Fatigue life calculations of structural

elements by means of equivalent load

spectrum and material properties for LCF
and HCF
Cite as: AIP Conference Proceedings 2028, 020007 (2018); https://doi.org/10.1063/1.5066397
Published Online: 02 November 2018

Bogdan Ligaj and Karolina Karolewska

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AIP Conference Proceedings 2028, 020007 (2018); https://doi.org/10.1063/1.5066397 2028, 020007

© 2018 Author(s).
 Fatigue Life Calculations of Structural Elements by Means
of Equivalent Load Spectrum and Material Properties for
LCF and HCF
Bogdan Ligaj1, a), Karolina Karolewska 1, b)
1
University of Science and Technology in Bydgoszcz, Faculty of Mechanical Engineering, Al. Prof. S. Kaliskiego 7,
85-796 Bydgoszcz
a)
bogdan.ligaj@utp.edu.pl
b)
karolina.karolewska@utp.edu.pl
Abstract: Structural elements are subjected to variable loads over time. The stochastic character of loads is consequence
of various factors e.g.: variability of operational loads, environmental conditions, physical properties of parts etc. Fatigue life
calculations for variable loads are performed on the basis of appointed sinusoidal cycles set due to apply one of the counting cycles
methods. The sinusoidal cycles in set are characterized by wide range of amplitude Sai and mean value Smi variability. The use of
fatigue life diagram Sa-N during calculations causes that mean value Sm of cycle is omitted. This may affected on exactitude of
calculations. The average value is taking into account by determining a substitute cycle characterized by mean value Sm = 0 and
amplitude Saz ≠ Sa. Fatigue life calculations were carried out based on hybrid method. This method combines calculations in strain
approach and in stress terms.

DESIGNATIONS
N – number of cycles (fatigue life),
N0 – base number of cycles (N0 = 106 cycles),
R – stress ratio (R = Smin/Smax),
Sa – sinusoidal cycle stress amplitude in MPa,
Saz – sinusoidal cycle equivalent amplitude with Sm i Sa parameters in MPa,
S (aT( R) ) – sinusoidal cycle stress amplitude with the given value of a stress ratio R determining a line of constant
fatigue life (N = const.) in MPa,
Sf (-1) – sinusoidal cycles fatigue limit with stress ratio (R=-1) for number of cycles N0 in MPa,
Si – local stress value at the i-th load level in MPa
Sm – sinusoidal cycle average value of stress in MPa
S(mT()R ) – sinusoidal cycle average value of stress with given value of stress ratio R determining a line of constant
fatigue life (N = const.) in MPa,
Smax – stress maximum value in a sinusoidal cycle in MPa,
Su – material tensile strength in MPa,
Sy – yield point of material in MPa,
k – exponent in the equation \N = N-k (log k = 1.973 – log Rm),
m(-1) –exponent in the formula describing fatigue (Wöhler) graph for the stress ratio R=-1,
ψN – material sensitivity coefficient for the asymmetry of the cycle for N ≠ N0,
λ – number of repetitions of a program to fatigue fracture.

Fatigue Failure and Fracture Mechanics XXVII

AIP Conf. Proc. 2028, 020007-1–020007-6; https://doi.org/10.1063/1.5066397
Published by AIP Publishing. 978-0-7354-1750-2/$30.00

