Lecture Fatigue Loading
Lecture Fatigue Loading
Lecture 07
Fatigue
plastic deformation
• Stage II – Progresses to macro-crack that
repeatedly opens and closes, creating bands
called beach marks
• Stage III – Crack has propagated far enough that
remaining material is insufficient to carry the
load, and fails by simple ultimate failure
Fig. 6–1
Mechanical Engineering Department, University of Bahrain, Bahrain
Schematics of Fatigue Fracture Surfaces
DOME MENG 375
Fig. 6–2
Mechanical Engineering Department, University of Bahrain, Bahrain
Schematics of Fatigue Fracture Surfaces
DOME MENG 375
Fig. 6–2
Mechanical Engineering Department, University of Bahrain, Bahrain
Schematics of Fatigue Fracture Surfaces
DOME MENG 375
Fig. 6–2
Mechanical Engineering Department, University of Bahrain, Bahrain
Schematics of Fatigue Fracture Surfaces
DOME MENG 375
Fig. 6–2
shaft
B– crack initiation at
stress concentration
in keyway
C– Final brittle
failure
Fig. 6–3
Mechanical Engineering Department, University of Bahrain, Bahrain
Fatigue Fracture Examples
Fatigue failure
DOME MENG 375
initiating at
mismatched grease
holes
Sharp corners (at
arrows) provided
stress concentrations
Fig. 6–4
Mechanical Engineering Department, University of Bahrain, Bahrain
Fatigue Fracture Examples
Fatigue failure of
DOME MENG 375
Fatigue failure of a
DOME MENG 375
200-mm diameter
piston rod of an alloy
steel steam hammer
Loaded axially
Crack initiated at a
forging flake internal to
the part
Internal crack grew
outward symmetrically
Fig. 6–6
Mechanical Engineering Department, University of Bahrain, Bahrain
Fatigue Fracture Examples
Fig. 6–9
Fig. 6–10
Mechanical Engineering Department, University of Bahrain, Bahrain
S-N Diagram for Steel
• Stress levels below Se predict infinite life
• Between 103 and 106 cycles, finite life is predicted
DOME MENG 375
Fig. 6–10
Mechanical Engineering Department, University of Bahrain, Bahrain
S-N Diagram for Nonferrous Metals
Nonferrous metals often do not have an endurance limit.
Fatigue strength Sf is reported at a specific number of cycles
DOME MENG 375
discontinuity
When stress at
discontinuity exceeds
elastic limit, plastic
strain occurs
Cyclic plastic strain can
change elastic limit,
leading to fatigue
Fig. 6–12 shows true
stress-true strain
hysteresis loops of the
first five stress reversals
Mechanical Engineering Department, University of Bahrain, Bahrain
Strain-Life Method
Fatigue failure almost
always begins at a local
DOME MENG 375
discontinuity
When stress at
discontinuity exceeds
elastic limit, plastic
strain occurs
Cyclic plastic strain can
change elastic limit,
leading to fatigue
Fig. 6–12 shows true
stress-true strain
hysteresis loops of the
first five stress reversals
Mechanical Engineering Department, University of Bahrain, Bahrain
Relation of Fatigue Life to Strain
Figure 6–13 plots relationship of fatigue life to true-strain
amplitude
DOME MENG 375
Fig. 6–13
Mechanical Engineering Department, University of Bahrain, Bahrain
Relation of Fatigue Life to Strain
Fatigue ductility exponent c is the slope of plastic-strain line, and is
the power to which the life 2N must be raised to be proportional to the
true plastic-strain amplitude. Note that 2N stress reversals corresponds
DOME MENG 375
to N cycles.
Fatigue strength exponent b is the slope of the elastic-strain line, and
is the power to which the life 2N must be raised to be proportional to
the true-stress amplitude.
Fig. 6–13
Mechanical Engineering Department, University of Bahrain, Bahrain
Relation of Fatigue Life to Strain
• Total strain is sum of elastic and plastic strain
DOME MENG 375
Fig. 6–14
Mechanical Engineering Department, University of Bahrain, Bahrain
Crack Growth
• Log-log plot of rate
of crack growth,
DOME MENG 375
Fig. 6–16
Fig. 5–27
strength
Fig.Engineering
Mechanical 6–17 Department, University of Bahrain, Bahrain
The Endurance Limit
• Simplified estimate of endurance limit for steels
for the rotating-beam specimen, S'e
DOME MENG 375
Fig. 6–17
Mechanical Engineering Department, University of Bahrain, Bahrain
Fatigue Strength
• For design, an approximation of the idealized S-
N diagram is desirable.
