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Microstructure based fatigue analysis of cast components under variable amplitude loading

: Eufinger, Jens; Heinrietz, Andre; Bruder, Thomas; Hanselka, Holger

Oechsner, M. ; TU Darmstadt; TU Darmstadt, Institut für Stahlbau und Werkstoffmechanik:
3rd Symposium on Structural Durability, SoSDiD 2011. Proceedings : May 26 - 27, 2011, Darmstadt, Germany
Darmstadt: Technische Universität Darmstadt, Institut für Stahlbau und Werkstoffmechanik, 2011
ISBN: 978-3-939195-26-9
Symposium on Structural Durability (SoSDiD) <3, 2011, Darmstadt>
Conference Paper
Fraunhofer LBF ()
microstructure; fatigue analysis; cast components; variable amplitude loading; cast iron; local strain approach; transferability; damage accumulation rule; load sequence effect; fracture mechanics; material fatigue; local strain

Reliable numerical fatigue life analyses are becoming increasingly important given the need to reduce the time and costs for product development and the need to evaluate large and single components. Stress-based approaches as well as the local strain approach and its fracture mechanics based extension (PJ model) are in use for that. Both the local strain approach and the PJ model require the supply of pure material data. This requirement for input data that are not component-specific makes such approaches interesting for widespread application. The accuracy of numerical fatigue life analyses is an essential criterion for the acceptance and the spread in industrial application. In the local strain approach, accuracy is determined on one hand by the transferability of material data for the fatigue life analysis of components and on the other by the damage accumulation rule. In this paper, the local strain approach and the PJ model are used to analyse fatigue life under both constant and variable amplitude loading. These analyses are based on the experimental results obtained from tests of a commercial vehicle component made of nodular cast iron EN-GJS-400-15. Aspects of transferability and damage accumulation are considered. Results obtained from using an elastic-plastic fracture mechanics based approach to estimate a PSWT-N-curve, taken into account the inhomogeneities in the microstructure of the cast iron, are also presented.