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Numerical study of fatigue damage under random loading using Rainflow

cycle counting

Preprint in International Journal of Structural Integrity · June 2020

DOI: 10.1108/IJSI-04-2020-0036

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 Numerical study of fatigue damage under random loading
using Rainflow cycle counting
Tayeb KEBIRa,*; José A.F.O. CORREIAb; Mohamed BENGUEDIABc; Abílio A.M. De JESUSd
a
Young Researcher, Laboratory of Materials and Systems Reactive, Facultyof Technology, Universtyof Sidi Bel
Abbes, Algeria; [email protected]
b
Researcher & Invited Professor, CONSTRUCT & Faculty of Engineering, University of Porto, 4200-465 Porto,
Portugal; [email protected]
c
Professor, Laboratory of Materials and Systems Reactive, Faculty of Technology, Universty of Sidi Bel Abbes,
Algeria; [email protected]
d
Associate Professor, INEGI& Faculty of Engineering, University of Porto, 4200-465 Porto, Portugal;
[email protected]
*Corresponding author: [email protected]

Abstract
The fatigue is a succession of mechanisms of damage which, under applying stresses or
deformations varying over time, modifies the local properties of a material. The study of
fatigue under random loading is based on same concepts which as constant loading with
addition of damage summation. The damage of materials due a stress cycle depends not
only on the alternating stress, but also on the mean stress. The purpose of this scientific
work is to simulate the fatigue damage under random loading taking into account the
mean stress effect on fatigue lifetime and using the Rainflow counting technique to assess
the fatigue damage, by the Ansys software. The used material is aluminum alloy 6082-T6.
A comparison with literature results were confirmed this investigation in this paper.
Keywords: Fatigue damage, lifetime, random loading, Rainflow cycle counting, mean
stress, alloy 6082-T6.

1. Introduction
The fatigue of metallic materials can be modeled by Wöhler diagram which established
curves connecting the amplitude of applied stress as a function of the number of cycles to
failure and highlight the notion of macroscopic fatigue limit[1], [2]. The basic problem in
material research is to study the fatigue behaviour of structures[3]. That is not only a material
problem, but also technology design, loading conditions and environmental properties that are
very significant. A service loading has usually a random character, and a loading signal must
be simulated, several authors have recently been studying this phenomena [4], [5].
Furthermore, for structures subjected to random loading cycles in service, it may be desirable
that fatigue failures occur [6]–[8]. The fatigue lifetime prediction in specimens made of
aluminum alloy subjected to random loading is studied by Kim et al. [9], It may be
successfully applied to predict fatigue crack growth under random loading[10]. Zengah et al.
[11] have studied fatigue life prediction by the rain-flow cycle counting, and concluded a
production of good results for random histories. Furthermore, new fatigue models and new
cycle counting systems are expressed by Calderón et al.[12], taking into account the effects of
average stresses on the fatigue life. Therefore, in such cases, the effect of mean stress on
fatigue lifetime under random loading should not be ignored [13]. So also, Wang et al.[14]
have proposed two algorithms for multiaxial cycle counting method by modifying the
rainflow and range cycle counting methods, for predict multiaxial fatigue life in both high-
cycle and low-cycle fatigue region. Barbosa et al. [15] suggested probabilistic S-N fields
based on statistical distributions applied to metallic and composite materials using various
fatigue models. So, the fatigue assessment based on stresses obtained from the global
dynamic analysis and local static is observed by Viana et al. [16] and the fatigue assessment
of critical connections in a historic eyebar suspension bridge studied by Liu et al. [17],
[18].Zhu et al. [19] proposed a comparative study for the fatigue life prediction of metals
based on nonlinear fatigue damage accumulation models.
In addition, the effects of variable amplitude loading on fatigue life has been studied taking
account the influence of compressive mean stress on fatigue lifetime under block loading
[20]. Fatigue damage accumulation of welded steel structures under random loading is studied
by Agerskov et al. [21], may give results, which are un-conservative, and the validity of the
results obtained from Miner’s rule will depend on the distribution of the load history in
tension and compression. However,Salvinder et al.[22] studied the effect of mean stress using
the Rainflowcycle counting technique to assess the fatigue damage employing the
crankshaft.That way, the influence of mean stress on fatigue lifetime under random loading
was considered by several works [12], [23], but not presenting the cyclic responses or the
hysteresis curves using cycle counting, allowed us to predict the fatigue behavior under
random loading of materials.
The main purpose of this scientific work is to simulate the fatigue damage under random
loading taking into account the mean stress (σm) effects on fatigue lifetime using the Morrow
criterion. This simulation was performed by the Ansys software using the flat type detail
made in aluminum alloy 6082-T6.

