Plastic Fatigue

Fatigue 2014. Melbourne, 06.03.
2014
MUL-AMB, 2013
Montanuniversitaet Leoben
Allgemeiner Maschinenbau
FATIGUE DESIGN METHODOLOGY OF
REINFORCED
ENGINEERING THERMOPLASTICS
Ch. Guster
1
, G. Pinter
2,3
, M. Msenbacher
1
, J. Brunbauer
2
1
Institute of Mechanical Engineering, Montanuniversitaet Leoben, Austria,
2
Institute of Materials Science and Testing of Polymers, Montanuniversitaet Leoben, Austria
3
Polymer Competence Center Leoben GmbH, Austria
1
Fatigue 2014. Melbourne, 06.03.2014
MUL-AMB, 2013
2
Polymers - motivation and destination
Trend:
Increasing substitution of metallic materials by short fibre-reinforced plastics for
automotive applications because of
Importance of lightweight constructions: advantage of high specific strength
Reducing of production time and costs because of favourable manufacturing
processes: injection moulding
Required:
For dimensioning of cyclically loaded parts, the knowledge of dynamical material
data (S/N-curve) is essential generation of a comprehensive database!
Appropriate design-methods / simulation tools because of:
Reduction of test times and development cycles
Improved utilization of lightweight construction potentials
Further expansion of the application area of this material group
Goal:
Continuous simulation chain
MUL-AMB, 2013
3
Fatigue life calculation with S/N-curves
MUL-AMB, 2013
4
Influences on fatigue behaviour (local S/N curve)
local S/N curve
log
a
material S/N curve
log N
loading
- type of loading
- mean stress
- LCF, plastic deformation
- loading order
- tribology
- thermo mechanical fatigue
- creep, stress relaxation
- High Cycle Fatigue (HCF )
- loading frequency
fabrication
- surface quality
- surface strenghtening
- technological effects
- residual stresses
- weld lines
ambience
- media influences
- temperature
- moisture
geometry
- design
- notches and
stress gradient
- dimension
material
- type
- ageing
- fibre concentration
- fibre orientation
- matrix
MUL-AMB, 2013
5
Load-time-history
lg
lg N
S/N curve
Material behaviour Geometry
Load-spectrum
Stress analysis
(FEM)
Local
S/N curve
lg
lg N
Influences, as
- stress gradient
- type of loading
- mean stress
- surface
- component size
- corrosion
- temperature
- etc.
12
,
13
,
23
G
12
, G
13
, G
23
E
1
, E
2
, E
3
Local anisotropic
material behaviour
1
1
1
3
3
2
2
1
1
=
+ +
b
i
i
b
i
i
b b b
N
n
N
n
N
n
N
n
N
n
Damage accumulation:
Fatigue Life Calculation
Moulding simulation:
Fibre
orientation
Fatigue life calculation with local stresses and local S/N-curves
Fabrication
Injection Moulding
Stress
distribution
MUL-AMB, 2013
Experimental test assembly
6
Servo hydraulic test rig + rotating bending machine
Characterisation of different sgfr materials
Different types of specimens for characterisation of
fibre orientation
notches, stress concentration factor (K
t
)
weld lines
Monotonic and cyclic tests (constant amplitude
fatigue tests) were performed
S/N tests: at least three specimens tested at each
stress level
Definition of fatigue limit: N=5x10
6
cycles
Testing frequency f=10 Hz to avoid hysteretic heating
Variation testing parameters
stress ratio R (0.1, -1, 10),
temperature T (23C, 80C, 120C),
moisture and media influences
Fibre orientation longitudinal and transversal to
loading direction
MUL-AMB, 2013
Characterised Materials
7
PA 6T/6I-GF40+MX25
PPA (Grivory XE3844)
40 mass-% short glass fibres
25 mass-% mineral filler
PA 6T/6I-GF50
PPA (Grivory HTV-5H1)
PA 6T/6I-GF50
PPA (Grivory HT1V-5HY)
PA6.6-GF30
PA (Durethan AKV 30 HR H2.0)
PA6.6-GF35
PA (Technyl A218 V35 black 34NG)
PEI-GX30
PEI (Ultem 2312)
30 mass-% milled short glass fibres
Short Specimen
(milled out of injection moulded plates)
Used for:
- fibre orientation
- stress ratio R
Standardised Specimen
(injection moulded)
Used for :
- basic characterisation
cross section PA 6T/6I-GF50
Used Specimens
MUL-AMB, 2013
8
UB-specimen
(rotating bending specimen,
injection moulded)
Used for:
- Fibre orientation
(web width 2 and 4mm)
- Type of loading
- weld line
- Stress concentration (notches)
Biax-specimen
(injection moulded)
Used for:
- fibre orientation
- stress ratio R
- temperature
- moisture
- media influences (ageing)
- weld line
for internal
use only!
Used Specimens
MUL-AMB, 2013
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
standardized specimen (K
t
=1.0), T=23C
PA 6T/6I-GF50
conditioned
v=1 mm/min
EMS-specimen (K
t
=1.6)
longitudinal transversal
T=23C
T=80C
T=120C

