Cyclic plastic zone-based notch analysis and damage evolution model for fatigue life prediction of metals

Fatigue strength analysis of critical components plays a vital role for ensuring structural integrity and operational reliability of major equipment. In notched components, the concept of cyclic plastic zone (CPZ) is commonly utilized for fatigue cracking analysis, in which the CPZ size normally relates to the material strength. In particular, materials with higher yield stress have shown smaller CPZ size and vice versa. According to this, a new approach for determining closed-form stress at the notch tip is proposed by considering the size of cyclic plastic zone, which can be used for the notch tip stress evaluation along the load direction under cyclic loadings. By implementing FE analysis, experimental data of 304 stainless steel, 40Cr steel and Ti-6Al-4V alloy are utilized for model validation and comparison. Results show that the scope of damaged CPZ alters the notch tip stress under fatigue loadings, and the proposed model yields better correlation of fatigue life predictions with experimental results of the three materials than other two models. (C) 2020 The Authors. Published by Elsevier Ltd