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fatigue-testing
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Experimental and Finite Element Analysis of Vehicle Steering Knuckle Fatigue Life under Road Driving Test
, M.Sc. Thesis Sharif University of Technology ; Farrahi, Gholamhossein (Supervisor)
Abstract
Steering Knuckle is a mechanical part in an automobile which connects the break, suspension system, hub, and steering system to the chassis. In the recent years due to the variant imposing forces on the steering knuckle this part’s fatigue life has attracted engineers and designers’ attention. The considered steering knuckle in this project is a steering knuckle from an Iranian car. The goal of this project is to determine the fatigue life of a steering knuckle under street loads. The fatigue life of a steering knuckle has been investigated with both experimental and finite element methods. In order to perform the fatigue test a test fixture was designed. The finite element analysis consists...
Effect of Different Defects of Spot Welded Joint in Automotive Body on Fatigue Strength: Experimental and Numerical Investigation
, M.Sc. Thesis Sharif University of Technology ; Farrahi, Gholamhossein (Supervisor) ; Mehmanparast, Ali (Supervisor) ; Reza Kashyzadeh, Kazem (Co-Supervisor)
Abstract
On average there are to resistance spot welding connections per vehicle. The quality of these welding directly affects the quality of the finished product and the strength of the vehicle against various loads, including road roughness, different maneuvers and even sudden impacts from accidents. During the spot welding process, unintentional failures occur due to the wrong choice of current, force and time. The aim of this study is to investigate the fatigue strength of three-sheets welding joints in numerical and laboratory methods, considering the defects of (Undersize weld, Stick, edge of sheet metal and Edge of sheet metal-SECANT) . For this purpose, a healthy spot welding model was first...
The Evaluation of Different Parameters on Fatigue Life of Carbon / Epoxy and Carbon / Phenolic Polymer Composite Rods under Tensile-pressure Loads
, M.Sc. Thesis Sharif University of Technology ; Hosseini Kordkheili, Ali (Supervisor)
Abstract
The aim of this dissertation is to analyze the tensile-stress fatigue of composite rods made of a combination of carbon-epoxy resin as well as carbon chopped-phenolic resin and to investigate the effect of different parameters on their fatigue life. The curing process is completely different in carbon / epoxy and carbon / phenolic composites, Carbon / Epoxy is a thermo-plastic composite, but carbon / phenolic is a thermo- set composite. Therefore, differences in the curing process, raw materials, changes in the volume percentage of resin and fibers, the effects of different loading during the production and curing process of the composite, cooling and heating rates during production can...
Geometrical Optimization of Aluminum Alloy Wheels for High Fatigue and Impact Strength
, M.Sc. Thesis Sharif University of Technology ; Khayyat, Ali Akbar (Supervisor) ; Pasharavesh, Abdolreza (Supervisor)
Abstract
After the rise of the automotive industry, aluminum wheels have superseded steel counterparts due to their numerous advantages. Foremost among these benefits is their reduced weight, leading to fuel savings and diminished environmental impact. Moreover, aluminum wheels offer enhanced aesthetics and greater strength in comparison to steel alternatives. This thesis focuses on the geometrical optimization of an aluminum wheel model conforming to the standards set by Iran's Department of Standards, aiming to achieve a higher strength-to-weight ratio. While prior research works have mainly focused on weight reduction while maintaining strength within approved standards, this thesis aims at the...
Thermo-mechanical stress analysis of thermal barrier coating system considering thickness and roughness effects
, Article Surface and Coatings Technology ; Vol. 243 , 2014 , pp. 91-99 ; ISSN: 02578972 ; Azadi, M ; Farrahi, G. H ; Sharif University of Technology
Abstract
Cast aluminium-silicon alloy, A356.0, is widely used in automotive and aerospace industries because of its outstanding mechanical, physical, and casting properties. Thermal barrier coatings can be applied to combustion chamber to reduce fuel consumption and pollutions and also improve fatigue life of components. The purpose of the present work is to simulate stress distribution of A356.0 under thermo-mechanical cyclic loadings, using a two-layer elastic-visco-plastic model of ABAQUS. The results of stress-strain hysteresis loop are validated by an out of phase thermo-mechanical fatigue test. Different thicknesses from 300 to 800. μm of top coat and also roughness of the interfaces are...