2. A perspective on fatigue damage under random loading

Fatigue loading causes accumulation of damage that may lead to the initiation of a macro-
crack and result in a catastrophic failure of materials. Therefore, the fatigue failure criterion
can be adopted within the cyclic plastic zonebased on the Manson-Coffin strain-life
relationship obtained from smooth specimens, strain-life relationship and can be described
either in terms of the plastic strain or stress range and the number of cycles to failure, 2Nf[24].
Taking the detrimental effect of a mean stress(σm) into account into Morrow’s
relationship[25].
∆𝜀 𝜎′ 𝑓 −𝜎𝑚 𝑏 𝑐
= 2𝑁𝑓 + 𝜀′𝑓 2𝑁𝑓 (1)
2 𝐸

Where; ε’f and c are, respectively, the fatigue ductility coefficient and fatigue ductility
exponent, σ’fis the fatigue strength coefficient, b is the fatigue strength exponent and E is the
Young’s modulus.

This model showed good predictions for the constant values of stress range and random
loading [4]. Also, it tended to underestimate the mean stress (σm)effect on the fatigue
lifetime[26], [27].The fatigue damage degree is determined only for the random loading using
the Palmgren-Miner linear damage hypothesis [6].
𝑛
𝑁𝑖
=1 (2)
𝑁𝑖𝑓
𝑖

The summations of the damage are given by the Eq. (2) and are the quotients of the number of
cycles at amplitude of stress Ni and of the respective number of cycles of failure Nif. However,
it should be noted that the Miner rule is often an inappropriate oversimplification. Depending
on the load history, the sum of damage may be greater or less than one [25][11].
The counting of stress cycles is an important step which must makes possible to filter the
information essential for the study of fatigue damage. It is for example recognized that only
the successive maximum and minimum of the stresses undergone by the structure have a
significant influence on its fatigue prediction[12], [28], [29].
 Figure1.Rainflow counting (AFNOR[30])
Several works [31]–[33] have been studying the Rainflow cycle counting techniques. The
usual procedure of the Rainflow method consists first of all in discretizing the stress history
by defining a number n of amplitude classes (French standard AFNOR[30]) then the history is
reduced to a sequence of local maximum and minimum (peaks and valleys). Each successive
maximum, u, and minimum, v, then represents a range 𝑒 = |𝑢 − 𝑣|. According to AFNOR
standard[30], the extraction of a cycle is based on the study of a sequence of three successive
ranges. A cycle is extracted when the studied range 𝑒𝑖 is less than or equal to the previous
range,𝑒𝑖−1 , and to the next range 𝑒𝑖+1 (𝑒𝑖−1 ≥ 𝑒𝑖 ≤ 𝑒𝑖+1 ). Then the range𝑒𝑖−1 is connected to
the range (𝑒𝑖+1 ) by removing from the sequence the maximum ui and the minimum vi
belonging to the range 𝑒𝑖 . The operation is repeated starting from the newly created scope and
this for the whole history.
Fatigue damage is related to amplitudes and average values of stress cycles. For a random
loading, the counting method due to extracts a set of cycles, each defined by a peak of level,u,
and a valley of level,v, or an amplitude,σ, and an average value,m; these terms being linked
together by the following expressions:
𝜎 = (𝑢 − 𝑣) / 2, 𝑚 = (𝑢 + 𝑣) / 2 (3)
The Rainflow counting method used in conjunction with the Palmgren-Miner cumulative law
gives reasonable fatigue prediction and is currently the most commonly used approach in
uniaxial fatigue.
3. Numerical simulation
To perform the tests of fatigue lifetime under random loading, the flat type specimen is used
(Fig.2). The material is an alloy of 6082 T6 Aluminum, for more details, see [34], [35] with
mechanical properties that are illustrated in Fig.2-a and S-N curve is represented in Fig.3-b
and reported in Table 1. This material has great importance in the technology industry
especially for example for the construction of a transport aircraft since it has high mechanical
strength, good corrosion resistance and high hardness [4], [35].

Figure 2. Specimen test (dimensions in mm)[4].

280
350
260
300
240
Applied Stress  [MPa]

250
220
Stress  [MPa]

200
200
150
180

100 160

50 140

0 120
0 2 4 6 8 10 12 14 16 18 2x10
7
3x10
7
4x10
7
5x10
7
6x10
7
7x10
7
8x10
7
9x10
7

Strain  [%] Number of cycle [N]

a) b)
Figure 3. Cyclic stress-strain and stress number of cycles curves at ratio R = -1,
experimental results[34], [35].

