Fatigue Test

2/25/2015
FATIGUE AND FRACTURE

– CONCEPTS AND
APPLICATION.
Raghu V Prakash
Professor
Department of Mechanical Engineering
Indian Institute of Technology Madras
Chennai 600 036
E-mail: raghuprakash@iitm.ac.in
Is Failure a stepping stone for

success?
1
2/25/2015
Aloha Airlines Accident – April

3
1988.
The aircraft lost 1/3 of its roof due to a stress fracture while cruising at 24,000 feet.
One Flight Attendant was sucked from the airplane, which subsequently made a
safe emergency landing.
Failure events.
4
Comet Aircraft (1950’s)
Two aircrafts after climbing

certain altitude underwent
explosive decompressions of
fuselage that resulted in loss of
lives and aircraft.
Cabin pressurization and

depressurization led to fatigue
loading.
2
2/25/2015
Failure events.
5
Japan Airlines Boeing

747SR crash, 1985.
Fatigue failure.
3
2/25/2015
Failure of crank shaft due to

7
fatigue.
Classification of Failures.
8
 Problems with loads and design.

 Problems with inspection, maintenance and repair.
 Problems due to operating environment.
 Despite several great strides in technology, failures
continue to occur, often with loss of human and
economic loss.
 Failure analysis provides an opportunity to understand
the intricate relationship between design, operation of
components, failure modes so that we can correct
designs, issue guidelines for operation and maintenance
to avoid recurrence of such events.
4
2/25/2015
Terminology
10
Amplitude
Range
Mean
5
2/25/2015
11
What makes Fatigue studies

12
interesting ?
SVCE-05Sep-2009
6
2/25/2015
Typical Fatigue Analysis.

13
Service Loads Component Testing
Dynamic Analysis
Stress Analysis Fatigue Analysis Component Life
Material Properties
SVCE-05Sep-2009
Essential Elements of Fatigue

14
Analysis.
 Material Properties.
 Fatigue Crack Initiation
 Stress Vs Life approach (Endurance limit of stress)
 Strain Vs Life approach (Low Cycle Fatigue)
 Fatigue Crack Propagation.
 Fracture Toughness.
 Geometry Details.
 Loading History.
 Environment.
SVCE-05Sep-2009
7
2/25/2015
Reality - Geometry
 Geometrical complexities
due to:
 Design requirements
 Functional requirements
 Limitations in space
 Aesthetics
 Inspection access
 Weight reduction
 Manufacturing process.
SVCE-05Sep-2009 15
Reality - Loading.
16
 Notalways a constant amplitude loading

 Loading is random in nature.
 Example: automobiles, aircraft, wind-turbines,
transmission towers.
Fighter aircraft
loading spectrum.
SVCE-05Sep-2009
8
2/25/2015
Reality – Environment.
17
 High temperature (varying temperature)

 Power-plant rotor components / turbines / compressors.
 Corrosive environment
 Marine structures / Chemical plant components.
 Low Temperature
 Structures working in Arctic regions / cold regions.
 Humidity levels
 More applicable for polymeric composite structures.
SVCE-05Sep-2009
18
9
2/25/2015
History of Fatigue.
19
History of Fatigue..
20
10
2/25/2015
History of Fatigue…
21
22
11
2/25/2015
23
24
12
2/25/2015
25
26
13
2/25/2015
27
28
14
2/25/2015
29
30
15
2/25/2015
31
38
16
2/25/2015
39
40
17
2/25/2015
41
42
18
2/25/2015
43
44
19
2/25/2015
45
46
20
2/25/2015
47
48
21
2/25/2015
49
50
22
2/25/2015
51
Stress-Life Approach to Design.
52
23
2/25/2015
53
54
24
2/25/2015
55
56
25
2/25/2015
57
58
26
2/25/2015
59
60
27
2/25/2015
61
62
28
2/25/2015
63
64
29
2/25/2015
65
66
30
2/25/2015
67
68
31
2/25/2015
69
70
32
2/25/2015
71
72
33
2/25/2015
73
74
34
2/25/2015
75
76
35
2/25/2015
77
78
36
2/25/2015
79
80
37
2/25/2015
81
82
38
2/25/2015
83
84
39
2/25/2015
85
86
40
2/25/2015
87
88
41
2/25/2015
89
90
42
2/25/2015
91
92
43
2/25/2015
93
94
44
2/25/2015
95
96
45
2/25/2015
97
98
46
2/25/2015
99
100
47
2/25/2015
101
102
48
2/25/2015
103
Effect of processing.
104
49
2/25/2015
Effect of Processing.
105
106
50
2/25/2015
108
51
2/25/2015
109
110
52
2/25/2015
111
112
53
2/25/2015
113
114
54
2/25/2015
115
116
55
2/25/2015
117
118
56
2/25/2015
119
120
57
2/25/2015
121
122
58
2/25/2015
Effect of mean stress on strain-

