Astm stp 1231 1994

STP 1231 Automation in Fatigue and Fracture: Testing and Analysis Claude Amzallag, Editor ASTM Publication Code Number (PCN): 04-012310-30 ASTM 1916 Race Street Philadelphia, PA 19103 Printed in the U.S.A Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:20:12 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized Library of Congress Cataloging-in-Publication Data Automation in fatigue and fracture: testing and analysis / Claude Amzallag, editor (STP: 1231) "ASTM publication code number (PCN) 04-012310-30." Includes bibliographical references and index ISBN 0-8031-1985-2 Materials Testing Automation Materials Fatigue Fracture mechanics I Amzallag, C II Series: ASTM special technical publication: 1231 TA410.A84 1994 620.1' 126 dc20 94-36845 CIP Copyright 1994 AMERICAN SOCIETY FOR TESTING AND MATERIALS, Philadelphia, PA All rights reserved This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film, or other distribution and storage media, without the written consent of the publisher Photocopy Rights Authorization to photocopy items for internal or personal use, or the interna~ or personal use of specific clients, is granted by the AMERICAN SOCIETY FOR TESTING AND MATERIALS for users registered with the Copyright Clearance Center (CCC) Transactional Reporting Service, provided that the base fee of $2.50 per copy, plus $0.50 per page is paid directly to CCC, 222 Rosewood Dr., Danvers, MA 01923; Phone: (508) 750-8400; Fax: (508) 750-4744 For those organizations that have been granted a photocopy license by CCC, a separate system of payment has been arranged The fee code for users of the Transactional Reporting Service is 0-8031-1985-2/94 $2.50 + 50 Peer Review Policy Each paper published in this volume was evaluated by three peer reviewers The authors addressed all of the reviewers' comments to the satisfaction of both the technical editor(s) and the ASTM Committee on Publications The quality of the papers in this publication reflects not only the obvious efforts of the authors and the technical editor(s), but also the work of these peer reviewers The ASTM Committee on Publications acknowledges with appreciation their dedication and contribution to time and effort on behalf of ASTM Printed in Fredericksburg, VA December 1994 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:20:12 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized Foreword The International Symposium on Automation in Fatigue and Fracture: Testing and Analysis, was held 15-17 June 1992 in Paris, France It was cosponsored by the: Societe Francaise de Metallurgie et de Materiaux (SF2M), Committee on Fatigue, France; and American Society for Testing and Materials (ASTM), Committee E9 on Fatigue, USA Also offering valuable cooperation were the: Society of Automotive Engineers (SAE); Fatigue Design and Evaluation Committee, USA; Engineering Integrity Society (EIS), UK; and National Research Institute for Metals (NRIM), Japan The Symposium was an extension of the series of International Spring Meetings of SF2M This publication is a result of this symposium Claude Amzallag, IRSID-Unieux, France, is the editor Acknowledgment The Organizing Committee, who helped develop the program and provide session chairmen and reviewers, are acknowledged for their assistance Ms Gail Leese, (PACCAR Technical Center, USA) and Dr Dale Wilson (Tennessee Technical University, USA) helped shape the symposium, provide reviewers, and graciously offered their time in reviewing papers In addition to the help of the technologists cited above, the editor wishes to express gratitude to the staff members of SF2M and ASTM, particularly Yves Franchot, SF2M, who handled the administration of the symposium Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:20:12 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized Contents Overview A U T O M A T E D TESTING SYSTEMS AND M E T H O D S A Historical Overview and Discussion of Computer-Aided Materials Testing A A BRAUN General Purpose Software for Fatigue Testing s DHARMAVASANAND S M C PEERS A Sampling of Mechanical Test Automation Methodologies Used in a Basic Research Laboratory -G A HARTMAN, N E ASHBAUGH, AND D J B U C H A N A N 18 36 C o m p u t e r Applications in Full-Scale Aircraft Fatigue Tests -R L HEWITT AND R S RUTLEDGE 51 Microprocessor-Based Controller for Actuators in Structural Testing R SUNDER AND C S, VENKATESH 70 An Automated Image Processing System for the Measurement of Short Fatigue Cracks at Room and Elevated Temperatures L Yl, R A, SMITH, AND L G R A B O W S K I 84 Computer-Aided Laser Interferometry for F r a c t u r e Testing A K MAJI AND J WANG Automated D a t a Acquisition and Data Bank Storage of Mechanical Test Data: An Integrated Approach -G BRACKE,J BRESSERS, M STEEN, AND H H OVER 95 108 Sampling Rate Effects in Automated Fatigue C r a c k Growth Rate T e s t i