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Metals
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Computational Methods for Fatigue and Fracture
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Computational Methods for Fatigue and Fracture

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 23786

Printed Edition Available!
A printed edition of this Special Issue is available here.

Special Issue Editors

Dr. Ricardo Branco

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Guest Editor
Department of Mechanical Engineering, University of Coimbra, 3030-788 Coimbra, Portugal
Interests: Glass-fiber reinforced polymers; 3D printed polymers; fatigue of polymers; ageing effects
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Filippo Berto

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Co-Guest Editor
Department of Chemical Engineering, Materials and Environment, Sapienza University of Rome, 00184 Rome, Italy
Interests: fatigue and fracture behavior of materials; mechanical characterization; structural integrity of conventional and innovative materials
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Shengchuan Wu

E-Mail Website
Guest Editor
State Key Laboratory of Traction Power, Southwest Jiaotong University, Chengdu 610031, China
Interests: in situ fatigue tests; fracture mechanics; fatigue crack growth model; fatigue life prediction; finite element simulation; structural integrity of railway vehicle; additive manufacturing; correlative 4D tomography
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The development of modern numerical methods has led to significant advances in the field of fatigue and fracture, which are pivotal issues in structural integrity. Because of the permanent tendency to shorten time-to-market periods and the development cost, the use of the finite element method, extended finite element method, peridynamics, or meshless methods, among others, has been a viable alternative to experimental methods. This Special Issue aims to focus on the new trends on computation methods to address fatigue and fracture problems. Examples of innovative and successful industrial applications, as well as nonconventional numerical approaches, are also encouraged. Research and review papers are welcome.

Prof. Dr. Ricardo Branco
Prof. Dr. Filippo Berto
Prof. Dr. Shengchuan Wu
Guest Editors

Manuscript Submission Information

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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. Metals is an international peer-reviewed open access monthly 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 2600 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

  • New computational approaches for fatigue
  • New computational approaches for fracture
  • Remeshing techniques
  • Finite element method
  • Boundary element method
  • Coupled FEM/BEM approaches for fatigue and fracture
  • Extended finite element method
  • Meshless methods
  • Peridynamics
  • Large-scale engineering applications
  • Multidisciplinary computational approaches for fatigue and fracture

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Related Special Issue

Published Papers (8 papers)

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Editorial

Jump to: Research, Review

2 pages, 181 KiB  
Editorial
Computational Methods for Fatigue and Fracture
by Ricardo Branco, Filippo Berto and Shengchuan Wu
Metals 2022, 12(5), 739; https://doi.org/10.3390/met12050739 - 27 Apr 2022
Viewed by 1449
Abstract
Fatigue and fracture are pivotal issues in structural integrity [...] Full article
(This article belongs to the Special Issue Computational Methods for Fatigue and Fracture)

