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2 Archives of Materials Science and Engineering

2 2017

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Mode I and mode II fatigue crack growth resistance characteristics of high tempered 65G steel

Lenkovskiy T. M., Kulyk V. V., Duriagina Z. A., Kovalchuk R. A., Topilnytskyy V. H., Vira V. V., Tepla T. L.

Archives of Materials Science and Engineering

2017

Vol. 84, nr 1

34--41

Purpose: To investigate the fatigue crack growth at normal tension and transverse shear of 65G steel with the high tempered martensite microstructure and to build an appropriate fatigue crack growth rate curves. To determine the main and auxiliary fatigue crack growth resistance characteristics, which are necessary for machine parts life-time estimation at rolling contact fatigue conditions. Design/methodology/approach: For determination of fatigue crack growth resistance at normal tension a standard compact specimens with edge crack were tested using a hydraulic testing machine and fatigue testing at transverse shear were performed on the I-beam specimens with the edge longitudinal crack using the original testing setup. For crack growth measurement an optical cathetometer B-630 was used. The crack growth rate V was calculated as crack length increment during loading cycles. The stress intensity factor range K was determined by dependence "K = (1 – R)Kmax accordingly to the standard test methods. To establish crack faces friction factor at transverse shear fragments of fractured beam specimen containing crack faces were cut out and tested as a friction pair according to Amontons Coulomb's law. On the base of test results the fatigue crack growth rate curves in logarithmic coordinates "K vs. V were built. These graphical dependencies for normal tension and transverse shear were used for determination of fatigue crack growth resistance characteristics: fatigue threshold "Kth, fracture toughness "Kfc, "K1-2 and "K2-3 which indicates the beginning and the end of middle-amplitude region of curve, "K*, parameters C and n of Paris’s equation. Metallographic and fractographic analyses were performed on the scanning electronic microscope Zeiss EVO 40XVP. Findings: Empirical dependences of the stress intensity factor range on fatigue crack growth rate at normal tension and transverse shear of 65G steel with the high tempered martensite microstructure are obtained. Based on these graphical dependencies the fatigue thresholds and fracture toughness as well as the parameters of Paris’s equation are determined. Research limitations/implications: The fatigue crack growth on 65G steel under low-, medium- and high-amplitude cyclic loading at normal tension and transverse shear was investigated. The fatigue crack growth rate values for a wide range of stress intensity factor are estimated. On the base of fractographical analysis the features of fracture of high tempered martensite in 65G steel at transverse shear are studied. It is shown that the transverse shear crack faces friction factor for high tempered martensite structure is less than for low tempered martensite. Practical implications: Using the fatigue crack growth resistance characteristics of 65G steel at normal tension and transverse shear and related fatigue crack growth rate curves it is possible to predict the life-time of machine parts made of steels with high tempered martensite structure, working at rolling contact fatigue conditions. Originality/value: Complete fatigue crack growth rate curves of 65G steel with tempered martensite structure at normal tension and transverse shear are built and the fatigue crack growth resistance characteristics for both modes of fracture are determined for the first time.

An effective crack tip region finite element sub-model for fracture mechanics analysis

Lenkovskiy T. M., Kulyk V. V., Duriagina Z. A., Kovalchuk R. A., Topilnytskyy V. G, Vira V. V., Tepla T. L., Bilash O. V., Lishchynska K. I.

Archives of Materials Science and Engineering

2017

Vol. 87, nr 2

56--65

Purpose: To create an effective in engineering strength calculation three-dimensional submodel of the near crack tip region in solids for hi-fidelity analysis of their stress-strain state by the finite element method. Design/methodology/approach: To create a volume near the crack tip, regular threedimensional 20-node prismatic isoparametric elements and 15-node special elements with edge length of 12.5 μm with shifted nodes in order to simulate the singularity of stress at the crack tip were used. Using these two types of elements, a cylindrical fragment of diameter of 100 μm was built. In its base is a 16-vertex polygon, and its axis is the crack front line. In the radial direction the size of the elements was smoothly enlarged by creating of 5 circular layers of elements, and in the axial direction 8 layers were created. For convenience of the sub-model usage, the cylindrical fragment was completed by regular elements to a cubic form with edge size 400 μm. For the sub-model approbation, the full-scale three-dimensional models of standard specimens with cracks were built. The stress intensity factor K at normal tension was calculated assuming small scale yielding conditions in a plane between 4th and 5th layers of special elements on the basis of analysis of displacement fields near the crack tip. Findings: An effective three-dimensional sub-model of the near crack tip region is proposed. The sub-model was used to obtain the dependence of the stress intensity factor on the relative crack length at normal tension for four types of standard specimens. The obtained dependences show excellent correlation with known analytical solutions. Research limitations/implications: The concept of finite element meshing at threedimensional modelling of the near crack tip region for high-fidelity stress-strain state analysis was generalized. A sub-model of the near crack tip region was created and used to determine the stress intensity factor at normal tension of four types of standard specimens. It is shown that the proposed methodology is effective for precise analysis of the stressstrain state of solids with cracks within the framework of linear fracture mechanics. Practical implications: By applying the generalized approach and the proposed threedimensional sub-model of the near crack tip region, one can determine the stress-strain state of structure elements and machine parts when analysing their workability by the finite element method. Originality/value: An effective finite-element sub-model for the stress-strain state analysis in the vicinity of the crack tip within the framework of the linear fracture mechanics is proposed.