Table 1 – Material properties of 6082 T6 [34], [35].

Young’s modulus E[GPa] 70
Poison’s ratio ν 0.33
Yield stress σy[MPa] 300
Yield ultimate σu[MPa] 245
Elongation strain εf% 9
Hardening coefficient K’[MPa] 443
Hardening exponentn’ 0.064
Ductility coefficient ε'f 0.773
Ductility exponent c’ -0.827
Fatigue coefficient σ'f[MPa] 485
Fatigue exponent b' -0.069
These parameters were introduced into the Ansys software. The principle of simulation
consists in fixing one side of the specimen and loading the other with a random loading,
carrying out three types of random loadings, classified according to the mean stress and the
nature of loading history (see Figure 5).
The finite element method (ANSYS) allowed us to access the history of stresses and strains
on the reduced part of the specimen. This makes it possible to know the theoretical life of the
specimen using the Morrow fatigue criterion.
The mesh used is type Solid185 with 8 nodes having three degrees of freedom at each node
which makes possible to visualize the deformations in three directions. The convergence has
been checked as shown in Figure 4. The model contains 34961 nodes and 7040 elements.

Figure 4. Test specimen meshing.

500

Spectrum (a) m > 0

400

300
[MPa]

200
Stress 

100

-100

-200
0 2000 4000 6000 8000 10000 12000 14000 16000

Number of cycle [N]

a)
 400
Spectrum (b) m = 0
300

200

[MPa]
100

Stress  -100

-200

-300

-400
0 10000 20000 30000 40000 50000 60000

Number of cycle [N]

b)

100
Spectrum (c) m < 0

0
Stress  [MPa]

-100

-200

-300

-400
0 200 400 600 800 1000

Number of cycle [N]

c)

Figure 5. The type of random loading classified according to mean stress: a) 𝜎𝑚 > 0; b) 𝜎𝑚 = 0; c)
𝜎𝑚 < 0.

4. Results
The linear static finite element analysis was performed using the Ansys software. The
equivalent von Mises stress contours and critical locations are shown in Figure 6. The middle
of specimen was found to be areas of high stress. The von Mises equivalent stresses are used
for subsequent fatigue life prediction analysis and comparisons.

Figure 6. The von Mises stress distribution(MPa).

Once the cycle has been identified, the fatigue damage for all cycles of the random loading is
added to the Miner’s linear damage rule in order to obtain the damage D for the complete
loading history. The results obtained when D=1show that the test specimen is damaged or
failing, the distribution of the lifetime along the test specimen shows that the failure life is in
the middle (red zone, see figure 7) and reported in Table 2. Therefore, the results obtained by
the simulation corresponding of spectrum (b) are in good agreement with the literature
results[4].

Spectrum a)

Spectrum b)

Spectrum c)
Figure 7. The fatigue lifetime of different spectrum.

Table 2. Fatigue lifetime obtained for each spectrum.

Spectrum Simulation Experimental Error % Ref.
(Exp –Sim) / Exp
a (σm> 0) 292730 cycle / /
b (σm = 0) 468245 cycle 499370 cycle 6.23 [4]
c (σm< 0) 832608 cycle / /

Table 2 represents the fatigue prediction to failure Nf for each spectrum. So, it can be
remarked for the spectrum when mean stress equals zero (σm = 0), the total lifetime calculated
from the simulation is a good agreement with results obtained by ref. [4]. Therefore, the
relative prediction error indicates that the convergence between predictions and experimental
reality (Relative error forecasting) are much more pronounced for this simulation. It should be
noted that that fatigue lifetime is important for the type of loading spectrum (compression-
compression) where the mean stress is less than zero, this is explained by a parametric effect
since the Morrow criterion is used and a mechanical effect when the material is under random
loading of the spectrum (compression-compression) and then the dislocations are slid slowly
until it causes delayed damage [34], [36]. When the material is damaged and undergoes
permanent plastic strain, the residual stresses are induced by hardening the material leading to
the long fatigue prediction. Experimental tests [8], [23] have shown that the presence of mean
stress of random loading changes the fatigue lifetime of material. Consequently, the authors
concluded that if m> 0 the fatigue life decreases, but when to mean stress m<0 the fatigue
life increases. In addition, the results were shown to be in good process to each other as well
as experimental measurements in the literatures[4], [8], [23].

