Sharif Digital Repository

The effect of contact geometry on fretting fatigue life was investigated by experiments and numerical simulation. The experiments were conducted for flat and cylindrical pads under the same contact normal force. The post-test examinations including crack growth measurements and fractography were carried out using optical and scanning electron microscopy (SEM). Numerical simulations of pad-specimen assembly with and without crack were performed using a finite element (FE) analysis. The experimental study revealed that the rate of crack growth was higher at the early stages of fretting fatigue for cylindrical pads. This stage corresponds to a higher KII for cylindrical contact model. After... 

Recent research studies on ductile fracture of metals have shown that the ductile fracture initiation is significantly affected by the stress state. In this study, the effects of the stress invariants as well as the effect of the reverse loading on ductile fracture are considered. To estimate the reduction of load carrying capacity and ductile fracture initiation, a scalar damage expression is proposed. This scalar damage is a function of the accumulated plastic strain, the first stress invariant and the Lode angle. To incorporate the effect of the reverse loading, the accumulated plastic strain is divided into the tension and compression components and each component has a different weight... 

Recent experiments on metals have shown that all of the stress invariants should be involved in the constitutive description of the material in plasticity. In this paper, a plasticity model for metals is defined for isotropic materials, which is a function of the first stress invariant in addition to the second and the third invariants of the deviatoric stress tensor. For this purpose, the Drucker-Prager yield criterion is extended by addition of a new term containing the second and the third deviatoric stress invariants. Furthermore for estimating the cyclic behavior, new terms are incorporated into the Chaboche's hardening evolution equation. These modifications are applied by adding new... 

In the present study, the out-of-phase thermomechanical fatigue (OP-TMF) behavior of a cast aluminum-silicon-magnesium alloy, the A356.0 alloy which has been widely used in diesel engine cylinder heads, is compared to room-temperature and high-temperature low cycle fatigue (RT-, HT-LCF) behaviors. For this purpose, strain/temperature-controlled isothermal and non-isothermal fatigue tests were performed based on realistic loading conditions in cylinder heads. Fatigue tests results showed that the plastic strain increased during cycles under constant mechanical strain amplitude, while the specimen failed. Under LCF loadings, the cyclic hardening occurred at low temperatures for the A356.0... 

The effects of nitriding, nitrocarburizing and shot peening on fatigue behavior of AISI D3 cold work tool steel were investigated. Five batches of fatigue specimens were manufactured according to the ASTM E466-96 standard. All specimens were quenched and tempered to a hardness of 50 HRC. One group of specimens was shot peened with an Almen intensity of 16 A, one group was nitrocarburized, one group was gas nitrided by single stage and another group was also nitrided by double stages. Rotating-bending fatigue tests were carried out. Our results showed that nitriding and nitrocarburizing treatments did not have a beneficial effect on the fatigue resistance of D3 tool steel. Fatigue test... 

In the present work, specimens were cut out from St-37 plates with 19 mm thickness. The thickness of plates was reduced to 12.5 mm by milling and grinding operations. Then a standard V-shaped fillet was made on one edge of the plates. Two plates were butt-welded by standard metal arc gas (MAG) welding process. Residual stresses induced by welding were measured on 20 specimens by centre hole drilling. Load controlled axial fatigue tests were carried out to determine the fatigue life of specimens. Crack growth rates were obtained from experiment. Fractography of specimens was performed. Genetic Algorithm (GA) was employed for prediction of residual stress value in weldments using the crack... 

In this paper residual stresses induced by butt metal arc gas welding (MAGW), in accordance with ASTM E837, are determined by hole drilling. The results are analyzed by probabilistic methods. Also, the effect of fatigue life on relaxation of welding residual stress is investigated. The specimens are tested to measure fatigue life and crack growth rates in accordance with ASTM E466 for force controlled amplitude axial fatigue testing. © 2008 Verlag Stahleisen GmbH, Düsseldorf  

The modified couple stress theory is employed in this paper in order to formulate the size-dependent strain energy release rate of Euler-Bernoulli and Timoshenko notched beams. As a case study, the normalized energy release rate of the aforementioned beams has been developed for three-point bending as a function of the ratio of material length scale parameter to the beam depth. The results of the current model are compared to the experimental data. The good agreement between the present results and the experimental values indicates that the current model can be successfully applied to evaluate size dependent energy release rate of structures  

The subject of this study is to investigate the effect of repair on the fatigue life of tubular joints. Six cracked specimens previously subjected to fatigue loading underwent weld repair. Two of these specimens were shot peened before primary fatigue loading. It is shown that repair for the original specimens increases the fatigue life by roughly 150%. The increase of fatigue life for shot peened and repaired specimens is around 105%. The in-depth residual stresses are measured on the repaired joints before and after fatigue loading. It can be stated that repair made a remarkable improvement on the fatigue behavior of tubular joints examined in this investigation. However, where repair is... 

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... 

