Advances in Fatigue Analysis Technologies

Dr. Yung-Li Lee, Technical Fellow Chrysler Group LLC

Presented at SAE Fatigue Design & Evaluation (FD&E) Committee Meeting Auburn Hills, Michigan on Tuesday, October 19, 2010

Identify, Develop and Deploy

Yung-Li Lee

Contents
1. Fatigue Analysis & Testing in Design 2. Technology Advances in Fatigue Analyses 3. Their Applications and Challenges 3-1 3-2 3-3 3-4 3-5 3-6 3-7 Multiaxial Fatigue Analysis Fatigue Analysis of Welded Joints Thermal-Mechanical Fatigue Analysis Fatigue Analysis of Rubbers Bearing Fatigue Analysis Vibration Fatigue Probabilistic micro-structural fatigue modeling

Contents
1. Fatigue Analysis & Testing in Design 2. Top Emerging Technologies in Fatigue Analyses 3. Their Applications and Challenges 3-1 3-2 3-3 3-4 3-5 Multiaxial Fatigue Analysis Fatigue Analysis of Welded Joints Thermal-Mechanical Fatigue Analysis Fatigue Analysis of Rubbers Bearing Fatigue Analysis
Yung-Li Lee

Expecting too much from FEA?

(Source: Machine Design by Engineers for Engineers, Paul Dvorak, July 10, 2008)

2. Validation by Testing

1. Design by Analysis

Contents
1. Fatigue Analysis & Testing in Design 2. Top 5 Emerging Technologies in Fatigue Analyses 3. Their Applications and Challenges 3-1 3-2 3-3 3-4 3-5 Multiaxial Fatigue Analysis Fatigue Analysis of Welded Joints Thermal-Mechanical Fatigue Analysis Fatigue Analysis of Rubbers Bearing Fatigue Analysis
Yung-Li Lee

Multiaxial fatigue analyses - overview

strain history theories of plasticity (non-proportional loading) stress history coordination transformation critical plane search method

load history

nonlinear transient analysis

stress & strain history

strain-based methods

cycle counting & damage cal. (proportional & uniaxial loading)

elastic transient analysis static or inertial relief analysis modal transient analysis elastic stress history

(non-proportional loading) coordination transformation critical plane search method

notch analysis stress-based methods

cycle counting & damage cal. (proportional & uniaxial loading)

Multiaxial fatigue analyses three challenges

1. Multiaxial notch analysis based on pseudo stresses a. Hoffmann-Seeger method (1989)
b. Buczynski-Glinka method (1995) c. Barkey-Socie-Hsia method (1994) d. Lee-Chiang-Wong method (1995)

2. Deficiencies in multiaxial fatigue damage models

a. Nonproportional hardening (NP) effect b. Loading path effect

3. Choice of cycle counting methods

a. Uniaxial cycle counting techniques b. Multiaxial cycle counting techniques

1. Multiaxial notch analysis LCWs 2-step concept

e 1, 1 e e 1 - 1 curve

e 1 - 1 curve

1 1 curve

e 1, 1

Lee, Y.L., Chiang, Y.J. and Wong, H.H. (1995) A Constitutive Model for Estimating Multiaxial Notch Strains, ASME Journal of Engineering Materials and Technology, Vol. 117, pp. 33-40. R. Gu and Y. Lee (1997) " A New Method for Estimating Non-proportional Notch-Root Stresses and Strains, ASME Journal of Engineering Materials and Technology, Vol. 119, pp. 40-44.

2. Multiaxial fatigue damage model - not accounting for NP hardening effect

log NP = 0.705 t,u t,y
NP K = 1.6 K 2
2

1.22
2 (n n )

K 3.8 K 2

(nn )

+ 2.2

Shamsaei, N. and Fatemi, A. (2010) Effect of microstructure and hardness on non-proportional cyclic hardening coefficient and predictions, Material Science and Engineering, A 527, pp. 3015-3024. Borodii, M.V. and Shukaev, S.M. (2007) Additional cyclic strain hardening and its relation to material structure, mechanical characteristics, and lifetime, International Journal of Fatigue, 29, pp. 1184-1191.

2. Multiaxial fatigue damage model - not accounting for loading path effect

fNP

C = r ref T 1,max

( sin (t )
0

1,max

(t) dt

Itoh, T., Sakane, M., Ohnami, M., and Socie, D. F. (1995) Nonproportional low cycle fatigue criterion for type 304 stainless steel, Journal of Engineering Materials and Technology, Vol. 117, pp. 285-292. Lee, Y.L., Tjhung, T., and Jordan, A. (2007) A life prediction model for welded joints under multiaxial variable amplitude loading histories, International Journal of Fatigue, 29, pp. 1162-1173.

