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Research Papers

Damage and Rupture Simulation for Mechanical Parts Under Cyclic Loadings

[+] Author and Article Information
Fabien Bogard

GRESPI/LMN, Université de Reims Champagne Ardenne, Moulin de la House, BP1039, 51687 Reims Cedex2, Francefabien.bogard@univ-reims.fr

Philippe Lestriez, Ying-Qiao Guo

GRESPI/LMN, Université de Reims Champagne Ardenne, Moulin de la House, BP1039, 51687 Reims Cedex2, France

J. Eng. Mater. Technol 132(2), 021003 (Feb 16, 2010) (8 pages) doi:10.1115/1.4000668 History: Received December 08, 2008; Revised October 22, 2009; Published February 16, 2010; Online February 16, 2010

The purpose of this study is to develop a numerical methodology to simulate the fatigue damage of revolving mechanical parts under cyclic loadings (such as rolling bearings). The methodology is based on the continuum damage mechanics and on a fatigue damage model. The fatigue damage can be caused by numerous loading cycles, even in an elastic state; the damage will then influence the elastoplastic behaviors. The coupling effect of both enfeebles the material strength and leads to the rupture. An important improvement on the Sines fatigue criterion is proposed, which allows the coupling behaviors of damage and plasticity to be described better. This paper deals with the following aspects: (i) the fatigue damage model and the identification of fatigue parameters using S-N curves; (ii) the elastoplastic constitutive behaviors coupled with the fatigue damage; (iii) a cycle jumping algorithm to reduce the computation time; and (iv) an adaptative remeshing to follow the rupture propagation. These mechanical and numerical models are implemented in the framework of ABAQUS software. Two applications are presented in this paper: the fatigue lifetime prediction for a cyclic tension specimen and the fatigue spalling (or chipping) initiation and growth in a thrust roller bearing under a cyclic loading. The present approach is very efficient and helpful for the lifetime prediction of revolving mechanical components.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

Theoretical three stages of the stress evolution under cyclic loading

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Figure 2

Elimination of isolated elements surrounded by damaged elements and boundary

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Figure 3

Flow chart of the used methodology

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Figure 4

Force versus number of cycles for various imposed cyclic amplitudes

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Figure 5

Damage and rupture evolution in the 2D specimen (u=0.075)

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Figure 6

Number of cycles needed for each damaged element

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Figure 7

Influence of the coupling effect on the lifetime of the specimen

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Figure 8

(a) Adaptative remeshing after stress stabilized stage. (b) Loading variation in the cycle used for the thrust roller bearing.

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Figure 9

Damage distribution and crack propagation on a thrust bearing

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Figure 10

First spalling appearance on the race surface at 7558 cycles

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