Metal Fatigue

Analysis Handbook
Practical Problem-Solving Techniques
for Computer-Aided Engineering

Yung-Li Lee

Mark E. Barkey
Hong-Tae Kang

AMSTERDAM •
BOSTON • HEIDELBERG •
LONDON

NEW YORK • OXFORD •

PARIS •
SAN DIEGO

ms- SAN FRANCISCO • SINGAPORE «

SYDNEY •
TOKYO

ELSEVIER Butterworth-Heinemann is an imprint of Elsevier

 Contents

xv
Preface
xix
Acknowledgments
About the Authors xxi

Nomenclature xxiii

1: Road Load Analysis Techniques in Automotive Engineering 1

Chapter
Xiaobo Yang, Peijun Xu

Introduction 1

Fundamentals of Multibody Dynamics 4

Conditions of Equilibrium 6
D'Alembert's Principle 7
10
Multibody Dynamics Systems
Generic Load Cases 12

Generic Load Events 13

Analysis Procedure 19

Results and 20
Report
22
Semianalytical Analysis
Powertrain Mount Load 22
Analyses
Component Load Analysis 30
Suspension
Vehicle Load Analysis Using 3D Digitized Road Profiles 39

Vehicle Model Description 42

Tire Model Description 43

Model Validation Process 46

56
Summary
References 57

vii
Contents

Chapter 2: Pseudo Stress Analysis Techniques 61

Yung-Li Lee, Mingchao Guo

Introduction 61

Static Stress Analysis 62

Fixed Reactive Analysis 63
Inertia Relief Analysis 66

Modal Transient Response Analysis 71

Natural Frequencies and Normal Modes 72
Orthonormalization of Normal Modes 73
Decoupled Modal Equations of Motion 77
Numerical Integration Method for Equations of Motion 80

Summary 85

References 86

Chapter 3: Rainflow Cycle Counting Techniques 89

Yung-Li Lee, Tana Tjhung

Introduction 89
Uniaxial Rainflow Cycle Counting Techniques 90
Rainflow Counting Method by Matsuishi and Endo 90
Three-Point Counting Technique 94
Four-Point Counting Technique 102
Multiaxial Rainflow Reversal Counting Techniques 106
Summary 112
References 113

Chapter 4: Stress-Based Uniaxial Fatigue Analysis 7 75

Yung-Li Lee, Mark E. Barkey

Introduction 116
Ultimate Tensile Strength of a Component 120
Reliability Correction Factor 121
Size Correction Factor 123
Temperature Correction Factor for Ultimate
and Yield Strengths 124
Stress Correction Factor 126
Load Correction Factor 126

Component Endurance Limit under Fully Reversed Loading 128

Temperature Correction Factor 130
Endurance Limit Factor 131

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Surface Treatment Factor 132

Roughness Correction Factor 132

Fatigue Notch Factor 134

Constant Amplitude Stress-Life Curve for a Notched

Component under Fully Reversed Loading 145

Constant Amplitude Nominal Stress-Life Curve 145
Constant Amplitude Pseudo Stress-Life Curve 147

Stress-Life Curve for a Component under Variable

Amplitude Loading 149

Mean Stress Effect 151

Summary 157

References 159

Chapter 5: Stress-Based Multiaxial Fatigue Analysis 767

Yung-Li Lee, Mark E. Barkey

Introduction 161

Fatigue Damage Models 168

Empirical FormulaApproach 168

Equivalent Stress Approach 170
Critical Plane Approach 186

Dang Van's Multiscale Approach 199

Summary 210
References 211

Chapter 6: Strain-Based Uniaxial Fatigue Analysis 275

Yung-Li Lee, Mark E. Barkey

Introduction 215

Steady StateCyclic Stress-Strain Relation 217

Fully Reversed, Constant Amplitude Strain-Life Relation 221

Estimate of Cyclic Material and Fatigue Properties 223

Strain-Life Equations with Mean Stress 224

Morrow 224

Smith, Watson, and Topper 225

Notch Analysis 231

Neuber 232

Nominally Elastic Behavior 234

Nominally Gross Yielding of a Net Section 235

Modified Neuber Rule 236

ix
Contents

Molsky and Glinka 239

Applications 246

Summary 249
References 250

Chapter 7: Fundamentals of Cyclic Plasticity Theories 253

Yung-Li Lee, Mark E. Barkey

Introduction 254
Tensor Notations 254

Theory of Elasticity 255

Monotonic Plasticity Theories 257

Yield Surface Function 257
Isotropic Hardening 259
Flow Rules 260
Plastic Strains 264

