An innovative fatigue life and critical defect size assessment method for structural components with pore defects

Studies on casting components have shown that micro-pore defects reduce the fatigue life. However, current methods are limited for application to full-scale structural components. This study aims to present a general method to assess the influence of type, morphology, and size of the pore defects on...

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Published inJournal of mechanical science and technology Vol. 37; no. 8; pp. 3985 - 3998
Main Authors Dou, Shuo, Liu, Zhiming, Mao, Liyong
Format Journal Article
LanguageEnglish
Published Seoul Korean Society of Mechanical Engineers 01.08.2023
Springer Nature B.V
대한기계학회
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Abstract Studies on casting components have shown that micro-pore defects reduce the fatigue life. However, current methods are limited for application to full-scale structural components. This study aims to present a general method to assess the influence of type, morphology, and size of the pore defects on the fatigue life of structural components. The ellipsoid and semiellipsoid were introduced to represent the internal and surface pore defects respectively, and the stress concentration factor (SCF) matrix was used to correlate the stress components between pore defect surface and structural surface. To suit to variable amplitude load conditions, the equivalent fatigue stress was introduced to the defect stress gradient (DSG) criterion. The detailed computational flow chart was presented and validated by comparison with the defect surface stress response and published experimental fatigue evidence. Finally, it was used to assess the fatigue life and critical defect size of the casting aluminum gearbox block of high-speed train. This method does not need the finite element model to describe the pore defects directly, and is applicable to the fatigue life and critical defect size assessment of full-scale structural components with pore defects, and can provide a quantitative index between the casting quality and service life of structures.
AbstractList Studies on casting components have shown that micro-pore defects reduce the fatigue life. However, current methods are limited for application to full-scale structural components. This study aims to present a general method to assess the influence of type, morphology, and size of the pore defects on the fatigue life of structural components. The ellipsoid and semiellipsoid were introduced to represent the internal and surface pore defects respectively, and the stress concentration factor (SCF) matrix was used to correlate the stress components between pore defect surface and structural surface. To suit to variable amplitude load conditions, the equivalent fatigue stress was introduced to the defect stress gradient (DSG) criterion. The detailed computational flow chart was presented and validated by comparison with the defect surface stress response and published experimental fatigue evidence. Finally, it was used to assess the fatigue life and critical defect size of the casting aluminum gearbox block of high-speed train. This method does not need the finite element model to describe the pore defects directly, and is applicable to the fatigue life and critical defect size assessment of fullscale structural components with pore defects, and can provide a quantitative index between the casting quality and service life of structures. KCI Citation Count: 0
Studies on casting components have shown that micro-pore defects reduce the fatigue life. However, current methods are limited for application to full-scale structural components. This study aims to present a general method to assess the influence of type, morphology, and size of the pore defects on the fatigue life of structural components. The ellipsoid and semiellipsoid were introduced to represent the internal and surface pore defects respectively, and the stress concentration factor (SCF) matrix was used to correlate the stress components between pore defect surface and structural surface. To suit to variable amplitude load conditions, the equivalent fatigue stress was introduced to the defect stress gradient (DSG) criterion. The detailed computational flow chart was presented and validated by comparison with the defect surface stress response and published experimental fatigue evidence. Finally, it was used to assess the fatigue life and critical defect size of the casting aluminum gearbox block of high-speed train. This method does not need the finite element model to describe the pore defects directly, and is applicable to the fatigue life and critical defect size assessment of full-scale structural components with pore defects, and can provide a quantitative index between the casting quality and service life of structures.
Author Dou, Shuo
Mao, Liyong
Liu, Zhiming
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  organization: School of Mechanical, Electronic and Control Engineering, Beijing Jiaotong University
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Issue 8
Keywords Fatigue life
Eshelby equivalent inclusion
Pore defect
Critical defect size
Defect stress gradient
Language English
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Springer Nature B.V
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Snippet Studies on casting components have shown that micro-pore defects reduce the fatigue life. However, current methods are limited for application to full-scale...
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StartPage 3985
SubjectTerms Casting defects
Control
Defects
Dynamical Systems
Engineering
Fatigue life assessment
Finite element method
Flow charts
Gearboxes
High speed rail
Industrial and Production Engineering
Mechanical Engineering
Original Article
Service life
Stress concentration
Vibration
기계공학
Title An innovative fatigue life and critical defect size assessment method for structural components with pore defects
URI https://link.springer.com/article/10.1007/s12206-023-0715-z
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