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    Fundamental Mechanical Properties: Fatigue

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    aap1
    Fatigue is caused by repeated application of stress or strain to the metal.  It is the failure of a material by fracture when subjected to a cyclic stress.

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    Fundamental Mechanical Properties: Fatigue

    Uploaded by

    aap1
    102 views11 pages
    Fatigue is caused by repeated application of stress or strain to the metal.  It is the failure of a material by fracture when subjected to a cyclic stress.

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    Fatigue is caused by repeated application of stress or strain to the metal.  It is the failure of a material by fracture when subjected to a cyclic stress.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    102 views11 pages

    Fundamental Mechanical Properties: Fatigue

    Uploaded by

    aap1
    Fatigue is caused by repeated application of stress or strain to the metal.  It is the failure of a material by fracture when subjected to a cyclic stress.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 11

    FundamentalMechanicalProperties

    Fatigue

    1
    Fatigue

    Fatigueiscausedbyrepeatedapplicationofstresstothe
    metal.Itisthefailureofamaterialbyfracturewhensubjectedtoa
    cyclicstress.

    Fatigueisdistinguishedbythreemainfeatures.
    i) Lossofstrength
    ii) Lossofductility
    iii) Increaseduncertaintyinstrengthand
    servicelife

    2
    Fatigue
    Fatigueisanimportantformofbehaviourinallmaterialsincludingmetals,
    plastics,rubberandconcrete.
    Allrotatingmachinepartsaresubjectedtoalternatingstresses.
    Example:aircraftwingsaresubjectedtorepeatedloads,oilandgaspipes
    areoftensubjectedtostaticloadsbutthedynamiceffectoftemperature
    variationwillcausefatigue.
    Therearemanyothersituationswherefatiguefailurewillbeveryharmful.
    Becauseofthedifficultyofrecognizingfatigueconditions,fatiguefailure
    comprisesalargepercentageofthefailuresoccurringinengineering.
    Toavoidstressconcentrations,roughsurfacesandtensileresidual
    stresses,fatiguespecimensmustbecarefullyprepared.

    3
    Fatigue
    TheSNCurve
    AveryusefulwaytovisualthefailureforaspecificmaterialiswiththeSN
    curve.
    TheSNmeansstressversecyclestofailure,whichwhenplottedusing
    thestressamplitudeontheverticalaxisandthenumberofcycletofailure
    onthehorizontalaxis.
    Animportantcharacteristictothisplotasseenisthefatiguelimit.

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    4
    Fatigue

    Thepointatwhichthecurveflattersoutistermedasfatiguelimitandis
    wellbelowthenormalyieldstress.
    Thesignificanceofthefatiguelimitisthatifthematerialisloadedbelow
    thisstress,thenitwillnotfail,regardlessofthenumberoftimesitis
    loaded.
    Materialssuchasaluminium,copperandmagnesiumdonotshowa
    fatiguelimit;thereforetheywillfailatanystressandnumberofcycles.
    Otherimportanttermsare fatiguestrength and fatiguelife.
    Thefatiguestrengthcanbedefinedasthestressthatproducesfailureina
    givennumberofcyclesusually107.
    Thefatiguelifecanbedefinedasthenumberofcyclesrequiredfora
    materialtofailatacertainstress.

    5
    Factorsaffectingfatigueproperties

    Surfacefinish:
    Scratchesdentsidentificationmarkscanactasstressraisersandsoreduce
    thefatigueproperties.
    Electroplatingproducestensileresidualstressesandhaveadeterimental
    effectonthefatigueproperties.

    Temperature:
    Asaconsequenceofoxidationorcorrosionofthemetalsurfaceincreasing,
    increaseintemperaturecanleadtoareductioninfatigueproperties.

    6
    Factorsaffectingfatigueproperties
    Residualstresses:
    Residualstressesareproducedbyfabricationandfinishing
    processes.
    Residualstressesonthesurfaceofthematerialwillimprove the
    fatigueproperties.
    Heattreatment:
    Hardeningandheattreatmentsreducethesurface compressive
    stresses;asaresultthefatiguepropertiesofthe materialsaregetting
    affected.
    Stressconcentrations:
    Thesearecausedbysuddenchangesincrosssectionholesorsharp
    cornerscanmoreeasilyleadtofatiguefailure.Evena smallhole
    lowersfatiguelimitby30%.

    7
    StressCycles

    Therearedifferentarrangementsoffatigueloading.
    Thesimplesttypeofloadisthealternatingstresswherethestressamplitudeis
    equaltothemaximumstressandthemeanoraveragestressiszero.Thebending
    stressinashaftvariesinthisway.

    8
    FatigueFailure
    Fatiguefractureresultsfromthepresenceoffatiguecracks,usually
    initiatedbycyclicstresses,atsurfaceimperfectionssuchasmachine
    markingandslipsteps.
    Theinitialstressconcentrationassociatedwiththesecracksaretoolowto
    causebrittlefracturetheymaybesufficienttocauseslowgrowthofthe
    cracksintotheinterior.
    Eventuallythecracksmaybecomesufficientlydeepsothatthestress
    concentrationexceedsthefracturestrengthandsuddenfailureoccurs.
    Theextentofthecrackpropagationprocessdependsuponthebrittleness
    ofthematerialundertest.
    Inbrittlematerialsthecrackgrowstoacriticalsizefromwhichit
    propagatesrightthroughthestructuresinafastmanner,whereaswith
    ductilematerialsthecrackkeepsgrowinguntiltheremainingareacannot
    supporttheloadandanalmostductilefracturesuddenlyoccurs.

    9
    FatigueFailure
    Failurecanberecognizedbytheappearanceoffracture.
    Foratypicalfracture,Twodistinctzonescanbedistinguished asmooth
    zonenearthefatiguecrackitselfwhich,hasbeensmoothenedbythe
    continualrubbingtogetherofthecrackedsurfaces,andarough
    crystallinelookingzonewhichisthefinalfracture.
    Occasionallyfatiguecracksshowroughconcentricringswhichcorrespond
    tosuccessivepositionsofthecrack.

    10
    DesignforFatigue

    Tosecuresatisfactoryfatiguelife
    Modificationofthedesigntoavoidstressconcentrationeliminatingsharp
    recessesandseverestressraisers.
    Precisecontrolofthesurfacefinishbyavoidingdamagetosurfaceby
    roughmachining,punching,stamping,shearingetc.
    Controlofcorrosionanderosionorchemicalattackinserviceandto
    preventofsurfacedecarburizationduringprocessingofheattreatment.
    Surfacetreatmentofthemetal.

    11

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