n g - J K DONALD 124 Procedure for Automated Tests of Fatigue Crack P r o p a g a t i o n - - v BACHMANN, G MARCI, AND P SENGEBUSCH Automation of Fatigue C r a c k Growth Data Acquisition for Contained and Through-Thickness Cracks Using E d d y - C u r r e n t and Potential Difference Methods M O HALLIDAYAND C I BEEVERS 146 164 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:20:12 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized A Computer-Aided Technique for the Determination of R-Curves from Center-Cracked Panels of Nonstandard Proportions G R SUTTON, 186 C E T H O M A S , C WHEELER, AND R N WILSON FATIGUEUNDERVARIABLEAMPLITUDELOADING The Significance of Variable Amplitude Fatigue Testing D SCH~3TZ 201 AND P HEULER Spectrum Fatigue Life Assessment of Notched Specimens Using a Fracture Mechanics Based Approach M VORMWALD, P HEULER, AND C KRAE 221 Spectrum Fatigue Testing Using Dedicated Software c MARQUISANDJ SOLIN 241 A Computerized Variable Amplitude Fatigue Crack Growth Rate Test Control System J A JOYCEAND W WRIGHT 257 Automated Fatigue Test System for Spectrum Loading Simulation of Railroad Rail Cracks D A JABLONSKI 273 High-Cycle Fatigue of Austenitic (316L) and Ferritic (A508) Steels Under Gaussian Random LoadingwJ.-P GAUTHIER, C A M Z A L L A G , J.-A LE DUFF, AND E.-S DIAZ 286 Crack Closure Measurements and Analysis of Fatigue Crack Propagation Under Variable Amplitude Loading c AMZALLAG,J.-A LE DUFF, C ROBIN,AND G MOTTET 311 A Fatigue Crack Propagation Model Under Variable Loading J GERALDAND 334 A MENEGAZZI Sensitivity of Equivalent Load Crack Propagation Life Assessment to Cycle-Counting Technique E LE PAUTREMAT,M OLAGNON, 353 AND A BIGNONNET FATIGUE AND F R A C T U R E A N A L Y S I S AND SIMULATION Fatigue Life Prediction Under Periodical or Random Muitiaxial Stress States-369 J.-L ROBERT, M FOGUE, AND J B A H U A U D Nenber-Based Life Prediction Procedure for Mnltiaxially Loaded Components-D H A N S C H M A N N , E MALDFELD, AND H NOWACK 388 Fatigue Test Methods and Damage Models Used by the SNCF for Railway Vehicle Structures A LELUAN 405 Load Simulation Test System for Agricultural Tractors K NISHIZAKI 419 Applying Contemporary Life Assessment Techniques to the Evaluation of Urban Bus Structures M M DE FREITAS, N M MAIA, J MONTALVAO E AND J D SILVA SILVA, 428 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:20:12 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized Fatigue and Fracture Analysis of Type 316L Thin-Walled Piping for Heavy Water Reactors: Crack Growth Prediction Over 60 Years (With and Without Stratification) and Flawed Pipe Testing A B POOLE 443 A Rule-Based System for Estimating High-Temperature Fatigue Life 466 P J B O N A C U S E Optimum Fracture Control Plan for Gas Turbine Engine Components T LASSEN 477 APPLICATIONS AND PREDICTION M E T H O D S Prediction of the Fatigue Life of Mechanical Structures -J.-E FLAVENOT 493 Fatigue Testing and Life Prediction for Notched Specimens of 2024 and 7010 Alloys Subjected to Aeronautical Spectra -c BLEUZEN, M CHAUDONNERET, L FARCY, J.-E FLAVENOT, AND N R A N G A N A T H A N 508 Using Maximum Likelihood Techniques in Evaluating Fatigue Crack Growth Curves -s E CUNNINGHAM AND C G ANNIS, JR 531 Advances in Hysteresis Loop Analysis and Interpretation by Low-Cycle Fatigue Test Computerization -G DEGALLA1X, P HOTTEBART, A SEDDOUKI, AND S DEGALLAIX Thermal-Mechanical Fatigue Testing A 546 KOSTER, E FLEURY, E VASSEUR, AND L REMY 563 Measurement of Transformation Strain During Fatigue Testing a w NEU AND H SEHITOGLU An Automatic Ultrasonic Fatigue Testing System for Studying Low Crack Growth at Room and High Temperatures -T wu, J NI, AND C BATHIAS 58 l 598 Database for Aluminum Fatigue DesigneD KOSTEAS,R ONDRA,AND W W SANDERS, JR Material Data Banks: Design and Use, an Example in the Automotive IndustrynA DIBOINE 608 622 Hypertext and Expert Systems Application in Fatigue Assessment and Advice-C A M c M A H O N , S BANERJEE, J H SIMS WILLIAMS, AND J DEVLUKIA 634 A Software System for the Enhancement of Laboratory Calculations A GALTIER 648 Author Index 657 Subject Index 659 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:20:12 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized STP1231-EB/Dec 1994 Overview In the diverse and complex technology of fatigue and fracture, it is increasingly important for societies and engirieers to exchange information of mutual interest It is thus critical to provide forums, such as the subject symposium, to allow for open exchange With knowledge of the needs of industry, researchers gain insight valuable in assuring their focus is on meaningful topics Armed with the latest developments from the research community, engineers, in turn, are able to apply and validate these concepts and findings from the research community The goal of the Symposium on Automation and Fatigue