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ABSTRACT
Cumulative damage during fatigue is studied analytically. Extensive reviews are performed on the published damage models. Three different cumulative damage models
are defined using several physical variables such as fatigue modulus and resultant
strain. Proposed model I is defined using fatigue modulus, while models II and III are
defined using resultant strains. Proposed models are derived as functions of normalized applied stress level, r, and number of fatigue cycle, n. It is verified that the
proposed cumulative damage model III has better agreement with the two stress level
fatigue experimental data than other models.
INTRODUCTION
SERVICES,
DURING
jected varing
to
acteristic variables.
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125
126
where,
number of
fatigue cycle
applied stress level
f : frequency
n:
r:
T: temperature
M: moisture content
As a first approach, constant frequency and environmental conditions are
assumed. In addition, the effect of temperature rise during a fatigue test is ignored. Then the Equation (1) is reduced,
following
two
F(n,r)
could be
expressed
as
either of
relations, i.e.,
or
With
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127
For
sequence
loading,
where,
N: number of cycles to failure
number of load sequence until final failure
AD,: amount of damage accumulation during fatigue at stress level r,
m :
Figure
1.
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128
Figure 2. Damage
as a
or
2. Then the
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129
Multi-stress level
1. Same as the
2. Find n23 , the cycle at r3 which has equivalent
curred under stresses r, and r2 , by equating
damage accumulation
oc-
or
where,
4D<~ - ,
(k - I)&dquo; load
1)&dquo;,
It should be pointed out that I:1D2 is not the same asj(n2/N2). Since AD2 is
defined by the damage accumulated under the stress level r2 , it becomes,
as
shown in
Figure
[Proof]
Since there is only
The damage
sum
one
stress
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130
Figure 3.
Four step
fatigue
life
models.
Finally it
can
be written
The function f in Equations (14) and (15) is same, therefore the arguments of
the function must be equal.
Namely,
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131
The Equation (16) represents Palmgren-Miners rule. That means the stress
independent models predict same multi-stress level fatigue life though they
could have different damage accumulation procedure during the fatigue test.
There is another damage summation method, the so called equivalent stress
approach (Leve [1]). According to this summation method, the damage sum
could be expressed,
If Equation (17) is used for damage sum, each stress independent model
predicts a different fatigue life. But the equivalent stress approach, which is
from the direct consideration of the result, fails to explain the effect of sequence of loading as well as the damage accumulation procedure.
REVIEWS
Because of its simplicity, this rule is still widely used. But this rule fails to
predict the effect of load history. Experimental data indicate that the order in
which various stress levels are applied, does have significant influences on the
fatigue behavior of materials. It is a generally known fact that the PalmgrenMiners damage sum to failure is greater than unity for low-high tests and less
than unity for high-low tests.
A nonlinear damage model, which is called modified Palmgren-Miners
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132
was considered for predicting multi-stress level fatigue life
cisely. The damage is defined as follows;
rule,
more
pre-
where,
S:
C,k :
applied
stress
constants (k is
greater than 1)
b : slope of the central portion of the S-N
curve
Where C, is a stress dependent constant. The value of C, should be determined in order to predict multi-stress level fatigue life. But evaluation of C, is
not possible unless the damage model matched with some physical variables
which can be detectable during fatigue tests. Only the following inequalities
can be obtainable from the Equation (6) and Figure 4.
where,
can
be
on
the
following
where,
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over-
133
K: material constant
limit of a virgin specimen
81: fatigue
2. When fatigue damage accumulates, both the K and 81 is general will be affected. Thus damage will have a new fatigue limit and a new fatigue life at
each stress level above the new fatigue limit value.
3. The K value for any degree of damage is assumed to be proportional to the
new specimen fatigue limit corresponding to the degree of damage.
The
damage is
defined as,
where,
following equation
to
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134
As
final result, he
presented,
where,
x:
cycle ratio,
q: overstress
n IN
ratio, (S - Sl )lSl
where,
m :
c,a :
constant.
The
relationship;
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135
Gatts [11] derived a life prediction equation using residual strength and
fatigue limit degradation approaches. He defined the damage as a power
function form of the load; that is
where,
St : fatigue limit
a:
For
1.
2.
3.
constant
developing
4. Failure
his theory,
occurs
when residual
he derived
For constant stress amplitude;
stress.
following equations.
At failure;
For
fatigue limit
where,
81: fatigue
limit of
virgin specimen
k, C :
constants
q: stress amplitude
q,:
ratio, S/S,
fatigue limit ratio, 8//81
Marin [12] proposed a cumulative damage theory based on the consideration of relations between damage as a function of cycle ratio and changes in
the S-N curve due to damage accumulation. As a result he derived a multistress level fatigue failure criterion which is exactly same as the CortenDorans criterion, Equation (32). Marin developed the Equation (32) further
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136
as
where,
tions,
propagation period;
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137
Owen and Howe [15] studied about debonding and resin cracking of a
glass-reinforced plastic during fatigue. They concluded that resin cracking
could represent fatigue damage in the composite. A stress independent model
was established based on the experimental results; that is
Where B and C are constants. It is interesting that the two constants can be
reduced to one if the failure condition (D 1 when n N) is considered, i.e.:
=
This model predicts the same multi-stress level fatigue life with PalmgrenMiners rule since it is a stress-independent model.
