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A model for predicting crack initiation in forged M3:2 tool steel under high cycle fatigue

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Abstract

AISI type M3 class 2 tool steel (or in German designation DIN: HS6-5-3 tool steel) is most commonly used in tooling industry, and also in some engine parts. Those components are usually subjected to cyclic stresses and mostly fail by fatigue. Fatigue crack initiation in this material occupies large fraction of total lifetime and strongly depends on microstructural features of primary and eutectic carbides, such as shape, shape ratio, volume fraction, the distribution of carbides as well as load ratio. To model fatigue initiation mechanisms of forged M3:2 tool steel, McDowell’s model was modified and developed for different length-scales. For fatigue crack formation and short crack growth, a hierarchical approach was used and the life time of these stages were estimated based on the local cyclic plasticity. Through this relation the effect of microstructural features on both fatigue crack formation and short crack growth in the material were identified. The results of the proposed model have explicitly reflected the influence of microstructural features on both fatigue crack formation and propagation in forged M3:2 tool steel. Moreover, the model can be used for improving the fatigue resistance of a tool steel component.

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Abbreviations

\(a\) :

Crack length

\(a_{inc}\) :

Crack incubation length

\(a_{o}\) :

Critical defect

\(a_{sc}\) :

Short crack length

\(\alpha \) :

Manson–Coffin law’s exponent

\(b\) :

Fatigue ductility exponent

\(c\) :

Kinematic hardening modulus

\(C_{inc}\) :

Manson–Coffin law’s coefficient

\(C_{\varepsilon }\) :

Constraint coefficient

\(d_{o}\) :

Dislocation barries spacing

\(D_{p}\) :

Average diameter of carbides

\(\varDelta {CTOD}\) :

Crack Tip Opening Diplacement

\(\varDelta {\varGamma }\) :

Fatemi–Socie parameter

\(\varDelta {K}\) :

Stress intensity factor

\(\varDelta {K_{th}}\) :

Threshold for long crack

\(\varDelta {K_{th,a}}\) :

Threshold for short crack

\(\frac{da}{dN}\) :

Crack growth rate

\(E\) :

Young modulus

\(\varepsilon '_{f}\) :

Fatigue ductility coefficient

\(F\) :

Strengthening ratio

\(HCF\) :

High Cycle Fatigue

\(h/w\) :

Shape ratio of primary carbide

\(K'\) :

Cyclic hardening coefficient

\(LCF\) :

Low Cycle Fatigue

\(MSF\) :

Multi-Stage Fatigue

\(n'\) :

Cyclic hardening exponent

\(N_{lc}\) :

Long crack life

\(N_{inc}\) :

Fatigue crack incubation life

\(N_{msc}\) :

Lifetime of microstructurally short crack

\(N_{psc}\) :

Lifetime of physically short crack

\(N_{T}\) :

Total lifetime

\(r\) :

Dynamic rate of back stress tensor

\(R_{\varepsilon }\) :

Load ratio

\(RVE\) :

Representative Volume Element

\(\varPhi \) :

Yield surface

\(s\) :

Striation spacing

\(S_{p}\) :

Average distance of primary carbides

\(\sigma _{y,m}\) :

Cyclic yield stress of the matrix

\(\sigma '_{y}\) :

Cyclic yield strength

\(\sigma _{ys}\) :

Yield strength

\(\sigma _{ult}\) :

Ultimate tensile strength

\(Y\) :

Geometry factor

\(U\) :

A function of load ratio

\(V_{m}\) :

Volume fraction of the matrix

\(V_{p}\) :

Volume fraction of primary carbides

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Authors and Affiliations

  1. RWTH Aachen University, Institute for Materials Application in Mechanical Engineering (IWM), Augustinerbach 4, 52062 , Aachen, Germany

    N. A. Giang, U. A. Ozden, A. Bezold & C. Broeckmann

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  1. N. A. Giang
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  2. U. A. Ozden
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  3. A. Bezold
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  4. C. Broeckmann
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Correspondence to N. A. Giang.

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Giang, N.A., Ozden, U.A., Bezold, A. et al. A model for predicting crack initiation in forged M3:2 tool steel under high cycle fatigue. Int J Fract 187, 145–158 (2014). https://doi.org/10.1007/s10704-013-9927-z

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