Fatigue lifetime of AZ91 magnesium alloy subjected to cyclic thermal and mechanical loadings
, Article Materials and Design ; Vol. 53, issue , 2014 , pp. 639-644 ; ISSN: 02613069 ; Farrahi, G. H ; Winter, G ; Eichlseder, W ; Sharif University of Technology
Abstract
In the present paper, thermo-mechanical fatigue (TMF) and low cycle fatigue (LCF) or isothermal fatigue (IF) lifetimes of a cast magnesium alloy (the AZ91 alloy) were studied. In addition to a heat treatment process (T6), several rare elements were added to the alloy to improve the material strength in the first step. Then, the cyclic behavior of the AZ91 was investigated. For this objective, strain-controlled tension-compression fatigue tests were carried out. The temperature varied between 50 and 200. °C in the out-of-phase (OP) TMF tests. The constraint factor which was defined as the ratio of the mechanical strain to the thermal strain, was set to 75%, 100% and 125%. For LCF tests,...
Numerical simulations of cyclic behaviors in light alloys under isothermal and thermo-mechanical fatigue loadings
, Article Materials and Design ; Vol. 56 , April , 2014 , pp. 245-253 ; ISSN: 02641275 ; Shamloo, A ; Felfeli, M ; Azadi, M ; Sharif University of Technology
Abstract
In this article, numerical simulations of cyclic behaviors in light alloys are conducted under isothermal and thermo-mechanical fatigue loadings. For this purpose, an aluminum alloy (A356) which is widely used in cylinder heads and a magnesium alloy (AZ91) which can be applicable in cylinder heads are considered to study their stress-strain hysteresis loops. Two plasticity approaches including the Chaboche's hardening model and the Nagode's spring-slider model are applied to simulate cyclic behaviors. To validate obtained results, strain-controlled fatigue tests are performed under low cycle and thermo-mechanical fatigue loadings. Numerical results demonstrate a good agreement with...
Stress–strain time-dependent behavior of A356.0 aluminum alloy subjected to cyclic thermal and mechanical loadings
, Article Mechanics of Time-Dependent Materials ; Vol. 18, issue. 3 , 2014 , p. 475-491 ; Ghodrati, M ; Azadi, M ; Rezvani Rad, M ; Sharif University of Technology
Abstract
This article presents the cyclic behavior of the A356.0 aluminum alloy under low-cycle fatigue (or isothermal) and thermo-mechanical fatigue loadings. Since the thermo-mechanical fatigue (TMF) test is time consuming and has high costs in comparison to low-cycle fatigue (LCF) tests, the purpose of this research is to use LCF test results to predict the TMF behavior of the material. A time-independent model, considering the combined nonlinear isotropic/kinematic hardening law, was used to predict the TMF behavior of the material. Material constants of this model were calibrated based on room-temperature and high-temperature low-cycle fatigue tests. The nonlinear isotropic/kinematic hardening...
Improvement of high temperature fatigue lifetime in AZ91 magnesium alloy by heat treatment
, Article Materials Science and Engineering A ; Volume 588 , December , 2013 , Pages 357-365 ; 09215093 (ISSN) ; Azadi, M ; Hossein Farrahi, G ; Winter, G ; Eichlseder, W ; Sharif University of Technology
2013
Abstract
In the present paper, an improvement in high temperature fatigue properties of the AZ91 magnesium alloy with rare earth elements has been obtained by a typical heat treatment, denoted by T6. For this objective, out-of-phase thermo-mechanical fatigue, room temperature and high temperature low cycle fatigue tests are performed to compare lifetimes. Several rare earth elements are initially added to the AZ91 alloy during a gravity casting process in permanent molds. Also, the type of the heat treatment is examined. Results of specimens with only the solution (the T4 heat treatment) and the solution with the ageing process (the T6 heat treatment) are compared under isothermal fatigue loadings....
Experimental fatigue lifetime of coated and uncoated aluminum alloy under isothermal and thermo-mechanical loadings
, Article Ceramics International ; Volume 39, Issue 8 , December , 2013 , Pages 9099-9107 ; 02728842 (ISSN) ; Farrahi, G. H ; Winter, G ; Eichlseder, W ; Sharif University of Technology
2013
Abstract
This paper presents the fatigue lifetime of an aluminum-silicon-magnesium alloy, widely used in diesel engine cylinder heads, both with and without a thermal barrier coating (TBC) system. The coating system in this study consists of two layers including a 150 μm thick metallic bond coat and a zirconium oxide top coat 350 μm thick. These coating layers were applied on the substrate of A356.0 alloy by air plasma thermal spraying. The isothermal fatigue tests were conducted in low cycle fatigue (LCF) regime at various temperatures. Out-of-phase thermo-mechanical fatigue (OP-TMF) tests were also performed at different maximum temperatures and constraint factors. Experimental results demonstrate...