Subramanyan [16] proposed a non-linear cumulative damage model based
on S-N curve, fatigue limit and isodamage line in S-N curve. As the final
results, he presented following equations.
Damage model;
where,
Nt
number of cycles at
Multi-stress level
fatigue limit
fatigue life;
fatigue life;
where,
x, :
n, IN,
S, : applied
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by con-
138
Lemaitre and Plumtree [ 18] proposed damage models in creep, fatigue and
Their fatigue damage model can be expressed;
creep-fatigue interaction.
where,
=
a =
1 /(p + 1 )
11(c + p + 1)
p: material constant
c:
For
curve
multi-stress level fatigue life with Palmgren[19] stated that the constant depends upon the
testing conditions including strain range. Socie et. al. [20] determined the
value of p from crack length, load drop and strain accumulation measurement. For cast iron, they presented a following relation.
same
Their result shows that better agreement of Equation (49) with experimental
Palmgren-Miners rule for the programmed strain control tests.
Fong [21]equated a non-linear damage model with the following assumptions.
data than
Namely,
where,
k, k :
constants
The solution to
The
Equation (51),
on
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139
where,
Z:
damage
sum
at failure
1, 2,
n &dquo;&dquo; Z and N, : random variables
n, : constant
(i
...,
m -
1)
Three different fatigue damage models are defined using fatigue modulus
and resultant strain. Those models are made mainly for the purpose of
predicting multi-stress level fatigue life. To derive the damage models as functions of number of cycle, the assumptions used in Reference [34] are needed.
The values of material constants B and C, which can be evaluated by one
stress level fatigue test, are used for the prediction of remaining fatigue life. It
is also postulated that the constant amplitude fatigue life is well followed by
the life equation which is derived in Reference [34].
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140
Substitution of Equations (7) and (8) in Reference [34] into the above equation provides,
Equation (55) has exactly same form with modified Palmgren-Miners model.
The constant C is determined by one stress level fatigue life equation, in
Reference [34]. It is expected that C is between null and unity regardless of
material system. Therefore this model predicts damage trend A in Figure 2.
The Equation (55) represents a stress-independent damage model. This result
is mainly due to the assumption that fatigue modulus is function of number
of cycle, n alone (refer to Reference [34]). If the stress effects on the fatigue
modulus were found, this model might be derived as a stress-dependent
model.
2.
at nth
cycle
The resultant strains are defined in the Figure 5. By the fatigue modulus concept, the applied stress and resultant strain could be written,
on
the above
equation pro-
vides,
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141
Figure 5.
where,
(60)
can
be also
expressed
as
followings (Refer
to
This model predicts damage amount r at n 0 (when stress reaches maximum applied stress level during first fatigue cycle) as shown in the Figure 6.
At a specific fatigue cycle, the damage is proportional to applied stress level
according to this model. This relation is presented in the Figure 7. The r, in
the Figure 7 is the applied stress level which has fatigue life N, cycles and r1 is
fatigue limit.
Multi-stress level fatigue life can be predicted by the procedure in the structure of damage function of this study. Two-stress level fatigue life is ex=
pressed as follows;
3. Proposed
as
III
follows;
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Figure
7. Stress effect
on
the
11 representation.
142
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143
where,
Substitution of Equations (57), (58), and (64) into Equation (63) provides,
The
Consideration of the
Equation (66)
can
on
be rewritten,
the
If the constant amplitude fatigue life Equation (13) in Reference [34] is considered on the damage Equation (67), the damage could be also equated as
follows,
This model predicts damage trend A in the Figure 2. The relation between
damage amount and applied stress level at a specific fatigue cycle can be also
predicted. Figure 8 shows this relation.
Mathematical calculations provide following equivalent cycles for two
stress level fatigue.
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Figure 8.
Stress effect
on
the
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Figure
Figure
10.
11.
Damage predIctIOn
Damage prediction
at each
at each
145
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Figure
Figure
12.
13.
Damage prediction
Damage prediction
at each
at each
146
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Rgure
II.
Rgure
III.
147
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148
Table 1. Comparison of predicted two-stress-level
fatigue life with experimental data.
* Palmgren- MinersRule,
Modified
Table 2. Two-stress-level
damage sum
to failure
10,000 cycles for the low-high test while 300 cycles for the high-low test. The
specimen material is glass fiber cloth epoxy composites (G-10 CR). The
fatigue life used here is the mean log fatigue life of ten experimental data
(both low-high and high-low tests). The results are presented in the Table 1.
The comparison shows that the presented model III has better agreement with
experimental data than the other models. The damage sums to failure are
evaluated in the Table 2. As it is expected, the result shows that the PalmgrenMiners damage sum to failure is greater than unity for low-high test and less
than unity for high-low test.
CONCLUDING REMARKS
(1) To explain multi-stress level fatigue phenomena and predict its life, the
cumulative damage model approach may be useful.
