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Lecture 3 - January 23

The document outlines various fatigue design methods, including strategies, criteria, and analysis/testing approaches. It discusses four primary fatigue life models: Nominal stress-life, Local strain-life, Fatigue crack growth, and a two-stage method, along with design criteria such as Infinite-Life, Safe-Life, Fail-Safe, and Damage-Tolerant designs. The importance of iterative design processes and the need for careful consideration of various factors in fatigue design are emphasized.

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10 views26 pages

Lecture 3 - January 23

The document outlines various fatigue design methods, including strategies, criteria, and analysis/testing approaches. It discusses four primary fatigue life models: Nominal stress-life, Local strain-life, Fatigue crack growth, and a two-stage method, along with design criteria such as Infinite-Life, Safe-Life, Fail-Safe, and Damage-Tolerant designs. The importance of iterative design processes and the need for careful consideration of various factors in fatigue design are emphasized.

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blessedbyshiva612
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Lecture 3

FATIGUE DESIGN METHODS

MIME 4320/5320: Fatigue of Materials and Structures


Meysam Haghshenas, PhD
Department of Mechanical Engineering
University of Toledo

Spring 2024
FATIGUE DESIGN METHODS

 STRATEGIES IN FATIGUE DESIGN

 FATIGUE DESIGN CRITERIA

 ANALYSIS AND TESTING

 STANDARDS
DESIGN
The process of originating and developing a plan for a product,
structure, system, component, or a problem.

• We must satisfy a variety of considerations

• Design is an iterative process

Example: class projects (review papers)


DESIGN CONSIDERATION
DESIGN CONSIDERATION

Quantitative

• Safety, strength, functionality, compatibility, cost, weight, size,


and so on

Qualitative

• Marketability, styling, liability, manufacturability, competitive


factors, repairability, and so on

More Recent Considerations

• Environmental impact, recyclability, socioeconomic concerns,


ergonomics, and so on
STRATEGIES IN FATIGUE DESIGN

-- Choosing the fatigue life model is a significant decision.


-- Four fatigue life models exist.

1. Nominal stress-life (S-N) method


 First formulated in the 1850s to 1870s.
 Uses nominal stresses and relates these to local fatigue
strengths for notched and unnotched members.

2. Local strain-life (-N) method


 First formulated in the 1960s.
 Local strain at a notch is related to smooth specimen strain-
controlled fatigue behavior.
 Analytical models can be used to determine local strains from
global or nominal stresses or strains.
STRATEGIES IN FATIGUE DESIGN (CONT’D)

3. Fatigue crack growth (da/dN-K) method


 First formulated in the 1960s.
 Requires the use of fracture mechanics to obtain the number of
cycles to grow a crack from a given length to another length
and/or to fracture.
 This model can be considered a total fatigue life model when used
in conjunction with existing initial crack size following manufacture.
Summary of THREE THEORIES

stress-based, for high-cycle fatigue,


Stress-Life aims to prevent crack initiation

useful when yielding begins (i.e.,


Strain-Life during crack initiation), for low-cycle
fatigue

LEFM (Fracture best model of crack propagation, for


Mechanics) low-cycle fatigue
STRATEGIES IN FATIGUE DESIGN (CONT’D)

4. Two-stage method by combining 2 and 3 to incorporate


both fatigue crack nucleation and growth

 Incorporates the local -N model to obtain the life to the


formation of a small macrocrack and then integration of the
fatigue crack growth rate equation for the remaining life.

 The two lives are added together to obtain the total fatigue life.

9
FATIGUE DESIGN CRITERIA

 The criteria for fatigue design include usage of the four fatigue
life models (S-N, -N, da/dN-K, two-stage method).

 These criteria are:

 Infinite-Life Design

 Safe-Life Design

 Fail-Safe Design

 Damage-Tolerant Design

10
INFINITE-LIFE DESIGN

 Infinite-Life Design

 Unlimited safety is the oldest criterion.

 It requires local stresses or strains to be


essentially elastic and safely below the
fatigue limit.

 For parts subjected to many millions of


cycles, like engine valve springs, this is
still a good design criterion.

 This criterion may not be


economical (i.e., global
car crank shaft – ~ 2.5×108 Rev/105 miles
competitiveness) or practical
(i.e., excessive weight of aircraft)
in many design situations.
INFINITE-LIFE DESIGN (CONT’D)

Infinite-Life Design
SAFE-LIFE DESIGN
 Safe-Life Design

 This is an approach which designs components with NO


tolerance for failure during the life of the part (zero-tolerance).

 Used on very critical parts or on those which cannot be inspected.


