Fatigue life prediction of machined components using finite element analysis of surface topography

Ås, Sigmund Kyrre; Skallerud, Bjørn; Tveiten, Bård Wathne; Holme, Børge

doi:10.1016/j.ijfatigue.2005.07.031

Cited by 66 publications

(29 citation statements)

References 7 publications

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“…The fatigue stress concentration factor K f was used for describing the effect of the surface roughness on the fatigue limit. It was the function of the stress concentration factor K t which can be estimated by the finite element method [5,6] or the empirical formula including the average geometric parameters of surface roughness [7,8]. A method has been also reported to estimate the fatigue life by:…”

Section: Introductionmentioning

confidence: 99%

Fatigue Life Estimation of Medium-Carbon Steel with Different Surface Roughness

Dai

Duan

et al. 2017

Applied Sciences

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Medium-carbon steel is commonly used for the rail, wire ropes, tire cord, cold heading, forging steels, cold finished steel bars, machinable steel and so on. Its fatigue behavior analysis and fatigue life estimation play an important role in the machinery industry. In this paper, the estimation of fatigue life of medium-carbon steel with different surface roughness using established S-N and P-S-N curves is presented. To estimate the fatigue life, the effect of the average surface roughness on the fatigue life of medium-carbon steel has been investigated using 75 fatigue tests in three groups with average surface roughness (R a ): 0.4 µm, 0.8 µm, and 1.6 µm, respectively. S-N curves and P-S-N curves have been established based on the fatigue tests. The fatigue life of medium-carbon steel is then estimated based on Tanaka-Mura crack initiation life model, the crack propagation life model using Paris law, and material constants of the S-N curves. Six more fatigue tests have been conducted to validate the presented fatigue life estimation formulation. The experimental results have shown that the presented model could estimate well the mean fatigue life of medium-carbon steel with different surface roughness.

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Section: Introductionmentioning

confidence: 99%

Fatigue Life Estimation of Medium-Carbon Steel with Different Surface Roughness

Dai

Duan

et al. 2017

Applied Sciences

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“…where λ refers to the ratio between spacing and depth of the asperities and is quite difficult to establish for machined surface textures. As et al [9] proposed to calculate K t from FE (Finite Element) simulations of the measured surface topography. They show that, in the case of an aluminium alloy, the use of K f , originally developed for the fatigue limit, yields satisfactory prediction in a narrow life time region but cannot be applied for the whole life region.…”

Section: Introductionmentioning

confidence: 99%

Modelling the influence of machined surface roughness on the fatigue life of aluminium alloy

Suraratchai¹,

Limido²,

Mabru³

et al. 2008

International Journal of Fatigue

237

120

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The influence of machined surface roughness on the fatigue life of 7010 aluminium alloy has been investigated. Four-point bending specimen have been machined according to various machining conditions and tested in fatigue. In order to explain the high dependence of SN curves on the surface roughness of the specimen, an approach based on the finite element analysis of measured surface topography is proposed. Surface grooves due to machining are supposed to generate stress concentrations that are so calculated. A model of fatigue life prediction is developed, using this definition of local K t .

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“…This factor is defined as the ratio between the fatigue limit of an un-notched (smooth) specimen and the fatigue limit of a notched (rough) specimen, and it can be related to the stress concentration factorK t À Á [43]. Ås et al [44,45] proposed to calculateK t from FE simulations of the surface topography. The application of this method to a 6082.52-T6 aluminium alloy prepared with emery paper provided more accurate fatigue life prediction than the semi-empirical model proposed by Arola et al [32,33], since the stress concentration estimation is based upon local measurements rather than averaged geometrical parameters.…”

Section: Prediction Of the Roughness Effectmentioning

confidence: 99%

Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Laamouri

Ghanem

Braham

et al. 2019

Int J Adv Manuf Technol

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. This is an author-deposited version published in: https://sam.ensam.eu Handle ID: .http://hdl.handle.net/10985/18458 To cite this version :Adnen LAAMOURI, Farhat GHANEM, Chedly BRAHAM, Habib SIDHOM -Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel Abstract This paper aims to compare the influences of the two peripheral milling modes, up-milling and down-milling, on surface integrity and fatigue strength of X160CrMoV12 high-alloy steel. The experimental investigations showed an important difference between integrity of both milled surfaces. The down-milled surface is lowly work-hardened and well finished (lower roughness), but subjected to tensile residual stresses and severely damaged by folds of metal and short micro-cracks. The up-milled surface is highly work-hardened and subjected to compressive residual stresses, but poorly finished (higher roughness) and damaged by a density of micro-cavities due to carbide extraction. The results of 3-point bending fatigue tests revealed that the fatigue limit at 2 × 10 6 cycles of the up-milled state is largely higher of about 26% in comparison with the down-milled state. The effects of surface integrity induced by each milling mode on fatigue strength were evaluated using a HCF behaviour predictive approach based on Dang Van's multiaxial criterion. The predictive results estimated that the pre-existing micro-cracks play a dominant role in the fatigue strength degradation of the down-milled surface while the other surface effects seem to be lower. On the contrary, the fatigue strength of the up-milled surface is less affected by the pre-existing micro-cavities. The detrimental roughness effect (stress concentration effect) is significantly reduced by the beneficial effects of superficial hardening and compressive residual stresses. So, this study revealed that up-milling is the more appropriate mode for a better surface integrity towards fatigue strength of X160CrMoV12 steel than the down-milling mode.

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Fatigue life prediction of machined components using finite element analysis of surface topography

Cited by 66 publications

References 7 publications

Fatigue Life Estimation of Medium-Carbon Steel with Different Surface Roughness

Fatigue Life Estimation of Medium-Carbon Steel with Different Surface Roughness

Modelling the influence of machined surface roughness on the fatigue life of aluminium alloy

Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

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