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Springer Series in Reliability Engineering
Reliability
and Statistical
Computing
Modeling, Methods and Applications
Springer Series in Reliability Engineering
Series Editor
Hoang Pham, Department of Industrial and Systems Engineering, Rutgers
University, Piscataway, NJ, USA
Today’s modern systems have become increasingly complex to design and build,
while the demand for reliability and cost effective development continues.
Reliability is one of the most important attributes in all these systems, including
aerospace applications, real-time control, medical applications, defense systems,
human decision-making, and home-security products. Growing international
competition has increased the need for all designers, managers, practitioners,
scientists and engineers to ensure a level of reliability of their product before release
at the lowest cost. The interest in reliability has been growing in recent years and
this trend will continue during the next decade and beyond.
The Springer Series in Reliability Engineering publishes books, monographs and
edited volumes in important areas of current theoretical research development in
reliability and in areas that attempt to bridge the gap between theory and application in
areas of interest to practitioners in industry, laboratories, business, and government.
**Indexed in Scopus**
Interested authors should contact the series editor, Hoang Pham, Department
of Industrial and Systems Engineering, Rutgers University, Piscataway,
NJ 08854, USA. Email: [email protected], or Anthony Doyle,
Executive Editor, Springer, London. Email: [email protected].
123
Editor
Hoang Pham
Department of Industrial and Systems
Engineering
Rutgers University
Piscataway, NJ, USA
This Springer imprint is published by the registered company Springer Nature Switzerland AG
The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland
Preface
We’re living in an era of fast and unpredictable change. Billions of people are
connected to each other through their mobile devices and the Internet of Things
(IoT). Data is being collected and processed like never before. The era of AI
through reliability and statistical machine computing as well as intelligent and
recommender systems with almost all applications and service industry has expe-
rienced a dramatic shift in the past two decades to a truly global industry, known as
the Industry 4.0. The forces that have driven this change are still at play and will
continue. Most of the products which affect our daily lives are becoming even more
complex than ever. This book, consisting of 18 chapters, aims to address both
research and practical aspects in reliability and statistical computing with emphasis
on the applications. Each chapter is written by active researchers and experienced
practitioners in the field aiming to connect the gap between the theory and practice
and to trigger new research challenges in reliability and statistical computing of
recent complex products and the customer needs in practices.
In chapter “Fatigue Life Distribution Estimation”, it discusses an empirically
based methodology for estimating the cumulative distribution functions for fatigue
life that incorporates available fatigue life data for various stresses given the applied
load. Chapter “Reliability Improvement Analysis Using Fractional Failure”
describes an approach to improve product reliability during development by using
fractional failure analysis method incorporating failure fix effectiveness during each
testing and failure fix phase. The chapter also describes a new product introduction
reliability improvement process with fractional failure analysis. Chapter “Modelling
Innovation Paths of European Firms Using Fuzzy Balanced Scorecard” discusses an
approach for modeling innovation paths of European firms and its strategic per-
formance measurement by integrating fuzzy balanced scorecard. The chapter also
provides empirical evidence for the effectiveness of the approach based on a large
dataset of European firms. Chapter “Innovation Environment in Europe—Efficiency
Analysis Case Study” discusses ways to assess the effectiveness, performance, and
productivity of comparable production units within EU28 countries based on their
innovation performance measured by European Commissions’ European
Innovation Scoreboard 2017.
v
vi Preface
on the conditional failure probability and the mean time to failure, given that the
unit is still survival at the mission arrival time where the mission arrival time
follows a gamma distribution and the failure time of the unit has a Weibull dis-
tribution. The chapter also presents various optimization maintenance models
including age replacement policies and the periodic policies with minimal repairs.
Chapter “Optimal Maintenance Models of Social Infrastructures Considering
Natural Disasters” discusses several optimal maintenance models of social infras-
tructures considering delay, multiple degradation levels, modified costs which
depend on damage levels, and disaster recovery which minimizes the expected cost
rates. The cost factors considered in the model include maintenance periods,
maintenance time delay, wide variety of preventive maintenance costs and degra-
dation levels, and natural disaster distribution.
