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International Journal of Fatigue 23 (2001) 525–532

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Parametric modelling and scatter prediction of rainflow matrices


M. Nagode *, J. Klemenc, M. Fajdiga
Faculty of Mechanical Engineering, University of Ljubljana, Aškerčeva 6, SI-1000 Ljubljana, Slovenia

Received 16 October 2000; received in revised form 8 January 2001; accepted 8 January 2001

Abstract

For service life prediction and stochastic reconstruction of load histories, rainflow matrices have been recently predominately
used to describe the scatter of loading. Typically, only limited data are available due to the costs of measurements. As a consequence
of this, discrete rainflow matrices have to be modelled and extrapolated. So far non-parametric methods have most frequently been
used to transform discrete matrices into smooth functions. In this paper, two appropriate parametric models: a mixture of joint
Weibull–normal distributions and a mixture of multi-variate normals, as well as two algorithms for parameter estimation: the EM
algorithm and the algorithm developed by Nagode and Fajdiga are thoroughly discussed and compared. Finally, a method to describe
the scatter of rainflow matrices is presented.  2001 Elsevier Science Ltd. All rights reserved.

Keywords: Load spectra characterisation; Load spectra extrapolation; Rainflow cycle counting method; Weibull–normal mixture; Multivariate nor-
mal mixture

1. Introduction and mean was given by Kowalewski [5]. He proved that


for the special case of Gaussian random process the joint
Fatigue design has to account for the scatter of distribution function of ranges and means could be
component geometry, material behaviour and loading defined as a product of the Rayleigh and normal distri-
[1]. The scatter of the first two variables is mainly due butions. Although he also proposed the method of
to manufacturing and material sourcing. Loading, on the unknown parameter estimation for a mixture of Gaussian
other hand, depends decisively on operating conditions processes, his graphical method of separating the modes
and customer usage. of the mixture has not met a wider response.
The most difficult is certainly the determination of In general, however, load time histories represent
loading. Tests on proving grounds [2] or even long-term quasi-stationary or even non-stationary random pro-
real-time measurements [3,4] are used to obtain actual cesses. Consequently, the shape of rainflow matrix is
load time histories. Because of the costs of measure- complex and cannot be modelled by a single unimodal
ments and safety measures, real-time measurements are distribution.
used only exceptionally to gain changes in the usage pro- A method of non-parametric smoothing of rainflow
file. matrices, developed by Dreßler et al. [6], has been lately
Analysing the scatter of loading in time domain is most often used. A multi-variate normal distribution is
often not feasible. By converting load time histories into taken as a kernel in this case. There are two major draw-
rainflow matrices, huge sets of data are reduced to man- backs of this method:
ageable two-dimensional (2D) arrays. These arrays con-
tain the number of load cycles ordered by range and 앫 The number of kernel estimators is large even if load
mean or by from- and to-reversal points. cycles are counted into a finite set of bins.
The first attempt to model a 2D array ordered by range 앫 Kernel estimators themselves do not tell us anything
about the loading process. They enable us only to
convert a discrete matrix into a smooth function.
* Corresponding author. Tel.: +386-1-4771-505; fax: +386-1-
2518-567. It has recently been shown that the necessary number of
E-mail address: marko.nagode@guest.arnes.si (M. Nagode). component distributions can be reduced substantially if

0142-1123/01/$ - see front matter  2001 Elsevier Science Ltd. All rights reserved.
PII: S 0 1 4 2 - 1 1 2 3 ( 0 1 ) 0 0 0 0 7 - X
526 M. Nagode et al. / International Journal of Fatigue 23 (2001) 525–532

