Robust Determination of Fatigue Crack Propagation Thresholds from Crack Growth Data.

The robust determination of the threshold against fatigue crack propagation ΔKth is of paramount importance in fracture mechanics based fatigue assessment procedures. The standards ASTM E647 and ISO 12108 introduce operational definitions of ΔKth based on the crack propagation rate da/dN and suggest linear fits of logarithmic ΔK- da/dN test data to calculate ΔKth. Since these fits typically suffer from a poor representation of the actual curvature of the crack propagation curve, a method for evaluating ΔKth using a nonlinear function is proposed. It is shown that the proposed method reduces the artificial conservativeness induced by the evaluation method as well as the susceptibility to scatter in test data and the influence of test data density.

A New Method for the Calculation of Characteristics of Disc Springs with Trapezoidal Cross-Sections and Rounded Edges.

In the European standards specifying disc spring manufacturing, geometry, shape and characteristic, an edge rounding is prescribed. Common methods for the calculation of disc spring characteristics, even in these standards, are based on a rectangular cross-section. This discrepancy can lead to a considerable divergence of the computed characteristic from the characteristic determined by testing. In literature, this divergence has not yet been examined with regard to rounded edges. In this paper, a new method addressing this problem is introduced. For this purpose, the geometry of idealized disc springs is parameterized. Based on four edge radii and two angles of the inner and outer faces, equations to compute the initial cone angle and the lever arm are introduced. These equations are used to formulate an algorithm to adapt other computation methods to non-rectangular cross-sections and rounded edges. The method is applied to the formulas by Almen-Laszlo, Curti-Orlando, Zheng and those by Kobelev. FE simulations of disc springs with rounded edges and a non-rectangular cross-section were used to verify the new formulas. The results show that the introduced method can be applied to known characteristic computation methods and result in a model expansion taking cross-section variations into account. The adjusted characteristics show more accurate alignment to the FE simulation for the cross-section variations investigated. These findings not only close the geometric gap between the manufacturing guidelines and the computation on an analytical basis, they also define a new parameter space for designs of disc springs and a corresponding force computation method to optimize spring characteristics.

On the Influence of Ultimate Number of Cycles on Lifetime Prediction for Compression Springs Manufactured from VDSiCr Class Spring Wire.

For the generation of fatigue curves by means of fatigue tests, an ultimate number of cycles must be chosen. This ultimate number of cycles also limits the permissible range of the fatigue curve for the design of components. This introduces extremely high costs for testing components that are to be used in the Very High Cycle Fatigue regime. In this paper, we examine the influence of the ultimate number of cycles of fatigue tests on lifetime prediction for compression springs manufactured from VDSiCr class spring wire. For this purpose, we propose a new kind of experiment, the Artificial Censoring Experiment (ACE). We show that ACEs may be used to permissibly extrapolate the results of fatigue tests on compression springs by ensuring that a batch-specific minimum ultimate number of cycles has been exceeded in testing. If the minimum ultimate number of cycles has not been exceeded, extrapolation is inadmissible. Extrapolated results may be highly non-conservative, especially for models assuming a pronounced fatigue limit.

A Novel Algorithm for the Determination of Walker Damage in Loaded Disc Springs.

In this paper, a novel algorithm for the determination of Walker damage in loaded disc springs is presented. The algorithm takes a 3D-scan of a disc spring, measured residual stresses, material parameters, and spring loads as inputs. It outputs a distribution of Walker damage over the surface area of the input disc spring. As the algorithm allows a fully automated determination of the Walker damage, it can be used by disc spring manufacturers to reduce the working time spent on this task by specialized engineers significantly. Compared to spreadsheet applications using analytical formulas and finite element models using idealized geometry, this approach offers a superior description of the stress states in disc springs.