In chapter “Optimal Checkpoint Intervals, Schemes and Structures for
Computing Modules”, it studies a high-reliability computing system with redun-
dancy techniques and recovery methods to prevent failure occurrences considering
two checkpoint schemes in which their respective interval times are periodic and
random. The chapter discusses the optimal checkpoint interval policies and struc-
tures with computing modules for periodic and random checkpoint models. Chapter
“Data Envelopment Analysis as a Tool to Evaluate Marketing Policy Reliability”
describes the data envelopment analysis design and its applications for effectiveness
evaluation of company marketing strategies. The data envelopment analysis
approach is a useful tool that can provide suggestions on the optimal marketing
strategies to achieve superior performance. Obtaining efficient and reliable software
under resource allocation constraint is an important goal of software management
science. Chapter “Computational Intelligence Approaches for Software Quality
Improvement” discusses the usage of artificial immune algorithms for software
testing and recent development paradigms of computational intelligence for soft-
ware quality improvement.
Postgraduates, researchers, data scientists, and engineers will definitely gain
great knowledge with the help of this book in the areas of reliability engineering
and safety, applied statistics, machine learning and recommender systems, and its
applications. The material is proposed for graduate and advanced undergraduate
level students.
I acknowledge Springer for this opportunity and professional support.
Importantly, I would like to thank all the chapter authors and reviewers for their
availability for this work.
ix
x Contents
Contributors
xi
xii Editor and Contributors
D. Gary Harlow
Nomenclature
1 Introduction
A difficulty with fatigue life data is the characterization of its variability, which can
be several orders of magnitude [1], especially for loading near operating conditions.
The variability is attributable to experimental error, as well as material microstruc-
ture or processing. Thus, estimation and prediction of fatigue life is challenging. A
key concern is the characterization of the cumulative distribution function (cdf) for
fatigue life, given an applied load, which may be either the stress range σ or the
strain range ε. The lower tail portion of the cdf which depicts high reliability is espe-
cially critical; however, that is where scatter is more pronounced, and sample sizes
are smaller. Empirically modeling fatigue life has been considered numerous times.
A simple internet search for statistical fatigue life modeling yields in excess of 10
million citations. A relatively recent work is [2], in which the authors incorporate sta-
tistical analysis with traditional stress-life, strain-life, or crack propagation models.
While empiricism is used, the thrust is to incorporate as much physically motivated
modeling as possible. More frequently, investigators attempt to fit a stress-life (S-N)
curve through the data, especially the medians for given σ or ε. A nice review
of such practices is [3]. Another example of statistical modeling of fatigue data is
contained in [4] in which over two chapters are devoted statistical methodologies.
Other examples of statistical stress-life analysis may be found in [5, 6]. While there
Fatigue Life Distribution Estimation 3
are many more papers, books, and conferences publications on statistical fatigue
modeling, these are representative. In spite of all these references, statistical fatigue
analysis is still an open area of investigation.
Herein, an empirically based approach for accurately estimating the fatigue life
cdf, given σ or ε is proposed. The methodology merges fatigue life data using a
statistical transformation for the estimation. The statistical technique increases the
sample size by merging fatigue data for more precise assessment. This is necessitated
because there is often large variability in S-N data, and the sample sizes are small.
Validation of the modeling is essential, especially for prediction of life outside of the
range of experimental observations. The validity of the methodology is evaluated by
considering percentile bounds estimated for the S-N data. The development of the
methodology and its subsequent validation is illustrated using three different fatigue
life datasets.
A fundamental issue in fatigue life estimation is the choice of an underlying
cdf. The cdf used in the ensuing analyses is a three-parameter Weibull cdf. A fairly
recent example of a traditional statistical S-N methodology using the three-parameter
Weibull cdf is [7] where fatigue of structural and rolling contact problems are con-
sidered. There seems to be a need for more experimental data to enhance modeling
in almost all fatigue analyses. This is addressed in [8] by using normalization for the
fatigue life data so that all the data are merged. The normalized data are then modeled
with a three-parameter Weibull cdf. Even though the intention in [8] is similar to the
emphasis herein, the methodology is somewhat different.
