Search results for: Fatigue failure
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 925

Search results for: Fatigue failure

835 Finite Element Prediction of Hip Fracture during a Sideways Fall

Authors: M. Ikhwan Z. Ridzwan, Bidyut Pal, Ulrich N. Hansen

Abstract:

Finite element method was applied to model damage development in the femoral neck during a sideways fall. The femoral failure was simulated using the maximum principal strain criterion. The evolution of damage was consistent with previous studies. It was initiated by compressive failure at the junction of the superior aspect of the femoral neck and the greater trochanter. It was followed by tensile failure that occurred at the inferior aspect of the femoral neck before a complete transcervical fracture was observed. The estimated failure line was less than 50° from the horizontal plane (Pauwels type II).

Keywords: Femoral Strength, Finite Element Models, Hip Fracture, Progressive Failure, Sideways Fall.

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834 Study of Effect of Gear Tooth Accuracy on Transmission Mount Vibration

Authors: Kalyan Deepak Kolla, Ketan Paua, Rajkumar Bhagate

Abstract:

Transmission dynamics occupy major role in customer perception of the product in both senses of touch and quality of sound. The quantity and quality of sound perceived is more concerned with the whine noise of the gears engaged. Whine noise is tonal in nature and tonal noises cause fatigue and irritation to customers, which in turn affect the quality of the product. Transmission error is the usual suspect for whine noise, which can be caused due to misalignments, tolerances, manufacturing variabilities. In-cabin noise is also more sensitive to the gear design. As the details of the gear tooth design and manufacturing are in microns, anything out of the tolerance zone, either in design or manufacturing, will cause a whine noise. This will also cause high variation in stress and deformation due to change in the load and leads to the fatigue failure of the gears. Hence gear design and development take priority in the transmission development process. This paper aims to study such variability by considering five pairs of helical spur gears and their effect on the transmission error, contact pattern and vibration level on the transmission.

Keywords: Gears, whine noise, manufacturing variability, mount vibration variability.

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833 A survey Method and new design Lecture Chair for Complied Ergonomics Guideline at Classroom Building 2 Suranaree University of Technology, Thailand

Authors: Sumalee B., Sirinapa L., Jenjira T., Jr., Setasak S.

Abstract:

The paper describes ergonomics problems trend of student at B5101 classroom building 2, Suranaree University of Technology. The objective to survey ergonomics problems and effect from use chairs for sitting in class room. The result from survey method 100 student they use lecture chair for sitting in classroom more than 2 hours/ day by RULA[1]. and Body discomfort survey[2]. The result from Body discomfort survey contribute fatigue problems at neck, lower back, upper back and right shoulder 2.93, 2.91, 2.33, 1.75 respectively and result from RULA contribute fatigue problems at neck, body and right upper arm 4.00, 3.75 and 3.00 respectively are consistent. After that the researcher provide improvement plan for design new chair support student fatigue reduction by prepare data of sample anthropometry and design ergonomics chair prototype 3 unit. Then sample 100 student trial to use new chair and evaluate again by RULA, Body discomfort and satisfaction. The result from trial new chair after improvement by RULA present fatigue reduction average of head and neck from 4.00 to 2.25 , body and trunk from 3.75 to 2.00 and arm force from 1.00 to 0.25 respectively. The result from trial new chair after improvement by Body discomfort present fatigue reduction average of lower back from 2.91 to 0.87, neck from 2.93 to 1.24, upper back 2.33 to 0.84 and right upper arm from 1.75 to 0.74. That statistical of RULA and Body discomfort survey present fatigue reduction after improvement significance with a confidence level of 95% (p-value 0.05). When analyzing the relationship of fatigue as part of the body by Chi – square test during RULA and Body discomfort that before and after improvements were consistent with the significant level of confidence 95% (p-value 0.05) . Moreover the students satisfaction result from trial with a new chair for 30 minutes [3]. 72 percent very satisfied of the folding of the secondary writing simple 66% the width of the writing plate, 64% the suitability of the writing plate, 62% of soft seat cushion and 61% easy to seat the chair.

