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DME-Online Class Sep2020-Module 2-PartB PDF

1) The document discusses fatigue failure that occurs in metals subjected to repetitive or fluctuating stresses over time. 2) It defines fatigue failure and the two fatigue regimes of low cycle fatigue (below 103 cycles) and high cycle fatigue (above 103 cycles). 3) Factors that influence fatigue strength and endurance limits are discussed, including stress concentration factors, surface finish, load factors, and material properties. 4) Different fatigue failure theories are summarized, including the stress-life model, strain-life model, and linear elastic fracture mechanics model. Design approaches for finite life and infinite life are also covered briefly.

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Mathew John
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391 views37 pages

DME-Online Class Sep2020-Module 2-PartB PDF

1) The document discusses fatigue failure that occurs in metals subjected to repetitive or fluctuating stresses over time. 2) It defines fatigue failure and the two fatigue regimes of low cycle fatigue (below 103 cycles) and high cycle fatigue (above 103 cycles). 3) Factors that influence fatigue strength and endurance limits are discussed, including stress concentration factors, surface finish, load factors, and material properties. 4) Different fatigue failure theories are summarized, including the stress-life model, strain-life model, and linear elastic fracture mechanics model. Design approaches for finite life and infinite life are also covered briefly.

Uploaded by

Mathew John
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We take content rights seriously. If you suspect this is your content, claim it here.
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You are on page 1/ 37

Online Classes GEC-BH - Sep 2020

S7 ME401: DESIGN OF MACHINE ELEMENTS - I

Module 2 (Part B)
(KTU Syllabus)

Dr. Mathew John


Department of Mechanical Engineering
Government Engineering College Barton Hill

Date of commencement of KTU odd semester classes: 17 Aug 2020 1


Fatigue Failure (Dynamic Loading)
A metal subjected to a repetitive or fluctuating stress will fail at a stress
much lower than that required to cause fracture on a single application
of load. Failures occurring under conditions of dynamic loading are
called Fatigue failure – because these failure occur only after a
considerable period of service.

Fatigue Failure: ASTM Definition


o The process of progressive localized permanent structural change
that occurring in a material subjected to conditions that produce
fluctuating stresses and strains at some point or points and that may
culminate in cracks or complete fracture after a sufficient number of
fluctuations.
o Fatigue Regimes
1. Low cycle fatigue ( Below 103 cycles)
2. High cycle fatigue ( Above 103 cycles)
With dynamic loads, the ductile material behave as if brittle in fatigue failures. 2
Callister

Dynamic loading

Random stress cycles Eg. Aircraft


structure

Cycle counting
Pls see slide No.32

Dr. Mathew John Govt. Engg. College Barton Hill


3
Situations under Fatigue Loading

4
Fatigue strength
Fatigue strength(𝝈𝒇 )
It is defined as the maximum stress that a component can withstand when
it is subjected to finite or specified number of cycles of load
applications.
It is always accompanied by a specific number of cycles.
Fatigue failure accounts for more than 80% of failure in metals

Characteristics of Fatigue
o Fatigue failure occurs at a stress well below yield point stress.
o Failure is always catastrophic in nature
o Greater the applied stress range(R) ,shorter the life
o Damage is cumulative
o Low cycle fatigue is associated with plasticity and hence strain
based parameters are used for life prediction.
o High cycle fatigue is described by stress based parameters

Dr. Mathew John Govt. Engg. College Barton Hill


5
S-N Curves from rotating-beam test

Highly polished specimen (0. 3” dia)

Ref. Machine Design- R. L Norton

Dr. Mathew John Govt. Engg. College Barton Hill


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Dr. Mathew John Govt. Engg. College Barton Hill
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S-N Curves (Wohler Curves)

Fatigue Parameters

For Metals

Ref: Meyers and Chowla 8


S-N Curve knee

Fatigue Limit

Fatigue strength at an arbitrary number of cycles (say 10 million cycles) - eg. Al 9


Endurance limit stress
Fatigue limit or Endurance limit (σ𝒆 )
It is defined as the maximum stress at which a material will never fail
when it is subjected to infinite number of cyclic load applications

(Endurance strength)

Dr. Mathew John Govt. Engg. College Barton Hill


10
Factors affecting Endurance limit
 Load Factor
 Size Factor
 Reliability factor
 Surface Finish/ surface effect
 Temperature effect
 Fatigue stress concentration Factor

Dr. Mathew John Govt. Engg. College Barton Hill


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Fully Reversed Cyclic loading

Fatigue of materials- S Suresh 12


Fatigue stress concentration factor (Kf)
 Experimental results show that the actual stress concentration factors
in fatigue are less than the theoretical stress concentration factors
predicted.
 This is due to different notch sensitivity of materials

 To accommodate the sensitivity of material, a fatigue stress


concentration factor (𝐾𝑓 ) is defined.

