Tutorial 3 - Desgn For Fatigue Strength - MD - I

Tutorial - 2: Machine Design I: Design for fatigue strength
1. The endurance limit of a steel member is 112 MPa and the tensile strength is 385 MPa. What is
the fatigue strength corresponding to a life of 70 (103) cycles? Ans: 166 MPa
2. A 1035 steel has a mean ultimate tensile strength of 480 MPa and is to be used for a part that sees
230oC in service. Estimate the Martin temperature modification factor and (S’e)230o if
(a) The room-temperature endurance limit by test is 270 MPa.
(b) Only the mean ultimate tensile strength at room temperature is known
(a) 1.022, 275.7 (b) 248.3 MPa
3. A spherical pressure vessel 600 mm in diameter is made of cold drawn sheet steel having Sut =
400 MPa, Sy = 370 MPa, and a thickness of 3 mm. The vessel is to withstand an infinite number
of pressure fluctuations from 0 to pmax.
(a) What maximum pressure will cause static yielding?
(b) What maximum pressure will eventually cause a fatigue failure? In any case, assume that the
joints and connections are adequately reinforced and do not weaken the vessel.
Ans. (a) pmax = 7400 kPa, (b) pmax = 5280 kPa
4. A bar of steel has Sut = 700 MPa, Sy = 500 MPa, and a fully corrected endurance limit Se = 200
MPa. For each of the cases below find the factor of safety which guard against static and fatigue
failures.
(a) τm = 140 MPa
(b) τm = 140 MPa, τa = 70 MPa
(c) τxym = 100 MPa, σxa = 80 MPa
(d) σxm = 60 MPa, σxa = 80 MPa, τxym = 70 MPa, τxya = 35 MPa
Ans. (a) 2.06 (b) n(static) = 1.37, n (fatigue) = 1.64 (c) n (static) = 2.62, n (fatigue) = 1.56
(d) n (static) = 2.18, n (fatigue) = 1.45
5. The figure 2.1 is an idealized representation of a machine member subjected to the action of an
alternating force F which places the member in completely reversed bending. The material is
hardened tempered to 190 Bhn. All surfaces are ground. Based on 50 percent reliability, infinite
life, and no margin of safety, determine the maximum value of alternating force F which can
probably be applied.
Fig.2.1
Ans. 1.06 kN
6. The shaft shown in Figure 2.2 rotates at 1720 rev/min and is to have a life of 3 min at 50 percent
reliability. The steel used has the following properties: Sut = 610 MPa, E = 207 GPa, HB = 178.
The shaft is finished by grinding. It is simply supported in bearings at A and B and is loaded by
the static forces F1 = 8.9 kN and F2 = 13.4 kN. Find the factor of safety guarding against failure.
Fig.2.2
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7. The rotating shaft shown in Figure 2.3 is machined from a 50-mm bar of cold-drawn steel. The
shaft is designed for an infinite life and a reliability of 99.99 percent. What factor of safety guards
against a fatigue failure if the force is 3.0 kN? Ans.1.55
Fig.2.3
8. The figure 2.4 shows a rotating shaft loaded by two bending forces having the bearing reactions
R1 and R2. Point A is a shaft shoulder which is required for positioning the left-hand bearing. The
grinding-relief groove at B is 2.5 mm deep (given to get geometric Stress Concentration Factor).
The surface AB is ground, but the groove is machined. The material of the shaft is hardened and
tempered steel to Sut = 1300 MPa. Determine the factor of safety corresponding to a life of 0.35
(10)6 revolutions of the shaft. Ans. 1.50
Fig.1.7
9. A bar of steel has the minimum properties Se = 276 MPa, Sy = 413 MPa, and Sut = 551 MPa. The
bar is subjected to a steady torsional stress of 103 MPa and an alternating bending stress of 172
MPa. Find the factor of safety guarding against a static failure, and either the factor of safety
guarding against a fatigue failure or the expected life of the part. For the fatigue analysis use:
(a) Modified Goodman criterion.
(b) Gerber criterion.
(c) ASME-elliptic criterion.
Ans: Yield: ny = 1.18. Fatigue: (a) nf = 1.06, (b) nf = 1.31, (c) nf = 1.32
10. A shaft shown in Figure 1.8 must transmit a torque of 1000 N m, with superimposed torsional
vibration causing an alternating torque of 250 N m. A safety factor of 2 is to be applied to both
loads. A heat-treated alloy steel is to be used, having Su = 1.2 GPa, and Sy = 1.0 GPa
(unfortunately, test data are not available for Sus or Sys). It is required that the shaft have a
shoulder, with D/d = 1.2 and r/d = 0.05 (as shown in Figure 4.35). A good-quality commercial
ground finish is to be specified. What diameter is required for infinite fatigue life?
Fig.1.8
11. A 36 mm-diameter bar has been machined from an AISI 1050 cold-drawn bar. This part is to
withstand a fluctuating tensile load varying from 0 to 70 kN. Because of the ends, and the fillet
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radius, a fatigue stress-concentration factor Kf is 1.85 for 106 or larger life. Find Sa and Sm and the
factor of safety guarding against fatigue and first-cycle yielding for (a) a Gerber fatigue locus and
(b) a DE-elliptic fatigue locus.
Ans. (a) Gerber: Sm = 440 MPa, Sa = 140 MPa, Yield: Sm = 290 MPa, Sa = 290 MPa, nf = 3.36,
ny = 4.56, primary threat from fatigue
(b) DE-elliptic: Sa = 218.6 MPa, Sm = 218.6 MPa, Primary threat is from fatigue, nf = 3.44
12. A shaft is made of 42- 3 4-mm AISI 1018 cold-drawn steel tubing and has a 6-mm diameter hole
drilled transversely through it. Estimate the factor of safety guarding against fatigue and static
failures using the Gerber and Langer failure criteria for the following loading conditions:
(a) The shaft is rotating and is subjected to a completely reversed torque of 120 N. m in phase
with a completely reversed bending moment of 150 N. m.
(b) The shaft is subjected to a pulsating torque fluctuating from 20 to 160 N. m and a steady
bending moment of 150 N. m.
Ans: (a) nf = 1.56, ny = 3.50, there is no localized yielding; the threat is from fatigue
(b) nf = 3.03, ny = 2.87, there is no notch yielding; the threat is from first-cycle yielding at the
notch.
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Tutorial - 2: Machine Design I: Design for fatigue strength

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