Keywords: Ergonomics, Work station design, ErgonomicsChair, Student, Fatigue

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832 Geometric Representation of Modified Forms of Seven Important Failure Criteria

Authors: Ranajay Bhowmick

Abstract:

Elastoplastic analysis of a structural system involves defining failure/yield criterion, flow rules and hardening rules. The failure/yield criterion defines the limit beyond which the material flows plastically and hardens/softens or remains perfectly plastic before ultimate collapse. The failure/yield criterion is represented geometrically in three/two dimensional Haigh-Westergaard stress-space to facilitate a better understanding of the behavior of the material. In the present study geometric representations in three and two-dimensional stress-space of a few important failure/yield criterion are presented. The criteria presented are the modified forms obtained due to the conditional solutions of the equation of stress invariants. A comparison of the failure/yield surfaces is also presented here to obtain the effectiveness of each of them and it has been found that for identical conditions the Rankine’s criterion gives the largest values of limiting stresses.

Keywords: Deviatoric plane, failure criteria, geometric representation, hydrostatic axis, modified form.

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831 An Investigation of Shipping Comb Failures due to usage in Manufacturing Processes using RCFA and FMEA

Authors: Atjanakul W, Chutima S., Kamnerdthong T.

Abstract:

Shipping comb is mounted on Head Stack Assembly (HSA) to prevent collision of the heads, maintain the gap between suspensions and protect HSA tips from unintentional contact damaged in the manufacturing process. Failure analysis of shipping comb in hard disk drive production processes is proposed .Field observations were performed to determine the fatal areas on shipping comb and their failure fraction. Root cause failure analysis (RCFA) is applied to specify the failure causes subjected to various loading conditions. For reliability improvement, failure mode and effects analysis (FMEA) procedure to evaluate the risk priority is performed. Consequently, the more suitable information design criterions were obtained.

Keywords: Shipping comb, Hard disk drive, Root cause failureanalysis, Failure mode and effects analysis

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830 A Partially Accelerated Life Test Planning with Competing Risks and Linear Degradation Path under Tampered Failure Rate Model

Authors: Fariba Azizi, Firoozeh Haghighi, Viliam Makis

Abstract:

In this paper, we propose a method to model the relationship between failure time and degradation for a simple step stress test where underlying degradation path is linear and different causes of failure are possible. It is assumed that the intensity function depends only on the degradation value. No assumptions are made about the distribution of the failure times. A simple step-stress test is used to shorten failure time of products and a tampered failure rate (TFR) model is proposed to describe the effect of the changing stress on the intensities. We assume that some of the products that fail during the test have a cause of failure that is only known to belong to a certain subset of all possible failures. This case is known as masking. In the presence of masking, the maximum likelihood estimates (MLEs) of the model parameters are obtained through an expectation-maximization (EM) algorithm by treating the causes of failure as missing values. The effect of incomplete information on the estimation of parameters is studied through a Monte-Carlo simulation. Finally, a real example is analyzed to illustrate the application of the proposed methods.

Keywords: Expectation-maximization (EM) algorithm, cause of failure, intensity, linear degradation path, masked data, reliability function.

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829 Stabilizer Fillet Weld Strength under Multiaxial Loading (Effect of Force, Size and Residual Stress)

Authors: Iman Hadipour, Javad Marzbanrad

Abstract:

In this paper, the strength of a stabilizer is determined when the static and fatigue multiaxial loading are applied. Stabilizer is a part of suspension system in the heavy truck for stabilizing the cabin against the vibration of the road which composes of a thin-walled tube joined to a forge component by fillet weld. The component is loaded by non proportional random sequence of torsion and bending. Residual stress of welding process is considered here for static loading. This static loading with road irregularities are applied in this study as fatigue case that can affected in the fillet welded area of this part. The stresses in the welded structure are calculated using FEA. In addition, the fatigue with multi axial loading in the fillet weld is also investigated and the critical zone of the stabilizer is specified and presented by graphs. Residual stresses that have been resulted by the thermal forces are considered in FEA. Force increasing is the element of finding the critical point of the component.

Keywords: Fillet weld, fatigue, weld toe crack, weld root crack, S-N curve, multiaxial load, residual stress, combined force.

