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Fatigue life calculation by rainflow cycle counting method

Arıduru, Seçil
In this thesis, fatigue life of a cantilever aluminum plate with a side notch under certain loading conditions is analyzed. Results of experimental stress analysis of the cantilever aluminum plate by using a uniaxial strain gage are presented. The strain gage is glued on a critical point at the specimen where stress concentration exists. Strain measurement is performed on the base-excited cantilever beam under random vibration test in order to examine the life profile simulation. The fatigue analysis of the test specimen is carried out in both time and frequency domains. Rainflow cycle counting in time domain is examined by taking the time history of load as an input. Number of cycles is determined from the time history. In frequency domain analysis, power spectral density function estimates of normal stress are obtained from the acquired strain data sampled at 1000 Hz. The moments of the power spectral density estimates are used to find the probability density function estimate from Dirlik̕s empirical expression. After the total number of cycles in both time and frequency domain approaches are found, Palmgren-Miner rule, cumulative damage theory, is used to estimate the fatigue life. Results of fatigue life estimation study in both domains are comparatively evaluated. Frequency domain approach is found to provide a marginally safer prediction tool in this study.