Research

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21 pages, 9229 KiB  
Article
Fatigue Life and Reliability of Steel Castings through Integrated Simulations and Experiments
by Muhammad Azhar Ali Khan, Anwar Khalil Sheikh, Zuhair Mattoug Gasem and Muhammad Asad
Metals 2022, 12(2), 339; https://doi.org/10.3390/met12020339 - 15 Feb 2022
Cited by 3 | Viewed by 2556
Abstract
The quality and performance of steel castings is always a concern due to porosities formed during solidification of the melt. Nowadays, computational tools are playing a pivotal role in analyzing such defects, followed by their minimization through mold design optimization. Even if the [...] Read more.
The quality and performance of steel castings is always a concern due to porosities formed during solidification of the melt. Nowadays, computational tools are playing a pivotal role in analyzing such defects, followed by their minimization through mold design optimization. Even if the castings are produced with defects in a permissible range, it is important to examine their service life and performance with those defects in a virtual domain using simulation software. This paper aims to develop a methodology with a similar idea of simulation-based optimization of mold design and predictions of life and reliability of components manufactured with minimized casting defects, especially porosities. The cast parts are standard fatigue specimens which are produced through an optimized multi-cavity mold. X-ray imaging is done to determine the soundness of cast parts. Experimental work includes load-controlled fatigue testing under fully reversed condition. The fatigue life of specimens is also simulated and compared with the experimental results. The classical strength-stress model is used to determine the reliability of cast parts through which a safe-load induced stress of steel castings is determined. Finally, probability distributions are fit to the reliability results to develop the reliability models. It is found that porosities can be minimized significantly in the mold design phase using casting simulations. Nevertheless, some porosities are bound to exist, which must be included in realistic estimation of fatigue life and reliability of cast parts. Full article
(This article belongs to the Special Issue Computational Methods for Fatigue and Fracture)
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17 pages, 11634 KiB  
Article
Early Crack Propagation in Single Tooth Bending Fatigue: Combination of Finite Element Analysis and Critical-Planes Fatigue Criteria
by Franco Concli, Lorenzo Maccioni, Lorenzo Fraccaroli and Luca Bonaiti
Metals 2021, 11(11), 1871; https://doi.org/10.3390/met11111871 - 21 Nov 2021
Cited by 14 | Viewed by 2736
Abstract
Mechanical components, such as gears, are usually subjected to variable loads that induce multiaxial non-proportional stress states, which in turn can lead to failure due to fatigue. However, the material properties are usually available in the forms of bending or shear fatigue limits. [...] Read more.
Mechanical components, such as gears, are usually subjected to variable loads that induce multiaxial non-proportional stress states, which in turn can lead to failure due to fatigue. However, the material properties are usually available in the forms of bending or shear fatigue limits. Multiaxial fatigue criteria can be used to bridge the gap between the available data and the actual loading conditions. However, different criteria could lead to different results. The main goal of this paper is to evaluate the accuracy of different criteria applied to real mechanical components. With respect to this, five different criteria based on the critical plane concept (i.e., Findley, Matake, McDiarmid, Papadopoulos, and Susmel) have been investigated. These criteria were selected because they not only assess the level of damage, but also predict the direction of crack propagation just after nucleation. Therefore, measurements (crack position and direction) on different fractured gear samples tested via Single Tooth Bending Fatigue (STBF) tests on two gear geometries were used as reference. The STBF configuration was numerically simulated via Finite Elements (FE) analyses. The results of FE were elaborated based on the above-mentioned criteria. The numerical results were compared with the experimental ones. The result of the comparison showed that all the fatigue criteria agree in identifying the most critical point. The Findley and Papadopulus criteria proved to be the most accurate in estimating the level of damage. The Susmel criterion turns out to be the most conservative one. With respect to the identification of the direction of early propagation of the crack, the Findley criterion revealed the most appropriate. Full article
(This article belongs to the Special Issue Computational Methods for Fatigue and Fracture)
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19 pages, 5460 KiB  
Article
Improving the Fatigue of Newly Designed Mechanical System Subjected to Repeated Impact Loading
by Seongwoo Woo, Dennis L. O’Neal, Dereje Engida Woldemichael, Samson Mekbib Atnaw and Muluneh Mekonnen Tulu
Metals 2021, 11(1), 139; https://doi.org/10.3390/met11010139 - 12 Jan 2021
Cited by 5 | Viewed by 2359
Abstract
This paper develops parametric accelerated life testing (ALT) as a systematic reliability method to produce the reliability quantitative (RQ) specifications—mission cycle—for recognizing missing design defects in mechanical products as applying the accelerated load, expressed as the inverse of stress ratio, R. Parametric ALT [...] Read more.
