Structural integrity and fatigue failure analysis : experimental, theoretical and numerical approaches

Preface
Contents
Part I Experimental Characterization & Microstructural Aspects of Fatigue and Fracture
1 Experimental Verification of the Survivability Model Under Mixed I+II Mode Fracture for Steels of Rolling Rolls
	1.1 Introduction
	1.2 General Regularities of Metals Behavior at the II Mode
		1.2.1 Approaches to an Estimation of Survivability at the Mixed Fracture
	1.3 Materials and Test Methods
	1.4 Experimental Results and Their Analysis
	1.5 Conclusions
	References
2 Accelerated Fatigue Test Procedure for Leaf Springs Applied to Semi-Trailers
	2.1 Introduction
	2.2 Materials and Methods
	2.3 Results
		2.3.1 Public Road Test
		2.3.2 Validation on Internal Test Ground
	2.4 Conclusions
	References
3 Early Evidences on the Rotating Bending Fatigue Properties of Ductile and Vermicular Cast Irons
	3.1 Introduction
		3.1.1 Cast Iron
		3.1.2 Cast Production
	3.2 Materials and Methods
		3.2.1 Samples
		3.2.2 Modified Staircase Method
		3.2.3 Bias Reduction
	3.3 Results and Discussion
		3.3.1 Experimental Data
		3.3.2 Fatigue Limits
	3.4 Conclusions
	References
4 Rotating Bending Fatigue of Spheroidal Cast Irons
	4.1 Introduction
		4.1.1 Spheroidal Cast Iron
		4.1.2 Spheroidal Cast Production
		4.1.3 Aim and Scope
	4.2 Materials and Methods
		4.2.1 Samples Production
		4.2.2 Fatigue Life
	4.3 Results and Discussion
		4.3.1 Experimental Data
		4.3.2 Fatigue Limit
	4.4 Conclusions
	References
5 Microstructural and Mechanical Characterization of Riveted 19th-century Steels in Terms of Fatigue Lifetime Prediction
	5.1 Introduction
	5.2 Plate Steel and Rivet Steel from Nineteenth-Century Bridges
		5.2.1 Puddled and Early Mild Steel
		5.2.2 Riveting
	5.3 Microstructural Analysis
	5.4 Mechanical Characterization and Degradation Processes–Fatigue Lifetime Reduction
	5.5 Conclusions
	References
Part II Fatigue Life Prediction
6 Acoustic Emission Characteristics for Determining Fatigue Damage Behaviour
	6.1 Introduction
	6.2 Experimental Programme
		6.2.1 Preparation of Reinforced Concrete Beam
		6.2.2 Laboratory Test
	6.3 Results and Discussion
		6.3.1 Absolute Energy
		6.3.2 Amplitude, Cumulative Average Frequency and Cumulative Amplitude
	6.4 Conclusions
	References
7 Predicting the Fatigue Life of Hydraulic Unit Under Variable Operating Conditions
	7.1 Introduction
	7.2 The Impact of Operating Modes
	7.3 Proposed Approach
	7.4 Results
	7.5 Conclusion
	References
8 Predicted Distribution in Measured Fatigue Life from Expected Distribution in Cyclic Stress–strain Properties Using a Strain-Energy Based Damage Model
	8.1 Probabilistic Fatigue
	8.2 Strain-Energy Density Damage
	8.3 Results
	8.4 Conclusion
		8.4.1 Discussion
		8.4.2 Future Work
	References
9 Modification Optimization-Based Fatigue Life Analysis and Improvement of EMU Gear
	9.1 Introduction
	9.2 The Establishment of EMU Gear Model
	9.3 Gear Modification Theory
	9.4 Transient Dynamic Analysis of EMU Gear
	9.5 Fatigue Life Prediction of EMU Gear
		9.5.1 Correction of S–N Curve
		9.5.2 Correction of Stress Amplitude
		9.5.3 Correction of Mean Stress
	9.6 Case Analysis
		9.6.1 Simplification of Gear Model
		9.6.2 Transient Dynamic Analysis and Modification Design of Gear
		9.6.3 Fatigue Life Analysis of Modification EMU Gear
	9.7 Conclusion
	References
10 Fatigue Life Analysis of Strain Loadings Using Effective Strain Damage Approach with the Consideration of Cycle Sequence Effects
	10.1 Introduction
	10.2 Methodology
		10.2.1 Finite Element Analysis
		10.2.2 Road Tests and Strain Histories Acquisition
		10.2.3 Fatigue Life Assessment Using Effective Strain Damage (ESD) and Strain-Life Models
	10.3 Results and Discussion
	10.4 Conclusion
	References
11 Fatigue in Trapezoidal Leaf Springs of Suspensions in Two-Axle Wagons—An Overview and Simulation
	11.1 Introduction
		11.1.1 Background of the Railway Sector
		11.1.2 UIC Double Link Suspension
