Article
Chemistry, Physical
Pawel J. Romanowicz, Dariusz Smolarski, Marek S. Kozien
Summary: A new approach based on the direct spectral method is proposed for fatigue analysis of elements subjected to bimodal stress histories. The method takes into account the influence of mean compressive stresses and estimates equivalent amplitude based on existing criteria. The proposed method is demonstrated using a thrust roller bearing and is shown to accurately identify stress components and determine fatigue life.
Article
Optics
Hui Yin, Jianping Peng, Xiang Zhang, Kang Tian, Yu Zhang, Jianqiang Guo
Summary: In this study, eddy current pulsed thermography was used for quantitative closed crack detection in railway defects. The method proved to be effective in measuring closed cracks, with simulation conclusions consistent with experimental results.
Article
Engineering, Mechanical
Abdul Haseeb Afridi, Hongtao Zhu, Eduardo Tovar Camacho, Guanyu Deng, Huijun Li
Summary: Rolling contact fatigue (RCF) crack is a dominant form of damage on rail surfaces caused by repeated contact with wheels. If left untreated, RCF defects such as squats and head checks can lead to rail fractures. Accurately predicting the damage under different operational conditions is crucial. A two-stage simulation strategy was proposed, investigating the mechanisms of RCF-induced cracks on rails through dynamic FEM for wheel-rail interaction and coupled static FEM/BEM for crack growth. The study found two critical wheel positions for crack propagation during wheel approach and departure from pre-existing cracks.
ENGINEERING FAILURE ANALYSIS
(2023)
Article
Mechanics
Thairon Reis, Allan Patrick Cordeiro Dias, Auteliano Antunes Santos
Summary: This paper proposes a new method to estimate the multiaxial non-proportional elastic-plastic stress and strain time histories developed in rails due to rolling contact, and evaluates its accuracy for fatigue analysis. The method allows for the fast determination of elastic-plastic stress and strain histories, and enables material parameter and load case studies.
INTERNATIONAL JOURNAL OF SOLIDS AND STRUCTURES
(2022)
Article
Engineering, Mechanical
Bjorn Kunzelmann, Pawel Rycerz, Yilun Xu, Nagaraj K. Arakere, Amir Kadiric
Summary: This paper investigates the application of linear elastic fracture mechanics (LEFM) principles in predicting the crack propagation of rolling contact fatigue (RCF) in machine elements such as rolling bearings and gears. Experimental tests are conducted on AISI 52100 bearing steel roller specimens to measure crack propagation rates and establish crack geometry. A numerical finite element model based on LEFM methods is developed to predict stress intensity factors (SIFs) during over-rolling, considering factors such as Hertzian contact stresses, contact friction, and crack face friction. The results show that LEFM can accurately predict the growth of RCF cracks and provide insights into the dominant propagation mode and the effects of crack face friction. The findings contribute to the development of tools for predicting the remaining useful life of machine components, enhancing the reliability of mechanical systems.
INTERNATIONAL JOURNAL OF FATIGUE
(2023)
Review
Engineering, Mechanical
Jan Papuga, Adam Kal'avsky, Maxim Lutovinov, Ivona Vizkova, Slavomir Parma, Martin Nesladek
Summary: This paper establishes clear rules for evaluating experimental data for validating multiaxial fatigue strength criteria, aiming to identify and eliminate data that could lead to erroneous conclusions, hide trends, or introduce bias. Various reasons for rejecting specific data sets are provided and two appendices list accepted and rejected data sources.
INTERNATIONAL JOURNAL OF FATIGUE
(2021)
Article
Engineering, Mechanical
Srikakulapu Kiranbabu, Lutz Morsdorf, Ivan Gonzalez, Michael Koelling, Christian Bross, Dirk Ponge, Michael Herbig, David Mayweg
Summary: This study investigates the causes of white etching cracks (WECs) in wind turbine gearbox (WTGB) bearings. The results show that the presence of MnS inclusions is a key factor in the initiation of WECs in WTGB bearings.
Article
Mechanics
Yiping Wu, Chung Lun Pun, Pu Huang, Darrien Welsby, Peter Mutton, Anna Paradowska, Wenyi Yan
Summary: In heavy-haul railway systems, the high traction force in curved tracks accelerates rolling contact fatigue crack growth. However, there is limited research on the influence of creepage on this crack growth behavior. This paper proposes a numerical method to investigate non-proportional mixed-mode crack growth in the presence of severe creepage. Results show that lateral and spin creepages significantly affect the phase and magnitude of stress intensity factors, with spin creepage having a more detrimental effect.
