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st
1
1st International
International Conference
Conference of
of the
the Greek
Greek Society
Society of
of Experimental
Experimental Mechanics
Mechanics of
of Materials
Materials

Experimental and analytical approach of fatigue behavior

XV Portuguese Conference on Fracture, PCF 2016, 10-12 February 2016, Paço de Arcos, Portugal
of stepped CK45 shaft with adjacent key groove
Thermo-mechanical D.G. Ntritsos, modeling
Ntritsos, A.D. Tsolakis,of a high
Tsolakis, pressure turbine blade of an
K.I. Giannakopoulos*
Giannakopoulos*
D.G. A.D. K.I.
University
University of
of West
West Attica
airplane
Attica (former
(former Piraeus
gas
Piraeus University
University of
turbine
of Applied
Applied Sciences,
engine
Sciences, 250
250 Thivon
Thivon Avenue,
Avenue, Egaleo,
Egaleo, 12244,
12244, Greece
Greece

P. Brandãoa, V. Infanteb, A.M. Deusc*

AbstractaDepartment of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa,
Abstract
Portugal
b
StressIDMEC, Department of Mechanical Engineering, shaft
Instituto Superior Técnico, Universidade de Lisboa, Av. engineering
Rovisco Pais, 1, 1049-001 Lisboa,
Stress concentration
concentration areasareas such
such asas keyways
keyways and and shaft steps
steps appear
appear frequently
frequently used
Portugal used in
in mechanical
mechanical engineering design.
design. Areas
Areas like
like
these
these are characterized
c are characterized by by difficulties in in accurately
accurately predicting
predicting part
part operating
operating lifetime,
lifetime, often
often driving
driving into
into premature
premature fractures causing
causing
CeFEMA, Department ofdifficulties
Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, fractures
1, 1049-001 Lisboa,
unplanned
unplanned machine
machine stoppages.
stoppages. The The impact
impact ofof such
such areas
areas in
in engineering
Portugal design
engineering design isis assessed
assessed with
with the
the aid
aid ofof the
the “k-factors”,
“k-factors”, however,
however,
these
these factors cover only the effect of a single notch on the whole structural element. In mechanical engineering design
factors cover only the effect of a single notch on the whole structural element. In mechanical engineering design it
it is
is common
common
for
for multiple
multiple stress
stress concentration
concentration areasareas toto coexist
coexist adjacently,
adjacently, where
where thethe existing
existing analytical
analytical theory
theory cannot
cannot bebe used
used to
to assess
assess the
the effect.
effect.
The
The effect of
Abstract
effect of adjacent
adjacent step
step and
and keyway
keyway on on aa DIN
DIN CK45
CK45 shaft
shaft is
is investigated
investigated in in the
the present
present paper.
paper. For
For this
this purpose,
purpose, aa DIN
DIN CK45
CK45 steel
steel
shaft
shaft specimen
specimen withwith aa standardized
standardized keyway
keyway and and aa diameter-step
diameter-step has has been
been tested
tested under
under rotating
rotating bending
bending toto investigate
investigate the
the interaction
interaction
of During
of two theirstress
two distinct
distinct operation,
stress modernareas.
concentration
concentration aircraft
areas. engine and
Analytical
Analytical components
and numericalare
numerical subjected
methods
methods havetobeen
have increasingly
been used
used to demanding
to support
support the operating conditions,
the conclusions.
conclusions.
especially the high pressure turbine (HPT) blades. Such conditions cause these parts to undergo different types of time-dependent
© 2018
2018 The Authors. Published bybyElsevier ALtd.
© degradation,
© 2018 The one of
The Authors.
Authors. which is
Published
Published creep.
by Elsevier
Elsevier model
Ltd. using the finite element method (FEM) was developed, in order to be able to predict
Ltd.
This
the
This is
is an
an open
creepopen access
behaviour
access article
of under
article HPT
underthe CCCC
blades.
the BY-NC-ND
Flight license
data (http://creativecommons.org/licenses/by-nc-nd/3.0/)
records (FDR) for a specific aircraft, provided by a commercial aviation
This is an open
Peer-review underaccess article under
responsibility of the the CC BY-NC-ND
BY-NC-ND
scientific committee
license
license
of the
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
1st International Conference of thecycles.
Greek Society
Peer-review
Peer-review
of Mechanics
Experimental
under
under
Mechanics
company,
responsibility
responsibility were
of the used to
scientificobtain thermal
committee of and
the 1 st mechanical
st
International data for
Conference three
of different
the Greek flight
Society of In order
Experimental to create the
of 3D model
Materials
Materials.forofthe
of needed the scientific committee of the 1 International Conference of the Greek Society of Experimental Mechanics of Materials
FEM analysis, a HPT blade scrap was scanned, and its chemical composition and material properties were
obtained.
Keywords:
Keywords: Shaft;
Thefatigue;
data that
Shaft; fatigue;
was
steel; gathered
steel; CK45;
CK45; step;
was feddesign;
step; keyway;
into the
keyway; design;
FEM model and different simulations were run, first with a simplified 3D
bending
bending
rectangular block shape, in order to better establish the model, and then with the real 3D mesh obtained from the blade scrap. The
overall expected behaviour in terms of displacement was observed, in particular at the trailing edge of the blade. Therefore such a
1. model can be useful in the goal of predicting turbine blade life, given a set of FDR data.
Introduction
1. Introduction
© 2016 The Authors. Published by Elsevier B.V.
Steel
Steel shafts are
are being
shaftsunder being used
used extensively
extensively as
as parts
parts of
of industrial
industrial machinery. The
The need
need to
to transmit
transmit torque
torque over
over aa given
Peer-review responsibility of the Scientific Committee of PCF machinery.
2016. given
distance
distance is
is aa common
common issue
issue that
that is
is frequently
frequently being
being resolved
resolved with
with the
the use
use of
of steel
steel shafts.
shafts. When
When operating
operating as
as aa part
part of
of aa
Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation.