and Fracture: Testing and Analysis, was to be just such a forum on an international scale Developers of testing methodology, researchers and scientists who evaluate and predict materials response, and engineers who apply the results to current day challenges in industry joined together to reflect on recent achievements in the areas of: Automated testing systems and methods, Models and methods for predicting fatigue life under complex loading, Fatigue and fracture analysis and simulation, and Applications and prediction methods This collaboration resulted in the presentation of 45 papers to an audience of around 150 technologists, representing more than 18 countries and continents The broad range of topics describe how advancements in digital computer hardware and software have opened up new opportunities in mechanical testing, modeling of physical processes, data analysis and interpretation, and, finally, applications in engineering environments This volume is offered as a valuable source of information for all those interested in deepening their understanding of fatigue and fracture phenomena It is the hope of all involved that this may spawn yet further ideas and innovations in applying multidisciplinary technologies to testing and analysis automation, which in turn may open new doors of understanding C Amzallag IRSID-Unieux, France; symposium chairman and editor Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:20:12 EST 2015 Copyright9 1994 www.astm.org Downloaded/printed byby ASTM International University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized Automated Testing Systems and Methods Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:20:12 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized A r t h u r A Braun t A Historical Overview and Discussion of Computer-Aided Materials Testing REFERENCE: Braun, A A., "A Historical Overview and Discussion of Computer-Aided Materials Testing," Automation in Fatigue and Fracture: Testing and Analysis, ASTM STP 1231, C Amzallag, Ed., American Society for Testing and Materials, Philadelphia, 1994, pp 5-17 ABSTRACT: Consistency of test data has always been a key concern in any materials testing application Test technique or method, operator skill and experience, and capabilities of the apparatus are all parameters that affect the consistency of the desired information The arrival of testing automation has contributed significantly to improving the consistency of materials testing apparatus, modifying existing test methods, creating new test methods due to enhanced capability, and improving the productivity of testing systems This paper surveys the development of computer-aided testing over the last 20 to 25 years and includes a discussion of current systems implementations and the emerging area of laboratory-wide automation The rapid development of materials testing automation capability has generally tracked the trends in the computer industry Advances in microprocessor hardware technology have driven testing automation by allowing for embedded intelligence in key test system components and by allowing for high-performance supervisory computer subsystems to control or supervise the overall test rig Software technology advances in concert with expanding hardware capability have provided truly useful real-time operating environments, more efficient applications development tools, and higher productivity through more intuitive user interface technology All together, these technology improvements have allowed for more sophisticated, consistent, and higher performance testing automation Further improvements will be realized through the true utilization of the emerging digitally based systems architectures and emerging networking technology This discussion concludes with a brief look at where emerging capabilities such as these will allow for new types of experiments to be performed and where information management will be enhanced, thus allowing for greater productivity in the test laboratory KEY WORDS: materials testing, test automation, controls, data acquisition, historical survey, fatigue (materials), fracture (materials), data analysis, testing methods This paper describes the historical development of automation applied to fatigue and fracture testing Automation capability for servohydraulic mechanical testing systems appeared in the late 1960s with the advent of lower-cost minicomputer capability and software options that allowed for the demanding real-time requirements of fatigue and fracture tests to be addressed As computer hardware and software improved, gains in increased test control and data acquisition performance as well as options to use the automation facility for new types of tests emerged This evolution occurred in several phases, which will be discussed here The first phase of early implementations was concerned primarily