Solution to Tutorial 2

1. The shaft shown in Figure 2 is machined from alloy steel heat-treated to 320 BHN
and rotates at high speed, whilst the imposed load, F, remains static.

(a) Draw the shear force and moment diagrams.

(b) What is the maximum allowable load so that the shaft will have infinite fatigue
life?

(c) What is the maximum allowable load so that the shaft will have 5×104 cycles
fatigue life?

Answer: (b) 14.92 kN; (c) 23.82 kN

F
D

L2 L1

Figure 2: A machined alloy steel shaft rotating at high speed

Given: D = 30 mm; L1 = 100 mm; L2 = 150 mm.

Load type
Factor
Bending Torsion Axial
CL 1.0 0.58 0.9*
1.0 for D ≤ 10 mm
CD 1.0
0.9 for 10 ≤ D ≤ 50 mm
CS From the respective figure
Solution

(a)

D
2F/5 3F/5

L2 L1

SFD

2F/5

−3F/5

MD

2FL2/5 = 3FL1/5

(b)

First we need to find CL, CD, and CS.

Load type
Factor
Bending Torsion Axial
CL 1.0 0.58 0.9*
1.0 for D ≤ 10 mm
CD 1.0
0.9 for 10 ≤ D ≤ 50 mm
CS From the respective figure

The load is rotating bending: ⇒ CL = 1

Size is such that: ⇒ CD = 0.9

BHN ≤ 350

⇒ Su (MPa) ≈ 3.45BHN

Su (MPa) ≈ 3.45 × 320 = 1104 (MPa)

⇒ CS = 0.68
To determine the 106 (infinite) cycle stress taking into the above factors we have:

S n = CLCDCS S n′ (we assume S n′ = 0.5Su )

S n = 1× 0.9 × 0.68 × (0.5 × 1104 ) = 337.8 (MPa)

The maximum stress occurs at the loading point.

32 M
σ nominal =
πD 3

32 × (0.4 F × 150)
σ nominal = = 2.264 × 10−2 F (MPa)
π × 303

337.8
Fn = = 14.92 (kN)
2.264 × 10 −2

(c)

We also need to know the fatigue strength at 103 cycles.

S103 = 0.9Su

S103 = 0.9 × 1104 = 993.6 (MPa)

32 M
σ nominal =
πD 3

32 × (0.4 F × 150)
σ nominal = = 2.264 × 10−2 F (MPa)
π × 30 3

993.6
F103 = = 43.89 (kN)
2.264 × 10−2

Similar to constructing an S-N plot, we are going to construct an F-N plot. In the range of
103 and 106 cycles, we have

F = aN b

At 103 cycles, F103 = a103b = 43.89 (kN)

At 106 cycles, Fn = a106b = 14.92 (kN)

Solving the equations we obtain

 Fn 14.92
103b = = = 0.34
F103 43.89

Thus,

log 0.34
b= = −0.1562
3

F103 43.89
a= 3b
= = 129.088
10 0.34

The maximum load at 5×104 cycles is then

(
F = 129.088 N −0.1562 = 129.088 × 5 ×10 4 )−0.1562
= 23.82 (kN)
2. Figure 3 shows a machined alloy steel shaft heat-treated to 320 BHN. The shaft
rotates at high speed while being subjected to a static load, F, distributed as shown.

(a) Draw the shear force and moment diagrams.

(b) What is the maximum allowable load so that the shaft will have infinite fatigue
life?

(c) What is the maximum allowable load so that the shaft will have 3×104 cycles
fatigue life?

Answer: (b) 17.22 kN; (c) 29.76 kN

0.4F 0.6F
D

L1 L1
L2

Figure 3: A machined alloy steel shaft rotating at high speed

Given: D = 30 mm; L1 = 100 mm; L2 = 150 mm.

Load type
Factor
Bending Torsion Axial
CL 1.0 0.58 0.9*
1.0 for D ≤ 10 mm
CD 1.0
0.9 for 10 ≤ D ≤ 50 mm
CS From the respective figure
Solution

(a)

0.4F 0.6F

D
FA FB

L1 L1
L2

∑M A = FB ⋅ 250 − 0.4 F ⋅100 − 0.6 F ⋅150 = 0

Thus, FB = 0.52 F .

∑F = F A + FB − 0.4 F − 0.6 F = 0

Thus, FA = 0.48 F .

The moment is given by

0.48 Fx 0 ≤ x ≤ 100 (mm)


M = 0.48 Fx − 0.4 F (x − 100 ) 100 ≤ x ≤ 150 (mm)
0.48 Fx − 0.4 F (x − 100 ) − 0.6 F (x − 150 ) 150 ≤ x ≤ 250 (mm)


which can be simplified to

0.48 Fx 0 ≤ x ≤ 100 (mm)


M = 40 F + 0.08 Fx 100 ≤ x ≤ 150 (mm)
130 F − 0.52 Fx 150 ≤ x ≤ 250 (mm)

SFD

0.48F
0.08F

−0.52F

MD

48F 52F

(b)

First we need to find CL, CD, and CS.

