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thesis.tex
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thesis.tex
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\documentclass[3p,times,procedia,number]{elsarticle}
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%% Title, authors and addresses
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%% \address{Address\fnref{label3}}
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\dochead{International Conference on Fatigue Damage of Structural Materials XI}
%\dochead{1st year PhD research result}
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\title{A new strategy for fatigue analysis in presence of general multiaxial time varying loadings}
%% use optional labels to link authors explicitly to addresses:
%% \author[label1,label2]{<author name>}
%% \address[label1]{<address>}
%% \address[label2]{<address>}
\author[a]{Ma Zepeng\corref{cor1}}
\author[b]{Patrick Le Tallec}
\author[c]{Habibou Maitournam}
\address[a]{Laboratory of Solid Mechanics, Ecole Polytechnique, 91128 Palaiseau Cedex, France}
\address[b]{Laboratory of Solid Mechanics, Ecole Polytechnique, 91128 Palaiseau Cedex, France}
\address[c]{IMSIA, ENSTA ParisTech, CNRS, CEA, EDF, Université Paris-Saclay, 828 bd des Maréchaux, 91762 Palaiseau cedex France}
\tableofcontents
\newpage
\begin{keyword}
Fatigue; Energy; High cycle; Plasticity; Mean stress
%% keywords here, in the form: keyword \sep keyword
%% PACS codes here, in the form: \PACS code \sep code
%% MSC codes here, in the form: \MSC code \sep code
%% or \MSC[2008] code \sep code (2000 is the default)
\end{keyword}
\cortext[cor1]{Corresponding author. Email address: [email protected] }
\end{frontmatter}
\clearpage
\begin{flushleft}
\textbf{Nomenclature}
\vspace{6pt}
\begin{table}[h]
\begin{tabular}{lllll}
$\Sigma_{max}$ & maximum stress during the loading cycles & & & \\
$\sigma_m$ & mean stress & & & \\
$\sigma_H$ & hydrostatic stress & & & \\
$\sigma_{-1}$ & fatigue limit for fully reversed condition & & & \\
$b$ & back stress & & & \\
$\sigma_{y}$ & macroscopic yield stress & & & \\
$N$& current number of cycles & & & \\
$N_F$& number of cycles to failure & & & \\
$\dot{p}$ & accumulated plastic strain rate given as $\sqrt{\frac{2}{3}}||\dot{\varepsilon}_p||$ & & & \\
$D$ & damage variable & & & \\
$\sigma_{a}$ & stress amplitude & & & \\
$\sigma_{u}$ & ultimate tensile stress & & & \\
$\langle$ $\rangle$& Macaulay bracket symbol.$\langle$ $\rangle$ is defined as $\langle m\rangle=0$ if $m\leqslant0$ , $\left\langle m\right\rangle=m$ if $m>0$& & & \\
$S_{max}$ & maximum deviatoric stress during the loading cycles & & & \\
$\dot{w}$ & energy dissipation rate at a certain scale & & & \\
$\dot{W}$ & energy dissipation rate at all scales & & & \\
$W$ & dissipated energy& & & \\
$W_{cyc}$ & dissipated energy per cycle & & & \\
$ \dot{\varepsilon}_p$ & rate of effective plastic strain & & & \\
$\dot{p}$ & accumulated plastic strain rate given as $\sqrt{\frac{2}{3}}||\dot{\varepsilon}_p||$ & & & \\
$W_F$ & dissipated energy to failure per unit volume & & & \\
$E$ & Young's modulus & & & \\
$k=500\sim800MPa$ & hardening parameter & & & \\
$\beta$ & weakening scales distribution exponent & & & \\
$\gamma$ & material parameter from Chaboche law(Wohler curve exponent) & & & \\
$\alpha=1 - a\left\langle \dfrac{\max\limits_{t}\sqrt{J_{2,a}}(t)+a_c{P_{max}(t)}-b_c}{ \sigma_{u} - 2\max\sqrt{J_{2,a}}}\right\rangle$ & characterizes non-linearity of damage accumulation & & & \\
$a$ & material parameter from Chaboche law & & & \\
$\lambda=0\sim5$& hydrostatic pressure sensitivity & & & \\
$\uline{\uline{S}}=dev\dot{\uline{\uline{\Sigma}}}$ & deviatoric part of the stress tensor & & & \\
$\sigma_H$& macroscopic hydrostatic pressure & & & \\
$A_{\uppercase\expandafter{\romannumeral2}}=\tau_{oct,a}=\sqrt{\dfrac{1}{3}J_{2,a}}$& the amplitude of octahedral shear stress & & & \\
$s_{-1}$& tensile fatigue limit for $R=-1$ & & & \\
$ \dot{\varepsilon}_p$ & rate of effective plastic strain & & & \\
$W_0$ & reference density of damage energy & & & \\
$J_2$ & The second principal invariant of the stress deviatoric tensor & & & \\
$\sigma_{VM}=\sqrt{3J_{2}}$& Von Mises stress & & & \\
\end{tabular}
\end{table}
\end{flushleft}
\clearpage
\section{General introduction}
The fatigue of metallic structures subjected to cyclic stresses is a phenomenon
Which is traditionally studied at two levels. The fatigue is respectively qualified
``low cycle" or ``high cycle" if the load causing the rupture is applied
during a small or a large number of cycles. In turn, ``high cycle fatigue" is divided
in two domains: ``limited endurance" where we speak of the finite lifetime regime
and "unlimited endurance" where the structure can support a number of cycles theoretically
infinite without it breaking.
The threshold value dividing low- and high-cycle fatigue is somewhat arbitrary, but is generally
based on the raw material’s behavior at the micro-structural level in response to the applied stresses. Low cycle
failures typically involve significant plastic deformation. An example would be reversed 90° bending
of a paper clip. Gross plastic deformation will take place on the first bend, but failure will not occur until
approximately 20 cycles. Plastic deformation does play a role in high cycle fatigue; however, the plastic
deformation is very localized and not necessarily discernible by a macroscopic evaluation of the
component. In summary, while a valve spring designer may consider a failure at 10,000 cycles very short
life, the failure can still be the result of high-cycle fatigue because the material response at the
micro-structural level is the same as in a 10,000,000-cycle failure under lower applied stresses.
Most metals with a body centered cubic crystal structure have a characteristic response to cyclic stresses.
These materials have a threshold stress limit below which fatigue cracks will not initiate. This threshold
stress value is often referred to as the endurance limit. In steels, the life associated with this behavior is
generally accepted to be $2x10^6$
cycles. In other words, if a given stress state does not induce a fatigue
failure within the first $2x10^6$
cycles, future failure of the component is considered unlikely. For spring
applications, a more realistic threshold life value would be $2x10^7$ cycles. Metals with a face center cubic
crystal structure (e.g. aluminum, austenitic stainless steels, copper, etc.) do not typically have an endurance
limit. For these materials, fatigue life continues to increase as stress levels decrease; however, a threshold
limit is not typically reached below which infinite life can be expected.
\subsection{Industrial background and motivation}
The search for the best performance at the best cost in the mechanical and
transport leads to conditions of use of the mechanical components increasingly
severe. The latter can cause the occurrence of a fatigue limit for levels of
very high loads (in tension or in compression) and important triaxiality rates
. Fatigue failures are widely studies
because it accounts for 90\% of all service
failures due to mechanical causes. Fatigue failures occur when metal is
subjected to a repetitive or fluctuating
stress and will fail at a stress much lower
than its tensile strength and the process happens without any plastic
deformation (no warning).