** Corresponding
Corresponding author.
author. Tel.:
Tel.: +30
+30 210
210 5381236
5381236
E-mail
E-mail address:
address: [email protected]
[email protected]
Received:
Received: May
May 06, 2018; Received
06, 2018; Received in
in revised
revised form:
form: June
June 26, 2018; Accepted:
26, 2018; Accepted: July
July 06,
06, 2018
2018

2452-3216 ©
2452-3216 © 2018
2018 The
The Authors.
Authors. Published
Published by
by Elsevier
Elsevier Ltd.
Ltd.
This
This is
is an
an open
open access
access article
article under
under the
the CC
CC BY-NC-ND
BY-NC-ND license license (http://creativecommons.org/licenses/by-nc-nd/3.0/).
(http://creativecommons.org/licenses/by-nc-nd/3.0/). Peer-review
Peer-review under
under
responsibility of
responsibility of the
the scientific
scientific committee
committee of the 11 stst International
of the International Conference
Conference ofof the
the Greek
Greek Society
Society of
of Experimental
Experimental Mechanics
Mechanics of
of Materials
Materials
* Corresponding author. Tel.: +351 218419991.
E-mail address: [email protected]

2452-3216 © 2016 The Authors. Published by Elsevier B.V.

2452-3216  2018 The Authors. Published by Elsevier Ltd.
Peer-review
This underarticle
is an open access responsibility of the
under the CC Scientific
BY-NC-ND Committee
license of PCF 2016.
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
Peer-review under responsibility of the scientific committee of the 1st International Conference of the Greek Society of Experimental
Mechanics of Materials.
10.1016/j.prostr.2018.09.040
 D.G. Ntritsos et al. / Procedia Structural Integrity 10 (2018) 288–294 289
2 D.G. Ntritsos et al. / Structural Integrity Procedia 00 (2018) 000–000

