A case study on

Application of Rainflow counting method for fatigue assessment

(For Connecting Rod of U650 Tractor)

Project work on

Fracture Mechanics and Fatigue (DMS6022)

By: Keyru Salia (RM7519/11)

Submitted to: Prof. Hirpa G. (PhD)

Submission date: 25/09/2019 GC.
 Acknowledgement

First of all, I am thankful to Prof. Hirpa G. (PhD) for giving me this work to upgrade my
knowledge of Fracture Mechanics and Finite Element Method to a bit advanced level. Because
of this project I am familiar with 3D and importing different CAD files in to ANSYS
Workbench. I also never forget the wonderful time we had while we are learning and I wish you
long live with health.

Next, I would like to appreciate Jimma Institute of technology for giving me the opportunity to
continue my education. This is the only way to upgrade one’s education level, so career.

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 Abstract

Rainflow cycle counting method has become the most widely accepted method for the processing
of random signals for fatigue analysis, and testing has demonstrated good agreement with
measured fatigue lives when compared to other counting algorithms. In this paper, an
introduction to Rainflow cycle counting method is discussed and how to use ANSYS in the
application of Rainflow method is also addressed. ANSYS Workbench 15.0 has been used to
analyse the Connecting Rod of U650 Tractor. Material properties and dimensions of the
Connecting Rod are dealt which are necessary in modelling the Connecting Rod in virtual as
well as real world. The developed model in Autodesk Inventor is imported in to ANSYS
workbench where the fatigue analysis by Rainflow cycle counting method is performed.

Keywords

Rainflow cycle counting method, Fatigue analysis, Fatigue lives, ANSYS Workbench, Connecting
Rod, Autodesk Inventor, U650 Tractor

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 Table of Contents
Acknowledgement........................................................................................................................... I

Abstract .......................................................................................................................................... II

List of Figure ............................................................................................................................... IV

1. Introduction ........................................................................................................................... 1

1.1 Procedures........................................................................................................................ 1

1.2 Rainflow algorithm in ANSYS ........................................................................................ 2

2. Objective of the Paper........................................................................................................... 2

3. Methodology .......................................................................................................................... 2

3.1 Connecting Rod ............................................................................................................... 2

3.1.1 Materials of the Connecting Rod .............................................................................. 3

3.1.2 Dimensions of the Connecting Rod ........................................................................... 3

3.1.3 Modelling the Connecting Rod in Autodesk Inventor software................................. 4

3.1.4 Loading Condition..................................................................................................... 5

4. Results and Discussion .......................................................................................................... 6

5. Conclusion .............................................................................................................................. 9

References .................................................................................................................................... 10

III
 List of Figures

Figure 1: Dimensions of the Connecting Rod ................................................................................. 4

Figure 2: 3D model of the Connecting Rod .................................................................................... 4

Figure 3: Load history of the Connecting Rod ................................................................................ 5

Figure 4: Meshed view of the Connecting Rod............................................................................... 6

Figure 5: Rainflow matrix of the Connecting Rod .......................................................................... 6

Figure 6: Damage matrix of the Connecting Rod ........................................................................... 7

Figure 7: Life cloud of the Connecting Rod ................................................................................... 7

Figure 8: Damage cloud of the Connecting Rod ............................................................................. 7

Figure 9: Equivalent von-mises stress in the Connecting Rod........................................................ 8

Figure 10: Maximum principal stress in the Connecting Rod ........................................................ 8

Figure 11: Maximum shear stress in the Connecting Rod .............................................................. 8

Figure 12: Fatigue life of the Connecting Rod in fully reversed loading condition ....................... 8

IV
 1. Introduction

The Rainflow cycle counting method (rain-flow counting algorithm) has initially been proposed
by M. Matsuiski and T. Endo in 1968 for counting fatigue cycles from a time history [1][2]. It
has become the most widely accepted method for the processing of random signals for fatigue
analysis, and testing has demonstrated good agreement with measured fatigue lives when
compared to other counting algorithms [3][4].

The Rainflow cycle counting method is based on the analogy of raindrops falling on a pagoda
roof and running down the edges of the roof. The history is rotated so that the time axis is
vertical and visualizing water poured on top. The flow starts at the top (beginning) of the history
and is also initiated at the inside of each maximum or minimum. Flow is stopped when it strikes
flow descending from above, or a point opposite a maximum or minimum whose magnitude
exceeds that at a point from which it is started. Flow also stops at the end of the record. Each
flow is a half cycle, and there is a complementary half cycle of opposite sign elsewhere in the
complete record. In this method, it cannot be assumed that a converging history would simply
skip the other lower peaks and no cycles are counted. It is applied for variable amplitude loading
condition and makes the use of Miner's rule in order to assess the fatigue life [4].

The Rainflow count method is adopted to improve the irregular load cycle count, the Palmgrn -
Mine law calculation of fatigue damage accumulation. According to Palmgren-Miner's law,
which is, in a given average stress and stress amplitude, the effective life span of each cycle is a
few percent of the sum, for a cycle times under a given stress amplitude, the life is exhausted
when the number of cycles reaches the failure rate [5].