These can lead to the emergence of fatigue for
very high level of stress gradient(for small scale or complex geometric structures) and non-constant multiaxial loading history
. For these so-called "extreme" solicitations, the mechanisms of damage
as well as fatigue resistance levels are mostly completely unknown.
This poses an important problem during the dimensioning phase since, on the one hand, the
existing endurance criteria struggle to account for behavior for this type of
loading, and on the other hand, the fatigue data that would allow to identify a model
adapted to this problem are almost non-existent.
On the other hand, the mechanical components are generally of complex nature undergoing
complex loads. Manufacturers are looking for a model of lifetime
of their components, which is simple to use, great applicability to metallic materials
and which treats almost all cases of possible loads. In the domain of
limited endurance, very few criteria are proposed. At present, none of them
can not be used in design offices, and does not fully meet the demand for a tool to
predictive lifetime. Indeed, most of the existing approaches rely on
methods of counting cycles, whose extension to the case of multiaxial stresses turns out to be
difficult or even impossible because of the difficulty of extracting and defining cycles.
Previous work carried out in collaboration with the PSA company shows that the criteria
of multi-axial endurance used for fatigue dimensioning (Papadopoulos model
and Dang Van's criterion) struggle to account effectively for these very
individuals. It therefore seems essential to characterize the mechanisms
damage of this type of loading and to implement a modeling
capable of reflecting these particular fatigue conditions.
The approach to solving the problem posed has four main stages:
$\bullet$ Decoupling the effects of the stress gradient and the size effect.
$\bullet$ Observations of the associated damage mechanisms during loading, by
understanding the non-linearity of damage accumulation and the history dependent sequence effect.
$\bullet$ Construction of a model of fatigue behavior that accounts for the effects of
microscopic plasticity as well as the major damage effect.
$\bullet$Numerical simulation of cyclic loading conditions and random loading history.
The aim of this thesis is to establish a deterministic model of lifetime
on metal structures working in limited endurance, which handles almost all load cases
(with constant and variable amplitudes) without recourse to cycle counting.
\subsection{Outline of the work}
The fatigue of materials with many cycles is one of the phenomena that can lead to
rupture of machine parts or structures in operation. Its progressive character
masked until sudden breakage does not allow easy prediction of the durability of the
structure.
The main factors influencing the fatigue resistance of materials are very numerous
(loading mode, temperature, microstructural heterogeneities, residual stresses ...),
making it a complex phenomenon to study. A lot of work has been done in the goal of
better understanding the influence of these different factors. One of the main parameters
influential, repeatedly studied, is the damage mechanism of the time varying stress.
Numerous experimental observations made on metallic materials have shown
That the damage mechanisms operating in fatigue with large number of cycles and
leading to breakup are two categories. In a first step known as the priming step,
microplasticity mechanisms, generally operating around heterogeneities specific to the
material (inclusions, porosities, etc.), are the origin of the appearance of microcracks. If the load level is high enough, these cracks increase and cross a number of
microstructural barriers (e.g. grain boundaries). When the crack has reached a size
sufficiently large in relation to the microstructure and that the plasticized zone is confined to
a second phase intervenes where it propagates according to the laws of the
mechanics of the rupture.
Two types of very distinct approaches are often used to model these mechanisms. The
first concerns priming and mainly uses the framework of the mechanics of the
microplasticity considered to be the main cause of onset
of a crack. The second uses the fracture mechanics framework to estimate the number
of cycles necessary for the propagation of a pre-existing crack.
Although the first bibliographic part of this document is devoted to the presentation of
criteria from different categories of approaches, it will be questioned, during the modeling of the
behavior of the cast aluminum alloy, a probabilistic model
competition between mechanisms related to the appearance of micro-cracks and others associated with the
Non-propagation of pre-existing cracks.
Therefore, in our work we consider both the two mechanisms exit and there are stochastic distribution of pre-existing micro-cracks which undergo strong plastic yielding in cyclic load history. The number of cycles to failure is determined from the plastic shakedown cycle.
The bibliographical study conducted in the first part of this thesis aims to
overview the basic multiaxial fatigue criteria and the physical basis of their origin. Models using the elastic adaptation concept, plasticity / damage on the mesoscopic scale as well as energy
are compared. We will show that some loading effects are correctly reflected, however for others, the predictions are very different from one approach to another.
The second part is devoted to the extension of some classic high cycle fatigue (HCF) criteria in order to take into account a sensitivity of the criteria to stress spatial variations, and second to compare the performances of the extensions through several experimental fatigue tests. The gradient beneficial effect on bending-torsion in comparison with tension-compression is presented. Mechanisms of different approaches are compared and a more practical and simple expression taking into account the gradient of the stress amplitude and the maximum hydrostatic stress. The generalization of the approach to other multiaxial fatigue criteria is also proposed. The proposition is then tested and applied to different simple situations such as cantilever rotative bending. The relative errors between the exact solutions and the experimental data are estimated. Biaxial bending-torsion tests are also simulated to demonstrate the capabilities of the approach.
The non-linearity of damage accumulation in fatigue is discussed in the third part using the application of loadings
The objective of this section is to contribute to the development life model that take into account the presence of complex variations of the stress tensor. We focus on Chaboche damage accumulation law in case of multiaxial high cycle fatigue. Heuristic formulations with different multiaxial fatigue criteria have been proposed.
In the fourth part, there is more particularly a question of the use of loading history from industrial component.
Cycle counting method to compare the effect of variable amplitude load histories to fatigue data and curves obtained with simple constant amplitude load cycles is presented. It will be shown that the use of an probabilistic, taking into account the impurities and hardness in the material method is proposed. A kinematic hardening under the assumptions of associative plasticity is also considered. Usually, the effect of the average stress on loading levels below the yield strength of the material seems well documented in the scientific literature. Beyond this threshold, the mechanisms of damage in play appear less known because less studied. The proposal of our model is to consider a plastic behavior at the mesoscopic scale with a dependence of the yield function not only on the deviatoric part of the stress but also on the hydrostatic part. For fatigue behavior observed under random loading history, the energy approach makes it possible to combine effectively with the damage accumulation law discussed in Section III.
The fifth chapter of the document deals with the numerical implementation of our method with different experimental results.
Instead of doing the integration directly which can be difficult for complex loading, the Gaussian
Quadrature rule with Legendre points is used to give the value of local dissipated energy rate. Cyclic and random tests on aluminum alloy used for automobile suspension arm is calibrated with our model. Then a multidimensional application is performed showing the capability of prediction on fatigue life of different material and loading patterns.
\section{Fatigue life calculation methods}
\subsection{Basic fatigue criteria }
This bibliographic chapter enables to present the methods to calculate the lifetime of multiaxial high cycle fatigue. In fact, the equivalent stress of multiaxial loading and variable amplitude loading reveals the necessity of study these methods. These criteria allows to determine whether the stress trajectory in the stress space leads to the failure of the points concerned.
Papadopoulos suggested, in particular, to group families of fatigue criteria into four categories:
\begin{itemize}
\item Criteria based on strain
\item Criteria based on stress
\item Criteria based on energy
\item Criteria based on plasticity-damage coupling
\end{itemize}
Generally, the criteria developed in strain(and sometimes in energy) are adapted to the oligocyclic fatigue where the tests are often carried out with imposed strain. Approaches in stress(and sometimes in energy), as well as those based on the coupling plasticity and damage(which have begun to emerge in recent years) are being applied in the domain of endurance. In particular, we will focus on the last three categories and analyze the different approaches.