Load type
Factor
Bending Torsion Axial
CL 1.0 0.58 0.9*
1.0 for D ≤ 10 mm
CD 1.0
0.9 for 10 ≤ D ≤ 50 mm
CS From the respective figure

The load is rotating bending: ⇒ CL = 1

Size is such that: ⇒ CD = 0.9

BHN ≤ 350

⇒ Su (MPa) ≈ 3.45BHN

Su (MPa) ≈ 3.45 × 320 = 1104 (MPa)

⇒ CS = 0.68
To determine the 106 (infinite) cycle stress taking into the above factors we have:

S n = CLCDCS S n′ (we assume S n′ = 0.5Su )

S n = 1× 0.9 × 0.68 × (0.5 × 1104 ) = 337.8 (MPa)

The maximum stress corresponds to the maximum moment.

32 M
σ nominal =
πD 3

32 × 52 F
σ nominal = = 1.962 × 10 −2 F (MPa)
π × 303

337.8
Fn = = 17.22 (kN)
1.962 × 10 −2

(c)

We also need to know the fatigue strength at 103 cycles.

S103 = 0.9Su

S103 = 0.9 × 1104 = 993.6 (MPa)

32 M
σ nominal =
πD 3

32 × 52 F
σ nominal = = 1.962 × 10 −2 F (MPa)
π × 30 3

993.6
F103 = = 50.64 (kN)
1.962 × 10 −2

Similar to constructing an S-N plot, we are going to construct an F-N plot. In the range of
103 and 106 cycles, we have

F = aN b

At 103 cycles, F103 = a103b = 50.64 (kN)

At 106 cycles, Fn = a106b = 17.22 (kN)

Solving the equations we obtain

 Fn 17.22
103b = = = 0.34
F103 50.64

Thus,

log 0.34
b= = −0.1562
3

F103 50.64
a= 3b
= = 148.94
10 0.34

The maximum load at 3×104 cycles is then

(
F = 148.94 N −0.1562 = 148.94 × 3 ×10 4 )
−0.1562
= 29.76 (kN)
3. For the fatigue test data of a titanium alloy, Ti-6Al-4V, which is common to
aerospace applications, as shown in Table 1, plot the median and lower bound S-N
curves using log-log coordinates. Determine the median: (a) fatigue limit; (b) fatigue
strength at 1×105 cycles, (c) fatigue life at S = 500 MPa.

Answer: (a) 412 MPa at 2.5×105 cycles; (b) 473 MPa; (c) 6.3×104 cycles.

Table 1: Test data of Ti-6Al-4V 1

Test number Cycles Stress (MPa) Notes
1 5.32e+03 774.03
2 6.74e+03 729.08
3 9.70e+03 699.84
4 2.02e+04 586.49
5 4.85e+04 546.29
6 3.78e+04 534.36
7 6.82e+04 499.89
8 1.03e+05 482.65
9 8.83e+04 465.41
10 1.13e+05 448.17
11 1.83e+05 430.94
12 4.96e+04 420.6
13 4.07e+05 420.6
14 5.91e+05 420.6
15 7.05e+06 420.6
16 1.00e+08 417.15 did not fail
17 1.00e+08 417.15 did not fail
18 2.06e+05 413.7
19 3.25e+06 413.7
20 6.55e+06 413.7
21 1.00e+07 413.7 did not fail
22 1.61e+05 413.7
23 8.75e+06 413.7
24 1.00e+08 413.7 did not fail
25 1.00e+08 413.7 did not fail
26 2.40e+06 413.7
27 1.00e+08 406.8 did not fail
28 1.00e+08 406.8 did not fail
29 1.00e+07 399.91 did not fail
30 1.10e+06 399.91
31 1.00e+09 398.19 did not fail
32 3.63e+05 393.02
33 4.49e+07 393.02
34 1.00e+08 393.02 did not fail
35 4.75e+05 379.23
36 1.84e+06 379.23

1
Pollak, Randall D., and Anthony N. Palazotto. "A comparison of maximum likelihood models for fatigue
strength characterization in materials exhibiting a fatigue limit." Probabilistic Engineering Mechanics 24.2
(2009): 236-241.
Solution

2.95

2.9

2.85

2.8
logS

2.75

2.7

2.65

2.6

2.55
3 5 7 9
logN

(a)

At the fatigue limit logS = 2.615 and logN = 5.4. Thus, the fatigue limit is 412 MPa at
2.5×105 cycles.

(b)

logN = 5. The corresponding logS = 2.675 and S = 473 MPa.

(c)

logS = 2.7. The corresponding logN = 4.8 and N = 6.3×104 cycles.