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828 Fear-Of-Failure and Women Entrepreneurship: Comparative Analysis Austria versus USA

Authors: Magdalena Meusburger, Caroline Maria Hofer

Abstract:

The advancement of women entrepreneurship in the last decade has been a vital driver for social and economic development. Despite the positive evolution, women entrepreneurs are still underrepresented in entrepreneurial ecosystems. Fear-of-failure is a major factor inhibiting their entrepreneurial activity. This survey-based research focused on aspiring and established entrepreneurial women in Austria and in the USA. It explored and compared the extent to which entrepreneurial fear-of-failure influences their self-employment and their aspirations to become self-employed. The results demonstrate that entrepreneurial fear-of-failure is significantly higher for women with the wish for self-employment than it is for women who are already self-employed. In terms of the geographical and cultural setting no major differences were confirmed.

Keywords: Entrepreneurial ecosystems, fear-of-failure, female entrepreneurship, women entrepreneurship.

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827 Non-Circular Carbon Fiber Reinforced Polymers Chainring Failure Analysis

Authors: A. Elmikaty, Z. Thanawarothon, L. Mezeix

Abstract:

This paper presents a finite element model to simulate the teeth failure of non-circular composite chainring. Model consists of the chainring and a part of the chain. To reduce the size of the model, only the first 11 rollers are simulated. In order to validate the model, it is firstly applied to a circular aluminum chainring and evolution of the stress in the teeth is compared with the literature. Then, effect of the non-circular shape is studied through three different loading positions. Strength of non-circular composite chainring and failure scenario is investigated. Moreover, two composite lay-ups are proposed to observe the influence of the stacking. Results show that composite material can be used but the lay-up has a large influence on the strength. Finally, loading position does not have influence on the first composite failure that always occurs in the first tooth.

Keywords: CFRP, composite failure, FEA, non-circular chainring.

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826 New Wavelet Indices to Assess Muscle Fatigue during Dynamic Contractions

Authors: González-Izal M., Rodríguez-Carreño I, Mallor-Giménez F, Malanda A, Izquierdo M

Abstract:

The purpose of this study was to evaluate and compare new indices based on the discrete wavelet transform with another spectral parameters proposed in the literature as mean average voltage, median frequency and ratios between spectral moments applied to estimate acute exercise-induced changes in power output, i.e., to assess peripheral muscle fatigue during a dynamic fatiguing protocol. 15 trained subjects performed 5 sets consisting of 10 leg press, with 2 minutes rest between sets. Surface electromyography was recorded from vastus medialis (VM) muscle. Several surface electromyographic parameters were compared to detect peripheral muscle fatigue. These were: mean average voltage (MAV), median spectral frequency (Fmed), Dimitrov spectral index of muscle fatigue (FInsm5), as well as other five parameters obtained from the discrete wavelet transform (DWT) as ratios between different scales. The new wavelet indices achieved the best results in Pearson correlation coefficients with power output changes during acute dynamic contractions. Their regressions were significantly different from MAV and Fmed. On the other hand, they showed the highest robustness in presence of additive white gaussian noise for different signal to noise ratios (SNRs). Therefore, peripheral impairments assessed by sEMG wavelet indices may be a relevant factor involved in the loss of power output after dynamic high-loading fatiguing task.

Keywords: Median Frequency, EMG, wavelet transform, muscle fatigue

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825 Designing and Analyzing Sensor and Actuator of a Nano/Micro-System for Fatigue and Fracture Characterization of Nanomaterials

Authors: Mohammad Reza Zamani Kouhpanji

Abstract:

This paper presents a MEMS/NEMS device for fatigue and fracture characterization of nanomaterials. This device can apply static loads, cyclic loads, and their combinations in nanomechanical experiments. It is based on the electromagnetic force induced between paired parallel wires carrying electrical currents. Using this concept, the actuator and sensor parts of the device were designed and analyzed while considering the practical limitations. Since the PWCC device only uses two wires for actuation part and sensing part, its fabrication process is extremely easier than the available MEMS/NEMS devices. The total gain and phase shift of the MEMS/NEMS device were calculated and investigated. Furthermore, the maximum gain and sensitivity of the MEMS/NEMS device were studied to demonstrate the capability and usability of the device for wide range of nanomaterials samples. This device can be readily integrated into SEM/TEM instruments to provide real time study of the mechanical behaviors of nanomaterials as well as their fatigue and fracture properties, softening or hardening behaviors, and initiation and propagation of nanocracks.