machine, steel shafts are subjected to dynamic loading cycles of complex nature. Common types of loadings that steel
shafts are routinely subjected to are torsion and bending. More often than not, the steel shafts drive a cog wheel that is
in turn connected to other cog wheels. The way the torque is transmitted to the cog when is through a mechanical link-
age, the common key. In order to successfully mate the shaft to the cog, the key must be in physical contact with both.
According to Pedersen and Leergaard (2010), despite the fact that keys are the predominant way of transmitting torque,
very little work has been done to fully assess the keyway design and the impact it has into the machine fatigue life. The
design of the keyway is dependent to the shaft diameter and no other functioning condition is taken into account.
On an experimental level the stress concentration of the keyway is studied in a number of papers, like Madayag
(1969), Fessler et al. (1969), Eissa and Fessler (1983), using the method of photoelasticity, in order to assess the effect
of the keyway design to the fatigue life of the machinery. In real life applications, the keyway is just one of the stress
concentration areas present in a machine. Frequently one comes across machinery parts that present sharp geometric
changes such as shaft steps, holes, keyways and threads. Although work has been put into developing stress
concentration factors for a single stress concentration area by Peterson (1953), the case where two or more areas are
adjacent remains and any work towards that remains non systemized and unstandardized.
In this paper, the interaction between two adjacent stress concentration areas in a steel shaft is studied using dif-
ferent methods, in order to establish if the coexistence of them affect the overall fatigue life behavior of the part and
to determine which one preponderate which. The first method is conducting actual fatigue tests using a testing
apparatus originally designed for fatigue strength testing on two distinct sets of specimens. The second method is
calculating the stress using the stress concentration factors found in Peterson (1953). The third method is the
numerical one. Due to the lack of a mathematical model that adequately models the behavior of a part with multiple
stress concentration areas, we created a parametric 3s model and then inserted in into to Autodesk Nastran Solver.
We then run FEM analyses.

2. Experimental approach

2.1. The experimental protocol

The effect of the adjacent stress concentration areas in DIN CK45 specimen fatigue life is studied using the reverse
bending fatigue tests. Tangible specimens were manufactured and tested using a conventional testing machine. The
geometry of the specimens is adjusted to the machine used. In this test two different sets of five specimens each are
compared. The first set includes single notched specimens without a keyway but with a single stress concentration area
in the form of a shaft step. The second set includes specimens with a keyway adjacent to the shaft step. For the test
procedure the ISO 1143:2010 standard has been taken into consideration.

2.2. Apparatus and specimens

For the experimental method a testing apparatus originally designed for material fatigue testing was used. The
machine we used for the tests is a TERCO brand, MT 3012-E model. The testing apparatus uses an asynchronous
single phase electric motor in order to rotate the specimen and a force application system capable of applying a
maximum value of 300 N. A schematic of the working principle of the machine used in the test is shown in Fig.1.

Fig. 1. TERCO MT-3012-E working principle.

290 D.G. Ntritsos et al. / Procedia Structural Integrity 10 (2018) 288–294
D.G. Ntritsos et al. / Structural Integrity Procedia 00 (2018) 000–000 3

The specimen used is typical of the testing apparatus TERCO MT 3012-E. Its geometry is shown in Fig.2a. In this
paper the effect of two adjacent stress concentration areas is studied, thus a second set of specimens is used, the geo-
metry of which is shown in Fig.2b. The difference is the second stress concentration area which is presented as a
keyway. The keyway of the specimens of the second set is manufactured according to ISO/R 773:1969, directly
related to the shaft diameter of 10 mm. The keyway geometry is common across mechanical engineering designs.

(a)

(b)

Fig. 2. Drawings of the specimens used in fatigue tests. (a) Single Notched; (b) Double Notched.

2.3. Manufacturing and heat treatment

The steel used for manufacturing the specimens according to the DIN standard for steels is CK45 grade and its
chemical composition is shown on Table 1. The specimens were manufactured following the guidelines in ISO
1143:2010. after the machining process, the specimens were gradually polished in order to reduce surface roughness
and then stress relieved in salt bath in order to eliminate remaining stresses.

Table 1. CK45 Chemical Composition.

Chemical Element Percentage
Carbon 0.45
Silicon 0.25
Manganese 0.65
Sulfur > 0.030

For the polishing process, four different grades of emery were used. The specimens were polished using one pass
of 80 grit, 120 grit, 150 grit and 240 grit and lastly with a double pass of 320 grit. After the polishing process was
done the specimens were stress relieved in salt bath in a set temperature of 350 oC for a time period of two hours.
After that, the specimens were measured, marked in both ends to secure identification after the tests and finally put
in a plastic container until the experiment process begun.

