Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
ABSTRACT
I n most c a s e s , f a t i g u e f a i l u r e o f s t r u c t u r e s s t a r t s from t h e s u r f a c e o f m a t e r i a l s
and p r o p a g a t e s i n t o t h e i n s i d e . T h e r e f o r e , v a r i o u s s u r f a c e t r e a t m e n t p r o c e s s e s
accompanied w i t h c o m p r e s s i v e r e s i d u a l s t r e s s a r e a d o p t e d t o improve t h e m e c h a n i c a l
c h a r a c t e r i s t i c s of s u r f a c e l a y e r . U n d e r s t a n d i n g f a t i g u e s u r f a c e c r a c k
propagation is e s s e n t i a l t o i n v e s t i g a t e t h e f a t i g u e c h a r a c t e r i s t i c s of s u r f a c e
s t r e n g t h e n e d m a t e r i a l s . About t h e e f f e c t o f r e s i d u d l s t r e s s e s on t h e t h r o u g h -
t h i c k n e s s c r a c k p r o p a g a t i o n , i t h a s b e e n shown t h a t t h e d e c r e a s e o f g r o w t h r a t e
by c o m p r e s s i v e r e s i d u a l s t r e s s e s and t h e i n c r e a s e by t e n s i l e r e s i d u a l s t r e s s e s i n
111
w e l d i n g , i n d u c t i o n h a r d e n i n g , q u e n c h i n g and t e m p e r i n g , s h o t - p e e n i n g and c o l d
working. I t i s a l s o r e c o g n i z e d t h a t t h e c r a c k growth r a t e i n t h e s p e c i m e n s w i t h
r e s i d u a l s t r e s s e s can be c o r r e l a t e d w i t h t h a t i n t h e ones without r e s i d u a l s t r e s s
i n t e r m s o f t h e e f f e c t i v e s t r e s s i n t e n s i t y b a s e d on t h e c r a c k c l o s u r e . Meanwhile
i n t h e c a s e o f s e m i - e l l i p t i c a l s u r f a c e c r a c k p r o p a g a t i o n , Kawahara 1-21 s u g g e s t e d
t h a t t h e d i r e c t a p p l i c a t i o n of P a r i s formula u s i n g numerical s o l u t i o n s of s t r e s s
i n t e n s i t y f a c t o r had n o t much a d v a n t a g e s i n p r e c i s i o n n o r i n s i m p l i f i c a t i o n of
analyses.
KEYWORDS
Shot-peening, f a t i g u e , c r a c k p r o p a g a t i o n , r e s i d u a l s t r e s s e s , P a r i s Law.
EXPERIHENTAL PROCEDURE
I I 1 I
[ Heat Treatment 810 ? , ZOrnin., A 1
(Heat t r e a t m e n t 8100C, 20 m i n . , A )
$0 3
Hole notch
Thickness h=2,46
..-0 --
N
+, 0
m
Fig. 1 Specimen c o n f i g u r a t i o n
A f u l l y r e v e r s e d b e n d i n g l o a d was p r o d u c e d by a Schenck t y p e b e n d i n g f a t i g u e
m a c h i n e . The h a l f c r a c k l e n g t h b a t t h e s u r f a c e was mcnsured hy r e p l i c a t i n g
method u s i n g a m i c r o s c o p e w i t h X50 m a g n i f i c a t i o n . The c r a c k s h a p c e v o l c ~ t i o n
b e h a v i o r was o b s e r v e d by t e m p e r c o l o r t e c h n i q u e .
The r e s i d u a l s t r e s s d i s t r i b u t i o n i n t h e d i r e c t i o n o f t h e d e p t h was m e a s u r e d by
t h e s u c c e s s i v e c h e m i c a l p o l i s h i n g method u s i n g 202 n i t r i c a c i d . Changes o f s u r f a c e
r e s i d u a l s t r e s s i n t h e a x i a l d i r e c t i o n were measured d u r i n g t h e f a t i g u e p r o c e s s
by t h e 0°-45O X-ray method, u s i n g C r a n o d e .
