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Fatigue Strength of Machines and Systems
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Fatigue Strength of Machines and Systems

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: closed (10 November 2024) | Viewed by 13015

Special Issue Editors

Dr. Przemysław Strzelecki

E-Mail Website
Guest Editor
Bydgoszcz University of Science and Technology, Bydgoszcz, Poland
Interests: fatigue; S-N curve; analytical methods; Weibull distribution; fatigue reliability
Special Issues, Collections and Topics in MDPI journals
Dr. Michał Stopel

E-Mail Website
Guest Editor
Bydgoszcz University of Technology and Life Sciences
Interests: Numerical methods in mechanical engineering, Finite Element Method, Dynamic loads, Crash tests, Road safety, Unmanned Aerial Systems
Special Issues, Collections and Topics in MDPI journals
Dr. Maciej Kotyk

E-Mail Website
Guest Editor
Bydgoszcz University of Technology and Life Sciences
Interests: fracture mechanics, experimental analysis, reduced temperatures
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The fatigue properties were investigated since XIX ages. Many researchers, from that time up today, tested and developed theories about it, but still occurs catastrophes caused by fatigue crack. To prevent fatigue crack different models are used. To use any of them it must be known the fatigue properties of the material, which will be used. These properties are specified by various constants. Many models have been developed to estimate the material’s constants from tensile tests or hardness measures. But these methods can lead to a large error. Especially, this could be happened for new material or using new heat treatment or plastic deformation. That is why it is important to correlate the fatigue properties of metal with elements of machine or system.

We invite researchers to contribute to the Special Issue on Fatigue Strength of Machines and Systems, which is intended to present structure, mechanical and fatigue or fracture properties of materials of structure.

Dr. Przemysław Strzelecki
Dr. Michał Stopel
Dr. Maciej Kotyk
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • fatigue
  • damage mechanics
  • short and long crack growth
  • structural integrity
  • crystal structure
  • fractography
  • heat treatment
  • plastic deformation
  • failure analysis

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Published Papers (10 papers)

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Editorial

Jump to: Research

3 pages, 160 KiB  
Editorial
Fatigue Strength of Machines and Systems
by Przemysław Strzelecki, Michał Stopel and Maciej Kotyk
Appl. Sci. 2025, 15(8), 4510; https://doi.org/10.3390/app15084510 - 19 Apr 2025
Viewed by 136
Abstract
Fatigue properties have been a topic of investigation since the nineteenth century [...] Full article
(This article belongs to the Special Issue Fatigue Strength of Machines and Systems)

