The scatter degree of the fatigue samples is reduced when the nodal force based structural method is used for steel welded joints, while it is still high for aluminum alloy welded joints. Statistical method and rough set theory is used to fatigue analysis so that fatigue characteristic domains are determined and S-N curves are fitted. Experiment results show that fatigue life of the aluminum alloy welded joints is under the influence of some key factors and the fatigue data with the same characteristics distribute in a relatively independent area. Accordingly, a novel S-N curve modeling method of aluminum alloy welded joints based on the fatigue characteristics domain is proposed. In the proposed method, the nodal force based structural stress method is used for stress calculation and neighborhood rough set theory is used for character extraction to obtain the key factors. Then fatigue characteristics domains are divided and S-N curves are fitted on each fatigue characteristics domain instead of on the whole domain so that a set of S-N curves are obtained. Statistical results show that selection of the S-N curve for the aluminum alloy welded joints according to different fatigue characteristic domain is more accurate.
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