading
4.2 Intermediate lives in block loading
5 Summary
References
2 Rainflow cycle counting methods
Abstract
Keywords
1 Introduction
2 Uniaxial rainflow cycle counting techniques
2.1 Reversal counting technique
2.2 Three-point cycle counting technique
2.3 Four-point cycle counting technique
3 Multiaxial rainflow reversal counting technique
3.1 Counting algorithm
3.2 Application technique
4 Summary
References
3 Introduction to stress-based fatigue life estimations
Abstract
Keywords
1 Introduction
2 Stress-based fatigue behavior and model
2.1 Nomenclatures
2.2 Double logarithmic fatigue behavior
2.3 SN models
2.4 Damage equivalent stress amplitude
3 High-cycle stress-life test
3.1 Test planning and execution
3.2 Data analysis—Median SN curve
3.3 Design SN curve—Owen’s one-sided tolerance limit
4 Endurance limit test
4.1 Test procedure
4.2 Data analysis
5 Mean stress effect
5.1 Mean stress and fatigue life
5.2 Empirical models and mean stress correction
6 Notch effect
6.1 Elastic stress concentration factor
6.2 Fatigue notch factor
6.3 Support factor
6.4 Life estimation methods for notched components
References
4 Introduction to strain-based fatigue life estimation methods
Abstract
Keywords
1 Introduction
2 Test procedures
2.1 Monotonic tension test
2.2 Strain-controlled axial fatigue test
3 Data analysis
3.1 Monotonic stress-strain response and model
3.2 Cyclic stress-strain response and model
3.3 Constant amplitude fatigue data
4 Mean stress correction methods
4.1 Morrow’s model
4.2 SWT’s model
5 Notch stress and strain analysis
5.1 Neuber’s method
5.2 Molski and Glinka’s model
References
5 Multiaxial fatigue theories
Abstract
Keywords
1 Introduction
2 Stress transformation techniques
2.1 Transfromation based on directional cosines
2.2 Transformation based on coordinates (θ, φ)
2.3 Mohr’s circle
3 Multiaxial loading
3.1 Proportional and nonproportional loading
3.2 Nonproportional hardening behavior
4 Stress-based multiaxial fatigue life models
4.1 Empirical fatigue endurance formula approach
4.2 Equivalent stress approach
4.3 Critical plane (or cutting plane) approach
4.4 Enclosing surface approach
5 Strain-based multiaxial fatigue theories
5.1 Equivalent strain methods
5.2 Critical plane approach
References
6 Theories of plasticity and applications
Abstract
Keywords
1 Introduction
2 Tensor definitions and notations
2.1 Introduction to tensors
2.2 Tensor operations
3 Multiaxial state of stresses
3.1 3D stresses
3.2 Normal stress and shear stress on an oblique plane
3.3 Principal stresses and stress invariants
3.4 Octahedral surface and stresses
3.5 Deviatoric stress and deviatoric stress invariants
3.6 von Mises yield criterion
4 Stress, Strain, and Hooke’s law
4.1 Plastic strain and volume incompressibility
4.2 Equivalent plastic strain rate under uniaxial stress
5 Flow rule
5.1 A perspective on Drucker’s postulate
5.2 Associated and normal flow rule
6 Isotropic hardening rule
6.1 Consistency condition
6.2 Linear isotropic hardening model
6.3 Nonlinear isotropic hardening model
7 Kinematic hardening rule
7.1 Prager hardening model
7.2 Armstrong-Frederick hardening model
7.3 Chaboche hardening model
8 Combined isotropic and kinematic hardening model
8.1 Consistency with strain increments
8.2 Consistency with stress increments
8.3 Tanaka model for nonproportional hardening
9 Notch stress and strain analyses
9.1 Hoffmann and Seeger
9.2 Buczynski and Glinka
9.3 Lee, Chiang, and Wong
References
7 Structural dynamics and spectral analysis
Abstract
Keywords
1 Introduction
2 Vibration of SDOF systems
2.1 Free vibration of systems
2.2 Vibration of systems to periodic force
2.3 Vibration of systems to arbitrary forces
3 Modal transient analysis of MDOF structures
3.1 Modal analysis
3.2 Modal transient analysis
4 Random vibration and spectral analysis
4.1 Random processes
4.2 Random vibration of MDOF systems
4.3 Spectral analysis of MDOF systems
5 Summary
References
8 Spectral fatigue damage estimation methods
Abstract
Keywords
1 Introduction
2 Time-domain fatigue damage estimation
3 Properties of power spectrum density function
3.1 Spectral moments
3.2 Level crossing rates
3.3 Irregularity factor and spectral width
4 Narrowband damage models
4.1 Bendat's method
5 Corrected narrowband damage models
5.1 Wirsching and Light's method
5.2 Ortiz and Chen's method
5.3 Larsen and Lutes’ method
5.4 Benasciutti and Tovo's method
5.5 The α.75 method
6 Probability density function-based damage models
6.1 Dirlik's method
6.2 Zhao and Baker's method
7 Summary
References
9 Vibration fatigue test development
Abstract
Keywords
1 Introduction
2 Single-frequency sweep test
2.1 Test control parameter
2.2 Frequency variation
2.3 Minimum sweep rate
2.4 Frequency damage spectrum of SDOF systems
2.5 Ordered-swept sinusoidal vibration test
3 Random vibration test
3.1 FDS
3.2 Specification development
References
10 Fatigue analysis of spot-welded and seam-welded joints
Abstract
Keywords
1 Introduction
2 Fatigue analysis of spot-welded joints
2.1 Structural stress calculation
2.2 The critical plane approach
2.3 Fatigue life estimation
2.4 Modeling techniques FDOR spot welded joints
2.5 Conclusions
3 Fatigue analysis of seam-welded joints
3.1 Unique aspects of seam welded joints
3.2 Local strain life approach
3.3 Local stress life approach
3.4 Dong's structural stress life method
3.5 Fermer's structural stress life method
3.6 Conclusions
References
11 Thermomechanical fatigue damage—The Neu-Sehitoglu method
Abstract
Keywords
1 Introduction
2 Mechanical fatigue damage
3 Oxidation damage
3.1 Oxidation laws
3.2 Effective total oxide growth curve
3.3 Derivation of oxidation damage and life estimation
3.4 Material calibration
4 Creep damage
4.1 Viscoplasticity
4.2 Creep damage
5 Summary
References
12 Reliability assessment and demonstration test methods
Abstract
Keywords
1 Introduction
2 Methods for non-repairable systems
2.1 Test-to-failure method
2.2 Attribute test method
2.3 Extended life test method
2.4 Step stress accelerated life test method
2.5 Summary
3 Methods for repairable systems
3.1 The Duane model
3.2 The crow-AMSAA model
3.3 Summary
References
13 Vehicle durability validation: Target-setting and execution strategies
Abstract
Keywords
1 Introduction
2 Duty cycle and mission profiles
2.1 Definitions
2.2 Data acquisition techniques
2.3 Telematic systems for data acquisitions
3 Vehicle-level durability validation tests
3.1 Stress-strength interference method
3.2 Extreme customer’s usage method
4 System-level durability validation tests
4.1 Block-loading cycle test
4.2 Real-time simulation test
References
Index

Life Sciences

Physical Sciences & Engineering

Social Sciences & Humanities

Health

Metal Fatigue Testing and Analysis

Theory and Practice

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Yung-Li Lee

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