Aircraft structure/I Dr.

Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

The Endurance Limit

We wish now to present a method for estimating endurance limits. Note that
estimates obtained from quantities of data obtained from many sources probably
have a large spread and might deviate significantly from the results of actual
laboratory tests of the mechanical properties of specimens obtained through strict
purchase-order specifications.
Since the area of uncertainty is greater, compensation must be made by employing
larger design factors than would be used for static design
For steels, simplifying our observation of Fig. 6–17, we will estimate the
endurance limit as.

where Sut is the minimum tensile strength. The prime mark on 𝑆 in this equation
refers to the rotating-beam specimen itself. We wish to reserve the unprimed
symbol Se for the endurance limit of an actual machine element subjected to any
kind of loading.

Fatigue Strength
a region of low-cycle fatigue extends from N = 1 to about 10 cycles. In this
region the fatigue strength Sf is only slightly smaller than the tensile strength Sut .
The high-cycle fatigue domain extends from 10 cycles for steels to the endurance
limit life Ne, which is about 10 to 10 cycles. The purpose of this section is to
develop methods of approximation of the S-N diagram in the high cycle region,
when information may be as sparse as the results of a simple tension test.
An analytical approach has been given for both high-cycle and low-cycle regions,
requiring the parameters of the Manson-Coffin equation plus the strain
strengthening exponent m.

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

where f is the fraction of Sut represented by (𝑆f )103 cycles. The process given for
finding f can be repeated for various ultimate strengths.
Figure 1 is a plot of f for 70 ≤ Sut ≤ 200 kpsi. To be conservative, for Sut < 70 kpsi,
let f = 0.9.

Figure 3 Fatigue strength fraction, f

If a completely reversed stress σrev is given, setting Sf = σrev , the number

of cycles-to-failure can be expressed as

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

Example 1
If the material has sy=2se, which of following is most dangerous condition when the
torque values varying from:
a) -T to T
b) -T/2 to T
c) 0 to T
d) T/2 to T
Solution:
according to the Soderberg criteria

When: (Sy=2 Se)

𝜎 𝜎 1
+ =
𝑆 2𝑆 𝑛
1 𝜎 1
(𝜎 + ) =
𝑆 2 𝑛
For:
( )
a) 𝜎 = =𝑇 , 𝜎 =0
𝜎
∴ (𝜎 + )∝𝑇
2
( / ) ( / )
b) 𝜎 = = , 𝜎 = =

∴ (𝜎 + )∝

c) 𝜎 = ,𝜎 =
𝜎 6𝑇
∴ (𝜎 + )∝
2 8

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

d) 𝜎 = , 𝜎 =
𝜎 6𝑇
∴ (𝜎 + )∝
2 8
So that (a) is most dangerous condition

Example 2
A rotating steel shaft supported at end, subjected to point load at center, has
maximum bending stress 100 Mpa completly reversed with sy =300 Mpa, sut=500
Mpa and se=200 Mpa
What will be factor of safety?
Solution:
𝜎 = 100 𝑀𝑝𝑎 , 𝜎 =? (We will take 𝜎 = −100) 𝑐𝑜𝑚𝑝𝑙𝑒𝑡𝑙𝑦 𝑟𝑒𝑣𝑒𝑟𝑠𝑒𝑑
according to the Soderberg criteria

( )
𝜎 = 𝜎 = 𝜎 = 100𝑀𝑝𝑎
( )
𝜎 = 𝜎 = 𝜎 =0

Sub 𝜎 𝑎𝑛𝑑 𝜎 𝑖𝑛 𝑠𝑜𝑑𝑒𝑟𝑏𝑒𝑟𝑔 𝑐𝑟𝑖𝑡𝑒𝑟𝑖𝑎 𝑓𝑜𝑟𝑚𝑢𝑙𝑎:

100 1
+0=
200 𝑛
n= 2
Note/ n=2 for Goodman and Gerber criteria

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

Example 3
A ductile material having se=196 N/mm2 and sy=294 N/mm2 under variable load
of stress concentration factor is 1.32. Calculate factor of safety as per Soderberg
criteria.
Solution:
𝜎 = 147 𝑀𝑝𝑎 , 𝜎 = 49 𝑀𝑝𝑎 , 𝐾𝑓 = 1.32
𝜎 −𝜎 𝜎 +𝜎
𝜎 = 𝑎𝑛𝑑 𝜎 =
2 2
𝜎 = ∴ 𝜎 = 49 𝑀𝑝𝑎

𝜎 = ∴ 𝜎 = 98 𝑀𝑝𝑎

according to the Soderberg criteria

𝜎 𝜎 1
+𝑘 =
𝑠𝑦 𝑠 𝑛
98 49 1
+ 1.32 =
294 196 𝑛
n=1.5

Example 4
Thin spherical pressure vessel of 200 mm diameter and 1mm thickness, subjected
to internal pressure varying from 4 to 8 Mpa, if sy=600 Mpa, sut=800 Mpa and
se=400 Mpa, what is factor of safety as per goodman criteria?
Solution:
Pmax =8 Mpa, Pmin = 4 Mpa, d=200 mm, t=1 mm
𝑝𝑑
𝜎 =
2𝑡
𝜎 , = ,𝜎 , =
×
∴𝜎 , = = 800 Mpa
×

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)
×
∴𝜎 , = = 400 Mpa
×
, ,
𝜎 , = = = 600 Mpa
, ,
𝜎 , = = = 200 Mpa

According to Goodman criteria

200 600 1
+ =
400 800 𝑛
n = 0.8

Example 5
A forged steel link of uniform diameter=30 mm at center is subjected to axial force
varying from 40 KN comp. to 160 KN tension when sut=600 Mpa, sy=420Mpa,
se=240Mpa what is factor of safety (using Soderberg criteria)?
Solution:
d=30 mm , Pmax =160 Mpa, Pmin = -40 Mpa, sut=600 Mpa, sy=420Mpa, se=240Mpa

