Reliability assessment of hydraulic cylinders considering service loads and flaw distribution

Manufacturing process, service conditions and material properties are all necessary requirements to a good design of tubular mechanical components subjected to fatigue. The most common approach to this design is usually deterministic, where a fixed NDT threshold, related to flaw acceptance limit, is set. However many uncertainties are left aside, i.e. the failure probability related to the fatigue strength under applied loads. This paper addresses the reliability evaluation of tubular mechanical components carrying some flaws and subjected to cyclic internal pressure variation. The aim is comparing the probability of failure obtained under several assumptions. A reliability assessment model, based on a random variable approach, has been implemented by using the Monte Carlo method. The analysis of the results, from a case study based on load spectra measurements of hydraulic cylinders of earth moving machines, has consented to evaluate the most important factors influencing the fatigue life prediction of these components. Highlights: ► Reliability evaluation of tubular components subjected to variable internal pressure. ► The dispersion of the threshold controls the stochasticity of crack growth. ► A random variable model has been developed using Monte Carlo. ► Initial crack size and spectrum shape are key factors in reliability evaluation.