Metal Fatigue Analysis Handbook. Practical problem-solving techniques for computer-aided engineering

613 Pages·2011·17.38 MB·English

by  Yung-Li Lee

Metal Fatigue
Analysis Handbook
Metal Fatigue
Analysis Handbook
Practical Problem-Solving Techniques
for Computer-Aided Engineering
Yung-Li Lee
Mark E. Barkey
Hong-Tae Kang
AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON
NEWYORK(cid:129)OXFORD(cid:129)PARIS(cid:129)SANDIEGO
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LibraryofCongressCataloging-in-PublicationData
Lee,Yung-Li.
Metalfatigueanalysishandbook:practicalproblem-solvingtechniquesfor
computer-aidedengineering/Yung-LiLee,MarkE.Barkey,Hong-TaeKang.
p.cm.
ISBN978-0-12-385204-5(hardback)
1.Metals–Fatigue.2.Computer-aidedengineering.I.Barkey,MarkE.
II.Kang,Hong-Tae.III.Title.
TA460.L4162011
620.1'66–dc23 2011020149
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PrintedintheUnitedStates
11 12 13 14 15 10 9 8 7 6 5 4 3 2 1
Thank you to our families for their inspiration, encouragement,
and patience!
To my friend, my love, my wife, Pai-Jen, and our
children, Timothy and Christine
Yung-Li Lee
To my wife, Tammy, and our daughters, Lauren,
Anna, and Colleen
Mark E. Barkey
To my wife, Jung-Me, and our son, Anthony
Hong-Tae Kang
Preface
Fatigue analysis of metals has been developing for more than 150 years from a
simple approach involving elementary stress calculation based on the theory of
elasticity, to a sophisticated treatment demanding a thorough knowledge of com-
plex multiaxial loading and material behavior. Present engineering practice for
comprehensive fatigue analysis requires computer-aided engineering (CAE) tools
that use knowledge of material properties for cyclic stress–strain and fatigue
behavior, structural kinematics for load simulations, finite element analysis for
stress–strain calculations, and fatigue damage assessment for crack initiation and
propagation life predictions.
Since the state-of-the-art technologies’ load, stress, and fatigue analyses and their
applications to engineering design for durability have been commonly adopted in
numerous commercial analysis products, this publication strives to present, in a
logical manner, the theoretical background needed for explaining and interpreting
the analysis requirement and outputs. Ultimately, this book is intended to serve the
reader as a theoretical manual or an analysis handbook. Beginning with coverage
of background material, including references to pertinent research, the development
of the formulas or theories applied in these CAE tools is followed by a number of
examples to illustrate the process of designing structures to prevent fatigue failures
in detail.
Considerable emphasis has been placed on including for the advanced student, as
well as the practicing engineer, the present techniques used in CAE for road load
simulations, pseudo stress calculations, estimates of material properties, incremen-
tal plasticity theories, and multiaxial fatigue life predictions. The understanding
of these is essential to properly applying mechanical designs for durability. The
specific illustrative examples are generally treated in separate sections within the
chapters so that the reader can easily grasp the concepts.
xv
Preface
The following list details the information provided in each chapter.
(cid:129) ChapterOnecoversthethreeroad-loadanalysistechniquestopredictvehicle
componentloadsformechanicaldesignfordurability.Theyarethegeneric
loadcaseanalysisforextremeloads;thesemianalyticalloadanalysiswiththe
inputoftheacquiredspindleforces,displacements,andaccelerations;andthe
vehicledynamicsanalysiswithatiremodelandtheinputofthree-dimensional
digitizedterrainprofiles.Commonlyusedcommercialtiremodelsarealso
introducedinthischapter.
(cid:129) ChapterTwodetailsthethreepseudostressanalysistechniques:fixedreactive
method,inertiareliefmethod,andmodaltransientresponseanalysismethod.
The pseudo stresses are the stresses calculated from a linear elastic finite
element analysis. These stresses are named because they are different from
the true stresses as plasticity occurs. The pseudo stresses can be directly
employed for stress-based fatigue assessment in the high cycle fatigue (HCF)
regime or for strain-based fatigue damage analysis in the low cycle fatigue
(LCF) regime in conjunction with the multiaxial notch analysis to estimate
the local true stresses and strains.
(cid:129) Chapter Three overviews the historical rainflow cycle counting techniques
for uniaxial load time history and the latest rainflow reversal extraction
techniques for multiaxial load time histories. For multiaxial fatigue analyses,
the uniaxial rainflow cycle counting method and the multiaxial rainflow
reversal extraction method have been widely employed in the critical plane
search approach and the equivalent stress–strain approach, respectively.
(cid:129) Chapter Four provides an in-depth presentation on the stress-based uniaxial
fatigue analysis, which focuses on the techniques provided by FKM-Guideline
(Analytical Strength Assessment of Components in Mechanical Engineering)
that are used to generate the synthetic nominal stress life and the local pseudo
stress-life curves of a component, based on a given material’s ultimate tensile
strength, and to account for the mean stress effect with the mean stress
sensitivity factor for various materials.
(cid:129) Chapter Five introduces the concept of proportional and nonproportional
loading, or stressing in the state of multiaxial stresses, and the nonproportional
loading effect on fatigue strength; it also presents the popular stress-based
theories (empirical formulas, equivalent stresses, critical plane approach, and
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Preface
Dang Van multiscale method) for assessing fatigue damage under the state of
multiaxial stresses.
(cid:129) Chapter Six reviews the strain-based fatigue analysis techniques for a
material under the state of uniaxial stress, which demands the familiar
Ramberg–Osgood and the Masing equations for hysteresis loop simulations,
the modified Neuber method or Molsky–Glinka’s energy density method
for the notch analysis, and finally the modified Morrow or Smith–Watson–
