1

Prepared by: Zekai Murat Kılıç The groove is machined and Sut = 690MPa , Figure 7-8 in the formula sheet
Room: B-175 Phone: 5256
E-mail: zmkilic@metu.edu.tr Date: 27/11/2008 gives k a = 0.73 .

ME 307 – MACHINE ELEMENTS I At this section, the point on the upper surface of the groove is the critical point. So the
TUTORIAL 8 diameter used in the analysis is the diameter of the grooved section. While determining
“FATIGUE DESIGN CRITERIA” the size factor k b , effective diameter for a non-rotating round bar should be calculated.
d e = 0.370 ⋅ D = 0.370 ⋅ 38 = 14.06mm Equation 6-24 (8-th edition of textbook)
Problem 1: A machine element made of cold drawn AISI 1050 steel is given in the 8mm < d e = 14.06mm < 50mm The size factor: k b = 0.85 from the formula sheet.
figure. It is a round shaft, grooved at section A and there is a transverse hole on it at
section B. The groove and the hole are machined. The shaft is subjected to a bending For reliability of 0.95, reliability factor can be found as, k c = 0.868 from Table 7.7 in the
moment which is fluctuating between 0 and Mmax. Determine the maximum value of formula sheet.
the bending moment for an infinite life with factor of safety of 2. The reliability is
0.95. Use the modified Goodman diagram. Dimensions are in mm. Nothing is mentioned about the temperature, the temperature factor can be taken as:
kd = 1

To determine the stress concentration factor ke, Kt and q values are needed. The notch
sensitivity can be read as q = 0.8 for r = 2mm and Sut = 690MPa from Figure 7-13 in the
formula sheet. For K t ,
r / d = 2 / 38 = 0.053
D / d = 40 / 38 = 1.053
K t = 2.0 from Figure A-23-14 in the formula sheet
Then, K f = 1 + q(K t − 1) = 1 + 0.8(2.0 − 1) = 1.8
k e = 1 / K f = 1 / 1.8 = 0.56
Solution :
There are two critical sections on the shaft, the grooved section (Sec. A) and the
section with the transverse hole (Sec. B). Stress concentrations on two sections are As nothing is specified, the miscellaneous effects factor k f can be taken as k f = 1 .
different, so both sections will be analyzed for fatigue failure.
In the analysis, the strength values of the material are needed. From Table A-18 (8-th The endurance limit of the machine element is the product of the endurance limit of the
edition of textbook), for AISI 1050 CD steel, test specimen and the endurance limit modifying factors. The endurance limit of the test
Sut = 690MPa , Sy = 580MPa specimen Se ' is the half of the ultimate tensile strength of the material for steels with
Sut<1400MPa.
Section A: Se ' = 0.5 ⋅ Sut = 0.5 ⋅ 690 = 345 MPa
In the fatigue failure analysis, tension is more critical. So, an infinitesimal element on Then, Se = k a ⋅ k b ⋅ k c ⋅ k d ⋅ k e ⋅ k f ⋅ Se ' = 0.73 ⋅ 0.85 ⋅ 0.868 ⋅1 ⋅ 0.56 ⋅1 ⋅ 345 = 104 MPa
the upper surface will be considered. The endurance limit ( Se ) M max of the shaft at
the section A is to be determined. The endurance limit modifying factors should be The bending stress at the critical point:
found.
Mc πd 4 d
σ= where I = , c = and M is the bending moment.
I 64 2