Keywords: Sensors and actuators, MEMS/NEMS devices, fatigue and fracture nanomechanical testing device, static and cyclic nanomechanical testing device.

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824 The Effects of Adding External Mass and Localised Fatigue upon Static and Dynamic Balance

Authors: K. Abuzayan, H. Alabed, S. Ali

Abstract:

The influence of physical (external added weight) and neurophysiological (fatigue) factors on static and dynamic balance in sport related activities was typified statically by the Romberg test (one foot flat, eyes open) and dynamically by jumping and hopping in both horizontal and vertical directions. Twenty healthy males were participated in this study. In Static condition, added weight increased body-s inertia and therefore decreased body sway in AP direction though not significantly. Dynamically, added weight significantly increased body sway in both ML and AP directions, indicating instability, and the use of the counter rotating segments mechanism to maintain balance was demonstrated. Fatigue on the other hand significantly increased body sway during static balance as a neurophysiological adaptation primarily to the inverted pendulum mechanism. Dynamically, fatigue significantly increased body sway in both ML and AP directions again indicating instability but with a greater use of counter rotating segments mechanism. Differential adaptations for each of the two balance mechanisms (inverted pendulum and counter rotating segments) were found between one foot flat and two feet flat dynamic conditions, as participants relied more heavily on the first in the one foot flat conditions and relied more on the second in the two feet flat conditions.

Keywords: Adding external mass, Dynamic balance, Localised fatigue, Static balance.

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823 Hybrid Fuzzy Selecting-Control-by- Range Controllers of a Servopneumatic Fatigue System

Authors: Marco Soares dos Santos, Jorge Augusto Ferreira, Camila Nicola Boeri, Fernando Neto da Silva

Abstract:

The present paper proposes high performance nonlinear force controllers for a servopneumatic real-time fatigue test machine. A CompactRIO® controller was used, being fully programmed using LabVIEW language. Fuzzy logic control algorithms were evaluated to tune the integral and derivative components in the development of hybrid controllers, namely a FLC P and a hybrid FLC PID real-time-based controllers. Their behaviours were described by using state diagrams. The main contribution is to ensure a smooth transition between control states, avoiding discrete transitions in controller outputs. Steady-state errors lower than 1.5 N were reached, without retuning the controllers. Good results were also obtained for sinusoidal tracking tasks from 1/¤Ç to 8/¤Ç Hz.

Keywords: Hybrid Fuzzy Selecting, Control, Range Controllers, Servopneumatic Fatigue System.

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822 A Redesigned Pedagogy in Introductory Programming Reduces Failure and Withdrawal Rates by Half

Authors: Said C. Fares, Mary A. Fares

Abstract:

It is well documented that introductory computer programming courses are difficult and that failure rates are high. The aim of this project was to reduce the high failure and withdrawal rates in learning to program. This paper presents a number of changes in module organization and instructional delivery system in teaching CS1. Daily out of class help sessions and tutoring services were applied, interactive lectures and laboratories, online resources, and timely feedback were introduced. Five years of data of 563 students in 21 sections was collected and analyzed. The primary results show that the failure and withdrawal rates were cut by more than half. Student surveys indicate a positive evaluation of the modified instructional approach, overall satisfaction with the course and consequently, higher success and retention rates.

Keywords: Failure Rate, Interactive Learning, Student engagement, CS1.

