Fatigue
Fatigue
Chapter 6
Fig. 6–1
Shigley’s Mechanical Engineering Design
Schematics of Fatigue Fracture Surfaces
Fig. 6–2
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Schematics of Fatigue Fracture Surfaces
Fig. 6–2
Shigley’s Mechanical Engineering Design
Schematics of Fatigue Fracture Surfaces
Fig. 6–2
Fig. 6–3
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Fatigue Fracture Examples
Fatigue failure
initiating at
mismatched grease
holes
Sharp corners (at
arrows) provided
stress concentrations
Fig. 6–4
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Fatigue Fracture Examples
Fatigue failure of
forged connecting rod
Crack initiated at flash
line of the forging at the
left edge of picture
Beach marks show
crack propagation
halfway around the hole
before ultimate fracture
Fig. 6–5
Fatigue failure of a
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
Fig. 6–9
Fig. 6–10
Shigley’s Mechanical Engineering Design
S-N Diagram for Steel
Stress levels below Se predict infinite life
Between 103 and 106 cycles, finite life is predicted
Below 103 cycles is known as low cycle, and is often considered
quasi-static. Yielding usually occurs before fatigue in this zone.
Fig. 6–10
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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
Figure 6–11 shows typical S-N diagram for aluminums
Fig. 6–17
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The Endurance Limit
Simplifiedestimate of endurance limit for steels for the rotating-
beam specimen, S'e
Fig. 6–17
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Fatigue Strength
For design, an approximation of the idealized S-N diagram is
desirable.
To estimate the fatigue strength at 103 cycles, start with Eq. (6-2)
At 103 cycles,
f is the fraction of Sut represented by ( S f ) 3
10
Solving for f,
Fig. 6–18
0.9000
0.8000
0.7000
0.6000
ground
0.5000 machined
Ka
Hot Rolled
0.4000 Forged
0.3000
0.2000
0.1000
0.0000
0 0 0 0 0 0 00 00 00 00 00 00 00 00 00 00 00
40 50 60 70 80 90 10 11 12 13 14 15 16 17 18 19 20
Sut
Equate 95% stress area for other conditions to Eq. (6–22) and
solve for d as the equivalent round rotating diameter
From Fig. 6–17, S'e = 0.5 Sut is typical of the data and represents
50% reliability.
Reliability factor adjusts to other reliabilities.
Only adjusts Fig. 6–17 assumption. Does not imply overall
reliability.
Fig. 6–17
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
Fluctuating
Repeated
Completely
Reversed
Fig. 6–24
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Master Fatigue Diagram
Displays four stress components as well as two stress ratios
Fig. 6–26
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Plot of Alternating vs Midrange Stress
Probably most common and simple to use is the plot of sa vs sm
Has gradually usurped the name of Goodman or Modified
Goodman diagram
Modified Goodman line from Se to Sut is one simple representation
of the limiting boundary for infinite life
Fig. 6–27
Fig. 6–27
Fig. 6–27
Fig. 6–28
Fig. 6–28
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Example 6-10
Fig. 6–30a
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Example 6-11
Fig. 6–30b
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Example 6-11
Or as a design equation,
Fig. 6–31a
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Example 6-13
Fig. 6–31b
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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
ductile, polished, notch-free, and cylindrical.
However, for less than perfect surfaces, the modified Goodman
line is more reasonable.
For pure torsion cases, use kc = 0.59 to convert normal endurance
strength to shear endurance strength.
For shear ultimate strength, recommended to use
For load factor, use kc = 1. The torsional load factor (kc = 0.59) is
inherently included in the von Mises equations.
If needed, axial load factor can be divided into the axial stress.
Fig. 6–32
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Example 6-14
Fig. 6–33
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Cumulative Fatigue Damage
Fig. 6–33
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Example 6-15
Fig. 6–34
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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.
◦ It does not account for the order in which the stresses are
applied
Fig. 6–35
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