Calculation and enhancement of fatigue life by ε-N approach and corrosion fatigue in steam turbine rotor

Silva, José Antônio da; Caetano, Diego Amorim; Filho, Sérgio Luiz Moni Ribeiro; Teixeira, Flávio Neves; Guimarães, Luiz Gustavo Monteiro

doi:10.1177/10567895221082209

Cited by 6 publications

(3 citation statements)

References 40 publications

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“…The shift indicates that the fatigue life of LSMSPed gears was positively correlated with air pressure and coverage. Silva et al [51] also concluded that the fatigue life of steam turbine rotors was extended by 10.5% after SP treatment. Maleki et al [52] reported that SP treatment can actually prolong the fatigue life of AlSi10Mg specimens by a maximum of 414 times.…”

Section: Contact Fatigue Test Results Of Gearsmentioning

confidence: 97%

The effect of shot peening on the contact fatigue performance of C40 steel gears after laser surface melting

Lv,

Cui,

Sun

et al. 2024

Surf. Topogr.: Metrol. Prop.

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In this paper, shot peening (SP) was employed as a post-processing technique for the laser surface melted (LSMed) gear. The aim was to improve the contact fatigue performance of laser surface melting+shot peened (LSMSPed) gears. The microstructure, surface roughness, residual stress, microhardness of C40 steel gears before and after SP treatment were characterized using scanning electron microscopy, X-ray diffraction stress analyzer, contour measuring instrument, and hardness tester. Fatigue test of gear was carried out with a Forschungsstelle für Zahnräder und Getriebebau (FZG) testing machine. Following the laser surface melting (LSM) treatment, a molten layer was observed on the gear teeth surface. The experimental results indicated that SP induced a hardened layer with a certain thickness and plastic deformation on the surface of LSMed gears. Importantly, as the SP parameters increased, there's a corresponding reduction in both the average grain diameter and the maximum grain diameter. The reduction was most pronounced when the shot diameter reached its maximum value. It's worth noting that once the optimal threshold for SP parameters is surpassed, the residual compressive stress and microhardness on the LSMSPed gear surface do not exhibit a continuous growth trend. Furthermore, the rise in SP parameters resulted in a gradual increase in the surface roughness of LSMSPed gears, albeit to varying degrees. In light of the combined effects of grain refinement, residual compressive stress, microhardness, and surface roughness, the contact fatigue performance of LSMSPed gears improved with increasing SP parameters. Notably, when comparing the contact fatigue life of LSMed gears with that of LSMSPed gears, we observed a substantial enhancement. However, it's essential to highlight that when the shot diameter reaches its maximum value, the contact fatigue life of the LSMSPed gear, somewhat unexpectedly, decreased.

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Section: Contact Fatigue Test Results Of Gearsmentioning

confidence: 97%

The effect of shot peening on the contact fatigue performance of C40 steel gears after laser surface melting

Lv,

Cui,

Sun

et al. 2024

Surf. Topogr.: Metrol. Prop.

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show abstract

“…Accuracy of the constitutive models with respect to experimental data has been established for steam/gas turbine rotor steels (Benaarbia et al, 2018;Cui et al, 2013;Wang et al, 2016c) and nickel-based alloys (Choi et al, 2023). The effect of corrosion on fatigue crack initiation was studied by Yang et al (2022) and Silva et al (2022). The advantages of having a thermal stress relief groove have been only qualitatively observed in the above cited studies.…”

Section: Introductionmentioning

confidence: 99%

“…The effect of corrosion on fatigue crack initiation was studied by Yang et al. (2022) and Silva et al. (2022).…”

Section: Introductionmentioning

confidence: 99%

Continuum damage mechanics of cyclic viscoplasticity using asymptotic numerical method

Sen,

Patel

2023

International Journal of Damage Mechanics

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Conscious efforts on reduction of greenhouse gas emissions have led to an energy transition to renewable energy, however uncertainties of renewable energy production have resulted in higher thermal cycling demands from conventional power plants. Thermal load cycling at high temperature regions of steam turbine components leads to enhanced creep-fatigue damage accumulation. It is well established that such damage mechanism is numerically best predicted by unified constitutive modeling including damage as a variable as per the formalism of continuum damage mechanics at an expense of considerable computational efforts using finite element analysis. In this paper, the non-iterative Asymptotic Numerical Method (ANM), currently limited to partial cycle analysis with linear hardening plasticity model, is proposed for the first time to address cyclic viscoplasticity problems including damage capable of handling multiple cycles and most generalized loading conditions. Regularization techniques additionally necessary to implement loading-unloading-reloading criteria and advanced constitutive models etc. are presented. The constitutive model chosen for the formulation includes the non-linear multiple back stress variable modified Chaboche model to include damage combined with modified Chaboche-Rousselier isotropic hardening model to include damage, power law for viscoplasticity, Lemaitre’s damage potential and Kachanov-Rabotnov’s creep damage law. The method is verified with defined error measures and then applied to two high pressure steam turbine rotors, one with and another without thermal stress relief groove (TSRG) at the inlet under service type loading conditions to study the beneficial effect of the TSRG on creep-fatigue damage evolution. The accumulated errors of the proposed ANM and computational time are compared to a conventional Newton-Raphson solution.

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Construction of Fatigue Life Prediction Model and Optimization of Structural Parameters for Gear-Rack Transmission Mechanism of Mountain Train

Li,

Liu

et al. 2024

Mechanisms and Machine Science

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Calculation and enhancement of fatigue life by ε-N approach and corrosion fatigue in steam turbine rotor

Cited by 6 publications

References 40 publications

The effect of shot peening on the contact fatigue performance of C40 steel gears after laser surface melting

The effect of shot peening on the contact fatigue performance of C40 steel gears after laser surface melting

Continuum damage mechanics of cyclic viscoplasticity using asymptotic numerical method

Construction of Fatigue Life Prediction Model and Optimization of Structural Parameters for Gear-Rack Transmission Mechanism of Mountain Train

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