parametric methods of distribution estimation are used where bl and ql stand for Weibull shape parameters, and
instead of non-parametric ones. A survey of the para- ml and sl denote mean value and standard deviation,
metric methods appropriate for a mixture of multi-variate respectively.
normals can be found in Ref. [7]. The advantages of In Eqs. (2) and (3) it is presumed that sr and sm corre-
these are as follows: sponding to the lth component distribution stand for
independent variables. However, a correlation may exist
앫 Unknown parameters of the mixture of multi-variate between the components forming the mixture, which can
normals can be estimated reliably by using the well- be proved if Eq. (2) is inserted in Eq. (1). Consequently,
known EM algorithm [8]. by choosing an appropriate number of components m,
앫 Eventual correlation between ranges and means can an arbitrary rainflow matrix can be modelled even if ran-
be taken into account. dom variables sr and sm are correlated. This can be
앫 The method can easily be widened to more than two assumed since there exist many similar examples, such
independent variables. as in Ref. [8], where mixtures of joint normals are used
to model any shaped empirical distributions, although
As a multi-variate normal probability density function the contours of constant probability density of the joint
(PDF) does not equal zero for negative ranges, it has to normal distribution Eq. (4) are ellipsoids.
be cut off. Therefore, its cumulative density function If random variables sr and sm in Eqs. (2) and (3) are
(CDF) F(+⬁) is less than one, unless it is compensated replaced with sr=|sf⫺st| and sm=0.5(sf+st), the distribution
[7]. It has to be stated that this can be done only if F(+⬁) function of the from–to matrix is obtained where sf and
is very close to one. Besides, multi-variate normals are st stand for from- and to-reversal points.
not appropriate for all load time histories, such as for Although a mixture of joint Weibull–normals seems
those where ranges obey the exponential law. to be the genuine distribution suitable for modelling any
If rainflow matrices are modelled by a mixture of joint rainflow matrix, a number of cases exist where the mix-
Weibull–normal distributions, the above shortcomings ture of multi-variate normals can assure satisfactory
can be avoided. results, too.
Multi-variate normal component PDF is defined as

2. Parametric estimators for rainflow matrices fl(s)⫽


1
(2π) |⌺l|
d/2 1/2 再 1
exp ⫺ (s⫺ml)T⌺−1
2 l (s⫺ml) 冎 (4)

Generally an arbitrary rainflow matrix can be defined


where mean ml is now a d-dimensional vector, ⌺l is a
as a weighted sum of component distributions
d×d covariance matrix and |⌺l| is the determinant of ⌺l.

冘 There are several methods by the use of which mixtures


m

f(s)⫽ wlfl(s) (1) of multi-variate normals can be estimated [8,10]. The


l⫽1 EM algorithm proved to be the most appropriate one [7].
where wlⱖ0 for (l=1,…,m) and Sml⫽1wl=1. Constant wl However, it turned out to be unsuitable for distributions
stands for a weighting factor, whereas fl(s) represents a like Weibull–normal mixtures because of the following:
component PDF of two random variables s=[sr,sm]T
which denote ranges and means or from- and to-rever- 앫 The estimated parameters depend decisively on the
sal points. initial conditions.
It was proved [9] that ranges can be modelled reliably 앫 The algorithm does not necessarily converge and/or
if a two-parameter Weibull distribution is taken as a is extremely slow, especially if the number of compo-
component distribution fl(sr). On the other hand, means nents m is high.
can well be described by a normal distribution fl(sm), as
was shown in Ref. [5]. The component PDF of ranges To overcome this problem, the algorithm developed by
and means can thus be defined as Nagode and Fajdiga [11] was expanded from one- to

冉冊 再冉冊bl bl
multi-dimensional space.
bl sr sr
fl(s)⫽fl(sr)fl(sm)⫽ exp ⫺ (2)
冑2πslsr ql ql


3. Component probability density estimation
(sm−ml)2

2s2l Suppose that the component PDF fl(s) represents a
Its component CDF is therefore multi-variate distribution, where s denotes the d-dimen-

冉 再 冉 冊 冎冊 冉 冊
sional random vector [s1,s2,…,sd]T. Let s1,s2,…,sN denote
sr bl
sm−ml an empirical sample of size N of random vectors. From
Fl(s)⫽Fl(sr)Fl(sm)⫽ 1⫺exp ⫺ ⌽ (3)
ql sl the random sample it is always possible to obtain the
M. Nagode et al. / International Journal of Fatigue 23 (2001) 525–532 527

density estimate f⬘(smax)=f⬘max/V at the global mode pos- d


f⬘(smax)⫽⑀d ⌸ f⬘(simax) (12)
ition smax=[s1max,s2max,…,sdmax]T where V is the volume i⫽1
and f⬘max is the relative frequency.
whilst empirical marginal densities f⬘(simax) can be
To prevent the fl(s) to shift from the global mode, the
determined from the random sample. Each of f⬘(simax)
following constraint has to be taken into account during
has to be multiplied by a factor ⑀ to ensure equality in
the rough parameter estimation phase
Eq. (12). Likewise the following set of constraints is
0⫽ln 冉
f⬘(smax)
fl(smax) 冊 (5)
obtained
⑀f⬘(simax)⫽fl(simax); (i⫽1,…,d) (13)