\subsubsection{Criteria based on stress}
\vspace{6pt}
Three types of approach can be distinguished:
\begin{itemize}
\item Critical Plan Approaches
\item Approaches based on stress invariants
\item The criteria based on mean stress in an elementary volume
\end{itemize}
For simplicity and to avoid too costly identification procedures of fatigue data, criteria are often expressed using two
parameters. The first relates generally to a shear stress (on a plane or on average over an elementary volume) while
the second reflects the normal stress effects (mean and amplitude) through the hydrostatic stress or the normal stress.
The criteria using the hydrostatic stress are the most numerous [Crossland 1956, Sines 1959 Morel 1999 Huyen Thi
Thu 2008]. The micro-macro approach applied to the field of endurance was born with the work of [Dang Van
1973], and since it has been used many times by including [Papadopoulos 1993] to take better account of loading path effects. The normal stress acting on the material planes is sometimes used on a critical plane [Findley 1959], or
through integration at every plane of an elementary volume [Liu and Zenner 1993]. [Huyen Thi Thu 2008] proposes, in
particular, a probabilistic approach that shows this type of integration.
\textbf{Crossland Criterion}
In several industries, the required design lifetime of many components often exceeds $ 10^8 $ cycles. This requirement is applicable to aircraft (gas turbine disks $ 10^{10} $ cycles), automobiles (car engine $ 10^8 $ cycles), and railways (high speed train $ 10^9 $ cycles). Although a large amount of fatigue data has been published in the form of S-N (where S is stress and N cycles numbers) curves, the data in the literature has been usually limited to fatigue lives up to $ 10^7 $ cycles. Using traditional fatigue criteria, a near hyperbolic relationship between stress and fatigue life is assumed, with an asymptotic limit defined as the endurance stress. To predict this asymptotic limit, the Crossland Criterion is probably the most widely known. Crossland proposed that the second invariant of the deviatoric stress tensor and the hydrostatic pressure are the variables governing the endurance limit.
Many fatigue limit criteria can be written as:
\begin{equation}
f(\tau)+g(\sigma) \leqslant 0
\end{equation}
where f and g are given functions of the shear stress τ and of the normal stress σ respectively, as applied to different interfaces within the material.
The classical Crossland criterion defines the fatigue limit of metallic specimens subjected to multi-axial in-phase cyclic stress\cite{Crossland} : \begin{equation}f(\sqrt{J_{2,a}},P_{max})=\tau_{eq}+aP_{max}-b\leqslant 0\end{equation}
where $\tau_{eq}=\sqrt{J_{2,a}}$ measures the amplitude of variation of the second invariant of the deviatoric stress and $P_{max}$ is the maximum hydrostatic stress observed during a loading cycle. If $f(\sqrt{J_{2,a}},P_{max})$ is negative or null, there is no damage. If $f(\sqrt{J_{2,a}},P_{max})$ is positive, there is likely to be damage. The physical constants $a$ and $b$ are material's constants that needs to be determined experimentally. The amplitude of the square root of the second invariant of the stress deviator can be defined, in general case, as the half-length of the longest chord of the deviatoric stress path\cite{Papadopoulos1997219}
\begin{equation}\sqrt{J_{2,a}}=\frac{1}{2\sqrt{2}}\min \limits_{\uline{\uline{S_1}}}\{\max \limits_{t}\sqrt{(\uline{\uline{S}}(t)-\uline{\uline{S_1}}):(\uline{\uline{S}}(t)-\uline{\uline{S_1}})}\}\end{equation}
Recall that the deviatoric stress $\uline{\uline{S}}$ associated to a stress tensor $\uline{\uline{\sigma}}$ is defined by
\begin{equation} \uline{\uline{S}}=\uline{\uline{\sigma}}-\frac{1}{3}tr\uline{\uline{\sigma}}
\end{equation}
The maximum value that the hydrostatic stress reaches during the loading cycle is on the other hand:
\begin{equation}
P_{max}=\max\limits_{t}\{\frac{1}{3}tr(\uline{\uline{\sigma(t)}})\}.
\end{equation}
For a proportional cyclic loading, if one introduces the two extreme stress tensors $\uline{\uline{\sigma^A}}$ and $\uline{\uline{\sigma^B}}$ observed during the loading path, together with the stress amplitude
\begin{equation}\uline{\uline{\Delta\sigma}}=\uline{\uline{\sigma^B}}-\uline{\uline{\sigma^A}}\end{equation}
and its deviatoric part $\uline{\uline{\Delta s}} $, the variation of
the second invariant of the stress deviator reduces to
\begin{equation}\sqrt{J_{2,a}}=\frac{1}{2}\max\limits_{t}\sqrt{\frac{1}{3}\uline{\uline{\Delta s}}:\uline{\uline{\Delta s}}}=\frac{1}{2}\max\limits_{t}\sqrt{\frac{1}{3}(\Delta s_{11}^2+\Delta s_{22}^2+\Delta s_{33}^2+2\Delta s_{12}^2+2\Delta s_{13}^2+2\Delta s_{23}^2)}.\end{equation}
The physical constants $a$ and $b$ can be related to the limit $t_{-1}$ of endurance in alternate pure shears and to the limit $f_{-1}$ of endurance in alternate pure traction and compression by
\begin{equation}
a=\frac{(t_{-1}-\frac{f_{-1}}{\sqrt{3}})}{\frac{f_{-1}}{3}}, \quad
b=t_{-1}.
\end{equation}
Thus the classical Crossland criterion can be written as:
\begin{equation}
\sqrt{J_{2,a}}+a{P_{max}}-b\leqslant 0
\end{equation}
\textbf{Dang Van Criterion}
In multiaxial fatigue with large number of cycles, the important role of local plasticity on the appearance of a fatigue limit is widely accepted and fully justifies the use of a multi-scale approach. Among the existing approaches, one of the most known and used is that of [Dang Van 1999]. This criterion is used in particular in the design of certain automotive structures at PSA and
Renault. The criterion [Dang Van 1973] belongs to the family of critical plane type approaches. The main physical
basis of this criterion focuses on the theory of elastic adaptation to two scales, mesoscopic and macroscopic. The macroscopic behavior of the material often remains elastic, only a grain oriented unfavorably undergo
plastic deformation. The author states the following hypothesis: `` The
multiscale approach is settled on the assumption that under high cycle fatigue loading a structure
will not be fractured by fatigue if an elastic shakedown is reached at the macroscopic scale as well
as at mesoscopic scale " [Dang Van 1999]. The approach developed first is
to describe the plasticity across the grain, assuming a yield criterion. The yield criterion is the law of Schmid with a
linear supposed isotropic hardening. The author then search the elastic adaptation \figref{figDV} formula and a fatigue
test locally (Δ represents the tensor defining the orientation of the sliding system, $\gamma$ is the plastic slip and $\tau$
is the amplitude of shear stress on the defined plan).
\begin{figure}[!h]
\centering
\includegraphics[width=0.7\textwidth]{figures//DV.png}
\caption{Elastic adaptation at the two scales [Dang Van 1999]}
\label{figDV}
\end{figure}
Finally, a micro to macro is applied to determine the criteria on the macroscopic scale. The localization law used is
Lin-Taylor model that assumes equality of deformations at two scales. Using empirical relationships, the harmful role of the mean stress on the fatigue
strength of the material is shown for type of uniaxial tensile stress. Dang Van shows the effect of the mean stress
with hydrostatic stress term in the criteria expressed as a linear combination of mesoscopic shear stress on the maximum shear plane $\tau_a$ and the hydrostatic stress $\Sigma_h$.