ENGINEERING FRACTURE MECHANICS
(2023)
Article
Automation & Control Systems
Junzhen Zhu, Philip John Withers, Jianbo Wu, Feng Liu, Qiuji Yi, Zijun Wang, Gui Yun Tian
Summary: This study focuses on the application of eddy current pulsed thermography (ECPT) technology in detecting rolling contact fatigue (RCF) cracks in railway tracks. The results show that longer time slots and pulse durations can provide clearer characterization of cracks with different inclination angles, and area-based and kurtosis-based features are the most suitable and robust measures for evaluating real RCF cracks.
IEEE TRANSACTIONS ON INDUSTRIAL INFORMATICS
(2021)
Article
Engineering, Mechanical
Steven J. Lorenz, Farshid Sadeghi, Akshat Sharma, Chinpei Wang, Ben Wang
Summary: This work presents an improved probabilistic continuum damage mechanics (CDM) finite element (FE) model to estimate rolling contact fatigue (RCF) life of critical tribological components. The model considers multiple failure criteria and describes critical damage material parameters using a distribution. Forty unique material microstructure models were created to capture the random pathways for crack growth. The results demonstrate that the Fatemi-Socie and shear stress reversal failure criteria compared favorably to Lundberg-Palmgren theory.
TRIBOLOGY INTERNATIONAL
(2023)
Article
Mechanics
B. Rodriguez-Arana, A. Bergara, N. Gil-Negrete, J. Nieto
Summary: This study investigates the influence of considering wheel-rail contact creepages on fatigue crack growth rates caused by Rolling Contact Fatigue (RCF). The developed methodology, which incorporates the FASTSIM algorithm and XFEM, has been validated and the results show that considering contact creepages is necessary for fatigue crack growth analysis.
ENGINEERING FRACTURE MECHANICS
(2022)
Article
Engineering, Mechanical
Lanwen Wang, Xuanyu Sheng, Zhimeng Yao, Jianbin Luo
Summary: A coupled mechanical-diffusion peridynamic(PD) fatigue model is proposed to simulate hydrogen-assisted white etching cracks in bearing steel under rolling contact fatigue. The PD model of microstructural alteration based on the dislocation-assisted carbon migration theory is used to simulate the formation of dark etching region and white etching area, and its validity is demonstrated by experimental observations. The PD stress-assisted diffusion model is utilized to simulate the diffusion of hydrogen, and then the polycrystalline fatigue simulation is implemented to analyze the evolution of hydrogen-assisted white etching cracks. The effects of contact conditions and internal inclusions on the evolution of white etching cracks are also discussed in this study.
INTERNATIONAL JOURNAL OF FATIGUE
(2023)
Article
Engineering, Mechanical
Zhida Ren, Beizhi Li, Qingzhi Zhou
Summary: This study investigates the damage caused by rolling contact fatigue (RCF) and the propagation of fatigue cracks in bearings. Through experiments and statistical analysis, the three-dimensional geometry of RCF cracks was characterized and reconstructed. Finite element analysis and numerical studies were conducted to reveal the crack propagation behavior and mechanisms on the contact surface and subsurface.
Article
Materials Science, Multidisciplinary
Haoran Li, Jiadong Wang, Juncheng Wang, Ming Hu, Yan Peng
Summary: This paper proposes a life prediction model for multiaxial high-cycle fatigue based on twin-shear unified yield criterion, considering the effect of equivalent shear amplitude and mean stress. The model is compared with experimental data for aluminum alloy LY12CZ and carbon structural steel SM45C, showing good agreement. Additionally, comparisons with other models are made to validate its competitiveness.
Article
Engineering, Mechanical
Yun-Shuai Su, Shu-Xin Li, Feng Yu, Si-Yuan Lu, Yong-Gang Wang
Summary: This study explores the common origin of the shear band (SB) and white etching area (WEA) in bearing steel under shear plastic deformation, revealing that they can both be considered as shear localization under large plastic deformation. The study compares the microstructures of SB and WEA, providing new insights into the origin and formation mechanism of WEA, and enhancing the understanding of bearing failure under rolling contact fatigue.
INTERNATIONAL JOURNAL OF FATIGUE
(2021)
Article
Chemistry, Physical
Francesco Sausto, Luca Patriarca, Stefano Foletti, Stefano Beretta, Erica Vacchieri
Summary: This study investigated the variability introduced by coarse-grained microstructure using Crystal Plasticity Finite Element simulations and Digital Image Correlations for strain measurements, with experimental validation. The aim was to predict the statistical variability of strain concentration factors and support component design.