2.4. Experimental process

The experiment described is a typical fully reversed bending fatigue test. The experimental procedure was as follows:
 The specimen is removed from the individual case it is kept in.
 The specimen is secured in place in the testing machine.
 The testing apparatus revolutions counter is reset to zero.
 The machine is then turned on.
 The force is gradually applied in the specimen
 D.G. Ntritsos et al. / Procedia Structural Integrity 10 (2018) 288–294 291
4 D.G. Ntritsos et al. / Structural Integrity Procedia 00 (2018) 000–000

 The test is carried on until the specimen breaks or the revolution counter surpasses the 10 7 mark.
 The specimen is then removed and placed on an individual case for further study.

3. Analytical approach

The analytical approach consists of two studies. Firstly the calculation of the stand-alone notches stress
concentration factors with the existing analytical theory and then after the simulation of the experiment procedure
using the Finite Element Analysis.

3.1. Stress concentration factor of stepped shaft

According to Peterson (1953) the stress concentration factor of a shaft step can be accurately determined using
data from past photoelastic tests. The static stress concentration factor Kt of a shaft stepped area is calculated
accordingly using Eq.(1):
2
 2h   2h  2h
 C1  C2    C3    C4 ( )3
Kt  (1)
D D D

Where D is the larger shaft’s diameter and h the step height. Applying Eq.(1) for the tested single stepped specimen
geometry is calculated below. Thus for

h 2.5 h
  6.25  2   20
r 0.4 r

The C parameters are

h h
C1 
1.232  0.832*  0.008* 3.262
r r

h h
C2 
3.813  0.968*  0.26* 3.018
r r

h h
C3 
7.423  4.868*  0.869* 0.68425
r r

h h
C4 
3.839  3.070*  0.6* 0.086
r r

Finally from the Eq.(1) Kt is

2 3
 2h   2h   2h 
Kt 
C1  C2    C3    C4    2.34
D
  D
  D

Thus the static stress for a bended stepped shaft is calculated as follows

32M
σ s  Kt (2)
π ( D  2h) 3

Where M is the applied bending load.

292 D.G. Ntritsos et al. / Procedia Structural Integrity 10 (2018) 288–294
D.G. Ntritsos et al. / Structural Integrity Procedia 00 (2018) 000–000 5

The dynamic loading stress concentration factor Kf is derived from Eq.(3):

Kf 
1  q( Kt  1) (3)

where the notch sensitivity factor q for CK45 and the given geometry is 0.68 for according to Peterson (1953).
Substituting Kt with Kf in Eq.(2) the fatigue stress is obtained as:

32M
σD  K f (4)
π ( D  2h ) 3

3.2. Stress concentration factor of keyway

For keyways the fatigue concentration factor Kf is given for profiled keyway, according to Madayag (1969), equal
to 1.6. According to Fessler et al. (1969), the Kt factor for keyways is equal to 2.2 which gives K f=1.48 applying
Eq.(3) for q=0.4 for CK45 and the keyway geometry. Subsequently the and stresses are calculated as follows

32M
σ s ( D )  Kt ( f ) (5)
πD3

3.3. Numerical analysis

Since there are no literature references for stress concentration in areas with conjuring notches, the Finite Element
Analyses were launched. The purpose of the Numerical Approach is to determine the maximum static bending
stresses due to the lack of a mathematical model that adequately specimen behavior. The mathematical model of the
specimens was created with Inventor Autodesk solid modeler and simulated using finite element analysis Nastran
solver for the estimation of the maximum stresses, typical results shown in Fig.3a.

Max: 757.8
Max:
757.8

Fig. 3. (a) Typical FEA results for double notched shaft; (b) plan view of stress concentration regions.
 D.G. Ntritsos et al. / Procedia Structural Integrity 10 (2018) 288–294 293
6 D.G. Ntritsos et al. / Structural Integrity Procedia 00 (2018) 000–000

FE analysis results that two stress concentration regions appear, one (region A) on the edge of keyway at about the
endpoint of the edge’s straight part and region B, on the step fillet as shown in Fig.3(a,b). A full loading cycle was
simulated and the values of Von Mises-, 1st Principal- and Z-normal-stresses were monitored on both stress con-
centration areas.

4. Results

4.1. Experimental results

The test ran for five different applied loads. At all the single notched specimens fractured started from the notch,
as it was expected but at all the double notched specimens the fracture started from region A (see Fig.3a) although
the region B was under greater loading. Typical fractured surfaces are shown on Figs.4(a,b).

