Faigue Life Prediction PDF
Faigue Life Prediction PDF
www.elsevier.com/locate/ijfatigue
a
Department of Naval Architecture and Ocean Engineering, Polytechnic School, São Paulo University, Av. Prof. Mello Morais 2231, São
Paulo, SP 05508-900, Brazil
b
Department of Civil Engineering, Polytechnic School, São Paulo University, Av. Prof. Mello Morais 2231, São Paulo, SP 05508-900, Brazil
c
Department of Mechanical Engineering, Polytechnic School, São Paulo University, Av. Prof. Mello Morais 2231, São Paulo, SP 05508-900,
Brazil
Received 12 October 1998; received in revised form 9 February 1999; accepted 8 August 1999
Abstract
In this paper, a method is developed to calculate the fatigue lifetime of submarine pressure hulls, applying linear elastic fracture
mechanics, based on the Paris equation. It is known that this structure is submitted to high stresses caused by variable hydrostatic
pressure and residual stresses due to the welding process. The association of those variables may cause, after a certain period of
time, material fatigue and fracture. Through the application of Paris’ law, and based on an initial crack size, the crack size after a
given number of load cycles, defined by the number of submarine dives, is obtained, furnishing information for possible pressure
hull maintenance action, regarding crack repairs. 1999 Elsevier Science Ltd. All rights reserved.
0142-1123/00/$ - see front matter 1999 Elsevier Science Ltd. All rights reserved.
PII: S 0 1 4 2 - 1 1 2 3 ( 9 9 ) 0 0 1 0 2 - 4
42 L.B.R. Robles et al. / International Journal of Fatigue 22 (2000) 41–52
hull fatigue becomes more important, as submarine loads that accumulate during time, causing the pressure
structural projects consider the application of high resist- hull fatigue process.
ance steels for hull construction, requiring more sophisti- The typical structure of a submarine is a cylindrical
cated welding processes, taking into account the follow- pressure hull, reinforced internally with frames and bulk-
ing problems: heads, and closed with conical hull and caps. This struc-
ture should resist the hydrostatic pressure that it will be
1. The welding of high strength steels should be carried submitted to during underwater operation [2].
out with more care, considering the high degree of
difficulty in preventing the occurrence of imperfec- 2.1. Considerations about fatigue of the pressure hull
tions in the welded materials, when compared with
steels of less strength. Submarine pressure hull fatigue has been analysed
2. High strength steels usually present a reduction in the many times since the beginning of the 1960s, after the
fracture toughness with an increase of the mechanical development of submarines using nuclear power, due to
strength. This reduction can imply a decrease of the the fact that they could operate for longer periods of
estimated fatigue lifetime for the structure, from the time, and at greater depths underwater than diesel-elec-
point of view of the process of crack propagation tric submarines, usually used by navies at that time [3].
under the action of cyclic stress. Several researchers have studied fatigue-induced
crack propagation in submarine pressure hulls. Dunham
The fatigue lifetime calculation for a structure, during [4] and Kilpatrick [5] conducted experiments with mod-
its operational phases is usually executed with the aid els of pressure hulls, submitted to the action of oscillat-
of empirical or semi-empirical theoretical relationships ing external pressure, monitoring crack propagation in
that try to analyse the phenomenon of crack propagation. the structure. The authors concluded that cracks grow in
Linear–elastic or elastic–plastic fracture mechanics the pressure hull inner part, in the toe of the welds, and
allow the calculation of the critical dimensions of the propagate first around the circumference of the pressure
flaw or defect, which for a given material type and under hull, becoming a long circumferential crack, and then
specific mechanical loading, will originate an unstable propagating through the thickness of the pressure hull
propagation, inducing the fracture of the component. [6].