Fatigue life data are most often presented on an S-N plot which shows the fatigue
data for a given load. The load is typically stress or strain. Thus S-N can represent
stress-life or strain-life. An additional way in which the fatigue data are presented is
on a probability plot. Both of these representations will be used subsequently. Three
different sets of fatigue life data are considered for the proposed method.
The first set considered is one of the special cases taken from [9]. Fatigue testing
was conducted on 2024-T4 aluminum alloy specimens. The fatigue tests were per-
formed on rectangular specimens with dimensions of 110 mm long, 52 mm wide, and
1 mm thick, and with a center cut circular hole of radius 5 mm. Holes were cut using
standard procedures with a lathe, and burrs were removed by polishing techniques.
Testing was conducted in laboratory environment where temperatures of 295–297 K
(approximately 22–24 °C) and relative humidities of 50–56% were observed. Con-
stant amplitude tests were performed at a frequency of 30 Hz on a single machine
with a single operator in order to minimize experimental error. Because of the exten-
siveness of this data, they have been used in a variety of analyses; e.g., [10–12].
These data are summarized in Table 1. A total of 222 specimens were tested using
eight different values for σ. The specimens were tested to fracture. The sample
coefficients of variation (cv) are nearly the same, approximately 9%, for the larger
4 D. Gary Harlow
Table 1 Statistical summary of fatigue life data for 2024-T4 specimens [9]
Load, σ (MPa) Size (m) Average (x̄) Standard deviation (s) cv (%)
255 21 18,200 1760 9.6
235 30 28,700 2500 8.7
206 30 59,400 4230 7.1
177 30 146,000 12,600 8.6
157 30 264,000 22,600 8.6
137 30 519,000 96,200 18.5
127 30 1,710,000 1,090,000 63.8
123 21 4,530,000 2,660,000 58.7
values of σ. When σ is 137 MPa, the cv is about double, and for the two smaller
values of σ the scatter increases significantly. The fatigue life data are plotted on
an S-N graph in Fig. 1 in the traditional linear versus logarithm S-N format. As σ
is reduced, the increase in the scatter in life is apparent. Modeling the increasing
variability for decreasing σis the challenge for accurate fatigue life prediction.
The second set of fatigue data to be considered is data collected at room temper-
ature for ASTM A969 hot dipped galvanized sheet steel with a gauge thickness of
1.78 mm [13]. ASTM A969 is a cold-rolled, low carbon, extra deep drawing steel.
This steel is very ductile and soft, and it is age resistant. The automotive industry uses
it in applications where severe forming is required, e.g., inner door components, dash
panels, body side components, and floor pans with spare tire tubs. Fatigue tests for
the ASTM A969 specimens were conducted using a triangular waveform at 25 Hz.
The fatigue tests were terminated, i.e., designated as a failure, when the tensile load
dropped by 50% of the maximum load. A total of 69 specimens were tested to failure.
The data are summarized in Table 2. The cv given ε is more scattered than those
for the 2024-T4 data. The smallest value of ε has the largest scatter, but the second
240
220
200
stress range
180
160
140
120
10 4 10 5 10 6 10 7
number of cycles, N
Fatigue Life Distribution Estimation 5
Table 2 Statistical summary of fatigue life data for ASTM A969 specimens [13]
Load, ε (mm/mm) Size (m) Average (x̄) Standard deviation (s) cv (%)
0.0080 3 4,100 815 19.8
0.0060 12 14,000 3,800 27.2
0.0050 6 34,600 7,030 20.3
0.0040 12 56,500 8,860 15.7
0.0030 12 107,000 12,900 12.1
0.0024 6 199,000 29,800 15.0
0.0020 11 499,000 68,300 13.7
0.0018 7 1,030,000 391,000 37.8
largest ε is rather large as well. This behavior is seen graphically on the S-N plot in
Fig. 2. Consequently, these data are not as statistically well behaved as the 2024-T4
data. These data have been used to investigate other types of fatigue modeling [14,
15].
The third set to assess is 9Cr-1Mo steel which were collated from a round-robin test
program and were reported in [16]. This steel is creep strengthen, and it is frequently
used in thermal power plants to improve the energy efficiency of the power plant
by increasing operating temperatures and pressures. Specifically, 9Cr-1Mo is often
used for steam generator components of both fossil fired and nuclear power plants.
