FATIGUE OF METALLIC MATERIALS AND STRUCTURES VS. COMPOSITES IN GENERAL STRENGTH THEORY

by

© Ph. D. & Dr. Sc. Lev Gelimson

RUAG Aerospace Services GmbH, Germany

Mechanical Monograph

The “Collegium” All World Academy of Sciences Publishers,

Munich (Germany), 2006

Abstract: Critical (limiting, ultimate) state criteria in solid mechanics and, consequently, so-called strength theories, by their physical sense, should be universal laws of nature. But well-known strength criteria are separate for diverse materials types, have nothing in common with simple and universal fundamental laws of nature, and possess evident defects. For known criteria applicable to some very special cases only, generalization and correction methods to consider any (ductile or brittle, isotropic or anisotropic) materials under stationary or variable loading are founded. For this, scalar or vectorial reduced relative stresses are introduced that are equal to the reciprocals to sign-preserving individual safety factors. Each of these relative stresses is defined as a usual stress divided by the modulus of its limit (ultimate value) of the same sign by vanishing all the remaining stresses under the same other loading conditions. For the first time, general strength theory is developed and entire hierarchies of universal strength laws of nature are discovered.

1. CRITICAL STATE CRITERIA

FOR AN ISOTROPIC DUCTILE MATERIAL

WITH EQUAL STRENGTH IN TENSION AND COMPRESSION

A critical state criterion for an isotropic ductile material is

σe = F(σ1 , σ2 , σ3) = σL (1)

where σe is the equidangerous uniaxial tensile stress that is equivalent to the triaxial stress state σ1 , σ2 , σ3 under consideration by the degree of the danger of the closest critical state (by yield, failure, etc.); F is a certain function of the principal stresses σ1 , σ2 , σ31 ≥ σ2 ≥ σ3 by vanishing the shear stresses τ12 , τ23 , τ31) and possibly of some material constants; σL is the uniaxial limiting stress in a corresponding critical state such as yield or failure of a solid's material, e.g., the yield stress, σy , or the ultimate strength, σu . The safety factor

nL = σLe = σL/F(σ1 , σ2 , σ3) (2)

in every triaxial stress state σ1 , σ2 , σ3 is equal to 1 if and only if the state is critical. Function F in formulas (1) and (2) is specified by diverse criteria. For the theory of maximum shearing stresses [1-3], of potential energy of distortion [1-3-8], and the Hosford’s criterion [5],

σe = σ1 - σ3 = σL , (3)

σe = σi ={[(σ1 - σ2)2 + (σ2 - σ3)2 + (σ3 - σ1)2]/2}1/2 = σLi the intensity of stresses), (4)

σe = σi ={[(σ1 - σ2)γ + (σ2 - σ3)γ + (σ3 - σ1)γ]/2}1/γ = σL (γ constant). (5)

2. UNIVERSALIZATION OF CRITICAL STATE CRITERIA

BY TRANSFORMING THE PRINCIPAL STRESSES

For criterion (3), its formula includes the specific value of the only constant σL for a given isotropic ductile material. Suppose criterion (3) be a specific manifestation of some unknown universal law of nature as applied to a given material. It is not the formula (3) itself that allows no generalization and so needs a transformation. Divide each principal stress by the modulus σl of its ultimate value ±σL in uniaxlal state:

σ10 = σ1L , σ20 = σ2L , σ30 = σ3L , σe0 = σeL = nL-1. (6)

Transformed criteria (3), (4), (5), and, generally, (1), respectively, become

σeL = σ1L - σ3L = σLL = 1; σe0 = σ10 - σ30 = 1, (7)

σe0 = σi0 = {[(σ10 - σ20)2 + (σ20 - σ30)2 + (σ30 - σ10)2]/2}1/2 = 1, (8)

σe0 = {[(σ10 - σ20)γ + (σ20 - σ30)γ + (σ30 - σ10)γ]/2}1/γ = 1, (9)

σe0 = F(σ10, σ20, σ30) = 1. (10)

It is important for their verifying that criteria (7) - (9) coincide with each other when σ20 is equal to σ10 or σ30. Transformation (6) is independent of any criterion. Transformed criteria (7) - (10) have no evident material constant and so allow to impart a generalized sense (in comparison with formulas (6)) to the reduced (relative) principal stresses σ10, σ20, σ30 according to the specific character of the strength of any given material.

