Metal Fatigue Analysis Handbook: Practical problem-solving techniques for computer-aided engineering

633 Pages·2011·15.05 MB·English

by  Yung-Li Lee

Metal Fatigue
Analysis Handbook
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Metal Fatigue
Analysis Handbook
Practical Problem-Solving Techniques
for Computer-Aided Engineering
Yung-Li Lee
Mark E. Barkey
Hong-Tae Kang

AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON
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LibraryofCongressCataloging-in-PublicationData
Lee,Yung-Li.
Metalfatigueanalysishandbook:practicalproblem-solvingtechniquesfor
computer-aidedengineering/Yung-LiLee,MarkE.Barkey,Hong-TaeKang.
p.cm.
ISBN978-0-12-385204-5(hardback)
1.Metals–Fatigue.2.Computer-aidedengineering.I.Barkey,MarkE.
II.Kang,Hong-Tae.III.Title.
TA460.L4162011
620.1'66–dc23 2011020149
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AcataloguerecordforthisbookisavailablefromtheBritishLibrary.
ForinformationonallButterworth-Heinemannpublications
visitourwebsite:ww w.elsevierdirect.com
PrintedintheUnitedStates
11 12 13 14 15 10 9 8 7 6 5 4 3 2 1
Thank you to our families for their inspiration, encouragement,
and patience!
To my friend, my love, my wife, Pai-Jen, and our
children, Timothy and Christine
Yung-Li Lee
To my wife, Tammy, and our daughters, Lauren,
Anna, and Colleen
Mark E. Barkey
To my wife, Jung-Me, and our son, Anthony
Hong-Tae Kang
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Contents
Preface................................................................................... xv
Acknowledgments..................................................................... xix
About the Authors................................................................... xxi
Nomenclature........................................................................ xxiii
Chapter 1: Road Load Analysis Techniques in Automotive Engineering..... 1
Xiaobo Yang, Peijun Xu
Introduction................................................................................. 1
Fundamentals of Multibody Dynamics.............................................4
Conditions of Equilibrium..........................................................6
D’Alembert’s Principle...............................................................7
Multibody Dynamics Systems....................................................10
Generic Load Cases..................................................................... 12
Generic Load Events................................................................13
Analysis Procedure..................................................................19
Results and Report...................................................................20
Semianalytical Analysis............................................................... 22
Powertrain Mount Load Analyses...............................................22
Suspension Component Load Analysis........................................30
Vehicle Load Analysis Using 3D Digitized Road Profiles................. 39
Vehicle Model Description........................................................42
Tire Model Description.............................................................43
Model Validation Process.........................................................46
Summary................................................................................... 56
References................................................................................. 57
vii
Contents
Chapter 2: Pseudo Stress Analysis Techniques................................ 61
Yung-Li Lee, Mingchao Guo
Introduction................................................................................ 61
Static Stress Analysis................................................................... 62
Fixed Reactive Analysis...........................................................63
Inertia Relief Analysis..............................................................66
Modal Transient Response Analysis............................................... 71
Natural Frequencies and Normal Modes......................................72
Orthonormalization of Normal Modes.........................................73
Decoupled Modal Equations of Motion.......................................77
Numerical Integration Method for Equations of Motion.................80
Summary................................................................................... 85
References................................................................................. 86
Chapter 3: Rainflow Cycle Counting Techniques.............................. 89
Yung-Li Lee, Tana Tjhung
Introduction................................................................................ 89
Uniaxial Rainflow Cycle Counting Techniques................................ 90
Rainflow Counting Method by Matsuishi and Endo......................90
Three-Point Counting Technique................................................94
Four-Point Counting Technique................................................102
Multiaxial Rainflow Reversal Counting Techniques........................ 106
Summary.................................................................................. 112
References................................................................................ 113
Chapter 4: Stress-Based Uniaxial Fatigue Analysis......................... 115
Yung-Li Lee, Mark E. Barkey
Introduction.............................................................................. 116
Ultimate Tensile Strength of a Component.................................... 120
Reliability C orrection Factor....................................................121
Size Correction Factor............................................................123
Temperature Correction Factor for Ultimate
and Yield Strengths................................................................124
Stress Correction Factor..........................................................126
Load Correction Factor...........................................................126
Component Endurance Limit under Fully Reversed Loading........... 128
Temperature Correction Factor.................................................130
Endurance Limit Factor...........................................................131
viii
Contents
Surface Treatment Factor........................................................132
Roughness Correction Factor...................................................132
Fatigue Notch Factor..............................................................134
Constant Amplitude Stress-Life Curve for a Notched
Component under Fully Reversed Loading.................................... 145
Constant Amplitude Nominal Stress-Life Curve..........................145
Constant Amplitude Pseudo Stress-Life Curve............................147
Stress-Life Curve for a Component under Variable
Amplitude Loading.................................................................... 149
Mean Stress Effect..................................................................... 151
Summary.................................................................................. 157
References................................................................................ 159
Chapter 5: Stress-Based Multiaxial Fatigue Analysis....................... 161
Yung-Li Lee, Mark E. Barkey
Introduction.............................................................................. 161
Fatigue Damage Models............................................................. 168
Empirical Formula Approach...................................................168
Equivalent Stress Approach.....................................................170
Critical Plane Approach..........................................................186
Dang Van’s Multiscale Approach.............................................199
Summary.................................................................................. 210
References................................................................................ 211
Chapter 6: Strain-Based Uniaxial Fatigue Analysis......................... 215
Yung-Li Lee, Mark E. Barkey
Introduction.............................................................................. 215
Steady State Cyclic Stress–Strain Relation.................................... 217
Fully Reversed, Constant Amplitude Strain-Life Relation................ 221
Estimate of Cyclic Material and Fatigue Properties......................... 223
Strain-Life Equations with Mean Stress........................................ 224
Morrow................................................................................224
Smith, Watson, and Topper.....................................................225
Notch Analysis......................................................................... 231
Neuber.................................................................................232
Nominally Elastic Behavior.....................................................234
Nominally Gross Yielding of a Net Section...............................235
Modified Neuber Rule............................................................236
ix