1.1 Procedures

The procedures to be followed while working with Rainflow method manually are [2]:

Rearrange the history to start with either the highest peak or the lowest valley (Turn the
sheet clockwise 90°, so the starting time is at the top).

If starting from the highest peak, go down to the next reversal. The Rainflow runs down
and continues, unless either the magnitude of the following peak is equal to or larger than
the peak from which it initiated, or a previous rain flow is encountered.

Repeat the same procedure for the next reversal & continue these steps to the end.

Repeat the procedure for all the ranges and parts of a range that were not used in previous
steps.

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 1.2 Rainflow algorithm in ANSYS

ANSYS is a powerful Finite Element Analysis (FEA) software in engineering used to simulate
variety of physical phenomena. Fatigue analysis by Rainflow counting method is one of them.

Steps to work on Rainflow method in ANSYS [5]

Open ANSYS Workbench[ANSYS Multiphysics]

Develop the Geometry(Surfaces & Solids only)

Assign Material Properties, including S-N Curves

Define Contact Regions

Define Mesh Controls

Include Loads and Supports

Request Results, including the Fatigue Tool

Solve the Model

Review Results

2. Objective of the Paper

The objective of this paper is to demonstrate the fatigue analysis of U650 Tractor Connecting
Rod by Rainflow cycle counting method using ANSYS software.

3. Methodology

The connecting rod is modelled using Autodesk inventor software and imported in to ANSYS
software. The ANSYS software is used for fatigue analysis of the connecting rod by Rainflow
cycle counting method. For this case study the Connecting Rod of U650 Tractor is selected to be
analysed.

3.1 Connecting Rod

Connecting rod is a major link of I.C. Engines which connects the piston and the crankshaft
together and helps to convert the reciprocating motion of the piston into rotatory motion of the
crankshaft [7]. The function of connecting rod in compressors is to transmit the power from
crankshaft to the piston to compress the air and in engine to transmit the power from piston to
the Crankshaft. The role of connecting rod is the conversion of rotary motion into reciprocating
motion or vice-versa [8]. Its main feature is that it should be able to withstand the stresses from
the combustion and the movement of the piston along with maintaining the uniform shape and
light weight characteristics [7].

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A connecting rod is a machine member which is subjected to alternating direct compressive and
tensile forces. Since the compressive forces are much higher than the tensile force, therefore the
cross-section of the connecting rod must be designed in such a way that it fulfils the requirement
[9]. Obviously, the Connecting Rod is subjected to a complex loading condition which is known
by its variable amplitude. The need of Rainflow cycle counting method is the fact that it is best
suited and probably the most widely acceptable method for such kinds of loads.

3.1.1 Materials of the Connecting Rod

Connecting Rods can be made from various grades of structural steel, Aluminium, and Titanium.
Steel rods are the most widely produced and used type of connecting rods. Their applications are
best used for daily drivers and endurance racing due to their high strength and long fatigue life.
The only problem with using steel rods is that the material is extremely heavy, which consumes
more power and adds stress to the rotating assembly. Performance steel rods can be made from
high strength alloy steels. C-70 steel is one of the high strength alloy steel with its tensile
strength, yield strength, and hardness depends on the temperature at which the steel is forged,
and how the steel is heat treated. Variations in the tempering temperature and quenching
procedure can produce extremely different results with tensile strength and yield strength
[10][11]. Table 1 [11] below gives the specific material property of the Connecting Rod to be
analysed.

Table 1: Universal Tractor (U650) Connecting Rod Data

Material Property Amount

Tensile Strength(MPa) 621
Yield Strength(MPa) 483
Brinell strength(HB) 229-269
Young modulus(GPa) 207
Shear modulus(GPa) 79
Poisson ratio 0.3
Density(kgm-3) 7700
Correction factor 0.8
Connecting Rod material C-70 Alloy steel

3.1.2 Dimensions of the Connecting Rod

The dimensions of the Connecting Rod are necessary for developing a model in virtual or real
world. All the dimensions of the Connecting Rod [11] are illustrated in the Figure 1 below with
all dimensions are in millimetre.

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 Figure 1: Dimensions of the Connecting Rod

3.1.3 Modelling the Connecting Rod in Autodesk Inventor software

The Connecting Rod is modelled using Autodesk Inventor software. Figure 2 below shows the
3D model of the Connecting Rod in the graphics windows of Autodesk Inventor software. In
modelling the Connecting Rod, all the dimensions are used and the magnitude of the external
filets dimension is assumed. Ones the model is successfully developed, it is exported in the form
of STP file format to be imported in to ANSYS software. It can be directly accessed by ANSYS
software, if older version of Autodesk Inventor software is used.

