os 012016 Miners Rule and Curative Damage Models Reliability HotWire —™ The eMagazine for the Reliability Professional Reliability Hotwire Issue 116, October 2010 Miner's Rule and Cumulative Damage Models Miner's rule is one of the most widely used cumulative damage models for falures caused by fatigue, Its called “Miners rule" because it ‘was popularized by M, A, Miner In 1985, In this article, we will explain what It Is and how its related to other more advanced cumulative ‘damage models in ALTA. Miner's rule is probably the simplest cumulative damage model, It states that if tere are k diferent st cycles to fallure at the ith stress, S,(s My then the damage fraction, C, Is: 138 levels and the average number of » y = @ where: + mis te number of cycles accumulated at stress}, + Cs the fraction of Ife consumed by exposure ta the cycles atthe clfferent stress levels, In general, when the camage fraction reaches 1, fllure occurs. “The above equation can be thought of as assessing the proportion of Ife consumed at each stress level and then adding the prapartions forall the levels together. Often an index for quantifying the damage is defined as the product of stress and the number of cycles operated under this stress, whieh is: W tical damage is the same across all the stress levels, then: =nx5, Assuming that he e Westy = Ny *S, 2 For example, les s8Y Wratre=80 for component. So the component wil fall after 10 cycles ata stress lve of 5 or after 25 cycles to fll at a stress level of 2, and soon. Using Eqn, (2) as theo tical value of damage that wil result in failure, Eqn, (2) becomes: SS o AN,xS, CC represents the proportion of the cumulative damage tothe enitcal value Example Use 2 simple example t illustrate how Miners rule is applied to model failures caused by fatigue. Assume we are interested in the "eycles to failure” of @ paperclip. As llustrated inthe following Figure, a cycle Is defined as opening and closing a clip. It is known that the angle of the two arms of the paper clip affects the number of cycles to fallure. So here the “angle” is treated as the "stress." fo 0.0 Le te Figure 4: One Cycle for a Paper Clip - Opening and Closing the Clip Assume that we know from previous testing that, at an angle of 90 degrees, the average value that causes fallure is 5 cycles. Soin this ipsa. webu. comfotwireissuet18hettopics 116 ham “4os 012016 Miner's Rule and Curidatve Damage Models example, Wentere=30XS=450. According to Miner's rule, this means that at about 30 degrees, a fallure will be observed after about 15 cycles at an angle of 30 degrees; or an average of 10 cycles will be needed to induce a failure a A paperclip has been tested according to the folowing test profile, Stress] Test | Damage at (Dearees) | cycles | stress Level_| Damage 15 z ia 6a 30 = 720 Ta a5 z 720. 30 Based on Miner's rule, how many adéltional cycles at 60 degrees are required In arder to break this paper clip? Using Eqn. (3): ISK 4430x4445 x44 60K 450 We find that x = 1.5 more cycles are needed at 60 dagrees in order te break the paper clip. From the above example, we can see there are several major limitations of Miner's rule: 1. Only the expected values are used. It ignores the variation of each test unit and falls to recognize the probabilistic nature of fatigue 2, A simple linear Me-stress relationship is assumed. This may not be true in many ceal-word applications Inverse Power Law Moda! “To avercome the drambacks of the Miner's rule model, probabilistic models are used in data analysis for accelerated life testing. There are to key ingredients in probabilistic models: 1, The erltcal damage that causes fellures Is nota fixed value, It follows @ certain alstrbution 21 tis not necessary for the damage to accumulate linearly Various lfe-stress models have been used, [1] The Inverse Power Law model describes the life which is tress relationship using a power function, LS) = ks" « US) represents the life at a stress of S. K anc n are model parameters. If L(S) isthe average life, we can see that Miner's rule Is @ special case of he inverse Power Law model Fr example, forthe previous paper cip examle, K=1/450 and net So the life atthe 90 degree angle in Seyles; at 60 degrees iti 1 450 US) =—q > aTS KS’ 60 eyetes However, to consider the probabilistic nature ofthe failures, Instead of letting L(S) be the average if at stress S, it Is treated as the “fe characteristic” of @ fallure time cistribution, For example, the paf for a Weibull distribution is et pty oe) p= Z{4] eu © nla oo gtlp Kea gly tenant f() = BK Sit Ke Septet 6 Let's use an example to expan the appication ofthe Well distribution withthe Inverse Power Law ife-stress relationship To study the numberof eyles to flare of 3 paper eli, the foowing test dota were obtained (Status (F or S)[Number of Cyeleslangie (Degrees) Bo hs bs lis be hs bs hs Bs his hs [so po [bo bo bo las las hs ES hs fo hs From the above table, we can see that S units are tasted under each ofthe stress levels of 15, 20 and 45 degrees. Gecause of the ipsa. webu. comfotwireissuet18hettopics 116 ham 45012016 Miners Rule and Curative Damage Models suspensions at the stress levels of 15 and 30, itis difficult to use Miner's rule because the average cycles to fare are not the averages of ‘he failure and suspension times at each stress level. Therefore, a Welbul cistribution with Inverse Power Law life-stress relationship is used Instead 23 ti | oor ct | Sie | Tine | mab 4] ole Fors Fors Cages I] + S 35 a5 5 s 35 35 6 F 2 a z F 8 Fil a] s 20 a : Er F 3 cs 2 F a0 s a F rr = F vn EBT Figure 2: Results of the Inverse Power Law Model Using ALTA (Once the model has been obtained, the reliability of the paper clip at any stress can be predicted. Figure 3 shows the reliability together with Its 90% conficence bounds at an angle of 5 degrees se toil Pobaty Mebal a co ih Figure 3: Predicted Reliability at 5 Degrees for a Paper Clip From the pot, we can see thatthe BLO life Is about 70 cycles. In other words, ata stress level of S degrees, 2 paper clip has @ 90% chance of surviving atleast 70 cycles. Conclusion In this article, we ciscussed the well-known Miner’ rule cumulative damage model and compared it with a more advanced probabilistic ‘model, the Inverse Power aw-Welbull model, Although Miner's rule is simple to use and easy to understand, it Jacks the probabilstc nature that is required forthe proper analysis of many fatigue fallures, For more detals on other cumulative damage models, please refer to itp//roliawiki ora/index.ohp/Accelerated Life Testing Oata Analysis Reference References [1] Rellasott Corporation, Accelerated Life Testing Reference, Tucson, AZ: RelaSoft Publshing, 2007. ipsa. webu. comfotwireissuet18hettopics 116 ham a45012016 ReliaSoft ipslvww. webu. comMotwireissuet18hettpies 116 Ham Miners Rule and Curative Damage Models 4