双剪连接件及双耳连接耳片疲劳寿命估算的逐次累计求和算法
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摘要
为了研究复杂连接件疲劳失效机理和估算其裂纹形成和扩展寿命,在双剪连接件和双耳连接耳片疲劳试验的基础上,首先,通过扫描电子显微镜(SEM)分析,研究了其破坏模式和机理,并利用断口定量反推技术判读了疲劳裂纹形成与扩展寿命。然后,根据应力严重系数法,建立了复杂连接件疲劳性能S-N-L(疲劳应力-寿命-应力严重系数)曲面;利用该曲面,发展了复杂连接件疲劳裂纹形成寿命估算算法;基于断裂力学理论,推导出裂纹扩展长度与扩展角度公式,建立了疲劳裂纹扩展寿命估算的累计求和算法。最后,运用寿命估算方法,估算了双剪连接件的疲劳裂纹形成寿命、双剪连接件和双耳连接耳片的裂纹扩展寿命,预测结果与断口判读结果吻合良好。本文寿命估算方法为复杂连接件疲劳定寿提供了理论依据。
This paper aims to investigate the failure mechanics of complex joints and evaluate the crack initiate and growth lifetimes of complex joints. Fatigue tests were respectively carried out on double-lap and double-lug joints,failure modes and mechanisms were investigated through scanning electron microscope( SEM) analysis,and fatigue lifetime for crack initiation and growth was determined from fractographic quantitatively interpreted data by using reverse inference method. From the stress severity factor method,fatigue S-N-L( stress-life-stress severity factor) surface model was developed to characterize fatigue characteristics of complex joints for predicting fatigue crack initiation life. Based on fracture mechanics,the formulations were crafted to predict the length and angle of crack growth,and the cycle-by-cycle accumulation algorithm was presented to assess the lifetime of crack growth of joint. Finally,the proposed model and algorithm were used to respectively simulate the lifetime of fatigue crack initiation and propagation for double-lap and double-lug joints,which demonstrates the good agreement between the prediction results and the fracture interpretation results. The proposed model and algorithm provide theoretical basis for determining fatigue lifetime of complex joints.
This paper aims to investigate the failure mechanics of complex joints and evaluate the crack initiate and growth lifetimes of complex joints. Fatigue tests were respectively carried out on double-lap and double-lug joints,failure modes and mechanisms were investigated through scanning electron microscope( SEM) analysis,and fatigue lifetime for crack initiation and growth was determined from fractographic quantitatively interpreted data by using reverse inference method. From the stress severity factor method,fatigue S-N-L( stress-life-stress severity factor) surface model was developed to characterize fatigue characteristics of complex joints for predicting fatigue crack initiation life. Based on fracture mechanics,the formulations were crafted to predict the length and angle of crack growth,and the cycle-by-cycle accumulation algorithm was presented to assess the lifetime of crack growth of joint. Finally,the proposed model and algorithm were used to respectively simulate the lifetime of fatigue crack initiation and propagation for double-lap and double-lug joints,which demonstrates the good agreement between the prediction results and the fracture interpretation results. The proposed model and algorithm provide theoretical basis for determining fatigue lifetime of complex joints.
引文
[1]ESMAEILI F,CHAKHERLOU T N,ZEHSAZ M.Investigation of bolt clamping force on the fatigue life of double lap simple bolted and hybrid(bolted/bonded)joints via experimental and numerical analysis[J].Engineering Failure Analysis,2014,45(8):406-420.
[2]ESMAEILI F,CHAKHERLOU T N.Investigation on the effect of tigthening torque on the stress distribution in double lap simple bolted and hybrid(bolted-bonded)joints[J].Journal of Solid Mechanics,2015,7(3):268-280.
[3]JIMNEZ-PEA C,TALEMI R H,ROSSI B,et al.Investigations on the fretting fatigue failure mechanism of bolted joints in high strength steel subjected to different levels of pre-tension[J].Tribology International,2016,108(4):128-140.
[4]ABAZADEH B,CHAKHERLOU T N,ALDERLIESTEN R C.Effect of interference fitting and/or bolt clamping on the fatigue behavior of Al alloy 2024-T3 double shear lap joints in different cyclic load ranges[J].International Journal of Mechanical Sciences,2013,72(7):2-12.