Article
Materials Science, Multidisciplinary
Marco Pisati, Marco Giuseppe Corneo, Stefano Beretta, Emanuele Riva, Francesco Braghin, Stefano Foletti
Summary: This study investigates the dynamic response of lattice structures, specifically Face-Centered-Cubic (FCC) and Diamond lattice-based structures, under resonant conditions and random vibrations. Finite Element (FE) models are used to estimate structural integrity and predict fatigue life, with good results in both resonant and random vibration scenarios.
Article
Mechanics
L. Barricelli, S. Beretta
Summary: Fatigue properties of parts built by Additive Manufacturing are influenced by process induced defects and complex surface morphology, with surface valleys and micro-notches acting as crack initiation sites. This study aims to understand how the surface complexity of L-PBF AlSi10Mg specimens in as-built condition affects fatigue behavior, with results indicating that traditional shielding factor can predict average geometric factor value for surface notches in L-PBF surfaces.
ENGINEERING FRACTURE MECHANICS
(2021)
Article
Engineering, Mechanical
Matteo Gavazzoni, Marco Pisati, Stefano Beretta, Stefano Foletti
Summary: This paper focuses on numerically predicting the multiaxial static strength of lattice structures made of AlSi10Mg aluminum alloy printed with Selective Laser Melting. The Gurson-Tveergard-Needleman damage model is used to predict failure in numerical simulations, which is validated through static tests. The study combines the damage model with computational micromechanics to investigate the effective multiaxial strength of lattice material.
FATIGUE & FRACTURE OF ENGINEERING MATERIALS & STRUCTURES
(2021)
Article
Engineering, Multidisciplinary
Prasad Mahendra Rao, Stefano Foletti, Luca Bonaiti, Franco Concli, Carlo Gorla, Stefano Beretta
Summary: This paper focuses on the assessment of Mode III crack propagation under Rolling Contact Fatigue (RCF) in integrated thin-rimmed planetary gears and its integrated bearings. It also presents the design and development of a test gearbox for full-scale testing. The research is part of the IDERPLANE project which aims to address the concern of high RCF in planetary gear bearings in aerospace applications.
FORSCHUNG IM INGENIEURWESEN-ENGINEERING RESEARCH
(2022)
Article
Materials Science, Multidisciplinary
Matteo Gavazzoni, Stefano Foletti, Damiano Pasini
Summary: This paper investigates the cyclic response of soft cellular materials undergoing repeated local instabilities, focusing on the coupling between material and geometric non-linearities and defects induced by 3D printing. Experimental and numerical analyses reveal that the activation of local buckling combined with material non-linearities leads to perturbations in lattice geometry and subsequent softening, reducing the tangent modulus and cyclic stresses. A theoretical model is presented to obtain stress bound estimates of the stabilized response under cycling loading, offering design guidelines for 3D printed soft metamaterials.
JOURNAL OF THE MECHANICS AND PHYSICS OF SOLIDS
(2022)
Article
Mechanics
L. Boniotti, S. Dancette, M. Gavazzoni, J. Lachambre, J. Y. Buffiere, S. Foletti
Summary: This study investigates the fatigue behavior of two strut-based topologies of micro-lattice materials, with a specific focus on the damage evolution during fatigue life. Experimental tests are conducted on micro-lattice specimens under different stress ratios, and a methodological approach for metal foams is adopted to analyze the test results and characterize the fatigue damage evolution. The results show that the finite element model based on the manufactured geometry and the use of a suitable multiaxial fatigue criterion are effective in predicting the location of fatigue failure.
ENGINEERING FRACTURE MECHANICS
(2022)
Article
Materials Science, Multidisciplinary
Francesco Sausto, Christian Tezzele, Stefano Beretta
Summary: The space and aerospace industries are gradually adopting Additive Manufacturing. A study comparing the fatigue performances of an additively manufactured AlSi10Mg material in different surface states found that residual stresses play a crucial role in determining fatigue properties, emphasizing the need for such approaches in the design phase.
Article
Engineering, Mechanical
F. Sausto, S. Romano, L. Patriarca, S. Miccoli, S. Beretta
Summary: The metal additive manufacturing (AM) technology offers the possibility of obtaining optimized components with reduced weight in the space and aero-nautic industries. However, this manufacturing technique often leads to internal defects, poor surface quality, and process-induced residual stresses, which greatly affect the fatigue performance and reproducibility of AMed parts. A probabilistic finite element post-processor called ProFACE was developed to assess the fatigue strength and critical locations of complex components with process-induced defects. It has been successfully used to predict the fatigue life of AlSi10Mg components and explore the variability of significant parameters affecting the fatigue strength.