At the end of the expected safe operation life, the component is
retired from service.

 Automotive, aircraft (e.g., landing gear) and jet engine


components.

 The margin for safety in safe-life design may be taken in terms of


life (calculated life = 20 × assumed life), in terms of load
(assumed load =0.5 × expected load), or by specifying that both
margins must be satisfied.

 It is a very conservative criterion.


14
SAFE-LIFE DESIGN (cont’d)

Safe-Life Design

15
FAIL-SAFE DESIGN

 Fail-Safe Design

 This is an approach which permits failure (e.g., crack


formation) but which compensates (pays-off) through
periodic inspections or slow accumulation rates.

 Fail-safe design requires that if one part fails, the system


does not fail (e.g., the concept of two-engine airplanes).

 Fail-safe design recognizes that fatigue cracks may occur, and


structures are arranged so that cracks will not lead to failure
of the structure before they are detected and repaired.

 Multiple load paths, load transfer between members, crack


stoppers built at intervals into the structure, and inspection are
some of the means used to achieve fail-safe design.
Materials with slow crack growth and high fracture toughness.
FAIL-SAFE DESIGN (cont’d)
• Used on components in which inspection is possible
• Less conservative that Safe-Life Design Approach
DAMAGE-TOLERANT DESIGN
 Damage-Tolerant Design
 This involves designing a
component to resist failure due
to the presence of flaws,
cracks, or other damage for a
specified period of unrepaired
usage.

 This philosophy is a refinement


of the fail-safe philosophy.

 It assumes that cracks exist and uses


fracture mechanics analyses (tests) to
check whether such cracks will grow
large enough to produce failures before
they are detected by periodic inspection.

18
DAMAGE-TOLERANT DESIGN

 Three key items are needed for successful damage-tolerant


design:

 residual strength,

 fatigue crack growth behavior, and

 crack detection involving nondestructive inspection.

 Damage-tolerant design has been required by the U.S. Air Force.

 In pressure vessel design “leak before burst” is an expression of


damage-tolerant philosophy.

19
FATIGUE DESIGN CRITERIA (CONT’D)

 Residual strength is the strength at any instant in the presence of


a crack.
 With no cracks, this could be the ultimate tensile strength or yield
strength depending upon failure criteria chosen.

 As a crack forms and grows under cyclic loading, the residual


strength decreases.

 Crack detection methods using different non-destructive


inspection techniques have been developed.

 Inspection periods must be laid out such that as the crack grows, the
applied stresses remain below the residual strength.

20
LEAK BEFORE BREAK
• Using principles of fracture mechanics, allowance is made for the
growth of a crack through the thickness of the vessel wall prior to the
occurrence of rapid crack propagation.

• Thus, the crack will completely penetrate the wall without catastrophic
failure, allowing for its detection by the leaking of pressurized fluid.

𝑝𝑟 2a = t
𝜎=
𝑡

≤
DAMAGE-TOLERANT DESIGN (CONT’D)

Inspection interval in damage-tolerant design


SUMMARY

1. Infinite life design

– Very old design type

– Based of fatigue limit

– Stress are some fractions (or) well below the endurance limit

2. Safe life design

– Finite life design – Life is fixed

– Implies life can be predicted

– Need safety margin to account for uncertainties


SUMMARY

3. Fail-safe design

– Recognizes some structural damage is inevitable

• Relies on detection and repair of cracks before failure

4. Damage-tolerant design

– This is an extension of fail-safe design incorporating materials that


have slow crack growth – high fracture toughness

– Fracture Mechanics approach

– Example pressure vessel “leak before burst”


DOS AND DON’TS IN DESIGN

• Do recognize that fatigue design is an iterative process


involving synthesis, analysis, and testing.

• Do recognize that different fatigue design criteria and different


analytical fatigue life models exist and that no one criterion or
analytical model is best for all situations.

• Don’t forget that damage-tolerant design may be necessary


due to the existence or development and growth of cracks in
safety critical structures.

• Don’t consider computational/analytical fatigue life


predictions/estimations as the end of the fatigue design
process.
DOS AND DON’TS IN DESIGN

• Do emphasize digital prototyping and rely on fatigue testing


primarily for product durability determination rather than product
development.

• Do place more emphasis on bringing the test track or proving


ground into the laboratory, but keep in mind that the more
closely testing simulates the real in-service conditions, the
greater the confidence in the results.

• Don’t neglect the advantages and limitations of accelerated


fatigue testing.

• Do pursue inspection of in-service components, structures,


and vehicles and continue to monitor customer usage.

• Don’t neglect the importance of environmental conditions in


both analytical and testing aspects of fatigue design.
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