[5]CHAKHERLOU T N,MIRZAJANZADEH M,ABAZADEH B,et al.An investigation about interference fit effect on improving fatigue life of a holed single plate in joints[J].European Journal of Mechanics A/Solids,2010,29(4):675-682.
[6]CHAKHERLOU T N,MIRZAJANZADEH M,VOGWELL J.Experimental and numerical investigations into the effect of an interference fit on fatigue life of double shear lap joints[J].Engineering Failure Analysis,2009,16(7):2066-2080.
[7]CHAKHERLOU T N,TAGHIZADEH H,AGHDAM A B.Experimental and numerical comparison of cold expansion and interference fit methods in improving fatigue life of holed plate in double shear lap joints[J].Aerospace Science and Technology,2013,29(1):351-362.
[8]GOPALAKRISHNA H D,MURTHY H N N,KRISHNA M,et al.Cold expansion of holes and resulting fatigue life enhancement and residual stresses in Al 2024 T3 alloy-An experimental study[J].Engineering Failure Analysis,2010,17(2):361-368.
[9]CHAKHERLOU T N,VOGWELL J.The effect of cold expansion on improving the fatigue life of fastener holes[J].Engineering Failure Analysis,2003,10(1):13-24.
[10]RALPH W C,JOHNSON W S,MAKEEV A,et al.Fatigue performance of production-quality aircraft fastener holes[J].International Journal of Fatigue,2007,29(7):1319-1327.
[11]MUCHA J,WITKOWSKI W.The experimental analysis of the double joint type change effect on the joint destruction process in uniaxial shearing test[J].Thin-Walled Structures,2013,66(5):39-49.
[12]SKORUPA M,MACHNIEWICZ T,SKORUPA A,et al.Fatigue life predictions for riveted lap joints[J].International Journal of Fatigue,2017,94(1):41-57.
[13]LIU J H,ZHANG R L,WEI Y B,et al.A new method for estimating fatigue life of notched specimen[J].Theoretical and Applied Fracture Mechanics,2018,93(1):137-143.
[14]田本鉴,熊峻江.非对称疲劳载荷作用铆钉连接件疲劳寿命估算[J].北京航空航天大学学报,2013,39(12):1649-1653.TIAN B J,XIONG J J.Fatigue life estimation of riveted joints subjected to asymmetrical loading[J].Journal of Beijing University of Aeronautics and Astronautics,2013,39(12):1649-1653(in Chinese).
[15]张天宇,何宇廷,陈涛,等.一种多钉铆接连接件的疲劳寿命分析方法[J].北京航空航天大学学报,2018,44(9):1933-1940.ZHANG T Y,HE Y T,CHEN T,et al.A fatigue life analysis method for multiple riveted joint[J].Journal of Beijing University of Aeronautics and Astronautics,2018,44(9):1933-1940(in Chinese).
[16]HUANG W,WANG T J,GARBATOV Y,et al.DFR based fatigue reliability assessment of riveted lap joint accounting for correlations[J].International Journal of Fatigue,2013,47(2):106-114.
[17]TIAN B J,XIONG J J,LIU J Z.A new approach for evaluating fatigue lives of multi-fastener mechanical joints based on a nominal stress concept and minimal datasets[J].International Journal of Fatigue,2015,80(11):257-265.
[18]DE JESUS A M P,DA SILVA A L L,CORREIA J A F O.Fatigue of riveted and bolted joints made of puddle iron-A numerical approach[J].Journal of Constructional Steel Research,2014,102(1):164-177.
[19]SANCHES R F,DE JESUS A M P,CORREIA J A F O,et al.Aprobabilistic fatigue approach for riveted joints using Monte Carlo simulation[J].Journal of Constructional Steel Research,2015,110(7):149-162.
[20]MIKKOLA E,MURAKAMI Y,MARQUIS G.Equivalent crack approach for fatigue life assessment of welded joints[J].Engineering Fracture Mechanics,2015,149:144-155.
[21]CORREIA J A F O,BLASN S,DE JESUS A M P,et al.Fatigue life prediction based on an equivalent initial flaw size approach and a new normalized fatigue crack growth model[J].Engineering Failure Analysis,2016,69(11):15-28.
[22]MIKKOLA E,MURAKAMI Y,MARQUIS G.Fatigue life assessment of welded joints by the equivalent crack length method[J].Procedia Materials Science,2014,3:1822-1827.