(a) (b)
Fig. 4. Stereoscopic pictures of double notched specimen fracture surfaces.

The experimental results are summarized in the diagram shown in Fig.5, where the number of specimen life-
cycles plotted versus applied load of the fatigue machine.

350
Single Notched
300 Double Notched
Single Notched Trendline
Double Notched Trendline
Load [N]

250

200

150

100
3.00E+04 3.00E+05 3.00E+06
Number of Cycles

Fig. 5. Comparative F-N Diagram, Single Notched versus Double Notched Specimen.
294 D.G. Ntritsos et al. / Procedia Structural Integrity 10 (2018) 288–294
D.G. Ntritsos et al. / Structural Integrity Procedia 00 (2018) 000–000 7

4.2. Analytical approach results

According to the analytical calculations described in sections 3.1 and 3.2 the static and fatigue stress was
calculated for un-notched and single notched shafts. The calculations corresponds to the regions A and B. For
bending load at each region the acting bending moment of the fatigue tests assumed. In Table 2 are shown the
calculated values for applying load equal to 150 N which was the endurance load for the double notched specimen.

Table 2. Analytically calculated values.

Kt Kf Static Stress Fatigue Stress
(MPa) (MPa)
Un- notched shaft (diameter 10mm-region A) 1 1 184.02 184.02
Un- notched shaft (diameter 10mm-region B) 1 1 188.22 184.02
Single notched shaft (keyway-region A) 2.20 1.48 404.84 411.76
Single notched shaft (stepped-region B) 2.34 1.91 440.43 357.62

The maximum stresses for both single and double notched specimens resulted from FEA simulation are given in
Table 3. The values correspond to equal applying load with the analytical calculations (150 N). Additionally in-
dicative values of Kt and Kf was derived taking in account the 1st Principal Stresses and Eq.(3).

Table 3. FEA results.

Static Von Mises Static 1st Princ. Static Z-Norm. Resulting Kt Resulting Kf
Stress (MPa) Stress (MPa) Stress (MPa)
Single notched shaft (stepped-region B) 400.54 484.92 365.19 2.58 2.07
Double notched shaft (region A) 449.96 451.07 439.39 2.45 1.99
Double notched shaft (region B) 471.99 565.49 479,74 3.00 2.36

4. Conclusions

An obvious and predominant conclusion is the expected worst fatigue behavior of the double notched shaft in
cyclic bending loading. Τhe following conclusion is the most critical and unexpected: Fragmentation occurs in an area
where analytical and numerical methods fall to indicate. Since static stresses are calculated with satisfactory accuracy, it
is obvious that the error lies in the calculation of the fatigue stresses. It seems, therefore, that the conjucting of the
notches directly affects the fatigue endurance by means of the notch sensitivity factor. The determination of the
design parameters for the safety of such geometries in fatigue is a subject of future study and research.

References

Eissa, M., Fessler, H., 1983. Reduction of elastic stress concentrations in end-milled keyed connections. Experimental Mechanics 23(4), 401-408.
Fessler, H., Rogers, C.C., Stanley, P., 1969. Stresses at end-milled keyways in plain shafts subjected to tension, bending, and torsion. J. Strain
Analysis 4(3), 180-189.
Fessler, H., Rogers, C.C., Stanley, P., 1969. Stresses at keyway ends near shoulders. J. Strain Analysis 4(4), 267-277.
Gowhari-Anaraki, A.R., Hardy S.J., Pipelzadeh, M.K., 2003. Experimental and analytical fatigue data for notched shafts in bending. Journal
Kejuruteraan 15, 15-31.
ISO 1143:2010, Metallic materials - Rotating bar bending fatigue testing.
Madayag, A.F., 1969. Metal Fatigue, New York.
Peterson, R.E., 1953. Stress Concentration Design Factors, John Wiley & Sons, New York.
Pedersen, N.L., 2010. Stress concentrations in keyways and optimization of keyway design. The journal of strain analysis for engineering design
45(8), 593-604.
Shigley, J.E., Mischke, C.R., 1989. Mechanical Engineering Design, 5th Ed., McGraw-Hill, Inc., New York.
SO/R 773:1969. Rectangular or square parallel keys and their corresponding keyways.