		11.1.3 UIC Leaf Springs
		11.1.4 Fatigue Failure
	11.2 Simulation Details
		11.2.1 Fatigue-Life Evaluation
		11.2.2 Material
		11.2.3 Geometric Model
		11.2.4 Material Definition and Discretization of Domain
		11.2.5 Definition of Contact Model
		11.2.6 Loading Conditions
		11.2.7 Stress–strain State Under Cyclic Conditions
	11.3 Results and Discussion
		11.3.1 Categorization of Stresses
		11.3.2 Normal Bending Stress for Straight Beams
		11.3.3 Determination of the Fatigue Crack Initiation Life
	11.4 Conclusions
	References
Part III Additive Manufacturing Metals
12 FE Modelling of the Fatigue Behaviour of L-PBF Inconel 718 with As-Built Surfaces
	12.1 Introduction
	12.2 As-Build Fatigue Behaviour
		12.2.1 Material and Specimen Fabrication
		12.2.2 Fatigue Testing and Results
	12.3 FE Analysis of As-Built Surfaces
		12.3.1 Characterization of As-Build Surface Profiles
		12.3.2 FE Analysis of As-Built Surfaces
	12.4 Results and Discussion
	12.5 Conclusions
	References
13 Three-Dimensional Fractography for Conventional and Additive Manufactured Steels After Bending-Torsion Fatigue
	13.1 Introduction
	13.2 Materials and Methods
	13.3 Results
	13.4 Conclusions
	References
14 Finite Element Analysis of Distortions, Residual Stresses and Residual Strains in Laser Powder Bed Fusion-Produced Components
	14.1 Introduction
	14.2 FEM Modeling of LPBF
		14.2.1 Simulation Approaches
		14.2.2 Selected Simulation Approaches
	14.3 Simulations and Results
		14.3.1 Convergence Study
		14.3.2 Comparison Between Approaches
		14.3.3 Comparison with Experimental Data
	14.4 Conclusions
	References
15 Metal Additive Manufacturing of End-Use Components and Parts: A Practical Overview
	15.1 Introduction
	15.2 Classification of Metal Additive Manufacturing Technologies
	15.3 Classification of Metal Additive Manufacturing Technologies
		15.3.1 Metal Powder Bed Fusion
		15.3.2 Direct Energy Deposition
		15.3.3 Binder Jetting
		15.3.4 Metal Additive Manufacturing Extrusion
	15.4 Conclusion
	References
16 Multiaxial Fatigue Behaviour of SLM 18Ni300 Steel
	16.1 Introduction
	16.2 Materials and Methods
	16.3 Results and Discussion
	16.4 Conclusions
	References
Part IV Composite Materials and Components
17 Study of Viscoelastic Properties of Sandwich Composites for Manufacturing Loudspeaker Membranes
	17.1 Introduction
	17.2 Methods of Measurements of Dynamical Properties
	17.3 Materials
	17.4 Results and Discussion
	17.5 Conclusions
	References
18 Experimental–Numerical Analysis of Radial Compression Test of CFRP/GFRP Composite Rebars
	18.1 Introduction
	18.2 Materials and Methods
		18.2.1 Material
		18.2.2 Out-of-Plane Compression
		18.2.3 Finite Element Method Analysis
	18.3 Results and Discussion
	18.4 Conclusions
	References
19 Numerical Analysis of the New Design of CFRP/GFRP Composite Rebars Subjected to Bending Loading
	19.1 Introduction
	19.2 Materials and Methods
	19.3 Results and Discussion
	19.4 Conclusions
	References
20 Numerical Analysis of Pultrusion Process of GFRP Composite Rebar
	20.1 Introduction
	20.2 Materials and Methods
		20.2.1 Pultrusion Die
		20.2.2 Materials
		20.2.3 Finite-Element Method Simulations
	20.3 Results and Discussion
	20.4 Conclusions
	References
21 Fracture Characterization of Hybrid Bonded Joints (CFRP/Steel) for Pure Mode I
	21.1 State of the Art and Methodology
		21.1.1 Introduction and Background
		21.1.2 Materials: Steel, Adhesive, and CFRP
		21.1.3 Fracture Mechanics on Hybrid Joints
	21.2 Numerical Simulation
		21.2.1 Introduction and Methodology
		21.2.2 Description of Numerical Model
		21.2.3 Results
	21.3 Experimental Work
		21.3.1 Specimens Preparation
		21.3.2 Experimental Tests and Results
	21.4 Conclusions and Future Work
	References
Part V Experimental Identification, Reliability and Structural Analysis
22 Durability Assessment of Multiaxial Strain Loads for Rural Road Condition in Time–Frequency Domain
	22.1 Introduction
	22.2 Methodology
		22.2.1 A Signal Acquisition Process
