Size optimization of shoulder filleted shafts with relief grooves for improving their fatigue life

González-Mendoza, Juan Manuel; Alcántara-Montes, Samuel; Silva-Lomelí, José de Jesús; Cruz-Alejo, Carlos De La; Ocampo-Ramírez, Arturo

doi:10.15446/ing.investig.v37n3.57957

Cited by 3 publications

(4 citation statements)

References 10 publications

(6 reference statements)

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“…Zeng clarified the optimal single-arc transition curve for sonotrodes with various cross-section ratios through finite element analysis [16]. Based on single-arc transition, González-Mendoza proposed that the design of a pressure relief groove can decrease the stress concentration [17]. Tu found that the effects of double-curvature arc transition, three-curvature arc transition, elliptical transition, and streamline transition on reducing stress concentration are superior to single-arc transition [18].…”

Section: Introductionmentioning

confidence: 99%

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Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

Mao,

Yang,

Chen

et al. 2024

Materials

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In the process of the ultrasonic-assisted arc welding of metal materials, traditional ultrasonic application methods, such as the low-frequency impact of ultrasonic horns on a base material, can easily cause the non-fusion defect. In order to solve this problem, a rotating sonotrode with a groove and double thin ends was designed in this study. The ultrasonic vibration is transmitted into the weld pool by the rolling of the sonotrode on both sides of the weld. The resonant frequency was set at 50 kHz. Firstly, based on the Mindlin theory, a rotating sonotrode without a groove was designed by solving the frequency equation and by conducting a finite element simulation. Secondly, the effects of the groove, perforation, and transition mode on the resonant frequency, stress distribution, and amplification factor were investigated by finite element simulation. Finally, the optimum rotating sonotrode with a groove was obtained. The results show that the size of a rotating sonotrode that has a small frequency error can be obtained by using the discrete interval solver method combined with finite element simulation. The groove can significantly reduce the resonant frequency. The stress concentration can be effectively reduced by using the elliptical transition mode. The resonant frequency and amplification factor of a rotating sonotrode with a groove could be effectively adjusted by a method of double-position joint perforation. The final resonant frequency was 49.721 kHz and the amplification factor was 3.02. This study provides an effective design method for a sonotrode with double thin ends and a groove structure.

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Section: Introductionmentioning

confidence: 99%

“…According to Relationship (17), a matrix between the force and displacement for the roller end can be derived. The expression for this is as follows:…”

mentioning

confidence: 99%

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

Mao,

Yang,

Chen

et al. 2024

Materials

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“…This study investigates the fatigue strength of hybrid buttwelded (BW) joints between a cast steel part and a UHSS plate, which have a crack-like defect in the weld root, parallel to the applied load direction and caused by permanent root backing. The studied hybrid BW joint has a significant difference in material thicknesses, and the axial misalignment may cause a considerable amount of secondary bending stresses in the welded joint [13]. The aim of this study is to investigate whether the fatigue capacity of joints can be enhanced by reducing stress concentration in the weld root through the implementation of a stress relief groove (SRG) design.…”

Section: Introductionmentioning

confidence: 99%

Fatigue design of stress relief grooves to prevent weld root fatigue in butt-welded cast steel to ultra-high-strength steel joints

Havia,

Lipiäinen,

Ahola

et al. 2024

Weld World

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In the welded joints, fatigue failures typically originate from defects or notch-like geometries under cyclic loading. This study investigates the impact of stress relief grooves (SRG) on the fatigue performance of butt-welded cast steel to ultra-high-strength steel components using experimental fatigue tests and finite element method. The experiments examined the fatigue properties of hybrid joints between G26CrMo4 cast steel (t = 20 mm) and S960 steel plate (t = 6 mm) with and without SRG. Gas metal arc welding process was used to weld the butt joints that had a permanent root backing machined on the cast steel part, causing a crack-like defect to the weld root. Additionally, the top surfaces of the welded parts were aligned, resulting in a significant axial misalignment in the butt joint. The SRG, positioned close to the weld root, was found to have a beneficial influence on the joint’s fatigue performance by a factor of 1.2 when using the nominal stress criterion. However, the fatigue capacity was still roughly 35% lower compared to the symmetrical equivalent due to the secondary bending stress, caused by axial misalignment. The finite element analyses indicated that the SRG reduces the amount of secondary stresses at the weld root leading to lower total structural stress. The study recommends using the FAT80 (m = 3) design curve in the structural stress method, for similar butt-welds having a crack-like defect, parallel to the loading direction, at the weld root. However, for welded joints with crack-like defects, it is advisable to use linear elastic fracture mechanics rather than relying solely on stress-based local approaches.

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“…An optimization approach for stress reduction in stepped specimens subjected to axial loads is proposed in [1]. The purpose of optimization is to minimize the maximum value of stresses in the main shoulder fillet, thus increasing the fatigue limit.…”

Section: Introductionmentioning

confidence: 99%

Methods for Reducing the Stress Concentration in Cylindrical Specimens, at Axial Loading

Raychev

Delova

2021

ETR

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The article presents specialized software methods for reducing stress concentration. Objects of study are cylindrical test specimens subjected to axial loading. Notching with different shapes and sizes on the specimens were formed to reduce the stresses in the endangered areas. The geometric parameters of notches identified through the specialized built-in modules to the ANSYS software. An analysis performed were to show the influence of stresses acting on the fatigue limit during different cycles. The results of the study were present in a graphical form.

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Size optimization of shoulder filleted shafts with relief grooves for improving their fatigue life

Cited by 3 publications

References 10 publications

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

Fatigue design of stress relief grooves to prevent weld root fatigue in butt-welded cast steel to ultra-high-strength steel joints

Methods for Reducing the Stress Concentration in Cylindrical Specimens, at Axial Loading

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