The Fatigue Damage Spectrum: Explained

Mr. Rob Plaskitt1 and Dr. Andrew Halfpenny2

1UK Application Engineering, 2Chief Technologist, HBM-nCode, UK

28th ICAF Symposium Helsinki, 35 June 2015

Abstract
The fatigue damage spectrum (FDS) is a very useful analysis
technique to quantitatively assess the potential for a fatigue failure
mode in components or systems operating in a mechanical
vibration environment.
The mathematical theory to calculate the FDS is presented in
AECTP-240 Environmental Test Methods (Edition 4) Leaflet 2410,
and is referenced by standards NATO STANAG 4370, UK DEF
STAN 00-35 and USA MIL-STD-810G.
However, using only the equations shown in Leaflet 2410, it is very
difficult to reproduce the FDS (and MRS) examples included to
illustrate the equations. To reproduce these examples requires the
previous edition of the standard, and following the references back
to the withdrawn French standard GAM-EG-13 [4].
This paper explains the FDS and demonstrates its calculation
using the examples from Leaflet 2410.
Example Application
All three of the FDS Applications were used during the successful
integration of external fuel tanks to a helicopter.
Existing vibration qualification test evidence was insufficient for
full type approval, but was sufficient to justify a limited number
of hours of experimental flight by read across evidence.
The health of this system was monitored during experimental
flight testing by comparing the cumulative FDS with the FDS of
the existing vibration qualification test evidence.
This showed that the cumulative FDS from experimental flight
testing increased rapidly at certain frequencies and would
exceed those from the qualification test evidence.
Identification of this led the supplier to a successful redesign of
their system to pass a new vibration qualification test tailored to
this specific helicopter vibration environment.
The qualification of the redesign was confirmed by further
experimental flight monitoring and FDS analysis of the
measured accelerations.
Conclusion
The purpose of this paper is to explain the fatigue damage
spectrum calculation.
Simple sinusoidal and broadband random examples from the
AECTP standard are used that can be easily reproduced by
spreadsheet calculation.
The calculation of MRS and FDS for these simple vibration
environments can become very complex and sometimes it is
necessary to use approximate equations with assumptions.
This is to give confidence in the use of the accurate equations for
more complex vibration environments which cannot be so easily
reproduced by spreadsheet calculation.

References to Fatigue Damage Calculation of Calculation of

Spectrum (FDS) in Standards Maximum Response Spectrum (MRS) Fatigue Damage Spectrum (FDS)
The use of FDS is explicit within Def Stan 00-35 and AECTP-240, which define FDS as;
Def Stan 00-35 [1], Chapter 1 Glossary: The fatigue damage spectrum is a curve that Calculation of MRS for Sine Dwell Vibration Environment Calculation of FDS for Sine Dwell Vibration Environment
represents the variation of damage, as defined by Miners Law, as a function of the
natural frequency of the system with one degree of freedom, for a given damping
factor.
AECTP-240 [2], Leaflet 2410/1 Annex C: The fatigue damage spectrum is a spectral
representation of a fatigue damage index as a function of any system's natural
frequency. This spectrum is computed directly from the power spectral density (PSD)
function representing a test situation or a field environment, and provides a relative
fatigue damage estimate based on acceleration level and exposure time.

The use of FDS is considered to be implicit within Mil Std 810 [3], Method 514.6
Vibration, Chapter 2 Tailoring Guidance. Though it does not refer to FDS by name, it
uses the phrase fatigue damage potential across the frequency range of importance.
This is considered to be a means of defining FDS as a curve that represents the
variation of damage across a frequency range without specifying that Miners Law must
be used for cumulative fatigue damage and without specifying that the system must be
represented by one degree of freedom with damping.

To understand the derivation and mathematics of FDS it is necessary to understand its

origins in the maximum response spectrum (MRS). Again MRS is explicitly referred to in
Def Stan 00-35 and AECTP-240, but is not in Mil Std 810. The MRS is defined exactly
the same in Def Stan 00-35 [1], Chapter 1 Glossary and AECTP-240 [2], Leaflet 2410/1
Annex E as;
When a vibration excitation is applied to a mechanical system with one degree of Calculation of MRS for Sine Sweep Vibration Environment
freedom, the maximum value of the response of this system for a deterministic signal,
or the probability of a maximum value for a random signal, can be calculated. This Calculation of FDS for Sine Sweep Vibration Environment
value is called the maximum or the extreme value. The maximum response
spectrum is the curve that represents variations of the maximum response value as a
function of the natural frequency of the system with one degree of freedom for a given
damping factor.