(2) For understanding multi-stress level fatigue phenomena, it is desirable
to define cumulative damage model by physical variables than by number of
cycles. It is because the direct use of number of cycles to define damage model
can not escape the empirical relation though the damage model predicts
multi-stress level fatigue life well.
(3) Fatigue modulus and resultant strain could be used as parameters of
representing damage.
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149
REFERENCES
1. Leve, H. L., "Cumulative Damage Theories," Metal Fatigue: Theory and Design, A. F.
Madayag, Ed., pp. 170-203 (1960).
2. Palmgren, A., "Die Lebensadauer von Kugellagern," Z. Vereines Deutcher Ingenieure, Vol.
68, pp. 339-341 (1924).
3.
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150
Subramanyan, S., "A Cumulative Damage Rule Based on the Knee Point of the S-N
Curve," J. of Eng. Mats. and Tech., pp. 316-321 (1976).
17. Srivatsavan, P. and Subramanyan, S., "A Cumulative Damage Rule Based on Successive
Reduction in Fatigue Limit," J. of Eng. Mats. and Tech., Vol. 100, pp. 212-214 (1978).
18. Lemaitre, J. and Plumtree, A., "Application of Damage Concepts to Predict Creep-Fatigue
Failures," J. of Eng. Mats. and Tech., Vol. 101, pp. 284-292 (1979).
19. Plumtree, A., Discussion, Fatigue Mechanisms, ASTM STP 675, J. T. Fong. Ed., pp.
620-621 (1979).
20. Socie, D. F., Fash, J. W. and Leckie, F. A., "A Continuum Damage Model for Fatigue
Analysis of Cast Iron," ASME International Conference on Advances in Life Prediction
Methods, pp. 53-64 (1983).
21. Fong, J. T., "What is Fatigue Damage? " Damage in Composite Materials, ASTM STP 775,
K. L. Reifsnider, Ed., pp. 243-266 (1982).
22. Cole, C. K., Cornish, R. H. and Elliott, J. P., "Effect of Voids and Structural Defects on the
Compressive Fatigue of Glass Reinforced Plastics," 21st Annual RP/CI Confer. Sec. 17-C
(1966).
23. Dibenedetto, A. T. and Salee, G., "Fatigue Crack Propagation in Graphite Fiber Reinforced
., Vol. 19, pp. 512-518 (1979).
Nylon 66," Polymer Eng. and Sci
24. Fitzgerald, J. E., "Some Divigations with Respect to an Operational Definition of Damage,"
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25. Wang, S. S. and Chim, E. S. M., "Fatigue Damage and Degradation in Random Short-Fiber
SMC Composite," J. of Com. Mat., Vol. 17, pp. 114-134 (1983).
26. Wang, S. S., Goetz, D. P. and Corten, H. T., "Shear Fatigue Degradation and Fracture of
Random Short-Fiber SMC Composite," J. of Com. Mat., Vol. 18, pp. 2-20 (1984).
27. Yang, J. N. and Jones, D. L., "Load Sequence Effects on the Fatigue of Unnotched Com, ASTM STP 723, pp. 213-232
posite Materials," Fatigue of Fibrous Composite Materials
(1981).
28. Yang, J. N. and Du, S., "An Exploratory Study into the Fatigue of Composites under
Spectrum Loading," J. of Com. Mat., Vol. 17, pp. 511-526 (1983).
29. Chou, P. C., "A Cumulative Damage Rule for Fatigue of Composite Materials," Modern
Developments in Composite Materials and Structures, J. R. Vinson, Ed., ASME, pp.
343-355 (1979).
30. Johnsen, S. E. J. and Doner, M., "A Statistical Simulation Model of Miners Rule," J. of
Eng. Mats. and Tech., Vol. 103, pp. 113-117 (1981).
31. Han, K. S. and Hamdi, M., "Fatigue Life Scattering of RP/C," 38th Annual RP/CI Conference, SPI (1983).
32. Collins, J. A., Failure of Materials m Mechanical Design: Analysis, Prediction, Prevention,
John Wiley and Sons (1981).
33. Wool, R. P., "Material Damage in Polymers," Workshop on a Continuum Mechanics Approach to Damage and Life Prediction, Carrollton, Kentucky, U.S.A., pp. 28-35 (May
1980).
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Prediction," Journal of Composite Materials
, Vol. 20 (March 1986).
16.
Palmgren-Miners Model
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151
2. Modified
3.
Palmgren-Miners Model
Shanleys Model
4. Marco-Starkeys Model
5.
Henrys Model
where,
6. Corten-Dolans Model
7. Gatts Model
8. Mansons Model
For Crack Initiation
For Crack
Propagation
9. Owen-Howes Model
10.
Subramanyans Model
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152
11. Lemaitre-Plumtrees Model
12.
Fongs Model
where,
C: attenuation of virgin specimen
A : total attenuation
AD: attenuation due to damage
14. Dibenedetto-Salees Model
where,
15.
Fitzgerald-Wangs Model
where,
E: modulus at a fatigue cycle
E* : reference modulus
18.
Proposed Model
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153
19.
Proposed Model II
20.
Proposed Model
III
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