S h o t - ~ e e n i n a Conditions
Shot-size @0.6 c u t w i r e
Wheel speed 78.5 ( m /set)
Flow r a t e of shot 35 (Kg/min)
The c r a c k c l o s u r e b e h a v i o r was o b s e r v e d by t h e e l a s t i c compliance method [3].
The c r a c k o p e n i n g l e v e l uOp was d e t e r m i n e d on t h e diagram r e p r e s e n t i n g t h e
r e l a t i o n s h i p between t h e maximum b e n d i n g s t r e s s and t h e o u t p u t of a s t r a i n gauge
l o c a t e d on t h e c e n t r a l p o i n t of t h e b o t t o m s u r f a c e .
AK a t an a r b i t r a r y p o i n t on a s e m i - e l l i p t i c a l c r a c k f r o n t was c a l c u l a t e d by
Newman-Raju's e q u a t i o n s [ 4 ] , i n which t e n s i l e s t r e s s component was c a l c u l a t e d
from t h e s h i f t i n g of n e u t r a l p l a n e accompanied w i t h t h e s u r f a c e c r a c k growth.
A Perpendicular to I
longitudinal axis 1
I
Fig. 2 Residual s t r e s s p a t t e r n
Measuring
point -
by X-ray
1o5
N (cycles)
where e x p e r i m e n t a l c o n s t a n t A = 0.169.
From e q u a t i o n (3)
B e s i d e s , t h e c r a c k opening r a t i o U was e x p r e s s e d a p p r o x i m a t e l y a s f o l l o w s ,
o Unpeened
A Shot - peened
The r e s u l t s o b t a i n e d i n t h i s s t u d y s u g g e s t t h a t t h e s u r f a c e c r a c k opens g r a d u a l l y
from t h e s u r f a c e t o t h e i n s i d e w i t h t h e i n c r e a s e of bending s t r e s s ( F i g . 8), and
based on t h i s model t h e a p p l i c a t i o n o f P a r i s formula h a s much a d v a n t a g e s i n
s u r f a c e crack propagation analyses.
Fig. 5 A semi-elliptical crack extends into another
semi-elliptical crack
F i g . 6 C r a c k growth r a t e dZldN a t a r b i t r a r y p o i n t s o n e l l i p t i c a l
c r a c k f r o n t v s Keff o f unpeened and s h o t - p e e n e d s p e c i m e n s
I : : : : : : : : : : ,
343
C : : : : : : : : : : ,
0 0.5 1.O
Depth from surface Z ( mm )
( a ) Unpeened ( b Shot -peened
Compressive Tensile
bending stress * bending stress
Fig. 8 S c h e m a t i c of s u r f a c e c r a c k o p e n i n g b e h a v i o r u n d e r p l a n e b e n d i n g
REFERENCES
1 E l b e r , W . (1974) E f f e c t s o f s h o t - p e e n i n g r e s i d u a l s t r e s s e s on t h e f r a c t u r e
and c r a c k g r o w t h p r o p e r t i e s o f D6AC s t e e l , ASTM STP, 5 5 9 , 45.
[2] Kawahara, M. and M. K u r i h a r a (1975) A p r e l i m i n a r y s t u d y on s u r f a c e c r a c k
growth i n combined t e n s i l e and b e n d i n g f a t i g u e p r o c e s s , J . SOC. Nau.
Arch. Japan, 1 3 7 , 297.
[3] K o t e r a z a w a , R. and S . Minamisaka ( 1 9 7 7 ) P r o p a g a t i o n of p a r t - t h r o u g h c r a c k s
by a l t e r n a t i n g b e n d i n g s t r e s s e s , J. Soc. Flat. Sc7'. cJapmz, 26, 955.
[4] Newman, J . C . J r . and I . S . R a j u (1981) An e m p i r i c a l s t r e s s i n t e n s i t y
f a c t o r e q u a t i o n f o r t h e s u r f a c e c r a c k , Eng. F r a c t . Mech. 1 5 , 185.