Strength of mining and building equipment materials subjected to gigacycle loading.
Leonavicius, Mindaugas Kazimieras ; Petraitis, Gediminas ; Suksta, Marijonas 等
Abstract. High-strength cast iron is used for manufacturing the
supporting elements of minerals and cement clinker grinding machines.
The dross layer remains inside large dimension castings after
manufacturing. It has worse mechanical properties and resistance to
fatigue crack formation and propagation. In this paper, the results of
an experimental investigation of cyclic bending strength of semi-natural
specimens from cast iron with a dross layer of 10-11 mm thickness are
presented. The mechanical properties and structures of the base and
dross layers differed considerably. Before testing the methods of
defectoscopy were applied to detect technology defects. The stress ratio
was r = -0,62 and the stress alternating range varied from 70 to 280
MPa. To 1 x [10.sup.8] cycles, crack growth was insignificant. Further
crack propagation was controlled. The 1st specimen was broken after 3 x
[10.sup.8] and the 2nd one after 2 x [10.sup.8] cycles. The dependencies
of crack propagation on cycle number and stress intensity factor range
were estimated. The dross layer stops crack propagation, when crack
front passes from dross to base metal.
Keywords: clinker mills, fatigue, crack propagation, stress
intensity threshold.
1. Introduction
The problems of strength and reliability of newly built and old
buildings are closely connected with mechanical properties of the
materials used and the ability of cracked structural elements to resist
the environmental effects. The use of new materials, methods of
calculation and criteria at the stage of design can ensure safe service
of newly designed buildings. In the elements or structures which have
been in service for some time, permanent deformations may occur or the
mechanical properties of materials may change due to variable loads.
Therefore, to increase the guaranteed life of such structural units,
they should be renewed (sometimes, even replaced), by the systems of
elements ensuring their further safe service. Any strength theory or
method of calculation should be based on modern research and experiments
as well as on analytic studies and numerical analysis aimed at
evaluating the mechanical state of any structural element. The failures
of actual bodies depend on their structure, chemical composition, type
of loading, defects, environmental effects and other factors. Therefore,
in order to determine the strength of a solid body or to predict and
control its failure, the parameters of micro and macro failure processes
should be considered [1-6].
The problems of fatigue strength associated with the failure of
metal units under variable cyclic load which is far below the fatigue
limit have been known for a long time now, however, their analysis is
still needed. In recent years, a great emphasis has been placed on
investigating gigacycle fatigue when the number of cycles is above
[10.sup.9]. The well-known investigations in this area were performed by
Bathias [6]. The extension of the fatigue limit is associated with the
fact that at present the service life of the most critical structures
reaches 50-100 years. The investigations have shown that under
[10.sup.8]-[10.sup.9] loading cycles, the fatigue limit in the above
range decreases; therefore, the conception of unlimited durability in
the range of stresses below the limit is not true. Therefore, the
methods used so far to determine the service life of structural elements
can hardly yield reliable results. It is mainly accounted for by the
changes of the causes and mechanisms of fatigue crack formation and
failure of structures, which, despite intense research, still remain
unexplained for fatigue caused by gigacycle loading [7-9]. The research
of this phenomenon is complicated because it is difficult to determine
the extent of failure and defects under a small range of loads by
non-destructive testing. Methods of controlling fatigue crack formation
under a large number of loading cycles based on well-known physical
phenomena are needed.
2. Loading analysis
According to Makhutov [9], fatigue has some specific features,
depending on the number of cycles and failure mechanisms. They are as
follows: [10.sup.0]-[10.sup.1] decacycle failure influenced by emergency
factors;
[10.sup.0]-[10.sup.3] hectocycle fatigue characterised by large
microplastic deformations in a failure zone at macrostructural level;
[10.sup.3]-[10.sup.5] kilocycle fatigue observed in the presence of
relatively small macroplastic deformations in a failure zone at
macroscopic level;
[10.sup.5]-[10.sup.8] megacycle fatigue developing in the presence
of microplastic deformations at micro- and macroscopic level near a
failure zone;
[10.sup.8]-[10.sup.9] gigacycle fatigue failure occurring under a
great number of loading cycles and microplastic deformations at
microscopic level near a failure zone;
[10.sup.10]-[10.sup.12] teracycle fatigue observed under a very
great number of loading cycles, with the deformations occurring at
macrostructural level.