INTERNATIONAL JOURNAL OF FATIGUE
(2022)
Article
Engineering, Mechanical
L. Barricelli, L. Patriarca, A. du Plessis, S. Beretta
Summary: The fatigue behavior of Laser-Powder Bed Fusion (L-PBF) produced parts is influenced by the surface morphology, which depends on the relative orientation between the surface and the build direction. This study focuses on investigating the factors that correlate with the fatigue performance of L-PBF Ti6Al4V specimens in different orientations. A Fracture Mechanics-based model, using measurable roughness parameters, is employed to predict the fatigue properties. The results show that the predicted stress-life curves are accurate when considering the maximum profile depth and the shielding factor, taking into account the effect of surface orientation.
INTERNATIONAL JOURNAL OF FATIGUE
(2023)
Article
Engineering, Mechanical
S. Romano, E. Peradotto, S. Beretta, D. Ugues, L. Barricelli, G. Maculotti, L. Patriarca, G. Genta
Summary: This research aims to develop a model that can robustly correlate parameters obtained through non-destructive measurements with the fatigue strength of a cobalt-chrome alloy manufactured via laser powder bed fusion (L-PBF).
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Materials Science, Multidisciplinary
A. Lo Conte, F. Bassi, S. Beretta, S. Foletti, M. E. Cristea
Summary: This article addresses the lack of standard codes for dealing with interactions between creep and fatigue and introduces a methodology for predicting initial crack growth in creep-fatigue conditions. The methodology takes into account small-scale creep, providing a more accurate assessment of creep-fatigue crack propagation.
MATERIALS AT HIGH TEMPERATURES
(2022)
Article
Mathematics, Interdisciplinary Applications
Matteo Gavazzoni, Nicola Ferro, Simona Perotto, Stefano Foletti
Summary: This paper presents a new algorithm for designing lightweight cellular materials with desired properties in a multi-physics context. It specifically focuses on thermo-elastic settings and promotes the design of unit cells with both isotropic and anisotropic behaviors in terms of mechanical and thermal requirements. The proposed algorithm extends the microSIMPATY algorithm to a thermo-elastic framework while preserving all the advantages of the reference design methodology. The resulting layouts exhibit unconventional topologies and sharp contours, reducing the need for post-processing before manufacturing. These new cellular materials demonstrate excellent thermo-elastic properties and sometimes outperform the current choices in engineering practice.
MATHEMATICAL AND COMPUTATIONAL APPLICATIONS
(2022)
Article
Engineering, Mechanical
F. Sausto, G. Marchese, E. Bassini, M. Calandri, S. Biamino, D. Ugues, S. Foletti, S. Beretta
Summary: Additive manufacturing shows promise for producing components for internal combustion engines, but issues such as poor surface quality, internal defects, and anisotropic mechanical behavior can impact fatigue strength. The study investigates the influence of building direction on component performance and crack propagation mechanisms.
FATIGUE & FRACTURE OF ENGINEERING MATERIALS & STRUCTURES
(2021)
Article
Engineering, Mechanical
Miloslav Kepka, Miloslav Kepka Jr, Radovan Minich
Summary: This paper focuses on the fatigue life evaluation of the bodywork of a new articulated electric (battery) bus. The findings resulted in recommendations to improve the operational reliability of a particular vehicle and provided challenges for future research.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
T. Dusautoir, B. Berthel, S. Fouvry, P. Matzen, K-D. Meck
Summary: This study investigates the impact of post-processing treatments on the fatigue limit of additive manufactured Ti-6Al-4V under stress gradients, with a focus on surface integrity.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Zhuofan Xia, Di Wu, Xiaochen Zhang, Jianqiu Wang, En -Hou Han
Summary: The study reveals the surface-initiated rolling contact fatigue (RCF) failure mechanism under heavy load and initial high roughness surface. The results indicate that precursor of collapsed morphology and nanocrystalline layer are the main factors causing lower RCF life with high roughness compared to low roughness surfaces. The spalling failure initiating from low roughness surface under heavy load is strongly dependent on surface plastic deformation.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Daniel Gren, Knut Andreas Meyer
Summary: Rolling contact loading can cause plastic deformation and fatigue cracks. Current rail standards do not consider the effect of plasticity on mechanical behavior. This study proposes a new method for evaluating the fatigue life of deformed material and finds that superimposed compressive axial loads can increase fatigue life.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
R. Kumar, S. Sanyal, J. Bhagyaraj, E. Hari Krishna, S. Mukherjee, K. Prasad, S. Mandal
Summary: This study investigates the thermomechanical fatigue (TMF) behavior of Timetal 834 alloy under different loading conditions. The results show that the alloy exhibits different cyclic hardening and softening responses at different strain amplitudes. The strain amplitude and phase angle have significant effects on the TMF life.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Kai Donnerbauer, Tobias Bill, Peter Starke, Ruth Acosta, Bharath Yerrapa, Christian Boller, Klaus Heckmann, Frank Walther