In the present paper, numerical simulation of thermal barrier coating system under thermo-mechanical loadings is performed, using the finite element method in ABAQUS software. The base material is Aluminum-silicon alloy, A356.0 which is widely used in automotive components such as diesel engine cylinder heads. Thermal barrier coatings (TBCs) are applied to combustion chamber in order to reduce fuel consumption and pollutions and also improve fatigue life of components. The roughness effect of coating layers on stress distribution of test specimens is investigated. Semi-ellipsoid roughness of the interfaces between substrate/bond coat and bond coat/top coat are simulated to get the stress... 

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... 

Ceramic thermal barrier coatings are applied on gas turbines and diesel engine components to protect metals from heat and this enhances the service lifetime by means of a reduction in working temperature. In the present paper, optimisation of plasma thermal spray parameters, including feed rate and nozzle distance from the specimen surface is performed by using the design of experiment method. Due to factorial approach, by considering two parameters with three variation levels, nine experiments of bending test are needed. The base material is cast aluminium alloy, A356.0-T7. The coating layers consist of a bond coat, Ni-Cr-Al-Y with a thickness of 150 μm and a top coat, ZrO2-8wt%Y2O3 with a... 

In this article, simulations of the stress-strain behavior in aluminum alloys were investigated under cyclic loadings at various strain rates. Four plasticity approaches were applied to simulate cyclic behaviors. To validate obtained results, strain-controlled tensile-compressive fatigue tests were performed in the low cycle fatigue regime. Isothermal fatigue experiments were conducted at various strain rates. Thermo-mechanical fatigue experiments were carried out at different rates of cooling and heating processes. Numerical results demonstrated a good agreement with experimental data at the mid-life cycle of the material. Material constants for different models were also presented for... 

The experimental observations indicate that the mechanical behavior of micro and nano scale structures is size-dependent. In this study, employing the modified couple stress theory the size-dependent strain energy release rate of notched Euler-Bernoulli beams made of functionally graded material (FGM) is formulated. The normalized energy release rate for the problem of three-point bending in notched FG beams is obtained using the procedure established by Kienzler and Herrmann [Kienzler R, Herrmann G, An elementary theory of defective beams. Acta Mech 1986; 62:37-46]. It is assumed that the material properties vary continuously along the beam thickness according to a power law distribution.... 

A thermodynamically consistent phase field model for crack propagation is analyzed. The thermodynamic driving force for the crack propagation is derived based on the laws of thermodynamics. The Helmholtz free energy satisfies the thermodynamic equilibrium and instability conditions for the crack propagation. Analytical solutions for the Ginzburg–Landau equation including the surface profile and the estimation of the kinetic coefficient are found. It is shown how kinetic coefficient affects the local stress field. The local critical stress for the crack propagation is calibrated with the theoretical strength which gives the value of the crack surface width. The finite element method is... 

Fretting fatigue occurs in engineering applications where two interacting surfaces are subjected to fluctuating forces. The fluctuating forces occasionally act as a combined loading condition. The present paper investigates fretting fatigue behaviour of 316L stainless steel under such combined (i.e. tensile and bending) loading conditions. A new fixture was developed in order to apply bending and tensile loads simultaneously. Using this fixture, the effect of different bending-to-tension ratios was investigated. The results showed that increasing the contribution of bending load improves fretting fatigue life. On the other hand, increasing grain size decreases fretting fatigue life.... 

A thermodynamically consistent phase field model for crack propagation is analyzed. The thermodynamic driving force for the crack propagation is derived based on the laws of thermodynamics. The Helmholtz free energy satisfies the thermodynamic equilibrium and instability conditions for the crack propagation. Analytical solutions for the Ginzburg–Landau equation including the surface profile and the estimation of the kinetic coefficient are found. It is shown how kinetic coefficient affects the local stress field. The local critical stress for the crack propagation is calibrated with the theoretical strength which gives the value of the crack surface width. The finite element method is... 

Shot peening is widely used to improve the fretting fatigue strength of critical surfaces. Fretting fatigue occurs in contacting parts that are subjected to fluctuating loads and sliding movements at the same time. This paper presents a sequential finite element simulation to investigate the shot peening effects on normal stress, shear stress, bulk stress and slip amplitude, which are considered to be the controlling parameters of fretting damage. The results demonstrated that among the modifications related to shot peening, compressive residual stress has a dominant effect on the fretting parameters  

Recent research indicates that accurate material behavior modeling plays an important role in the estimation of residual stresses in the bore of autofrettaged tubes. In this paper, the material behavior under plastic deformation is considered to be a function of the first stress invariant in addition to the second and the third invariants of the deviatoric stress tensor. The yield surface is assumed to depend on the first stress invariant and the Lode angle parameter which is defined as a function of the second and the third invariants of the deviatoric stress tensor. Furthermore for estimating the unloading behavior, the Chaboche's hardening evolution equation is modified. These...