[23]WU Y Z,XU Y W,GUO X,et al.Fatigue life prediction based on equivalent initial flaw size for Al-Li 2297 under spectrum loading[J].International Journal of Fatigue,2017,103(14):39-47.
[24]张丽娜,吴学仁,刘建中.疲劳裂纹扩展中单峰过载引起的残余应力强度因子计算[J].机械强度,2011,33(3):432-437.ZHANG L N,WU X R,LIU J Z.Computation of residual stress intensity factors induced by single overload during fatigue crack growth[J].Journal of Mechanical Strength,2011,33(3):432-437(in Chinese).
[25]王延忠,田志敏,侯良威,等.航空重载面齿轮三维裂纹分析与疲劳裂纹扩展寿命预测[J].北京航空航天大学学报,2014,40(2):148-153.WANG Y Z,TIAN Z M,HOU L W,et al.Three-dimensional crack analysis and fatigue life prediction of aero heavy-load face gear[J].Journal of Beijing University of Aeronautics and Astronautics,2014,40(2):148-153(in Chinese).
[26]KUMAR S A,BHATTACHARYA A,BABU N C M.Fatigue crack growth life prediction around cold expanded hole using finite element method[J].Procedia Materials Science,2014,5:316-325.
[27]BERGARA A,DORADO J I,MEIZOSO A M,et al.Fatigue crack propagation in complex stress fields:Experimental and numerical simulations using the extended finite element method(XFEM)[J].International Journal of Fatigue,2017,103(14):112-121.
[28]NASRI K,ZENASNI M.Fatigue crack growth simulation in coated materials using X-FEM[J].Comptes Rendus Mecanique,2017,345(4):271-280.
[29]熊峻江.飞行器结构疲劳与寿命设计[M].北京:北京航空航天大学出版社,2004.XIONG J J.Fatigue life design for aircraft structure[M].Beijing:Beihang University Press,2004.
[30]赵少汴.抗疲劳设计手册[M].北京:机械工业出版社,2015.ZHAO S B.Fatigue design manual[M].Beijing:China Machine Press,2015.
[31]FU Y,XIONG J J,SHENOI R A.Practical models for characterizing corrosion fatigue behaviours of metallic materials and for evaluating calendar lives of aircraft structural components[J].Proceedings of Institution of Mechanical Engineers Part C-Journal of Mechanical Engineering Science,2017,231:207-222.
[32]HERTZBERG R W.Deformation and fracture mechanics of engineering materials[M].Hoboken:Wiley Jones and Sons,1996.
[33]CHANG J,XU J Q,MUTOH Y.A general mixed-mode brittle fracture criterion for cracked materials[J].Engineering Fracture Mechanics,2006,73(9):1249-1263.
[34]AYGL M,AL-EMRANI M,BARSOUM Z,et al.An investigation of distortion-induced fatigue cracking under variable amplitude loading using 3D crack propagation analysis[J].Engineering Failure Analysis,2014,45(10):151-163.
[35]Federal Aviation Administration.Metallic materials properties development and standardization[M].Columbia:U.S.Department of Transportation,2006:3-94.
[36]ASTM.Standard practice for:Presentation of constant amplitude fatigue test results for metallic materials:ASTM E468-90[S].West Conshohocken:ASTM International,2004:1-6.
[37]刘新灵,张铮,陶春虎.疲劳断口定量分析[M].北京:国防工业出版社,2010.LIU X L,ZHANG Z,TAO C H.Fatigue fractography quantitative analysis[J].Beijing:National Defense Industry Press,2010(in Chinese).
[38]郑晓玲,刘文珽,李令芳,等.民机结构耐久性与损伤容限设计手册[M].北京:航空工业出版社,2003.ZHENG X L,LIU W T,LI L F,et al.Design manual for durability and damage tolerance of civil aircraft structures[M].Beijing:Aviation Industry Press,2003(in Chinese).
[2]ESMAEILI F,CHAKHERLOU T N.Investigation on the effect of tigthening torque on the stress distribution in double lap simple bolted and hybrid(bolted-bonded)joints[J].Journal of Solid Mechanics,2015,7(3):268-280.
[3]JIMNEZ-PEA C,TALEMI R H,ROSSI B,et al.Investigations on the fretting fatigue failure mechanism of bolted joints in high strength steel subjected to different levels of pre-tension[J].Tribology International,2016,108(4):128-140.