The Dang Van criterion presented in \cite{ballard1995high} is expressed as:
\begin{equation}
\max \limits_{\vec{n}}\left\lbrace \max \limits_{t}\left\{\tau_a{(\vec{n},t)}+a_D\Sigma_h(t)\right\}\right\rbrace \leqslant b_D.
\label{dv}
\end{equation}
$\tau_a$ denotes the mesoscopic shear stress amplitude and is obtained from a mesoscopic stress tensor $\hat{\bm{\sigma}}$ defined by:
$$\hat{\bm{\sigma}}(t)=(\bm{\sigma}(t)-s^\star).$$
$s^\star$ is the center of the smallest hypersphere circumscribed to the loading path in deviatoric stress space. It is obtained by solving a ``min-max" problem as follows:
$$s^\star = arg \min\limits_{s_1}\left\{\max\limits_t\parallel s(t)-s_1\parallel\right\}.$$
In the case of fully reversed loading, the values $s^\star=0$ can be directly deduced without solving the ``min-max problem" as in general case.
The principal stress values of stress tensor $\widetilde{\sigma}$ denoting by $\hat{\sigma}_{\Rmnum{3}}(t)\leqslant\hat{\sigma}_{\Rmnum{2}}(t)\leqslant\hat{\sigma}_{\Rmnum{1}}(t)$, one gets the amplitude of shear stress by:
$$\tau(t)=\frac{1}{2}(\hat{\sigma}_{\Rmnum{1}}(t)-\hat{\sigma}_{\Rmnum{3}}(t)).$$
$\Sigma_h(t)$is the hydrostatic stress as a function of the time, given by:$$\Sigma_h(t)=\frac{\sigma_{kk}(t)}{3}.$$
The material characteristic parameters $a_D$ and $b_D$ of the Dang Van
criterion, can be related to the fully reversed bending (or tension-
compression because of the same stress state between them)fatigue limit, denoted by $f_{-1}$ (or $S_{-1}$), and to the torsion fatigue limit, denoted by $t_{-1}$,
$$a_D=\frac{3t_{-1}}{s_{-1}}-\frac{3}{2};$$ $$b_D=t_{-1}.$$
In the particular case of the uniaxial tension, the criterion is written as:
$$\Sigma_{xx,a}\left(\dfrac{1}{2}+\dfrac{a_D}{3} \right)+\Sigma_{xx,m}\left(\dfrac{a_D}{3} \right) =b_D$$
\textbf{Papadopoulos Criterion}
The approach proposed by \cite{papadopoulos1993fatigue} also uses the concept of elastic adaptation and even the localization law. According to him, "the observations at the mesoscopic scale show that the initiation of a fatigue crack is
defined as the occurrence of micro-cracks corresponding to the rupture of the most deformed crystal grains in an
aggregate. Thus, a fatigue limit criterion can be modeled by a limit value of the accumulated plastic strain in the
most distorted grain."
$$\gamma_{cum}\leqslant\gamma_\infty$$
He proposes to opt for a mean value of the accumulated plastic strain on all possible slip systems of representative elementary volume(REV). So he chose to use a average value of accumulated plastic deformation rather than looking at failure of a single crystal. A spherical coordinate system(\figref{fig50}) to guide the vector of normal in material plane, and the unit direction vector $r$ linked to a sliding direction of this plan is used to conduct the integration over all possible orientations.
\begin{figure}[h!]
\centering
\includegraphics[width=0.5\textwidth]{figures//demopp.png}
\caption{Material plane $\Delta$ passing through point O of a body and its
associated (n, l, r) frame.}
\label{fig50}
\end{figure}
At any point $O$ of a body, a material plane $\Delta$ can be defined by its unit normal vector $\bf n$. This vector
$\bf n$ makes an angle $\theta$ with the z-axis of a $Oxyz$ frame attached to the body, and its projection on the $xy$ plane
makes an angle $\varphi$ with axis $x$. For each plane $\Delta$ a new quantity is introduced called $generalised$ $shear$ $stress$ amplitude and denoted as $T_a$.This shear stress quantity was first introduced in Papadopoulos [6]
and was subsequently used by other researchers.The critical plane according to our proposal is that onto which $T_a(\varphi,\theta)$ achieves its maximum value. The fatigue limit criterion is written as:
\begin{equation}
max T_a+\alpha_\infty \Sigma_{h,max}\leqslant \gamma_\infty
\end{equation}
where $\alpha_\infty$ and $\gamma_\infty$ are material parameters to be determined\cite{papadopoulos2001long}.
$$\Sigma_{h,max}=\max\limits_{t}\left\lbrace \frac{1}{3}tr(\uline{\uline{\sigma}}(t))\right\rbrace $$
He introduced the resolved shear stress $\tau$:
\begin{equation}
\begin{split}
\tau=&[sin\theta cos\varphi\sigma_{xx}+sin\theta sin\varphi\sigma_{xy}+cos\theta\sigma_{xz}](-sin\varphi cos\chi-cos\theta cos\varphi sin\chi)+\\&[sin\theta cos\varphi\sigma_{xy}+sin\theta sin\varphi\sigma_{yy}+cos\theta\sigma_{yz}](cos\varphi cos\chi-cos\theta sin\varphi sin\chi)+\\&[sin\theta cos\varphi\sigma_{xz}+sin\theta sin\varphi\sigma_{yz}+cos\theta\sigma_{zz}]sin\theta sin\chi
\end{split}
\label{eqres}
\end{equation}
It is clear that the resolved shear stress is a function of
$\varphi$, $\theta$, $\chi$ and of time $t$ in the case of variable loading, i.e. $\tau=\tau(\varphi, \theta, \chi, t)$. Upon fixing a couple $(\varphi, \theta)$ (i.e. a plane
$\Delta$) and an angle $\chi$ (i.e. a line $\xi$ on $\Delta$), one can define the amplitude of the resolved shear stress $\tau_a$, acting on $\Delta$
along $\xi$ by the formula:
\begin{equation}
\tau_a(\varphi,\theta,\chi)=\frac{1}{2}\big[\max \limits_{t\in P}\tau_a(\varphi,\theta,\chi ,t)-\min \limits_{t\in P}\tau_a(\varphi,\theta,\chi ,t)\big]
\end{equation}
Finally, for a given plane $\Delta$, i.e. for a fixed couple ($\varphi$, $\theta$),
the generalized shear stress amplitude $T_a$ is defined as:
\begin{equation}
T_a(\varphi,\theta)=\sqrt{\frac{1}{\pi}\int_{x=0}^{\frac{\pi}{2}} \tau_a^2(\varphi,\theta,\chi)d\chi}
\label{Ta}
\end{equation}
We note the fatigue limit in fully reversed torsion $t_{-1}$ and the fatigue limit in fully reversed bending $f_{-1}$. From these two tests we get the parameters:
$$\gamma_\infty=t_{-1},$$
$$\alpha_\infty=3\left( \frac{t_{-1}}{f_{-1}}-\frac{1}{2}\right) .$$
The Papadopoulos fatigue limit criterion achieves the form:
\begin{equation}
maxT_a+3\left( t_{-1}/f_{-1}-1/2\right) \Sigma_{h,max}\leqslant t_{-1}.