A method based on maximising the likelihood of the If presumed that the derivatives of Eq. (11) with
parameters for the given data set can be used to deter- respect to s at the global mode position equal zero, the
mine the fl(s). The negative log-likelihood for the data second set of constraints is obtained
set is given by
∂fl(simax)


N

ln L⫽⫺ ln(fl(si))⫺l ln
i⫽1
f⬘(smax)
fl(smax)冉 冊 (6)
∂si
⫽0; (i⫽1,…,d) (14)

taking into account the constraint (5) by introducing Considering both sets, unknown parameters of the
Lagrange multiplier l. joint Weibull–normal distribution are
Let us first consider the case of the multi-variate nor- 1
ml⫽smmax, sl⫽ , ql (15)
⑀冑2πf⬘(smmax)
mal distribution (4). Hence it follows that the mean value
can roughly be estimated by taking ml=smax. Constraint
(5) can also be rewritten as
1
0⫽ln((2π)d/2f⬘(smax))⫹ ln|⌺l| (7)
⫽srmax 冉 冊 bl
bl−1
1/bl

2 Values ml, sl, bl and ql stand for mean value, standard


Inserting Eqs. (4) and (7) into Eq. (6) yields deviation and the shape parameters, respectively. bl is
obtained from

N
N−l 1
ln L⫽ ln|⌺l|⫹ (s ⫺ml)⌺−1
l (si⫺ml) ⫹const
T
(8) 0⫽⑀f⬘(srmax)srmax⫺(bl⫺1)e−(bl−1)/bl (16)
2 2i⫽1 i

If the first derivative of Eq. (8) with respect to ⌺l is set As the global mode position smax is affected by the
to zero, a rough estimate of the covariance matrix is neighbouring component densities, the exact mode
obtained location of the observed distribution does not necessarily


N coincide with smax. Therefore, during the optimal para-
1
⌺l⫽ (s ⫺ml)(si⫺ml)T (9) meter estimation phase Lagrange multiplier l in Eq. (6)
N−li⫽1 i has to be set to zero
where Lagrange multiplier l can be easily found by

N

inserting |⌺l| into Eq. (7) ln L⫽⫺ ln(fl(si)) (17)

再 |冘 |冎
i⫽1
N 1/d
l⫽N⫺2π f⬘(smax)2 (si⫺ml)(si⫺ml)T (10)
i⫽1 If the above equation is now minimised with respect
to unknown parameters, optimal estimate of the compo-
It is not easy to determine the parameters of fl(s) for nent PDF fl(s) is reached. Choosing fl(s) as a multi-vari-
any multi-variate distribution by minimizing Eq. (6). If ate normal distribution results in
random vector components (see Eq. (2)) are inde-
冘 冘
N N
pendent, parameters can be roughly estimated as 1 1
shown below. ml ⫽ s and ⌺l⫽ (s ⫺ml)(si⫺ml)T (18)
Ni⫽1 i Ni⫽1 i
The joint component distribution of s is now
d
On the other hand, if component PDF is a joint Weibull–
fl(s)⫽ ⌸ fl(si) (11) normal distribution, we get

冘 冘
i⫽1
N N
1 1
The constraint that the global mode should be preserved ml⫽ s s2l ⫽ (s ⫺m )2 ql (19)
during rough parameter estimation yields Ni⫽1 mi Ni⫽1 mi l
528 M. Nagode et al. / International Journal of Fatigue 23 (2001) 525–532

冉冘 冊 冘
l⫺1
N
1 1/bl
wl⫽1⫺ wi (22)
⫽ sbl
Ni⫽1 ri i⫽1

where bl is the solution of the equation (ii) A rough estimate of the lth component distribution


N is made according to the findings discussed in the
sbril ln(sri) preceding section.