The performance of complex structures and equipment is associated
with variable external loads of particular elements, with the number of
cycles ranging from [10.sup.0] to [10.sup.9]. To ensure durability
(longevity) of these structures, their installation, use, emergency
operation, control and technological modes should be considered and
based on theoretical research and practical testing.
To ensure the strength and reliability of large buildings, power
plants, vehicles and mining equipment, methods of calculation based on
the theories of elasticity, plasticity, adaptability and failure are
used. These methods rely on the analysis of the conditions of structural
element loading and deformation as well as on theoretical research and
testing.
For many structures, including mining machinery, the service
problems are similar. In Fig 1 the variation of loading parameters of
various structures under operational conditions is shown [9].
[FIGURE 1 OMITTED]
Loading parameters include mechanical, electromagnetic, inertial
and gravitational loads, pressure, and temperature. These factors
generate stresses [sigma] ([[sigma].sub.max], [[sigma].sub.min],
[[sigma].sub.a], [DELTA][sigma]) and deformations. The operational time
t of a structure may be divided into the stages of installation, testing
(with the number of cycles [10.sup.0]-[10.sup.1]), putting into
operation, regulation of power and braking (with the number of cycles
[10.sup.2]-[10.sup.3]), as well as technological, control, vibration,
local pulsation, stationary operation modes (with the number of cycles
[10.sup.4]-[10.sup.12]) and the emergency modes (with the number of
cycles [10.sup.0]-[10.sup.1]). At these stages the loading parameters
vary. For instance, under emergency conditions, stresses can exceed the
yield stress and the ultimate strength. This causes dynamic, static or
quasi-static failure. In structures under stationary conditions of
operation, the rated stresses should not exceed the yield stress. They
are usually lower than the limit of proportionality, ie [sigma] <<
[[sigma].sub.pr] (stationary vibration modes). The lower the values of
cycling load, the longer the fatigue life. The mechanisms of crack
formation and propagation change when fatigue enters the gigacycle and a
higher range. The load at other stages may vary within a wide range of
values.
Structural and technological non-homogeneity of large elements in
operational conditions leads to the formation of fatigue crack, causing
its propagation and a complete failure of the element. However, the
structures do not collapse immediately after the fracture process
appearance inside the structural elements. Therefore, metal parts with
cracks can operate for a long time. Failure caused by fatigue takes
place in the following stages: (1) microcrack formation, (2) small
cracks propagation, (3) propagation of large cracks and (4) ultimate
failure. The first two stages are usually referred to as crack
formation, while the growth of large cracks is called crack propagation.
It is hardly possible to determine the transition of the developed crack
to the stage of propagation. However, the period of crack formation
largely determines the service life of an element, especially, under
cyclic fatigue conditions. The durability service life) of structures
and elements subject to cyclic loads is the sum of the cycles number
before crack formation Ni and the number of cycles in the period of
crack propagation, when it grows from the initial to critical length Np
as shown in Fig 2a representing the relationship between the service
life of mechanical elements and the interval .o between stresses [10].
The [DELTA][[sigma].sub.FL] is the interval between stresses
corresponding to the fatigue limit.
[FIGURE 2 OMITTED]
The design longevity of many presently operating devices has
finished or is drawing to an end. Determining the remaining longevity is
an important factor for assuring the safety of operating objects. The
diagram of the longevity distribution of construction elements with
defects is shown in Fig 2b. Excluding non-allowable operation states,
the allowable crack size may be:
[h.sub.adm max] > [h.sub.adm] > [h.sub.d adm], (1)
where [h.sub.adm max] is the operational marginal size of the crack
which must never be exceeded because the component may break;
[h.sub.adm] is the allowable control size of the crack determined by
non-destructing control methods; [h.sub.d adm] is the marginal size of
the non-propagating crack (the present crack does not propagate under
operational loading).
