0
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

Professor
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.

Copyright © 2019 by ASME
Your Session has timed out. Please sign back in to continue.

References

Pfitzner, M. , and Waschka, W. , 2000, “ Development of an Aeroengine Secondary Air System Employing Vortex Reducers,” 22nd ICAS Congress, Harogate, UK, Aug. 28–Sept. 1, pp. 511.1–511.10. http://www.icas.org/ICAS_ARCHIVE/ICAS2000/PAPERS/ICA0511.PDF
Yao, W. , 2003, Structural Fatigue Life Analysis, National Defense Industry Press, Beijing, China.
Nishioka, K. , and Hirakawa, K. , 1969, “ Fundamental Investigations of Fretting Fatigue—Part 5: The Effect of Relative Slip Amplitude,” Bull. JSME, 34(268), pp. 2068–2073. [CrossRef]
Singh, A. , 2003, “ Development and Validation of an S-N Based Two Phase Bending Fatigue Life Prediction Model,” ASME J. Mech. Des., 125(3), pp. 540–544. [CrossRef]
Topper, T. H. , Wetzel, R. M. , and Morrow, J. D. , 1969, “ Neuber's Rule Applied to Fatigue of Notched Specimens,” J. Mater., 4(1), pp. 200–209. https://ci.nii.ac.jp/naid/10020994501/
Dowling, N. E. , Brose, W. R. , and Wilson, W. K. , 1977, “ Notched Member Fatigue Life Prediction by the Local Strain Approach,” Adv. Eng. Fatigue Complex Loading, 6, pp. 55–84.
Morrow, J. D. , 1965, “ Cyclic Plastic Strain Energy and Fatigue of Metals,” ASTM International, West Conshohocken, PA, Standard no. STP378.
Manson, S. S. , 1953, “ Behavior of Materials Under Conditions of Thermal Stress,” NACA Lewis Flight Propulsion Lab., Cleveland, OH, Report No. NACA-TN-2933. https://ntrs.nasa.gov/search.jsp?R=19930092197
Coffin, L. F. J. , 1953, A Study of the Effect of Cyclic Thermal Stresses on a Ductile Metal, Knolls Atomic Power Laboratory, New York.
Navarro, C. , Muñoz, S. , and Domínguez, J. , 2008, “ On the Use of Multiaxial Fatigue Criteria for Fretting Fatigue Life Assessment,” Int. J. Fatigue, 30(1), pp. 32–44. [CrossRef]
Golden, P. J. , and Grandt, A. F., Jr. , 2004, “ Fracture Mechanics Based Fretting Fatigue Life Predictions in Ti–6Al–4V,” Eng. Fract. Mech., 71(15), pp. 2229–2243. [CrossRef]
Szolwinski, M. P. , and Farris, T. N. , 1996, “ Mechanics of Fretting Fatigue Crack Formation,” Wear, 198(1–2), pp. 93–107. [CrossRef]
Smith, K. N. , Watson, P. , and Topper, T. H. , 1970, “ A Stress-Strain Function for the Fatigue of Metals,” J. Mater., 5(4), pp. 767–778. https://ci.nii.ac.jp/naid/10027461014/
Fatemi, A. , and Socie, D. F. , 1988, “ A Critical Plane Approach to Multiaxial Fatigue Damage Including Out-of-Phase Loading,” Fatigue Fract. Eng. Mater. Struct., 11(3), pp. 149–165. [CrossRef]
McDiarmid, D. L. , 2007, “ A General Criterion for High Cycle Multiaxial Fatigue Failure,” Fatigue Fract. Eng. Mater. Struct., 14(4), pp. 429–453. [CrossRef]
Findley, W. N. , 1958, “ A Theory for the Effect of Mean Stress on Fatigue of Metals Under Combined Torsion and Axial Load or Bending,” Engineering Materials Research Laboratory, Division of Engineering, Brown University, Providence, RI.
Araújo, J. A. , and Nowell, D. , 2002, “ The Effect of Rapidly Varying Contact Stress Fields on Fretting Fatigue,” Int. J. Fatigue, 24(7), pp. 763–775. [CrossRef]
Hotait, M. A. , and Kahraman, A. , 2013, “ Estimation of Bending Fatigue Life of Hypoid Gears Using a Multiaxial Fatigue Criterion,” ASME J. Mech. Des., 135(10), p. 101005. [CrossRef]
Ruiz, C. , Boddington, P. H. B. , and Chen, K. C. , 1984, “ An Investigation of Fatigue and Fretting in a Dovetail Joint,” Exp. Mech., 24(3), pp. 208–217. [CrossRef]
Lykins, C. D. , Mall, S. , and Jain, V. , 2000, “ An Evaluation of Parameters for Predicting Fretting Fatigue Crack Initiation,” Int. J. Fatigue, 22(8), pp. 703–716. [CrossRef]
Vidner, J. , and Leidich, E. , 2007, “ Enhanced Ruiz Criterion for the Evaluation of Crack Initiation in Contact Subjected to Fretting Fatigue,” Int. J. Fatigue, 29(9–11), pp. 2040–2049. [CrossRef]
Lemaitre, J. , and Chaboche, J. L. , 1990, Mechanics of Solid Materials, Cambridge University Press, Cambridge, UK.
Chaudonneret, M. , 1993, “ A Simple and Efficient Multiaxial Fatigue Damage Model for Engineering Applications of Macro-Crack Initiation,” ASME J. Eng. Mater. Technol., 115(4), pp. 373–379. [CrossRef]
Zhang, T. , McHugh, P. E. , and Leen, S. B. , 2012, “ Finite Element Implementation of Multiaxial Continuum Damage Mechanics for Plain and Fretting Fatigue,” Int. J. Fatigue, 44(2), pp. 260–272. [CrossRef]
Neuber, H. , 1958, Theory of Notch Stresses: Principles of Exact Calculation of Strength With Reference to Structural Form and Material, 2nd ed., Springer-Verlag, Berlin.
Peterson, R. E. , 1959, Metal Fatigue: Notch-Sensitivity, McGraw-Hill, New York.
Baldwin, J. D. , and Thacker, J. G. , 1995, “ A Strain-Based Fatigue Reliability Analysis Method,” ASME J. Mech. Des., 117(2A), pp. 229–234. [CrossRef]
Qylafku, G. , Azari, Z. , and Gjonaj, M. , 1998, “ On the Fatigue Failure and Life Prediction for Notched Specimens,” Mater. Sci., 34(5), pp. 604–618. [CrossRef]
Susmel, L. , 2008, “ The Theory of Critical Distances: A Review of Its Applications in Fatigue,” Eng. Fract. Mech., 75(7), pp. 1706–1724. [CrossRef]
Susmel, L. , and Taylor, D. , 2010, “ An Elasto-Plastic Reformulation of the Theory of Critical Distances to Estimate Lifetime of Notched Components Failing in the Low/Medium-Cycle Fatigue Regime,” ASME J. Eng. Mater. Technol., 132(2), pp. 179–181. [CrossRef]
Leis, B. N. , 1978, “ Fatigue Life Prediction of Complex Structures,” ASME J. Mech. Des., 100(1), p. 2. [CrossRef]
Stamoulis, K. , and Giannakopoulos, A. E. , 2008, “ Size Effects on Strength, Toughness and Fatigue Crack Growth of Gradient Elastic Solids,” Int. J. Solids Struct., 45(18–19), pp. 4921–4935. [CrossRef]
Zeng, P. , Yu, X. , and Yan, Y. , 1988, “ Absolute Size Effect of Fatigue,” J. Aeronaut., 9(s1), pp. 146–149. http://www.cnki.com.cn/Article/CJFDTotal-HKXB1988S1029.htm
Draper, J. , 1999, Modern Metal Fatigue Analysis, EMAS Publishing Company, Sheffield, UK.
Socie, D. F. , Mitchell, M. R. , and Caulfield, E. M. , 1978, “ Fundamentals of Modern Fatigue Analysis,” University of Illinois, Urbana, IL, Technical Report No. 26. http://fcp.mechse.illinois.edu/fcp_report026/
Manson, S. S. , 1965, “ Fatigue: A Complex Subject—Some Simple Approximations,” Exp. Mech., 5(4), pp. 193–226. [CrossRef]
Wang, Y. , and Li, H. , 2013, “ Method for Notched Fatigue Life Prediction With Stress Gradient,” J. Aerosp. Power, 28(6), pp. 1208–1214.
Wang, Y. , and Li, H. , 2014, “ A Method for Determination of Parameters in Total Strain Life Equation,” J. Aerosp. Power, 29(4), pp. 881–886.
Morrow, J. D. , 1968, Fatigue Design Handbook (Advances in Engineering), Vol. 4, Society of Automotive Engineers, Warrendale, PA, pp. 21–29.
Walker, K. , 1970, “ The Effect of Stress Ratio During Crack Propagation and Fatigue for 2024-T3 and 7075-T6 Aluminum,” ASTM Int., 462(1), pp. 1–14.
Dowling, N. E. , 2004, “ Mean Stress Effects in Stress-Life and Strain-Life Fatigue,” SAE Paper No. 2004-01-2227.
Filippini, M. , 2000, “ Stress Gradient Calculations at Notches,” Int. J. Fatigue, 22(5), pp. 397–409. [CrossRef]
Yu, H. , and Wu, X. , 2014, Handbook of Materials Properties for Aero-Engine Design, 4th ed., Aeronautical Industry Press, Beijing, China.
Yan, M. , 2002, China Aeronautical Materials Handbook, 2nd ed., Standards Press of China, Beijing, China.