METU – ME 307 Machine Elements I – Fall 2008

 2
Mc 32M 32M
σ= = = = 1.856 ⋅10−4 M MPa where M is in N ⋅ mm .
I πd 3 π(38)3 σa
The value of the bending moment M changes between 0 and M max . The minimum
and the maximum normal stress at the critical point will be:
M c 580
σ min = min = 0 MPa
I
M max c Load line
σ max = = 1.856 ⋅10−4 M max MPa
I
The mean and the alternating normal stresses can be found as:
σ + σ max 0 + 1.856 ⋅10−4 M max
σ m = min = = 9.28 ⋅10−5 M max Yield line Goodman line
2 2 104
σ − σ min 1.856 ⋅10−4 M max − 0
σa = max = = 9.28 ⋅10−5 M max
2 2
The ratio of the alternating and the mean normal stresses is 1 and it corresponds to a σm
slope of 45° on the σa − σm curve. The Goodman line intersects with the Yield line 580 690
for 2° . The intersection can be found as follows: So the failure will be because of fatigue and the Goodman line is to be used. If the load
σm σa line intersected with the Yield line first, the failure would be because of yielding and the
+ =1 Equation of yield line
Sy Sy Yield line were to be used.
σa σ m 1
σm σa + =
+ =1 Equation the Goodman line Se Sut n
Sut Se
At the intersection point, both equations should be satisfied. 9.28 ⋅10−5 M max 9.28 ⋅10−5 M max 1
+ =
σ m = Sy − σ a 104 690 2
From the first equation and, substituting σ m into the second equation: M max = 486949 N ⋅ mm = 487 N ⋅ m
Sy − σ a σa
+ =1 Section B:
Sut Se
Substituting known values: The endurance limit modifying factors should be found.
580 − σa σa
+ =1 The hole is machined and Sut = 690MPa , Figure 7-8 in the formula sheet gives k a = 0.73 .
690 104
σa = 19.5 MPa , σ m = 560.5 MPa at the intersection point
At this section, the effective diameter is 0.370 ⋅ 40mm = 14.8mm .
The slope of the line drawn from origin to the intersection point is
8mm < d = 14.8mm < 50mm
tan −1 (19.5 / 560.5) = 2°
The size factor: k b = 0.85 from the formula sheet.

For reliability of 0.95, reliability factor can be found as, k c = 0.868 from Table 7.7 in the
formula sheet.

METU – ME 307 Machine Elements I – Fall 2008

 3
Nothing is mentioned about the temperature, the temperature factor can be taken as: σa σ m 1
kd = 1 + =
Se Sut n
9.58 ⋅10−5 M max 9.58 ⋅10−5 M max 1
To determine the stress concentration factor k e , K t and q values are needed. The + =
91 690 2
notch sensitivity can be read as q = 0.8 for r = 2mm and Sut = 690MPa from Figure
7-13 in the formula sheet. For K t ,
d / D = 4 / 40 = 0.1 So, the maximum value of the bending moment for an infinite life with factor of safety of
K t = 2.3 From Figure A-23-11 in the formula sheet 2 is 419.6 N ⋅ m .
Then, K f = 1 + q(K t − 1) = 1 + 0.8(2.3 − 1) = 2.04 M max = 419608 N ⋅ mm = 419.6 N ⋅ m
k e = 1 / K f = 1 / 2.04 = 0.49

As nothing is specified, the miscellaneous effects factor k f can be taken as k f = 1 .

Se ' = 0.5 ⋅ Sut = 0.5 ⋅ 690 = 345MPa
Then, Se = k a ⋅ k b ⋅ k c ⋅ k d ⋅ k e ⋅ k f ⋅ Se ' = 0.73 ⋅ 0.85 ⋅ 0.868 ⋅1 ⋅ 0.49 ⋅1 ⋅ 345 = 91MPa

From Figure A-23-11 in the formula sheet, the bending stress on the round shaft in
bending with a transverse hole:
M
σ= 3
where M is the bending moment.
πD dD 2
[( )−( )]
32 6
M
σ= = 1.917 ⋅10−4 M MPa where M is in N ⋅ mm .
π403 4 ⋅ 402
[( )−( )]
32 6
The value of the bending moment M changes between 0 and M max . The minimum
and the maximum normal stress at the critical point will be:
σ min = 0 MPa
σ = 1.917 ⋅10−4 M max MPa
The mean and the alternating normal stresses can be found as:
σ + σ max 0 + 1.917 ⋅10−4 M max
σ m = min = = 9.58 ⋅10−5 M max
2 2
σ − σ min 1.917 ⋅10−4 M max − 0
σa = max = = 9.58 ⋅10−5 M max
2 2
The ratio of the alternating and the mean normal stresses 1 and it corresponds to a
slope of 45° on the σa − σm curve. The Goodman line intersects with the Yield line
for 1.7° . So failure will be because of fatigue and the Goodman line is to be used.