Making use of the obtained dependencies of crack propagation it is
possible to determine the duration of operation. The longevity of the
structures from the initial value [h.sub.0] to the critical size
[h.sub.c] (it might reach the allowable regulating value) is determined
by the number cycles N. Structural units and elements of massive and
expensive mills and crushers' equipment are paid special attention
in design and operation because they determine the performance of the
whole structure. Rock crushers and clinker mills are drums or cylinders
which, when revolving, cause clods loaded in them to rub against each
other and thus to break spontaneously. Drums are set in rotary motion by
large-diameter gear drives (Fig 3).
[FIGURE 3 OMITTED]
The early crushing mills with autogenous grinding had quite a lot
design defects causing frequent failures of the equipment. The use of
the mills has revealed that their structure does not meet the
requirements. Larger and more efficient and reliable crushing mills were
needed. Some structural elements of the mills are now made of
high-strength cast iron (eg elements of their bodies and bearing
elements) and high-strength austempered ductile cast iron (ADI) (eg gear
drives) to meet the requirement of more than 25 year-service life.
Casting causes some foreign material (dross) and scum to deposit on
the surface of bearing units. This material of muddy structure shown in
Fig 4 can cover smaller or larger surface areas, considerably decreasing
wall thickness of a casting. In casting practice the thickness of dross
layer can be up to [b.sub.1]=12 mm. The efforts are made to eliminate
the dross, however minor part may remain. Usually, this material cannot
be detected by non-destructive testing. This layer can be described as
the damaged area. The crack propagation characteristics in such irons
were investigated [11, 12]. Thermal treatment has only a slight effect
on it. Static mechanical properties of a deposit are usually worse than
those of a base metal. If the above material is formed in the
cross-section, it is subjected to varying load. Therefore, the strength
and durability of an element depend on the layer of some foreign matter.
It particularly applies to gigacycle range below the endurance limit,
since inclusions of non-homogeneous material and other defects cause
crack formation.
[FIGURE 4 OMITTED]
3. Experiment. Analytical analysis
The specimens were prepared according to real structures, using the
same manufacturing technology. The dross layer thickness was about 10-11
mm. The structure of the base, transitional and dross layers, were
subjected to additional metallographic analyses. In the base layer, the
graphite is spherical in shape. In the transitional layer, the graphite
is in shape of flakes. The structure of porous layer consists of flakes,
plates, inserts, different shape cavities, and non-homogeneous
formations. Mechanical properties have been determined after making 3
standard cylindrical tension specimens from the base and dross layers
with diameter of 10 mm of proving section. The mechanical properties
obtained are shown in Table 1.
The specimens of a rectangular cross-section were applied to pure
bending (four point) so that in external layers of proving section (l =
94 mm) the maximum stresses rise, ie, the maximum stresses rise in the
dross layer.
Before testing, the specimens were analysed by the methods of
defectoscopy. Luminescence magnetic method was applied to determine
small defects. During the cyclic loading the test machines were
periodically stopped to measure the propagation of cracks on
non-machined surfaces of dross layer. According to the loading program
up to [10.sup.8] cycles, the maximum stress was [[sigma].sub.max] = 42,8
MPa and the minimum [[sigma].sub.min] - = -26,2 MPa with the range of
stress [DELTA][sigma] = 69 MPa. The stresses were calculated assuming
that the specimens were continuous and homogeneous. Up to [10.sup.8]
cycles the defects--cracks have increased insignificantly.
