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What is fatigue?
In materials science, fatigue is the progressive and localized
structural damage that occurs when a material is subjected
to cyclic loading (material is stressed repeatedly).
Clients tous diffrents
Contraintes
Fatigue Design in
Automotive Industry
Conception fiable
Rsistances
3s
3s
Dispersion matriau
Dispersion de production
Fatigue
Fracture mechanics can be divided into three
stages:
1. Crack nucleation
2. Crack-growth
3. Ultimate ductile failure
Historical background
In comparison to the classical stress analysis,
fatigue theory is a relative new phenomenon.
The need to understand fatigue arose after
the industrial revolution introduced steel
structures. Three areas were particularly
involved in early failures: Railway trains,
Mining equipment and Bridges.
Historical background
1837: Wilhelm Albert publishes the first article on fatigue. He devised a test
machine for conveyor chains used in the Clausthal mines.
1839: Jean-Victor Poncelet describes metals as being tired in his lectures at
the military school at Metz.
1870: Whler summarizes his work on railroad axles. He concludes that
cyclic stress range is more important than peak stress and introduces the
concept of endurance limit.
1910: O. H. Basquin proposes a log-log relationship for SN curves, using
Whler's test data.
1945: A. M. Miner popularizes A. Palmgren's (1924) linear damage
hypothesis as a practical design tool.
1954: L. F. Coffin and S. S. Manson explain fatigue crack-growth in terms of
plastic strain in the tip of cracks.
1968: Tatsuo Endo and M. Matsuiski devise the rainflow-counting algorithm
and enable the reliable application of Miner's rule to random loadings.
Historical background
Fatigue theory is basically empirical. This means
that the process of initiation of micro cracks that
finally will form macroscopic cracks in the
material is not accounted for in detail in the
equations.
Fatigue properties must be treated by statistical
means due to large variation during testing.
Virtually all mathematical equations dealing
with fatigue are fitted to test results coming
from materials testing.
Loading types
When minimum and maximum
stress levels are constant, this is
referred to as constant amplitude
loading. This is a much more simple
case and will be discussed first.
Loading types
The loading may be proportional or nonproportional: - Proportional loading means
that the ratio of the principal stresses is
constant, and the principal stress axes do
not change over time. This essentially means
that the response with an increase or
reversal of load can easily be calculated.
- Conversely, non-proportional loading means
that there is no implied relationship between
the stress components. Typical cases include
the following:
Alternating between two different load cases,
An alternating load superimposed on a static
load ,
Nonlinear boundary conditions .
Terminology
Consider the case of constant amplitude, proportional loading, with
min and max stress values min and max:
The stress range is defined as (max- min)
The mean stress m is defined as (max+ min)/2
The stress amplitude or alternating stress a is /2
The stress ratio R is min/max
Fully-reversed loading occurs when an equal and opposite load is
applied. This is a case of m = 0 and R = -1.
Zero-based loading occurs when a load is applied and removed. This
is a case of m = max/2 and R = 0.
y = Yield Strength
a = Strain Amplitude
2Nf = Number of reversals to failure
En None
En - Morrow
En None
EN Smith-Watson-Topper
and:
Ramberg-Osgood:
= ( E, , K, n)
K = Material strength coefficient
n = Material hardening exponent
and:
Material properties
Material Properties
Material testing is performed at constant amplitude loading for a
number of samples at each amplitude.
Material properties
Variants of the fatigue curves
Fatigue Classes
Fatigue Classes or weld joint classes, C or FAT
The fatigue class is the stress range in MPa for a
corresponding fatigue life of N=2106 load cycles.
The fatigue class stress range is specified at an average fatigue life
time minus 2 of standard deviation, corresponding to n=2,3%
probability to failure.
IIW-1823 and Eurocode 3 have the following fatigue strength
classes, FAT: 36, 40, 45, 50, 56, 63, 71, 80, 90, 100, 112, 125 and 160
DNV RP C203 have the following fatigue strength classes, FAT: 36,
40, 45, 50, 56, 63, 71, 80, 90, 100, 112, 125, 140 and 160
Fatigue Classes
Fatigue Classes (FAT)
In the fatigue evaluation using nominal stress method or hot spot
method, the fatigue data used is depending on the current
geometry of the weld joint.
DNV-RP-C203, appendix A show the Detail category (FAT) with
corresponding Construction detail
Figure showing detail category for lap joint (W1) from DNV-RP-C203.
Fatigue Classes
Fatigue Classes (FAT)
IIW-1823, chapter 3-2 show the different classified details (joints)
and their FAT values.
Figure showing FAT category for lap joint (W1) from IIW-1823
Figure showing FAT category for lap joint (W1) from EN1991-1-9
Fatigue Classes
Fatigue Classes (FAT), comparison between different codes
Fatigue Classes
Fatigue Classes (FAT), comparison between different
codes, continued:
Calculate the fatigue life (if the stiffener has a length L=60 mm) as:
For DNV RCP-203, the stress range at the hot spot of tubular joints
should be combined with the T-curve which corresponds to FAT=90
(D-curve). For other geometries than tubular joints use the D-curve.
Weld profiling