COMPLAS 2025

Fatigue Life Prediction of High-Strength Steels Affected by Manufacturing Induced Roughness and Residual Stresses

  • Gonçalves, Luis Antonio (CIMNE-UPC)
  • Jiménez, Sergio (CIMNE-UPC)
  • Cornejo, Alejandro (UPC-CIMNE)
  • Barbu, Lucia Gratiela (UPC-CIMNE)

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Manufacturing-induced residual stresses can significantly impact the fatigue performance of a material, either enhancing or degrading its fatigue life depending on their nature and distribution. These stresses are generated by various processes such as shear-cutting, welding, machining, forming, and heat treatment. Shear-cutting, for example, can lead to tensile residual stresses at the cut edge and increased surface roughness, making it a critical factor in fatigue-sensitive components. This study employs an isotropic damage-based high-cycle fatigue model [1, 2] to estimate the fatigue life of trimmed and punched specimens of two complex-phase steels. The model integrates residual stresses obtained from process simulations and surface roughness measurements to account for the influence of shear-cutting on fatigue strength. The main advantage is it requires only standard uniaxial tensile properties and S-N data from as-polished specimens, providing as output virtual S-N curves of residual stress affected specimens, enabling a significant reduction in the experimental characterization effort. The numerical predictions show good agreement with experimental results. These findings demonstrate the potential of numerical modelling as an effective tool for evaluating the fatigue behaviour of high-strength metals affected by manufacturing induced residual stresses, such as from shear-cutting processes.