Skip to main content
Top
Published in: Journal of Materials Engineering and Performance 12/2013

01-12-2013

Prediction of Contact Fatigue Life of Alloy Cast Steel Rolls Using Back-Propagation Neural Network

Authors: Huijin Jin, Sujun Wu, Yuncheng Peng

Published in: Journal of Materials Engineering and Performance | Issue 12/2013

Log in

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

In this study, an artificial neural network (ANN) was employed to predict the contact fatigue life of alloy cast steel rolls (ACSRs) as a function of alloy composition, heat treatment parameters, and contact stress by utilizing the back-propagation algorithm. The ANN was trained and tested using experimental data and a very good performance of the neural network was achieved. The well-trained neural network was then adopted to predict the contact fatigue life of chromium alloyed cast steel rolls with different alloy compositions and heat treatment processes. The prediction results showed that the maximum value of contact fatigue life was obtained with quenching at 960 °C, tempering at 520 °C, and under the contact stress of 2355 MPa. The optimal alloy composition was C-0.54, Si-0.66, Mn-0.67, Cr-4.74, Mo-0.46, V-0.13, Ni-0.34, and Fe-balance (wt.%). Some explanations of the predicted results from the metallurgical viewpoints are given. A convenient and powerful method of optimizing alloy composition and heat treatment parameters of ACSRs has been developed.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

