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Microstructure-based fatigue modelling with residual stresses: Prediction of the microcrack initiation around inclusions

机译：具有残余应力的基于微观结构的疲劳建模：夹杂物周围微裂纹萌生的预测

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摘要

In the investigation of fatigue properties of metals, the microstructure-based modelling has shown its powerful applicability in predicting the microcrack initiation as well as the fatigue life. However, proper treatment of the inclusions, which are the major fatigue crack trigger especially for the very high cycle fatigue regime, is still missing. It is emphasised that in addition to the geometrical representation and the basic mechanical properties assignment of the inclusions, the residual stresses developed between the steel matrix and inclusions during the cooling processes due to their distinct thermal expansion coefficients play a non-negligible role in determining the fatigue properties. Therefore, it is aimed, in this study, to propose a microstructure-based modelling approach to account for the effects of residual stresses induced by the rapid cooling process on the fatigue crack initiation behaviour of a martensitic steel, for which the majority of the fatigue crack is formed around the calcium aluminate inclusions in experiments. The entire approach is decomposed into two processes: i) simulation of the cooling process to obtain the residual stress profile around the inclusion and ii) fatigue simulation using a crystal plasticity model including the mapped residual stress profile from the previous step. It is shown that the proposed approach accurately predicts the fatigue crack initiation sites around the inclusions corresponding to the experimental findings, while the modelling approach without the residual stresses fails to predict the correct locations of the crack initiation, revealing the necessity to consider the residual stresses for the future fatigue modelling and assessment.
机译：在金属的疲劳性能研究中，基于微观结构的建模显示出其在预测微裂纹萌生以及疲劳寿命方面的强大适用性。但是，仍然缺少对夹杂物的适当处理，这些夹杂物是主要的疲劳裂纹触发，尤其是对于非常高的循环疲劳状态。需要强调的是，除了夹杂物的几何表示和基本力学性能分配外，由于冷却过程中钢基体与夹杂物之间的热膨胀系数不同而产生的残余应力在确定夹杂物时起着不可忽略的作用。疲劳性能。因此，本研究旨在提出一种基于微观结构的建模方法，以解决由快速冷却过程引起的残余应力对马氏体钢疲劳裂纹萌生行为的影响。实验中在铝酸钙夹杂物周围形成裂纹。整个方法可分解为两个过程：i）冷却过程的模拟，以获取夹杂物周围的残余应力分布； ii）使用晶体可塑性模型进行疲劳模拟，包括先前步骤中映射的残余应力分布。结果表明，所提出的方法能够准确地预测与实验结果相对应的夹杂物周围的疲劳裂纹萌生部位，而没有残余应力的建模方法则无法预测裂纹萌生的正确位置，这表明考虑残余应力的必要性。用于将来的疲劳建模和评估。

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