5. Rainflow cycle counting application

The Rainflow cycle counting method extracts the composition of variable amplitude loading
history. This method was implemented in the Ansys software and the hysteresis loops was
generated.
Figure 8 represents the hysteresis loops found from spectrum (a) when loading (σm> 0) so the
mean stress is well noticed. Indeed, a small ratchet was observed which corresponds to a
stabilized asymptotic state in which during the plastic deformations it is believe that tend
towards a constant value. The response of the structure is then purely plastic as shown in
Figure 8, which will cause the failure of the structure in a relatively very small number of
cycles.
400

Spectrum (a) m > 0

300

200
[MPa]

100
Stress 

-100

-200

-300
-0,002 0,000 0,002 0,004 0,006 0,008

Strain  [mm/mm]

Figure 8. The hysteresis loops corresponding to the spectrum (a), when (σm> 0)
The cyclic response under the effect of the second Spectrum is made under almost zero mean
stress (σm = 0), it’s possible to observe a phenomenon of accommodation corresponding to a
stabilized limit state where the plastic deformations remain limited. In other words, the
structure plasticizes at each cycle, but after a certain number of cycles, the plastic
deformations find at the cycle to failure (see Figure 9). Indeed, the fatigue life prediction is
relatively increased than the first type of load (σm> 0).

300
Spectrum (b) m = 0

200
[MPa]

100

0
Stress 

-100

-200

-300

-0,008 -0,006 -0,004 -0,002 0,000 0,002 0,004

Strain  [mm/mm]

Figure 9. The hysteresis loops corresponding to the spectrum (b) when (σm = 0)

In this case of type of loading (compression-compression) when (σm<0), a negative ratchet

phenomenon can be observed which accounts for the material undergoing permanent plastic
deformation which has made the material hardened and consequently the fatigue life is
increased, see Figure 10.

300
Spectrum (c) m < 0
200

100
[MPa]

0
Stress 

-100

-200

-300

-0,016 -0,014 -0,012 -0,010 -0,008 -0,006 -0,004 -0,002 0,000

Strain  [mm/mm]

Figure 10. The hysteresis loops corresponding to the spectrum (c) when (σm< 0)
The matrix results are only available for studies based on the cumulative fatigue damage with
variable amplitude. A matrix result of Rainflow is a 3D histogram in which the X and Y axes
represent strain and mean stress, respectively. The Z axis represents the percentage damages
caused by cycle for the damage matrix result. Indeed, the results of the Rainflow and damage
matrix can be useful for determining the effects of small stress cycles in the loading history.
Figure 11 (right) represents the damage matrix for the three spectrums studied; these results
can be extended and similar to the Rainflow matrix (left). Indeed, in all the cases studied, it’s
noticed that most of the Rainflow matrix counts occur at small alternating stresses (or range),
and the damage observed for important strain and indicated in percentage. According to
Miner's law, if the damage is 1 (or 100%) then the failure is assured. In this example, even if
the low or medium damage cycles occur most often, the highest values cause the most
damage or failure. The analysis of the damage by fatigue shows the relative number of
damage due to each cycle.

Spectrum (a) (σm = 0)

 Spectrum (b) (σm> 0)

Spectrum (c) (σm< 0)

Figure 11. 3D histograms with the Rainflow matrix (left histogram) and damage matrix (right
histogram)

6. Conclusions
The purpose of this scientific work is to simulate fatigue damage and predict it under random
loading taking account the effects of mean stress. Based on the simulations and literature
study done in this work, the following conclusions can be drawn:
 The fatigue damage under random loading of this alloy 6082 T6 can be predicted by
simulation.
 The fatigue lifetime can be increased if random cyclic loading is done with mean
stress above zero, the spectrum compression-compression, which can explain by a
mobility of weak sliding bands comparable to the traction-traction case.
  When the material is undergoing permanent plastic deformation that has hardened, due
to the type of compression-compression loading, the fatigue lifetime prediction
increases.
 If the mean stress is increased the fatigue lifetime prediction decreases.
 The cycles counting simulation method allows to quantify the hysteresis loops, even if
for small amplitude stresses.
 For all the cases studied, the Rainflow matrix counting occurs at small alternating
stresses and the damage is observed.
 If the cycles are low or medium; the damage occurs most often, the higher values of
alternating stresses cause the most failure of materials.
 Analysis of the fatigue prediction under random loading shows that the damage due to
each cycle.

Acknowledgements
This work was financially supported by: Base Funding - UIDB/04708/2020 and
Programmatic Funding - UIDP/04708/2020 of the CONSTRUCT - Instituto de I&D
emEstruturas e Construções - funded by national funds through the FCT/MCTES (PIDDAC).

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