With regard to submarine pressure hull fatigue analy- These authors also concluded that pressure hull struc-
sis, in addition to the definition of the external and tural geometry, the magnitude of cyclic hydrostatic load-
internal cyclic loads acting on the structure due to ing and initial crack size are essential parameters for the
applied hydrostatic pressure and the action of residual evaluation of pressure hull fatigue damage.
stress, it is necessary to estimate the size and the
geometry of the defects introduced into the structure dur-
2.2. Crack growth propagation model
ing the manufacturing steps, and the material mechanical
properties such as Paris’ law constants and fracture
toughness, which represent the parameters that govern Linear elastic fracture mechanics describe the fracture
fatigue crack growth and unstable fracture. resistance of a structure in terms of a parameter named
In this paper, a method is proposed for calculation of stress intensity factor (K), which depends on the
the fatigue lifetime of submarine pressure hulls, taking geometry of the structure, the crack size and stress
into consideration the oscillating nature of the stress induced by internal or external loads.
induced by hydrostatic pressure during the immersion Paris and Erdogan [7] developed a semi-empirical
and submersion periods, the presence of physical defects relationship that relates the rate of crack growth (da/dN)
introduced by the welding process, such as cracks, and with the variation of the stress intensity factor range ⌬K,
also thermally induced residual stress. including a dependence relationship with a constant (C)
and a coefficient (m) obtained experimentally, which
characterize the material. This relationship is showed
2. Submarine structure below:
da
A submarine is by definition ‘A vessel that works or ⫽C(⌬K)m (1)
dN
usually operates below the surface of the water.’ In the
naval sense the submarine operates in great oceans and where da/dN is the fatigue-crack-growth rate,
seas in a salt water environment. When submerged, the ⌬K=Kmax⫺Kmin is the stress-intensity factor range, and
hull is under external hydrostatic pressure, which is Kmax and Kmin are the maximum and minimum values of
dependent on the depth at which the vessel is operating. K in cyclic loading, related to the maximum and mini-
So, the constant variations of depth, related to the mili- mum stresses in the load cycle.
tary aspects of the vessel’s mission, generate cycles of Linear elastic fracture mechanics considers a small
L.B.R. Robles et al. / International Journal of Fatigue 22 (2000) 41–52 43
plastic deformation ahead of the crack tip [8,9]. If the Furthermore, in these areas, due to the hull construc-
plastic zone is large compared to the crack size, a correc- tion planning, there are several welding lines that can
tion in the stress intensity factor must be considered, in induce the presence of residual stress and cracks.
order to account for the effects of this plastic zone. Paris’ Therefore, regarding crack growth under cyclic load-
law is employed in the model of pressure hull fatigue ing, these areas can be considered to be the most critical
analysis. for fatigue analysed in this study, the most critical area
is a cone–cone intersection, near the stern of the submar-
ine.
3. Method of fatigue lifetime calculation The conclusion of this theorical study is similar to
the experimental results presented by Kilpatrick [5], and
As for fatigue analysis, the definition of the structural Dunham [4], where fatigue failure, defined by crack
detail that is submitted to the highest stress is very growth under cyclic loading, until hull perforation,
important, because it is the most probable region for always happened in the areas where there were intersec-
fatigue failure. tions of two axisymetrical solids, and close to welding
Considering the typical structure of a submarine press- lines.
ure hull, shown in Fig. 1, a great amount of stress analy-
sis was executed by the authors, employing analytical 3.1. Crack model
semi-empirical and numerical methods, such as the finite
element method, considering as external loading hydro- Considering the analysis related above, in this study
static pressure, in order to define the stress distribution we will consider a crack along the circumference of the
in several areas of the hull. hull, in the cone–cone intersection, close to the weld line
It was verified that the most critical areas for fatigue that joins the two solids. The growth of the crack depth
evaluation are the intersection between two axisymetr- through the thickness is considered to be constant along
ical solids, such as cone–cylinder, cone–cap, or between the circumference of the hull. The model of the crack
two cones with different conicity, due to the high stress assumes a plane strain condition, where the relationship
acting on these areas induced by hydrostatic loading. of the circumferential stress (sq) and the longitudinal
3.2. Calculation of stress intensity factor Fig. 3. Model for moment bending [10].
冕
(afinal)k
and considering many crack depths. These results will
1
be obtained according to Eq. (6), as a combination of Nk⫽ (⌬K(a)k)−mda (8)
the stress intensity factors calculated for the effects C
(ainitial)k
of the external load, as well as for the effect of the
residual stress, as a function of crack length. These where (ainitial)k is the initial value of the crack depth
values will be presented in the form of tables and in the instant that the submarine enters the range of
graphs. depth k, (afinal)k is the final value of the crack depth
2. Compute the stress intensity range, considering a in the instant that the submarine leaves the range of
given crack depth and a given stress range, equivalent the depth k, Nk is the number of cycles that the sub-
to a variation of the operational depth of the submar- marine has to execute in the range of the depth k,
ine. This stress intensity range is defined as: varying among the quotas i and j, until the crack
reaches the (afinal)k.