Schematic to calculate MRS and FDS from measured acceleration

Calculation of MRS for Broadband Random Vibration Environment

FDS Applications
FDS should be used as a relative comparison method between two or more time history
waveforms or vibration test environments. Used in this way the fatigue properties of the
material are the same for each case and the relative similarity or difference of the time Calculation of FDS for Broadband Random Vibration Environment
history waveforms or vibration test environments are revealed. For such relative
analyses the only fatigue property required is the Basquin exponent b, the gradient of
the stress-life curve in log space. The other primary assumption, and limitation, is the
unknown damping factor Q. In practice this is usually defaulted to 10, and again for a
relative analysis reveals the similarities and differences between the vibration
environments.

This means that the FDS can be used to compare the potential cumulative fatigue
damage for the duration of various vibration environments, such as within;
Test Tailoring: Def Stan 00-35 [1], AECTP-240 [2] and Mil Std 810 [3] all recommend
test tailoring of laboratory vibration test schedules. The vibration chapter of Mil Std
810 begins with the words Tailoring is essential, and AECTP-240 [2] Leaflet 2410/1
Annex C describes the FDS as an attractive technique in development of a laboratory
vibration test schedule.
Vibration Qualification by Read Across Evidence: In many cases existing vibration
qualification test evidence is available for equipment to be used in a specific aircraft
vibration environment or to an environment defined by one the Def Stan 00-35, References
AECTP-240 or Mil Std 810 standards. In such cases FDS comparison of existing test
evidence with the manufacturers vibration requirements may prove sufficient for the
[1] UK Ministry of Defence, Defence Standard 00-35 Issue 4 (2006). Environmental
new aircraft enabling full type approval to be awarded without recourse to additional
Handbook for Defence Materiel: Part 3: Environmental Test Methods
testing. This offers huge cost savings because vibration tests are very expensive on
[2] NATO Standardisation Agency, STANAG 4370 (2009). AECTP-240 (Edition 1)
account of the direct testing costs and the cost of the test component which is life
Mechanical Conditions, (http://nso.nato.int/nso/nsdd/apdetails.html?APNo=1252)
expired at the end of the test. If the existing test evidence is insufficient for full type
[3] USA Department of Defense, Test Method Standard Mil-Std-810G (2008).
approval, it is often sufficient to justify experimental flight approval subject to a limited
Environmental Engineering Considerations and Laboratory Tests
flight envelope or number of flight hours.
[4] France Ministre de la Dfense, Dlgation Gnrale pour lArmement (2002), GAM
Health Usage Monitoring: The FDS is an analysis method that can increase the
EG-13 Annexe Gnrale Mcanique
capability of on-board health usage monitoring systems (HUMS). For many years
[5] NATO Standardisation Agency, STANAG 4370 (2006). AECTP-200 (Edition 3)
aircraft have used fatigue meters and counting accelerometers to monitor their in-
Mechanical Conditions
flight acceleration levels in order to estimate their structural life consumed during
[6] Lalanne, C. (2002), Mechanical Vibration and Shock, Volume 2 Mechanical Shock,
flight. This FDS approach is very suitable for assessment of vibration life consumed,
Volume 4 Fatigue Damage, Volume 5 Specification Development, Hermes Penton Ltd.
with respect to the vibration qualification test evidence, for sensitive materiel (e.g.
[7] Halfpenny, A. and Walton, T. (2010), New Techniques for Vibration Qualification of
electronic equipment and missile structures, ref AECTP-200 [5] Leaflet 2410/1) and
Vibrating Components on Aircraft, Proceedings of Aircraft Airworthiness & Sustainment
localised complex systems such as hydraulics, fuel systems, etc.
2010, (http://www.meetingdata.utcdayton.com/agenda/airworthiness/2010/agenda.htm)
[8] Halfpenny, A. (2008), Accelerated Testing Theory and User Manual, HBMnCode
Halfpenny and Walton [7] present case studies using FDS from their work with
GlyphWorks Product Documentation.
helicopters for Test Tailoring and Vibration Qualification by Read Across Evidence.

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