After [10.sup.8] + 2 x [10.sup.6] cycles the side walls of the
specimens were cut off by 0,5 o 1,0 mm every [10.sup.6] cycles to
specify the behaviour of the cracks deeper in the metal. The cutting
scheme is in Fig 5. It helped better determine the cracks behaviour at a
particular cycle number and loading. The cutting enabled to observe that
some cracks had decreased and the others--increased. During the
experiments the colour imprint and the optical methods were also adopted
to measure the crack size. The cracks depths have been revised
additionally according to front shape. For stress intensity factor K
calculations, the assumption that crack front is parallel to specimens
surfaces was used. Retaining the stress ratio r = - 0,62, the stress
range was changed: [DELTA][sigma] = 69 MPa, N = 1 x [10.sup.8];
[DELTA][sigma] = 90 MPa, N = 2 x [10.sup.7]; [DELTA][sigma] = 110 MPa, N
= 2 x [10.sup.7]; [DELTA][sigma] =140 MPa, N = 2 x [10.sup.7];
[DELTA][sigma] = 150 MPa, N = 2 x [10.sup.7]; [DELTA][sigma] = 160 MPa,
N = 2 x [10.sup.7]; [DELTA][sigma] = 170 MPa, N = 2 x [10.sup.7];
[DELTA][sigma] = 180 MPa, N = 6 x [10.sup.7] (specimen 1) and
[DELTA][sigma] = 70 MPa, N = 1 x [10.sup.8]; [DELTA][sigma] = 150 MPa, N
= 2 x [10.sup.7]; [DELTA][sigma] = 160 MPa, N = 2 x [10.sup.7];
[DELTA][sigma] = 170 MPa, N = 4 x [10.sup.7]; [DELTA][sigma]= 180 MPa, N
= 1 x [10.sup.7]; [DELTA][sigma] = 200 MPa, N = 1 x [10.sup.7];
[DELTA][sigma] = 220 MPa, N = 1 x [10.sup.7]; [DELTA][sigma] = 240 MPa,
N = 1 x [10.sup.7]; [DELTA][sigma] = 260 MPa, N = 1 x [10.sup.7];
[DELTA][sigma] = 280 MPa, N = 2 x [10.sup.7] (specimen 2).
[FIGURE 5 OMITTED]
The testing programme in the gigacycle loading range was
coordinated to determine the crack appearance in the defective places
and to observe crack propagation in the dross and main layers.
In Fig 6 the extension of longitudinal cracks on the surface of the
specimens 1 and 2, depending on the number of loading cycles, is shown.
The breaks in the curve are caused by the variation of the programmed
loading. The length of the above crack is the total length of small
cracks on the trajectory of the main crack.
[FIGURE 6 OMITTED]
The main crack causing a complete failure of a specimen or an
element is formed due to a number of factors. Non-localised fatigue
crack-like defects on the specimen surface may occur in a large area
with local plastic deformation zones. A great number of unevenly spread
crack-like defects and inclusions of non-homogeneous material causing
crack formation are found in the surface structure of cast iron. Small
cracks are extending and propagating deeper in the cross-section of a
specimen under the cyclic loading.
It is interesting to observe that two main cracks have been formed
in the second specimen as a result of merging smaller cracks extending
on different planes of the specimen subjected to various numbers of
loading cycles. Under an increasing cyclic load, they are extending in
length and depth. For K determining the generalised crack depth was
used.
To define crack propagation rates, the stress intensity factor was
determined.
The assumption was made that crack propagation front is parallel to
the specimen surface. Then the stress intensity factor [K.sub.1] for
rectangular cross-section specimen in pure bending can be calculated
according to the formula:
[K.sub.1] = [sigma][square root of [pi]a] f ([alpha]), (2)
where [sigma] - maximum tensile stress in crack zone; a--initial
crack length; f(a)--geometry function:
(f) ([alpha]) = 1,122 - 1,40 [alpha] + 7,33 [[alpha].sup.2] - 13,08
[[alpha].sup.3] + 14,0 [[alpha].sup.4] (3)
where [alpha]--is the ratio of the crack length a to the specimens
width W.
Crack propagation rate versus the maximum stress intensity factor
(according to programmed loading) in two layer plates are shown in Fig
7.
[FIGURE 7 OMITTED]
To determine the stress intensity range threshold
[DELTA][K.sub.th], the CT specimens were made of the basic metal and
dross layer (their width is W = 42 mm and thickness B = 10 mm). The
dependences of crack growth rate versus the stress intensity factor
range were determined (Fig 8) by testing requirements and the specified
calculation technique (according to ASTM E 647-00). In the CT specimen
made of basic metal, the crack plane was perpendicular to bending normal
stresses.
[FIGURE 8 OMITTED]
The threshold of dross layer is [DELTA][K.sub.th] = 7,7 MPa m x
[square root of m.]
The threshold of base metal is [DELTA][K.sub.th] = 9,3 MPa [square
root of m].