Summary: Given the aging of nuclear power plants, it is important to develop methods for evaluating the integrity of components and structures in nuclear engineering. Suitable nondestructive testing methods can detect material degradation and determine its fatigue life. This study utilized various NDT parameters and scanning electron microscopic methods to explore the relationship between microstructure evolution and NDT data.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Liuyong He, Jiang Zheng, Tianjiao Li, Houkun Zhou, Lihong Xia, Bin Jiang
Summary: This study quantitatively analyzed the effects of precipitates on the deformation mode, cracking mode, and mechanical behavior of WE54 magnesium alloy during low-cycle fatigue. It was found that precipitates promoted the activation of dislocation slip and suppressed the activation of twinning, affecting the cracking mode and mechanical behavior.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Xiangkang Zeng, Conghui Zhang, Wenguang Zhu, Mingliang Zhu, Tongguang Zhai, Xiaomei He, Kangkai Song, Zhuohang Xie
Summary: The cyclic deformation behaviors and damage mechanisms of pure Zr were investigated. The cyclic stress response was mainly influenced by substructure evolutions. Prismatic < a > dislocation slip was identified as the dominant deformation mechanism. Fatigue damage was not only influenced by the initial texture, but also other factors.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Jingyu Yang, Bingbing Li, Yiming Zheng, Gang Chen, Xu Chen
Summary: Heat treatment is used to improve the low-cycle fatigue performance of additive manufactured 316LN stainless steel. The heat-treated material demonstrates initially cyclic hardening followed by softening behavior, and shows a stronger resistance to crack propagation compared to the as-built material, resulting in a longer fatigue life.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Lang Zou, Dongfang Zeng, Xiong Chen, Jun Li, Hai Zhao, Liantao Lu
Summary: This study investigates the competitive relationship between fretting fatigue and plain fatigue in press-fitted railway axles. By changing the depth of the stress relief groove, the plain fatigue limit and fretting fatigue strength were tested. Detailed information was gathered, and an evaluation methodology integrating finite element simulation and the Modified Wohler Curve Method was established. The study concludes that the optimal groove depth, which balances the anti-fatigue capabilities, depends on the number of test cycles.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Davide Leonetti, Koji Kinoshita, Yukina Takai, Alain Nussbaumer
Summary: This paper investigates the fatigue behavior of non-load-carrying transverse welded steel attachments, including fatigue crack monitoring and fracture surface analysis under constant and variable amplitude loading. A procedure is proposed to obtain a Markov transition matrix based on the measured strain signal and to randomly resample the stress history for variable amplitude fatigue tests.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Zhe Zhang, Bing Yang, Yuedong Wang, Shoune Xiao
Summary: This paper presents a method for designing fatigue life prediction models with small sample sizes by handling limited sample data. The method integrates the equivalent structural stress method with the maximum likelihood estimation method and adds reliability verification, resulting in enhanced goodness of fit, stability, and optimized sample quantity.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Cooper K. Hansen, Gary F. Whelan, Jacob D. Hochhalter
Summary: This paper presents a method to address the computational demand issue of computing FIPs using CPFEM by developing an interpretable machine learning model. Genetic programming is used to evolve interpretable expressions of FIPs from microstructure features, and these models can serve as efficient substitutes for CPFEM and be easily integrated into engineering workflows.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Luca Susmel
Summary: This paper discusses the problem of estimating notch fatigue limits using machine learning. The results show that machine learning is a promising approach for designing notched components against fatigue. The accuracy in estimating the fatigue limit can be increased by increasing the size and quality of the calibration dataset, as well as including additional input features.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
Article
Engineering, Mechanical
Kefeng Gao, Guoqi Tan, Yanyan Liu, Qiang Wang, Qian Tang, Xuegang Wang, Qiqiang Duan, Zengqian Liu, Zhe Yi, Zhefeng Zhang
Summary: Bioinspired architectures have significant effects on material enhancement. This study investigates the fatigue properties of bioinspired ceramic-polymer composites and natural nacre, revealing the close relationship between architectural types, orientations, fatigue performance, and damage mechanisms.
INTERNATIONAL JOURNAL OF FATIGUE
(2024)
