Manufacturing processes’ role over the residual stress state evolution of crankshafts

Fonseca, Luiz Aun; Faria, Alfredo R. de; Batalha, Mário Henrique Fernandes; Jahed, Hamid

doi:10.1007/s00170-020-06392-6

Cited by 8 publications

(3 citation statements)

References 23 publications

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“…However, the energy input by the test load was not sufficient to surpass the barrier imposed by the compressive residual stress peak exemplified by Figure 5B. More information on crankshaft residual stress data can be found in Fonseca and Faria, 37 Fonseca et al, 33 Faria et al 38 and Fonseca et al 39 The natural frequency shift, therefore, indicates the crack size.…”

Section: Resultsmentioning

confidence: 97%

Crack propagation mapping at component‐level fatigue testing by means of natural frequency tracking control

Cunha

Rego

Victor

et al. 2022

Fatigue Fract Eng Mat Struct

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Advancements seeking structural components' strength and weight reduction necessarily pass through fatigue testing. Understanding failure phenomena and crack evolution is a way of methodologically achieving such a goal. An own-designed resonant fatigue test rig was used to study the behavior of three distinctly manufactured crankshaft batches. A control system and a resonant frequency estimator were developed to follow the overall stiffness reduction with crack advancement. The control algorithm followed the frequency decay to compensate for the input load. The control strategies were validated by finding the system's natural frequency at the beginning of the test and maintaining a constant nominal load. Fractographies made with failed and non-failed specimens revealed the connection between the expected physical results and the natural frequency shift evolution. The implemented logic enables crack advancement tracking and failure determination. The developments here can be overflown to different resonance fatigue systems to characterize their endurance performance.

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Section: Resultsmentioning

confidence: 97%

Crack propagation mapping at component‐level fatigue testing by means of natural frequency tracking control

Cunha

Rego

Victor

et al. 2022

Fatigue Fract Eng Mat Struct

Self Cite

View full text Add to dashboard Cite

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“…Fonseca analyzed the influence of the manufacturing process on the residual stress, which was caused by deep rolling with the combination of the finite element analysis and the corresponding fatigue tests. The research results could provide the theoretical basis for the optimization design of the process [17,18]. Antunes analyzed the finite element meshes for the optimal modeling of plasticity-induced crack closure and proposed the analytical expression of the most refined region along the crack propagation area.…”

Section: Introductionmentioning

confidence: 99%

Crankshaft High-Cycle Bending Fatigue Experiment Design Method Based on Unscented Kalman Filtering and the Theory of Crack Propagation

Que,

Jiang,

Sun

et al. 2023

Materials

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The high-cycle bending fatigue experiment is one of the most important necessary steps in guiding the crankshaft manufacturing process, especially for high-power engines. In this paper, an accelerated method was proposed to shorten the time period of this experiment. First, the loading period was quickened through the prediction of the residual fatigue life based on the unscented Kalman filtering algorithm approach and the crack growth speed. Then, the accuracy of the predictions was improved obviously based on the modified training section based on the theory of fracture mechanics. Finally, the fatigue limit load analysis result was proposed based on the predicted fatigue life and the modified SAFL (statistical analysis for the fatigue limit) method. The main conclusion proposed from this paper is that compared with the conventional training sections, the modified training sections based on the theory of fracture mechanics can obviously improve the accuracy of the remaining fatigue life prediction results, which makes this approach more suitable for the application. In addition, compared with the system’s inherent natural frequency, the fatigue crack can save the experiment time more effectively and thus is superior to the former factor as the failure criterion parameter.

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“…Fonseca analyzed the influence of the manufacturing process on the residual stress, which was caused by deep rolling with the combination of the finite element analysis and the corresponding fatigue tests. The research results could provide the theoretical basis for the optimization design of the process [17,18]. Antunes analyzed the finite element meshes for optimal modeling of plasticity-induced crack closure and proposed the analytical expression of the most refined region along the crack propagation area.…”

Section: Introductionmentioning

confidence: 99%

Research on the Bending Fatigue Property of Quenched Crankshaft Based on the Multi-Physics Coupling Numerical Simulation Approaches and the KBM Model

Sun

Gong

2022

Metals

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In modern engineering, electromagnetic induction quenching is usually adopted in improving the fatigue performance of steel engine parts such as crankshafts. In order to provide the theoretical basis for the design of the process, correct evaluation of the strengthening effect of this technique is necessary. In this paper, the research aim is the strengthening effect of this technique on a given type of steel crankshaft. First the magnetic-thermal coupling process was simulated by a 3D finite element model to obtain information on the temperature field during the heating and cooling stages. Then the residual stress field after cooling was simulated based on the same model. At last, the fatigue property of this crankshaft was predicted based on the combination of three parameters: the KBM (Kandil–Brown–Miller) multi-axial fatigue model, the residual stress field and the fatigue strength of the material. The experimental results showed that this method can achieve a much more reasonable prediction than the traditional strengthening factor, and thus can be applied in guiding the design of the quenching process.

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Manufacturing processes’ role over the residual stress state evolution of crankshafts

Cited by 8 publications

References 23 publications

Crack propagation mapping at component‐level fatigue testing by means of natural frequency tracking control

Crack propagation mapping at component‐level fatigue testing by means of natural frequency tracking control

Crankshaft High-Cycle Bending Fatigue Experiment Design Method Based on Unscented Kalman Filtering and the Theory of Crack Propagation

Research on the Bending Fatigue Property of Quenched Crankshaft Based on the Multi-Physics Coupling Numerical Simulation Approaches and the KBM Model

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