Journal of Mechanical Science and Technology

, Volume 32, Issue 9, pp 4183–4190 | Cite as

Numerical and experimental method for the prediction of the propagation life of fatigue crack on metallic materials

  • Chen Ni
  • Lin HuaEmail author
  • Xiaokai Wang
  • Zhou Wang
  • Zhikui Ma


A prediction method for the propagation life of fatigue crack for cracked components was provided and verified in this study to predict the propagation life of fatigue cracks on components in engineering applications conveniently and directly. In the simulation aspect, a finite element (FE) model of cracked specimen was created to obtain the stress intensity factor range ΔK. The FE model was verified by comparing simulated ΔK to a formulary calculated one. The simulated ΔK could be used for studying the relationship with crack size. In the experimental aspect, the fatigue crack propagation test was conducted on three specimens. The material coefficients C and m were fitted according to Paris’ law. The load cycles with different crack depths were recorded in the testing process. The propagation life of fatigue cracks of specimen was predicted via the relationship between ΔK and crack size a according to Paris’ law. The comparison between predicted life and experimental life of specimens indicated the feasibility of the method. The proposed prediction method in this study for the propagation life of fatigue cracks can be used in engineering applications.


Crack depth Engineering application Fatigue crack propagation life Finite element model with crack Stress intensity factor range 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