Research

Jump to: Editorial

29 pages, 15135 KiB  
Article
Fatigue Analysis of 3D-Printed Materials for Temporary Reconstructions on Dental Implants—A Pilot Study
by Adam Nowicki, Karina Krawiec, Karolina Osypko, Adam Kurzawa, Mateusz Stachowicz, Piotr Kotowski and Dariusz Pyka
Appl. Sci. 2025, 15(6), 3212; https://doi.org/10.3390/app15063212 - 15 Mar 2025
Viewed by 710
Abstract
The rapid development of 3D printing technology has enabled its application in many fields, including dentistry. One of the key applications is temporary prosthetic restorations on dental implants, used during the osteointegration process. These restorations provide functionality and aesthetics, but their durability under [...] Read more.
The rapid development of 3D printing technology has enabled its application in many fields, including dentistry. One of the key applications is temporary prosthetic restorations on dental implants, used during the osteointegration process. These restorations provide functionality and aesthetics, but their durability under oral conditions exposed to dynamic loads remains a challenge. This pilot study evaluated the thermal expansion and fatigue resistance of three commercially available photopolymer materials used in 3D printing: NextDent Denture 3D, NextDent C&B MFH Bleach, and Graphy TC-80DP. Thermal expansion and dimensional stability analyses were performed on samples subjected to cyclic heating and cooling. Fatigue tests were designed to evaluate the behaviour of the materials under repetitive mechanical loads mimicking chewing. Microscopic analyses (SEM) made it possible to identify the internal structure of the materials and their damage mechanisms. The results showed that the tested materials have a low coefficient of thermal expansion and high dimensional stability after cyclic heating and cooling. However, significant differences were observed in their mechanical properties and fatigue resistance. The best results were obtained for the Graphy TC-80DP material, while NextDent Denture 3D showed the least resistance to cyclic loading. NextDent Denture 3D exhibited the highest thermal expansion coefficient (123.6 × 10−6/K), while Graphy TC-80DP showed the lowest (83.9 × 10−6/K), ensuring better dimensional stability. Fatigue tests revealed that Graphy TC-80DP withstood up to 675,221 cycles at 51 MPa, while NextDent Denture 3D failed after 420 cycles. SEM analysis confirmed that Graphy TC-80DP maintained structural integrity longer, while NextDent Denture 3D exhibited early crack propagation. This study fills a gap in the knowledge of the behaviour of dental materials produced with 3D printing technology under real-world conditions and provides a basis for further, more advanced research to improve their properties and patient comfort. Full article
(This article belongs to the Special Issue Fatigue Strength of Machines and Systems)
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11 pages, 823 KiB  
Article
Methodology to Determine the Stress Distribution Based on Fatigue Data with Bilinear Behavior and Its P–S–N Field and Testing Plan
by Osvaldo Monclova-Quintana, Manuel R. Piña-Monarrez, María M. Hernández-Ramos and Jesús F. Ortiz-Yáñez
Appl. Sci. 2025, 15(5), 2295; https://doi.org/10.3390/app15052295 - 21 Feb 2025
Cited by 1 | Viewed by 440
Abstract
In this paper, based on the Weibull Inverse Power Law, we present a methodology to determine the following: (1) the failure percentiles, referred to as the P–S–N field, of an S–N curve for a 42CrMo4 steel material exhibiting bilinear ( [...] Read more.
In this paper, based on the Weibull Inverse Power Law, we present a methodology to determine the following: (1) the failure percentiles, referred to as the P–S–N field, of an S–N curve for a 42CrMo4 steel material exhibiting bilinear (s1 and s2) behavior (e.g., a competence failure mode); (2) the Weibull family that characterizes the entire bilinear behavior; and (3) the zero-vibration test plan that meets the required vibration reliability index of Rt=0.97 with a reliability confidence level of CL=0.75. From the application, based on the formulated normal–Weibull relationship, we determine the failure percentiles for the normal (one, two, and three) sigma levels, as well as those failure percentiles corresponding to the capability (Cp) and ability (Cpk) indices. Finally, we present the formulation to determine the Rt index and the CL level associated with each normal percentile, along with their numerical values. Full article
(This article belongs to the Special Issue Fatigue Strength of Machines and Systems)
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18 pages, 2931 KiB  
Article
Influence of Nonstationary Processes in Drill Rigs on the Durability of Structural Elements
by Yevhen Kharchenko, Yaroslav Blikharskyy, Andriy Bilovus, Volodymyr Vira, Jacek Selejdak and Zinoviy Blikharskyy
Appl. Sci. 2024, 14(13), 5930; https://doi.org/10.3390/app14135930 - 7 Jul 2024
Viewed by 1410
Abstract
Assessing the effects that nonstationary dynamic processes have on the durability of structural elements belongs to an important trend in modern dynamics and technical diagnostics of machines. Normally, fatigue strength calculations are performed taking into account only periodically variable stresses, as steady operating [...] Read more.
Assessing the effects that nonstationary dynamic processes have on the durability of structural elements belongs to an important trend in modern dynamics and technical diagnostics of machines. Normally, fatigue strength calculations are performed taking into account only periodically variable stresses, as steady operating modes of machines are much longer in comparison with transient modes. However, a significant role in fatigue failure in machines and engineering structures is also played by nonstationary loads. This is explained by emerging intensive oscillations in the mechanical system during accelerating, braking, or changing the operation mode of a machine unit, which often lead to the accumulation of fatigue damages in the materials of parts in heavy loaded assemblies. The combination of stationary and nonstationary dynamic loads manifests itself, particularly in drilling rigs, where technological cycles include steady motion modes, starts, and stops. This paper represents a generalized mathematical model describing nonstationary processes in the lift system of a drill rig, which considers the relationship between electromagnetic processes in asynchronous motors and mechanical oscillatory phenomena, with the purpose of determining dynamic loads and stresses in structural elements of the rigs. Nonlinear physical systems include mechanical members with both concentrated and clearly expressed distributed parameters. The durability of structural elements is evaluated by means of a computer algorithm for analysis of crack growth rates using the NASGRO equation obtained with the presence of plastic deformation zones. An example of the crown block axis illustrates the influence of nonstationary dynamic processes in drill rigs on the durability of structural elements. Full article
(This article belongs to the Special Issue Fatigue Strength of Machines and Systems)
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9 pages, 1788 KiB  
Article
Evaluation of the Technical Condition of Pipes during the Transportation of Hydrogen Mixtures According to the Energy Approach
by Yaroslav Ivanytskyi, Yaroslav Blikharskyy, Jarosław Sęp, Zinoviy Blikharskyy, Jacek Selejdak and Oleh Holiian
Appl. Sci. 2024, 14(12), 5040; https://doi.org/10.3390/app14125040 - 10 Jun 2024