N
o
r
m
a
l
i
z
e
d

S
t
r
e
s
s

[
-
]
Strain [%]
9
Results / curves
Effect of fibre orientation and temperature on the tensile /-curve
Tests with conditioned
specimens: T=23 C,
80 C and 120 C;
50 %RH
No distinctive yield points
Failure without any signs of
necking or plastic deformation
Youngs modulus E and
tensile strength R
m
increase
with increasing fibre
arrangement in specimens
Essential influence of fibre
orientation
Essential influence of testing
temperature
Youngs modulus E and tensile strength R
m
decrease with increasing testing temperature
Fracture elongation increases with increasing testing temperature
Reference:
Guster Ch., Pinter G., Eichlseder W., Lang R.W. (2009): "Effects of temperature and moisture on the tensile/tensile fatigue behavior of an injection molded sgf-reinforced
partial aromatic polyamide", 12th International Conference on Fracture, CD-Proceedings ICF 12, 12.-17.7.2009, Ottawa, (CDN).
MUL-AMB, 2013
10
Results S/N curves
10000 100000 1000000 1E7
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
PA 6T/6I-GF50
EMS-specimen
K
t
=1.6 R=0.1
f=10 Hz
1x
k
1
=5
k
1
=5
k
1
=6
longitudinal transversal
T=23C
T=80C
T=120C
k
1
=10
N
o
r
m
a
l
i
z
e
d

S
t
r
e
s
s

A
m
p
l
i
t
u
d
e

a

(
l
o
g
.
)

[
-
]
Number of Cycles N (log.) [-]
1x
k
1
=14
k
1
=11
2x
1x
Effect of temperature on the fatigue behaviour (S/N-curve)
Tests with conditioned
specimens: T=23 C,
80 C and 120 C;
50 %RH
Very small statistical scatter
No distinctive fatigue
strength
Slope k is smaller for the
transversal tested
specimens and nearly
constant even at higher
temperatures
Reachable stress amplitudes
are significantly influenced
by testing temperature
Reachable stress amplitudes at T=120 C of the longitudinal tested specimens are higher
than the results of the transversal tested at T=23 C
Reference:
Guster Ch., Pinter G., Eichlseder W., Lang R.W. (2009): "Effects of temperature and moisture on the tensile/tensile fatigue behavior of an injection molded sgf-reinforced
partial aromatic polyamide", 12th International Conference on Fracture, CD-Proceedings ICF 12, 12.-17.7.2009, Ottawa, (CDN).
MUL-AMB, 2013
11
Goal - continuous simulation chain
ABAQUS
Abaqus Interface
for MOLDFLOW
ABAQUS
Finite Element
Stress analysis
FEMFAT
Fatigue life
calculation
MOLDFLOW
Injection Moulding
simulation
12
,
13
,
23
G
12
, G
13
, G
23
E
1
, E
2
, E
3
FE-structure (mesh,)
stresses
12
,
13
,
23
G
12
, G
13
, G
23
E
1
, E
2
, E
3
.odb .xml
.inp
.opt
.tpt
.mpt
job-name_fiber_tensor.xml
Orientation-
tensor aij
MUL-AMB, 2013
First Verification screw wrench
Component test
Damage
distribution
Maximum
Stress distribution
Injection location
Maximum
Simulation
Location of failure correctly estimated
Lifetime estimation is conservative (factor ca. 2)
MUL-AMB, 2013
13
material: PEI - GX30
max. operating temperature: T=120C
min. operating temperature : T=-40C
ambient medium: air
loading situation: cyclic loading, vibration
critical
area
model derivation
injection moulding
simulation
FE-stress-
simulation
lifetime
calculation
component tests
VALIDATION
Pilot Study for Method Development Lens Holder (ZKW)
MUL-AMB, 2013
14
Derivation of fatigue models based on S/N-curves
1000 10000 100000 1000000 1E7 1E8
0,4
0,6
0,8
1
1,2
1,4
1,6
1,8
2
1x
1x
1x
Fibre reinforced material
rotating bending test
RB-specimen
unnotched mild sharp
RT
T1
T2
n
o
r
m
a
l
i
z
e
d

n
o
m
i
n
a
l

s
t
r
e
s
s

a
m
p
l
i
t
u
d
e

a
,
n

(
l
o
g
.
)