(⌬KI)k⫽(KI)i⫺(KI)j (7)
For a group of specific operational depth ranges,
where i and j are indicative of the depth quotas pre- considering a given initial crack depth, the number of
established by the analyst, in function of the probable cycles necessary for the crack to grow to a given final
missions of the submarine, and k is the index that crack depth can be defined through the application of
identifies the range of the variation of the referring Eq. (8), and the date can be shown in a graphical
stress to the quotas of the indexes i and j. form, as shown in Fig. 7.
Considering a given crack depth, the stress inten- 4. Define the operational profile of the submarine, con-
sity factor range can be related to that crack depth, sidering the number of dives that the submarine will
according to a given submarine depth operational do, classifying the variation in operational depth
range. So, a graphical representation of the stress ranges in each of these dives according to the depth
intensity factor range according to a given crack depth operational range defined in (2). Put the classified
46 L.B.R. Robles et al. / International Journal of Fatigue 22 (2000) 41–52
Fig. 6. Stress intensity range (⌬K) as a function of the operational depth range and crack depth (a).
Fig. 7. Number of cycles in a given depth operational range for the crack growth to a specific depth.
dive sequence in a given order, such as, the submarine for the dive sequence defined in item (4), it is possible
will first dive according to operational range 1, then to define the expected final crack depth at the end of
according to operational range 4, and so on. This this operational sequence.
diving sequence is defined by the submarine designer 7. The maximum crack depth admissible for the submar-
or by the submarine operator or according to a deal ine structure is defined through the application of the
between them. linear elastic fracture mechanics concepts, where
5. Considering the given initial crack depth, and the first there will be an unstable fracture when the stress
sequence of dive, for example N1 diving cycles in intensity factor defined by Eq. (6) equals the material
operational range 1, it is possible to define, through critical stress intensity factor (KIC). This maximum
the graphical representation shown in Fig. 8, the final crack depth is defined as:
crack depth at the end of this diving cycle.
KT(acritical)⫽KIC (9)
6. The afinal crack depth, defined in (5), will be used as
the ainitial crack depth for the second sequence of dive 8. If the crack depth defined at the end of step 1 is bigger
in a given operational range, and repeating the pro- than the critical crack depth, the pressure hull struc-
cedure shown in (5), the crack depth at the final dive ture will present unstable fatigue fracture during the
of the sequence is defined. Applying this procedure previously predicted operational life. So the oper-
L.B.R. Robles et al. / International Journal of Fatigue 22 (2000) 41–52 47
ational dive sequence must be changed or the struc- slint(hmax)=⫺301.7 MPa, which is the longitudinal nor-
tural design must be reviewed, in order to fulfil the mal stress in the internal face of the plate at the
requirements of the operational life of the submarine. maximum operation depth.
Applying the integral defined in Eq. (8), for the slext(hmax)=⫺18.82 MPa, which is the longitudinal nor-
operational range, in the device sequence where the mal stress in the external face of the plate at the
final crack depth is expected to be bigger than the maximum operation depth.
critical crack depth, and defining afinal equal to acritical,
it is possible to define the maximum number of diving Based on these results, knowing that the distribution of
cycles for this operational range, in order to prevent the membrane stress and bending stress are dependent
unstable fracture; this number of cycles is named Np. on the operational depth (h), the following equations are
9. The total number of diving cycles for the submarine obtained, to express the hydrostatic pressure-induced
could be defined as the sum of the number of diving stress acting on the submarine pressure hull:
cycles defined for each operational range, the number
of cycles (Nv) is N1+N2+…Np, where Np was defined h
slext⫽slext(hmax) (10)
in item (8). hmax
h
slint⫽slint(hmax) (11)
hmax
4. Application of the method of calculation slint−slext h
sF(h)⫽ (12)
2 hmax
In this section, the methodology for pressure hull
fatigue evaluation will be applied to the submarine, the sn(h)⫽slint⫺sF(h) (13)
structural plan of which is presented in Fig. 1. The struc-
ture of this submarine is constructed with HY-80 high
strength structural steel, and the analysis will be made
for the cone–cone connection. slext(hmax), longitudinal normal stress in the external
part of the plate at the maximum depth.