The material from which the data were generated was a single cast, rolled plate
with a nominal tensile strength of 623 MPa [16]. A total of 130 specimens were
tested to failure. The data are summarized in Table 3. The cv given ε is even more
scattered than the above datasets. In fact, there does not seem to be any discernible
pattern. The data are shown on Fig. 3. The reason for the unusual statistical behavior
would require more in depth analysis than is provided in [16]. Usually round-robin
testing has considerably more variability in results because testing conditions and
1e-2
7e-3
5e-3
strain range,
3e-3
2e-3
1e-3
10 3 10 4 10 5 10 6 10 7
cycles to failure, Nf
6 D. Gary Harlow
Table 3 Statistical summary of fatigue life data for 9Cr-1Mo specimens [16]
Load, ε (mm/mm) Size (m) Average (x̄) Standard deviation (s) cv (%)
0.021 5 472 88 18.8
0.020 32 542 189 34.9
0.019 8 572 345 60.2
0.012 34 1,260 357 28.4
0.011 6 1,290 475 36.9
0.006 37 4,820 2,000 41.6
0.005 8 12,700 7,700 60.8
2e-2
1e-2
strain range,
7e-3
5e-3
3e-3
102 103 104 105
cycles to failure, Nf
methodologies are not consistent. Nevertheless, the data will serve as an excellent
case for the proposed modeling approach.
The following is a purely empirical method to improve fatigue life modeling. Because
fatigue data are usually limited in number for relatively few different loading con-
ditions, modeling is crude. A methodology that has been developed to account for
uncertainty for static properties [17] is adapted for fatigue life data. The basis of
the approach is a linear transformation of a collection of experimental observations
{y j : 1 ≤ j ≤ n} into another set of values {z j : 1 ≤ j ≤ n} so that both sets have
the same average and sample standard deviation. Let
z j = ay j + b. (1)
Fatigue Life Distribution Estimation 7
The choices of a and b in Eq. (1) are easily determined by simple algebra to be
the following:
sA sA
a= and b = N A − ȳ, (2)
sy sy
where ȳ is the average and sy is the sample standard deviation for {y j : 1 ≤ j ≤ n},
and N A and sA are arbitrary values chosen for normalization.
For fatigue data the life times are distributed over several orders of magnitude
that the procedure in Eqs. (1) and (2) is applied to the natural logarithm of the
life times. Let m be the number of different values of applied stress or strain, i.e.,
{σk : 1 ≤ k ≤ m} or {εk : 1 ≤ k ≤ m}. Given σk or εk the associated life
times are {Nk, j : 1 ≤ j ≤ n k } where nk is its sample size. Let
be the transformed life times. Substituting Eq. (2) into Eq. (1) leads to the following:
sA
z k, j = (yk. j − ȳk ) + N A . (4)
s y,k
sA
Fy,k (y) = FZ ( (y − ȳk ) + N A ). (5)
s y,k
The approach is designated as the Fatigue Life Transformation (FLT). Recall that
the above methodology is applied to natural logarithms. In order to make observations
on the actual fatigue lives, the values must be changed back to actual cycles.
