High cycle fatigue analysis in the presence of autofrettage compressive residual stress

V. Okorokov, D. MacKenzie, Y. Gorash, M. Morgantini, R. van Rijswick, T. Comlekci

Research output: Contribution to journalArticle

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Abstract

An experimental and numerical investigation of the effect of residual compressive stress on the high cycle fatigue life of notched low carbon steel test specimens is presented. Experimentally determined cyclic stress strain curves for S355 low carbon steel are utilized in a Finite Element Analysis plasticity modelling framework incorporating a new cyclic plasticity material model representative of cyclic hardening and softening, cyclic mean stress relaxation and ratcheting behaviors. Fatigue test results are presented for standard tensile fatigue test specimens and novel double notch specimens. Double notch specimens are tested with and without compressive residual stress prior-induced through tensile overload. It is shown that cyclic plasticity phenomena have a significant influence on the induced residual stress distribution and also on material behavior when fatigue tested in the high cycle regime. It is observed that higher initial compressive residual stresses magnitude does not necessarily lead to a longer fatigue life. Finite Element Analysis using the new cyclic plasticity material model shows this behavior is due to combined residual stress redistribution under fatigue test cyclic loading and cyclic hardening effects. A fatigue life methodology based on the stress-life approach augmented by a critical distance method is proposed and shown to give good agreement with experimental results for test specimens with no induced residual stress. The results obtained for specimens with induced residual stress are more conservative but the degree of conservatism is significantly lower than that in the conventional stress life approach. The proposed methodology is therefore suitable for analysis and design assessment of components with pre-service induced compressive residual stress, such as autofrettaged pressure components.
Original languageEnglish
Pages (from-to)2305-2320
Number of pages16
JournalFatigue and Fracture of Engineering Materials and Structures
Volume41
Issue number11
Early online date15 Jun 2018
DOIs
Publication statusPublished - 30 Nov 2018

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Compressive stress
Residual stresses
Fatigue of materials
Plasticity
Low carbon steel
Hardening
Finite element method
Stress relaxation
Stress-strain curves
Stress concentration

Keywords

  • compressive residual stress
  • autofrettage
  • re-autofrettage
  • cyclic plasticity
  • high cycle fatigue
  • theory of critical distance

Cite this

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abstract = "An experimental and numerical investigation of the effect of residual compressive stress on the high cycle fatigue life of notched low carbon steel test specimens is presented. Experimentally determined cyclic stress strain curves for S355 low carbon steel are utilized in a Finite Element Analysis plasticity modelling framework incorporating a new cyclic plasticity material model representative of cyclic hardening and softening, cyclic mean stress relaxation and ratcheting behaviors. Fatigue test results are presented for standard tensile fatigue test specimens and novel double notch specimens. Double notch specimens are tested with and without compressive residual stress prior-induced through tensile overload. It is shown that cyclic plasticity phenomena have a significant influence on the induced residual stress distribution and also on material behavior when fatigue tested in the high cycle regime. It is observed that higher initial compressive residual stresses magnitude does not necessarily lead to a longer fatigue life. Finite Element Analysis using the new cyclic plasticity material model shows this behavior is due to combined residual stress redistribution under fatigue test cyclic loading and cyclic hardening effects. A fatigue life methodology based on the stress-life approach augmented by a critical distance method is proposed and shown to give good agreement with experimental results for test specimens with no induced residual stress. The results obtained for specimens with induced residual stress are more conservative but the degree of conservatism is significantly lower than that in the conventional stress life approach. The proposed methodology is therefore suitable for analysis and design assessment of components with pre-service induced compressive residual stress, such as autofrettaged pressure components.",
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High cycle fatigue analysis in the presence of autofrettage compressive residual stress. / Okorokov, V.; MacKenzie, D.; Gorash, Y.; Morgantini, M.; van Rijswick, R.; Comlekci, T.

In: Fatigue and Fracture of Engineering Materials and Structures, Vol. 41, No. 11, 30.11.2018, p. 2305-2320.

Research output: Contribution to journalArticle

TY - JOUR

T1 - High cycle fatigue analysis in the presence of autofrettage compressive residual stress

AU - Okorokov, V.

AU - MacKenzie, D.

AU - Gorash, Y.

AU - Morgantini, M.

AU - van Rijswick, R.

AU - Comlekci, T.

PY - 2018/11/30

Y1 - 2018/11/30

N2 - An experimental and numerical investigation of the effect of residual compressive stress on the high cycle fatigue life of notched low carbon steel test specimens is presented. Experimentally determined cyclic stress strain curves for S355 low carbon steel are utilized in a Finite Element Analysis plasticity modelling framework incorporating a new cyclic plasticity material model representative of cyclic hardening and softening, cyclic mean stress relaxation and ratcheting behaviors. Fatigue test results are presented for standard tensile fatigue test specimens and novel double notch specimens. Double notch specimens are tested with and without compressive residual stress prior-induced through tensile overload. It is shown that cyclic plasticity phenomena have a significant influence on the induced residual stress distribution and also on material behavior when fatigue tested in the high cycle regime. It is observed that higher initial compressive residual stresses magnitude does not necessarily lead to a longer fatigue life. Finite Element Analysis using the new cyclic plasticity material model shows this behavior is due to combined residual stress redistribution under fatigue test cyclic loading and cyclic hardening effects. A fatigue life methodology based on the stress-life approach augmented by a critical distance method is proposed and shown to give good agreement with experimental results for test specimens with no induced residual stress. The results obtained for specimens with induced residual stress are more conservative but the degree of conservatism is significantly lower than that in the conventional stress life approach. The proposed methodology is therefore suitable for analysis and design assessment of components with pre-service induced compressive residual stress, such as autofrettaged pressure components.

AB - An experimental and numerical investigation of the effect of residual compressive stress on the high cycle fatigue life of notched low carbon steel test specimens is presented. Experimentally determined cyclic stress strain curves for S355 low carbon steel are utilized in a Finite Element Analysis plasticity modelling framework incorporating a new cyclic plasticity material model representative of cyclic hardening and softening, cyclic mean stress relaxation and ratcheting behaviors. Fatigue test results are presented for standard tensile fatigue test specimens and novel double notch specimens. Double notch specimens are tested with and without compressive residual stress prior-induced through tensile overload. It is shown that cyclic plasticity phenomena have a significant influence on the induced residual stress distribution and also on material behavior when fatigue tested in the high cycle regime. It is observed that higher initial compressive residual stresses magnitude does not necessarily lead to a longer fatigue life. Finite Element Analysis using the new cyclic plasticity material model shows this behavior is due to combined residual stress redistribution under fatigue test cyclic loading and cyclic hardening effects. A fatigue life methodology based on the stress-life approach augmented by a critical distance method is proposed and shown to give good agreement with experimental results for test specimens with no induced residual stress. The results obtained for specimens with induced residual stress are more conservative but the degree of conservatism is significantly lower than that in the conventional stress life approach. The proposed methodology is therefore suitable for analysis and design assessment of components with pre-service induced compressive residual stress, such as autofrettaged pressure components.

KW - compressive residual stress

KW - autofrettage

KW - re-autofrettage

KW - cyclic plasticity

KW - high cycle fatigue

KW - theory of critical distance

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M3 - Article

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JO - Fatigue and Fracture of Engineering Materials and Structures

JF - Fatigue and Fracture of Engineering Materials and Structures

SN - 8756-758X

IS - 11

ER -