Predicting fatigue crack initiation in milled aerospace grade Ti-6Al-4V parts using CPFEM

Mauro Francisco Arcidiacono*, Ioannis Violatos, Salaheddin Rahimi

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution book

Abstract

A Crystal Plasticity Finite Element Method (CPFEM) model is proposed for determining the likelihood of fatigue crack initiation and its sites in an aerospace-grade Ti-6Al-4V machined part. The methodology is based on a digitally reconstructed Electron Backscatter Diffraction (EBSD) microstructural model that incorporates the previous deformation history, the residual stress distribution and the roughness profile which result from milling. The constitutive model employs the Armstrong-Frederick nonlinear formulation and implements microstructure sensitive fatigue initiation parameters. Findings suggest that fatigue initiation is significantly influenced by the surface topology and the pre-existing strain and stress fields. The simulation predicts the formation of persistent slip bands within the deformed microstructure and ratcheting that causes local plastic strain accumulation. The model indicates that at the surface and near-surface regions fatigue initiation is mainly driven by local topography, while orientation becomes more dominant at higher depths.
Original languageEnglish
Title of host publicationProceedings of the 9th Engineering Integrity Society International Conference on Durability & Fatigue
EditorsE. R. Cawte, H. L. Cockings, S. Stekovic, J. R. Yates
Place of PublicationCambridge, UK
Pages115-126
DOIs
Publication statusPublished - 19 Jun 2024
Event9th Engineering Integrity Society International Conference on Durability & Fatigue (Fatigue 2024) - Jesus College, Cambridge, United Kingdom
Duration: 19 Jun 202421 Jun 2024
Conference number: 9th
https://fatigue2024.com/

Conference

Conference9th Engineering Integrity Society International Conference on Durability & Fatigue (Fatigue 2024)
Abbreviated titleFatigue 2024
Country/TerritoryUnited Kingdom
CityCambridge
Period19/06/2421/06/24
Internet address

Keywords

  • Crystal plasticity
  • Fatigue initiation parameters
  • Crack initiation

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