Appendix
Available only for authorised users
Literature
1.
go back to reference G. Sun, Y. Zhang, C. Liu, K. Luo, Q. Tao, and P. Li, Microstructure and Wear Resistance Enhancement of Cast Steel Rolls by Laser Surface Alloying NiCr-Cr3C2, Mater. Des., 2010, 31, p 2737–2744CrossRef G. Sun, Y. Zhang, C. Liu, K. Luo, Q. Tao, and P. Li, Microstructure and Wear Resistance Enhancement of Cast Steel Rolls by Laser Surface Alloying NiCr-Cr3C2, Mater. Des., 2010, 31, p 2737–2744CrossRef
2.
go back to reference Y. Fujii and K. Maeda, Flaking Failure in Rolling Contact Fatigue Caused by Indentations on Mating Surface (I): Reproduction of Flaking Failure Accompanied by Cracks Extending Bi-Directionally Relative to the Load-Movement, Wear, 2002, 252, p 787–798CrossRef Y. Fujii and K. Maeda, Flaking Failure in Rolling Contact Fatigue Caused by Indentations on Mating Surface (I): Reproduction of Flaking Failure Accompanied by Cracks Extending Bi-Directionally Relative to the Load-Movement, Wear, 2002, 252, p 787–798CrossRef
3.
go back to reference Y. Fujii and K. Maeda, Flaking Failure in Rolling Contact Fatigue Caused by Indentations on Mating Surface (II): Formation Process of Flaking Failure Accompanied by Cracks Extending Bi-Directionally Relative to the Load-Movement, Wear, 2002, 252, p 799–810CrossRef Y. Fujii and K. Maeda, Flaking Failure in Rolling Contact Fatigue Caused by Indentations on Mating Surface (II): Formation Process of Flaking Failure Accompanied by Cracks Extending Bi-Directionally Relative to the Load-Movement, Wear, 2002, 252, p 799–810CrossRef
4.
go back to reference Y. Fujii and K. Maeda, Flaking Failure in Rolling Contact Fatigue Caused by Indentations on Mating Surface (III): Mechanism of Crack Growth in the Direction Opposite to the Load-Movement, Wear, 2002, 252, p 811–823CrossRef Y. Fujii and K. Maeda, Flaking Failure in Rolling Contact Fatigue Caused by Indentations on Mating Surface (III): Mechanism of Crack Growth in the Direction Opposite to the Load-Movement, Wear, 2002, 252, p 811–823CrossRef
5.
go back to reference L. Dimitrov, D. Michalopoulos, Ch.Alk. Apostolopoulos, and T.D. Neshkov, Investigation of Contact Fatigue of High Strength Steel Gears Subjected to Surface Treatment, J. Mater. Eng. Perform., 2009, 18, p 939–946CrossRef L. Dimitrov, D. Michalopoulos, Ch.Alk. Apostolopoulos, and T.D. Neshkov, Investigation of Contact Fatigue of High Strength Steel Gears Subjected to Surface Treatment, J. Mater. Eng. Perform., 2009, 18, p 939–946CrossRef
6.
go back to reference Y. Kimura, M. Sekizawa, and A. Nitanai, Wear and Fatigue in Rolling Contact, Wear, 2002, 253, p 9–16CrossRef Y. Kimura, M. Sekizawa, and A. Nitanai, Wear and Fatigue in Rolling Contact, Wear, 2002, 253, p 9–16CrossRef
7.
go back to reference Y. Gao, Influence of Deep-Nitriding and Shot Peening on Rolling Contact Fatigue Performance of 32Cr3MoVA Steel, J. Mater. Eng. Perform., 2008, 17, p 455–459CrossRef Y. Gao, Influence of Deep-Nitriding and Shot Peening on Rolling Contact Fatigue Performance of 32Cr3MoVA Steel, J. Mater. Eng. Perform., 2008, 17, p 455–459CrossRef
8.
go back to reference P. Orbanić and M. Fajdiga, A Neural Network Approach to Describing the Fretting Fatigue in Aluminium-Steel Couplings, Int. J. Fatigue, 2003, 25, p 201–207CrossRef P. Orbanić and M. Fajdiga, A Neural Network Approach to Describing the Fretting Fatigue in Aluminium-Steel Couplings, Int. J. Fatigue, 2003, 25, p 201–207CrossRef
9.
go back to reference N.B. Fredj, M.B. Nasr, A.B. Rhouma, C. Braham, and H. Sidhom, Fatigue Life Improvements of the AISI, 304 Stainless Steel Ground Surfaces by Wire Brushing, J. Mater. Eng. Perform., 2004, 13, p 564–574CrossRef N.B. Fredj, M.B. Nasr, A.B. Rhouma, C. Braham, and H. Sidhom, Fatigue Life Improvements of the AISI, 304 Stainless Steel Ground Surfaces by Wire Brushing, J. Mater. Eng. Perform., 2004, 13, p 564–574CrossRef
10.