4.1. Stress due to hydrostatic pressure slint(hmax), longitudinal normal stress in the internal
part of the plate at the maximum depth.
The stress is calculated using a hydrostatic pressure slint, longitudinal normal stress in the internal part of
of 2.5 MPa (250 m of maximum depth of the submarine) the plate at an operational depth h.
applied on the external face of the pressure hull plate, slext, longitudinal normal stress in the external part of
in the cone–cone connection region, as shown in Fig. 1. the plate at an operational depth h.
Thus, employing the finite element program Algor sF(h), stress that generates bending at an operational
[14] to model this structural region, the following results depth h.
were obtained for the stress action on the pressure hull sn(h), stress that generates compression at an oper-
at the cone–cone connection: ational depth h.
48 L.B.R. Robles et al. / International Journal of Fatigue 22 (2000) 41–52
Fig. 10. Stress intensity factor Vs crack depth, with correction due to plasticity.
Fig. 11. Variation of the stress intensity factor (⌬K) Vs depth of crack.
冕
a
107 mm just for numerical analysis.
N⫽ (⌬K(a))−2.25da ⌬KI⫺MPa. In Fig. 13, schematically representing Fig. 12, is
1.3534
0.2 shown the process of calculation of the total number of
50 L.B.R. Robles et al. / International Journal of Fatigue 22 (2000) 41–52
Fig. 12. Lifetime of the fatigue in cycles (N) Vs depth of the crack (a).
cycles for fatigue occurrence, being the supposed differ- crack depth is smaller than the maximum allowed crack
ent numbers of cycles, Ni, being realized in different depth, the procedure is repeated for more operational life
operational depth ranges and in a certain sequence, cycles, for one and a half years, always considering the
defined by the typical mission of the submarine through- final crack depth at the end of one operational life cycle
out its lifetime. In order to define the crack growth as the initial crack depth at the beginning of another
throughout the submarine’s operational life, an oper- operational life cycle. The results of this calculation pro-
ational depth classification was developed, taking into cedure are shown graphically in Fig. 14, for the typical
consideration the maneuvers executed by a submarine operational profile that was adopted, where the expected
similar to the analysis in this study, during one and half crack depth is presented as a function of the years pre-
years. The operational depth ranges, in meters, employed dicted for the operational life of the submarine.
in this study are: (50–0), (150–0), (100–0), (200–50), Based on the results presented in Fig. 14, it can be
(250–150), (250–50), (250–0). seen that, for the typical operational depth cycle
Applying items (5) to (9) of the fatigue lifetime algor- employed in this paper corresponding to operational
ithm, the behavior of the crack growth is a function of cycles of one and a half years, the maximum crack depth
the number of cycles of dives, for several operational allowable for the pressure hull structure will be achieved
ranges. Thus, given an operational range when the sub- after 40 years of the submarine’s operational life, that is
marine goes from a depth of 0 to 250 m (⌬H=250–0), almost twice the usual life of military submarines.
with an initial crack depth (a(initial)1), diving N1 cycles in Furthermore, at the beginning of the operational life
this range, a depth for the final crack a2 will be obtained, the crack growth is very small, becoming greater after
which will be the initial crack for the following oper- the 20 operational years.
ation. If the submarine dives, for example, in another This fact strengthens the necessity for detailed struc-
operational depth range ⌬H=250–50, etc. a new dimen- tural inspections of the submarine pressure hull during
sion of the crack at the end of this dive cycle will be its operational life, especially when it is close to its orig-
obtained. This procedure is repeated, successively, to inal predicted operational lifetime, because the crack can
other operational depth ranges, covering the typical dive grow very fast after this period of time.
profile for one and half years of the submarine’s life. Finally, it must be remembered that the crack growth
At the end of this procedure, the crack depth at the history presented is dependent on the dive cycle esti-
end of this operational life cycle is defined. As the final mated for the submarine. Any change in this cycle will