Optimization of air plasma sprayed thermal barrier coating parameters in diesel engine applications
, Article Journal of Materials Engineering and Performance ; Volume 22, Issue 11 , 2013 , Pages 3530-3538 ; 10599495 (ISSN) ; Farrahi, G. H ; Moridi, A ; Sharif University of Technology
2013
Abstract
In the present paper, an optimization of thermal barrier coating parameters is performed for diesel engine applications. The substrate is A356.0-T7, a cast aluminum alloy which has a vast application in diesel engines, and the alloy is coated by plasma sprayed ZrO2-8 wt.% Y2O3. Parameters including the feed rate of coating powders, the nozzle distance to specimen surfaces, and the coating thickness are optimized by thermal shock fatigue tests and bending tests. Optimum values of the feed rate and the nozzle distance are 30 g/min and 80 mm, respectively, when the objective is considered as maximizing the bending strength. Thermal shock tests demonstrate that lower thickness of coating layers...
Effects of strain rate and mean strain on cyclic behavior of aluminum alloys under isothermal and thermo-mechanical fatigue loadings
, Article International Journal of Fatigue ; Volume 47 , 2013 , Pages 148-153 ; 01421123 (ISSN) ; Sharif University of Technology
2013
Abstract
In this paper, effects of strain rate and mean strain on the cyclic behavior and the lifetime of aluminum-silicon alloys are investigated under thermo-mechanical and isothermal fatigue loadings. To achieve these goals, low cycle fatigue tests are accomplished at evaluated temperatures under various strain rates (by changing the loading frequency) and different strain ratios (minimum to maximum strain). Thermo-mechanical fatigue experiments are performed in an out-of-phase condition where the temperature varies between 50 and 250 °C. Various heating/cooling rates are taken into account to assess the strain rate effect and different starting temperatures are considered to study the mean strain...
Fatigue life estimation of bolt clamped and interference fitted-bolt clamped double shear lap joints using multiaxial fatigue criteria
, Article Materials and Design ; Volume 43 , 2013 , Pages 327-336 ; 02641275 (ISSN) ; Chakherlou, T. N ; Farrahi, G. H ; Alderliesten, R. C ; Sharif University of Technology
2013
Abstract
In this paper seven different multiaxial fatigue criteria based on stress, strain and energy were employed to estimate the fatigue lives of double shear lap joint specimens of aluminum 2024-T3 with bolt clamped and interference fitted-bolt clamped fastener holes. Detailed finite element (FE) simulations were conducted to obtain the stress and strain distributions in the joint to be used to as basic data in estimating the fatigue lives using multiaxial fatigue criteria. The estimated lives were compared with available experimental fatigue test results to investigate the capability of the criteria in predicting the fatigue lives. The results showed that the accuracy of life estimation for any...
The effect of pre-straining at intermediate temperatures on the mechanical behavior of high-bainite dual phase (HBDP) steels
, Article Materials Science and Engineering A ; Volume 543 , May , 2012 , Pages 224-230 ; 09215093 (ISSN) ; Haghshenas Fatmehsari, D ; Ekrami, A ; Sharif University of Technology
Abstract
High-bainite dual phase (HBDP) steels with 34. vol.% ferrite were subjected to tensile strains of 1%, 3%, and 5% at intermediate temperatures (150-450. °C). Mechanical behavior of pre-deformed steels was then investigated at room temperature. A maximum value for both yield stress and ultimate tensile strength was observed for pre-deformed steels. A minimum elongation was also found in the same pre-deformed specimens at the range of 250-350. °C. It was found that dynamic strain aging (DSA) plays the major role in mechanical properties of pre-strained HBDP steels. The DSA indicator parameter (DSAP) was introduced to evaluate DSA mechanism. Maxima of DSAP were likewise observed at the range of...
The effect of shot peening on fatigue life of welded tubular joint in offshore structure
, Article Materials and Design ; Volume 36 , 2012 , Pages 250-257 ; 02641275 (ISSN) ; H-Gangaraj, S. M ; Farrahi, G. H ; Majzoobi, G. H ; Mahmoudi, A. H ; Daghigh, M ; Yari, A ; Moridi, A ; Sharif University of Technology
2012
Abstract
An offshore structure is exposed to environmental loading and cyclic stress variations throughout its life. This would result in the possibility of fatigue cracking in its members. Cracks in these structures usually initiate around welded areas, then grow progressively from the heat-affected zone to base metal through the thickness of the tubular members. Therefore, fatigue life improvement of offshore structures is of great importance. In this paper, structural analysis of an offshore platform is carried out and the critical joint is specified. The welding process is simulated and the residual stresses due to the welding are determined. Experimental residual stress measurement is carried...
