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Fatigue analysis services denote a process of thoroughly evaluating the durability and reliability of materials and structures under cyclic loading conditions. It is instrumental in preventing failures and optimizing performance in various applications, such as aerospace, automotive, biomedical, and civil engineering. Notably,
Fatigue failure of critical components led to the Aloha Airlines Flight 243 Boeing 737 incident in 1988 and the Delta Air Lines Flight 1288 MD-88 accident in 1996.
This is why one of the most common and effective methods for conducting fatigue analysis is FEA (Finite Element Analysis).
FEA is a numеrical technique that can simulatе complex gеometries, loading conditions, and matеrial propеrtiеs and provide dеtailеd information on stress, strain, and damagе distribution. It can incorporate various fatigue modеls and criteria, such as stress life, strain life, and fracture mеchanics.
This article will discuss the fatigue analysis and provide valuable insights and expert tips.
There are different approaches to fatigue design, depending on the level of risk and uncertainty involved. Some of the common approaches are:
Safe life design: This approach assumes that the structure has a finite fatigue life and must be replaced before it reaches the end of its life. The advantage of this approach is its simplicity and straightforward implementation, but it may lead to overdesign and waste of resources.
Damage-tolerant design: It also recognizes that the structure may develop cracks or defects during its service life. This also aims to prevent them from growing to a critical size that causes failure. The notable advantage is that it can extend the fatigue life and reduce the cost of replacement, but it requires sophisticated methods and tools for comprehensive damage analysis.
Fail-safe design: This approach ensures that the structure can tolerate a partial or complete failure of one or more of its components without compromising the overall integrity and functionality of the system. It can enhance the robustness and resilience of the structure but may also increase the complexity and weight of the system.
Fatigue life estimation methods are techniques for predicting the duration of time that a material or a structure can withstand under cyclic loading before failure. There are three main methods:
Stress-life method: This is based on the S-N curve, which plots the stress amplitude versus the number of cycles to failure for a given material. It is widely used for designing components such as gears, shafts, springs, and bearings.
Strain-life method: It relies on the ε-N curve, which plots the strain amplitude versus the number of cycles to failure for a given material. It is used in designing pressure vessels, pipelines, and weldments.
Fracture mechanics method: This method measures the crack growth rate, which relates the rate of crack extension to the stress intensity factor for a given material. It is It is used in designing aircraft wings, bridges, and turbines.
FEA can be used to perform fatigue analysis by fatigue analysis services in the following way:
The fatigue analysis service defines the loading conditions, such as the magnitude, frequency, and direction of the applied forces or pressures, that the product or material will experience in its service life.
It defines the geometry and mesh of the model, such as the shape, size, and discretization of the elements that represent the product or material in the FEA software.
The analysis then outlines the material properties, such as the stress-strain curve, fatigue strength, fatigue life, and damage parameters, that characterize the behavior of the product or material under cyclic loading.
Subsequently, the fatigue analysis service performs the analysis, such as calculating the stress and strain distributions, the stress or strain amplitude, the mean stress or strain, the stress or strain ratio, etc.
As a final outcome, the fatigue analysis service interprets the results, such as evaluating the fatigue life, the fatigue damage, the safety factor, the critical locations, etc., using the FEA software or other tools.
Mechartes is a prominent consulting and advanced engineering services company that provides simulation services and solutions for various industries, such as building and construction, power, oil and gas, wastewater and process plants, etc.
One of the key services that we provide is FEA fatigue analysis, which extends the following benefits:
We have the experience and expertise to implement the right fatigue model and criteria, account for the effects of various factors, validate and verify the FEA results, and optimize the design and improve fatigue performance.
We have a portfolio of successful projects and satisfied clients in various domains, such as analyzing aircraft sewage system durability, designing a high-pressure vessel, optimizing a wind turbine blade, etc.
This study amalgamates two insightful articles that shed light on using fatigue analysis services and exploring various methods and techniques to estimate fatigue life.
Goal of the Study:
The synthesis aims to bridge the gap between understanding fatigue life estimation in metals and its practical application in product design.
Methods Used:
One of the articles extensively reviews methods such as stress-fatigue, strain-fatigue, and stress-field intensity for estimating fatigue life. In parallel, the other article focuses on stress-based and strain-based fatigue analysis, highlighting the linear nature of stress-based techniques and the non-linear accuracy of strain-based methods, particularly for non-metallic materials.
Results:
The synthesis underscores the complexity and challenges inherent in fatigue analysis services, emphasizing the absence of a one-size-fits-all solution across materials and loading conditions. While one article identifies promising areas for future research, including novel fatigue life prediction models and advanced material applications, the other article concludes with a resounding affirmation of fatigue analysis as an indispensable aspect of the design process.
Check out the resources here.
From stress-based to strain-based approaches, Finite Element Analysis (FEA) plays a pivotal role in creating three-dimensional models, providing invaluable insights into stress, strain, and damage distribution.
For those seeking expert guidance in FEA fatigue analysis services, Mechartes stands as a reliable partner. With advanced simulation techniques, experience, and a successful track record, Mechartes offers a comprehensive solution to predict, analyze, and enhance the fatigue performance of products and materials.
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