Abstract
This paper estimates total fatigue and transition life using strain-controlled fatigue data generated for various cast materials, using a practical example of a structural hub casting that has been in service for many years. The material data generated from recent testing, service loads and boundary conditions from the potential failure modes are entered into a finite element analysis (FEA) to predict the stress amplitudes using the same geometry that is employed for predicting the fatigue life.
For the same loading, the investigators observed that the elastic modulus and specific strength have an impact on the predicted stresses. Strain-life material parameters impact the predicted strain fatigue life. At low loads (in the elastic regime), the overall exercise yields a different choice of material than at higher loads (in the elastic-plastic regime), which is driven by the strain-controlled material data properties.
As an example, a sensitivity analysis was done on one alloy by varying all of its properties as well as by individually varying relevant material property data and constants. The loading and geometry were kept constant in this sensitivity analysis, to illustrate the significance of the potential error a design engineer might encounter in estimating service life.
In the real world at the early design stage, various candidate cast alloys can be evaluated using this approach to achieve the desired fatigue life for the identical service loads. This methodology will yield an optimized geometry through FEA-based validations using the latest strain controlled fatigue material database for various cast alloys generated by the American Foundry Society (AFS) through sponsored research.
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Shah, J., Tartaglia, J.M. A Case Study of Finite Element Analysis and Designing with Data from the AFS Strain-Life Fatigue Database. Inter Metalcast 9, 7–18 (2015). https://doi.org/10.1007/BF03356035
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DOI: https://doi.org/10.1007/BF03356035