Fluctuating Stresses: SUBJECT: Design of Machine Elements M.V.S.S.Hemant

FLUCTUATING STRESSES
SUBJECT: Design of machine elements

M.V.S.S.HEMANT
FATIGUE LOAD
 The loads, which vary in magnitude and/or direction with respect to
time, are known as fatigue, fluctuating or alternating loads.
 It has been observed that, when the mechanical component is
subjected to fluctuating loads, it fails at a stress considerably below
the ultimate strength and quite frequently even below the yield
strength. Such failure is Fatigue failure.
B
Instantaneuos
Fast Fracture!
A
Crack
nucleation
and Growth
FLUCTUATING STRESSES
 When the mechanical component is subjected to the fatigue or
fluctuating load, the stress induced is known as fluctuating stress.
REPEATED & REVERSED
STRESS
 an element subjected to a repeated and alternating tensile and compressive
stresses.
Continuous total load reversal over time

DEFINITIONS:
  max   min
a   = Alternating stress
2 2
 max   min
m  = Mean stress
2
 min
R = R value:
 max R = 0, repeated and one direction, i.e. stress

cycles from 0 to max value.
R =-1, Fully reversed (R-R Moore)
1.REPEATED AND REVERSED
STRESS
 min
R  1
 max
The average or mean stress is zero.
FLUCTUATING STRESS
 When an element experiences alternating stress, but the mean stress is NOT
zero.
Load varies between P and Q over time

2.FLUCTUATING STRESS
EXAMPLE • Bending of Rocker Arm
Valve Spring Force
Valve Open
Valve Closed
• Tension in Valve Stem

Valve Closed
Valve Spring Force
Valve
Open
TENSILE STRESS W/ TENSILE
MEAN
max  min
a 
2
max  min
m 
2
PARTIALLY REVERSED W/
TENSILE MEAN
max  min
a 
2
max  min
m 
2
max is tensile and min is compressive

PARTIALLY REVERSED W/
COMPRESSIVE MEAN
max  min
a 
2
max  min
m 
2
max is tensile and min is compressive

COMPRESSIVE STRESS W/
COMPRESSIVE MEAN
max  min
a 
2
max  min
m 
2
max and min are both compressive

REPEATED – ONE DIRECTION
STRESS
FATIGUE FAILURE, S-N CURVE
Test specimen geometry for R.R. Moore

rotating beam machine. The surface is polished
in the axial direction. A constant bending load is
applied.
Typical testing apparatus, pure bending
Motor
Load
Rotating beam machine – applies fully reverse bending stress

FATIGUE FAILURE, S-N
CURVE
N < 103 N > 103
Finite life Infinite life
S′e
Se′ = endurance limit of the specimen

Design for Finite Life
Sn = a (N)b equation of the fatigue line

A A
S B S B
Sf
Se
N 103 5x108 N
103 106
Sn = .9Sut Sn = .9Sut
Point A Point A
N = 103 N = 103
Sn = Se Sn = Sf
Point B Point B
6
N = 10 N = 5x108
Sn = a (N)b log Sn = log a + b log N
2
(.9Sut)
a=
log .9Sut = log a + b log 103 Se
log Se = log a + b log 106 1 .9Sut
b= log
3 Se
S
e
⅓ log ( )
N .9Sut
Sn = Se ( 10 )6
Calculate Sn and replace Se in the design equation

Sn
K f a = Design equation
n
Design of components subjected to fluctuating
stresses for infinite life
a
Sy Yield line
Gerber curve
Se
Alternating
stress Goodman line
Sy Sut m
Soderberg line
Mean stress
THE EFFECT OF MEAN STRESS ON
FATIGUE LIFE MODIFIED GOODMAN
DIAGRAM
 a
Sy Yield line
Se
Alternating
stress Goodman line
C
Safe zone
Sy Sut m
Mean stress
a
Sy Yield line
Se
Goodman line
C
Safe zone Safe zone
- m - Syc Sy Sut + m
Fatigue, m ≤ 0 Fatigue, m > 0
a a m 1
+ = Infinite life
Se Sut nf
Se a m
a = n + =1 Finite life
f Sn Sut
Yield Se
Sy Yield
a + m = n Sy
y
C
a +  m = n
y
Safe zone Safe zone
- m - Syc Sy Sut + m
COMBINED LOADING
All four components of stress exist,
xa alternating component of normal stress
xm mean component of normal stress
xya alternating component of shear stress
xym mean component of shear stress
Calculate the alternating and mean principal stresses,
1a, 2a = (xa /2) ± (xa /2)2 + (xya)2
1m, 2m = (xm /2) ± (xm /2)2 + (xym)2

Calculate the alternating and mean von Mises stresses,
2 2
a′ = (1a + 2a - 1a2a)1/2
2 2
m′ = (1m + 2m - 1m2m)1/2
Fatigue design equation
′a ′m 1
+ = Infinite life
Se Sut nf
THANK YOU

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FLUCTUATING STRESSES

SUBJECT: Design of machine elements

Continuous total load reversal over time

 max R = 0, repeated and one direction, i.e. stress

Load varies between P and Q over time

• Tension in Valve Stem

max is tensile and min is compressive

max is tensile and min is compressive

max and min are both compressive

Test specimen geometry for R.R. Moore

Typical testing apparatus, pure bending

Rotating beam machine – applies fully reverse bending stress

Finite life Infinite life

Se′ = endurance limit of the specimen

Sn = a (N)b equation of the fatigue line

Calculate Sn and replace Se in the design equation

xya alternating component of shear stress

xym mean component of shear stress

Calculate the alternating and mean principal stresses,

1a, 2a = (xa /2) ± (xa /2)2 + (xya)2

1m, 2m = (xm /2) ± (xm /2)2 + (xym)2

m′ = (1m + 2m - 1m2m)1/2

Fatigue design equation

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