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821 Influence of Cyclic Thermal Loading on Fatigue Behavior of Thermal Barrier Coatings

Authors: Vidyasagar H. N., S. Gopal Prakash, Shivrudraiah, K. V. Sharma

Abstract:

Thermally insulating ceramic coatings also known as thermal barrier coatings (TBCs) have been essential technologies to improve the performance and efficiency of advanced gas turbines in service at extremely high temperatures. The damage mechanisms of air-plasma sprayed YSZ thermal barrier coatings (TBC) with various microstructures were studied by microscopic techniques after thermal cycling. The typical degradation of plasma TBCs that occurs during cyclic furnace testing of an YSZ and alumina coating on a Titanium alloy are analyzed. During the present investigation the effects of topcoat thickness, bond coat oxidation, thermal cycle lengths and test temperature are investigated using thermal cycling. These results were correlated with stresses measured by a spectroscopic technique in order to understand specific damage mechanism. The failure mechanism of former bond coats was found to involve fracture initiation at the thermally grown oxide (TGO) interface and at the TGO bond coat interface. The failure mechanism of the YZ was found to involve combination of fracture along the interface between TGO and bond coat.

Keywords: Thermal barrier coatings, thermal loading.

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820 Study of the Green Composite Jute/Epoxy

Authors: A. Mir, C. Aribi, B. Bezzazi

Abstract:

Work presented is interested in the characterization of the quasistatic mechanical properties and in fatigue of a composite laminated in jute/epoxy. The natural fibers offer promising prospects thanks to their interesting specific properties, because of their low density, but also with their bio-deterioration. Several scientific studies highlighted the good mechanical resistance of the vegetable fiber composites reinforced, even after several recycling. Because of the environmental standards that become increasingly severe, one attends the emergence of eco-materials at the base of natural fibers such as flax, bamboo, hemp, sisal, jute. The fatigue tests on elementary vegetable fibers show an increase of about 60% of the rigidity of elementary fibers of hemp subjected to cyclic loadings. In this study, the test-tubes manufactured by the method infusion have sequences of stacking of 0/90° and ± 45° for the shearing and tensile tests. The quasistatic tests reveal a variability of the mechanical properties of about 8%. The tensile fatigue tests were carried out for levels of constraints equivalent to half of the ultimate values of the composite. Once the fatigue tests carried out for well-defined values of cycles, a series of static tests of traction type highlights the influence of the number of cycles on the quasi-static mechanical behavior of the laminate jute/epoxy.

Keywords: Jute, epoxy resin, mechanical, static, dynamic behavior.

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819 Performance Comparison of Prim’s and Ant Colony Optimization Algorithm to Select Shortest Path in Case of Link Failure

Authors: Rimmy Yadav, Avtar Singh

Abstract:

Ant Colony Optimization (ACO) is a promising modern approach to the unused combinatorial optimization. Here ACO is applied to finding the shortest during communication link failure. In this paper, the performances of the prim’s and ACO algorithm are made. By comparing the time complexity and program execution time as set of parameters, we demonstrate the pleasant performance of ACO in finding excellent solution to finding shortest path during communication link failure.

Keywords: Ant colony optimization, link failure, prim’s algorithm.

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818 Turbulent Mixing and its Effects on Thermal Fatigue in Nuclear Reactors

Authors: Eggertson, E.C. Kapulla, R, Fokken, J, Prasser, H.M.

Abstract:

The turbulent mixing of coolant streams of different temperature and density can cause severe temperature fluctuations in piping systems in nuclear reactors. In certain periodic contraction cycles these conditions lead to thermal fatigue. The resulting aging effect prompts investigation in how the mixing of flows over a sharp temperature/density interface evolves. To study the fundamental turbulent mixing phenomena in the presence of density gradients, isokinetic (shear-free) mixing experiments are performed in a square channel with Reynolds numbers ranging from 2-500 to 60-000. Sucrose is used to create the density difference. A Wire Mesh Sensor (WMS) is used to determine the concentration map of the flow in the cross section. The mean interface width as a function of velocity, density difference and distance from the mixing point are analyzed based on traditional methods chosen for the purposes of atmospheric/oceanic stratification analyses. A definition of the mixing layer thickness more appropriate to thermal fatigue and based on mixedness is devised. This definition shows that the thermal fatigue risk assessed using simple mixing layer growth can be misleading and why an approach that separates the effects of large scale (turbulent) and small scale (molecular) mixing is necessary.