Endurance limit of un notched specimen(axial or bending)


 𝐾𝑓 =
Endurance limit of notched specimen(axial or bending)

Endurance limit of un notched specimen(𝑇𝑜𝑟𝑠𝑖𝑜𝑛)


 𝐾𝑓𝑠 =
Endurance limit of notched specimen(𝑇𝑜𝑟𝑠𝑖𝑜𝑛)

Dr. Mathew John Govt. Engg. College Barton Hill


13
Notch Sensitivity Factor (q)
• Notch Sensitivity Factor (q)
𝐼𝑛𝑐𝑟𝑒𝑎𝑠𝑒 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠𝑠 𝑜𝑣𝑒𝑟 𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠
q=
𝐼𝑛𝑐𝑟𝑒𝑎𝑠𝑒 𝑜𝑓 𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑣𝑒𝑟 𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠

𝐾𝑓 𝜎−𝜎
q=
𝐾𝑡 𝜎 −𝜎

𝐾𝑓 −1
q= Page 46,
𝐾𝑡 −1
DHB
Mahadevan
𝐾𝑓 = 1+q(𝐾𝑡 -1)

When q=1,the material has full notch sensitivity and 𝐾𝑓 =𝐾𝑡 , High
strength and hard materials are more sensitive to notches.
When q=0, No notch sensitivity and 𝐾𝑓 =1
q for steel ranges from 0.15 to 1,for low grade C.I, 0.05
Dr. Mathew John Govt. Engg. College Barton Hill
14
NOTCH SENSITIVITY FACTOR
 The sensitivity of a material to stress concentration is called
notch sensitivity.
 Materials have different sensitivity to stress concentration
 More ductile the material less sensitive
 Brittle materials are more notch sensitive
 As notch radius approaches zero, the notch sensitivity also
approaches zero (serendipitous !).

Dr. Mathew John Govt. Engg. College Barton Hill


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Summary

Please refer: Design Data book by K. Mahadevan (4e)-Fig. 2. 31, P-46 16


Factors to be considered To avoid
Fatigue Failure
 Variation in size should be as gradual as possible
 Notches, holes and other stress raisers should be reduced
or avoided as possible
 Fillets and notches should be provided wherever necessary
 Protecting parts from corrosion
 Provide smooth surface finish
 High fatigue strength materials should be used
 Impart residual compressive strength on the surface of the
part to improve the fatigue strength.

Dr. Mathew John Govt. Engg. College Barton Hill


17
Fatigue failure models
1. Stress Life Model ( SN-Curve or Wohler’s curve based on rotating
beam experiment )
o This is the oldest theory( Classical theory)
o Stress based model
o Fatigue strength and Endurance limit are the basis for the design
o For low cycle fatigue ,it is less accurate.
2. Strain Life Model
o It gives a reasonably accurate picture of the crack initiation stage
o Combination of fatigue and temperature can be considered in this
o Mostly applied to LCF and finite life problems.
3. Linear Elastic Fracture Mechanics (LEFM)
o It defines crack propagation stage
o Most useful in predicting remaining life of cracked parts in service.

Dr. Mathew John Govt. Engg. College Barton Hill


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Fatigue strength modification factors

Values of Cx can be obtained from the Tables/ Eqns in the design data book. Suffix x
stands for load, surface finish, Size, temperature or reliability .
19
Please refer:
Design Data book
by K. Mahadevan (4e)
Page No. 23

20
Design for Finite Life

Dr. Mathew John Govt. Engg. College Barton Hill


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Design for Infinite Life (mean stress =0)

Dr. Mathew John Govt. Engg. College Barton Hill


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Fatigue Failure Theories (Dynamic Loading)

Ref. Machine Design- R. L Norton


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Dr. Mathew John Govt. Engg. College Barton Hill
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Ref: Design of Machine Elements-V B Bhandari 25
Modified Goodman Diagram

Ref: Design of Machine Elements-V B Bhandari

26
Ref. Machine Design- R. L Norton

Dr. Mathew John Govt. Engg. College Barton Hill


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Fatigue Design under Combined Stresses

Then use modified Goodman diagram

Dr. Mathew John Govt. Engg. College Barton Hill


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Design for Fatigue Design Data book by K. Mahadevan (4e)

(Infinite Life)

Factor of Safety (n)

29
Design Data book by K. Mahadevan (4e) – Page 24, 25

30
Shock and Impact Loads

The impact stress due to Bending, Torsion


Ref: Design of Machine Elements-V B Bhandari 31
Appendix

32
Ref: Fatigue of materials- S Suresh

Dr. Mathew John Govt. Engg. College Barton Hill


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34
Tutorial ( Module 2 Part B) Method-1

35
Method-2
Equivalent Maximum shear and normal stresses
(Then design based on static failure theories!)

Design Data book by K. Mahadevan (4e) – Page 26


Method 1 : First Static failure criterion and then Fatigue Failure Criterion
Method 2 : First Fatigue failure criterion (equivalent stress) then Static failure criterion. 36
37
Dr. Mathew John S7 ME – DME-1 GEC Barton Hill

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