020007-1
 INTRODUCTION
Fatigue life is a major criterion for selecting machine elements, which is crucial during the process of operation
and maintenance. Fatigue life calculations under operating load conditions require the use of: characteristics
describing material properties in the mentioned conditions, linear damage summation hypothesis and load spectrum
developed for the indicated loads.
According to the stochastic processes theory, operational loads might be classified into two groups: with narrow
spectrum or broad spectrum. Due to fatigue life, significant differences between the mentioned loads concern the
cycles share from a certain range of stress ratio R values and the occurrence of cycles with high amplitude values
(where the maximum amplitude Sa ≈ Smax).
Fatigue life calculations for narrow load spectrum are performed by the use of block load spectrum (1D spectra)
developed on the basis of a cycles set determined by the means of the one of cycles counting method. In cause of
broad load spectrum, the realization of fatigue life calculations is based on load spectrum, which describe cycles
parmateres Smi and Sai variabilities (2D spectra). The use of type of spectrum is connected with cycles stress ratio
values -∞ < R < +∞ occuring in cycles loads and their impact on fatigue life.
Two-parameter load spectrum (2D spectra) can be replaced by one-parameter spectrum (1D spectra) based on
method of equivalent amplitude Saz determination by means of two-parameter fatigue characteristic. In the paper
model IM and model II of two-parameter characteristics were assumed.
The fatigue life calculations were performed by use of hybrid method. In this method, load cycles characterized
by amplitudes below criterion value (HCF), are included in calcultions by using Wöhler diagram. While load cycles
with amplitudes above criterion value (LCF) require the Manson-Coffin diagram.
The aim of the paper is to present the results of fatigue life calculations in operational load condition. Calculations
were performed by use of hybrid method of calculations and included substitute load spectrum (1D spectra).
The scope of paper includes cycles counting of operational load on the basis of full cycles counting method and
rainflow method [3]. By means of developed 2D load spectra, which will be converted into 1D block load spectra,
fatigue life will be determined. Calculations results will be subjected to comparative analysis allowing to formulation
of conclusions.

METHOD OF DETERMINING SUBSTITUTE LOAD VALUE

In order to carry out the assessment of fatigue life for the operational load, it is necessary to replace the random
course of loads with sinusoidal cycles. For the purpose of this work, the full cycles counting method and the rainflow
method [1] were used to count the number of cycles. Both methods are characterized by the cycles of load, which are
closed stress-strain hysteresis loops.
Single load cycles, from operational load run, vary in their mean value Sm and stress amplitude Sa. The cycles
characterized by these parameters should be changed into equivalent cycles with the average value Sm = 0 and the
equivalent amplitude Saz. Determining substitute amplitudes Saz is done using two-parameter fatigue characteristics.
The two-parameter fatigue characteristics allow to determine substitute amplitude Sazi. There are various models
of the characteristics described in paper [7]. To determine the substitute load spectrum the article is limited to model
IM (Fig.1a) and model II (Fig.1b). Model IM (Fig. 1a) [6] was developed on the basis of the model I presented in the
works [9, 10].
Model IM (Fig. 1a) is divided into four zones characterized by the proper values of stress ratio R. To determine
the equivalent stress amplitude Sazi, a line of constant fatigue life (N=const.) is plotted taking into account stress
amplitude Sai value and mean value Smi of sinusoidal cycle. Selection of stress amplitude value Sai on the ordinate axis,
and mean value Smi on the abscissa axis determines the G point. This point is interpolated to point C, in which the line
of constant fatigue life intersects with the ordinate axis, determining the load equivalent cycle with the average value
Sm = 0. Several load cycles, which are located on the same line of constant fatigue life, have the same equivalent stress
amplitude Sazi and are characterized by the stress ratio R = -1 regardless of the area of two-parameter characteristic
they are located in.
Model II (Fig. 1b) is based on the Wöhler fatigue diagram for the stress ratio R = -1. Under symmetrical cycle
of load, point A corresponds to the tensile strength of the material Su, while point C corresponds to the fatigue limit
Sf(-1). The ACE line is the constant fatigue life line (N = const.) in sinusoidal loads condition for the rage of stress ratio
-∞< R < 1 with variable stress amplitudes Sai and mean values Smi.

020007-2
 Sa R = -1 Sa R = -1
Rm Rm
Ro± 3 2 R=0 Ro± 3 2 R=0
E
Saz i Saz i
C Sa i
E B
C
4 1 4 G 1
N = const. N = const.
Sa i
F A F A
G R=1 R=1

-Rm Sm i 0 Rm -Rm Sm i 0 Rm
Sm Sm

(a) (b)
FIGURE 1. Diagrams of the two-parameter characteristics models: (a) Model IM, (b) Model II [4].

On the basis of the obtained sinusoidal cycles sets by use of the presented cycles counting methods, substitute
amplitudes were determined, which allowed to receive the block spectra of loads.