	22.3 Results and Discussion
	22.4 Conclusion
	References
23 Mode Superposition Techniques for a Priori High Stress Detection and Fatigue Hotspot Identification
	23.1 Introduction
	23.2 Basic Equations
	23.3 Modal Fields of Consideration
		23.3.1 Mode Normalisation
	23.4 Loading Influence
		23.4.1 Modal Damage Participation
	23.5 Threshold Values
	23.6 Industrial Application
		23.6.1 Fatigue Life Estimation
		23.6.2 Results
	23.7 Summary and Conclusion
	References
24 On Stochastic Method for Scale-Structural Failure Estimating and Structure Durability at Safety Operational Loading
	24.1 Introduction
	24.2 The Criterion of Structural Reliability
	24.3 The Safe Operation Criterion
	References
25 Experimental Study of the Rolling Friction Coefficient in Highly Loaded Supports of Rotary Kilns
	25.1 Introduction
	25.2 The Methodology of Research
	25.3 Experimental Stand
	25.4 Results of Experiments
		25.4.1 Rolling Moment
		25.4.2 Rolling Speed
		25.4.3 Effect of Contact Pressure
		25.4.4 Effect of Oil Viscosity and Abrasive
		25.4.5 Effect of Loading Cycles
		25.4.6 Case Study of Friction Losses Calculation
	25.5 Conclusions
	References
26 Safe Operation of Underground Mining Vehicles Based on Cyclic Fatigue Monitoring of Powertrains
	26.1 Introduction
	26.2 Underground Mining Vehicles
	26.3 Dynamical Model
	26.4 Conclusions
	References
27 Optimization of Wastes Compaction Parameters in Case of Gradual Wear of the Briquetting Press Rolls
	27.1 Introduction
	27.2 Methodology
		27.2.1 The Constitutive Model of the Rolls Wear
	27.3 Industrial Trials
		27.3.1 The Operational Parameters of the Press
		27.3.2 Process Parameters Optimisation
	27.4 Conclusions
	References
28 Multiple Linear Regression Parameters for Generating Fatigue-Based Entropy Characteristics of Magnesium Alloy
	28.1 Introduction
	28.2 Literature Background
		28.2.1 Fatigue Crack Growth Assessment Toward Entropy Generation
		28.2.2 Entropy Generation Method
		28.2.3 Multiple Linear Regression (MLR)
	28.3 Experimental Procedure
	28.4 Results and Discussion
	28.5 Conclusions
	References
29 Constructal Design Applied to Biaxial Elasto-Plastic Buckling Analysis of Square Steel Plates with Cutout
	29.1 Introduction
	29.2 Buckling and Post-Buckling of Plates
	29.3 Computational Model
	29.4 Constructal Design (CD)
	29.5 Results and Discussions
	29.6 Conclusion
	References
30 Numerical Study of FPSO Platform Brackets for Different Geometric Configurations Subjected to Environmental Loads
	30.1 Introduction
	30.2 Definition of Environmental Loads and Reaction Forces
	30.3 Computational Model for Prediction of Stress in Brackets
	30.4 Results and Discussion
	30.5 Conclusion Remarks
	References
31 Experimental Identification of Viscoelastic Properties of Plates Made of Quiet Aluminum
	31.1 Introduction
	31.2 Identification Method
	31.3 Experimental Results
	31.4 Conclusions
	References
32 Machine Learning Approach Based on the Finite Element Method to Predict Reaction Forces
	32.1 Introduction
	32.2 Methods
		32.2.1 Problem Description
		32.2.2 Data Generation Process
		32.2.3 Neural Network
	32.3 Results
	32.4 Conclusions
	References
33 Electric Moto3 Welded Chassis-Structural Analysis and Measurements
	33.1 Introduction
	33.2 Material and Methods
		33.2.1 Materials
		33.2.2 Welding Stances
		33.2.3 3D Scan
		33.2.4 X-Ray Scan
	33.3 Results and Discussion
	33.4 Conclusion
	References
34 Analysis of the Impact of Vibrations on a Micro-Hydraulic Valve by Sequence Graph Method
	34.1 Introduction
	34.2 Test Bench
	34.3 Selected Results of Experimental Tests
	34.4 Using the Sequence Method to Include the Evaluation Measures of Decision Rules
		34.4.1 Problems in Applying Decision Rules and Machine Learning Theory in the New Object Classification Approach
		34.4.2 The Possible Use of Sequential Graphs
	34.5 Analysis with Sequence Graphs
		34.5.1 The Possible Use of Graphs to Analyze Sequentially the Function Properties
	34.6 Summary and Conclusions
	References
Index