Journal of Failure Analysis and Prevention

, Volume 12, Issue 4, pp 419–426 | Cite as

Fatigue Crack Growth in a Solid Circular Shaft Under Fully Reversed Rotating Bending

Technical Article---Peer-Reviewed

Abstract

The axle of a load train failed after 5.37 × 106 cycles from its service. Macro-fractography showed clearly the fatigue fracture. The stress distribution in the shaft revealed that the maximum alternating stress was considerably less than the material modified fatigue limit obtained at 107 cycles from the S–N diagram. Micro-fractography reported from the metallurgical laboratory proved the existence of a surface flaw. Ultimately, fatigue crack growth simulation was performed based on the simple Paris–Erdogan model for estimating the fatigue life of the defective axle. The results showed that the actual life of the axle could be satisfactorily predicted by means of the Paris–Erdogan model.

Keywords

Fatigue crack growth Railway axle Finite element method Flaw Rotating bending 

Nomenclature

3D

Three dimensional

FE

Finite element

KI

Mode I stress intensity factor

KII

Mode II stress intensity factor

KIII

Mode III stress intensity factor

KIc

Plane-strain fracture toughness

Se

Material endurance limit

Su

Ultimate tensile strength

SIF

Stress intensity factor

ΔKth

Fatigue crack propagation threshold

Notes

Acknowledgments

The authors gratefully thank Dr. Sadat-Hosseini (the managing director of the IRRC) for supporting and paying his kind attention to this research. Also, Mr. Eng. Saharkhiz (the director of IRRC) is thanked for his cooperation in gathering the failure evidences and related data. The first author wishes to thank Ms. Eng. Elnaz Ghorbani for her typesetting and final check of the manuscript text. This study was done under the research contract,# 23 S/8798.

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Copyright information

© ASM International 2012

Authors and Affiliations

  1. 1.Fracture Research Laboratory, Department of Aerospace Engineering, Faculty of New Science and TechnologiesUniversity of TehranTehranIran
  2. 2.Fatigue and Fracture Research Laboratory, School of Mechanical EngineeringIran University of Science and TechnologyTehranIran

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