FATIGUE LIFE CALCULATIONS METHOD

The operational load run due to its random character, causes that the developed load spectra based on the two-
parameter characteristics, include sets of cycles of low and high-cycle fatigue. The hybrid method used to determine
fatigue life, combines the method of calculation in stress approach (HCF) based on the Wöhler diagram and the
calculation method in terms of strain (LCF) defined by means of the Manson-Coffin chart.
noj
Load level:
Hac Hac - Hac 1,
1 LCF
2 - Hac 2,
Hca k Hca k
3
4
Range LCF 0 0
3
S 7 n 2Nf j 2Nf
1 5
-Hca k
Sy
no
0 DO = DL + DH
t Sa Sa
noi
-Sy 1
2 6
2 Load level:
8
Sa k Sa k - Sa 3,
3 HCF
4
4
- Sa4,
Range HCF 0 0

Division criterion: n Ni N
- for Sa-N Sy o Sa k -Sa k
- for Hac-2Nf Sy o Hac k
no

FIGURE 2. Schematic presentation of hybrid calculation method [5].

The value of the yield point of material Re determined in the tensile test is taken as the criterion for separated into
the low cycles fatigue (LCF) and high cycle fatigue (HCF) for the hybrid method. From the load run shown in Figure
2 it is evaluated that cycles marked as 1-2 and 5-6 are characterized by an amplitude lower than the yield point Re.
However cycles 3-4 and 7-8 have an amplitude with a higher value than the yield point. Therefore cycles 1-2 and 5-6
have been classified to the high-cycle range, and fatigue life calculations are made on the basis of the Wöhler chart.
Cycles 3-4 and 7-8 according to the adopted method were assigned to the low-cycle range by calculations based on
the Manson-Coffin diagram.
Calculation of fatigue life was performed for S355J0 steel. This material is a low-alloy steel with increased
strength, with a pearlitic-ferritic structure. The S355J0 steel has the following static properties [7], tensile strength Rm
at 678 MPa and the yield stress Re of 499 MPa, as well as Young's modulus E = 208159 MPa. Cyclic properties of
S355J0 steel on the basis of calculations were made [7]: m (-1) = 12.33, C (-1) = 1.145˜1036, Sf (-1) = 243.1 MPa, k =
0.1386, \N = 0.1205.
Figure 3 presents the fragment of the stresses changes run in the structural element registered under operational
loads, which became the basis for determining fatigue life. The course is shown in a relative Si / Smax form, where
Smax is the maximum value occurring in the course of loads.

020007-3
 1
2s

Naprężenie
0.5

Si/Smax
0
-0.5
Czas t, s
-1

FIGURE 3. Stress changes run in the form of the relative values Si/Smax.
From the course of load presented in Figure 3 determined sinusoidal cycles set using the full cycle counting method
and rainflow method. The determined data sets contained sinusoidal cycles with Sai/Smax and Smi/Smax parameters from
the variability of the stress ratio -∞ < R < 1, which is characteristic for loads with broad spectrum. On the basis of the
obtained data developed cycle sets characterized by Sm = 0 and equivalent amplitude Saz, which were determined by
means of two-parameter fatigue characteristics.
Block load spectrum for operational load run was obtained by using one of the equivalent amplitude Saz method
determination (model IM, model II).The basis for the development of spectra was a sinusoidal cycles set determined
by the adopted methods of cycle counting.
700 700
600 600
Model IM MPC Model II MPC
500 500
Naprężenie Saz, MPa

Naprężenie Saz, MPa

400 400
300 300
200 200
100 100

0 0
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1
Liczba cykli ni/nc Liczba cykli ni/nc
(a) (b)
700 700
600 600
Model IM MRF Model II MRF
500 500
Naprężenie Saz, MPa

Naprężenie Saz, MPa

400 400
300 300
200 200
100 100
0 0
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1
Liczba cykli ni/nc Liczba cykli ni/nc
(c) (d)
FIGURE 4. Block load spectra developed for the assumed operational course for Smax = 650 MPa: (a) Full cycle
counting method for the IM model, (b) Full cycle counting method for the II model, (c) Rainflow method for the IM
model, (d) rainflow for the II model.

