1. EUROnu WP2 meeting, Cracow 14 October 20101/32M.Kozień & B.Szybiński NEXT STEPS IN STRENGTH ANALYSIS OF THE HORN EUROnu Project Cracow University of Technology Cracow University of Technology Institute of Applied Mechanics Institute of Applied Mechanics M.Kozień & B.Szybiński

2. EUROnu WP2 meeting, Cracow 14 October 20102/32M.Kozień & B.Szybiński Outline of the talk  Character of dynamic stress  S-N aluminium curves  Chosen methods of cycle counting  Ansys fatigue analysis  Very high cycle fatigue analysis  Questions

3. EUROnu WP2 meeting, Cracow 14 October 20103/32M.Kozień & B.Szybiński Fatigue estimation for EUROnu horn – stress due to a single heat from second. particles

4. EUROnu WP2 meeting, Cracow 14 October 20104/32M.Kozień & B.Szybiński Rain – flow cycle counting method (after Dowling)

5. EUROnu WP2 meeting, Cracow 14 October 20105/32M.Kozień & B.Szybiński Spectral method (Lagoda et al.)

6. EUROnu WP2 meeting, Cracow 14 October 20106/32M.Kozień & B.Szybiński Calculation scheme in frequency domain (Osgood)

7. EUROnu WP2 meeting, Cracow 14 October 20107/32M.Kozień & B.Szybiński Palmgren-Miner damage cumulation rule

8. EUROnu WP2 meeting, Cracow 14 October 20108/32M.Kozień & B.Szybiński S-N aluminum curve (6082) „Infinite large” number of cycles, fatigue limit - stress for N = 10 8 or N = 5·10 8

9. EUROnu WP2 meeting, Cracow 14 October 20109/32M.Kozień & B.Szybiński S-N aluminum curve (6061)

10. EUROnu WP2 meeting, Cracow 14 October 201010/32M.Kozień & B.Szybiński S-N aluminum curve (6082) EN 6082 AW mechanical properties Yield strength R p0,2 341 [MPa] Tensile strength R m 356 [MPa] Elongation A (%) 11.2 Area red., Z (%) 47.5

11. EUROnu WP2 meeting, Cracow 14 October 201011/32M.Kozień & B.Szybiński Aluminum crack (6082)

12. EUROnu WP2 meeting, Cracow 14 October 201012/32M.Kozień & B.Szybiński Fatigue limit (Bathias, Sonsino) In 1999 Bathias stated that there is no infinite life in metallic materials. The decrease of fatigue strength was described by Sonsino in 2006, this was observed at very high number of cycles. For metals such as austenitic stells, Al- and Cu- alloys a decrease in fatigue strength is common fact. LCF – Low Cycle Fatigue (N f = 10 4 ÷ 10 5 ) HCF – High Cycle Fatigue (10 4 < N f < 10 7 ) VCHF – Very High Cycle Fatigue (N f > 10 7 )

13. EUROnu WP2 meeting, Cracow 14 October 201013/32M.Kozień & B.Szybiński Fatigue limit (Bathias, Sonsino) Investigations of smooth specimens show that failure in VHCF region occurs in metals with fatigue strength values below the conventional fatigue limit. The fatigue strength decreases with increasing number of cycles. There is no real fatigue limit, so that it cannot be a general material property. The term fatigue limit should not be used and is to substitute better by fatigue strength at a definite number of cycles.

14. EUROnu WP2 meeting, Cracow 14 October 201014/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis I. Geometry

15. EUROnu WP2 meeting, Cracow 14 October 201015/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis II. Material

16. EUROnu WP2 meeting, Cracow 14 October 201016/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis III. S-N curve

17. EUROnu WP2 meeting, Cracow 14 October 201017/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis IV. Static structural

18. EUROnu WP2 meeting, Cracow 14 October 201018/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis V. External loading

19. EUROnu WP2 meeting, Cracow 14 October 201019/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis VI. Structural deformation

20. EUROnu WP2 meeting, Cracow 14 October 201020/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis VII. Normal elastic strain

21. EUROnu WP2 meeting, Cracow 14 October 201021/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis VIII. Normal stress

22. EUROnu WP2 meeting, Cracow 14 October 201022/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis IX. Notch coefficient

23. EUROnu WP2 meeting, Cracow 14 October 201023/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis

24. EUROnu WP2 meeting, Cracow 14 October 201024/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis

25. EUROnu WP2 meeting, Cracow 14 October 201025/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis X. Fatigue solution

26. EUROnu WP2 meeting, Cracow 14 October 201026/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis XI. Time history 1

27. EUROnu WP2 meeting, Cracow 14 October 201027/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis XII. Equivalent stress 1

28. EUROnu WP2 meeting, Cracow 14 October 201028/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis XIII. Fatigue life 1

29. EUROnu WP2 meeting, Cracow 14 October 201029/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis XIV. Time history 2

30. EUROnu WP2 meeting, Cracow 14 October 201030/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis XV. Fatigue life 2

31. EUROnu WP2 meeting, Cracow 14 October 201031/32M.Kozień & B.Szybiński Ansys FEM fatigue analysis XVI. Fatigue damage 2

32. EUROnu WP2 meeting, Cracow 14 October 201032/32M.Kozień & B.Szybiński Questions  Methods of cycle counting (time vs. frequency attempt)  Sensitivity of stress level for fatigue analysis  Fatigue limit  S-N curve for very high cycle fatigue analysis (experiment ?)