In the specimen made of dross layer, crack formation and
propagation depend on many factors.
At the initial stage (crack depth 2-3 mm) crack is formed in the
area, which is under the influence of the CT specimen notch
(concentrator) and is almost perpendicular to normal stresses. The
heterogeneity and anisotropy of separate layers of material have a great
influence on further crack propagation. Cavities, heterogeneous
formations and inserts change the stress-strain state at crack tip. The
integral influences of structure on the separate segments determine the
crack propagation, thus its trajectory passes through slip planes and
cavities in various directions. On the sides of CT specimen, the crack
changes not only its direction, but split into separate fronts.
The zigzag crack path was determined by the microstructure.
Therefore the obtained dross layer's threshold [DELTA][K.sub.th] is
conditional, taking into account the assumption that a crack is
perpendicular to normal bending stresses. It should be noted that the
obtained data are similar to two specimens. The views of fractures of
semi-natural and compact tension specimens are shown in Figs 9, 10.
[FIGURES 9-10 OMITTED]
4. Discussion
The threshold of stress intensity factor range [DELTA][K.sub.th]
also depends on stress ratio, temperature, environment effect,
overloading, non-homogeneity and other factors. The investigations [1,
2] disclose the increase of threshold [DELTA][K.sub.th] and fatigue
crack growth rate under the change of stress ratio from 0 to 0,9, stress
concentration and surface conditions [13]. For practical calculations of
[DELTA][K.sub.th], by assessing the stress ratio r, can be used the
expression [1]:
[DELTA][K.sub.th] = [DELTA][K.sub.th0] [(1-r).sup.[gamma]], (4)
here [DELTA][K.sub.th0] is the limit range of stress intensity
factor, when r = 0; [gamma] is the coefficient dependent on the
material and fluctuates from 0,5 up to 1. Formula (4) shows a good
agreement for steel, when 6 , 0 0 < < r .
In the fracture mechanics the general expression of stress
intensity factor is
[K.sub.1] Y x [sigma] [square root of ([alpha] + [[alpha].sub.0])
(5)
here Y is geometric factor; [sigma] is stress, [alpha] is crack
size, [[alpha].sub.0] is structural defect size.
When [alpha] = 0, [sigma] = [[sigma].sub.R] (durability limit),
[K.sub.1] = [DELTA][K.sub.th], we shall have the threshold stress
intensity range
[DELTA][K.sub.th] = Y x [[sigma].sup.R] [square root of
([[alpha].sub.0])]. (6)
If there is a crack of the length 2l on the surface of a detail,
the crack development will be stopped, when the limit stress interval
correspondent with th [DELTA][K.sub.th] does not exceed
[DELTA][[sigma].sub.th] calculated by formula
[DELTA][[sigma].sub.th] = [DELTA][K.sub.th]/Y[square root of 21].
(7)
The obtained results of experimental and analytical investigation
of semi-natural and CT specimens may be applied to design calculations
of real structural elements. The short crack behaviour was not analysed
in this paper.
5. Conclusions
1. The mechanical characteristics, hardness and strength of the
structure differ significantly in the base and dross layers.
In the base layer, the graphite is spherical in shape. The
structure of dross layer consists of flakes, plates, inserts, different
shape cavities, and inhomogeneous formations.
2. It has been found that the ultimate strength of basic metal
([[sigma].sub.u] 507 = MPa) is 2,2 times greater than that of the dross
layer ([[sigma].sub.u] = 225 MPa). Basic metal threshold ([DELTA]
[K.sub.th] = 9,3 MPa x [square root of m]) is 1,2 times greater than
that of the porous layer ([DELTA][K.sub.th] 7,7 Mpa x [square root of
m].).
3. Testing the CT specimens taken from the dross layer has shown
that there simultaneously exist opening and shear crack surface
displacement modes.
4. The experimental and analytical investigations show that the
computation of constructions elements can be validated by stress
intensity factor of the damaged layer.