\label{eq:papadopoulos}
\end{equation}
In the particular case of the uniaxial tension, the criterion is written as:
$$\Sigma_{xx,a}\left(\dfrac{1}{\sqrt{3}}+\dfrac{\alpha_\infty}{3} \right)+\Sigma_{xx,m}\left(\dfrac{a_\infty}{3} \right) =\gamma_\infty$$
\subsubsection{Criteria based on energy}
Depending on the type of density of deformation energy considered per cycle, the
Energy criteria are divided into three groups [Macha et al 1999]:
\begin{itemize}
\item criteria based on law of thermodynamics
\item criteria based on elastic energy
\item criteria based on plastic energy
\item criteria based on the sum of elastic and plastic energies
\end{itemize}
The criteria based on the elastic deformation energy can be used in fatigue with a large number of cycles, whereas those based on the plastic deformation energy are more suitable for oligocyclic fatigue.
[Ellyin 1974]\cite{Ellyin1974} is one of the first to propose a fatigue criterion based on cyclic shear deformation energy. This approach was taken up and complemented by [Lefebvre et al 1981]\cite{neale1981criterion} and [Ellyin et al., 1991]\cite{ellyin1991phase} for the case of multiaxial loadings. In France, this approach is reflected in the work of [Froustrey-Lasserre 1992]\cite{Froustey1992} and then in [Palin-Luc 1996]\cite{palin1996fatigue} and [Banvillet 2001]\cite{vidal1996prevision}.
\paragraph{Energy dissipation based on law of thermodynamics}
In case of shell model. We assume the temperature in the thickness direction does not change. Based on the first and second law of thermodynamics, for any point M, we define $T(M,t)$ is the temperature field of $M$ at time $t$. Its 2D heat transfer function is \cite{yuan2013prediction}:
$$\rho C \frac{\partial T(M,t)}{\partial t}-k\Delta_2 T(M,t)+\frac{2\sigma_e\varepsilon_mT(M,t)^4}{e}+\frac{2h}{e}[T(M,t)-T(M,t)^{air}]=d_1(M,t)+S_{th}(M,t)+r(M,t)$$
$\rho$ is the density of the steel, C is specific heat capacity, k is heat transfer coefficient, $\sigma_e$ is the bolzmann constant, $\varepsilon_m$ is the surface thermal emissivity, h is heat convection factor,$T(M,t)^{air}$ is the environment temperature at point M, $\Delta_2$ is two dimensional Laplace operator. $d_1(M,t)$ is the dissipative source of fatigue relevant irreversible strain $\varepsilon_{ir}$, strain hysteresis $\varepsilon_{ve}$ and micro structure deformation; $S_{th}(M,t)$ is the thermoelastic source composing of elastic strain $\varepsilon_e$; $r(M,t)$ is thermal radiation term.
In a single cycle the dissipated energy is only a function of dissipative source $d_1(M,t)$:
$$E_{d_1}(t)=\int_{t-\frac{t_f}{2}}^{t+\frac{t_f}{2}}d_1(t)dt$$
Experiments with different stress amplitude loadings shows that the correlation coefficient between dissipated energy in one cycle and fatigue life is more than S-N curve.
$lgE_{d_1}^m=-0.77lgN_F+8.33$ correlation coefficient:0.94
$lg\sigma_a=-0.13lgN_F+2.85$ correlation coefficient:0.89
\paragraph{Energy dissipation based on strain energy density}
In their fatigue criterion, Froustey et al. (1992) have considered a complete cycle of
stresses. They use the mean value on one cycle of
the volumic density of the elastic strain energy, $W_a$, whatever the point
M in the mechanical part.
$$W_a(M)=\frac{1}{T}\int_{0}^{T}\frac{1}{2}\sigma_{ij}(M,t)\varepsilon_{ij}^e(M,t)dt$$
where $\sigma_{ij}(M,t)$ and $\varepsilon_{ij}^e(M,t)$ are respectively the tensor of stresses and the tensor of
elastic strains at the considered point $M$ function of time $T$.Usually the endurance limit
is low enough to consider that the material remains elastic at the macroscopic scale
(Lemaitre and Chaboche, 1988). Thus, $W_a$ can be considered as the mean value on one
cycle of the total strain energy density at the considered point.
In 1998 Thierry PALIN-LUC and Serge LASSERRE \cite{palin1998energy} proposed the failure criterion of $W_a$:
Their studies show that another limit, called $\sigma^*$, can be defined below
the usual endurance limit of the material, $\sigma_D$. At a considered point a stress amplitude
below this new limit does not initiate observable damage at the microscopic scale (no
micro-cracks).
From $\sigma^*$ and by analogy with a sinusoidal traction load the corresponding mean value
of the strain energy volumetric density, $W_{a^*}$, can be calculated , where E is the
Young modulus of the material.
$$W_{a^*}=\frac{\sigma^{*2}}{4E}$$
Around each point it is always possible to define
the volume $V^* (C_i)$ by the set of points M where $W_a (M)$ is higher than $W_{a^*} (C_i)$
. They postulate that the part of $W_a (M)$ exceeding $W_{a^*} (C_i)$ is the damaging part
of the strain energy volumetric density. $\overline{\omega}_a(C_i)$ is
the volumetric mean value of the strain energy around the critical point $C_i$
$$V^*(C_i)=\lbrace points\, M(x,y,z) \,around\, C_i \,such\, that \,W_a(M)\geqslant W_{a^*}(C_i) \rbrace$$
$$\overline{\omega}_a(C_i)=\frac{1}{V^*(C_i)}\int\int\int_{V^*(C_i)}^{}[W_a(x,y,z)-W_{a^*}(C_i)]d\nu$$
This stress limit $\sigma^*$ can be estimated from
fatigue test results in fully reversed tension and in rotating
bending
$$\sigma^*=\sqrt{2(\sigma_{Ten,-1}^D)^2-(\sigma_{RotBend,-1}^D)^2}$$
\paragraph{A critical plane approach based on energy concepts}
In 1999 Tadeusz et al.\cite{lagoda1999critical} proposed under multiaxial loadings the normal strain energy density in the critical plane (i.e. the plane of the maximum damage) is understood as the energy parameter. The history of strain energy density is schematized with use of the rain-flow algorithm. Fatigue damage is accumulated according to Palmgren-Miner hypothesis and the standard fatigue characteristic of the material, rescaled with use of the considered energy parameter.
$$W(t)=\frac{1}{2}\sigma(t)\varepsilon(t)sgn[\sigma(t),\varepsilon(t)]$$
$$sgn(x,y)=\frac{sgn(x)+sgn(y)}{2}$$
$sgn(x),sgn(y)=0,1,-1$ for distinguishing positive and negative works in a
fatigue cycle.
