Abstract
The fatigue performance of a workpiece depends on its surface quality. In traditional fatigue life prediction, the effect of surface quality is commonly accounted for by using empirical correction factors, which is imprecise when safety is of great concern. For surface quality, the surface topography is an important parameter, which introduces stress concentration that reduces the fatigue life. It is not feasible to test the stress concentration of different surface topographies. On the one hand, it is time-consuming and high-cost, and on the other hand, it cannot reflect the general statistical characteristics. With the help of surface reconstruction technology and interpolation method, a more efficient and economic approach is proposed, where FE simulation of workpiece with the reconstructed surface topography is used as a foundation for fatigue life prediction. The relationship between surface roughness (Sa) and fatigue life of the workpiece is studied with the proposed approach.
摘要
本文研究工件三维表面形貌的应力集中效应对工件疲劳寿命的影响。 通过实验测试不同表面三维微观形貌的应力集中影响是不合适的, 一方面需要大量的时间和成本, 另外一方面单个工件的表面形貌不能反应统计特征。 因此, 本文提出一种更经济、 更有效的方法基于表面重构技术和插值技术: 利用重建后插值得到的工件三维表面形貌采用有限元方法进行受力分析, 将应力云图结果作为疲劳寿命预测的基础, 研究了工件表面粗糙度 Sa 与工件疲劳寿命之间的关系。
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
NOVOVIC D, DEWES R C, ASPINWALL D K, VOICE W, BOWEN P. The effect of machined topography and integrity on fatigue life [J]. International Journal of Machine Tools & Manufacture, 2004, 44(2, 3): 125–134.
TAYLOR D, CLANCY O M. The fatigue performance of machined surfaces [J]. Fatigue & Fracture of Engineering Materials & Structures, 1991, 14(2, 3): 329–336.
PETERSON R E. Stress concentration factors [M]. New York: John Wiley and Sons, 1974: 134–246.
BAKOLAS V. Numerical generation of arbitrarily oriented non-Gaussian three-dimensional rough surfaces [J]. Wear, 2003, 254: 546–554.
MANESH K K, RAMAMOORTHY B, SINGAPERUMAL M. Numerical generation of anisotropic 3D non-Gaussian engineering surfaces with specified 3D surface roughness parameters [J]. Wear, 2010. 268(11, 12): 1371–1379.
YANG Guo-qing, XIONG Mei-hua, HONG Jun, LIU Hui-jing, WANG Fei. Numerical characterization and contact performances for 3D rough surfaces [J]. Journal of Xi’an Jiaotong University, 2012, 46(11): 58–63.
PU Wei, ZHU Dong, WANG Jia-xu, WANG Q J. Rolling–sliding contact fatigue of surfaces with sinusoidal roughness [J]. International Journal of Fatigue, 2016, 90: 57–68.
NEUBER H. Theory of notch stresses [M]. Berlin, Germany: Springer Verlag, 1958: 204–210.
AROLA D, WILLIAMS C L. Estimating the fatigue stress concentration factor of machined surfaces [J]. International Journal of Fatigue, 2002, 24(9): 923–930.
ÅS S K, SKALLERUD B, TVEITEN B W, HOLME B. Fatigue life prediction of machined components using finite element analysis of surface topography [J]. International Journal of Fatigue, 2005, 27(10): 1590–1596.
SURARATCHAI M, LIMIDO J, MABRU C, CHIERAGATTI R. Modelling the influence of machined surface roughness on the fatigue life of aluminium alloy [J]. International Journal of Fatigue, 2008, 30(12): 2119–2126.
ÅS S K, SKALLERUD B, TVEITEN B W. Surface roughness characterization for fatigue life predictions using finite element analysis [J]. International Journal of Fatigue, 2008, 30(12): 2200–2209.
CHEN Hai-feng, TANG Jin-yuan. A model for prediction of surface roughness in ultrasonic-assisted grinding [J]. The International Journal of Advanced Manufacturing Technology, 2014, 77(1–4): 643–651.
CHEN Hai-feng, TANG Jin-yuan, ZHOU Wei. An experimental study of the effects of ultrasonic vibration on grinding surface roughness of C45 carbon steel [J]. The International Journal of Advanced Manufacturing Technology, 2013, 68(9–12): 2095–2098.
ZHOU Wei, TANG Jin-yuan, HE Yan-fei, LIAO Dong-ri. Associated rules between microstructure characterization parameters and contact characteristic parameters of two cylinders [J]. Journal of Central South University, 2015, 22(11): 4228–4234.
SHEWCHUK J R. An introduction to the conjugate gradient method without the agonizing [M]// Pittsburgh: Carnegie Mellon University, 1994: 23–68.
DENG G, SUZUKI S, NAKANISHI T. Effects of surface roughness and abnormal surface layer on fatigue strength [J]. Applied Mechanics & Materials, 2011, 86: 867–870.
Author information
Authors and Affiliations
Corresponding author
Additional information
Foundation item: Projects(51535012, U1604255) supported by the National Natural Science Foundation of China; Project(2016JC2001) supported by the Key Research and Development Project of Hunan Province, China
Rights and permissions
About this article
Cite this article
Li, Gw., Tang, Jy., Zhou, W. et al. Fatigue life prediction of workpiece with 3D rough surface topography based on surface reconstruction technology. J. Cent. South Univ. 25, 2069–2075 (2018). https://doi.org/10.1007/s11771-018-3896-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11771-018-3896-3