DOME MENG 375
• At 103 cycles,
• f is the fraction of Sut represented by ( S f )103
• Solving for f,
• Eqs. (6–11) and (6–12) can be substituted into Eqs. (6–9) and
(6–10) to obtain expressions for S'f and f
• Use f from plot for S'f = f Sut at 103 cycles on S-N diagram
• Assumes Se = S'e= 0.5Sut at 106 cycles
Fig. 6–18
Mechanical Engineering Department, University of Bahrain, Bahrain
Equations for S-N Diagram
stress concentrations
• Surface factor is a function of ultimate strength. Higher strengths
are more sensitive to rough surfaces.
• Equate 95% stress area for other conditions to Eq. (6–22) and
solve for d as the equivalent round rotating diameter
Fig. 6–17
Mechanical Engineering Department, University of Bahrain, Bahrain
Reliability Factor ke
• Simply obtain ke for desired reliability from Table
DOME MENG 375
6–5.
Table 6–5
• For q = 0, Kf = 1
• For q = 1, Kf = Kt
Fig. 6–20
Bending or axial:
Torsion:
nf
Se
1/ K f Se
K f
Fig. 6–22
Fig. 6–22
General
DOME MENG 375
Fluctuating
Repeated
Completely
Reversed
Fig. 6–24
Mechanical Engineering Department, University of Bahrain, Bahrain
Master Fatigue Diagram
• Displays four stress components as well as two stress ratios
DOME MENG 375
Fig.
Mechanical 6–26 Department, University of Bahrain, Bahrain
Engineering
Plot of Alternating vs Midrange Stress
• Probably most common and simple to use is the plot of a vs m
• Has gradually usurped the name of Goodman or Modified
DOME MENG 375
Goodman diagram
• Modified Goodman line from Se to Sut is one simple representation
of the limiting boundary for infinite life
Fig. 6–27
criteria
• The first row gives fatigue criterion
• The second row gives yield criterion
• The third row gives the intersection of static and fatigue criteria
• The fourth row gives the equation for fatigue factor of safety
• The first column gives the intersecting equations
• The second column gives the coordinates of the intersection
Fig. 6–28
Mechanical Engineering Department, University of Bahrain, Bahrain
Example 6-10
DOME MENG 375
Fig. 6–28
Mechanical Engineering Department, University of Bahrain, Bahrain
Example 6-10
DOME MENG 375
Fig. 6–30a
Mechanical Engineering Department, University of Bahrain, Bahrain
Example 6-11
DOME MENG 375
Fig. 6–30b
Mechanical Engineering Department, University of Bahrain, Bahrain
Example 6-11
DOME MENG 375
• Or as a design equation,
Fig.University
Mechanical Engineering Department, 6–31b of Bahrain, Bahrain
Torsional Fatigue Strength
• Testing has found that the steady-stress component has no effect
on the endurance limit for torsional loading if the material is
DOME MENG 375
and alternating)
• Stress concentration factors are not necessary to check for
yielding at first cycle
2 1/2
a m 3 a m
2
max
Sy
ny
max
Fig. 6–32
Mechanical Engineering Department, University of Bahrain, Bahrain
Example 6-14
DOME MENG 375
Fig. 6–33
Mechanical Engineering Department, University of Bahrain, Bahrain
Cumulative Fatigue Damage
A common situation is to load at 1 for n1 cycles, then at 2 for n2
cycles, etc.
DOME MENG 375
Fig. 6–33
Mechanical Engineering Department, University of Bahrain, Bahrain
Example 6-15
DOME MENG 375
Fig. 6–34
Mechanical Engineering Department, University of Bahrain, Bahrain
Weaknesses of Miner’s Rule
• Miner’s rule fails to agree with experimental results in two ways
– It predicts the static strength Sut is damaged.
DOME MENG 375
– It does not account for the order in which the stresses are
applied
• AGMA uses
Table 6–9
Fig. 6–36
Example 6-16
DOME MENG 375
Example 6-17
DOME MENG 375
Example 6-17
DOME MENG 375
Example 6-18
DOME MENG 375
Example 6-18
DOME MENG 375
Example 6-19
DOME MENG 375
Fig. 6–37
Example 6-19
DOME MENG 375
Example 6-19
DOME MENG 375
Example 6-19
DOME MENG 375
Example 6-19
DOME MENG 375
Example 6-19
DOME MENG 375
Example 6-19
DOME MENG 375
Example 6-20
DOME MENG 375
Example 6-20
DOME MENG 375
Example 6-20
DOME MENG 375
Example 6-20
DOME MENG 375
Example 6-20
DOME MENG 375
Example 6-20
DOME MENG 375
Example 6-20
DOME MENG 375
Example 6-20
DOME MENG 375
Fig.Engineering
Mechanical 6–38 Department, University of Bahrain, Bahrain
Stochastic Analysis
• Design Factor in Fatigue
DOME MENG 375
Example 6-21
DOME MENG 375
Example 6-21
DOME MENG 375
Example 6-21
DOME MENG 375
Example 6-21
DOME MENG 375