3. CRITICAL STATE CRITERIA

FOR AN ISOTROPIC BRITTLE MATERIAL

WITH UNEQUAL STRENGTH IN TENSION AND COMPRESSION

Again, divide each principal stress by the modulus of its ultimate value in the corresponding uniaxial state, namely σt in tension and σc > 0 in compression:

σj0 = σjtj ≥ 0), σj0 = σjcj ≤ 0); j ∈ {1, 2, 3, e}. (11)

Transformation (11) independent of any critical state criterion is an immediate expression of the proposed method generalizing critical state criteria for any isotropic material with unequal strength in tension and compression. Test (11) by the known experimental data on biaxial critical stress states in diverse ductile and brittle isotropic materials (commercial quality steel, hard steel, copper, nickel, gray iron, gypsum, porous iron, and concrete) collected in [2]. Dividing the principal stresses by σt [2] unifies all data (the points) without their separation for diverse materials only in the first quadrant σ1 ≥ 0, σ2 ≥ 0 (Fig. 1) but not in the fourth one σ1 ≥ 0, σ2 ≤ 0 (Fig. 2 with straight line (3) and curve (4)) that are both borrowed from [2]. However, reduction (11) unifies all the data (and they can be approximated by criteria (7, the broken line) and (8, the curve)) in both the first and the fourth quadrants (see Fig. 1).

Fig1.gif
Fig2.gif

Figs. 1, 2

Therefore, transformation (11) is adequate and allows to use universal criteria (7) - (10) for any isotropic brittle material. (Further we shall call a solid material natural one.) Their expressions are usual and invariant in the space of the reduced (relative) principal stresses, σ10, σ20, σ30, but depend on the combination of the signs of the usual principal stresses, σ10, σ20, σ30, in their space. The corresponding expressions of criterion (7)

σe = σ1 - σ3 = σc (0 ≥ σ1 ≥ σ2 ≥ σ3);

σe = σ1 - χσ3 = σt1 ≥ 0 ≥ σ3 , χ = σtc);

σe = σ1 - σ3 = σt1 ≥ σ2 ≥ σ3 ≥ 0)

have obvious physical sense: If the signs of all the nonzero principal stresses are identical, a natural material having unequal strength in tension and compression is similar to the two model materials. Each of them has equal moduli (either σt or σc , both instead of σL in criterion (3)) of the limiting stresses in tension and compression and is used when all the principal stresses are either nonnegative or nonpositive, respectively. If there are principal stresses with distinct signs, the critical states of a natural material are described by criterion (7) that coincides with Coulomb’s criterion [2,6] as the linear approximation of Mohr’s theory [2,6]

σe = σ1 - χσ3 = σt (12)

in this case only. This can be regarded as the suggestion to determine the applicability range of that theory, which is not quite obvious [6]. In fact, the well-known method [6] to obtain formula (12) is latently based on the distinction between the signs of the principal stresses. Otherwise, the proportional increase of the corresponding Mohr circle based on segment [σ3 , σ1] results in its contacts with the approximating straight line (12) not between its contacts with the Mohr circles based on segments [-σc , 0] and [0, σt]. Furthermore, if σ1 < 0, then the equivalent stress, σe , by (12) can be negative and should be compared not with σt > 0 but with -σc < 0 like it is in the theory of maximum normal stresses [2,3,6]

c ≤ σj ≤ σt (j = 1, 2, 3). (13)

