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Physics Review
Mirrored from the repository. The canonical copy is docs/PHYSICS_REVIEW.md. The typeset version with the reviewer sign-off table is docs/PHYSICS_REVIEW.pdf.
David Fieser and Hugh Shortt. Both authors contributed equally.
This is a self-contained statement of the fatigue physics implemented in the toolkit, written for review by a materials or fatigue specialist. It contains the equations, the symbols and units, the conventions, and the source for each relation. It contains no software detail. The typeset version with a reviewer sign-off table is PHYSICS_REVIEW.pdf.
All analysis uses true stress and true strain. Stress and modulus are in MPa.
Strain is a dimensionless fraction. Life is expressed in reversals
| Symbol | Meaning | Unit |
|---|---|---|
| true stress, true strain | MPa, - | |
| stress, total strain amplitude | MPa, - | |
| elastic, plastic strain amplitude | - | |
| mean stress, maximum stress | MPa | |
| stress ratio, strain ratio | - | |
| Young's modulus | MPa | |
| fatigue strength coefficient, exponent | MPa, - | |
| fatigue ductility coefficient, exponent | - | |
| cyclic strength coefficient, strain-hardening exponent | MPa, - | |
| reversals to failure | - | |
| stress concentration, fatigue notch factor, notch sensitivity | - |
Engineering values
Valid up to necking. Reference: Dowling, Mechanical Behavior of Materials, 4th ed.
The second form is the doubled hysteresis branch. Reference: Ramberg and Osgood 1943, NACA TN 902. Dowling 4th ed., Eq. 14.12.
Elastic, Basquin:
Plastic, Coffin-Manson:
Total strain-life and the elastic-plastic transition life:
Compatibility, checked and reported but not forced:
The plastic line is fit over the low cycle regime, excluding near-runout points whose plastic strain is at measurement noise level. References: Basquin 1910, Coffin 1954, Manson 1953, Dowling 4th ed. Eq. 14.3 to 14.6.
The asymmetry of a constant amplitude cycle is the stress ratio
| Ratio | Loading | Minimum load | Maximum load |
|---|---|---|---|
| fully reversed, the LCF baseline | compression | equal tension | |
| pulsating tension | zero | tension | |
| tension-tension | tension | higher tension | |
| pulsating compression | compression | zero | |
| compression-compression | higher compression | compression |
The control mode decides what a nonzero mean does over the life of a test. Under strain control the mean stress relaxes toward zero as plastic strain accumulates, and Morrow suits balanced or compressive means while SWT suits tensile means. Under stress control the specimen ratchets, accumulating strain in the direction of the mean stress, and the Walker fitted exponent captures the stress ratio sensitivity. The corrections in this section apply to the stabilized cycle. References: Dowling 4th ed. ch. 9.
The cycle-dependent evolution is modeled separately. Mean stress relaxation
under strain control follows the power law
Morrow, elastic term shifted by the mean stress:
Modified Morrow, both terms shifted:
Smith-Watson-Topper:
Walker, with the equivalent fully-reversed amplitude and the steel estimate of the exponent:
Morrow equivalent fully-reversed amplitude:
With
The plastic strain energy density per cycle is the closed loop area
The tension-compression asymmetry of a cycle is
The stabilized plastic strain energy per cycle correlates with life through the power law
with the energy-life coefficient
with the total stress range
Irregular histories are reduced to closed cycles by the rainflow method, which pairs reversals into hysteresis loops while preserving their order in time. Reference: ASTM E1049-85(2017), Downing and Socie 1982, Matsuishi and Endo 1968.
Level-crossing counting records positive-slope crossings at and above a reference level and negative-slope crossings below it. Peak counting records peaks at and above the reference and valleys below it. Both follow ASTM E1049-85(2017), sections 5.2 and 5.3.
The racetrack (gate) filter condenses a history before counting by removing swings smaller than a gate while keeping the order of the large reversals. Reference: Fuchs, Nelson, Burke, and Toomay, SAE paper 730565, 1973.
A repeating strain history block is rotated to its global maximum and its stress response simulated: the initial loading follows the cyclic Ramberg-Osgood curve, every subsequent branch follows the doubled hysteresis form given above from its reversal origin, and material memory follows the rainflow closure rule, so a closed interior loop leaves the outer branch exactly where it would have been without the interruption. Each closed loop carries its strain amplitude and its simulated peak and mean stress, its life comes from the SWT, Morrow, or uncorrected strain-life relation above, and the damage is Miner-summed to blocks to failure. Sequence effects enter through the loop means: a small cycle riding on a large branch carries the mean stress of its position.