If the stress and strain reach their maximum values,
$\sigma_a$ and $\varepsilon_a$, then the maximum energy density value is
$$W_a=\frac{1}{2}\sigma_a\varepsilon_a$$
In the case of high-cycle fatigue,
when the characteristic ($\sigma_a-N_F$) is used, the axis $\sigma_a$
should be replaced by $W_a$, where
$$W_a=\frac{\sigma_a^2}{2E}$$
In the case of low and high-cycle fatigue, when the
characteristic ($\varepsilon_a-N_F$) is used, we can do similar rescaling. We assume $$\sigma_a=\sigma_f'(2N_F)^b$$
From Manson-Coffin-Basquin equation we obtain
$$\varepsilon_a=\varepsilon_a^e+\varepsilon_a^p=\frac{\sigma_f'}{E}(2N_F)^b+\varepsilon_f'(2N_F)^c$$
$$W_a=\frac{1}{2}\sigma_a\varepsilon_a=\frac{\sigma_a}{2}\left[\frac{\sigma_f'}{E}(2N_F)^b+\varepsilon_f'(2N_F)^c\right]=\frac{(\sigma_f')^2}{2E}(2N_F)^{2b}+0.5\varepsilon_f'\sigma_f'(2N_F)^{b+c}$$
Fatigue characteristic for high-cycle fatigue
takes the form
$$W_a=\frac{(\sigma_f')^2}{2E}(2N_F)^{2b}$$
For the stress model we have:
$$lgN_F=A-mlg\sigma_a$$
For the energy model we have:
$$lgN_F=A'-m'lgW_a$$
$m'$ is slope of fatigue curve
expressed by energy.
\paragraph{Lamefip Criterion}
Ellyin\cite{ellyin2012fatigue} showed that the use of both the plastic and elastic strain work can be used
as damage parameter in multiaxial fatigue. The LAMEFIP criterion (Banvillet et al. [2003]\cite{banvillet2003volumetric}),
devoted to the field of endurance or limited endurance, uses for damage parameter, the volumetric density of the strain work given to the material per loading cycles after elastic shakedown(supposed to be reached after a few thousands cycles ).
The proposal is based on two main hypothesis : (i) the strain work given to the material per loading cycle is considered as the driving force for fatigue crack initiation and (ii) it is calculated after macroscopic elastic shakedown.
Many authors use cycle counting techniques to extract, from a random stress tensor sequence, cycles from which the damage could be estimated. These techniques have two main drawbacks : (i) the choice of the cycle counting algorithm influences the calculated fatigue life since the number of counted cycles is algorithm dependent (Dowling [1983]\cite{dowling1983fatigue}), and (ii) for multiaxial non-proportional stress states, in many approaches from the literature, the variable chosen for cycle counting differs from the damage parameter. To avoid such drawbacks an incremental model has been developed. The strain work density given at a point M is written in an incremental way as follows :
$$dW_g(M,t)=\sum_{i=1}^{3}\sum_{j=1}^{3}\sigma_{ij}\left( M,t\right)\dot{\epsilon}_{ij}\left( M,t\right)H\left( \sigma_{ij}\left( M,t\right),\dot{\sigma}_{ij}\left( M,t\right)\right)dt .$$
\noindent
- where $\epsilon_{ij}\left( M,t\right)$ are the strain tensor components and $\dot{x}= dx/dt$,\\
- $\sigma_{ij}\left( M,t\right)$ are the stress tensor components,\\
- and H represents the Heaviside function : $H(a) = 1$ if $a \geqslant 0$; $H(a) = 0$ if $a < 0$.
As underlined by Ellyin\cite{ellyin2012fatigue}, the strain work can be calculated as the sum of elastic and plastic strain works, so that :
$$dW_g(M,t)=dW_g^e(M,t)+dW_g^p(M,t).$$
The framework of this study being HCF and MCF, they choose to consider only the elastic part of the strain work (Eq.\eqref{eq.lamefip1}) in the elastic shakedown state. The cumulated strain work on a time
sequence of duration $T$ is equivalent to the integral of $dW_g^e(M,t)$ over $T$ as in Eq.\eqref{eq.lamefip2}. Banvillet et al. [2003]\cite{banvillet2003volumetric} has shown that for an uniaxial stress state $W_g$ is not shape dependent (sinus, triangle,square, etc...).
\begin{equation}
dW_g^e(M,t)=\sum_{i=1}^{3}\sum_{j=1}^{3}\sigma_{ij}\left( M,t\right)\dot{\epsilon}_{ij}^e\left( M,t\right)H\left( \sigma_{ij}\left( M,t\right),\dot{\sigma}_{ij}\left( M,t\right)\right)dt .
\label{eq.lamefip1}
\end{equation}
\begin{equation}W_g(M,t)=\int_{T}dW_g(M,t).\label{eq.lamefip2}
\end{equation}
To take into account the material sensitivity to the stress triaxiality, the triaxiality degree at a point M is defined by the ratio of the strain work associated with the spherical part of the stress tensor over the total given in the work of Banvillet et al.[2003]\cite{banvillet2003volumetric}, but in an incremental way :
$$dT(M,t)=\dfrac{dW_g^{Sph}(M,t)}{dW_g(M,t)} \ \ if \ \ dW_g(M,t)\neq0,\ otherwise \ \ dT(M,t)=0,$$
with
$$dW_g^{Sph}(M,t)=\dfrac{1}{3}\sum_{k=1}^{3}\sigma_{kk}(M,t)\sum_{l=1}^{3}\dot{\epsilon}_{ll}^e(M,t)H\left( \sum_{k=1}^{3}\sigma_{kk}(M,t)\sum_{l=1}^{3}\dot{\epsilon}_{ll}^e(M,t)\right)dt .$$
The material sensitivity to stress triaxiality is considered by using an empirical function
$F(dT,\beta_m)$ (Eq.\eqref{eq.lamefip3}) depending on the material parameter $\beta_m$ identified from two fully reversed
fatigue limits (rotating bending and torsion). At any instant, for a multiaxial stress state, the
strain work given to the material is corrected to evaluate an uniaxial equivalent strain work
$d{W_f}_{eq} (M,t)$ (Eq.\eqref{eq.lamefip4}). Under uniaxial stress state $d{W_g}_{eq} (M,t)=dW_g(M,t)$.
\begin{equation}
F(dT(M,t),\beta_m)=\dfrac{1}{1-dT(M,t)}\left[ 1-\dfrac{1}{\beta_m}ln\left[1+dT(M,t)(e^{\beta_m}-1) \right] \right] .
\label{eq.lamefip3}
\end{equation}
\begin{equation}
d{W_g}_{eq} (M,t)=d{W_g}(M,t)\dfrac{F(dT_{uniax,\beta_m})}{F(dT(M,t),\beta_m)}.
\label{eq.lamefip4}
\end{equation}
\subsubsection{Criteria based on plasticity-damage coupling}
In recent years, a new class of criteria coupling mesoplasticity and damage has emerged. [Lemaitre Sermage Desmorat 1999]\cite{lemaitre1999two} have, for example, evolved the approach introduced by [Lemaitre and Chaboche 1985]\cite{lemaitre1985mecanique} based on the thermodynamics of irreversible processes and the mechanics of continuous media. [Flaceli{\`e}re et al. 2004]\cite{flaceliere2004contribution} also proposed a model based on a plasticity-damage coupling and attempted to account for the phenomena of damage observed experimentally on a C35 steel. In this work, we will focus on a more recent approach proposed by [Monchiet et al 2006]\cite{monchiet2006contributions}.
\paragraph{Criterion of Monchiet et al}
In order to account for the coupling plasticity-damage in HCF, [Monchiet et al. 2006]\cite{monchiet2006contributions} uses a micro-mechanical approach based on the work of [Gurson 1977]\cite{gurson1977continuum}. The damage is represented by a magnitude $f$ related to the development of porosity in the sliding bands at the origin of the initiation of the fatigue cracks. A load surface, of the type defined by Gurson, is used:
\begin{equation}
\dfrac{\Sigma_{equ}^2}{\Sigma_0^2}+2fcosh\left(\dfrac{3}{2}\dfrac{\Sigma_h}{\Sigma_0}-1-f^2=0 \right),
\label{eq.monchiet1}
\end{equation}
where $\Sigma_{equ}$ Is the equivalent stress, $\Sigma_h$ The hydrostatic stress and $\Sigma_0$ the elastic limit of the matrix.
