Title

Finite Element Analysis for Diagnosis of Fatigue Failure of Composite Materials in Product Development

Document Type

Article

Publication Date

2016

Publication Source

The International Journal of Advanced Manufacturing Technology

Volume

87

Issue

5-8

Inclusive pages

2245-2257

DOI

https://doi.org/10.1007/s00170-016-8619-z

Publisher

Springer

ISBN/ISSN

1433-3015

Abstract

In contrast to homogenous materials, composite materials can be customized to achieve desirable strength-to-weight ratios, corrosion prevention, and fatigue resistances. However, the heterogeneity in composite materials brings the challenges in design, production, characterization, and testing. Trial and error practices and numerous experiments are usually required to deal with the uncertainties of composite material properties. Mathematical modeling or numerical simulations have been studied to shorten product development cycles. In this paper, we use finite element analysis (FEA) approach to diagnose the fatigue failure of composite materials. The proposed approach is novel in sense that (1) the new procedure and guideline has been developed for defining fluctuated loads in actual applications, (2) the motion simulation is conducted to characterize dynamic loads, (3) FEA is suggested as a diagnosis tool to detect design defects when failure occurs; and (4) conventional Minor’s rule is expended to evaluate the fatigue life of machine elements with the consideration of both the variations of magnitudes and frequencies of stresses. A case study is provided to illustrate the analysis of the fatigue failure of products. A comparison of simulation and experimental results has verified the effectiveness of the developed approaches.

Keywords

Sustainable manufacturing, Composite materials, Fatigue failures, Motion simulation, Finite element analysis

Disciplines

Engineering

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