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JOURNAL OF IRON
Abstract: Mechanical, physical and manufacturing properties of cast iron make it attractive for many fields of application, such as cranks and cylinder holds. As in design of all metals, fatigue life prediction is an intrinsic part of the
design process of structural sections that are made of cast iron. A methodology to predict high-cycle fatigue life of
cast iron is proposed. Stress amplitudestrain amplitude, strain amplitudenumber of loading cycles relationships of
cast iron are investigated. Also, fatigue life prediction in terms of Smith, Watson and Topper parameter is carried
out using the proposed method. Results indicate that the analytical outcomes of the proposed methodology are in
good accordance with the experimental data for the two studied types of cast iron: EN-GJS400 and EN-GJSGOO.
Key words: high-cycle fatigue; fatigue behavior; fatigue life prediction; cast iron
Symbol List
.--Strain
E-Young's
K'-Cyclic
n'-Cyclic
a'i-Fatigue
6-Fatigue
amplitude;
modulus;
strength coefficient;
strain hardening exponent;
strength coefficient;
strength exponent;
e'f-Fatigue
ductility coefficient;
c-Fatigue
ductility exponent;
R,-Ultimate
tensile strength;
NE-Number
of cycles at endurance limit;
PswT-Smith,
Watson and Topper damage parameter.
Male, Master;
Issue 8
A Methodology to Predict Fatigue Life of Cast Iron: Uniform Material Law for Cast Iron
Table 1
n'
af
Ef
' / MPa
I
K'/MPa
43
0,
b/c
R,
0.58
Cast iron
LTf
'/ (Ef
')nf
0. 1
1.34
Cl+(G)
(G+O.
01
- Ig(of '/LTE) /6
oE/MPa
R,
R,+208
0. 26
-I g ( a ' / w) /6
R,
0. 4
-0. 58
-0.
NE
500 000
1000 000
(G
0 . 5 * ( c o s [ x (R,400)/22001+1)
(0.32+$/6)
~~
44 '
Vol. 18
Table 2
Si
Mn
Cr
Mo
cu
Ni
EN-GJS400
3. 700
2.390
0.480
0.030
0.020
<0.050
0.800
0.037
0. 005
EN-GTSGOO
3.680
2.540
(0.080
<0.050
0.030
0.020
(0.040
0.030
0.002
lo-'
.s
3 102
A UMLCI
+ Experimental data
~~
0.01
0.02
0.03
Strain amplitude
0.04
0.05
5
10 3
100
700
500
UMLCl
+ Experimentaldata
300
0
0.1
0.2
Strain amplitude
Fig. 2
10
'
0.3
Fig. 5 and Fig. 6 give Smith, Watson and Topper parameter values (MPa) of EN-GJS-400 and ENGJS-600, respectively. Smith, Watson and Topper
parameterCz7'gives fatigue life of materials taking into account mean stress effect.
Results indicate that there is a good overlap between the fatigue prediction carried out using UMLCI
and the experimental data.
10'
rn Emerimentall
d3
lo1
Fig. 4
900
102
1ff
Number of loadmg cycles
loL
'2
10"
Fig. 5
103
10'
Number of loading cycles
104
6
10.'
;10'
a:
lV
10 A
loz
lo4
Number of loading cycles
10"
Fig. 6
10'
104
Number of loadmg cycles
106
Issue 8
Conclusions
EN-GJS-600.
3 ) Fatigue life prediction of cast iron in terms of
Smith, Watson and Topper parameter is predicted
with precision using UMLCI. Mean stress effect is
taken into account using Smith, Watson and Topper
parameter along with UMLCI.
4) UMLCI is designed to predict different types
of cast irons since the methodology takes into account changes in material properties, such as ultimate tensile strength.
CZl
c31
c41
C51
C61
171
45