Improved Sample Polymerization Principle and the Applications onto Fatigue Assessment of Railway Vehicle Structures

doi:10.3901/JME.2019.04.042

Abstract

Abstract: Fatigue S-N curves are the most fundamental material input to design the lightweight structures and assess the service safety of high-speed railway vehicles. How to reduce the dispersion of fatigue life data and to improve the prediction precision of fatigue performance are frequently the principal attention on long life service of railway vehicle structures. Classical sample polymerization principle (SPP) can effectively solve the small size sample, while the accuracy of fatigue life is still of primary concern. An improved SPP (iSPP) to build the fatigue probabilistic S-N (P-S-N) curve is therefore proposed to pursue an optimized search parameter related with the standard deviation (SD), thus obtaining the optimal life SD under different stress levels. Results show the slope and intercept of newly-built P-S-N curves from (X-x-x-x) type life data have the relative error less than 3%, and predicted fatigue life is approximately 5% of the group method (TGM) estimation in contrast with the TGM. Moreover, the predicted fatigue life is only 0.1% of traditional fitted method for (x-x-x-x) type life data. For the welded joints with defect induced dispersion, iSPP can achieve more conservative and reliable life predictions.It shows the iSPP and optimal parameter search method can not only ensure the accuracy of small sample but also acquire a more conservative P-S-N curve into engineering applications.

Key words: P-S-N curve, fatigue life, railway vehicles, sample congregation, small size sample

CLC Number:

TG156

LI Cunhai, WU Shengchuan, LIU Yuxuan. Improved Sample Polymerization Principle and the Applications onto Fatigue Assessment of Railway Vehicle Structures[J]. Journal of Mechanical Engineering, 2019, 55(4): 42-53.