Besides that, by criterion (12), each stress state with σ1 = χσ3 seems to be quite safe, and uniform triaxial compression does not. Such contradictions do not concern criterion (7). The last is natural if the signs of the nonzero principal stresses are identical and coincides with (12) if not all these signs coincide, in particular in biaxial stress state, and is corroborated by verifying (12). If σt = σc , then criterion (13) is transformed by (11) into criterion

σe0 = max{|σ10|, |σ20|, |σ30|} = 1 (14)

that is equivalent to (13) for any σt and σc . For the criterion by Pisarenko and Lebedev [2]

σe0 = (1 - χ)σ1 + χσi = σt , (15)

σe0 = (1 - χ)max{|σ10|, |σ20|, |σ30|} + χσi0 = 1. (16)

In the space of σ10, σ20, σ30, the physical sense, expression, and graphical interpretation of each general criterion (10) are usual and invariant. In the space of σ1 , σ2 , σ3 , the expression and graphical interpretation of (10) are not invariant and can be obtained from their invariant images by inverting the transformation (11). In the both cases (in particular in Figs. 1 and 2), the continuity of the corresponding geometrical images is achieved by introducing the unregulated principal stresses, σ1u , σ2u , σ3u , instead of σ1 ≥ σ2 ≥ σ3 (similarly to [12]) and the unregulated reduced (relative) principal stresses, σ1u0, σ2u0, σ3u0, instead of σ10 ≥ σ20 ≥ σ30. In particular, criterion (7) is represented in the space of σ1u , σ2u , σ3u by two similar semi-infinite hexahedral Tresca’s prisms placed out of the layer -σc ≤ σ1u + σ2u + σ3u ≤ σt and connected by Mohr’s truncated pyramid within this layer; criterion (8) is represented by circumscribing two semi-infinite von Mises’ cylinders and the connecting truncated cone (Fig. 3). In biaxial state σ1u , σ2u3u = 0), criteria (3, interrupted broken line), (4, interrupted curve), (7, broken line), and (8, curve) are interpreted in the plane (Fig. 4); (7) and (12) coincide. There are local failures of convexity in the limiting surfaces in the space of σ1u , σ2u , σ3u but those failures of Drucker’s postulate [7] in plasticity theory are directly proportional to the degree of the brittleness of the material and are well-known even in biaxial state for gypsum, graphite, and crystalline glass [8]. Perhaps a certain convexity postulate in the reduced (relative) principal stresses holds. Criteria (7) and (8) give values 1/(1 + χ) and (1 + χ + χ2)-1/2, respectively, for the ratio of pure shear ultimate strength τu to σt standing many tests.

Fig3.gif

Fig. 3

Fig4.gif

Fig. 4

4. CRITICAL STATE CRITERIA FOR AN ORTHOTROPIC MATERIAL WHEN ITS BASIC DIRECTIONS COINCIDE

WITH THE PRINCIPAL DIRECTIONS OF A STRESS STATE

Generalize (11) for such a material with limiting stresses σt1 , σt2 , σt3 in uniaxial tensions, σc1 , σc2 , σc3 in uniaxial compressions in the basic and simultaneously principal directions 1, 2, 3:

σj0 = σjtjj ≥ 0), σj0 = σjcjj ≤ 0); j ∈ {1, 2, 3, e}. (17)

Universal criteria (7) - (10), (14), and (16) in the reduced principal stresses are invariant. But (17) does not keep the regulation of the principal stresses, and their renumbering that gives

σ10 ≥ σ20 ≥ σ30 (18)

is necessary for criterion (7) but not essential for (8). A particular case of (17) was perhaps implied by the Hu and Marin generalization [9] of criterion (4) as applied to yielding an orthotropic material having equal yield stress σyj in tensions and compressions [12]:

σ12/(σy1)2 + σ22/(σy2)2 + σ32/(σy3)2 - σ1σ2/(σy1σy2) - σ2σ3/(σy2σy3) - σ3σ1/(σy3σy1) = 1.