METU – ME 307 Machine Elements I – Fall 2008

 4
Problem 2: The figure is a schematic drawing of a rotating countershaft that supports The next step is to obtain the moment diagram. The forces act in y and z directions on the
two V-belt pulleys. For each pulley, the belt tensions are parallel. The pulleys are shaft. The reactions at bearings also act in these directions. It is needed to analyze the
mounted on the shaft with key and profiled keyway arrangements. For pulley A forces on the shaft in x-z and x-y planes separately.
consider the loose belt tension is 15% of the tension on the tight side. An
AISI1030HR steel shaft of uniform diameter is to be selected for this application. x-z plane:
Find a safe diameter for the shaft for factor of safety of 3. Take reliability as 99.9%, 1
and for profiled keyway Kf =1.6 for bending and Kf =1.3 for torsion. All dimensions FzA = (T1 + T2 ) cos(45ο ) = 1.15(T2 ) = 253 N (in -z direction)
2
are in mm’s. Figure is taken from 8th edition of textbook.
FzB = 320 N (in +z direction)
∑M Oy = 0 : Cz (850) − 320(700) + 253(300) = 0
Cz = 174N
∑F z = 0 : O z + 253 − 320 + Cz = 0
O z = −107N
The shear and bending moment diagrams are as below:

300 400 150

x
z

Oz 253N 320N Cz

Solution : Shear
At first one should perform the force analysis of the system. During operation, torque 146N
on the shaft is steady, so does the torsional stress on the shaft. Also the forces in y and
z directions are steady. However, because of the rotation of the shaft bending stresses
on the shaft do change periodically.
-107N
T1 and T2 is found from the torque balance on the shaft ( ∑ T = 0 ) by using the
174N
relation between them:
Moment 26.3N.m
d d
∑ T = 0 : (T2 − T1 ) 2A = (270 − 50) 2B = 220(0.15) = 33 N.m
It is given that force on the loose side of the pulley is 15% of the force on the tight
side. Knowing T2>T1:
d d -32.1N.m
(T2 − 0.15(T2 )) A = (270 − 50) B
2 2
300
0.85(T2 ) = 220 → T2 = 311N and T1 = 46.6N
250

METU – ME 307 Machine Elements I – Fall 2008

 5
x-y plane: 2
M A = 32.1 + 48.9 = 58.5 N.m 2

∑ M Oz = 0 : − C y (850) + 253(300) = 0 T = 33 N.m

C y = 89.1 N Now that the force analysis is completed and the following fatigue analysis can be done.
∑F y = 0 : − O y + 253 − C y = 0 Properties of the given material (Table A-18 from 8-th edition of textbook):
Sut = 470MPa Sy = 260MPa
O y = 163 N
S'e = 0.5 Sut = 235MPa (from equation 6-8)
The Shear and Bending Moment diagrams are as below:
Endurance limit of shafts used in machine elements is found by finding the modification
300 400 150 factors:
Figure 7-8 in the formula sheet: k a = 0.65 for hot rolled material with Sut = 470MPa
y Since the diameter is not known, assume that it is in the range 8<d<50, then for bending
kb=0.85.
x Other factors are:
k c = 0.753 (Table 7-7 in the formula sheet)
Oy 253N Cy k d = 1 (nothing is given)
k e = 1 (K f ,bending is used as stress increasing factor for σ a )
Shear k f = 1 (nothing mentioned about miscellaneous effects)
89.1N Se = k a k b k c k d k e k f Se' = 0.65(0.85)0.753(1)1(1)235 = 97.8MPa
A steady torsion and completely reversed bending is applied on the shaft. In other words,
the torsional stress has only mean component, and the bending stress has only alternating
-163N component.
Distortion energy theory:
Moment
The Von Mises alternating stress is:
2 2
σ'a = (K f ,bending σa ) + 3 ( K f ,torsion τa ) where, τa = 0 → σ'a = K f ,bending σa
-48.9N.m σ'm = σ m 2 + 3τm 2 where, σ m = 0 → σ'm = 3τm
For the critical differential element at A:
Torque on the shaft is:
M c
σa' = K f ,bending σ a = (1.6)σ bending = (1.6) A
Torque
33N.m Ι
d
1.6(32)M A 9.50 ⋅105
σ'a = (1.6)M A 42 = = MPa (d is in mm's)
x πd d3 d3
64
d
Tc 16 3T 2.90 ⋅105
The maximum bending moment occurs at the position of pulley A. The critical section σ'm = 3τm = 3τtorsion = 3 = 3T 42 = = MPa (d is in mm's)
J πd πd 3 d3
of the system is at A. Moment at the section A is a combination of moments on x-y 32
and y-z planes: Slope of the load line:

METU – ME 307 Machine Elements I – Fall 2008

 6
σ  ' Problem 3: A notched rectangular bar shown in the figure is subjected to fully reversed
 9.50 
tan −1  'a  = tan −1   = 73.0
ο
bending moment of magnitude M = 650 N ⋅ m . The material of the bar is normalized AISI
σ   2.90 
 m 1030 steel, the ultimate tensile strength is 521 MPa and the yield strength is 345 MPa .
Although the slope of the load line is high enough, it is better to check the intersection
The notch is machined. Reliability: 0.999.
point of the Yield line and the modified Goodman line:
a) For a factor of safety of 1.5, find the depth of the bar b .
Equation of the Yield line: σ'a + σ'm = Sy b) For the depth b , calculated in part a) estimate the expected life if the
σ'a σ'm magnitude of the bending moment M is doubled and tripled separately.
Equation of the Goodman line: + =1
Se Sut
Intersection point is:
Sy
1−
σa' Sy − σ'a Sut
+ = 1 → σ'a = = 55.2 MPa
Se Sut 1 1
−
Se Sut
σ'm = Sy − σ'a = 205 MPa
σ   55.2 
Slope of the intersection: tan −1  a  = tan −1   = 15.1
ο

σ
 m  205 
Since 15.1°<73.0°, failure is expected to be due to fatigue. Thus, the Goodman line
determines the factor of safety.
σ'a σ'm 1
+ =
Se Sut n Solution :
K f ,bending σa σ' 1 a)
+ m = There is only alternating stress on the bar. The value of the safety factor is the ratio of the
Se Sut n
alternating stress value and the endurance limit of the bar at the critical section. The
9.50 ⋅105 2.50 ⋅105 critical section is the section with the notch. The alternating stress and the endurance limit
d3 d3 1 will be calculated for this section.
+ =
97.8 470 3 The endurance limit for the test specimen is:
d > 31.5 mm Se ' = 0.5 ⋅ Sut = 0.5 ⋅ 521 = 260.5 MPa
For d=32mm, the operation will be safe. Note that for that diameter the size factor (kb) The endurance limit modifying factor at the critical section:
from the formula sheet is 0.85 which is equal to the assumed value.
Surface factor k a :
For machined surface and Sut = 0.521 GPa , surface factor is: k a = 0.78 approximately.

Size factor k b :
The equivalent diameter for a non-rotating rectangular cross-section: (Table 6-3, 8-th
edition of textbook)
d e = 0.808(h ⋅ b)1/ 2 For a cross-section of h × b

METU – ME 307 Machine Elements I – Fall 2008

 7
1/ 2 1/ 2 1/ 2
d e = 0.808(h ⋅ b) = 0.808(100 ⋅ b) = 8.08(b) mm where b is in mm. The depth can be taken as: b = 7.4 mm . Note the assumption for the size factor holds.
Assume, 1 mm ≤ b ≤ 38.3 mm , so that 8 mm ≤ d e ≤ 50 mm, k b = 0.85
b)
If the magnitude of the bending moment is doubled, the value of the alternating stress will
Reliability factor k c :
be doubled. Then, the alternating stress value at the critical section will be greater than the
For 0.999 reliability, k c = 0.753 endurance limit of the bar at the critical section. This will result in a finite life. Using log
S - log N diagram (given below), the life of the bar can be determined.
Temperature factor k d :
Nothing mentioned, k d = 1 σ1 = 52.9 ⋅ 2 = 105.8 MPa