The authors take into account two mechanisms of damage:
\vspace{6pt}
\begin{itemize}
\item The first is related to the creation of gaps by annihilation of dislocations. This mechanism is at the origin of the accumulation of point defects of the lacunar or interstitial type along the persistent slip bands (PSB). The phenomenological model proposed by [Essmann et al 1979]\cite{doi:10.1080/01418618108239541} gives access to the porosity $f_a$:
\begin{equation}
f_a= A_0\left\lbrace k_a\gamma_{cum}-1+exp\left(-k_a\gamma_{cum} \right) \right\rbrace .
\label{eq.monchiet2}
\end{equation}
\item The second mechanism is related to the growth of micro-cavities. Using an incompressibility hypothesis, $f_g$ is defined by:
\begin{equation}
f_g=\left\lbrace 1-exp\left(3\epsilon_h^p \right) \right\rbrace.
\label{eq.monchiet3}
\end{equation}
\end{itemize}
It is important to note that the first mechanism involves the accumulated plasticity $\gamma_{cum}$, related to amplitude effects. The second mechanism depends on the hydrostatic plastic deformation $\epsilon_h^p$, and allows the taking into account of the mean stress effects.
The fatigue criterion is established on the basis of the following hypothesis: "a sufficient condition for nucleation of a fatigue crack is obtained if the porosity reaches a critical value $f_c$".
\begin{equation}
f\left( \gamma_{cum},\epsilon_h^p\right) =f_a+f_g\leqslant f_c.
\label{eq.monchiet4}
\end{equation}
Noting $\gamma_c$, the critical value of the cumulative plasticity for which the fatigue criterion is reached when $\epsilon_h^p=0$, it becomes:
\begin{equation}
f_c=\left\lbrace A_0\left\lbrace k_a\gamma_{c}-1+exp\left(-k_a\gamma_{c} \right) \right\rbrace \right\rbrace.
\label{eq.monchiet5}
\end{equation}
The use of Eq.\eqref{eq.monchiet4} and Eq.\eqref{eq.monchiet5} leads, for the limiting cases $k_a >> 1$ Eq.\eqref{eq.monchiet6}, $k_a << 1$ Eq.\eqref{eq.monchiet7}, noting $\epsilon_c$(The critical plastic deformation, equal to $f_c / 3$ in the case of $\gamma_{cum} 0$), there is:
\begin{equation}
\dfrac{\gamma_{cum}}{\gamma_{c}}+\dfrac{\epsilon_h^p}{\epsilon_c}=1,
\label{eq.monchiet6}
\end{equation}
\begin{equation}
\left( \dfrac{\gamma_{cum}}{\gamma_{c}}\right) ^2+\dfrac{\epsilon_h^p}{\epsilon_c}=1.
\label{eq.monchiet7}
\end{equation}
The effect of the mean stress is taken into account by the term hydrostatic deformation. Since $\gamma_{cum}$ and $\epsilon_h^p$ are defined on the grain scale, the macroscopic expression of the criterion requires to link these quantities to the macroscopic magnitudes of the loading.
The next step is to look for elastic adaptation conditions and to apply a micro-macro path. The numerical results obtained make it possible to establish the following relations between the loading parameters and the parameters of the local criterion:
\begin{equation}
\left( \dfrac{T_a}{\tau_d}\right) ^2+2f_ccosh\left\lbrace\dfrac{\sqrt{3}}{2}\dfrac{\Sigma_{h,a}}{\tau_h} \right\rbrace-1-f_c^2=0.
\label{eq.monchiet8}
\end{equation}
\begin{equation}
\Sigma_{h,m}=-\left( \dfrac{4c}{f_cln(f_c)}\left( 1-f_c\right)+3k^{\ast} \right) \epsilon_h^p.
\label{eq.monchiet9}
\end{equation}
In Eq.\eqref{eq.monchiet8}, $\tau_d$ and $\tau_h$ are the deviatoric and hydrostatic part of the plastic flow threshold associated with an isotropic hardening.
In Eq.\eqref{eq.monchiet8}, $c$ and $k^{\ast}$ are parameters related respectively to the kinematic hardening and to the homogenization scheme.
The implementation of this criterion requires the identification of 12 parameters:
\begin{flushleft}
\qquad - \qquad two parameters, $\gamma_c$ and $\epsilon_c$ linked to the local criterion.\\
\qquad - \qquad two parameters, $A_0$ and $k_a$, related to the mechanisms of nucleation of cracks.\\
\qquad - \qquad three parameters related to hardening, $R_0$ And $\tau_0$ linked to the isotropic hardening, $c$ linked to\\
\qquad \ \ \qquad the kinematic hardening\\
\qquad - \qquad two coefficients linked to the homogenization scheme, $\mu$ and $k$.\\
\qquad - \qquad a cubic anisotropy coefficient of the grain $p_1$\\
\qquad - \qquad a latent coefficient of strain hardening h\\
\qquad - \qquad a critical porosity coefficient $f_c$\\
\end{flushleft}
All of these parameters are microscopic, which poses a problem in their identification. Some elements of this modeling have been taken up by [Charkaluk and Constantinescu 2009]\cite{charkaluk2009revisiting}, [Charkaluk et al. 2007]\cite{charkaluk2007approche} in dissipative approaches.
\subsection{Basquin curve}
\vspace{6pt}
\textbf{Stress-Life Diagram (S-N Diagram)}
The basis of the Stress-Life method is the Wohler S-N diagram, shown schematically for two
materials in \figref{fig.sn}. The S-N diagram plots nominal stress amplitude S versus cycles to
failure N. There are numerous testing procedures to generate the required data for a proper
S-N diagram. S-N test data are usually displayed on a log-log plot, with the actual S-N line
representing the mean of the data from several tests.
\begin{figure}[!h]
\centering
\includegraphics[width=0.7\textwidth]{figures//sn.png}
\caption{Typical S-N curve.}
\label{fig.sn}
\end{figure}
\textbf{Endurance Limit}
Certain materials have a fatigue limit or endurance limit which represents a stress level below
which the material does not fail and can be cycled infinitely. If the applied stress level is below
the endurance limit of the material, the structure is said to have an infinite life. This is
characteristic of steel and titanium in benign environmental conditions. A typical S-N curve
corresponding to this type of material is shown Curve A in \figref{fig.sn}.
Many non-ferrous metals and alloys, such as aluminum, magnesium, and copper alloys, do not
exhibit well-defined endurance limits. These materials instead display a continuously
decreasing S-N response, similar to Curve B in \figref{fig.sn}. In such cases a fatigue strength $S_f$ for
a given number of cycles must be specified. An effective endurance limit for these materials is
sometimes defined as the stress that causes failure at $1x10^8$ or $5x10^8$ loading cycles.