123
life curve.
124
59
2/25/2015
125
126
60
2/25/2015
127
Failure Life Data.
128
61
2/25/2015
62
2/25/2015
63
2/25/2015
In-situ property evaluation
In-situ measurement of mechanical properties
NDE Methods Miniature specimen

method
Miniature tensile Automated Ball

Shear punch
specimen Indentation
method
Static Cyclic Indentation

Infrared Non-linear Indentation
thermography Ulltrasonics
133
Small specimen test methods

• Test Methods to evaluate:
– Tensile properties (σy.s, σUTS, % Elongation, K and n)
– Fracture properties (K1c, KJc, J1c).
– Impact strength properties (CVN energy).
– Fatigue Properties (failure life, crack growth).
– Transition temperature (DBTT).
Raghu Prakash, IIT-M 134
64
2/25/2015
Basics of Indentation Testing.

 Instrumented Indentation test has been
proposed to be a better option among non-
conventional tests to determine σ-εproperties.
 Indenters: Prismatic, Cylindrical, Spherical
 Strain beneath the indenter is a function of
penetration depth for spherical indenter which
helps in derivation of stress-strain curve.
 Shallow indentation impressions are less
damaging for the component.
 Point to point variation of properties can be
measured.
135
Automated ball indentation test

method.
• A non-destructive method of
evaluating the tensile properties of
materials.
• Strain controlled multiple
indentations at a single location on a
polished surface using a tungsten
carbide spherical indenter.
• Max. depth of penetration is about
15-20% of indenter diameter.
• Load-displacement record provides
the basis for property evaluation.
136
65
2/25/2015
Theory
True stress and strain due to indentation testing has been
expressed by: [Ref: Haggag et al, 1993]
t  4 P  d p 2 
 p  0.2 d p D
   
2

d p  0.5CD  hp 2   d p 2    hp 2   d p 2   hp D 
2
C  5.47 P 1 E1  1 E2  hp Force vs displacement

0
1.12  1 -0.35 -0.3 -0.25 -0.2 -0.15 -0.1 -0.05 0

  1.12   ln  1<   27
-500
   27
 max
-1000
Force, N
 p E2
-1500

0.43 t Stainless steel
-2000
-2500
 max  2.87 m    max  1.12 ln  27 

-3000
Displacement, mm
Residual plastic depth estimation
Static indentation response after

fatigue cycling..
SS 304
Changes in material property due to

prior damage can be estimated
using static indentation results.
138
66
2/25/2015
Load-displacement for P12, SA299 and serviced material
True Stress vs. Plastic Strain curves for SA299 Samples
67
2/25/2015
True Stress vs. Plastic Strain curves for SM Samples
142
68

Fatigue Test

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Fatigue Test

Încărcat de

Drepturi de autor:

Formate disponibile

2/25/2015

FATIGUE AND FRACTURE

Is Failure a stepping stone for

Aloha Airlines Accident – April

Comet Aircraft (1950’s)

Two aircrafts after climbing

Cabin pressurization and

Japan Airlines Boeing

Failure of crank shaft due to

 Problems with loads and design.

What makes Fatigue studies

Typical Fatigue Analysis.

Service Loads Component Testing

Stress Analysis Fatigue Analysis Component Life

Essential Elements of Fatigue

 Notalways a constant amplitude loading

 High temperature (varying temperature)

Effect of mean stress on strain-

Failure Life Data.

In-situ property evaluation

In-situ measurement of mechanical properties

NDE Methods Miniature specimen

Miniature tensile Automated Ball

Static Cyclic Indentation

Small specimen test methods

– Tensile properties (σy.s, σUTS, % Elongation, K and n)

– Fracture properties (K1c, KJc, J1c).

– Impact strength properties (CVN energy).

– Fatigue Properties (failure life, crack growth).

– Transition temperature (DBTT).

Raghu Prakash, IIT-M 134

Basics of Indentation Testing.

Automated ball indentation test

C  5.47 P 1 E1  1 E2  hp Force vs displacement

1.12  1 -0.35 -0.3 -0.25 -0.2 -0.15 -0.1 -0.05 0

 max  2.87 m    max  1.12 ln  27 

Residual plastic depth estimation

Static indentation response after

Changes in material property due to

Load-displacement for P12, SA299 and serviced material

True Stress vs. Plastic Strain curves for SA299 Samples

True Stress vs. Plastic Strain curves for SM Samples

S-ar putea să vă placă și