If such a material has unequal strength in tension and compression in some direction, then generalization (8) of criterion (4) in σ1 , σ2 , σ3, depends on their signs combination. For instance, if σ1 ≥ 0, σ2 ≤ 0, and σ3 ≤ 0, then

e0)2 = σ12/(σt1)2 + σ22/(σc2)2 + σ32/(σc3)2 - σ1σ2/(σt1σc2) - σ2σ3/(σc2σc3) - σ3σ1/(σc3σt1) = 1.

In biaxial stress state σ1 ≥ σ2 = 0 ≥ σ3 , this criterion (σe0)2 = σ12/(σt1)2 - σ1σ3/(σt1σc3) + σ32/(σc3)2 = 1 approximates the experimental data on tubes of textolite and bakelite with cotton [3].

5. CRITICAL STATE CRITERIA FOR ANY ANISOTROPIC MATERIAL AND ARBITRARY STATIC LOADING

In this case, the reduction (17) can be generalized by transformation

σj0 = σj/|σLj|. (19)

where σLj is the limiting value of a sole (uniaxial) principal stress σj . That value has the direction and sign of stress σj and acts at the same solid’s point under the same other loading conditions. This is a new generalized re-comprehension of reduction (17) if σtj and σcj mean the limiting stresses in tension and compression both in the direction of the principal stress σj but not indispensably in the basic directions of the anisotropic material, which are not obliged to exist. If a material is orthotropic, these limiting stresses in every direction might be determined in the way [6]. In contrast to the well-known criteria [1-3], universal critical state criteria in the reduced (relative) principal stresses always conserve their simple forms like all fundamental laws of nature.

Transformation (19) and its particular cases are natural but not the only. If a material has unequal strengths in tensions and compressions in the principal directions of the stress state at a solid’s point under consideration, there is also another possibility. It is not less natural even if loading is static, but cannot be discovered within the bounds of statics. In the case of cyclic loading, the limiting amplitude of stresses, σaj (Fig. 5), reaches its peak, σajmax , in the diagram when the cycle is asymmetric and possibly the cycle mean stress, σm0j , is nonzero.

Fig5.gif

Fig. 5

So the stress state when the principal stresses, σj = σm0j , j = 1, 2, 3, as opposed to the zero stress state (with σj = 0), can be considered as initial one instead of the zero state. So a material having unequal strengths in tension and compression in some direction can be considered as one having not only equal strength in each tension and compression but also the corresponding initial stresses. Then instead of (19),

σj0 = (σj - σm0j)/|σLj - σm0j| (20)

generalizes (18) that is a particular case of (20) by σm0j = 0. By σm0j = (σtj - σcj)/2, (20) gives

σj0 =(2σj + σcj - σtj)/(σtj + σcj) (21)

that coincides with Lode-Nadai’s parameter [10]

μσ = (2σ2 - σ1 - σ3)/(σ1 - σ3) (22)

when σ1 = σtj , σ2 = σj , σ3 = -σcj , -σcj ≤ σj ≤ σtj (these inequalities not necessarily hold in triaxial stress). If a material is isotropic, indexation of σtj and σcj by j becomes unnecessary.

6. CRITICAL PROCESS CRITERIA FOR ANY

ANISOTROPIC MATERIAL AND ARBITRARY VARIABLE LOADING

As always, the unique postulate is: If a stress process at any solid’s point is critical then, for every critical state criterion, the corresponding functional dependence between the reduced (relative) principal stresses is universal.

