Fatigue of a Rotor: Predicting Life Expectancy with Variable Cyclic Stresses

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SUMMARY

This discussion focuses on predicting the life expectancy of a rotor subjected to variable cyclic stresses, specifically in the context of a fast-rotating impeller or turbine. The rotor experiences static loads of 400 MPa and variable cyclic stresses ranging from 20 to 140 MPa, influenced by both gravitational forces and aerodynamic effects. The user seeks methods to estimate fatigue life using equivalent strain calculations and finite element analysis (FEA) for stress distribution, emphasizing the need for accurate predictions to avoid costly physical testing iterations.

PREREQUISITES
  • Understanding of rotor dynamics and centripetal forces
  • Knowledge of fatigue analysis and equivalent strain concepts
  • Familiarity with finite element analysis (FEA) techniques
  • Basic principles of material science, particularly yield strength
NEXT STEPS
  • Research methods for calculating fatigue life using equivalent strain
  • Explore advanced finite element analysis (FEA) software for rotor stress distribution
  • Investigate material fatigue data specific to metals under cyclic loading
  • Learn about the impact of high-frequency vibrations on rotor performance
USEFUL FOR

Engineers, rotor dynamics specialists, and material scientists involved in the design and analysis of rotating machinery, particularly in aerospace applications.

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I have a fast rotating rotor spinning over 2 axis (over its main axis and over an external axis - the two axis are perpendicular to each other). Easiest to imagine this is like a windturbine yawing as it follows the wind direction.Each of the two rotations obviously causes a distinct centripetal force which causes stress on the rotor.

1. Do I correctly presume these loads can be understood as static (like a preload) as long as the rotations have constant velocities?Additionally as the rotor is rotating with its axis perpendicular to the gravity field, gravity is causing a cyclic load on rotor parts. Plus i have a small aerodynamic force which is variable. This adds up to peaks and dips in the stress experienced by the rotor - on top of the static loads described under the point 1. above.

2. How do i predict the max number of cycles the rotor can endure?I presume i need data for fatigue with applied preload, but i am unable to find any for metals. I presume i could somehow calculate the life expectancy using equivalent strain, but i am not sure how to go about it.

3. Is it possible to calculate the life expectancy using equivalent strain? If yes, can you please point me into the right direction, thank you.
At the moment my “static” stresses amount to 400 MPa and my variable cyclic stresses amount to 20 - 140 MPa.

20 MPa are the high frequency (sinus) cycles and 120 MPa are low frequency (step).

Since the high frequency (sinus) cycles are only 5% of the main load, i presume they may be considered as vibrations? But then again it depends on the yield strength, correct?
 
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Please start again from the beginning . Draw the mechanism , describe what it does and show some basic loads , speeds and dimensions .
 
Last edited:
It is a small impeller/turbine.
Imagine it powering an acrobatic plane - in turns it can experience up to 6 g's, and surges in the airflow.

Roots of the blades - where the blades are molded together with the hub - experience very high stresses. I need to determine how long these blades will endure at specific flight conditions/patterns.

I can do physical tests but at this point it would require several iterations which would be costly. So I'm looking to estimate the life expectancy first.
Due to the complex blade geometry i am using fea to calculate stess distribution in the blades. But i can't use it to estimate the life expectancy.For what it's worth, in one of the flight patterns the stresses/time would roughly look like on the attached picture.
(the graph is non-normalized - sorry i quickly made it just for my own refference yesterday)
 

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