The concept of an endurance limit is used in infinite-life or safe stress designs. It is due to
interstitial elements (such as carbon or nitrogen in iron) that pin dislocations, thus preventing
the slip mechanism that leads to the formation of microcracks. Care must be taken when
using an endurance limit in design applications because it can disappear due to:
\vspace{6pt}
$\bullet$ Periodic overloads (unpin dislocations)
$\bullet$ Corrosive environments (due to fatigue corrosion interaction)
$\bullet$ High temperatures (mobilize dislocations)
\vspace{6pt}
The endurance limit is not a true property of a material, since other significant influences such
as surface finish cannot be entirely eliminated. However, a test values ($S_e'$) obtained from
polished specimens provide a baseline to which other factors can be applied. Influences that
can affect the endurance limit include:
\vspace{6pt}
$\bullet$ Surface Finish
$\bullet$ Temperature
$\bullet$ Stress Concentration
$\bullet$ Notch Sensitivity
$\bullet$ Size
$\bullet$ Environment
$\bullet$ Reliability
\vspace{6pt}
\textbf{Power Relationship}
When plotted on a log-log scale, an S-N curve can be approximated by a straight line as shown
in \figref{fig.basquin}. Basquin’s equation is a power law relationship\ref{eq.basquin} which describes the linear relationship between the applied stress cycles (S) in the y-axis and the number of cycles to failure in the x-axis plotted on a log-log scale.
\begin{equation}
N=BS^\frac{1}{b}
\label{eq.basquin}
\end{equation}
To calculate the slope of the Basquin equation, solve the system of equations:
$$N_1=N_2\left(\dfrac{S_1}{S_2}\right)^\frac{1}{b},$$
$$b=\dfrac{logS_1-logS_2}{logN_1-logN_2},$$
where $b$ is the slope of the line.
$$B=N_1S_1^{-\frac{1}{b}}=N_2S_2^{-\frac{1}{b}}.$$
For the constant B, in industry the stress range value (from the maximum cyclic stress to the minimum cyclic stress) is often considered. If the stress values of the S-N curve are given as alternating stresses (which is the common practice), multiply these stresses by 2 to calculate the constant B (stress range = 2* alternating stress, assuming a zero mean stress and full reversal of the cyclic load). If the S-N curve data are given in stress range values, apply them directly in the equation for estimating the constant B.
\begin{figure}[h!]
\centering
\includegraphics[width=0.7\textwidth]{figures//basquin.png}
\caption{Idealized S-N curve for high cycle fatigue.}
\label{fig.basquin}
\end{figure}
The power relationship is only valid for fatigue lives that are on the design line. For ferrous metals this range is from $1x10^3$ to $1x10^6$ cycles. For non-ferrous metals, this range is from
$1x10^3$ to $5x10^8$ cycles.
\subsection{Calculation method without cycle counting}
This part presents the existing method of prediction of lifetime, which does not need the algorithm of cycle counting. These kind of methods are still minority and usually more delicate to implement, but present the advantage of free the choice of variable of counting proved to be ``dangerous''. The method presented here is the morel method which is based on stress.
\subsubsection{Morel's method}
Morel's method\cite{Morel2000101} is based on a mesoscopic approach to critical plane type with the
choice of plastic deformation as mesoscopic cumulative damage variable. Multiaxial and variable amplitude loading can be analyzed with this method.
\begin{flushleft}
Macroscopic quantities
\begin{table}[!h]
\begin{tabular}{lllll}
$\uline{\uline{\Sigma}}$ & macroscopic stress tensor & & & \\
$\uline{\uline{E}}$ & macroscopic strain tensor & & & \\
$\uline{\uline{C}}$ & macroscopic shear stress vector & & & \\
$\uline{\uline{T}}$ & macroscopic resolved shear stress vector acting on an easy glide direction& & & \\
$T_a$ & amplitude of the macroscopic resolved shear stress & & & \\
$P$ & macroscopic hydrostatic stress & & & \\
\end{tabular}
\end{table}
Mesoscopic quantities
\begin{table}[!h]
\begin{tabular}{lllll}
$\uline{\uline{\sigma}}$& mesoscopic stress tensor & & & \\
$\uline{\uline{\varepsilon}}$ & mesoscopic strain tensor & & & \\
$\uline{\tau}$& mesoscopic resolved shear stress vector acting on an easy glide direction & & & \\
$\gamma^p$& mesoscopic shear plastic strain & & & \\
$\Gamma$ & accumulated plastic mesostrain & & & \\
$T_\sigma$ & measure proportional to an upper bound of the plastic mesostrain accumulated on an elementary
material plane $\Delta$, also average value of $T_a$ & & & \\
$T_\Sigma$ & maximum value of $T_\sigma$& & & \\
$H$ & phase-difference coefficient& & & \\
\end{tabular}
\end{table}
\end{flushleft}
\textbf{Constant amplitude loading}
\vspace{6pt}
\textbf{Local stress estimation in high cycle fatigue}
By assuming that only one glide system (defined by a normal vector $\uline{n}$ to a plane and a vector
(direction) $\uline{M}$ within this plane) is active for every plastically deforming grain of the metal, Papadopoulos [9]
established a macro–meso passage for a glide system activated in a flowing crystal:
\begin{equation}
\uline{\tau}=\uline{T}-\mu\gamma^p\uline{m}
\label{macromeso}
\end{equation}
where $\uline{\tau}$ and $\uline{T}$ are the mesoscopic and macroscopic
resolved shear stresses acting along the slip direction $\uline{m}$ and defined by:
\begin{equation}
\uline{\tau}=(\uline{m}\cdot\uuline{\sigma}\cdot\uline{n})\uline{m}
\label{tau}
\end{equation}
\begin{equation}
\uline{T}=(\uline{m}\cdot\uuline{\Sigma}\cdot\uline{n})\uline{m}
\label{T}
\end{equation}
$\gamma^p$ is the plastic mesoscopic shear strain.
\begin{figure}[h!]
\centering
\includegraphics[width=0.8\textwidth]{figures//glid.png}
\caption{Path of the macroscopic shear stress $\uline{C}$ acting on a material plane $\Delta$ and the corresponding path of the macroscopic resolved shear stress $\uline{T}$ acting on an easy glide direction.}
\label{glid}
\end{figure}
\textbf{Initiation of slip in the crystal}
The plasticity criterion is determined by Schmid's law with isotropic and kinematic hardening:
\begin{equation}
f(\uline{\tau},\uline{b},\tau_y)=(\uline{\tau}-\uline{b})\cdot(\uline{\tau}-\uline{b})-\tau_y^2=0
\label{Schmid}
\end{equation}
where $\uline{b}$ is the kinematical hardening parameter back stress.
In the description of his method, the author draws heavily on the work developed by
Papadopoulos including the use of a measure of plastic deformation mesoscopic
Cumulative $T_\sigma$ associated with a particular material plane and modeling the behavior of
grain in three distinct phases (hardening, saturation and softening); he considers the cumulative mesoscopic plastic deformation $\Gamma$ as damage parameter and assumes that the initiation of a fatigue crack occurs when the latter reaches a
critical value $D = D_R = \Gamma_R$ (\figref{3phases}).
\begin{figure}[h!]
\centering
\includegraphics[width=0.5\textwidth]{figures//3phases.png}
\caption{Yield limit and damage evolutions in the three behavior phases (hardening, saturation and softening) when a cyclic loading is applied.}
\label{3phases}
\end{figure}
\textbf{Loading limit estimation}
The estimation of the yield limit in the saturation phase $\tau_s$ (defining the cyclic behavior of the crystal) is
carried out by the definition of a limit loading.
\begin{equation}
T_{\Sigma lim}+\alpha P_{max lim}=\beta
\end{equation}
\begin{equation}