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Experimental Mechanics

, Volume 59, Issue 2, pp 263–276 | Cite as

Enhanced Pre-Strain Application for Goodman Data Generated with Vibration-Based Testing

  • K. KnappEmail author
  • A. Palazotto
  • O. Scott-Emuakpor
  • C. Holycross
Article
  • 116 Downloads

Abstract

Imparting residual stress is an essential step in the generation of Goodman data via Air Force Research Laboratory’s vibration-based fatigue test. Conventional Goodman data is constructed through uniaxial fatigue testing at a rate of 40 Hz, while the vibration-based testing excites stresses at 1,600 Hz in a stress state similar to those of gas turbine engine (GTE) airfoils in service. Fully reversed oscillating fatigue loads are combined with a steady residual stress imparted by a preliminary plastic straining procedure, and a finite element model (FEM) is used to predict the residual stress distribution at the fatigue zone of the sample. The goal of this work is enhancing the Pre-strain procedure that imparts residual stresses to develop a less conservative design approach that captures GTE phenomena on a modified Goodman line. Improvements were made to the FEM by more effectively incorporating empirical tensile stress-strain behavior, in addition to more accurately representing the pressures and forces acting on the specimen during monotonic loading. Results are demonstrated on Aluminum 6061-T6 by comparing strain field results from digital image correlation to FEM analysis. The converged FEM solution had a standard deviation in εyy of 2,557 microstrain and predicted a residual σyy of 73.91 MPa, while the optimized solution had a standard deviation in εyy of 495.2 microstrain (akin to the experimental variation of 376.1 microstrain) and predicted a residual σyy of 31.03 MPa.

Keywords

Plastic deformation Residual stress Digital image correlation Finite element modeling Fatigue life approximation 

Nomenclature

Symbol

Description

\(\varepsilon ^{peak}_{tot}\)

Total strain at peak load

\(\varepsilon ^{zero}_{tot}\)

Total strain at zero

\(\varepsilon ^{rec}_{tot}\)

Total strain recovered

εp

Plastic strain

\(\varepsilon ^{res}_{e}\)

Elastic residual strain

σpeak

Stress at peak load

σres

Residual stress

ν

Poisson’s ratio

E

Young’s modulus

\(R=\frac {\sigma _{min}}{\sigma _{max}}\)

Stress ratio

σfail

Stress amplitude at failure

Nfail

Cycles to failure during last step

σpr

Stress amplitude during previous step

Nstep

Specified dwell fatigue cycles

σa

Stress amplitude for failure at Nstep

\(\varepsilon _{_{FEM}}\)

Total strain predicted by FEM

\(\varepsilon _{_{DIC}}\)

Total strain measured by DIC

Notes

Acknowledgements

The authors would like to thank the Air Force Research Laboratories (AFRL), specifically the Turbine Engine Fatigue Facility (TEFF) for their financial support, facility and equipment access, and encouragement of this research.

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Copyright information

© This is a U.S. government work and its text is not subject to copyright protection in the United States; however, its text may be subject to foreign copyright protection 2019

Authors and Affiliations

  • K. Knapp
    • 1
    Email author
  • A. Palazotto
    • 2
  • O. Scott-Emuakpor
    • 3
  • C. Holycross
    • 3
  1. 1.Department of Engineering MechanicsUnited States Air Force AcademyColorado SpringsUSA
  2. 2.Department of Aeronautics & AstronauticsAir Force Institute of Technology, Wright-Patterson AFBDaytonUSA
  3. 3.Air Force Research LaboratoryWright-Patterson AFBDaytonUSA

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