White Paper: Physical Sciences
Fatigue Analysis: Approaches to Design Characterization and the Reduction of Catastrophic Failure
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Fatigue Analysis is a very powerful tool that can help engineers to improve their products through accurate predictions of fatigue failure of manufactured parts. This white paper explains how the right software and readily assembled hardware can make quick work of the problem. It walks through the basics of fatigue and fatigue analysis as well as outlines how even those not very familiar with the physics of the phenomenon, or how to measure it, can use a combination of market-available software and hardware to arrive at reliable predictions for behavior of manufactured parts under repeated stress and strain. Using these techniques helps develop safe and reliable products and bring them to market quickly.
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Overview
The document discusses the critical concept of fatigue in materials, particularly in engineering and product design. Fatigue refers to the systematic weakening of materials under repeated loads, which can lead to sudden and catastrophic failures. This phenomenon is exemplified by the 2024 recall of Babboe cargo bicycles, which were found to crack and pose safety hazards due to fatigue-related failures.
The document outlines the importance of fatigue analysis as a powerful tool for engineers to predict and prevent such failures. It emphasizes that traditional methods of testing maximum load-bearing strength are insufficient for assessing fatigue, as fatigue is primarily concerned with the effects of repetitive dynamic load cycles. For instance, daily use of a bicycle on rough terrain can lead to gradual degradation of components due to constant vibrations and loads.
To effectively evaluate fatigue, the document introduces various methodologies, including class counting and rainflow analysis. These techniques simplify and accelerate the characterization of fatigue processes, allowing engineers to gather relevant data efficiently. Class counting organizes data into discrete "bins" for easier manipulation, while rainflow analysis helps in quantifying the accumulated damage from load cycles.
The document also highlights the role of strain gauge technology and data acquisition systems (DAQ) in fatigue analysis. It describes how software, such as imc FAMOS, integrates with hardware components to process and analyze data from strain gauge measurements. This combination enables accurate predictions of fatigue behavior, helping engineers optimize designs for improved service life while considering factors like cost and energy efficiency.
Furthermore, the document emphasizes the flexibility and scalability of modern measurement systems, which can adapt to various environments and requirements. For instance, the imc CRONOS-SL data logger is designed for rugged outdoor use, making it suitable for diverse applications in civil and industrial engineering.
In conclusion, the document underscores the significance of fatigue analysis in enhancing product durability and safety. By leveraging advanced software and hardware solutions, engineers can develop reliable products that meet the demands of modern applications, ultimately leading to a competitive advantage in the market.