Figures

Grahic Jump Location
Fig. 1

Model of the vortex reducer

Grahic Jump Location
Fig. 2

Normalized local stress distributions of notched specimens along the normalized distance

Grahic Jump Location
Fig. 3

Normalized local stress distributions of notched specimens

Grahic Jump Location
Fig. 4

Fitting life curve of smooth specimens

Grahic Jump Location
Fig. 5

Life prediction with two sets of parameters

Grahic Jump Location
Fig. 6

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

Grahic Jump Location
Fig. 7

Stress distributions of the V-notch round bar specimens

Grahic Jump Location
Fig. 8

Stress gradient impact index m versus life 2Nf

Grahic Jump Location
Fig. 9

Life prediction of notched specimens

Grahic Jump Location
Fig. 10

Life prediction of the Incoloy 901 specimens

Grahic Jump Location
Fig. 11

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

Grahic Jump Location
Fig. 12

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

Grahic Jump Location
Fig. 13

Circumferential stress distributions of the vortex reducer and the disk

Grahic Jump Location
Fig. 14

Circumferential strain distributions of the vortex reducer and the disk

Grahic Jump Location
Fig. 15

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

Grahic Jump Location
Fig. 16

Normalized local stress distributions of the vortex reducer and notched specimens

Tables

Errata

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In