References

[1] 李炳华,杜欣. 高速机车车辆车轴的疲劳设计[J]. 内燃机车,2000(1):14-20. LI Binghua,DU Xin. Fatigue design of wheel axles of locomotives and rolling stocks with high speed[J]. Diesel Locomotives,2000(1):14-20.
[2] HFFERN T V. Probabilistic modeling and simulation of metal fatigue life prediction[D]. California:Naval Postgraduate School,2002.
[3] 傅惠民. 异方差分析方法[J]. 机械强度,2005,27(2):196-201. FU Huimin. Method for heteroscedastic analysis[J]. Journal of Mechanical Strength,2005,27(2):196-201.
[4] 傅惠民,刘成瑞. S-N曲线和P-S-N曲线小子样测试方法[J]. 机械强度,2006,28(4):552-555. FU Huimin,LIU Chengrui. Small sample test method S-N for and P-S-N curves[J]. Journal of Mechanical Streneth,2006,28(4):552-555.
[5] ZHAO Y X,YANG B,FENG M F,et al. Probabilisticfatigue S-N curves including the super-long life regime ofa railway axle steel[J]. International Journal of Fatigue,2009,31(10):1550-1558.
[6] GUIDA M,PENTA F. A Bayesian analysis of fatiguedata[J]. Structural Safety,2010,32(1):64-76.
[7] KLEMENC J,FAJDIGA M. Estimating S-N curves and their scatter using a differential ant-stigmergy algorithm[J]. International Journal of Fatigue,2012,43(1):90-97.
[8] XIE L Y,LIU J Z,WU N X,et al. Backwards statistical inference method for P-S-N curve fitting with small-sample experiment data[J]. International Journal of Fatigue,2014,63(63):62-67.
[9] 谢里阳,刘建中. 样本信息聚集原理与P-S-N曲线拟合方法[J]. 机械工程学报,2013,49(15):96-104. XIE Liyang,LIU Jianzhong. Principle of sample polymerization and method of P-S-N curve fitting[J]. Journal of Mechanical Engineering,2013,49(15):96-104.
[10] 白鑫,谢里阳,任俊刚,等. 金属材料疲劳试验与数据处理方法[J]. 理化检验-物理分册,2015,51(6):375-380. BAI Xin,XIE Liyang,REN Jungang,et al. Fatigue test methods and their data processing methods of metallic materials[J]. Physical Testing and Chemical Analysis,2015,51(6):375-380.
[11] 白鑫,谢里阳,钱文学. 基于样本集聚原理的疲劳可靠性评估方法及其在零部件上的应用[J]. 机械工程学报,2016,52(6):206-212. BAI Xin,XIE Liyang,QIAN Wenxue. Fatigue probability evaluation method based on the principle of sample-polymerization[J]. Journal of Mechanical Engineering,2016,52(6):206-212.
[12] ZHAI J M,LI X Y. A methodology to determine a conditional probability density distribution surface from S-N data[J]. International Journal of Fatigue,2012,44:107-115.
[13] 中华人民共和国航空工业部. HB/Z 112-86,材料疲劳试验统计分析方法[S]. 北京:中国标准出版社,1986. Ministry of Aviation industry of the People's Republic of China. HB/Z 112-86,Statistical analysis method of material fatigue test[S]. Beijing:Standards Press of China,1986.
[14] 中华人民共和国国家质量监督检验检疫总局,中国国家标准化管理委员会. GB/T 24176-2009/ISO 12107:2003,金属材料疲劳试验数据统计方案与分析方法[S]. 北京:中国标准出版社,2009. General Administration of Quality Supervision,Inspectionand Quarantine of the People's Republic of China,China National Standardization Management Committee. GB/T 24176-2009/ISO 12107:2003,metallic materials-fatigue testing-statistical planning and analysis of data[S]. Beijing:Standards Press of China,2009.
[15] LEE Y L,PAN J,HATHAWAY R,et al. Fatigue testing and analysis:Theory and practice[M]. Boston:Butterworth-Heinemann,Amsterdam,2004.
[16] GAO J X,AN Z W,LIU B. A new method for obtaining P-S-N curves under the condition of small sample[J]. Journal of Risk and Reliability,2017,231(4):130-127.
[17] LUKE M,VARFOLOMEEV I,LÜTKEPOHL K,et al. Fatigue crack growth in railway axles:Assessment concept and validation tests[J]. Engineering Fracture Mechanics,2011,78(5):714-730.
[18] FILIPPINI M,LUKE M,VARFOLOMEEV I,et al. Fatigue strength assessment of railway axles considering small-scale tests and damage calculations[J]. Procedia Structural Integrity,2017,4:11-18.
[19] BERETTA S,REGAZZI D. Probabilistic fatigue assessment for railway axles and derivation of a simple format for damage calculations[J]. International Journal of Fatigue,2016,86:13-23.
[20] WU S C,XU ZW,LIU Y X,et al. On the residual life assessment of high-speed railway axles due to induction hardening[J]. International Journal of Rail Transportation 2018,DOI:10.1080/23248378.2018.1427008.
[21] 刘雪松,李书齐,王苹,等. 6N01-T5铝合金焊接接头疲劳断裂分析[J]. 焊接学报,2009,30(10):25-29. LIU Xuesong,LI Shuqi,WANG Ping,et al.Fatigue failure analysis of 6N01-T5 aluminum alloy weldedjoints[J]. Transactions of the China Welding Institution,2009,30(10):25-29.
[22] 赵旭,陈辉. 7N01铝合金平滑焊接接头疲劳性能研究[J]. 热加工工艺,2016,45(21):181-186. ZHAOXu,CHEN Hui.Research on fatigue property of smooth weld joints in 7N01 aluminum alloy[J]. Hot Working Technology,2016,45(21):181-186.
[23] 杨新岐,吴铁,张家龙,等. 厚板铝合金FSW和MIG焊接接头疲劳性能[J]. 焊接学报,2012,33(5):5-9. YANG Xinqi,WU Tie,ZHANG Jialong,et al. Fatigue properties for FSW and MIG welded joints of thickness plate aluminum alloy[J]. Transactions of the China Welding Institution,2012,33(5):5-9.
[24] 胡雅楠,吴圣川,宋哲,等. 激光复合焊接7020铝合金的疲劳性能及损伤行为[J]. 中国激光,2018,45(3),302003. HU Yanan,WU Shengchuan,SONG Zhe,et al. Fatigue property and fracture behavior of 7020 aluminum alloys welded by laser MIG hybrid welding[J]. Chinese Journal of Lasers,2018,45(3):302003.
[25] 赵旭. SMA490BW激光-MAG电弧复合焊接头疲劳断口定量评价[D]. 成都:西南交通大学,2016. ZHAO Xu. Quantitative evaluation of fatigue fracture laser-mag hybridwelding of SMA490BW[D]. Chengdu:Southwest Jiaotong University,2016.
[26] 何柏林,邓海鹏,魏康. 超声冲击对SMA490BW钢焊接接头超高周疲劳性能的影响[J]. 中国表面工程,2017,30(4):64-70. HE Bolin,DENG Haipeng,WEIKang. Influence of UIT on VHCF Performance of SMA490BW Steel Welded Joints[J]. China Surface Engineering,2017,30(4):64-70.
[27] 张丹丹,曲文卿,杨模聪,等. Al-Li合金搅拌摩擦焊搭接接头的疲劳性能[J]. 北京航空航天大学学报,2013,39(5):674-678. ZHANG Dandan,QU Wenqing,YANG Mocong,et al. Fatigue property of Al-Li alloy friction stir welded lap joints[J]. Journal of Beijing University of Aeronautics and Astronautics,2013,39(5):647-678.
[28] HOBBACHER A F. Recommendations for fatigue designof welded joints and components:XⅢ-1539-96/XV-845-86[S]. Paris:InternationalInstitute of Welding,2002.