go back to reference B. Li, L. Reis, and M. de Freitas, Simulation of Cyclic Stress/Strain Evolutions for Multiaxial Fatigue Life Prediction, Int. J. Fatigue, 2006, 28, p 451–458CrossRef B. Li, L. Reis, and M. de Freitas, Simulation of Cyclic Stress/Strain Evolutions for Multiaxial Fatigue Life Prediction, Int. J. Fatigue, 2006, 28, p 451–458CrossRef
11.
go back to reference B.P. Conner, T.C. Lindley, T. Nicholas, and S. Suresh, Application of a Fracture Mechanics Based Life Prediction Method for Contact Fatigue, Int. J. Fatigue, 2004, 26, p 511–520CrossRef B.P. Conner, T.C. Lindley, T. Nicholas, and S. Suresh, Application of a Fracture Mechanics Based Life Prediction Method for Contact Fatigue, Int. J. Fatigue, 2004, 26, p 511–520CrossRef
12.
go back to reference K.S. Kim, K.M. Nam, G.J. Kwak, and S.M. Hwang, A Fatigue Life Model for 5% Chrome Work Roll Steel Under Multiaxial Loading, Int. J. Fatigue, 2004, 26, p 683–689CrossRef K.S. Kim, K.M. Nam, G.J. Kwak, and S.M. Hwang, A Fatigue Life Model for 5% Chrome Work Roll Steel Under Multiaxial Loading, Int. J. Fatigue, 2004, 26, p 683–689CrossRef
13.
go back to reference H. White, Connectionist Non-parametric Regression: Multilayer Feed Forward Networks Can Learn Arbitrary Mappings, Neural Netw., 1990, 3, p 535–549CrossRef H. White, Connectionist Non-parametric Regression: Multilayer Feed Forward Networks Can Learn Arbitrary Mappings, Neural Netw., 1990, 3, p 535–549CrossRef
14.
go back to reference M.Q. Li, X.M. Liu, and A.M. Xiong, Prediction of the Mechanical Properties of Forged TC11 Titanium Alloy by ANN, J. Mater. Process. Technol., 2002, 121, p 1–4CrossRef M.Q. Li, X.M. Liu, and A.M. Xiong, Prediction of the Mechanical Properties of Forged TC11 Titanium Alloy by ANN, J. Mater. Process. Technol., 2002, 121, p 1–4CrossRef
15.
go back to reference Y.L. Han, Artificial Neural Network Technology as a Method to Evaluate the Fatigue Life of Weldments with Welding Defects, Int. J. Press. Vessels Pip., 1995, 63, p 205–209CrossRef Y.L. Han, Artificial Neural Network Technology as a Method to Evaluate the Fatigue Life of Weldments with Welding Defects, Int. J. Press. Vessels Pip., 1995, 63, p 205–209CrossRef
16.
go back to reference J.A. Lee, D.P. Almond, and B. Harris, The Use of Neural Networks for the Prediction of Fatigue Lives of Composite Materials, Composites A, 1999, 30, p 1159–1169CrossRef J.A. Lee, D.P. Almond, and B. Harris, The Use of Neural Networks for the Prediction of Fatigue Lives of Composite Materials, Composites A, 1999, 30, p 1159–1169CrossRef
17.
go back to reference T.T. Pleune and O.K. Chopra, Using Artificial Neural Networks to Predict the Fatigue Life of Carbon and Low-Alloy Steels, Nucl. Eng. Des., 2000, 197, p 1–12CrossRef T.T. Pleune and O.K. Chopra, Using Artificial Neural Networks to Predict the Fatigue Life of Carbon and Low-Alloy Steels, Nucl. Eng. Des., 2000, 197, p 1–12CrossRef
18.
go back to reference V.S. Srinivasan, M.K. Valsan, K.B.S. Rao, S.L. Mannan, and B. Raj, Low Cycle Fatigue and Creep-Fatigue Interaction Behavior of 316L (N) Stainless Steel and Life Prediction by Artificial Neural Network Approach, Int. J. Fatigue, 2003, 25, p 1327–1338CrossRef V.S. Srinivasan, M.K. Valsan, K.B.S. Rao, S.L. Mannan, and B. Raj, Low Cycle Fatigue and Creep-Fatigue Interaction Behavior of 316L (N) Stainless Steel and Life Prediction by Artificial Neural Network Approach, Int. J. Fatigue, 2003, 25, p 1327–1338CrossRef
19.
go back to reference K. Genel, Application of Artificial Neural Network for Predicting Strain-Life Fatigue Properties of Steels on the Basis of Tensile Tests, Int. J. Fatigue, 2004, 26, p 1027–1035CrossRef K. Genel, Application of Artificial Neural Network for Predicting Strain-Life Fatigue Properties of Steels on the Basis of Tensile Tests, Int. J. Fatigue, 2004, 26, p 1027–1035CrossRef
20.
go back to reference J.M. Park and H.T. Kang, Prediction of Fatigue Life for Spot Welds Using Back-Propagation Neural Networks, Mater. Des., 2007, 28, p 2577–2584CrossRef J.M. Park and H.T. Kang, Prediction of Fatigue Life for Spot Welds Using Back-Propagation Neural Networks, Mater. Des., 2007, 28, p 2577–2584CrossRef
