Investigating the Effect of Residual Stress on Fatigue Crack Propagation by Modified J-integral and Experimental Method

Journal of Modern Processes in Manufacturing and Production

دوره 12، شماره 1، اردیبهشت 2023، صفحه 5-16   

نوع مقاله: Research Paper

نویسندگان

Ali Moarrefzadeh^{* 1}؛ Shahram Shahrooi²

¹Department of Mechanical Engineering, Mahshahr Branch, Islamic Azad University, Mahshahr, Iran

²Department of Mechanical Engineering, Ahvaz Branch, Islamic Azad University, Ahvaz, Iran

چکیده

This paper is introduced new method for predicting of fatigue crack propagation (FCP) in residual stress (RS) field due to welding. If there is stress in the material and is subjected to loading, the effects of loading and RS must be considered simultaneously. For this purpose, stress intensity factor (SIF) in liner elastic fracture mechanics (LEFM) approach and J-integral in elastic-plastic fracture mechanics (EPFM) approach are used. The superposition principle based on LEFM is used to consider the RS effects on the cycle ratio and SIF. To achieve more appropriate results based on EPFM, the J-integral is modified to consider the simultaneous effects of RS and external loading. Finally, the FCP equations are modified to consider into calculation the simultaneous influences of RS and cyclic loading. Results from FCP equation based on J-integral are in good agreement with experimental results. The obtained results show that the MLPG method is suitable for calculating the residual stress and the modified J-integral method is the best method for predicting FCP in the RS field caused by welding.

کلیدواژه‌ها

Residual Stress؛ Welding؛ Stress Intensity Factor؛ J-integral؛ Fatigue Crack Propagation

مراجع

[1] Zubairuddin M., Albert S.K., Vasudevan M., Mahadevan S., Chaudhari V. and Suri V.K. 2017. Numerical simulation of multi-pass GTA welding of grade 91 steel. Journal of manufacturing process. 27:87–97.                        

[2] Muzamil M., Akhtar M., Samiuddin M., Mehdi M. 2016. Effect of heat treatment on impact resistance of AU5GT and AS7G06 aluminum alloys. Journal of Mechanical Science and Technology. 30: 4543–4548.                             

[3] Spaniel M., Jurenka H., Kuzelka J. 2009. Verification of FE model of fatigue crack propagation under mixed mode conditions.  Meccanica. 44:189-195                                                                                                                   

[4] Ismail, A.E., Ariffin A.K., Abdullah S.A. and Ghazali, M.J. 2012. Stress intensity factors foe surface cracks in round bar under single and combined loadings. Meccanica. 47:1141-1156                                                                             

[5] Wu, X. and Carlsson, J. 1984. Welding Residual Stress Intensity Factors for Half- Elliptical Surface Cracks in thin and thick Plates, Engineering Fracture Mechanics. 19(3):407-426.                                                                                                    

[6] Itoh Y. and Suruga C. 1989. Prediction of Fatigue Crack Growth Rate in Welding Residual  Stress Fields, Engineering Fracture Mechanics. 33:397-407.                                                                                                                                  

[7] Teng L. and Lin C.H. 1998. Effect of welding conditions on residual stresses due to butt welds,  International Journal of Pressure Vessels and Piping. 75:857-864.                                                                                                               

[8] Bao R., Xiang Z. and Norvahida, A. 2010. Evaluating stress intensity factors due to weld residual stresses by the weight function and finite element methods. Engineering Fracture Mechanics. 7:2550–2566.                                               

[9] Seifi, R. 2011. Effect of residual stress on fracture parameters of through cracks in welded plates. Procedia Engineering. 10:1895-1900.

[10] Moarrefzadeh A., Shahrooi S. and Jalali Azizpour M. 2019. The application of the meshless local Petrov-Galerkin method for the analysis of heat conduction and residual stress due to welding. The International Journal of Advanced Manufacturing Technology. 104: 723-742.

[11] Moarrefzadeh, A., Shahrooi S. and Jalali Azizpour M. 2019. Predicting fatigue crack propagation in residual stress field due to welding by meshless local Petrov-Galerkin method. Journal of Manufacturing Processes. 45: 379-391.

[12] Wu, X.R. and Carlsson J. 1984. Welding Residual Stress Intensity Factors for Half- Elliptical Surface Cracks in thin and thick Plates. Engineering Fracture Mechanics. 19(3): 407-426.

[13] Wu, X.R. 1984. The Effect of Welding Residual Stress on Brittle Fracture of Plates with Surface Cracks, Engineering Fracture Mechanics. 19(3): 427-439.

[14] Beghini, M. and Bertini L. 1990. Fatigue Crack Propagation through Residual Stress Field with Closure Phenomena, Engineering Fracture Mechanics. 36(3): 379-387.

[15] Qi, D.M. 1992. Recommendations on the Treatment of Residual Stresses in PD6493 for the Assessment of the Significance of Weld Defects. Engineering Fracture Mechanics. 41(2): 257-270.

[16] Finch, D.M.  and Burdekin F.M. 1992. Effect of welding residual stress on significance of detects in various type if welded joints, Engineering Fracture Mechanics. 41(5): 721-735.

[17] Finch D.M. 1992. Effect of Welding Residual Stress on Significance of Defects in Various Types of Weld Joints, Engineering Fracture Mechanics. 42(3): 479-500.

[18] Meith, W.A. and Hill M.R. 2002. Domain-independent values of the J-integral for cracks in three-dimensional residual stress bearing bodies. Engineering Fracture Mechanics. 69: 1301-1314.                                                                                                                                                        

[19] ASTM Standard E837-01. 2013. Standard Test Method for Determining Residual Stress by the Hole-Drilling Srain-Gauge Method. Annual Book of ASTM Standards. ASTM International, West Conshohoken, PA.     

[20] Glinka G. 1979. Effect of residual stress on fatigue crack propagation in steel weldments under constant and variable amplitude load in Fracture mechanics, ASTM STP 677, American society of testing and materials, 198-214   

[21] Yahiaoui B., Petrequim P. 1974. Teude de la propagation de fissures par fatigue dans de aciers anoxyydabels austenitiques a bas carbon due type 304L and 316L. Review Physics Application (France). 9(4): 683-690.

[22] ASTM Standard E647-05. 1998. Standard Test Method for Measurement of Fatigue Crack Growth Rates, Annual Book of ASTM Standards, ASTM International, West Conshohoken, PA.