A load-input mode covers notched members: given a nominal stress history
and
Assumptions, stated plainly: stabilized cyclic properties throughout, no cycle-dependent mean stress relaxation, no ratcheting. The simulation is consistent with the constant-amplitude solvers and with rainflow counting by construction and by test. Validation, strain input: against the published SAE smooth-specimen dataset of Conle (MSc thesis, University of Waterloo, 1974, data distributed by the SAE FD and E committee), predictions fall within a factor of two of experiment for the transmission and bracket histories and about a factor of three, non-conservative, for the suspension history, consistent with the documented scatter of linear-damage local-strain predictions on this program. Validation, load input: against the SAE keyhole benchmark (AE-6, Wetzel ed., 1977, inputs and results preserved on the Internet Archive copy of the eFatigue benchmark page), the constant-amplitude RQC-100 case predicts within 4 percent of the benchmark's own strain-life calculation and conservatively against the crack-based experimental life, and the Man-Ten suspension variable-amplitude case predicts within a factor of two of the three experimental lives. References: Masing 1926 (Proc. 2nd Int. Congress for Applied Mechanics, Zurich), Dowling 4th ed. ch. 14, ASTM E1049-85(2017), Neuber 1961, Conle 1974 and the SAE FD and E archive via fde.uwaterloo.ca.
Palmgren-Miner linear damage, failure at a critical sum, the default being one:
Double Linear Damage Rule, Manson-Halford, with the Phase I life fraction referenced to the longest life in the spectrum:
Phase I accumulates to one, then Phase II accumulates to one. Corten-Dolan, where
References: Palmgren 1924, Miner 1945, Manson and Halford 1981 (Int. J. Fracture 17:169), Corten and Dolan 1956.
For stress-based collectives the allowable life comes from a one-slope Woehler
line with a knee at
and below the knee one of three treatments: infinite life (Miner original),
the same slope
References: Miner 1945, Haibach 1970, described in Haibach, Betriebsfestigkeit, 3rd ed., Springer, 2006.
Neuber, combined with the cyclic curve, and its range form:
Glinka equivalent strain energy density:
Fatigue notch factor and notch sensitivity:
Neuber tends to overestimate and Glinka to underestimate the local strain. The measured value usually lies between them. References: Neuber 1961, Molski and Glinka 1981, Peterson 1974.
Life is the dependent variable in the linearized regression,
The censored maximum-likelihood layer follows the framework behind the ASTM
replacement work item WK88010. With
where
with
The fatigue limit from a staircase (up-and-down) test is estimated by the
Dixon-Mood method. With
with the minus sign when the analysis uses failures and the plus sign for
survivals. Below the 0.3 variability bound the standard deviation is the
approximate fallback
where
The random fatigue limit model treats each specimen's fatigue limit
so the S-N curve flattens naturally near the limit and runouts enter the
likelihood as censored observations, including the probability that the
limit sits above the test stress. The five parameters are fit by maximum
likelihood with the marginal integral over
Outlier screening operates on the residuals of the log-life regression.
Runouts are censored observations, not outliers, and are excluded from the
screen. A single suspect point uses the two-sided Grubbs test, several suspect
points use the generalized extreme studentized deviate test, whose
approximation is intended for
When no strain-controlled test data exists, the four constants are estimated
from monotonic properties.
Medians method, steels (recommended default) and aluminum alloys:
Uniform Material Law, steels, with the ductility correction
and for aluminum and titanium alloys
Universal slopes, any metal:
Modified universal slopes, steels:
Hardness method, steels with roughly 150 to 700 HB:
References: Meggiolaro and Castro 2004 (Int. J. Fatigue 26:463, also the comparative evaluation over 845 metals), Baeumel and Seeger 1990, Manson 1965 (Exp. Mech. 5:193), Muralidharan and Manson 1988 (J. Eng. Mater. Technol. 110:55), Roessle and Fatemi 2000 (Int. J. Fatigue 22:495).
Frequency-modified Coffin-Manson, coefficient form:
Linear time-fraction creep-fatigue damage, fatigue plus creep:
checked against a bilinear creep-fatigue interaction envelope. References: Coffin 1971, Robinson 1952, ASTM E2714-13(2020).
Critical-plane parameters:
The plane search takes strain and stress tensor component histories sampled
over one cycle and scans plane normals over a hemisphere grid. Per plane,
the normal strain history is
References: Fatemi and Socie 1988 (Fatigue Fract. Eng. Mater. Struct. 11(3):149), Brown and Miller 1973, Smith, Watson, Topper 1970, Socie and Marquis, Multiaxial Fatigue, SAE, 2000.
- True stress-strain conversion assumed valid up to necking.
- Plastic strain amplitude taken as
$\Delta\varepsilon_t/2 - \Delta\sigma/(2E)$ . - Failure criterion is a percent load drop from the stabilized half-life peak load, default 30 percent.
- Default mean-stress model for variable amplitude is SWT, notch default is Neuber, damage default is Miner.
- The plastic strain-life line is fit over the low cycle regime only.
lcf-strain-life, by David Fieser and Hugh Shortt, both authors contributed equally. MIT license. Cite via CITATION.cff or DOI 10.5281/zenodo.21222820.
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