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Related Experiment Videos

Shape optimisation to maximise crack initiation time.

H S Hedia1

  • 1Faculty of Engineering, Mansoura University, Mansoura, Eygpt. hedia@mum.mans.eun.eg

Bio-Medical Materials and Engineering
|January 16, 2002
PubMed
Summary

Optimizing the shape of tension bar fillets significantly increases crack initiation time and reduces stress concentration. This method enhances the durability of machine parts and artificial joints by minimizing fatigue notch factors.

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Area of Science:

  • Mechanical Engineering
  • Materials Science
  • Computational Mechanics

Background:

  • Fillets are common in machine parts and artificial joints, connecting varying diameters or widths.
  • These geometric features can act as stress concentrators, potentially leading to component failure.
  • Understanding and mitigating stress concentration at fillets is crucial for component longevity.

Purpose of the Study:

  • To present an optimization method for the longitudinal profile of tension bar transition lengths.
  • To maximize crack initiation time by minimizing the fatigue notch factor (Kf).
  • To investigate the relationship between stress concentration factor (kt) and crack initiation time.

Main Methods:

  • Utilized ANSYS software for optimization and analysis.

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  • Developed a program using Ansys Parametric Design Language (APDL) to calculate the fatigue notch factor.
  • Analyzed tension bars with varying transition lengths (t/d ratios of 0.333, 0.4167, 0.5, and 0.583).

    • Main Results:

    • The optimization method successfully minimized the stress concentration factor (kt).
    • Crack initiation time increased by 7% to 17% for the optimized shapes across different transition lengths.
    • A direct correlation was observed: higher statistical parameter 'k' values corresponded to minimized stress concentration and maximized crack initiation time.

    Conclusions:

    • The proposed optimization method effectively enhances component durability by improving fillet geometry.
    • Minimizing the fatigue notch factor is a viable strategy for extending the service life of components with varying diameters.
    • The findings are applicable to the design of critical components in machinery and biomedical implants.