N
1 1 (iii) Firstly, the mean value of absolute relative devi-
0⫽ ⫹
i⫽1
ln(sri)⫺ (20)
bl Ni⫽1
冘 ations Da(I)
N
bl

冘| 冕
s
冘 |冘
ri
K K K
i⫽1
Da(I)⫽ |⌬f⬘i|⫽ f⬘i⫺ fl(s) ds ⬇ |f⬘i (23)
i⫽1 i⫽1 i⫽1
Vi
A numerical method, such as the Newton–Raphson
one, can be used to solve Eqs. (16) and (20). ⫺Vifl(si)|
and relative differences

4. Mixed probability density estimation



f⬘i− fl(s) ds
Vi f⬘i−Vifl(si)
⑀i⫽ ⬇

By the known EM algorithm [8] all the parameters ; (i⫽1,…,K) (24)
of the mixture (1) as well as the weighting factors are Vifl(si)
fl(s) ds
determined simultaneously after each iteration. If the
initial values of the parameters are guessed correctly, the Vi

procedure may converge after a certain number of iter- are computed for those indices i for which empirical
ations. Nevertheless, it was noticed that the EM algor- relative frequencies f⬘i⬎0 and fl(si) is greater than a
ithm becomes slow and unreliable, especially if the num- pre-determined small number in order to avoid
ber of component distributions is high. division by zero. Secondly, maximal relative differ-
A new algorithm (NA) suitable for mixture distri- ence is extracted
butions [11] works equally well with any distribution
function. Its reliability does not depend on the number ⑀max⫽max{⑀i; i⫽1,…,K} (25)
of component distributions. Besides, it is also much
quicker than the EM algorithm. Initially, the algorithm
The discrepancy between two successive iter-
in question was developed solely for the mixtures of one
ations I is then
random variable, which is the reason why the expansion
of the algorithm to multi-dimensional space is dis- Da(I⫺1)⫺Da(I)ⱕer (26)
cussed next.
It was proved that when the size of random sample N If it is less or equal to error rate er and if parameters
and/or the number of random variables d are high, the are estimated roughly, go to point (ii) and replace
performance of the algorithm can be improved substan- rough estimate by the optimal one. Reset Da to its
tially if random vectors s1,s2,…,sN are rounded to pre- initial value. When inequality is fulfilled the next
determined grid points s∗1 ,s∗2 ,…,s∗K, while KN. Let Vi time, optimal parameter estimate is reached.
denote the volume of a hypersquare with sides of length Increase l=l+1, set f⬘i=r⬘i for (i=1,…,K) and return
h1,h2,…,hd centred on grid point si∗, whilst the relative to (i). If none of the above is true, proceed with
number of points falling within Vi is defined as point (iv).
(iv) For the indices i fulfilling the condition (f⬘i⬎
ni 0⵪ri⬎0)⵩(⑀i⬍0⵪⑀iⱖ⑀max) the following transform-
f⬘i⫽ ; (i⫽1,…,K) (21) ation is carried out:
N
where the adjoining volumes should not overlap. f⬘i⫽f⬘i⫺⌬f⬘i, r⬘i⫽r⬘i⫹⌬f⬘i, wl⫽wl⫺⌬f⬘i (27)
The proposed procedure of working out unknown con-
stants is iterative and carried out in the following stages: The negative value of ⌬f⬘i should never be greater
than the residuum value. However, if this is not true,
(i) Global mode position smax∗
=[s1max
∗ ∗
,s2max ∗
,…,sdmax ]T and the error has to be corrected ⌬f⬘i=⫺r⬘i before the

its probability density f⬘(smax) are obtained from the above transformation is made.
random sample. Residuum r⬘i=0 for (i=1,…,K). The whole procedure should be repeated (m⫺1)
Further, the initial weighting factor stems from times, once for each fl(s). The remaining residuum
M. Nagode et al. / International Journal of Fatigue 23 (2001) 525–532 529