Using similarity of the triangles ACF & ADG :
Stress concentration factor k e :
log(0.8 ⋅ Sut ) − log(σ1 ) log(N1 ) − 3
Figure A-23-4 in the formula sheet gives K t = 1.8 for w / d = 105 /100 = 1.05 and =
log(0.8 ⋅ Sut ) − log(Se ) 6−3
r / d = 10 / 100 = 0.1 . Figure 7-13 gives q = 0.8 approximately for Sut = 0.521 GPa
log(416.8) − log(105.8) log(N1 ) − 3
and r = 10 mm > 4 mm . =
log(416.8) − log(79.3) 6−3
K f = 1 + q(K t − 1) = 1 + 0.8(1.8 − 1) = 1.64
k e = 1/ K f = 1/1.64 = 0.610 which gives N1 = 301130 cycles

Miscellaneous effect factor k f : For the tripled moment case:

Nothing mentioned, k f = 1 σ 2 = 52.9 ⋅ 3 = 158.7 MPa

The Endurance limit at the notched section: Using similarity of the triangles ABE & ADG :
Se = k a ⋅ k b ⋅ k c ⋅ k d ⋅ k e ⋅ k f ⋅ Se ' = 0.78 ⋅ 0.85 ⋅ 0.753 ⋅1 ⋅ 0.610 ⋅1 ⋅ 260.5 = 79.3 MPa log(0.8 ⋅ Sut ) − log(σ 2 ) log(N 2 ) − 3
=
log(0.8 ⋅ Sut ) − log(Se ) 6−3
The alternating stress due to bending moment: log(416.8) − log(158.7) log(N 2 ) − 3
=
Mc h 1 log(416.8) − log(79.3) 6−3
σa = , c = , I = bh 3
I 2 12
6M which gives N 2 = 55681 cycles
σa = 2
bh

The alternating stress value can be found from the safety factor relation:
S S 79.3
n = e , σa = e = = 52.9 MPa
σa n 1.5

The depth of the bar can now be determined:

6M 6 ⋅ 650 ⋅103
b= = = 7.4 mm
σa h 2 52.9 ⋅1002

METU – ME 307 Machine Elements I – Fall 2008

 8
Problem 4: A machine component made up of SAE1050HR steel is designed for finite
log S life. In the first 200000 cycles, the periodic loading on the part has mean and alternating
stresses of 80MPa and 120MPa, respectively. In the following 50000 cycles, both
alternating and mean stresses have increased by 25%. Reliability is 99% and kb=0.85.
After these loadings:
log (0.8Sut) A
a) Determine the endurance limit of the part after the loadings given.
b) Estimate the remaining life of the part for 200MPa completely reversed loading.
B E c) Estimate the maximum value of completely reversed stress if the part is to be
log ( σ 2 )
loaded for 100000 cycles. Use the Manson’s rule in (a), (b) and (c).
C F d) Repeat (b) using the Miner’s rule.
log ( σ 1 )

log (Se) D G Solution:

The properties of the material (Table A-18 from 8-th edition of textbook):
Sut = 620 MPa Sy = 340 MPa
log N S'e = 0.5 Sut = 310 MPa (from equation 6-8)
log 103 log (N2) log (N1) log 106
The endurance limit modifying factors:
Figure 7-8 in the formula sheet: k a = 0.57 for hot rolled material with Sut = 620MPa
k b = 0.85
k c = 0.814 (Table 7-7 in the formula sheet)
k d = k e = k f = 1 As nothing mentioned
Se = k a k b k c k d k e k f S'e = 0.57(0.85)0.814(310) = 122MPa

a)
First loading:
The Modified Goodman approach is used in this question. It is the second most
conservative criterion after the Soderberg line.
According to the Manson’s rule, each cyclic loading has a decreasing effect on the
endurance limit of the part. Therefore, the endurance limit should be recalculated after
each period of loading. If the loading is in the finite life region (in the modified Goodman
diagram for this question), the fatigue strength of the part would be different than its
endurance limit. By using the modified Goodman diagram, its fatigue strength can be
estimated. By this fatigue strength its new endurance limit (after period of loading) can be
obtained from the S-N diagram.
As seen in Figure 1(a), the mean stress of the loading is tensile, and the loading is in the
finite life region (above the Goodman line joining Se and Sut).