Topper(SWT)meanstresscorrectedstrain-lifeequationforfatiguebehavior.
Theincorporationofresidualstressandsurfacefinishfactorinthenotchstress
analysisispresented.
(cid:129) Chapter Seven details the presentations of theories of plasticity, including
the introduction of associated flow rule, consistency condition, and kinematic
hardening rules, for simulating the material hysteresis behaviors under the
state of multiaxial stresses, and of the multiaxial notch analysis techniques
for estimating local material responses based on the input of pseudo
stresses.
(cid:129) Chapter Eight extends the discussion of multiaxial stress–strain relation
and multiaxial notch analysis methods of Chapter Seven, and focuses on
the presentation of strain-based fatigue damage assessment techniques for
a material under multiaxial stress state. Particularly, the critical plane
approach with the damage parameter such as the Fatemi–Socie, SWT,
or Brown–Miller method has been introduced and discussed for the
pros and cons.
(cid:129) Chapter Nine presents an analytical solution to assess fatigue damage
severity for various vibration test specifications. This chapter also reviews
the fundamentals of sinusoidal and random vibration test methods and
introduces the fatigue damage spectrum (FDS) calculation technique for
each test method.
(cid:129) Chapter Ten introduces some fatigue analysis techniques for seam-welded
joints using linear elastic finite element analysis results. Especially, structural
stress approaches developed by Dong and Femer were described in detail
with examples.
(cid:129) Chapter Eleven presents a summary of the primary factors affecting fatigue
life and strength of resistance spot-welded joints and then focuses on some
xvii
Preface
particular fatigue analysis techniques (the linear elastic fracture mechanics
approach and the structural stress approach) and the relation of basic
material specimens test to design.
(cid:129) Chapter Twelve introduces the basics of the VDI 2230 guideline for ISO
metric bolted joints to prevent potential failure modes such as embedding,
clamp load loss, clamped plates crushing and slipping, bolt yielding, thread
stripping, and bolt fatigue failure. The assumptions and the calculation
procedure to estimate the elastic compliances of the bolt and the clamped
plates are also described. In addition, the last portion of this chapter presents
the commonly used finite element (FE) bolt-modeling techniques for forces
and stress analysis, and recommends the appropriate fatigue damage
assessment method for two different threaded bolts (e.g., rolled before and
after heat treatment).
This bookdoesnotcover present nonlinear damage rules, butinsteaditemphasizes
the application of the linear damage rule (LDR). The LDR has been universally
adopted due to its simplicity and can account for load sequence and hardening
effect, if used with the appropriate damage parameter. This book does not address
detailedanalyticalmodelsforcrack growthbehaviorsuchascrackgrowthdirection,
growth rates, closures, R ratio effect, small crack effects, and threshold. However,
the book does present the crack initiation life prediction models for metallic
components subjected to the state of uniaxial and multiaxial stresses, and the
crack growth approaches for life predictions of welded joints.
The plasticity theories introduced here do not apply to rate-dependent yielding,
elevated temperature effect, and anisotropic materials. This book is not intended
to be a comprehensive review of all published research in each respective sub-
ject area, but instead it presents the theories and problem-solving techniques
commonly employed in automotive engineering.
xviii
Acknowledgments
Special thanks are due to Dr. Xiaobo Yang of Oshkosh Corporation, Dr. Peijun
Xu of Ebco Inc., Dr. Mingchao (Mike) Guo of Chrysler Group LLC, Dr. Tana
Tjhung of Chrysler Group LLC, and Mr. Hsin-Chung (Simon) Ho of Chrysler
Group LLC for contributing to some chapters. Also, the authors are greatly
indebted to Professor Jwo Pan of The University of Michigan–Ann Arbor,
Professor Norman Dowling of Virginia Polytechnic Institute and State University,
Professor Steve Tipton of the University of Tulsa, and Dr. Peter Heyes of HBM-
nCode International for their valuable suggestions and encouragement.
xix
About the Authors
Yung-Li Lee is a Technical Fellow in Science Labs & Proving Grounds at
Chrysler Group LLC where he started his career as a product development
engineer in 1988. He was elected as a Fellow of the Society of Automotive
Engineers (SAE) and received the SAE Forest R. McFarland Award in 2006.
His expertise includes durability/reliability testing and simulation.
Since 1997, he has been an Adjunct Professor of Mechanical Engineering at
Oakland University in Rochester, Michigan, where he teaches graduate school
courses on fundamentals of metal fatigue, accelerated test method development,
reliability demonstration test planning, vibration test method development,
frequency-based fatigue analysis, multiaxial fatigue, and fatigue of bolted and
welded joints.
He received his B.S. in Civil Engineering from the National Central University in
Taiwan in 1979, and M.S. and Ph.D. in Structural Engineering from the University
of Wisconsin–Madison in 1984 and 1988, respectively. He is the primary author
of the book, Fatigue Testing and Analysis: Theory and Practice, published by
Elsevierin2005.
Mark E. Barkey is a Professor in the Aerospace Engineering and Mechanics
Department at the University of Alabama, where he joined the faculty in 1995.
During this time, he has directed student theses and research in the area of fati-
gue testing and analysis of materials and structures. He has received support for
his research from Ford, General Motors, Chrysler, Sandia National Laboratories,
and NASA. He received a B.S. in Engineering Mechanics with a Minor in
Mathematics from the University of Missouri-Rolla in 1989, and an M.S. and
Ph.D. from the University of Illinois in Theoretical and Applied Mechanics in
1991 and 1993, respectively. He served as a Visiting Assistant Professor in the
Mechanical and Industrial Engineering Department at the University of Illinois
in 1994.
xxi