[
-
]
cycles to failure N
f
(log.) [-]
1x
Analyses of relevant influencing parameters (specimen scale):
model derivation
injection moulding
simulation
FE-stress-
simulation
lifetime
calculation
component tests
VALIDATION
model derivation
0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0
0,5
0,6
0,7
0,8
0,9
1
1,1
1,2
1,3
1,4
1,5
a,0
m
isotropic 0,55 0,84
anisotropic 0,64 0,91
weld line 0,53 0,00
R=-1, N = 10
6
moisture f = 0 %
P
A
= 50 %
PEI-GX30
injection moulded

n
o
r
m
a
l
i
s
e
d

s
t
r
e
s
s

a
m
p
l
i
t
u
d
e

a

(
l
o
g
)

[
N
/
m
m
]
fibre content in loading direction [-]
Influence of Fibre Orientation
0 1 2 3 4 5 6 7 8
0,000
0,125
0,250
0,375
0,500
0,625
0,750
0,875
1,000
PEI-GX30
injection moulded

short specimen
t = 4 mm
R = -1
K
D
= 0,58
isotropic
anisotropic
weld line
n
o
r
m
a
l
i
s
e
d

l
o
c
a
l

e
n
d
u
r
a
n
c
e

l
i
m
i
t

a

[
N
/
m
m
]
relative stress gradient [1/mm]
N = 10
6
P
A
= 50 %
Influence of Stress Gradient
Influence of Mean Stress
0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00
0,0
0,2
0,3
0,5
0,7
0,8
1,0
s
Rm
R

=

-
1
R

=

0
,
5

n
o
r
m
a
l
i
s
e
d

e
n
d
u
r
a
b
l
e

s
t
r
e
s
s

a
m
p
l
i
t
u
d
e
a

[
M
P
a
]

a
t

N

=

1
0
6
normalised means stress amplitude
M
[MPa]
measuring points
FKM-guideline
FEMFAT
R

=

0
m
a
x

=

R
m
Rp
0,2
w
Haigh-Diagram
PEI-GX30 longitudinal
anisotropic stresses
moisture f = 0,0 %
M = 0,3
N = 10
6
Zyklen
= 0,77
MUL-AMB, 2013
15
Process Simulation injection moulding
Information obtained from injection moulding simulation for
continuing FE-stress calculation and fatigue analyses:
C
a
r
r
i
e
d