Cited by 1 | Viewed by 1079
Abstract
In this study, a theoretical–experimental methodology for determining the stress–strain state in pipeline systems, taking into account the hydrogen environment, was developed. A complex of theoretical and experimental studies was conducted to determine the specific energy of destruction as an invariant characteristic of [...] Read more.
In this study, a theoretical–experimental methodology for determining the stress–strain state in pipeline systems, taking into account the hydrogen environment, was developed. A complex of theoretical and experimental studies was conducted to determine the specific energy of destruction as an invariant characteristic of the material’s resistance to strain at different hydrogen concentrations. The technique is based on the construction of complete diagrams of the destruction of the material based on the determination of true strains and stresses in the local volume using the method involving the optical–digital correlation of speckle images. A complex of research was carried out, and true diagrams of material destruction were constructed, depending on the previous elastic–plastic strain and the action of the hydrogen environment. The change in the concentration of hydrogen absorbed by the material was estimated, depending on the value of the specific energy of destruction. A study was conducted on tubular samples, and the degree of damage to the material of the inner wall under the action of hydrogen and stress from the internal pressure was evaluated according to the change in specific energy, depending on the value of the true strain established with the help of an optical–digital correlator on the outer surface, and the degree of damage was determined. It has been established that the specific fracture energy of 17G1S steel decreases by 70–90% under the influence of hydrogen. The effect of the change in the amount of strain energy on the thickness of the pipe wall is illustrated. Full article
(This article belongs to the Special Issue Fatigue Strength of Machines and Systems)
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24 pages, 13244 KiB  
Article
Upgrade of the Universal Testing Machine for the Possibilities of Fatigue Tests in a Limited Mode
by Róbert Huňady, Peter Sivák, Ingrid Delyová, Jozef Bocko, Ján Vavro, Jr. and Darina Hroncová
Appl. Sci. 2024, 14(10), 3973; https://doi.org/10.3390/app14103973 - 7 May 2024
Cited by 2 | Viewed by 2237
Abstract
The object of the upgrade presented in this paper was an older analogue-based universal testing machine preferably designed for tensile testing. The objective of the upgrade was to create a new digitized measurement chain capable of also operating in the mode of simple [...] Read more.
The object of the upgrade presented in this paper was an older analogue-based universal testing machine preferably designed for tensile testing. The objective of the upgrade was to create a new digitized measurement chain capable of also operating in the mode of simple fatigue tests with cyclic tensile stresses. The upgrade of the equipment mainly included the processes of calibration, creation of related calibration jigs, creation of transformation dependencies and digitization, creation or completion of missing parts of chain-signal conditioning modules, A/D converters, special jigs, etc., as elements of the experimental hardware. The degree of correctness of the calibration and of the transformation dependencies created was verified by regression analysis, and this was verified by simple correlation analysis. The correctness of the proposed modifications, was verified on the basis of the fatigue tests performed for cyclic loading. Thus, it was possible to design, develop and functionally verify a new measurement chain based on an older universal testing machine. Thus, a partially digitized pulsator was created for the possibility of fatigue testing in a technically or functionally limited mode, mainly for educational purposes as a temporary replacement for the order of magnitude more expensive commercially produced test systems. Full article
(This article belongs to the Special Issue Fatigue Strength of Machines and Systems)
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17 pages, 5590 KiB  
Article
Unconventional Wells Interference: Supervised Machine Learning for Detecting Fracture Hits
by Guoxiang Liu, Xiongjun Wu and Vyacheslav Romanov
Appl. Sci. 2024, 14(7), 2927; https://doi.org/10.3390/app14072927 - 30 Mar 2024
Cited by 2 | Viewed by 1670
Abstract
The primary objective of the study was development of a machine learning (ML)-based workflow for fracture hit (“frac hit”) detection and monitoring using shale oil-field data such as drilling surveys, production history (oil and produced water), pressure, and fracking start time and duration [...] Read more.
The primary objective of the study was development of a machine learning (ML)-based workflow for fracture hit (“frac hit”) detection and monitoring using shale oil-field data such as drilling surveys, production history (oil and produced water), pressure, and fracking start time and duration records. The ML method takes advantage of long short-term memory (LSTM) and multilayer perceptron (MLP) neural networks to identify the frac hits due to hydraulic communication between the fracking child well(s) and the producing parent well(s) within the same pad (intra-pad interaction) and/or on different pads (inter-pad interaction). It utilizes time series of pressure and production data from within a pad and from adjacent pads. The workflow can capture time variable features of frac hits when the model architecture is deep and wide enough, with enough trainable parameters for deep learning and feature extraction, as demonstrated in this paper by using training and testing subsets of the field data from selected neighboring pads with over a couple of hundred wells. The study was focused on frac-hit interaction among paired wells and demonstrated that the ML model, once trained, can predict the frac-hit probability. Full article
(This article belongs to the Special Issue Fatigue Strength of Machines and Systems)
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13 pages, 2867 KiB  
Article
Determination of the Statistical Power of Fatigue Characteristics in Relation to the Number of Samples
by Przemysław Strzelecki and Janusz Sempruch
Appl. Sci. 2024, 14(6), 2440; https://doi.org/10.3390/app14062440 - 14 Mar 2024
Viewed by 1203
Abstract
The paper presents guidelines included in the ISO 12107:2003 standard regarding the number of samples for determining the fatigue characteristics in the high cycle range. The proposed normative values were compared with the classical statistical approach. Fatigue test results for S355J2+C steel for [...] Read more.
The paper presents guidelines included in the ISO 12107:2003 standard regarding the number of samples for determining the fatigue characteristics in the high cycle range. The proposed normative values were compared with the classical statistical approach. Fatigue test results for S355J2+C steel for rotary bending were used for verification. In addition, the error and power of a statistical test were determined for characteristics with different sample sizes. It determined the number of specimens to estimate the fatigue curve, which required significant error and power of the statistical test. Full article
(This article belongs to the Special Issue Fatigue Strength of Machines and Systems)
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Graphical abstract

