Research Papers: Design for Manufacture and the Life Cycle

Fatigue Life Prediction of Vortex Reducer Based on Stress Gradient

[+] Author and Article Information
Yanbin Luo

School of Energy and Power Engineering,
Beihang University,
Beijing 100083, China
e-mail: luoyanbin1206@buaa.edu.cn

Yanrong Wang

School of Energy and Power Engineering,
Beihang University,
Beijing 100083, China
e-mail: yrwang@buaa.edu.cn

Bo Zhong

School of Energy and Power Engineering,
Beihang University,
Beijing 100083, China
e-mail: zhongbobuaa@163.com

Jiazhe Zhao

School of Energy and Power Engineering,
Beihang University,
Beijing 100083, China
e-mail: zhaojiazhe@buaa.edu.cn

Xiaojie Zhang

School of Energy and Power Engineering,
Beihang University,
Beijing 100083, China
e-mail: zxjbuaa@buaa.edu.cn

1Corresponding author.

Contributed by the Design for Manufacturing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received June 28, 2018; final manuscript received December 1, 2018; published online January 10, 2019. Assoc. Editor: Paul Witherell.

J. Mech. Des 141(3), 031701 (Jan 10, 2019) (10 pages) Paper No: MD-18-1494; doi: 10.1115/1.4042189 History: Received June 28, 2018; Revised December 01, 2018

The effects of stress gradient and size effect on fatigue life are investigated based on the distribution of stress at the notch root of notched specimens of GH4169 alloy. The relationship between the life of notched specimens and smooth specimens is correlated by introducing the stress gradient impact coefficient, and a new life model of predicting notched specimens based on the Walker modification for the mean stress effect is established. In order to improve the prediction precision of life model with the equation parameters having a definite physical significance, the relationships among fatigue parameters, monotonic ultimate tensile strength, and reduction of area are established. Three-dimensional elastic finite element (FE) analysis of a vortex reducer is carried out to obtain the data of stress and strain for predicting its life. The results show that there is a high-stress gradient at the edge of the air holes of the vortex reducer, and it is thus a dangerous point for fatigue crack initiation. The prediction result of the vortex reducer is more reasonable if the mean stress, the stress gradient, and the size effect are considered comprehensively. The developed life model can reflect the effects of many factors well, especially the stress concentration. The life of notched specimens predicted by this model give a high estimation precision, and the prediction life data mainly fall into the scatter band of factor 2.

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Fig. 1

Model of the vortex reducer

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Fig. 2

Normalized local stress distributions of notched specimens along the normalized distance

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Fig. 3

Normalized local stress distributions of notched specimens

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Fig. 4

Fitting life curve of smooth specimens

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Fig. 5

Life prediction with two sets of parameters

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Fig. 6

Fitting life curve modified by the Walker correction factor of mean stress

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Fig. 7

Stress distributions of the V-notch round bar specimens

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Fig. 8

Stress gradient impact index m versus life 2Nf

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Fig. 9

Life prediction of notched specimens

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Fig. 10

Life prediction of the Incoloy 901 specimens

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Fig. 11

Finite element model of the combined structure of vortex reducer and disk (1/18 sector)

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Fig. 12

Finite element model of the support ring of vortex reducer (1/18 sector)

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Fig. 13

Circumferential stress distributions of the vortex reducer and the disk

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Fig. 14

Circumferential strain distributions of the vortex reducer and the disk

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Fig. 15

Normalized local stress distributions of the vortex reducer along the normalized distance

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Fig. 16

Normalized local stress distributions of the vortex reducer and notched specimens



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