Figure 2: 3D model of the Connecting Rod

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 3.2 Loading Condition

From the outset, Rainflow cycle counting method is used in complex loading condition i.e. non-
constant amplitude loading. It is supposed to be specified in the form of load history. This load
history gives the instantaneous value the load acting on the Connecting Rod. The maximum load
that occurs in the Connecting Rod [11] is 9500 N. But this load is not constant, and it has a
varying nature which is shown in the Figure 3 below.

3.3 ANSYS Analysis

The ANSYS software is used for the dynamic simulation of the Connecting Rod. This dynamic
simulation is the fatigue analysis by Rainflow cycle counting method. It begins by importing the
3D model of the Connecting Rod developed using Autodesk Inventor software in to ANSYS
software Workbench. Ones the model is successfully imported, in to ANSYS Workbench it
needs to be meshed i.e. dividing the model in to finite number of elements before the boundary
condition and external load is applied. Figure 4 below shows the meshed view of the Connecting
Rod model in the graphics window of ANSYS software. The model is divided in to 4806
elements with 9134 nodes.

After meshing is completed, appropriate boundary conditions and external loads needed to be
specified. The big end of the Connecting Rod is assumed to be fixed and external load is applied
at small end. The next step is requesting for the fatigue module. In the fatigue module of ANSYS
software different parameters determining fatigue life estimation can be requested before solving
the problem. Among these parameters Rainflow matrix is the one in which this paper is focused
on. The other parameters are Damage matrix, life, Damage, Safety factor, Fatigue sensitivity and
so on. The fatigue analysis type used is stress-life approach as it is used for high cycle operation.

Figure 3: Load history of the Connecting Rod

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 Figure 4: Meshed view of the Connecting Rod

4. Results and Discussion

The results for the Rainflow matrix, Damage matrix, Life, Damage, equivalent von-mises stress,
maximum principal stress, maximum shear stress and fatigue life of the fully reversed loading
condition are provided in the Figures 5 through 12 respectively.

Figure 5: Rainflow matrix of the Connecting Rod

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Figure 6: Damage matrix of the Connecting Rod

Figure 7: Life cloud of the Connecting Rod

Figure 8: Damage cloud of the Connecting Rod

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 Figure 9: Equivalent von-mises stress in the Connecting Rod

Figure 10: Maximum principal stress in the Connecting Rod

Figure 11: Maximum shear stress in the Connecting Rod

Figure 12: Fatigue life of the Connecting Rod in fully reversed loading condition

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Figure 5 shows the cloud map of rain flow matrix. Rain flow matrix can change the alternating
stress and average stress into the digital information of a member. The z-coordinate value
represents the size of the count, and the maximum value is 22. Figure 6 shows the damage matrix
cloud map, which is the result of the Rainflow cycle count and the z-coordinate value of the
damage matrix represents the relative damage degree, and the maximum damage degree is 1.61.
The fatigue life and fatigue damage of the connecting rod can be calculated by the rain flow
matrix and damage matrix of the Connecting Rod and the fatigue life of the engine connecting
rod under asymmetric load can be predicted. From the Rainflow matrix, it can be seen that a lot
of cycles with a low stress range and fewer with a high range. The height of each tower
represents the number of cycles at that particular stress range and mean. Each tower is used to
obtain damage on the S-N curve and damage is summed over all towers. Figure 6 also shows that
lower stress ranges produced zero damage. It is also showed that, the high stress ranges were
found to give the most of the damage and a fairly wide damage distribution at the higher ranges
which mean that it cannot point to a single event causing damage.

Figures 7 and 8 show the Life and Damage of the Connecting Rod. They are opposite to one
another. From the Figures the maximum life is 4.8 × 106 which shows the design is for high
cycle fatigue and the minimum damage is 208.

Figures 9 through 11 show von-mises stress, maximum principal stress and maximum shear
stress. These all figures show the small end of the Connecting Rod is subjected to maximum
stress value.

Figure 12 shows the fatigue life of fully reversed condition. This is the case when the load is
applied in a way that it has equal amount of positive and negative values in a cycle. In this case,
the life of material is more likely to live longer life. The fatigue life of non-constant amplitude
loading condition is lower which show it is more severe than fully reversed condition.

5. Conclusion

The 3D model of U650 Tractor is successfully developed in Autodesk Inventor software and
imported in ANSYS software to be analysed. The application of ANSYS to carry out numerical
simulation, reduce not only the input manpower and material resources, but also saves the
development cost and shorten the development cycle. The Connecting Rod is subjected of a
complex loading condition which makes the use of Rainflow method compulsory. By using
Rainflow method the fatigue life of U650 Connecting Rod is successfully analysed. Compared to
the fully reversed condition, the non-constant amplitude condition is more sever and so
equipments subjected to such kinds of load needs additional consideration for their durability.

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 References

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Johanning, Review and application of Rainflow residue processing techniques for accurate
fatigue damage estimation, International Journal of Fatigue 82 (2016) 757–765.
[4]. K. L. Singh and V. R. Ranganath, Cycle counting using Rainflow algorithm for fatigue
analysis, National Seminar on Aerospace Structures, 2000.
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Method, Advances in Engineering Research 154 (2018) 270-273
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