Keywords: Concentration measurements, Mixedness, Stablystratified turbulent isokinetic mixing layer, Wire mesh sensor

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817 A New Approach for Prioritization of Failure Modes in Design FMEA using ANOVA

Authors: Sellappan Narayanagounder, Karuppusami Gurusami

Abstract:

The traditional Failure Mode and Effects Analysis (FMEA) uses Risk Priority Number (RPN) to evaluate the risk level of a component or process. The RPN index is determined by calculating the product of severity, occurrence and detection indexes. The most critically debated disadvantage of this approach is that various sets of these three indexes may produce an identical value of RPN. This research paper seeks to address the drawbacks in traditional FMEA and to propose a new approach to overcome these shortcomings. The Risk Priority Code (RPC) is used to prioritize failure modes, when two or more failure modes have the same RPN. A new method is proposed to prioritize failure modes, when there is a disagreement in ranking scale for severity, occurrence and detection. An Analysis of Variance (ANOVA) is used to compare means of RPN values. SPSS (Statistical Package for the Social Sciences) statistical analysis package is used to analyze the data. The results presented are based on two case studies. It is found that the proposed new methodology/approach resolves the limitations of traditional FMEA approach.

Keywords: Failure mode and effects analysis, Risk priority code, Critical failure mode, Analysis of variance.

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816 ME/CFS Health Outcomes: The Interaction of Mode of Illness Onset and Psychiatric Comorbidity

Authors: Mary Gloria C. Njoku, Leonard A. Jason, Nicole Porter, Molly Brown

Abstract:

The objective of this study was to examine the interaction between mode of illness onset and psychiatric comorbidity on the health outcomes of persons with ME/CFS. A total of 114 individuals with ME/CFS participated in this study. Individuals completed a battery of baseline measures including the fatigue severity scale and measures of disability. Findings indicated that those with sudden illness onset had more impaired physical health functioning. In addition, among individuals with sudden onset, those without psychiatric comorbidity had greater fatigue severity and lower overall physical health than those with psychiatric comordibity. In contrast, among individuals with gradual illness onset, those with psychiatric comorbity had higher fatigue severity than those without comorbid psychiatric disorders. The health outcomes of individuals who have ME/CFS with or without psychiatric comorbidity are impacted by the mode of illness onset and this suggest that it is important to examine these factors in future research.

Keywords: Health Outcomes, ME/CFS, Mode of Illness Onset, Psychiatric Comorbidity.

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815 WDM-Based Storage Area Network (SAN) for Disaster Recovery Operations

Authors: Sandeep P. Abhang, Girish V. Chowdhay

Abstract:

This paper proposes a Wavelength Division Multiplexing (WDM) technology based Storage Area Network (SAN) for all type of Disaster recovery operation. It considers recovery when all paths failure in the network as well as the main SAN site failure also the all backup sites failure by the effect of natural disasters such as earthquakes, fires and floods, power outage, and terrorist attacks, as initially SAN were designed to work within distance limited environments[2]. Paper also presents a NEW PATH algorithm when path failure occurs. The simulation result and analysis is presented for the proposed architecture with performance consideration.

Keywords: SAN, WDM, FC, Ring, IP, network load, iSCSI, miles, disaster.

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814 Solution of S3 Problem of Deformation Mechanics for a Definite Condition and Resulting Modifications of Important Failure Theories

Authors: Ranajay Bhowmick

Abstract:

Analysis of stresses for an infinitesimal tetrahedron leads to a situation where we obtain a cubic equation consisting of three stress invariants. This cubic equation, when solved for a definite condition, gives the principal stresses directly without requiring any cumbersome and time-consuming trial and error methods or iterative numerical procedures. Since the failure criterion of different materials are generally expressed as functions of principal stresses, an attempt has been made in this study to incorporate the solutions of the cubic equation in the form of principal stresses, obtained for a definite condition, into some of the established failure theories to determine their modified descriptions. It has been observed that the failure theories can be represented using the quadratic stress invariant and the orientation of the principal plane.

Keywords: Cubic equation, stress invariant, trigonometric, explicit solution, principal stress, failure criterion.

