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  • 1
    Online Resource
    Online Resource
    MDPI AG ; 2023
    In:  Applied Mechanics Vol. 4, No. 2 ( 2023-04-27), p. 528-566
    In: Applied Mechanics, MDPI AG, Vol. 4, No. 2 ( 2023-04-27), p. 528-566
    Abstract: The fatigue strength of cast steel components is severely affected by manufacturing process-based bulk and surface imperfections. As these defect structures possess an arbitrary spatial shape, the utilization of local assessment methods is encouraged to design for service strength. This work applies the elastic–plastic strain energy density concept to study the fatigue strength properties of a high-strength cast steel alloy G12MnMo7-4+QT. A fatigue design limit curve is derived based on non-linear finite element analyses which merges experimental high-cycle fatigue results of unnotched and notched small-scale specimens tested at three different stress ratios into a unique narrow scatter band characterized by a scatter index of 1:TΔW¯(t)=2.43. A comparison to the linear–elastic assessment conducted in a preceding study reveals a significant improvement in prediction accuracy which is assigned to the consideration of the elastic–plastic material behaviour. In order to reduce computational effort, a novel approximation is presented which facilitates the calculation of the elastic–plastic strain energy density based on linear–elastic finite element results and Neuber’s concept. Validation of the assessment framework reveals a satisfying agreement to non-linear simulation results, showing an average root mean square deviation of only approximately eight percent in terms of total strain energy density. In order to study the effect of bulk and surface imperfections on the fatigue strength of cast steel components, defect-afflicted large-scale specimens are assessed by the presented elastic–plastic framework, yielding fatigue strength results which merge into the scatter band of the derived design limit curve. As the conducted fatigue assessment is based solely on linear–elastic two-dimensional simulations, the computational effort is substantially decreased. Within the present study, a reduction of approximately 400 times in computation time is observed. Hence, the established assessment framework presents an engineering-feasible method to evaluate the fatigue life of imperfective cast steel components based on rapid total strain energy density calculations.
    Type of Medium: Online Resource
    ISSN: 2673-3161
    Language: English
    Publisher: MDPI AG
    Publication Date: 2023
    detail.hit.zdb_id: 3001011-1
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  • 2
    Online Resource
    Online Resource
    Elsevier BV ; 2023
    In:  Procedia Structural Integrity Vol. 43 ( 2023), p. 240-245
    In: Procedia Structural Integrity, Elsevier BV, Vol. 43 ( 2023), p. 240-245
    Type of Medium: Online Resource
    ISSN: 2452-3216
    Language: English
    Publisher: Elsevier BV
    Publication Date: 2023
    detail.hit.zdb_id: 2880750-9
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  • 3
    Online Resource
    Online Resource
    AGHU University of Science and Technology Press ; 2021
    In:  Journal of Casting & Materials Engineering Vol. 5, No. 4 ( 2021-11-24), p. 84-88
    In: Journal of Casting & Materials Engineering, AGHU University of Science and Technology Press, Vol. 5, No. 4 ( 2021-11-24), p. 84-88
    Abstract: In components, crack propagation is subjected to crack-closure-mechanisms which affect the build-up of the relevant threshold stress intensity factor range during cyclic loading. As structural parts are exposed to service loads incorporating a variety of load ratios, a significant change of the long-crack threshold value occurs, leading to a severe stress ratio dependency of crack-closure-mechanisms. Thus, an extensive number of crack propagation experiments is required to gain statistically proven fracture mechanical parameters describing the build-up of closure effects as crack growth resistance curves.The article presents a generalized dataset to assess the formation of crack-closure-mechanisms of cast steel G21Mn5+N. Numerous crack propagation experiments utilizing single edge notched bending (SENB) sample geometries are conducted, incorporating alternate to tumescent stress ratios. The statistically derived, generalized crack growth resistance curve features the impact of closure effects on the crack propagation rate in a uniform manner. To extend the dataset to arbitrary load ratios, the long-crack threshold approach according to Newman is invoked. The generalized dataset for the cast steel G21Mn5+N is validated by analytical fracture mechanical calculations for the utilized SENB-sample geometries. Incorporating a modified NASGRO equation, a sound correlation of analytical and experimental crack propagation rates is observed. Moreover, the derived master crack propagation resistance curve is implemented as a user-defined script into a numerical crack growth calculation tool and supports a local, node--based numerical crack propagation study as demonstrated for a representative SENB-sample. Concluding, the derived dataset facilitates the calculation of fatigue life of crack-affected cast steel components subjected to arbitrary stress ratios.
