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Book of Abstracts Book of Abstracts 37th Dayton-Cincinnati Aerospace Sciences Symposium 6 March 2012 SESSION 1 FATIGUE AND FRACTURE CHAIR: MICHAEL FALUGI AFRL/RB Effect of Re-Peening and Relaxation in Fatigue Life Estimation of Complex Geometries in Laser Shock Processing Vasu, Anoop, Wright State University, Dayton, OH Grandhi, Ramana V, Wright State University, Dayton, OH We are living in a society where safety is a primary concern. Prevention of failure in materials has been extensively researched for centuries by people all over the world. External loading is a major cause of failure in most situations. There can be other contributing factors such as manufacturing defects and presence of unfavorable residual stresses. But residual stresses can also play a positive role and can enhance life of the component, if applied properly. Laser Peening (LP) is a surface enhancement technique which can impede crack initiation and propagation by inducing favorable compressive residual stresses in the peened components. Laser Peening can generate deeper compressive stresses compared to other surface enhancement methods such as shot peening and has been widely used to improve the fatigue life of components in aerospace, automotive and medical applications. In this work, three dimensional finite element simulation models are created using ABAQUS© to predict the effects of Laser Peening on peened material. Crack initiation often occurs along the curved regions or fillets of structural components because of high stress concentrations. These critical regions are modeled as a curved geometry to capture the curvature effects using simulation models. Concave and Convex simulation models are created and compared with flat geometry to investigate the effects of curvature in a laser peening problem. Residual stresses generated by Laser Peening or any other Surface Enhancement Technique on an aerospace structure or other mechanical components will be subjected to complicated external loading conditions in their service life. We can consider it as an application of cyclic loading in a residual stress field. The residual stress field generated by any surface treatments can relax as a result of these cyclic loading in the peened components. This effect is commonly known as Cyclic Stress Relaxation can reduce the beneficial effects of peening methods. Neglecting this relaxation effect can lead to incorrect fatigue life prediction and can be hazardous for the peened applications. This work plans to explain the effect of relaxation by utilizing simulation and analytical models depending on different loading conditions. Extending these ideas of relaxation effect on simple geometries to complex curvatures is proposed. i.e. The effect of curved geometries in cyclic loading will be investigated to identify the importance of curvature. If found critical, an analytical model with radius of curvature as an additional parameter will be suggested based on finite element simulations. Understanding the phenomenon of stress relaxation helps us to analyze the effect of application of Laser Peening during their life cycle. This process known as Re-peening will be investigated to determine how Laser Peening can make an impact in increasing the fatigue life of components which has undergone a certain service life. Maximizing the fatigue life has been a task of utmost importance for experimentalists and researchers alike. Performing an effective optimization strategy using numerical models can help to reduce the cost incurred due to large number of experimental tests for fatigue life prediction. This research plans to build a framework and perform optimization of the Laser Peening input parameters for increasing the fatigue life of peened components in an efficient manner. A DOE based w-stack RSM method is currently considered for optimization. The Evaluation of Material Failure Due To High-Speed Sliding Buentello, Rodolfo G., USAF, Wright Patterson AFB, OH Palazotto, Anthony N., AFIT/ENY, Wright Patterson AFB, OH This research focuses on the mechanical material failure due to high-speed sliding between two surfaces. The by- product of this relative movement is the phenomenom of wear. The high costs associated with the field experimentation of systems subject to high-speed sliding, has prevented the collection of the necessary data required to fully characterize this phenomena. Simulating this through Finite Elements (FE) would enable its prediction under different scenarios and will reduce experimentation. In the aerospace, automotive and weapon industries such a model can aid in material selection, design and/or testing of systems subjected to wear in bearings, gears, brakes, slippers or even rocket test tracks. The objective of this research is to present an