[4]ABAZADEH B,CHAKHERLOU T N,ALDERLIESTEN R C.Effect of interference fitting and/or bolt clamping on the fatigue behavior of Al alloy 2024-T3 double shear lap joints in different cyclic load ranges[J].International Journal of Mechanical Sciences,2013,72(7):2-12.
[5]CHAKHERLOU T N,MIRZAJANZADEH M,ABAZADEH B,et al.An investigation about interference fit effect on improving fatigue life of a holed single plate in joints[J].European Journal of Mechanics A/Solids,2010,29(4):675-682.
[6]CHAKHERLOU T N,MIRZAJANZADEH M,VOGWELL J.Experimental and numerical investigations into the effect of an interference fit on fatigue life of double shear lap joints[J].Engineering Failure Analysis,2009,16(7):2066-2080.
[7]CHAKHERLOU T N,TAGHIZADEH H,AGHDAM A B.Experimental and numerical comparison of cold expansion and interference fit methods in improving fatigue life of holed plate in double shear lap joints[J].Aerospace Science and Technology,2013,29(1):351-362.
[8]GOPALAKRISHNA H D,MURTHY H N N,KRISHNA M,et al.Cold expansion of holes and resulting fatigue life enhancement and residual stresses in Al 2024 T3 alloy-An experimental study[J].Engineering Failure Analysis,2010,17(2):361-368.
[9]CHAKHERLOU T N,VOGWELL J.The effect of cold expansion on improving the fatigue life of fastener holes[J].Engineering Failure Analysis,2003,10(1):13-24.
[10]RALPH W C,JOHNSON W S,MAKEEV A,et al.Fatigue performance of production-quality aircraft fastener holes[J].International Journal of Fatigue,2007,29(7):1319-1327.
[11]MUCHA J,WITKOWSKI W.The experimental analysis of the double joint type change effect on the joint destruction process in uniaxial shearing test[J].Thin-Walled Structures,2013,66(5):39-49.
[12]SKORUPA M,MACHNIEWICZ T,SKORUPA A,et al.Fatigue life predictions for riveted lap joints[J].International Journal of Fatigue,2017,94(1):41-57.
[13]LIU J H,ZHANG R L,WEI Y B,et al.A new method for estimating fatigue life of notched specimen[J].Theoretical and Applied Fracture Mechanics,2018,93(1):137-143.
[14]田本鉴,熊峻江.非对称疲劳载荷作用铆钉连接件疲劳寿命估算[J].北京航空航天大学学报,2013,39(12):1649-1653.TIAN B J,XIONG J J.Fatigue life estimation of riveted joints subjected to asymmetrical loading[J].Journal of Beijing University of Aeronautics and Astronautics,2013,39(12):1649-1653(in Chinese).
[15]张天宇,何宇廷,陈涛,等.一种多钉铆接连接件的疲劳寿命分析方法[J].北京航空航天大学学报,2018,44(9):1933-1940.ZHANG T Y,HE Y T,CHEN T,et al.A fatigue life analysis method for multiple riveted joint[J].Journal of Beijing University of Aeronautics and Astronautics,2018,44(9):1933-1940(in Chinese).
[16]HUANG W,WANG T J,GARBATOV Y,et al.DFR based fatigue reliability assessment of riveted lap joint accounting for correlations[J].International Journal of Fatigue,2013,47(2):106-114.
[17]TIAN B J,XIONG J J,LIU J Z.A new approach for evaluating fatigue lives of multi-fastener mechanical joints based on a nominal stress concept and minimal datasets[J].International Journal of Fatigue,2015,80(11):257-265.
[18]DE JESUS A M P,DA SILVA A L L,CORREIA J A F O.Fatigue of riveted and bolted joints made of puddle iron-A numerical approach[J].Journal of Constructional Steel Research,2014,102(1):164-177.
[19]SANCHES R F,DE JESUS A M P,CORREIA J A F O,et al.Aprobabilistic fatigue approach for riveted joints using Monte Carlo simulation[J].Journal of Constructional Steel Research,2015,110(7):149-162.
[20]MIKKOLA E,MURAKAMI Y,MARQUIS G.Equivalent crack approach for fatigue life assessment of welded joints[J].Engineering Fracture Mechanics,2015,149:144-155.