Cyclic Plasticity Theories 265

Elastic and Plastic Processes 270
Associated Flow Rule 271
Consistency Condition 272
Kinematic Hardening Models 272
Determination of a Generalized Plastic Modulus 274
Stresses and Strains 283

Applications: Notch Analyses Based on Pseudo Stresses 284

Hoffmann and Seeger 285
Buczynski and Glinka 289
Lee, Chiang, and Wong 292

Summary 293
References 294

Chapter 8: Strain-Based Multiaxial Fatigue Analysis 299

Mark E. Barkey, Yung-Li Lee

Introduction 299
Fatigue Damage Models 300
Equivalent Strain
Approaches 300
Energy Approaches 309
Critical PlaneApproaches 311
Strain Gage Analysis
Rosette 316
Strain Data Acquisitions 318
Fatigue Analysis with Plasticity 323

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Summary 329
References 330

Chapter 9: Vibration Fatigue Testing and Analysis 333

Yung-Li Lee, Hong-Tae Kang

Introduction 333

Swept Sinusodial or Single-Frequency Sweep Test 336

Response to a Linear
Single-Degree-of-Freedom System
Subjected to Sinusoidal-Based Excitation 337

Fatigue Damage Calculation 341

Random Vibration Test 345
Characteristics of Random Vibration 345
Responses to a Linear
Single-Degree-of-Freedom System
Subjected to Base Random Vibration 356
Fatigue Damage Models under Random Stress Process 361

Summary 381
References 381

Chapter 10: Fatigue Life Prediction Methods of Seam-Welded

Joints 383

Hong-Tae Kang Yung-Li Lee

Introduction 383
Parameters Affecting Fatigue Lives of Seam-Welded Joints 384

Fatigue Life Prediction Methods 387

Nominal Stress Approaches 388
Structural Stress Approaches 389
Notch Pseudo Stress or RXMS Approach 407

Summary 421
References 423

Chapter 11: Fatigue Life Prediction Methods of Resistance

Spot-Welded Joints 429

Hong-Tae Kang Yung-Li Lee

Introduction 429
Parameters Affecting Spot-Welded Joints 430

Nugget Diameter 430

Sheet Metal Thickness 431

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Specimen Width 431

Base Metal Strength 432

Specimen Type 432

Multiaxial Loading 433

Fatigue Life Prediction Methods 435

Load Life Approach 435
Linear Elastic Fracture Mechanics Approach 436
Structural Stress Approach 442

Applications 448

Summary 455
References 456

Chapter 12:Design and Analysis of Metric Bolted Joints—VDI

Guideline and Finite Element Analysis 461

Yung-Li Lee, Hsin-Chung Ho

Introduction 462

Overview of Bolted Joints and Mechanical Properties 462

Estimate of a Bolt Diameter 471

Estimate of Joint Elastic Compliance (Resilience) 472
Elastic Compliance of a Bolt 473
Elastic Compliance of Clamped Plates for Concentrically
Bolted Joints 475
External Loads—Load Plan Factor (n) and Load Factor (<J>) 479

Assembly Loads on Bolted Joints 482

Embedding Effect 483

Tightening Torque 484

Assembly Preload 485

Clamped Plate Pressure 491
Minimum Thread Engagement Length 491

Service Loads on Bolted Joints 495

BoltYielding Due to Overstressing 495
Clamp Load Loss Due to Gapping 496
Thread Stripping 496
Clamped Plates Crushing Due to Excessive Pressure 496
Slipping Due to Transverse Loads 497
Fatigue Failure 497

Application 498
Solution 499

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Finite Element-Based Fatigue Analysis of Thread Bolts 507

Solid Bolt Model 508
Spider Bolt Model 510

Summary 512
References 513

Index 515

xiii