matrices is important when a certain level of reliability


has to be assured.
The scatter of rainflow matrices can be reached
empirically, if measurements are repeated several times.
This way the influence of a user upon the scatter can be
studied [6]. On the other hand, it was proved [12,13]
that it is possible to determine the scatter corresponding
to a particular user irrespective of the variability of
operating conditions and without experiment replication
if conditional distributions of load ranges and of the
number of load cycles are known. Next, the method
Fig. 1. Joint Weibull–normal mixture PDF with its marginal PDFs initially developed for one random variable [12] will be
(m=5). expanded to a multi-variate case.
Suppose that event S denotes an ordered set of ran-
dom vectors
joins the last mth component density, using optimal
S⫽[s1,s2,…,sn,…,sN]
parameter estimate (see Section 3).
from a population with distribution F(s). Let the subset
It may occur that the optimal estimate (ii) fails if, e.g. of possible outcomes of random vector s, for which
the number of data points in f⬘i is very low or if the si⬎s (i=1,…,n⫺1) holds, be denoted by Sn−1 and let event
points are extremely dispersed. Omitting the optimal Sn correspond to sn=s. The complement of
estimate turned out to be a reasonable solution of this SN−n=Sn−1傼Sn is then an event S cN−n, including elements
problem. si⬍s for (i=n+1,…,N). The probability of event Sn−1 is
To explain distributions treated so far, rainflow cycles then (1⫺F(s)), the probability that sn=s is f(s)ds and
ordered by range and mean were modelled by the Weib- finally the probability of complement S cN−n equals F(s).
ull–normal mixture. The empirical and hypothetical This yields
probability density functions as well as cumulative dis-
N!
tributions are depicted in Figs. 1 and 2. For the number f(s|n)⫽ F(s)N−n(1⫺F(s))n−1f(s) (28)
of load cycles a logarithmic scale was used. Thus the (N−n)!(n−1)!
agreement between empirical and hypothetical distri- Eq. (28) represents the conditional PDF of vector s,
butions can be viewed better also in the region of low given that the number of load cycles n is a fixed value.
probability. Its CDF F(s|n) under condition n can be expressed by
an incomplete beta function

5. Scatter prediction and matrix extrapolation BF(s)(N−n+1,n)


F(s|n)⫽ ⫽IF(s)(N⫺N⫹1,n) (29)
B(N−n+1,n)
It is well known that rainflow matrices differ if, e.g.
the loads acting upon a vehicle are measured several The structure of the conditional distribution f(s|n) for
times under identical conditions. Generally, the longer the case of two random variables s=[sr,sm]T standing for
the loading process is monitored, the higher the largest ranges and means is illustrated in Fig. 3. In this parti-
amplitude encountered. Knowing the scatter of rainflow

Fig. 2. Joint Weibull–normal mixture CDF with its marginal CDFs Fig. 3. The conditional PDFs of the number of load cycles f(n兩s) and
(m=5). of vector s f(s兩n).
530 M. Nagode et al. / International Journal of Fatigue 23 (2001) 525–532

cular case f(srsm|n) defines the scatter of ranges and can be approximated well by normal distribution [15]
means, given that n is fixed. (see Fig. 3). This yields

再 冉 冊冎
For reliable fatigue damage prediction, the ran- 2
domness of fatigue resistance of material as well as the 1 1 n−m(s)
f(n|s)⫽ exp ⫺ (37)
randomness of loading have to be considered [14]. Since 冑2πs(s) 2 s(s)
the resistance of material is usually described with a con-
ditional PDF of the number of cycles to failure, con-
ditional PDF of the number of load cycles f(n|s) is of Mean value m(s) and standard deviation s(s) have values
great significance, too. m(s)⫽1⫹(N⫺1)(1⫺F(s)) s(s) (38)
When f(s), f(s|n) and f(n) are known, conditional PDF
of the number of load cycles f(n|s) can be determined ⫽冑(N−1)(1−F(s))F(s)
by the Bayesian theorem
f(s|n)f(n) Conditional distribution functions as defined in Eqs. (28,
f(n|s)⫽ (30) 36) and (37) can thus be applied for any mixture irres-
f(s)
pective of the number of random variables and their cor-
relation.
The unknown PDF of the number of load cycles f(n) can
be obtained by introducing the one-to-one transform-
ation 6. Discussion
g1(s)⫽n⫽N(1⫺F(s)),g2(s)⫽s2,…,gd(s)⫽sd (31)
The characteristics of the two methods of parameter
estimation and the distinction between the multi-variate
Let distribution f(n,s2,…,sd) first be expressed as normal and Weibull–normal mixtures are discussed next.
f(s) f(s) An empirical complex shaped rainflow matrix (see
f(n,s2,…,sd)⫽ ⫽ (32) Fig. 10) was modelled in three ways: firstly, by the Wei-
|J(s)| N∂F(s)/∂s1
bull–normal mixture, whilst the unknown parameters
where were estimated by the NA. Secondly, the EM algorithm
was employed instead of the new one. Thirdly, a multi-
∂g1 ∂g1
% variate normal mixture with the EM algorithm was used
∂s1 ∂sd