21.
go back to reference M.D. Mathew, D.W. Kim, and W.S. Ryu, A Neural Network Model to Predict Low Cycle Fatigue Life of Nitrogen-Alloyed 316L Stainless Steel, Mater. Sci. Eng. A, 2008, 474, p 247–253CrossRef M.D. Mathew, D.W. Kim, and W.S. Ryu, A Neural Network Model to Predict Low Cycle Fatigue Life of Nitrogen-Alloyed 316L Stainless Steel, Mater. Sci. Eng. A, 2008, 474, p 247–253CrossRef
22.
go back to reference M.R. Green, W.M. Rainforth, M.F. Frolish, and J.H. Beynon, The Effect of Microstructure and Composition on the Rolling Contact Fatigue Behaviour of Cast Bainitic Steels, Wear, 2007, 263, p 756–765CrossRef M.R. Green, W.M. Rainforth, M.F. Frolish, and J.H. Beynon, The Effect of Microstructure and Composition on the Rolling Contact Fatigue Behaviour of Cast Bainitic Steels, Wear, 2007, 263, p 756–765CrossRef
23.
go back to reference R. Rojas, Neural Network, a Systematic Introduction, Springer, Berlin, 1996 R. Rojas, Neural Network, a Systematic Introduction, Springer, Berlin, 1996
24.
go back to reference M. Smith, Neural Networks for Statistical Modeling, Van Nostrand Reinhold, New York, 1993 M. Smith, Neural Networks for Statistical Modeling, Van Nostrand Reinhold, New York, 1993
25.
go back to reference J.M. Zurad, Introduction to Artificial Neural Networks, West Publishing Co, St. Paul, 1992 J.M. Zurad, Introduction to Artificial Neural Networks, West Publishing Co, St. Paul, 1992
26.
go back to reference S. Haykin, Neural Networks, a Comprehensive Foundation, MacMillan College Publishing Company, New York, 1994 S. Haykin, Neural Networks, a Comprehensive Foundation, MacMillan College Publishing Company, New York, 1994
27.
go back to reference Z. Guo and W. Sha, Modeling the Correlation Between Processing Parameters and Properties of Maraging Steels Using Artificial Neural Network, Comput. Mater. Sci., 2004, 29, p 12–28CrossRef Z. Guo and W. Sha, Modeling the Correlation Between Processing Parameters and Properties of Maraging Steels Using Artificial Neural Network, Comput. Mater. Sci., 2004, 29, p 12–28CrossRef
28.
go back to reference M.S. Ozerdem and S. Kolukisa, Artificial Neural Network Approach to Predict the Mechanical Properties of Cu-Sn-Pb-Zn-Ni Cast Alloys, Mater. Des., 2009, 30, p 764–769CrossRef M.S. Ozerdem and S. Kolukisa, Artificial Neural Network Approach to Predict the Mechanical Properties of Cu-Sn-Pb-Zn-Ni Cast Alloys, Mater. Des., 2009, 30, p 764–769CrossRef
29.
go back to reference L. Xu, J. Xing, S. Wei, Y. Zhang, and R. Long, Optimization of Heat Treatment Technique of High-Vanadium High-Speed Steel Based on Back-Propagation Neural Networks, Mater. Des., 2007, 28, p 1425–1432CrossRef L. Xu, J. Xing, S. Wei, Y. Zhang, and R. Long, Optimization of Heat Treatment Technique of High-Vanadium High-Speed Steel Based on Back-Propagation Neural Networks, Mater. Des., 2007, 28, p 1425–1432CrossRef
30.
go back to reference L. Xu, J. Xing, S. Wei, Y. Zhang, and R. Long, Optimisation of Chemical Composition of High Speed Steel with High Vanadium Content for Abrasive Wear Using an Artificial Neural Network, Mater. Des., 2007, 28, p 1031–1037CrossRef L. Xu, J. Xing, S. Wei, Y. Zhang, and R. Long, Optimisation of Chemical Composition of High Speed Steel with High Vanadium Content for Abrasive Wear Using an Artificial Neural Network, Mater. Des., 2007, 28, p 1031–1037CrossRef
Metadata
Title
Prediction of Contact Fatigue Life of Alloy Cast Steel Rolls Using Back-Propagation Neural Network
Authors
Huijin Jin
Sujun Wu
Yuncheng Peng
Publication date
01-12-2013
Publisher
Springer US
Published in
Journal of Materials Engineering and Performance / Issue 12/2013
Print ISSN: 1059-9495
Electronic ISSN: 1544-1024
DOI
https://doi.org/10.1007/s11665-013-0695-8

Other articles of this Issue 12/2013

Journal of Materials Engineering and Performance 12/2013 Go to the issue

Premium Partners