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813 Methods for Better Assessment of Fatigue and Deterioration in Bridges and Other Steel or Concrete Constructions

Authors: J. Menčík, B. Culek, Jr., L. Beran, J. Mareš

Abstract:

Large metal and concrete structures suffer by various kinds of deterioration, and accurate prediction of the remaining life is important. This paper informs about two methods for its assessment. One method, suitable for steel bridges and other constructions exposed to fatigue, monitors the loads and damage accumulation using information systems for the operation and the finite element model of the construction. In addition to the operation load, the dead weight of the construction and thermal stresses can be included into the model. The second method is suitable for concrete bridges and other structures, which suffer by carbonatation and other degradation processes, driven by diffusion. The diffusion constant, important for the prediction of future development, can be determined from the depth-profile of pH, obtained by pH measurement at various depths. Comparison with measurements on real objects illustrates the suitability of both methods.

Keywords: Bridges, carbonatation, concrete, diagnostics, fatigue, life prediction, monitoring, railway, simulation, structures.

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812 Fatigue Behavior of Friction Stir Welded EN AW 5754 Aluminum Alloy Using Load Increase Procedure

Authors: A. B. Chehreh, M. Grätzel, M. Klein, J. P. Bergmann, F. Walther

Abstract:

Friction stir welding (FSW) is an advantageous method in the thermal joining processes, featuring the welding of various dissimilar and similar material combinations, joining temperatures below the melting point which prevents irregularities such as pores and hot cracks as well as high strengths mechanical joints near the base material. The FSW process consists of a rotating tool which is made of a shoulder and a probe. The welding process is based on a rotating tool which plunges in the workpiece under axial pressure. As a result, the material is plasticized by frictional heat which leads to a decrease in the flow stress. During the welding procedure, the material is continuously displaced by the tool, creating a firmly bonded weld seam behind the tool. However, the mechanical properties of the weld seam are affected by the design and geometry of the tool. These include in particular microstructural and surface properties which can favor crack initiation. Following investigation compares the dynamic properties of FSW weld seams with conventional and stationary shoulder geometry based on load increase test (LIT). Compared to classical Woehler tests, it is possible to determine the fatigue strength of the specimens after a short amount of time. The investigations were carried out on a robotized welding setup on 2 mm thick EN AW 5754 aluminum alloy sheets. It was shown that an increased tensile and fatigue strength can be achieved by using the stationary shoulder concept. Furthermore, it could be demonstrated that the LIT is a valid method to describe the fatigue behavior of FSW weld seams.

Keywords: Aluminum alloy, fatigue performance, fracture, friction stir welding.

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811 Analyzing Defects with Failure Assessment Diagrams of Gas Pipelines

Authors: Alfred Hasanaj, Ardit Gjeta, Miranda Kullolli

Abstract:

The approach in analyzing defects on different pipe lines is conducted through Failure Assessment Diagram (FAD). These methods of analyses have further extended in recent years. This approach is used to identify and stress out a solution for the defects which randomly occur with gas pipes such are corrosion defects, gauge defects, and combination of defects where gauge and dents are included. Few of the defects are to be analyzed in this paper where our main focus will be the fracture of cast Iron pipes, elastic-plastic failure and plastic collapse of X52 steel pipes for gas transport. We need to conduct a calculation of probability of the defects in order to predict and avoid such costly defects.

Keywords: Defects, Failure Assessment Diagrams, Safety Factor Steel Pipes.

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810 A Comparison of Double Sided Friction Stir Welding in Air and Underwater for 6mm S275 Steel Plate

Authors: Philip Baillie, Stuart W. Campbell, Alexander M. Galloway, Stephen R. Cater, Norman A. McPherson

Abstract:

This study compared the mechanical and microstructural properties produced during friction stir welding (FSW) of S275 structural steel in air and underwater. Post weld tests assessed the tensile strength, micro-hardness, distortion, Charpy impact toughness and fatigue performance in each case. The study showed that there was no significant difference in the strength, hardness or fatigue life of the air and underwater specimens. However, Charpy impact toughness was shown to decrease for the underwater specimens and was attributed to a lower degree of recrystallization caused by the higher rate of heat loss experienced when welding underwater. Reduced angular and longitudinal distortion was observed in the underwater welded plate compared to the plate welded in air.

