Research on Fatigue Life Prediction Method of Key Component of Turning Mechanism Based on Improved TCD
Abstract
:1. Introduction
2. Materials and Methods
2.1. Theory of Critical Distances
- (1)
- Point Method (PM)
- (2)
- Line Method (LM)
2.2. Improved Theory of Critical Distances
2.2.1. Presentation of Novel Stress Function
2.2.2. Verification of the Validity of the Novel Function
2.2.3. Modification of the Critical Distance
3. Simulation and Experimental Validation
3.1. Prediction of Fatigue Strength of Notched Components with Regular Shape
3.2. Experimental Verification
3.2.1. Tensile Test of Standard Specimen
3.2.2. Fatigue Test of Notched Specimen
3.2.3. Results Analysis
4. Fatigue Life Prediction of the Rotating Arm Based on Improved TCD
4.1. Establishment of Finite Element Model and Stress Analysis
4.2. Calculation of the Rotating Arm Effective Stress
- (1)
- Determine the coordinates of the point of maximum stress in the rotating arm, then draw a circle with that point as the center and a radius of 30 mm.
- (2)
- Select the directions 0°, 20°, 40°, 60°, −20°, −40°, and −60° in the circumferential direction and draw the corresponding stress–distance curves, as shown in Figure 17.
4.3. Establishment of S–N Curve
4.4. Analysis of Fatigue Life Prediction Results
5. Conclusions
- (1)
- The traditional theory of critical distances is improved in terms of both the stress function and the critical distance length. By analyzing the influence mechanism of the crucial dimensional parameters of the structure on the stress, a high-computational-efficiency and high-accuracy stress function is proposed by introducing the notch depth and net width into the traditional function. In addition, in this paper, we introduce a stress concentration factor to modify the critical distance length.
- (2)
- To verify the effectiveness of the improved TCD, a notched component with regular shape is selected for fatigue strength prediction. In addition, fatigue a test is carried out on the notched component. The error between the predicted and tested value is found to be 3.5%, indicating that the improved TCD in this paper is accurate and applicable to the fatigue study of notched components with regular shapes.
- (3)
- To accurately predict the fatigue life of key components of turning mechanisms with irregular shapes, the improved TCD method is used for fatigue life analysis. In comparison with existing test results, it is found that the improved TCD method has a higher prediction accuracy than the nominal stress method. This shows that the improved TCD can be used for fatigue life prediction of key components of turning mechanisms and provide a theoretical basis for fatigue life study of other notched components with irregular shapes in engineering.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Function | Semicircular Notch | V-Notch | U-Notch |
---|---|---|---|
Function (3) | 0.9850 | 0.8502 | 0.8444 |
Function (4) | 0.9160 | 0.9225 | 0.9261 |
Function (5) | 0.9200 | 0.9175 | 0.9140 |
Function (6) | 0.9967 | 0.9732 | 0.9739 |
Function (7) | 0.9992 | 0.9994 | 0.9995 |
Function (8) | 0.9996 | 0.9998 | 0.9999 |
Material | (MPa·m1/2) | |||||
---|---|---|---|---|---|---|
Q355 | 500 | 425 | −1 | 6.36 | 252 | 0.203 |
Node Number | Distance of the Extracted Point (mm) | Maximum Principal Stress (MPa) |
---|---|---|
1 | 0 | 79.55 |
2 | 0.20 | 63.12 |
3 | 0.40 | 52.12 |
4 | 0.60 | 46.76 |
5 | 0.80 | 42.73 |
6 | 1.00 | 40.08 |
7 | 1.20 | 38.21 |
8 | 1.40 | 36.84 |
9 | 1.60 | 35.92 |
10 | 1.80 | 35.19 |
11 | 2.00 | 34.62 |
12 | 2.20 | 34.25 |
13 | 2.40 | 33.89 |
14 | 2.60 | 33.71 |
15 | 2.80 | 33.52 |
16 | 3.00 | 33.40 |
17 | 3.20 | 33.31 |
18 | 3.40 | 33.24 |
19 | 3.60 | 33.20 |
20 | 3.80 | 33.17 |
21 | 4.00 | 33.17 |
0.2775 | −0.1477 | 1.1768 | −0.3068 |
Element | C | Si | Mn | P | S | Cr | Ni |
---|---|---|---|---|---|---|---|
Content (%) | 0.14 | 0.25 | 0.33 | 0.021 | 0.007 | 0.04 | 0.01 |
Specimen Number | (MPa) | (MPa) | (GPa) |
---|---|---|---|
1 | 500 | 426 | 206 |
2 | 497 | 422 | 212 |
3 | 503 | 426 | 211 |
Mean value | 500 | 425 | 210 |
(MPa) | ||||
---|---|---|---|---|
165.00 | 3 | 1 | 3 | 9 |
151.25 | 2 | 4 | 8 | 16 |
137.50 | 1 | 1 | 1 | 1 |
Sum | - | 6 | 12 | 26 |
Experimental Mean Value | Classic TCD | Improved TCD | |||
---|---|---|---|---|---|
Only Improved Stress Function | Only Improved Critical Distance Value | Both | |||
Fatigue Strength (MPa) | 172 | 154.60 | 154.27 | 179.05 | 178 |
Error | - | 10% | 10% | 4% | 3.5% |
Experimental Life | Nominal Stress Method | Improved TCD | |
---|---|---|---|
Fatigue life (cycle) | 240,000 | 167,850 | 282,580 |
Error | - | 30% | 18% |
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Wang, T.; Zhang, H.; Duan, Y.; Wang, M.; Qin, D. Research on Fatigue Life Prediction Method of Key Component of Turning Mechanism Based on Improved TCD. Metals 2022, 12, 506. https://doi.org/10.3390/met12030506
Wang T, Zhang H, Duan Y, Wang M, Qin D. Research on Fatigue Life Prediction Method of Key Component of Turning Mechanism Based on Improved TCD. Metals. 2022; 12(3):506. https://doi.org/10.3390/met12030506
Chicago/Turabian StyleWang, Tingting, Han Zhang, Yuechen Duan, Mengjian Wang, and Dongchen Qin. 2022. "Research on Fatigue Life Prediction Method of Key Component of Turning Mechanism Based on Improved TCD" Metals 12, no. 3: 506. https://doi.org/10.3390/met12030506