    Type of Medium: Online Resource
    ISSN: 2543-9901 , 2543-9901
    Language: Unknown
    Publisher: AGHU University of Science and Technology Press
    Publication Date: 2021
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  • 4
    Online Resource
    Online Resource
    Elsevier BV ; 2022
    In:  International Journal of Fatigue Vol. 163 ( 2022-10), p. 107082-
    In: International Journal of Fatigue, Elsevier BV, Vol. 163 ( 2022-10), p. 107082-
    Type of Medium: Online Resource
    ISSN: 0142-1123
    Language: English
    Publisher: Elsevier BV
    Publication Date: 2022
    detail.hit.zdb_id: 2013377-7
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  • 5
    In: Metals, MDPI AG, Vol. 9, No. 10 ( 2019-10-11), p. 1097-
    Abstract: Shrinkage porosities and non-metallic inclusions are common manufacturing process based defects that are present within cast materials. Conventional fatigue design recommendations, such as the FKM guideline (“Forschungskuratorium Maschinenbau”), therefore propose general safety factors for the fatigue assessment of cast structures. In fact, these factors mostly lead to oversized components and do not facilitate a lightweight design process. In this work, the effect of shrinkage porosities on the fatigue strength of defect-afflicted large-scale specimens manufactured from the cast steel G21Mn5 is studied by means of a notch stress intensity factor-based (NSIF-based) generalized Kitagawa diagram. Additionally, the mean stress sensitivity of the material is taken into account and establishes a load stress ratio enhanced diagram. Thereby, the fatigue assessment approach is performed by utilizing the defects sizes taken either from the fracture surface of the tested specimens or from non-destructive X-ray investigations. Additionally, a numerical algorithm invoking cellular automata, which enables the generation of artificial defects, is presented. Conclusively, a comparison to the results of the experimental investigations reveals a sound agreement to the generated spatial pore geometries. To sum up, the generalized Kitagawa diagram, as well as a concept utilizing artificially generated defects, is capable of assessing the local fatigue limit of cast steel G21Mn5 components and features the mapping of imperfection grades to their corresponding fatigue strength limit.
    Type of Medium: Online Resource
    ISSN: 2075-4701
    Language: English
    Publisher: MDPI AG
    Publication Date: 2019
    detail.hit.zdb_id: 2662252-X
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  • 6
    Online Resource
    Online Resource
    MDPI AG ; 2023
    In:  Materials Vol. 16, No. 13 ( 2023-06-30), p. 4755-
    In: Materials, MDPI AG, Vol. 16, No. 13 ( 2023-06-30), p. 4755-
    Abstract: The endurance limit of structural mechanical components is affected by the residual stress state, which depends strongly on the manufacturing process. In general, compressive residual stresses tend to result in an increased fatigue strength. Post-manufacturing processes such as shot peening or vibratory finishing may achieve such a compressive residual stress state. But within complex components, manufacturing-process-based imperfections severely limit the fatigue strength. Thus, the interactions of imperfections, residual stress state and material strength are key aspects in fatigue design. In this work, cast steel and aluminium alloys are investigated, each of them in vibratory finished and polished surface condition. A layer-based fatigue assessment concept is extended towards stable effective mean stress state considering the elastic–plastic material behaviour. Murakami’s concept was applied to incorporate the effect of hardness change and residual stress state. Residual stress relaxation is determined by elastic–plastic simulations invoking a combined hardening model. If the effective stress ratio within the local layer-based fatigue strength is evaluated as critical distance value, a sound calculation of fatigue strength can be achieved. Summing up, the layer-based fatigue strength design is extended and features an enhanced understanding of the effective stabilized mean stress state during cyclic loading.
    Type of Medium: Online Resource
    ISSN: 1996-1944
    Language: English
    Publisher: MDPI AG
    Publication Date: 2023
    detail.hit.zdb_id: 2487261-1
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  • 7
    In: Applied Sciences, MDPI AG, Vol. 13, No. 4 ( 2023-02-09), p. 2247-
    Abstract: The fatigue strength of structural components is strongly affected by notches and imperfections. Both can be treated similarly, as local notch fatigue strength methods can also be applied to interior defects. Even though Murakami’s √area approach is commonly used in the threshold-based fatigue design of single imperfections, advanced concepts such as the Theory of Critical Distances (TCD), Notch Stress Intensity Factors (N-SIF), or Elastic Strain Energy Density (ESED) methods provide additional insight into the local fatigue strength distribution of irregularly shaped defects under varying uniaxial load vectors. The latter methods are based on the evaluation of the elastic stress field in the vicinity of the notch for each single load vector. Thus, this work provides numerically efficient methods to assess the local fatigue strength by means of TCD, N-SIF, and ESED, targeting the minimization of the required load case count, optimization of stress field evaluation data points, and utilization of multi-processing. Furthermore, the Peak Stress Method (PSM) is adapted for large opening angles, as in the case of globular defects. In detail, two numerical strategies are devised and comprehensively evaluated, either using a sub-case-based stress evaluation of the defect vicinity with an unchanged mesh pattern and varying load vector on the exterior model region with optimized load angle stepping or by the invocation of stress and strain tensor transformation equations to derive load angle-dependent result superposition while leaving the initial mesh unaltered. Both methods provide numerically efficient fatigue post-processing, as the mesh in the evaluated defect region is retained for varying load vectors. The key functions of the fatigue strength assessment, such as the evaluation of appropriate planar notch radius and determination of notch opening angle for the discretized imperfections, are presented. Although the presented numerical methods apply to planar simulation studies, the basic methodology can be easily expanded toward spatial fatigue assessment.