[21]CORREIA J A F O,BLASN S,DE JESUS A M P,et al.Fatigue life prediction based on an equivalent initial flaw size approach and a new normalized fatigue crack growth model[J].Engineering Failure Analysis,2016,69(11):15-28.
[22]MIKKOLA E,MURAKAMI Y,MARQUIS G.Fatigue life assessment of welded joints by the equivalent crack length method[J].Procedia Materials Science,2014,3:1822-1827.
[23]WU Y Z,XU Y W,GUO X,et al.Fatigue life prediction based on equivalent initial flaw size for Al-Li 2297 under spectrum loading[J].International Journal of Fatigue,2017,103(14):39-47.
[24]张丽娜,吴学仁,刘建中.疲劳裂纹扩展中单峰过载引起的残余应力强度因子计算[J].机械强度,2011,33(3):432-437.ZHANG L N,WU X R,LIU J Z.Computation of residual stress intensity factors induced by single overload during fatigue crack growth[J].Journal of Mechanical Strength,2011,33(3):432-437(in Chinese).
[25]王延忠,田志敏,侯良威,等.航空重载面齿轮三维裂纹分析与疲劳裂纹扩展寿命预测[J].北京航空航天大学学报,2014,40(2):148-153.WANG Y Z,TIAN Z M,HOU L W,et al.Three-dimensional crack analysis and fatigue life prediction of aero heavy-load face gear[J].Journal of Beijing University of Aeronautics and Astronautics,2014,40(2):148-153(in Chinese).
[26]KUMAR S A,BHATTACHARYA A,BABU N C M.Fatigue crack growth life prediction around cold expanded hole using finite element method[J].Procedia Materials Science,2014,5:316-325.
[27]BERGARA A,DORADO J I,MEIZOSO A M,et al.Fatigue crack propagation in complex stress fields:Experimental and numerical simulations using the extended finite element method(XFEM)[J].International Journal of Fatigue,2017,103(14):112-121.
[28]NASRI K,ZENASNI M.Fatigue crack growth simulation in coated materials using X-FEM[J].Comptes Rendus Mecanique,2017,345(4):271-280.
[29]熊峻江.飞行器结构疲劳与寿命设计[M].北京:北京航空航天大学出版社,2004.XIONG J J.Fatigue life design for aircraft structure[M].Beijing:Beihang University Press,2004.
[30]赵少汴.抗疲劳设计手册[M].北京:机械工业出版社,2015.ZHAO S B.Fatigue design manual[M].Beijing:China Machine Press,2015.
[31]FU Y,XIONG J J,SHENOI R A.Practical models for characterizing corrosion fatigue behaviours of metallic materials and for evaluating calendar lives of aircraft structural components[J].Proceedings of Institution of Mechanical Engineers Part C-Journal of Mechanical Engineering Science,2017,231:207-222.
[32]HERTZBERG R W.Deformation and fracture mechanics of engineering materials[M].Hoboken:Wiley Jones and Sons,1996.
[33]CHANG J,XU J Q,MUTOH Y.A general mixed-mode brittle fracture criterion for cracked materials[J].Engineering Fracture Mechanics,2006,73(9):1249-1263.
[34]AYGL M,AL-EMRANI M,BARSOUM Z,et al.An investigation of distortion-induced fatigue cracking under variable amplitude loading using 3D crack propagation analysis[J].Engineering Failure Analysis,2014,45(10):151-163.
[35]Federal Aviation Administration.Metallic materials properties development and standardization[M].Columbia:U.S.Department of Transportation,2006:3-94.
[36]ASTM.Standard practice for:Presentation of constant amplitude fatigue test results for metallic materials:ASTM E468-90[S].West Conshohocken:ASTM International,2004:1-6.
[37]刘新灵,张铮,陶春虎.疲劳断口定量分析[M].北京:国防工业出版社,2010.LIU X L,ZHANG Z,TAO C H.Fatigue fractography quantitative analysis[J].Beijing:National Defense Industry Press,2010(in Chinese).
[38]郑晓玲,刘文珽,李令芳,等.民机结构耐久性与损伤容限设计手册[M].北京:航空工业出版社,2003.ZHENG X L,LIU W T,LI L F,et al.Design manual for durability and damage tolerance of civil aircraft structures[M].Beijing:Aviation Industry Press,2003(in Chinese).