2. Multiaxial fatigue damage model - two solutions

Solution #1 Strain-based model + plasticity model enhancement + uniaxial rainflow cycle counting
1. Tanakas 4th order tensor + Y. Jiangs plasticity model (a modified Armstrong-Frederick model)

Solution #2 Stress-based model + equivalent stress/strain amplitude parameter + multiaxial rainflow cycle counting
1. Itohs equivalent strain amplitude or LTJs equivalent stress amplitude + multiaxial RF counting

Yung-Li Lee

3. Choice of cycle counting methods - overview

1. 2. Signed equivalent stress/strain approach Extension of Matsuishi and Endos reversal counting approach (1968)
a. Maximum von Mises strain range (Wang-Brown, 1996) b. Maximum von Mises stress range (Lee-Tjhung-Jordan, 2007) c. Maximum fracture-based stress range (Dong-Wei-Hong, 2010)

1. Matsuishi, M. and Endo, T. (1968) Fatigue of metals subjected to varying stress, presented to the Japan Society of Mechanical Engineers, Fukuoka, Japan. 2. Wang, C. H. and Brown, M. W. (1996) Life Prediction Techniques for Variable Amplitude Multiaxial Fatigue Part 1: Theories, Journal of Engineering Materials and Technology, Vol. 118, pp. 367-370. 3. Lee, Y.L., Tjhung, T., and Jordan, A. (2007) A Life Prediction Model for Welded Joints under Multiaxial Variable Amplitude Loading, International Journal of Fatigue, Vol. 29, pp. 1162-1173. 4. Dong, P., Wei, Z., Hong, J. K. (2010) A path-dependent cycle counting method for variable-amplitude multi-axial loading, International Journal of Fatigue, Vol. 32, pp. 720-734.

Yung-Li Lee

3. Choice of cycle counting methods - concept

A
1000 800 600 Stress, MPa 400 200 0 -200 0 -400 -600 -800 -1000 normal stress shear stress 1 2 3 4 5 6

Contents
1. Fatigue Analysis & Testing in Design 2. Top 5 Emerging Technologies in Fatigue Analyses 3. Their Applications and Challenges 3-1 3-2 3-3 3-4 3-5 Multiaxial Fatigue Analysis Fatigue analysis of Welded Joints (seam welds & spot welds) Thermal-Mechanical Fatigue Analysis Fatigue Analysis of Rubbers Bearing Fatigue Analysis
Yung-Li Lee

Overview of fatigue analysis of seam welds - I

1. Nominal Stress Approach a. Design Codes e.g., British standards, IIW recommendations, FKM-Guideline, etc. 2. Structural Stress Approach (Geometrical Stress or Hot Spot Stress) a. Dongs approach b. Fermers approach 3. Local Stress Approach

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Stress definition

Yung-Li Lee

I. Structural stress approach by P. Dong

Step 1: nodal force -> unit line weld stress

Step 2: Calculate the stress intensity factor

Yung-Li Lee

I. Structural stress approach by P. Dong

Step 3: Establish unified growth behavior

Yung-Li Lee

I. Structural stress approach by P. Dong

Step 4: Define S-N curve from Paris law

Yung-Li Lee

II. Structural stress approach by Fermer, et al.

Step 1: FE stresses based on the mesh rules

Yung-Li Lee

II. Structural stress approach by Fermer, et al.

Step 2: Haighs diagram for mean stress correction

a
R = 1
R=

R= 0

ar = a + M1m
M =0 1
R>1

ar = (1+ M1 )
R= 0.5

a + M2m 1+ M2

M 1

ar

I
M2

M =0 1

0
M1 = 0.25

+
M2 = 0.097

Yung-Li Lee

II. Structural stress approach by Fermer, et al.

Step 3: Empirical S-N curves

Yung-Li Lee

Pros and cons of using the structural stress approach

Advantages Manufacturing and residual effects are directly included in the database. A large empirical database exists for structural steels. It is easy to calculate the structural stress parameters and is FE mesh independent. Residual stress effect due to a different manufacturing process is not taken into account Multiaxial fatigue is not appropriately considered.