    Type of Medium: Online Resource
    ISSN: 2076-3417
    Language: English
    Publisher: MDPI AG
    Publication Date: 2023
    detail.hit.zdb_id: 2704225-X
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  • 8
    Online Resource
    Online Resource
    MDPI AG ; 2023
    In:  Applied Sciences Vol. 13, No. 6 ( 2023-03-15), p. 3768-
    In: Applied Sciences, MDPI AG, Vol. 13, No. 6 ( 2023-03-15), p. 3768-
    Abstract: Cast steel components are affected by manufacturing process-based imperfections, which severely limit their fatigue strength. In this work, the linear-elastic strain energy density concept is applied to assess the fatigue behaviour of bulk defect-afflicted components made of high-strength cast steel alloy G12MnMo7-4+QT. Based on analytical calculations, an energy-based design limit curve is derived which merges experimental results of notched and unnotched small–scale specimens into a statistically proven scatter band. The stress ratio dependency is also investigated. Moreover, a numerical methodology is introduced, which facilitates the energy-based fatigue assessment of complex spatial imperfections on the basis of radiographs. Validation of the established framework utilizing experimental results of defect-afflicted large–scale specimens leads to sound accordance of numerically and experimentally derived fatigue strength values, showing an average deviation of about only eight percent.
    Type of Medium: Online Resource
    ISSN: 2076-3417
    Language: English
    Publisher: MDPI AG
    Publication Date: 2023
    detail.hit.zdb_id: 2704225-X
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  • 9
    Online Resource
    Online Resource
    EDP Sciences ; 2018
    In:  MATEC Web of Conferences Vol. 165 ( 2018), p. 14010-
    In: MATEC Web of Conferences, EDP Sciences, Vol. 165 ( 2018), p. 14010-
    Abstract: An accurate assessment of cast steel components including cast imperfections minimizes production rejects and moreover facilitates lightweight design. In order to improve the fatigue assessment of cast steel structures exhibiting macroscopic imperfections, a generalized Kitagawa diagram based on the linear elastic fracture mechanical theory is presented. Therefore, single-edge-notch-bending crack propagation tests as well as extensive fatigue tests utilizing un-notched base material specimens are conducted. Both the stress intensity factor threshold range and the plain material fatigue limit act as basis to set-up the generalized Kitagawa diagram. In addition, fatigue tests under rotating bending as well as axial loading using round V-notched specimens with varying opening angles are additionally conducted for validation. It was observed that the notch-stress-intensity-factor (NSIF) calculation based on El-Haddad’s material length leads to slightly non-conservative designs for this cast material. But if the intrinsic material length is calculated by Neuber’s stress averaging approach or Peterson’s microstructural length instead, the presented NSIF-based fatigue assessment reveals a sound comparability to the experimentally determined fatigue reference strength. Summing up, the presented generalized Kitagawa diagram provides a feasible engineering-applicable fatigue assessment tool incorporating varying imperfection opening angles and load conditions for G21Mn5 cast steel.
    Type of Medium: Online Resource
    ISSN: 2261-236X
    Language: English
    Publisher: EDP Sciences
    Publication Date: 2018
    detail.hit.zdb_id: 2673602-0
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  • 10
    Online Resource
    Online Resource
    Inderscience Publishers ; 2011
    In:  International Journal of Microstructure and Materials Properties Vol. 6, No. 1/2 ( 2011), p. 105-
    In: International Journal of Microstructure and Materials Properties, Inderscience Publishers, Vol. 6, No. 1/2 ( 2011), p. 105-
    Type of Medium: Online Resource
    ISSN: 1741-8410 , 1741-8429
    Language: English
    Publisher: Inderscience Publishers
    Publication Date: 2011
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