14 pages, 991 KiB  
Article
Study on Load Distribution and Fatigue Elastic Life of Ball Screw under Ultimate Conditions
by Lei Lv, Changhou Lu, Shujiang Chen and Weike Wang
Appl. Sci. 2024, 14(5), 1966; https://doi.org/10.3390/app14051966 - 28 Feb 2024
Cited by 2 | Viewed by 1424
Abstract
When subjected to extreme loads and ultra-low cycling conditions, the primary mode of failure in a ball screw is that excessive plastic contact deformation of the raceway surface exceeds acceptable limits. Consequently, traditional fatigue life theories based on pitting fatigue are not applicable [...] Read more.
When subjected to extreme loads and ultra-low cycling conditions, the primary mode of failure in a ball screw is that excessive plastic contact deformation of the raceway surface exceeds acceptable limits. Consequently, traditional fatigue life theories based on pitting fatigue are not applicable in this context. This study evaluated the load distribution within the ball screw, considering factors such as the nut position and screw length. The plastic deformation of the raceway surfaces is analyzed using Thornton’s elastoplastic theory. Furthermore, this paper integrates the concepts of plastic deformation and fatigue elastic life to investigate the fatigue elastic life of ball screws under extreme conditions. To validate the proposed approach, the calculated results are compared with those from previous experimental studies, confirming its effectiveness. When the ratio of the nut position to the screw length approaches 0.7, the fatigue elastic life of the ball screw achieves its maximum. An increase in screw length, load, or raceway conformity ratio leads to a decrease in fatigue elastic life. Conversely, an increase in contact angle and ball diameter enhances the fatigue elastic life. Full article
(This article belongs to the Special Issue Fatigue Strength of Machines and Systems)
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20 pages, 9943 KiB  
Article
Study on the Residual Strength of Nonlinear Fatigue-Damaged Pipeline Structures
by Wenlan Wei, Rui Zhang, Yuwen Zhang, Jiarui Cheng, Yinping Cao and Fengying Fang
Appl. Sci. 2024, 14(2), 754; https://doi.org/10.3390/app14020754 - 16 Jan 2024
Cited by 1 | Viewed by 1359
Abstract
The heat alternation and bending during the service process of the pipeline structure are the key issues affecting its residual strength. The nonuniform plastic deformation of its cross-section causes nonlinear damage to the structure, which makes it difficult to calculate the residual strength [...] Read more.
The heat alternation and bending during the service process of the pipeline structure are the key issues affecting its residual strength. The nonuniform plastic deformation of its cross-section causes nonlinear damage to the structure, which makes it difficult to calculate the residual strength of the overall structure. This study proposed a novel variable-strength material damage model with damage accumulation, which achieved the coupling analysis of structural damage and material fatigue residual strength, making the structural strength of nonlinear damage cross-section computable. Based on this, a theoretical ultimate load model for nonlinear damage cross-section and a finite element analysis model for dynamic material strength with damage accumulation were established. The analysis was conducted on the repeated banding damage to coiled tubing. The results showed that the residual yield strength of nonlinear damaged coiled tubing showed a trend of first rapid decrease and then slow decrease with damage accumulation, and the tensile displacement showed an increasing trend with damage accumulation. The ultimate internal pressure strength of nonlinear damaged structures showed a similar downward trend to the yield strength. The nonlinear damage coupling analysis model proposed in this study has significant practical engineering application value. Full article
(This article belongs to the Special Issue Fatigue Strength of Machines and Systems)
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