ABAQUs FE model to simulate this failure mechanism in a 3D configuration. The model assumes material damage can be represented by the relative movement of two bodies whereby one body collides with an asperity representing surface roughness. This model employs the Johnson-Cook's visco-plastic and dynamic failure algorithms and also incorporates a shear failure criteria. A preliminary run with many default parameters showed promising results. The results were compared against those measured from a slipper that traveled along the Holloman High Speed Test Track on January 2008. The slipper traveled 5,816 meters in 8.14 seconds and reached a velocity of 1,530 m/s. Simulating Fatigue Cracks in Healthy Beam Models for Faster Analysis and Identification Cooley, Phillip E., Wright State University, Beavercreek, OH Slater, Joseph C., Wright State University, Dayton, OH Crack identification in critical aircraft components is often expensive and time consuming. It is the goal of this research is to use nonlinear vibration features to develop faster and more reliable methods for identifying cracks in simple structures that can then be applied to more complex geometries such as bladed disk assemblies. To facilitate faster computation, the closed form response of a cracked spring hinge-free beam to base excitation is obtained by treating the crack as a point bending moment input rather than a structural entity. Nonlinearities in the beam response introduced by crack self-excitation are magnified and used to generate spectral crack signature profiles for identification of crack location and severity. Closed form results are validated against simulation data, and future experiments will be used for calibration and further validation. Successful crack characterization with this method is expected to contribute to the development of an automated Structural Health Monitoring (SHM) system for the detection of fatigue cracks in aircraft engines and other turbomachinery. High Cycle Fatigue Simulation using Extended Space-Time Finite Element Method Coupled with Continuum Damage Mechanics Bhamare, Sagar, College of Engineering and Applied Science, University of Cincinnati, Cincinnati, OH Qian, Dong, College of Engineering and Applied Science, University of Cincinnati, Cincinnati, OH Eason, Thomas, Air Force Research Laboratory, Air Vehicles Directorate, Wright-Patterson Air Force Base, OH Liu, Guirong, College of Engineering and Applied Science, University of Cincinnati, Cincinnati, OH Safe-life and damage-tolerance approaches used for fatigue life predictions have some limitations due to their empirical nature. Limitations of the traditional methods can be handled by performing a full-scale simulation of the fatigue loading history using numerical methods such as the finite element method (FEM). Time-scale associated with the fatigue problem especially in high cycle fatigue (HCF) applications proposes the main challenge for such a simulation. Semi-discrete methods, currently used for simulating the structural response under dynamic conditions have time-step limitations making HCF simulation an elusive task. An extended space-time method (XTFEM) based on the time discontinuous Galerkin formulation [1-3] is proposed to handle the time-scale issues in fatigue problems. This method is stable for any large time-step and accurately handles high frequency loadings. Advantages of our XTFEM in handling practical fatigue loading histories over semi-discrete methods are presented. XTFEM is coupled with the two-scale continuum damage mechanics model [4] for evaluating fatigue damage accumulation, with a damage model governing the fatigue crack-initiation and propagation as the simulation progresses. HCF simulations are performed using the proposed methodology on a notched specimen of AISI 304L steel. Results obtained for the total fatigue life of specimen (fatigue crack initiation and propagation) under different loading conditions are presented. Proposed simulation can serve as the robust tool for predicting the service and the residual life of structural components. References: 1. Chessa, J. and T. Belytschko, Arbitrary discontinuities in space-time finite elements by level sets and X- FEM. International Journal for Numerical Methods in Engineering, 2004. 61(61): p. 2595-2614. 2. Hulbert, G.M. and T.J.R. Hughes, Space-Time Finite-Element Methods For 2nd-Order Hyperbolic- Equations. Computer methods in applied mechanics and engineering, 1990. 84(3): p. 327-348. 3. Chirputkar, S.U. and D. Qian, Coupled atomistic/continuum simulation based on extended space-time finite element method. Cmes-Computer Modeling In Engineering & Sciences, 2008. 24(2-3): p. 185-202. 4. Desmorat, R., et al., Two scale damage model and related numerical issues for thermo-mechanical
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