To evaluate the effectiveness of the proposed FLT methodology, the fatigue life data
summarized in Table 1 and shown on Fig. 1 is considered. Recall that the FLT is
8 D. Gary Harlow
applied to the natural logarithm of the fatigue data; see Eq. (3). The arbitrarily cho-
sen values for N A and sA are 26 and 1, respectively. The rather large value for N A
was chosen to assure that zk,j in Eq. (4) is positive. The 222 FLT data are shown
on Fig. 4, where the axes are labeled to be easily read. Each set of data for a given
σk are transformed using FLT. These transformed data are well grouped so that it
is reasonable to merge them. Figure 5 shows the entire 222 FLT values merged into
a common sample space. The FLT merged data contain approximately 7–10 times
more data than those for each given σk . Thus, estimation for the cdf is necessar-
ily more accurate which results in a better characterization of its lower tail. Also,
notice that the cycles are transformed using the FLT procedure; they are not actual
cycles to failure, i.e., they are not equivalent to the data shown on Fig. 1. The solid
line is the maximum likelihood estimation (MLE) for a three–parameter Weibull cdf
W(α, β, γ), where α is the shape parameter, β is the scale parameter, and γ is the
location parameter. The form of W(α, β, γ) is
= 255 MPa
= 235 MPa
0.100 = 206 MPa
0.050 = 177 MPa
= 157 MPa
= 137 MPa
0.010 = 127 MPa
0.005 = 123 MPa
0.001
1010 1011 1012 1013
transformed cycles
0.100
0.050 W( , , ) MLE
= 2.894
= 2.986
0.010 = 23.327
0.005 KS = 0.043
AD = 0.292
0.001
1010 1011 1012 1013
transformed cycles
Fatigue Life Distribution Estimation 9
Recall that the arbitrary constants N A and sA are 26 and 1, respectively. Equa-
tion (7) can be rewritten to put it into the standard Weibull cdf form W(α, β,
γ);
s y,k s y,k α̂
Fy,k (y) = 1 − exp{−[(y − [ ȳk + (γ̂ − N A )( )])/β̂( )] }, (8)
sA sA
where the shape parameter α̂ is the same for each individual cdf, but the scale
parameter β̂k and location parameter γ̂k are
s y,k s y,k
β̂k = β̂( ); and γ̂k = ȳk + (γ̂ − N A )( ), (9)
sA sA
which are explicitly dependent on the sample parameters for the fatigue life data
given σk and the arbitrary constants N A and sA . Recall that the FLT is for ln(N f );
consequently, the range of values is considerably smaller than that for N f . Table 4
contains the FLT cdf W(α, βk , γk ) parameters for each given σk . Figure 6 shows
the fatigue life data plotted on two parameter Weibull probability paper with the
corresponding FLT cdfs W(α, βk , γk ). Graphically, these cdfs appear to fit the data
well. Indeed, the KS goodness of fit test indicates that all these cdfs are acceptable
for any αs less than 0.25. The AD test, which focuses on the quality of the fit in
the tails, is more discriminating. The cdfs when σk equals 127, 177, 206, 235, or
255 MPa are acceptable for any αs less than 0.25. When σk equals 123 or 157 MPa,
however, the cdfs are acceptable for any αs less than 0.05. When σk equals 137, the
AD test implies that the cdf is not acceptable. Although it is not obvious on Fig. 6
10 D. Gary Harlow
because the cycles scale is so large, both the upper and lower tail of the FLT cdf are
sufficiently different from the life data. Even so, the overall deduction is that the FLT
transformation is acceptable for these fatigue life data. Again, the KS test supports
that conclusion, and there is only one value for σk , 137 MPa, for which the AD test
indicates otherwise.
Another way to assess the quality of the proposed FLT methodology is to consider
percentiles p of the estimated cdfs. The percentiles are given by
which are computed from Eqs. (8) and (9). One of the most common percentiles that
is considered is the median y1/2 , i.e., p is 0.5. Figure 7 is an S-N graph, identical
to Fig. 1, where the solid line is the FLT estimated median, and the dashed lines
are the FLT estimated 99% percentile bounds. The 99% bounds are very tight while
encapsulating the entire set of data for each σk . They also follow the trend in the
S–N data in that they are very narrow when the life data have very little variability,
but they are broader when the life data have larger variability. This lends credence
to the FLT approach for the 2024-T4 fatigue data.
Fatigue Life Distribution Estimation 11
, MPa
FLT estimated median
FLT estimated
220 99% percentile bounds
200
stress range
180
160
140
120
The second applications of the FLT method is for the ASTM A969 fatigue data.
Again, the arbitrarily chosen values for N A and sA are 26 and 1, respectively. Figure 8
shows the entire 69 FLT values merged into a common sample space. The solid line
is the MLE W(α, β, γ), Eq. (6). The KS and AD goodness of fit test statistics are
0.047 and 0.524, respectively. The MLE is acceptable according to the KS test for
any significance level αs less than 0.3. For the AD test, however, it is acceptable only
for αs less than 0.2 because there is some deviation between the data and the MLE
in the lower tail. Even so, the FLT data are well represented by the MLE W(α, β, γ)
cdf. The MLE estimated parameters are α̂ = 3.057; β̂ = 2.964; and γ̂ = 23.289.
