Component HCF Research Based on the Theory of Critical Distance and a Relative Stress Gradient Modification

For the critical engine parts such as the crankshaft, the fatigue limit load is one of the most important parameters involved the design and manufacture stage. In previous engineering applications, this parameter has always been obtained by experiment, which is expensive and time-consuming. This paper, based on the theory of critical distance (TCD), first analyzes the stress distribution of a crankshaft under its limit load. In this way, the length of the critical distance can be obtained. Then a certain load is applied to a new crankshaft made of the same material and the effective stress is calculated based on the critical distance above. Finally, the fatigue limit load of the new crankshaft can be obtained by comparing the effective stress and the fatigue limit of the material. Comparison between the prediction and the corresponding experimental data shows that the traditional TCD may result in bigger errors on some occasions, while the modified TCD proposed in this paper can provide a more satisfactory result in terms of the fatigue limit for a quick engineering prediction.