o
u
t

b
y

Z
K
W
-
Z
i
z
a
l
a
L
i
c
h
t
s
y
s
t
e
m
e
G
m
b
H
fibre orientation weld lines
model derivation
injection moulding
simulation
FE-stress-
simulation
lifetime
calculation
component tests
VALIDATION
injection moulding
simulation
temperature
control system
2 lens holder/
injection mould
gating system
MUL-AMB, 2013
16
FE-Stress Simulation (unit) tension loading
FE-model:
clamping made of steel
E = 210000 MPa, v = 0.33
lens holder
anisotropic material data
From injection moulding simulation
element type: C3D10
number of elements: 344862
Stress distribution at
tension loading
(unit load F=1N)
loading due to
bolt pre load
stress concentration
in critical area
tension loading
inside
model derivation
injection moulding
simulation
FE-stress-
simulation
lifetime
calculation
component tests
VALIDATION
FE-stress-
simulation
CAD-model:
MUL-AMB, 2013
17
tension/tension loading
inside the lens holder
Pos. 2
Pos. 1
critical area
Calculated fatigue life
load amplitude 20 N
Pos. 1: N = 130 000 cycles
Pos. 2: N = 90 000 cycles
model derivation
injection moulding
simulation
FE-stress-
simulation
lifetime
calculation
component tests
VALIDATION
lifetime
calculation
Fatigue Life Calculation (FEMFAT) tension/tension R=0.1
MUL-AMB, 2013
18
Component Tests tension/tension R=0.1
hydraulic cylinder (15 kN) 1 kN load cell
clamping
device
Lens holder
clamping cyclic loading
model derivation
injection moulding
simulation
FE-stress-
simulation
lifetime
calculation
component tests
VALIDATION
component tests
MUL-AMB, 2013
19
Validation simulation vs. test
Pos. 2
Pos. 1
Simulation:
Pos. 1
Pos. 2
80% fracture Pos. 1
20% fracture Pos. 2
Component test:
Good correlation of the slope of
the whler lines
Lifetime estimation is
conservative (factor ca. 1,5)
model derivation
injection moulding
simulation
FE-stress-
simulation
lifetime
calculation
component tests
VALIDATION VALIDATION
Location of failure
correctly estimated
MUL-AMB, 2013
Outlook
testing at variable amplitudes and determination of
Gassner-lines
effect of very sharp notches
torsional and multi-axial loads
temperature, media effects and aging
special material conditions resulting from injection
molding: flow lines and internal stresses
20
MUL-AMB, 2013
Projects Fatigue strength fibre reinforced plastics
K
plus
: Polymer Competence Center Leoben GmbH
"Fatigue design methodology for automotive application of engineering
plastics, Part I + II
07/2003 09/2009
FFG-Bridge Brcke 1, Nr. 818112/16653:
"Berechnungsmodell fr kurzfaserverstrkte Kunststoffbauteile mit
Temperatur- und Umgebungsmedieneinfluss
12/2008 - 05/2012
CORNET
Advanced PartSim2: Advanced Simulation Methods for part and
process development of complex injection moulded plastic parts
tailored for SMEs
01/2011 04/2013
Comet: Polymer Competence Center Leoben GmbH
Fatigue design methodology of reinforced engineering plastics
01/2013 12/2016
21
MUL-AMB, 2013
References
22
Msenbacher A., Guster Ch.: Fatigue behaviour of a short glass fibre reinforced polyamide: Effect of notches and temperature ,
Tagungsband 3rd Fatigue Symposium Leoben, 18.-19.4.2012, Leoben.
Msenbacher A., Guster Ch., Pinter G., Eichlseder W. Investigation of Concepts Describing the Influence of Stress
Concentration on the Fatigue Behaviour of Short Glass Fibre Reinforced Polyamide, ECCM 15, 24.-28.6.2012, Venedig.
Guster Ch., Pinter G., Msenbacher A., Eichlseder W.: Evaluation of a Simulation Process for Fatigue Life Calculation of Short
Fibre Reinforced Plastic Components, ICM 11, Procedia Engineering 10 (2011) 210421095. 5. 9.6.2011, Como.
Guster Ch., Eichlseder W.: Methodenentwicklung zur Lebensdauerbewertung kurzglasfaserverstrkter Kunststoffbauteile, EMPA
Tagung Schadensprvention hochbeanspruchter Bauteile und Komponenten, 8.11.2011, EMPA Dbendorf.
Gaier C., Fleischer H., Guster Ch., Pinter G.: Einfluss von Faserorientierung, Temperatur und Feuchtigkeit auf das
Schwingfestigkeitsverhalten von spritzgegossenen kurzfaserverstrkten Thermoplasten, MP Materials Testing 52 (2010) 7-8,
Seite 534 bis 542, Carl Hanser Verlag, Mnchen.
Guster Ch.: Anstze zur Lebensdauerberechnung von kurzglasfaserverstrkten Polymeren, Dissertation, Lehrstuhl fr
Allgemeinen Maschinenbau, Montanuniversitt Leoben, 2009.
Ch. Guster, G. Pinter, H. Fleischer, R.W. Lang, W. Eichlseder: Betriebsfeste Dimensionierung von faserverstrkten
Kunststoffkomponenten - eine durchgngig Simulationskette von der Spritzgusimulation zur Schdigungsrechnung, IKV-
Fachtagung: Kunststoffgerecht simulieren - Auslegung von Spritzgussbauteilen mit CAE, IKV der RWTH Aachen, 19.-
20.03.2009, Aachen.
Fleischer H., Brune M., Thornagel M., Thomas B., Guster Ch. (2009): "Von der Spritzgiesimulation zur Betriebsfestigkeits-
dimensionierung Entwicklung und Einsatz einer durchgngigen Simulationskette", VDI Fachtagung: Kunststoffe im
Automobilbau 2009, 25.-26.3.2009, Mannheim (D).
Guster Ch., Pinter G., Eichlseder W., Lang R.W. (2009): "Effects of temperature and moisture on the tensile/tensile fatigue
behavior of an injection molded sgf-reinforced partial aromatic polyamide", 12
th
International Conference on Fracture, CD-
Proceedings ICF 12, 12.-17.7.2009, Ottawa.
Guster, Ch.; Pinter, G.; Eichlseder, W.; Lang, R. W: The Influence of Fiber-Orientation and Stress Ratio on the Fatigue Behavior
of Short-Glassfiber-Reinforced Polymers, Annual Technical Conference (ANTEC) 2007, Society of Plastics Engineers, CD
Conference Proceedings, ISBN 0-9753707-5-8, 6.-11.5.2007, Cincinnati, Ohio.
Guster, Ch.; Eichlseder, W.; Pinter, G.; Lang R.W.: Kurzglasfaserverstrkte Kunststoffe Charakterisierung der Werkstoff-
aniosotropie und Untersuchung deren Einfluss auf das Schwingfestigkeitsverhalten, VLK-News, 15. Jahrg., 2/2007, 16-20.

Plastic Fatigue

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Plastic Fatigue

Hochgeladen von

Copyright:

Verfügbare Formate

Fatigue 2014. Melbourne, 06.03.

Das könnte Ihnen auch gefallen