Publications

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Several programs at Sandia National Laboratories have adopted energy spectra as a metric to relate the severity of mechanical insults to structural capacity. The purpose being to gain insight into the system's capability, reliability, and to quantify the ultimate margin between the normal operating envelope and the likely system failure point -- a system margin assessment. The fundamental concern with the use of energy metrics was that the applicability domain and implementation details were not completely defined for many problems of interest. The goal of this WSEAT project was to examine that domain of applicability and work out the necessary implementation details. The goal of this project was to provide experimental validation for the energy spectra based methods in the context of margin assessment as they relate to shock environments. The extensive test results concluded that failure predictions using energy methods did not agree with failure predictions using S-N data. As a result, a modification to the energy methods was developed following the form of Basquin's equation to incorporate the power law exponent for fatigue damage. This update to the energy-based framework brings the energy based metrics into agreement with experimental data and historical S-N data.

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Vibration and shock qualification testing of components can be an expensive and time-consuming process. If the component is small, often two or more units can be mounted on a fixture and tested simultaneously to reduce test time. There is an inherent danger in simultaneously testing two or more identical components as the fundamental natural frequencies and mode shapes of the individual components will be nearly identical with some slight variation due to manufacturing variability. Testing in this manner can create a situation where closely spaced vibration modes produce unwanted interference between the two units under test. This phenomenon could result in a case where one unit is over-tested while the other is under-tested. This paper presents some experimental results from simultaneously testing pairs of components which show distinct interference between the units. Some analysis will also be presented showing how variations in the components can alter the intended test response, potentially impacting component qualification.

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Materials subject to cyclic loading have been studied extensively and experimentally determined comparisons of stress to number of cycles are used to estimate fatigue life under various loading scenarios. Fatigue data are traditionally presented in the form of S-N curves. Normally, S-N data are derived from cyclic loading but the S-N results are also applicable to random vibration loading and, to some extent, shock. This paper presents an alternate presentation of fatigue data in terms of input energy and number of cycles to failure. In conjunction with this study, a series of shock tests was conducted on 3D printed cantilever beams using a 6-DOF shaker table. All of the beams were tested to failure at shock levels in the low-cycle fatigue regime. From these data, a nominal fatigue curve in terms of input energy and number of shocks to failure was generated and compared with the theoretical developments.