Using Eqs. (7)–(9), Fig. 9 has the ASTM A969 data with the FLT cdfs W(α, βk ,
γk ). Graphically, the FLT cdfs appear to characterize the data well. In fact, the KS
test indicates that all these cdfs are acceptable for any αs less than 0.3. The AD test,
however, implies that the FLT cdfs are marginal, at best. Clearly, the FLT cdfs are
0.250
0.100 W( , , ) MLE
0.050 = 3.057
= 2.964
0.025
= 23.289
0.010 KS = 0.047
AD = 0.524
0.005
0.003
10 11 12 13
10 10 10 10
transformed cycles
12 D. Gary Harlow
probability
0.60 0.0050
0.50 0.0060
0.0080
0.40 FLT cdfs
0.30
0.20
0.10
0.07
0.05
103 104 105 106 5x106
cycles to failure, Nf
7e-3
5e-3
strain range,
3e-3
2e-3
1e-3
103 104 105 106 107
cycles to failure, Nf
not as accurate in the tails. No doubt, larger samples for each εk would help with
characterization of the extremes. Using Eq. (10), Fig. 10 is an S-N graph, identical
to Fig. 2, with the addition of the FLT estimated median, and the FLT estimated 99%
percentile bounds. The 99% bounds are very tight, and the all the data are within the
bounds for each εk . They are somewhat jagged because they follow the pattern of
the S-N data. The analysis is not as crisp as that for the 2024-T4 data; however, there
seems to be merit in using the FLT approach for the ASTM A969 fatigue data.
The third application of the FLT method for the 9Cr-1Mo fatigue data does not
perform very well. Figure 3 shows unusually large scatter for the higher values of
εk which is a good test for the FLT methodology. The arbitrary scaling factors
are the same; N A and sA are 26 and 1, respectively. Figure 11 shows the 130 FLT
merged values with the MLE W(α, β, γ). The KS and AD goodness of fit test statistics
Fatigue Life Distribution Estimation 13
probability
0.250
0.100 W( , , ) MLE
0.050 = 2.497
= 2.475
0.025
= 23.769
0.010 KS = 0.028
AD = 0.300
0.005
0.003
10 11 12 13
10 10 10 10
transformed cycles
are 0.028 and 0.300, respectively. The MLE is acceptable according to the KS and
AD tests for any significance level αs less than 0.3. The merged data are very well
characterized by this cdf. The corresponding MLE estimated parameters are α̂ =
2.497; β̂ = 2.475; and γ̂ = 23.769.
The FLT cdfs W(α, βk , γk ), Eqs. (7)–(9), for 9Cr-1Mo are shown on Fig. 12.
Graphically, the FLT cdfs appear to be acceptable, at least for the cases with more
data. Clearly, when εk is 0.019, the fit is borderline. The KS test indicates that all
these cdfs are acceptable for any αs less than 0.3. On the other hand, the AD test
indicates that none of the FLT cdfs are acceptable. The compressed graphical scale
for the cycles to failure masks the poor fit of the FLT cdfs to the tails of the data.
Figure 13 is the S-N graph, Fig. 3, with the FLT estimated median, and the FLT
estimated 99% percentile bounds. Because the FLT cdfs are not very representative
of the fatigue data, the 99% bounds are erratic. All the data are within the bounds
for each εk . That is somewhat positive. They are quite jagged because they follow
the S-N data pattern. One of the difficulties in modeling these data are that there are
three values for εk that have several replicates, but the other values have only a few.
Also the scatter in the data when εk is 0.020 appears to be larger than expected.
0.50 0.019
0.40 0.020
0.30 0.021
FLT cdfs
0.20
0.10
0.07
0.05
0.01
102 2x10 2 5x10 2 103 2x10 3 5x10 3 104 2x10 4 5x10 4
cycles to failure, Nf
14 D. Gary Harlow
, (mm/mm)
with FLT percentile bounds 2e-2 FLT 99% bounds
1e-2
strain range,
7e-3
5e-3
3e-3
102 103 104 105
cycles to failure, Nf
Since there is no explanation for this in [16], the reason would purely speculation.