Contact of an asymmetrical rounded apex wedge with a half plane
, Article International Journal of Engineering Science ; Volume 50, Issue 1 , January , 2012 , Pages 192-197 ; 00207225 (ISSN) ; Sharafbafi, F ; Ghanati, P ; Sharif University of Technology
Abstract
Two-dimensional elastic contact problem of an asymmetrical rounded apex wedge with a half plane is considered and an analytical solution is presented for vertical and horizontal external loading in the presence of coulomb friction. The pressure and shear distribution functions are found in closed form under partial slip condition. Further by utilizing a new relation Muskhelishvili's potential function is obtained and results are analyzed. Designing better cutting tools, selecting fretting fatigue test pads and deeper lap joint analyzing are several practical applications of the outcomes
Coating thickness and roughness effect on stress distribution of A356.0 under thermo-mechanical loadings
, Article Procedia Engineering, 5 June 2011 through 9 June 2011 ; Volume 10 , June , 2011 , Pages 1372-1377 ; 18777058 (ISSN) ; Azadi, M ; Farrahi, G. H ; Sharif University of Technology
2011
Abstract
Cast aluminium-silicon alloy, A356.0, is widely used in automotive components such as diesel engine cylinder heads and also in aerospace industries because of its outstanding mechanical, physical, and casting properties. Thermal barrier coatings are applied to combustion chamber in order to reduce fuel consumption and pollutions and also improve fatigue life of components. However, studies on behaviour of A356.0 with thermal barrier coating are still rare. The purpose of the present work is to simulate stress distribution of A356.0 under thermo-mechanical cyclic loadings, using a two-layer elastic-visco-plastic model of ABAQUS software. The results of stress-strain hysteresis loop are...
Mechanical and electrochemical behaviors of butt-welded high temperature steel pipes
, Article Engineering Failure Analysis ; 2016 ; 13506307 (ISSN) ; Vanini, S. A. S ; Fereiduni, E ; Rokni, M. H ; Sharif University of Technology
Elsevier Ltd
2016
Abstract
In this study, fatigue, corrosion fatigue and electrochemical behaviors of butt-welded A106-B steel pipes were investigated. These pipes were subjected to mechanical and thermal cyclic stresses due to the internal pressure fluctuations and cooling-heating cycles. Residual stress measurements were carried out for three different depths through the thickness and were correlated to the microstructural observations and microhardness measurements. Results showed that the maximum tensile residual stresses existed at the boundary of weld metal and base metal because of the contraction-expansion effects resulting from phase transformations and cooling rate differences. Fatigue fractures occurred at...
The effects of combination of severe plastic deformation and Shot Peening surface treatment on fatigue behavior of 6082 aluminum alloy
, Article Russian Journal of Non-Ferrous Metals ; Volume 56, Issue 2 , 2015 , Pages 206-211 ; 10678212 (ISSN) ; Irani, M ; Karimi Taheri, A ; Sharif University of Technology
Abstract
In this paper, the effects of Equal Channel Angular Pressing process (ECAP) followed by Shot Peening process (SP) on the fatigue properties of 6082 aluminum alloy are investigated. Several samples of the alloy are ECAPed and SPed and then their mechanical behavior are characterized using tensile, micro-hardness, and fatigue tests. The results indicate that shot peening and then polishing the specimen after one-pass ECAP is an effective method to improve the fatigue life of the alloy. Moreover, by increasing the number of ECAP passes before shot peening, a local work softening occurs at the subsurface layer, leading to a significant decrease in the fatigue life of the alloy. The results of...
Damage prediction for un-coated and coated aluminum alloys under thermal and mechanical fatigue loadings based on a modified plastic strain energy approach
, Article Materials and Design ; Volume 66, Issue PB , 2015 , Pages 587-595 ; 02613069 (ISSN) ; Farrahi, G. H ; Winter, G ; Huter, P ; Eichlseder, W ; Sharif University of Technology
Abstract
In this article, a novel energy-based lifetime prediction model has been presented for uncoated and coated aluminum alloys, subjected to thermal and mechanical fatigue loadings. For this objective, isothermal and thermo-mechanical fatigue tests were performed on the A356.0 alloy, with and without thermal barrier coating systems. This model, which was based on the plastic strain energy, had three correction factors including temperature, strain and mean stress effects. The predicted lifetime showed a proper agreement with experimental data. By the present model, higher accuracy was obtained in comparison to other existed approaches. Besides, the present model had lower number of material...