We can use any initial critical state criterion (1) for a model isotropic material with equal strength in tension and compression under stationary loading. Then the corresponding general critical process criterion at any point of a solid of any natural material possibly anisotropic under arbitrary variable loading can be created due to the following algorithm:

1) for each unregulated principal stress, σj(t), by a stationary numeration on the whole time interval T = [t0 , t1] (t0 ≤ t ≤ t1) of loading, the reserve (safety) factor nj for the uniaxial stress process σj(t) is obtained from the condition that the uniaxial stress process njσj(t) is limiting. This process is similar to the realized one, σj(t), and their variable directions at a point under consideration in a solid of a natural material possibly anisotropic are synchronized, i.e., coincide at every moment t ∈ T = [t0 , t1] just as the values of these processes are proportional to each other. At every moment t , it is possible to take into account the damage accumulation in limiting uniaxial stress process njσj(t’) on the previous time subinterval [t0 , t];

2) each principal stress σj(t) is synchronously reduced to

σj0(t) = [σj(t) - σm0j(t)]/|σLj(t) - σm0j(t)| (23)

where σm0j(t) is the mean cycle stress that secures the maximum limiting amplitude of stresses, σajmax(t), at the same moment t ∈ T = [t0 , t1] in a cycle of the value of the sole (uniaxial) principal stress σj(t) only in the stationary direction coinciding with the variable direction of the stress σj(t) at the selected moment t only, if the triaxial stress state σm01(t), σm02(t), σm03(t) is considered initial;

σm0j(t) = 0 for every moment t ∈ T = [t0 , t1] and for each j = 1, 2, 3 if the zero stress state is regarded as the initial one;

σLj(t) is the limiting value of the uniaxial stress in the stationary direction coinciding with the variable direction of the principal stress σj(t) just at the selected moment t ∈ T = [t0 , t1], the sign of the value coinciding with the sign of the difference σj(t) - σm0j(t) just at the selected moment t , under the same other loading conditions such as speed, temperature, radiation level, etc. At every moment t ∈ T = [t0 , t1], it is possible to take into account the damage accumulation in uniaxial stress process σLj(t’) on the previous time subinterval [t0 , t];

3) the stationary reduced (relative) mean stress

σmj0 = [supt∈Tσj0(t) + inft∈Tσj0(t)]/2

using its least upper bound and greatest lower one in uniaxial stress process σj0(t) in a model material is determined;

4) in a model material, a stationary reduced amplitude stress σaj0 in the uniaxial stress cycle, whose mean stress is just σmj0 and which is as safe as the uniaxial stress process σj(t) in a natural material on the time interval T = [t0 , t1], is determined as sup σaj00. These values σaj00 are such that every uniaxial stress process σj’(t), which has a direction coinciding with the direction of the real process σj(t) at every moment t ∈ T = [t0 , t1] in the natural material and is reduced by transformation (23) to some cycle having the mean stress σmj0 and the amplitude stress σaj0 in the model material, has a safety factor not less than nj . If the set of such amplitude stresses σaj00 is empty (there is no σaj00 ≥ 0), then the mean cycle stress σmj0 in the model material is so changed that the modulus (absolute value) of the change is as small as possible, and we take σaj0 = 0.

Let us assume that the both limiting stresses σLj(t) (σtj(t) in tension and σcj(t) in compression) at the natural solid's point under consideration are stationary. This holds, e.g., in the case of damage nonaccumulation and stationary temperature, radiation level, etc. if the directions of the principal stresses in the natural material are stationary or if it is isotropic. In that stationary case for the natural material, the diagram (Figs. 6 and 7) of the limiting stresses (the maximum σjmax and the minimum σjmin) in the uniaxlal stress cycle, whose direction coincides with the direction of the principal stress σj(t) at every moment t ∈ T = [t0 , t1] and which is as safe as the stress σj(t), can be directly determined. Then both the abscissa and the ordinate of each point in the diagram are separately reduced by the transformation (23) and give the interrupted curve consisting of the upper branch for σjmax(t) and the lower branch for σjmin(t) (Fig. 6 by σm0j = 0 and Fig. 7 by σm0j ≠ 0). Further each couple of the diagram's points having equal abscissas are replaced in the vertical direction to straighten the diagram's middle line so that their common abscissa and the difference or their ordinates are invariant and the middle of the segment connecting those replaced points lies on the principal diagonal σj = σm0j of the first and the third quadrants. The obtained diagram of the limiting stresses σjmax0 and σjmin0 (continuous lines in Figs. 6 and 7) allows to determine Haigh's diagram [11] of the limiting amplitude stresses σaj0 (see Figs. 6 and 7) by halving that difference for each abscissa and to directly obtain the amplitude σaj0 of the uniaxial stress cycle;