References
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MEDZIAGU, SKIRTU MALUNU IR UOLIENU SMULKINTUVU IRENGINIAMS,
ATSPARUMAS GIGACIKLEI APKROVAI
M. K. Leonavicius, G. Petraitis, M. Suksta, V. Svalbonas
Santrauka
Uolienu smulkintuvu ir cemento klinkerio malunu atraminiu mazgu
gamybai naudojamas stiprusis ketus. Dideliu matmenu detalese liejimo
proceso metu lieka nuodegu ir neaiskiu pagrindinio metalo dariniu. Ju
blogesni mechaniniu savybiu rodikliai ir geba priesintis plysio
atsiradimui bei plitimui. Straipsnyje pateikiami pusiau naturiniu
staciakampio skerspjuvio bandiniu is ketaus su 10-11 mm storio nuodegu
sluoksniu eksperimentiniai ciklinio lenkimo tyrimo rezultatai. Pries eksperimenta defektoskopijos metodu buvo nustatyti technologiniai
defektai. Ciklinio deformavimo asimetrijos koeficientas r = -0,62,
itempiu intervalas kito nuo 70 iki 280 MPa. Ciklu plysiai iki 1.108
didejo nezymiai. Toliau varginant ir didinant itempiu intervala, plysio
augimas buvo kontroliuojamas. Pirmasis bandinys suiro po 3.[10.sup.8],
antrasis--po 2 x [10.sup.8] ciklu. Eksperimentiskai nustatyta plysio
plitimo rodikliu priklausomybe nuo ciklu skaiciaus ir itempiu
intensyvumo koeficiento kitimo intervalo. Plysio plitima stabdo tarpinis
sluoksnis, pereinant nuo nuodegu sluoksnio i pagrindini metala.
Reiksminiai zodziai: uolienu trupintuvas, nuovargis, plysio
plitimas, itempiu intensyvumo slenkstis.
Mindaugas Kazimieras Leonavieius (1), Gediminas Petraitis (1),
Marijonas Suksta (1), Vytas Svalbonas (2)
(1) Dept Strength of Materials, Vilnius Gediminas Technical
University, Sauletekio al. 11, LT-10223 Vilnius, Lithuania.
(2) Metso Minerals Industries, Inc. Arch Street, P.O. Box 15312,
York, PA 17405-7312, USA. E-mail: 1marsu@fm.vtu.lt,
2vytas.svalbonas@metso.com
Mindaugas Kazimieras LEONAVIEIUS. Prof Dr Habil at the Dept of
Strength of Materials, Vilnius Gediminas Technical University,
Lithuania. Author of more than 100 scientific articles. Research
interests: fatigue, fracture mechanics and shakedown.
Gediminas PETRAITIS. PhD student at the Dept of Strength of
Materials, Vilnius Gediminas Technical University, Lithuania. Research
interests: fatigue, fracture mechanics.
Marijonas SUKSTA. Doctor, Assoc Professor at the Dept of Strength
of Materials, Vilnius Gediminas Technical University, Lithuania.
Research interests: analysis of elasto-plastic strain hardening
structures and shakedown.
Vytas SVALBONAS. Director, Engineering Technologies Metso Minerals,
USA. Research interests: fatigue, fracture mechanics, longevity of
structures.
Received 09 Jan 2006; accepted 16 March 2006
Table 1. Mechanical properties of material
Base metal
Proportional limit [[sigma].sub.pr], MPa 223
Yield stress [[sigma].sub.02], MPa 323
Ultimate strength [[sigma].sub.u], MPa 523
Elastic modulus E, GPa 180
Elongation [delta], % 4,6
Reduction of area [PSI], % 6,5
Dross layer
Proportional limit [[sigma].sub.pr], MPa 150
Yield stress [[sigma].sub.02], MPa 240
Ultimate strength [[sigma].sub.u], MPa 218
Elastic modulus E, GPa 148
Elongation [delta], % < 1
Reduction of area [PSI], % < 1
Base metal
Proportional limit 223 238
Yield stress 327 334
Ultimate strength 484 515
Elastic modulus 173 178
Elongation 3,6 3,3
Reduction of area 5,0 5,0
Dross layer
Proportional limit 142 157
Yield stress 214 209
Ultimate strength 223 233
Elastic modulus 142 144
Elongation < 1 < 1
Reduction of area < 1 < 1