Limitations

Yung-Li Lee

Case study # 1

H. Kang, Y. Lee, and X.J. Sun, Effects of Residual Stress and Heat Treatment on Fatigue Strength of Weldments, Materials Science & Engineering, A497, 2008, pp. 37-43.

Contents
1. Fatigue Analysis & Testing in Design 2. Top 5 Emerging Technologies in Fatigue Analyses 3. Their Applications and Challenges 3-1 3-2 3-3 3-4 3-5 Multiaxial Fatigue Analysis Fatigue Analysis of Welded Joints Thermal-Mechanical Fatigue Analysis Fatigue Analysis of Rubbers Bearing Fatigue Analysis
Yung-Li Lee

Concept of TMF

Influences on TMF: 1. Dwell time 2. Strain rate 3. Creep 4. Stress relaxation 5. Aging 6. Softening 7. etc.

Combined loading (TMF, LCF, HCF, various influences)

Real component

TMF Applications

EVP material model

1) 2)

Tairas damage model Sehitoglus damage model

Contents
1. Fatigue Analysis & Testing in Design 2. Top 5 Emerging Technologies in Fatigue Analyses 3. Their Applications and Challenges 3-1 3-2 3-3 3-4 3-5 Multiaxial Fatigue Analysis Fatigue Analysis of Welded Joints Thermal-Mechanical Fatigue Analysis Fatigue Analysis of Rubbers Bearing Fatigue Analysis
Yung-Li Lee

Fatigue of rubber components

Contents
1. Fatigue Analysis & Testing in Design 2. Top 5 Emerging Technologies in Fatigue Analyses 3. Their Applications and Challenges 3-1 3-2 3-3 3-4 3-5 Multiaxial Fatigue Analysis Fatigue Analysis of Welded Joints Thermal-Mechanical Fatigue Analysis Fatigue Analysis of Rubber Components Bearing Fatigue Analysis
Yung-Li Lee

Bearing fatigue

Contact Pressure

max

Conclusions
1. CAE fatigue analysis can be the best tool used for A-to-B comparison. 2. CAE fatigue analysis results need to be verified and validated. 3. There is no universal solutions/answers to all the fatigue problems. So there is room for improvement in fatigue analysis technology. 4. Testing is always required in design. 5. What is the testing in design? a) validation testing b) reliability demonstration testing.

Yung-Li Lee

QUESTIONS ???

BACKUP MATERIALS

Overview of fatigue analysis of spot welds - II

1. Radajs and Zhangs model (1989) 2. Swellam and Lawrences stress intensity factor model (1992) 3. Sheppards structural stress model (1993) 4. Rupps structural stress model (1995) 5. Y. Lees nominal stress model (1996) 6. Zhangs stress intensity factor model (1997) 7. Lin-Pans local stress model (1999-2003) 8. Chao-Wangs nominal stress model (2006-2009)

Yung-Li Lee Spot welds

36

Ultimate strength of spot welds - II

Weld Size

Spacing Galvannealed

Tensile Shear

DP590

Loading mode

Ultimate Strength

Material Type Galvannealed

Cross Tension

MS6000

Adhesive

Thickness

Edge distance

MS-CD-457A

Yung-Li Lee

Design of experiments
25

TS-D+-N-1-H-TA
20

Load, P(kN)

15 10 5 0 0 2 4 6 8 10 12 14

Displacement, u(mm)

DOE No. DOE 1 DOE 2 DOE 3 DOE 4 DOE 5 DOE 6 DOE 7 DOE 8 DOE 9 DOE 10 DOE 11 DOE 12

Factory D (mm) E (mm) No. 2I 2J 2K 2L 2M 2N 2O 2P 2Q 2R 2S 2T 5.0 5.0 5.0 5.0 6.0 6.0 6.0 6.0 7.0 7.0 7.0 7.0 10 45 10 45 10 45 10 45 45 10 45 10

S (mm) 15 29 44 15 29 44 15 29 44 29 15 44

Spec. No. 2 2 2 2 2 2 2 2 2 2 2 2

UTS (kN) #1 9.32 10.09 10.77 12.41 13.37 10.15 11.95 16.90 13.19 14.78 13.74 #2 9.75 10.08 9.16 11.26 12.29 14.45 12.28 13.51 16.34 15.72 11.81

UTS-A (kN) #1 11.06 12.01 11.22 12.07 11.32 14.01 12.05 12.90 13.51 12.77 16.12 10.83 #2 9.93 11.53 10.99 12.29 8.71 12.82 12.27 14.28 14.74 12.72 12.84 11.92

Yung-Li Lee