This paper develops parametric accelerated life testing (ALT) as a systematic reliability method to produce the reliability quantitative (RQ) specifications—mission cycle—for recognizing missing design defects in mechanical products as applying the accelerated load, expressed as the inverse of stress ratio, R. Parametric ALT is a way to enhance the prediction of fatigue failure for mechanical systems subjected to repeated impact loading. It incorporates: (1) A parametric ALT plan formed on the system BX lifetime, (2) a fatigue failure and design, (3) customized ALTs with design alternatives, and (4) an assessment of whether the last design(s) of the system fulfills the objective BX lifetime. A BX life concept with a generalized life-stress model and a sample size equation are suggested. A domestic refrigerator hinge kit system (HKS), which was a newly designed mechanical product, was used to illustrate the methodology. The HKS was subjected to repeated impact loading resulting in failure of the HKS in the field. To conduct ALTs, a force and momentum balance was utilized on the HKS. A straightforward impact loading of the HKS in closing the refrigerator door was examined. At the first ALT, the housing of the HKS failed. As an action plan, the hinge kit housing was modified by attaching inside supporting ribs to the HKS to provide sufficient mechanical strength against its loading. At the second ALT, the torsional shaft in the HKS made with austenitic ductile iron (18 wt% Ni) failed. The cracked torsional shaft for the 2nd ALTs came from its insufficient rounding, which failed due to repeated stress. As an action plan, to have sufficient material strength for the repetitive impact loads, the torsional shaft was reshaped to give it more rounding from R0.5 mm to R2.0 mm. After these modifications, there were no problems at the third ALT. The lifetime of the HKS in the domestic refrigerator was assured to be B1 life 10 years. Full article
(This article belongs to the Special Issue Computational Methods for Fatigue and Fracture)
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11 pages, 7292 KiB  
Article
Coupling Finite Element Analysis and the Theory of Critical Distances to Estimate Critical Loads in Al6060-T66 Tubular Beams Containing Notches
by Marcos Sánchez, Sergio Cicero, Borja Arroyo and José Alberto Álvarez
Metals 2020, 10(10), 1395; https://doi.org/10.3390/met10101395 - 20 Oct 2020
Cited by 8 | Viewed by 2063
Abstract
This paper validates a methodology for the estimation of critical loads in tubular beams containing notch-type defects. The methodology is particularized for the case of Al6060-T66 tubular cantilever beams containing U-shaped notches. It consists in obtaining the stress field at the notch tip [...] Read more.
This paper validates a methodology for the estimation of critical loads in tubular beams containing notch-type defects. The methodology is particularized for the case of Al6060-T66 tubular cantilever beams containing U-shaped notches. It consists in obtaining the stress field at the notch tip using finite element analysis (FEA) and the subsequent application of the theory of critical distances (TCD) to derive the corresponding critical load (or load-bearing capacity). The results demonstrate that this methodology provides satisfactory predictions of fracture loads. Full article
(This article belongs to the Special Issue Computational Methods for Fatigue and Fracture)
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29 pages, 10903 KiB  
Article
Analysis and Optimization of Tooth Surface Contact Stress of Gears with Tooth Profile Deviations, Meshing Errors and Lead Crowning Modifications Based on Finite Element Method and Taguchi Method
by Qiang Li and Liyang Xie
Metals 2020, 10(10), 1370; https://doi.org/10.3390/met10101370 - 14 Oct 2020
Cited by 13 | Viewed by 3107
Abstract
Based on the three-dimensional (3D) finite element method (FEM) and Taguchi method (TM), this paper analyzes the tooth surface contact stress (TSCS) of spur gears with three different influence factors: tooth profile deviations (TPD), meshing errors (ME) and lead crowning modifications (LCM), especially [...] Read more.
Based on the three-dimensional (3D) finite element method (FEM) and Taguchi method (TM), this paper analyzes the tooth surface contact stress (TSCS) of spur gears with three different influence factors: tooth profile deviations (TPD), meshing errors (ME) and lead crowning modifications (LCM), especially researching and analyzing the interactions between TPD, ME and LCM and their degree of influence on the TSCS. In this paper, firstly, a 3D FEM model of one pair of engaged teeth is modeled and the mesh of the contact area is refined by FEM software. In the model, the refined area mesh and the non-refined area mesh are connected by multi-point constraint (MPC); at the same time, in order to save the time of the FEM solution on the premise of ensuring the solution’s accuracy, the reasonable size of the refined area is studied and confirmed. Secondly, the TSCS analyses of gears with one single influence factor (other factors are all ideal) are carried out. By inputting the values of different levels of one single factor into the FEM model, especially using the real measurement data of TPD, and conducting the TSCS analysis under different torques, the influence degree of one single factor on TSCS is discussed by comparing the ideal model, and it is found that when the influence factors exist alone, each factor has a great influence on the TSCS. Finally, through TM, an orthogonal test is designed for the three influence factors. According to the test results, the interactions between the influence factors and the influence degree of the factors on the TSCS are analyzed when the three factors exist on the gear at the same time, and it is found that the TPD has the greatest influence on the TSCS, followed by the lead crowning modified quantity. The ME is relatively much small, and there is obvious interaction between ME and LCM. In addition, the optimal combination of factor levels is determined, and compared with the original combination of a gear factory, we see that the contact fatigue performance of the gear with the optimal combination is much better. The research of this paper has a certain reference significance for the control of TPD, ME and LCM when machining and assembling the gears. Full article
(This article belongs to the Special Issue Computational Methods for Fatigue and Fracture)
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Review