  1. [1]
    P. Rubio, L. Rubio, B. Muñoz-Abella and L. Montero, Determination of the stress intensity factor of an elliptical breathing crack in a rotating shaft, International Journal of Fatigue, 77 (2015) 216–231.CrossRefGoogle Scholar
  2. [2]
    L. J. Zhang, Y. R. Zhao and H. F. Xiang, Research of stress intensity factor of V-shaped notch tip in precision cropping, International Journal of Advanced Manufacturing Technology, 65 (1–4) (2013) 549–555.CrossRefGoogle Scholar
  3. [3]
    Z. Jin and X. Wang, Weight functions for the determination of stress intensity factor and T-stress for semi-elliptical cracks in finite thickness plate, Fatigue & Fracture of Engineering Materials & Structures, 36 (10) (2013) 1051–1066.CrossRefGoogle Scholar
  4. [4]
    H. Sanati, A. Amini, F. Reshadi, N. Soltani, G. Faraji and E. Zalnezhad, The stress intensity factors (SIFs) of cracked half-plane specimen in contact with semi-circular object, Theoretical and Applied Fracture Mechanics, 75 (2015) 104–112.CrossRefGoogle Scholar
  5. [5]
    H. J. Shen and W. L. Guo, 3D constraint effect on 3D fatigue crack propagation, International Journal of Fatigue, 27 (6) (2005) 617–623.CrossRefGoogle Scholar
  6. [6]
    Y. Yao, M. E. Fine and L. M. Keer, An energy approach to predict fatigue crack propagation in metals and alloys, International Journal of Fracture, 146 (3) (2007) 149–158.CrossRefzbMATHGoogle Scholar
  7. [7]
    D. V. Ramsamooj, Analytical prediction of fatigue crack propagation in metals, Journal of Engineering Mechanics, 129 (6) (2003) 672–682.CrossRefGoogle Scholar
  8. [8]
    S. Deng, X. P. Qin and S. Huang, A study on the effect of subsurface crack propagation on rolling contact fatigue in a bearing ring, Journal of Mechanical Science and Technology, 29 (3) (2015) 1029–1038.CrossRefGoogle Scholar
  9. [9]
    F. Ghanem, N. B. Fredj, H. Sidhom and C. Braham, Effects of finishing processes on the fatigue life improvements of electro-machined surfaces of tool steel, International Journal of Advanced Manufacturing Technology, 52 (5–8) (2011) 583–595.CrossRefGoogle Scholar
  10. [10]
    L. Lazzeri and U. Mariani, Application of damage tolerance principles to the design of helicopters, International Journal of Fatigue, 31 (6) (2009) 1039–1045.CrossRefzbMATHGoogle Scholar
  11. [11]
    U. Zerbst, S. Beretta, G. Köhler, A. Lawton, M. Vormwald, H. Th. Beier, C. Klinger, I. Černý, J. Rudlin, T. Heckel and D. Klingbeil, Safe life and damage tolerance aspects of railway axles-A review, Engineering Fracture Mechanics, 98 (2013) 214–271.CrossRefGoogle Scholar
  12. [12]
    V. L. Neelakantha, T. Jayaraju, P. Naik, K. D. Kumar, C. R. Rajashekar and Mohankumar, Determination of fracture toughness and fatigue crack growth rate using circumferentially cracked round bar specimens of Al2014T651, Aerospace Science and Technology, 47 (2015) 92–97.CrossRefGoogle Scholar
  13. [13]
    G. M. Domínguez Almaraz, J. L. Ávila Ambriz and E. Cadenas Calderón, Fatigue endurance and crack propagation under rotating bending fatigue tests on aluminum alloy AISI 6063-T5 with controlled corrosion attack, Engineering Fracture Mechanics, 93 (2012) 119–131.CrossRefGoogle Scholar
  14. [14]
    K. R. Gadelrab, M. Chiesa, M. Hecker and H. J. Engelmann, Modeling crack propagation for advanced 4-point bending testing of metal-dielectric thin film stacks, Engineering Fracture Mechanics, 96 (2012) 490–499.CrossRefGoogle Scholar
  15. [15]
    Y. Kim, K. Lee and H. Li, Fatigue life prediction method for contact wire using maximum local stress, Journal of Mechanical Science and Technology, 29 (1) (2015) 67–70.CrossRefGoogle Scholar
  16. [16]
    V. Tran, S. Geniaut, E. Galenne and I. Nistor, A modal analysis for computation of stress intensity factors under dynamic loading conditions at low frequency using extended finite element method, Engineering Fracture Mechanics, 98 (2013) 122–136.CrossRefGoogle Scholar
  17. [17]
    C. S. Shin and C. Q. Cai, Experimental and finite element analyses on stress intensity factors of an elliptical surface crack in a circular shaft under tension and bending, International Journal of Fracture, 129 (2004) 239–264.CrossRefzbMATHGoogle Scholar
  18. [18]
    G. Meneghetti, C. Guzzella and B. Atzori, The peak stress method combined with 3D finite element models for fatigue assessment of toe and root cracking in steel welded joints subjected to axial or bending loading, Fatigue & Fracture of Engineering Materials & Structures, 37 (7) (2014) 722–739.Google Scholar
  19. [19]
    J. C. Passieux, J. Réthoré, A. Gravouil and M. C. Baietto, Local/global non-intrusive crack propagation simulation using a multigrid X-FEM solver, Computational Mechanics, 52 (6) (2013) 1381–1393.CrossRefzbMATHGoogle Scholar
  20. [20]
    J. Lebahn, H. Heyer and M. Sander, Numerical stress intensity factor calculation in flawed round bars validated by crack propagation tests, Engineering Fracture Mechanics, 108 (2013) 37–49.CrossRefGoogle Scholar
  21. [21]
    M. Heyder and G. Kuhn, 3D fatigue crack propagation: Experimental studies, International Journal of Fatigue, 28 (5–6) (2006) 627–634.CrossRefzbMATHGoogle Scholar
  22. [22]
    C. Ni, L. Hua, X. K. Wang, Z. Wang, X. P. Qin and Z. Fang, Coupling method of magnetic memory and eddy current nondestructive testing for retired crankshafts, Journal of Mechanical Science and Technology, 30 (7) (2016) 3097–3104.CrossRefGoogle Scholar
  23. [23]
    J. Toribio, F. J. Ayaso, B. González, J. C. Matos, D. Vergara and M. Lorenzo, Critical stress intensity factors in steel cracked wires, Materials & Design, 32 (8–9) (2011) 4424–4429.CrossRefGoogle Scholar
  24. [24]
    Y. Peng, L. W. Tong, X. L. Zhao and Z. G. Xiao, Modified stress intensity factor equations for semi-elliptical surface cracks in finite thickness and width plates, Procedia Engineering, 14 (2011) 2601–2608.CrossRefGoogle Scholar

Copyright information

© The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature 2018

Authors and Affiliations

  • Chen Ni
    • 1
    • 2
  • Lin Hua
    • 2
    • 3
    Email author
  • Xiaokai Wang
    • 2
    • 3
  • Zhou Wang
    • 2
    • 3
  • Zhikui Ma
    • 1
    • 2
  1. 1.School of Materials Science and EngineeringWuhan University of TechnologyWuhanChina
  2. 2.Hubei Key Laboratory of Advanced Technology for Automotive ComponentsWuhan University of TechnologyWuhanChina
  3. 3.School of Automotive EngineeringWuhan University of TechnologyWuhanChina

Personalised recommendations