PSI - Issue 18

Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2019) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2019) 000–000 ScienceDirect

www.elsevier.com/locate/procedia

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ScienceDirect

Procedia Structural Integrity 18 (2019) 490–500

© 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. © 2019 The Authors. Published by Elsevier B.V. P er-review under r sponsibility of the Gruppo Italiano Frattura (IGF) ExCo. Keywords: Cyclic material behavior, Fatigue Life Curve, digital twin 25th International Conference on Fracture and Structural Integrity Description of the cyclic material behaviour of aluminium wrought alloys as basis for a digital twin Rainer Wagener, Andreas Maciolek, Heinz Kaufmann Fraunhofer Institute for Structural Durability and System Reliability LBF, Bartningstraße 47, 64289 Darmstadt, Germany Abstract In order to consider the cyclic material behaviour during the design process of cyclically loaded components and safety relevant parts, the importance of local strain-based fatigue design approaches is growing continuously. For the damage impact of load ‐ time histories on components such as chassis parts, standard service loads with amplitudes settled in the High Cycle Fatigue (HCF) and Very High Cycle Fatigue (VHCF) regime, as well as overloads and misuse with load amplitudes in the Low Cycle Fatigue (LCF) regime, must be considered in order to perform a reliable fatigue life estimation. Therefore, a continuous fatigue life curve from the LCF up to the VHCF regime, which covers all relevant damage mechanisms, is required. In the case of aluminium wrought alloys the tri-linear strain-life curve, which has been developed and validated during previous research, enhances the accuracy of the mathematical approximation of test results. Due to this reason, the tri-linear strain-life curve is qualified for the integration into a digital twin, considering the requirements of fatigue and structural durability. 25th International Conference on Fracture and Structural Integrity Description of the cyclic material behaviour of aluminium wrought alloys as basis for a digital twin Rainer Wagener, Andreas Maciolek, Heinz Kaufmann Fraunhofer Institute for Structural Durability and System Reliability LBF, Bartningstraße 47, 64289 Darmstadt, Germany Abstract In order to consider the cyclic material behaviour during the design process of cyclically loaded components and safety relevant parts, the importance of local strain-based fatigue design approaches is growing continuously. For the damage impact of load ‐ time histories on compone ts such as chassis parts, standard service loads with a plitudes s ttled in the High Cycle Fatigue (HCF) and Very High Cycle Fatigue (VHCF) regime, as well as overloads and misuse with load amplitud s in the Low Cycle Fati ue (LCF) regime, must be considered in order to perform a reliable fatigue life estimation. Therefore, onti uous fatigue life curve from the LCF up to the VHCF regim , which covers all relevant damage mech nisms, is r q ired. In the case of aluminium wrought lloys the tri-linear strain-lif curve, which has been developed and validated during previous research, enhances the accuracy of the mathematical approximation of test results. Due to this reason, the tri-linear strain-life curve is qualified for the integration into a digital twin, considering the requirements of fatigue and structural durability. 1. Introduction In the course of the ongoing digitisation, the product development of metal components and structures will be performed in virtual environments. In order to obtain a high-quality product that can be used for safety components under cyclic loading conditions, the fatigue assessment including the structure optimisation with respect to the component-related material behaviour has to be executed numerically. Therefore, the local component-related material behaviour must be available and considered. Due to the production process consisting of metal forming and heat treatment, the material properties are distributed with local gradients. Moreover, in view of the industrial needs for low development time and numerical effort, the requirement to integrate the aspect of fatigue in a digital twin is growing and only accomplishable with an adjusted numerical concept with optimised parameters. Referring to the 1. Introduction In the course of the ongoing digitisation, the product development of metal components and structures will be performed in virtual environments. In order to obtain a high-quality product that can be used for safety components under cyclic loading conditions, the fatigue assessment including the structure optimisation with respect to the component-related material behaviour has to be executed numerically. Therefore, the local component-related material behaviour must be available and considered. Due to the production process consisting of metal forming and heat treatment, the material properties are distributed with local gradients. Moreover, in view of the industrial needs for low development time and numerical effort, the requirement to integrate the aspect of fatigue in a digital twin is growing and only accomplishable with an adjusted numerical concept with optimised parameters. Referring to the Keywords: Cyclic material behavior, Fatigue Life Curve, digital twin

2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. 2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo.

2452-3216  2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. 10.1016/j.prostr.2019.08.191