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14 pages, 4803 KiB  
Review
Fatigue Crack Growth Analysis with Extended Finite Element for 3D Linear Elastic Material
by Yahya Ali Fageehi
Metals 2021, 11(3), 397; https://doi.org/10.3390/met11030397 - 1 Mar 2021
Cited by 13 | Viewed by 3799
Abstract
This paper presents computational modeling of a crack growth path under mixed-mode loadings in linear elastic materials and investigates the influence of a hole on both fatigue crack propagation and fatigue life when subjected to constant amplitude loading conditions. Though the crack propagation [...] Read more.
This paper presents computational modeling of a crack growth path under mixed-mode loadings in linear elastic materials and investigates the influence of a hole on both fatigue crack propagation and fatigue life when subjected to constant amplitude loading conditions. Though the crack propagation is inevitable, the simulation specified the crack propagation path such that the critical structure domain was not exceeded. ANSYS Mechanical APDL 19.2 was introduced with the aid of a new feature in ANSYS: Smart Crack growth technology. It predicts the propagation direction and subsequent fatigue life for structural components using the extended finite element method (XFEM). The Paris law model was used to evaluate the mixed-mode fatigue life for both a modified four-point bending beam and a cracked plate with three holes under the linear elastic fracture mechanics (LEFM) assumption. Precise estimates of the stress intensity factors (SIFs), the trajectory of crack growth, and the fatigue life by an incremental crack propagation analysis were recorded. The findings of this analysis are confirmed in published works in terms of crack propagation trajectories under mixed-mode loading conditions. Full article
(This article belongs to the Special Issue Computational Methods for Fatigue and Fracture)
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16 pages, 6065 KiB  
Review
Simulation of Quasi-Static Crack Propagation by Adaptive Finite Element Method
by Abdulnaser M. Alshoaibi and Yahya Ali Fageehi
Metals 2021, 11(1), 98; https://doi.org/10.3390/met11010098 - 6 Jan 2021
Cited by 20 | Viewed by 3625
Abstract
The finite element method (FEM) is a widely used technique in research, including but not restricted to the growth of cracks in engineering applications. However, failure to use fine meshes poses problems in modeling the singular stress field around the crack tip in [...] Read more.
The finite element method (FEM) is a widely used technique in research, including but not restricted to the growth of cracks in engineering applications. However, failure to use fine meshes poses problems in modeling the singular stress field around the crack tip in the singular element region. This work aims at using the original source code program by Visual FORTRAN language to predict the crack propagation and fatigue lifetime using the adaptive dens mesh finite element method. This developed program involves the adaptive mesh generator according to the advancing front method as well as both the pre-processing and post-processing for the crack growth simulation under linear elastic fracture mechanics theory. The stress state at a crack tip is characterized by the stress intensity factor associated with the rate of crack growth. The quarter-point singular elements are constructed around the crack tip to accurately represent the singularity of this region. Under linear elastic fracture mechanics (LEFM) with an assumption in various configurations, the Paris law model was employed to evaluate mixed-mode fatigue life for two specimens under constant amplitude loading. The framework includes a progressive analysis of the stress intensity factors (SIFs), the direction of crack growth, and the estimation of fatigue life. The results of the analysis are consistent with other experimental and numerical studies in the literature for the prediction of the fatigue crack growth trajectories as well as the calculation of stress intensity factors. Full article
(This article belongs to the Special Issue Computational Methods for Fatigue and Fracture)
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