Fig6.gif

Fig. 6

Fig7.gif

Fig. 7

5) the stationary vector

σj0 = (σmj0, σaj0) (24)

for the model material in the limiting amplitude diagram (see Figs. 6 and 7) in the cycle, which is as safe as the variable uniaxial stress process σj(t) in the natural material, is determined;

6) the range of triaxial stress processes stationarily safe

σes0(t) = maxju(t)F[σ1u0(t), σ2u0(t), σ3u0(t)] = maxju(t)F[j = 13σju0(t)] ≤ 1

is determined using the synchronous values of the uniaxial principal stress processes σ1(t), σ2(t), σ3(t). Such a permutation (depending on t) 1u , 2u , 3u of indices 1, 2, 3 at every moment t that function F takes its maximum value should be chosen to satisfy inequalities (18). The stress state process at any moment t is considered stationary. Introduce designating a set of indexed elements, in particular, of arguments of a function. On T = [t0 , t1] (Fig. 8), the range is σes0 = supt∈Tσes0(t) ≤ 1;

Fig8.gif

Fig. 8

7) the range of triaxial stress processes variably safe at the natural solid’s point under consideration (Fig. 9)

Fig9.gif

Fig. 9

σev0 = maxju|F[j = 13σju0]| ≤ 1

is determined according to the rules of vector algebra by selecting such a stationary permutation 1u , 2u , 3u of the indexes 1, 2, 3 that the modulus is maximum. In the modulus of possibly vectorial function F , the three independent (irrespective of their synchronization) uniaxial stress processes are replaced with the stress cycles as safe as the corresponding processes. These cycles hold in the model material and are described by the three stationary vectorial reduced stresses σ10, σ20, σ30. Interpreting σju0, j = 1, 2, 3, by complex numbers might be acceptable geometrically but not algebraically because a sum of squared complex numbers can vanish not only by vanishing each of those numbers. This might lead to the illusion that limiting stress processes can be absolutely safe;

8) the range of safe triaxial stress processes at the natural solid's point under consideration is determined by combining the last two results. First the three (relative) uniaxial principal stress processes synchronously reduced in the model material at every moment t ∈ T = [t0 , t1] are taken into account in assumption that each triaxial stress process is considered stationary. Uniting this with the combination of the three independent (irrespective of their synchronization) uniaxial stress processes (the both conditions in the aggregate generalize the well-known verification of static strength in cyclic loading [12]), we obtain

σe0 = max{σes0, σev0} ≤ 1.

So any critical process criterion for any anisotropic material under arbitrary variable loading is

σe0 = max{σes0, σev0}= 1,

σe0 = max{supt∈Tmaxju(t)F[j = 13σju0(t)], maxju|F[j = 13σju0]|} = 1. (25)

Formula (25) for criteria (3) and (4) give known results 1/(1 + χ) and (1 + χ + χ2)-1/2 [2,3], respectively, for the ratio τ-1-1 of the limiting amplitudes of stresses in symmetric cycles under torsion and bending and the well-known formula by Gough and Pollard nστ-2 = nσ-2 + nτ-2 for a cyclic safety factor nστ by bending (with a partial safety factor nσ) and torsion (with a partial safety factor nτ) combined.

BASIC RESULTS AND CONCLUSIONS

1. The known strength criteria have nothing in common with universal laws of nature. They have evident contradictions, restricted and vague ranges of adequacy and applicability.

2. The proposed general strength theory including generalization and correction methods for critical state criteria and safety factors gives entire hierarchies of universal strength laws of nature. They are applicable to the general case of any anisotropic solid with different strengths in tensions and compressions in any directions under arbitrary nonstationary loading.

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