𝑝 = ,𝑝 =
( ) ( )
𝑝 = = 60 KN , 𝑝 = = 100 KN
∗
𝜎 = = = 84.88 𝑁/𝑚𝑚
( )
∗
𝜎 = = = 141.47 𝑁/𝑚𝑚
( )

according to the Soderberg criteria

𝜎 𝜎 1
+𝑘 =
𝑠𝑦 𝑠 𝑛
. .
+1 = n=1.26

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

Example 6
Abar is subjected to fluctuating tensile load of 20KN to 100 KN, when s yt=240
Mpa , se=160 Mpa, factor of safety= 2, what is the value of the area as per
Soderberg criteria ?
Solution:
Pmax =100 Mpa, Pmin = 20 Mpa, se=160Mpa, n=2
𝜎 = ,𝜎 =
∗ ∗
𝜎 = ,𝜎 =

𝜎 = ,𝜎 =
∗ ∗
𝜎 = ,𝜎 =

Soderberg criteria
𝜎 𝜎 1
+𝑘 =
𝑠𝑦 𝑠 𝑛
∗ ∗
+ =
∗ ∗

A=1000 𝑚𝑚

Example 7
For a given loading of minimum stress equal to 50 Mpa and maximum stress equal
to 150 Mpa and se=200 Mpa, sut=400 Mpa. what is the factor of safety according
to:
a) Goodman criteria
b) Gerber criteria
solution:
𝜎 = 50 𝑀𝑝𝑎 , 𝜎 = 150 𝑀𝑝𝑎
𝜎 = 100 𝑀𝑝𝑎 , 𝜎 = 50 𝑀𝑝𝑎

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

a) Goodman criteria

50 100 1
+ =
200 400 𝑛
n= 2
b) Gerber criteria

𝑛 ∗ 50 𝑛 ∗ 10
+ =1
200 16 ∗ 10

n=2.4

Example 8
A steel shaft is subjected to cyclic loading such that maximum stress =60 𝐾𝑝𝑠𝑖,
minimum stress = -20 𝐾𝑝𝑠𝑖, with sut=80 𝐾𝑝𝑠𝑖, syt=65 𝐾𝑝𝑠𝑖, fully corrected
endurance strength =40 𝐾𝑝𝑠𝑖 (at 103 cycles f=0.9). calculate life cycle of shaft
using:
a) Goodman criteria
b) Gerber parabola

solution:
σ = −20 𝐾𝑝𝑠𝑖 , σ = 60 𝐾𝑝𝑠𝑖
σ = 20 𝐾𝑝𝑠𝑖 , σ = 40 𝐾𝑝𝑠𝑖

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

a) Goodman criteria

Note/ se = 𝜎 . At (n=1)

+ =
.

40 20
+ =1
𝜎 . 80
𝜎 . = 53.3 𝐾𝑝𝑠𝑖

(0.9 ∗ 80)
𝑎= = 129.6
40

1 0.9 ∗ 80
𝑏 = − log = −0.08509
3 40

53.3=129.6 N-0.0851
N=3.4*104 cycles
b) Gerber criteria

+ =1 𝜎 = 42.7 𝐾𝑝𝑠𝑖 and N=4.6*105 cycles

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

Example 9
A steel shaft in bending has an ultimate strength of 690 MPa and a shoulder with a
fillet radius of 3 mm connecting a 32-mm diameter with a 38-mm diameter.
Estimate Kf when Kt=1.65
Solution:
First we obtained Kt from figure 4
When r/d=0.0937
D/d=1.18
We can get to Kt=1.65
Second we obtained q from figure 5
When raduise of fillet =3mm ,
su =0.6 Gpa
we can get (q=0.84) Fig .4

Kf=1+0.84(1.65-1)
Kf=1.55

Figure 5

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

Example 10
For the step-shaft of Ex. 9, it is determined that the fully corrected endurance limit
is Se = 280 MPa. Consider the shaft undergoes a fully reversing nominal stress in
the fillet of (σrev) nom = 260 MPa. Estimate the number of cycles to failure.
Solution:
(σrev)max = Kf (σrev)nom = 1.55(260) = 403 Mpa

(0.84 ∗ 690)
𝑎= = 1214 𝑀𝑃𝑎
280
1 0.84 ∗ 690
𝑏 = − 𝑙𝑜𝑔 = −0.1062
3 280

N= 32.3*103 cycles

Example 11
Given a 1050 HR steel when Sut = 90 kpsi , estimate
(a) the rotating-beam endurance limit at 106 cycles.
(b) the endurance strength of a polished rotating-beam specimen corresponding to
104 cycles to failure
(c) the expected life of a polished rotating-beam specimen under a completely
reversed stress of 55 kpsi.
Solution:
a) 𝑠 ̀ = 0.5(90) = 45 kpsi
𝑏)for Sut = 90 kpsi, f .=0.86.
a = 133.1 kpsi , b = −0.0785
Sf= 133.1 N−0.0785
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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

For 104 cycles to failure, Sf= 133.1(10 4) −0.0785 = 64.6 kpsi

c) with σrev = 55 kpsi,

N = 7.75(104) cycles

Example 12
This problem asks that we compute the maximum and minimum loads to which a
15.2 mm diameter 2014-T6 aluminum alloy specimen may be subjected in order to
yield a fatigue life of 1.0 x 108 cycles; for a mean stress 35 Mpa and a stress
amplitude 140 MPa
Solution:

Since σm = 35 Mpa

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Aircraft structure/I Dr. Samara Munaem
Chapter 15 Lecture 4 (Fatigue)

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