The load spectra shown in figure 4 were characterized by a distinct cycle value for various stress values. The
difference were achieved from the cycle counting method and the adopted model of the two-parameter characteristics.
It can be seen that for the II model of two-parameter fatigue characteristics the number of cycles from the low-cycle
fatigue is greater than for the IM model.
Using the hybrid method, substitute load cycles were divided into low- and high-cycle ranges. For the low-cycle
fatigue, the values of the equivalent amplitudes were assigned to the corresponding strain values based on the

020007-4
Ramberg-Osgood cyclic deformation diagram. The number of cycles for the low-cycle fatigue was determined using
the Manson-Coffin chart.
For the low cycle fatigue and high cycle fatigue, calculation was performed using the Palmgren-Miner rule [2, 8,
11, 12], which is expressed by the formula:
k
ni
D ¦N i 1 i
1.0 (1)

According to the hybrid method, the low-cycle and high-cycle fatigue damage is added separately. The results of
fatigue life for the total damage are presented in the form of the number of completed load blocks, which were
calculated from the following equation:
1
O (2)
D
The fatigue life expressed in the number of cycles Nc was estimated from the equation:

ܰ௖ ൌ ߣ ή ݊௢ (3)

The calculations made it possible to determine the graphs of fatigue life Smax = f(λ). The fatigue life chart compares
the results of calculations for the IM model and the II model with experimental tests.

CALCULATION RESULTS

Figure 5 shows the results of fatigue life calculation for the operational load. The results were presented for two
models of two-parameter characteristics and two ways to schematize the number of cycles. The calculations for the
IM model are characterized by a higher durability compared to the II model. Comparing the cycle counting methods,
it can be concluded that fatigue life was obtained for cycles set counted using the full cycle method. This may be
influenced by the presence of a larger number of substitute cycles with amplitude Saz above the yield point Re in the
II model, which was a criterion value for the classification of the area for low- or high-cycle fatigue. For the IM model,
the fatigue life calculations are higher for the rainflow method due to fact that the load spectra for these method
contained a smaller number of cycles from the area above the yield point Re. A higher durability was obtained in
calculations taking the full cycle counting method in the II model into account. For this method, the load spectrum
was characterized by a smaller number of cycles above the adopted criterion value.
Comparing the obtained results of calculations with the results of experimental tests, it appears that the most
accurate result of fatigue life calculations was achieved for the model II using the rainflow method. The determined
fatigue life line for model II using the full cycle counting method is not much lower than the durability determined
during the experimental tests. Fatigue life determined using the IM model, including the rainflow method and full
cycles counting method, is higher than the experimental results.
1000
800
600
Naprężenie Saz max, MPa

400

Model IM RFM
Model IM FCM
200
Model II RFM
Model II FCM
Experimental
100
1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07
Liczba cykli

FIGURE 5. Results of calculations for loads spectrum determined by use of two-parameter fatigue characteristics.

020007-5
 CONCLUSION
The hybrid calculation method allows for considering dynamic excitations from the high-cycle fatigue and
kinematic excitations for the low-cycle area of fatigue. It is important in operational load runs, which is characterized
by variable amplitude values in low and high cycle fatigue. The use of two-parameter characteristics gives the
possibility to take into account the average stress value as opposed to calculations based on the Sa-N graph, which
ignore the influence of this magnitude. This is important especially in case of broad load spectrum for operating loads.
Use of the hybrid method and the two-parameter fatigue characteristics has a significant impact on the results of
fatigue life calculations
In addition to the fatigue characteristics models, the cycle counting method also affects the fatigue life results. If
a various cycle counting method is used, the calculated fatigue life values are different. The fatigue life graphs show
that the highest durability characterized the results obtained on the basis of the load spectrum for the IM model of the
two-parameter fatigue characteristics. The lowest fatigue life was obtained for calculations based on the II model of
the two-parameter characteristics. However, it is comparable to the durability determined in experimental tests. Model
II based on the rainflow method, as the method of cycles counting is the most accurate for calculations of steel S355J0.
Significant differences in the fatigue life results between IM and II models of two-parameter fatigue characteristics
can be affected by the range in which the chosen characteristics are used [4].
Model II is used for the stress ratio -∞ < R < -1, omitting area 4 (Fig.2) with range of stress ratio 1 < R < + ∞. It
can therefore be concluded that the selection of the appropriate model of the two-parameter fatigue characteristic has
a significant impact on the fatigue life calculations results. The choice of the proper model is related to the cyclic
properties of researched material [4].

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020007-6