Keywords: Charpy impact toughness, distortion, fatigue, friction stir welding (FSW), micro-hardness, underwater.

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809 Multi-Scale Damage and Mechanical Behavior of Sheet Molding Compound Composites Subjected to Fatigue, Dynamic, and Post-Fatigue Dynamic Loadings

Authors: M. Shirinbayan, J. Fitoussi, N. Abbasnezhad, A. Lucas, A. Tcharkhtchi

Abstract:

Sheet Molding Compounds (SMCs) with special microstructures are very attractive to use in automobile structures especially when they are accidentally subjected to collision type accidents because of their high energy absorption capacity. These are materials designated as standard SMC, Advanced Sheet Molding Compounds (A-SMC), Low-Density SMC (LD-SMC) and etc. In this study, testing methods have been performed to compare the mechanical responses and damage phenomena of SMC, LD-SMC, and A-SMC under quasi-static and high strain rate tensile tests. The paper also aims at investigating the effect of an initial pre-damage induced by fatigue on the tensile dynamic behavior of A-SMC. In the case of SMCs and A-SMCs, whatever the fibers orientation and applied strain rate are, the first observed phenomenon of damage corresponds to decohesion of the fiber-matrix interface which is followed by coalescence and multiplication of these micro-cracks and their propagations. For LD-SMCs, damage mechanisms depend on the presence of Hollow Glass Microspheres (HGM) and fibers orientation.

Keywords: SMC, LD-SMC, A-SMC, HGM, damage.

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808 The Analysis of Duct Model Through Structural and Dynamic Schemes

Authors: S. H. Yahaya, J. M. Ali, M. R. Arham

Abstract:

This paper presents the analysis of duct design using static and dynamic approaches. The static approach is used to find out applicability between the design and material applied. The material used in this paper is Thermoplastic Olefins (TPO). For the dynamic approach, the focusing is only on the CFD simulations. The fatigue life in this design and material applied also covered.

Keywords: CFD, structural analysis, fluid analysis, duct design, fatigue life

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807 Failure Analysis of Methanol Evaporator

Authors: D. Sufi Ahmadi, B. Bagheri

Abstract:

Thermal water hammer is a special type of water hammer which rarely occurs in heat exchangers. In biphasic fluids, if steam bubbles are surrounded by condensate, regarding lower condensate temperature than steam, they will suddenly collapse. As a result, the vacuum caused by an extreme change in volume lead to movement of the condensates in all directions and their collision the force produced by this collision leads to a severe stress in the pipe wall. This phenomenon is a special type of water hammer. According to fluid mechanics, this phenomenon is a particular type of transient flows during which abrupt change of fluid leads to sudden pressure change inside the tube. In this paper, the mechanism of abrupt failure of 80 tubes of 481 tubes of a methanol heat exchanger is discussed. Initially, due to excessive temperature differences between heat transfer fluids and simultaneous failure of 80 tubes, thermal shock was presupposed as the reason of failure. Deeper investigation on cross-section of failed tubes showed that failure was, ductile type of failure, so the first hypothesis was rejected. Further analysis and more accurate experiments revealed that failure of tubes caused by thermal water hammer. Finally, the causes of thermal water hammer and various solutions to avoid such mechanism are discussed.

Keywords: Thermal water hammer, Brittle Failure, Condensate thermal shock

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806 Residual Life Prediction for a System Subject to Condition Monitoring and Two Failure Modes

Authors: Akram Khaleghei Ghosheh Balagh, Viliam Makis

Abstract:

In this paper, we investigate the residual life prediction problem for a partially observable system subject to two failure modes, namely a catastrophic failure and a failure due to the system degradation. The system is subject to condition monitoring and the degradation process is described by a hidden Markov model with unknown parameters. The parameter estimation procedure based on an EM algorithm is developed and the formulas for the conditional reliability function and the mean residual life are derived, illustrated by a numerical example.

Keywords: Partially observable system, hidden Markov model, competing risks, residual life prediction.

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