with interfacing lowercost minicomputers with the system analog controls for data acquisition and program generation Group manager, Applications Engineering, Aerospace Structures and Materials Testing, MTS Systems Corporation, Eden Prairie, MN 55344 Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:20:12 EST 2015 Copyright+ 1994 bybyASTM International www.astm.org Downloaded/printed University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized 652 A U T O M A T I O N IN FATIGUE AND FRACTURE In order to avoid overloading each file with all of the data related to its history and repeating data that is common to several test samples, we decided to classify all of the files This way, a tree structure can be created for actions, where each node has a file grouping (or factorizing) logic Each of these nodes is defined by keywords (up to five) For example, during a steel fatigue behavior study, a Wohler fully reversed tension-compression curve was established A node identified as "Wohler curve" contains a file grouping all of the results and generates two other nodes (endurance limit and Level 1) that will group, in addition to the summary file (staircase method or Henry's curve), one file for each sample tested (see Fig 4) (It would also be possible to group all of the data within a single node.) One feature of VALOTES is the arrangement of a file that describes the resulting acquisition process (machine, in our context), with its successive evolutions and possible configurations Stee4 ~1 T,~s,=~, ~-~ Oyna~rdcthe, L M~ul*clu,~e Mm9h l n l t l O G;inding ~ nmmage Un-ex~o|ed f~ T~ =r AIIoyl M(mOlOn;Cr T,sa**,~ Un-sxposed Level I He,.v W6hll~r eummaey rest eemtdeem: 2.02 3.05 1.25 Stlemi:T4mmls Fet;oue toot Machine : Viblopho*e _l JIB I l llll I[ d=,;,.g: ,,, C= I Test |lmpk* : 3.05 Rouohnell : 0.07 u~ Mean Dries= : MPe Revised suess : 420 MPa Enclunmr umlt *umm~ne Test s=,l~es : 2.02 3.O5 1.25 R : -1 E= " il W~hler curve Dynamic Reversed s,= Endurance limit Staircase m e t h o d Un-exposed Tensile Faf;OueteM Test samples : 5.21 Roughness : 0.07 ur b Moo01stlesl : O MPe Htm~ "s r summary Test ravages : 5.21 8.32 1.17 : : r,,,, - ,.~ ,= ; i I 21 " iii; Inl I IIII Level Henry : , ! FIG -Example of data organization Copyright by ASTM Int'l (all rights reserved); Wed Dec 23 19:20:12 EST 2015 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized GALTIER ON SOFTWARE FOR LABORATORY CALCULATIONS 653 The scientist looking for data will have the available to him, starting with the date of the test, the historical record as well as the precise status of the machine generating the results (see Fig that shows Vibrophore's "machine historical record" file) A second application is the arrangement of a historical record file for a test sample starting with the purchase of the material and continuing on This should be useful when looking for explanations of abnormal behavior The operator can also include new fields, data entry forms, files, nodes, etc according to his requirements Access, Retrieval, and Selection These functions should be modified for the scientist's main interests A balance between thoroughness (to avoid loss of data due to over-selective filters) and selectivity (to provide the user with a concise vision of all of the data) is necessary This feature of the software, originated with some of the choices described earlier Using a direct path, according to tree structure, "access" displays the data contained in each of the nodes "Retrieval" of one or several fields is carried out through a command line or a filter made up of fields, in the same way as the data entry forms For example, give the names of all indexed materials and list all couples (cro, Rm for the same material.) Within retrieval, the user can add a "selection" according to one or several conditions on one or several fields For example, give all triples ((rd~ = planar bending endurance limit, Cr#r = rotational bending endurance limit, and cry, = tensile endurance limit) with 400 MPa < tr~r < 800 MPa or 200 MPa < Crd/r Which materials have Rm greater than 1000 MPa? It is understood that retrieval and selection permit the use of calculation and analysis modules Note that retrieval can be limited to one or several parts of the storage tree This operation can be carried out either manually, or by selecting the keywords that are attached to the nodes For example, searching for Reo2 for all steels will be easy, provided base nodes differentiating between steels and other materials have been created MACHINE FILE Machine 9Vibrophore Identification : Description of Actions Date t 0/12/1987 Inst;~liotion of the t sensor Alignment of the anvils by bending seelsor N'2 Maximum parasitic bending = MPa Force measurment calibration by traction sensor N'I 25/04/1988 Static and dynamic calibration using sensor N~ 05/11/198~ Measurement of parasitic bending