| |
to model the empirical matrix. For the sake of compar-
∂F(s)
J(s)⫽ ⯗ % ⯗ ⫽⫺N (33) ability number of components m was set to 5 in all three
∂s1 cases. The empirical and hypothetical PDFs as well as
∂gd ∂gd
% the corresponding CDFs are depicted in Figs. 4–9. To
∂s1 ∂sd distinguish one from another, empirical probabilities
is the Jacobian of the transformation (31). As the con- were marked with black circles.
ditional distribution of the number of load cycles All three approaches result in a fairly good agreement
between empirical and hypothetical values in the region
f(n,s2,…sd) 1 of high probability. However, the best agreement in this
f(n|s2,…sd)⫽ N ⫽ (34)


N region is obtained if a Weibull–normal mixture com-
f(n,s2,…sd) dn bined with the EM algorithm is used. In the region of
low probability, the probability of occurrence of high
0

does not depend on the condition, it follows that


1
f(n)⫽f(n|s2…sd)⫽ ; (n⫽1,…,N) (35)
N

By inserting Eqs. (28) and (35) into Eq. (30) the con-
ditional PDF of the number of load cycles is finally
obtained

f(n|s)⫽ 冉 冊
N−1
n−1
F(s)N−n(1⫺F(s))n−1 (36)

Fig. 4. Joint Weibull–normal mixture PDF with its marginal PDFs


It was shown that for (N⫺1)(1⫺F(s))F(s)1 Eq. (35) (NA).
M. Nagode et al. / International Journal of Fatigue 23 (2001) 525–532 531

Fig. 8. Multi-variate normal mixture PDF with its marginal PDFs


Fig. 5. Joint Weibull–normal mixture CDF with its marginal CDFs
(EM).
(NA).

Fig. 6. Joint Weibull–normal mixture PDF with its marginal PDFs


(EM). Fig. 9. Multi-variate normal mixture CDF with its marginal CDFs
(EM).

The original and 10 times extrapolated rainflow matr-


ices are depicted in Figs. 10 and 11. For this extrapol-
ation the Weibull–normal mixture and the NA were
used. As distinguished from the non-parametric esti-
mation where the extrapolated load cycles are condensed
around the measured ones [6], parametric extrapolation
results in higher scatter in the region of low probability.
This seems to be reasonable as it is not possible to expect
that rare events would occur with low dispersion.
Fig. 7. Joint Weibull–normal mixture CDF with its marginal CDFs
(EM).

ranges is underestimated if EM algorithm is used irre-


gardless of the distribution selection. Even if rainflow
matrices were generated randomly and extrapolated up
to 100 times, the highest range sr=12.3 was never gained.
Better result was obtained when the NA was applied
instead of the EM one, as can be seen in Figs. 4 and 5.
To compare the performance of both algorithms, the
parameters of the Weibull–normal mixture were first
estimated by the NA. Afterwards they were taken as the
first approximate in the EM algorithm. Surprisingly, the
NA took only 0.4 s in an ordinary PC and was thus 225
times faster than the EM algorithm. Fig. 10. Measured rainflow matrix.
532 M. Nagode et al. / International Journal of Fatigue 23 (2001) 525–532

er. The higher the error rate, the lower the number of m
and vice versa. As components are estimated one by one,
the number of cycles left in the residuum is falling if
component index l is rising, which influences the number
of components, too. In other words, when the residuum
is (nearly) empty, no further component can be assigned
to the mixture any more.
Besides, it was noted that the treatment of the last
component is significant if components are far between.
Both phenomena are left to further research.

Fig. 11. Ten times extrapolated rainflow matrix. References

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