The analysis is marginal for the 9Cr-1Mo data. There may be merit in using the FLT
approach for some insight, but conclusions would need to be made very cautiously.
Three sets of fatigue life data were considered for the proposed FLT method. These
datasets were selected because of they have replicate data for several applied stress
or strain ranges, σk or εk , respectively. The primary reason for the proposed FLT
method is to accurately model the statistical nature of fatigue life data. Specifically,
the estimation of underlying cdfs is crucial. It is well known that fatigue life data have
rather large amounts of variability particularly for applied loads similar to typical
operating conditions. Modeling these data is very challenging. Associated with this
is that many fatigue life data sets have relatively few choices for σk or εk , and
each choice has limited observations.
The FLT introduced in this paper attempts to help improve fatigue life modeling
by using a statistically based transformation to merge data, thereby increasing the
effective sample size. The FLT approach transforms the fatigue life data for each
given σk or εk so that the averages and standard deviations are the same. Subse-
quently, the data are merged, and a suitable cdf is statistically estimated for the entire
collection. The cdf for each given σk or εk is obtained by standard change-of-
variables methods using the cdf that characterizes the entire transformed and merged
data.
Using the 2024-T4 fatigue life in [9], the FLT is very promising partly because
there are eight different values for σk and a total of 222 data being considered. A
three–parameter Weibull cdf W(α, β, γ) is an excellent representation of the merged
FLT data, and a W(α, β, γ) is also appropriate characterization for the underlying cdfs
given σk . Consequently, there is assurance that the lower tail behavior is adequately
Fatigue Life Distribution Estimation 15
modeled because of the methodology. Additionally, the validation for the approach is
the computed FLT percentiles for the S-N data. The computed FLT 99% percentiles
fully encompass all the S-N data, but more importantly, the bounds are quite tight.
The conclusion from this analysis is that the FLT methodology is warranted.
To corroborate this conclusion, two other sets of fatigue life data were considered;
ASTM A969 [13] and 9Cr-1Mo [16]. In both cases, the merged FLT data are well
characterized by a W(α, β, γ). The KS test indicates that the transformed W(α, β, γ) is
also suitable for the underlying cdfs given εk , but the AD test is more discriminating.
The tail behavior of the underlying cdfs given εk are marginally acceptable at best,
if at all. The 99% percentiles for the ASTM A969 S-N data are quite good. They
are encompass the data, and they are tight. For the 9Cr-1Mo S-N data, however, the
percentile lines are not very regular. They do encompass the data, but the data have
so much variability that little is gained by the analysis.
Based on these three examples, the FLT approach should be employed for fatigue
life data analysis when an empirical method is desired. The FLT method excellent for
one of the cases, 2024-T4, acceptable for another case, ASTM A969, and marginal
for the other case, 9Cr-1Mo. As with all empirical analyses, caution must be exer-
cised when it is implemented. Limited applied loads with limited replicate data for
each load hinders accurate modeling for any method including the FLT. As with
all empirical methods, the more data there is, the better the accuracy will be. The
example which was the worst, 9Cr-1Mo, seems to be poor because there is overly
large scatter in the data for the higher loading conditions coupled with applied loads
with only a few replicates. Again, the FLT methodology should be implemented with
care.
Many sets of experimental fatigue life data contain censoring. This will be inves-
tigated in the future. In this case the cdf estimation is more advanced, especially for
a three-parameter cdf. In principle the FLT methodology should be similar except
for the adjustment for censoring. All things considered, the proposed FLT approach
has sufficient promise that further investigation and analysis is certainly warranted.
The overarching observation is that the FLT approach is useful if the fatigue data are
reasonably well behaved.
References
1. Harlow DG, Wei RP, Sakai T, Oguma N (2006) Crack growth based probability modeling of
S-N response for high strength steel. Int J Fatigue 28:1479–1485
2. Castillo E, Fernández-Canteli A (2009) A unified statistical methodology for modeling fatigue
damage. Springer Science and Business Media B.V., Berlin
3. Schneider CRA, Maddox SJ (2003) Best practice guide on statistical analysis of fatigue data.
International Institute of Welding, IIW-XIII-WG1-114-03, United Kingdom
4. Collins JA (1993) Failure of materials in mechanical design: analysis, prediction, prevention,
2nd edn. Wiley-Interscience Publications, New York
5. Little RE, Ekvall JC (eds) (1981) Statistical analysis of fatigue data. ASTM STP744, American
Society for Testing and Materials, Philadelphia
16 D. Gary Harlow
and probably his sources of the Nile grew in his mind as his
Mountains of the Moon had grown under his hand.
[11] The following extract from the Proceedings of the R. Geographical
Society, May 9, 1859, will best illustrate what I mean:—
Mr. Macqueen, f.r.g.s., said the question of the sources of the Nile had
cost him much trouble and research, and he was sure there was no
material error either in longitude or latitude in the position he had ascribed
to them, namely, a little to the eastward of the meridian of 35°, and a little
northward of the equator. That was the principal source of the White Nile.
The mountains there were exceedingly high, from the equator north to
Kaffa Enarea. All the authorities, from east, west, north, or south, now
perfectly competent to form judgments upon such a matter, agreed with
him; and among them were the officers commanding the Egyptian
commission. It was impossible they could all be mistaken. Dr. Krapf had
been within a very short distance of it; he was more than 180 miles from
Mombas, and he saw snow upon the mountains. He conversed with the
people who came from them, and who told him of the snow and exceeding
coldness of the temperature. The line of perpetual congelation, it was well
known, was 17,000 feet above the sea. He had an account of the navigation
of the White Nile by the Egyptian expedition. It was then given as 3° 30′ N.
lat. and 31° E. long. At this point the expedition turned back for want of a
sufficient depth of water. Here the river was 1370 feet broad, and the
velocity of the current one-quarter of a mile per hour. The journals also
gave a specific and daily current, the depth and width of the river, and
every thing, indeed, connected with it. Surely, looking at the current of the
river, the height of the Cartoom above the level of the sea, and the distance
thence up to the equator, the sources of the Nile must be 6000 or 8000 feet
above the level of the sea, and still much below the line of the snow, which
was 6000 or 8000 feet farther above them. He deeply regretted he was
unable to complete the diagram for the rest of the papers he had given to
the Society, for it was more important than any others he had previously
given. It contained the journey over Africa from sea to sea, second only to
that of Dr. Livingstone. But all the rivers coming down from the mountains
in question, and running south-eastward, had been clearly stated by Dr.
Krapf, who gave every particular concerning them. He should like to know
what the natives had said was to the northward of the large lake? Did they
say the rivers ran out from or into the lake? How could the Egyptian officers
be mistaken?
Captain Speke replied. They were not mistaken; and if they had pursued
their journey 50 miles farther, they would undoubtedly have found
themselves at the northern borders of this lake.
Mr. Macqueen said that other travellers, Don Angelo for instance, had
been within one and a half degree of the Equator, and saw the mountain of
Kimborat under the Line, and persisted in the statement, adding, that
travellers had been up the river until they found it a mere brook. He felt
convinced that the large lake alluded to by Captain Speke was not the
source of the Nile: it was impossible it could be so, for it was not at a
sufficiently high altitude.
The paper presented to the Society, when fully read in conjunction with
the map, will clearly show that the Bahr-el-Abied has no connection with
Kilimanjaro, that it has no connection whatever with any lake or river to the
south of the Equator, and that the swelling of the river Nile proceeds from
the tropical rains of the northern torrid zone, as was stated emphatically to
Julius Cæsar by the chief Egyptian priest Amoreis 2000 years ago.
In nearly 3° N. lat. there is a great cataract, which boats cannot pass. It
is called Gherba. About half-way (50 miles) above, and between this
cataract and Robego, the capital of Kuenda, the river becomes so narrow as
to be crossed by a bridge formed by a tree thrown across it. Above Gherba
no stream joins the river either from the south or south-west.
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