METU – ME 307 Machine Elements I – Fall 2008

 9
Note that on the S-N diagram, at 103 cycles the fatigue strength is taken as 0.8(Sut). 0.8 is
σa an average value taken for fatigue strength fraction, f (for high-cycle fatigue). Figure 6-18
in the 8-th edition of textbook gives more accurate value, it suggests to take f=0.86 for
Sut=620 MPa. For this problem, it is taken as f=0.8.
Sy
Figure 1 shows the reduction of endurance limit after each loading (Manson’s rule).
At first, the remaining life should be determined.
Equation of the S-N curve is:
Sf2 log(0.8Sut ) − log(Se )
(σ ,σ ) log(S) = log(0.8Sut ) − [log(103 ) − log(N)]
a2 m2
log(103 ) − log(106 )
Sf1 (σ ,σ ) log(0.8Sut ) − log(Se )
a1 m1 log(S) = log(0.8Sut ) − [log(N) − 3]
3
Se Lifetime, N1, corresponding to 138MPa in the initial S-N diagram (Figure 2):
S = Sf 1 = 138MPa and N = N1
log(Sf 1 ) − log(0.8Sut ) log(N1 ) − 3
=
log(Se ) − log(0.8Sut ) 3
Sy Sut σm
log(138) − log(0.8(620)) log(N1 ) − 3
= N1 ≅ 555000 cycles
Figure 1. Constant life lines for each loading log(122) − log(0.8(620)) 3
The Remaining life for the part at 138MPa loading is
To find the fatigue life of the part under the first loading, the constant life line is to be N r1 = N1 − n1 = 555000 − 200000 = 355000 cycles
considered by joining Sut on σa axis to the stress point (σa1, σm1) as shown in Figure 1. As mentioned before according to the Manson’s rule, the machine component is damaged
That line passes through Sf1 on σa axis (where σm=0) i.e. the fatigue strength of first after the first loading, i.e. its endurance limit is decreased. The S-N diagram now passes
loading. Then, the equation of the constant life line is: through (103,0.8(Sut)), (Nr1,Sf1) and (106,Se1). The new S-N equation is:
σa1 σ m1 log(0.8Sut ) − log(Sf 1 )
+ =1 log(S) = log(0.8Sut ) − [log(103 ) − log(N)]
Sf 1 Sut log(103 ) − log(N r1 )
So, Sf1 can be found by substituting σa1=120 MPa and σm1=80 MPa,
log(0.8Sut ) − log(138)
120 80 120 620 − 80 log(S) = log(0.8Sut ) − [3 − log(N)]
+ =1 → = 3 − log(355000)
Sf 1 620 Sf 1 620 gives
The new endurance limit is:
Sf 1 = 138 MPa
S = Se1 and N = 106
Sf1 is greater than Se, so, this point corresponds to a finite life, N1, on the S-N diagram
(Figure 2). The Manson’s rule says that to find the new endurance limit, Se1, of the log(0.8Sut ) − log(138)
log(Se1 ) = log(0.8Sut ) − [3 − log(106 )]
part, a new line should be drawn on log(S)-log(N) curve joining (103,0.8(Sut)) and 3 − log(355000)
(Nr1,Sf1) points, where Nr1 is the remaining life after the first loading. This line is log(Se1 ) − log(0.8Sut ) 3
extended until 106 life (106,Se1). By this way, the damaged material Se1 is obtained. =−
log(138) − log(0.8Sut ) 3 − log(355000)
Note that 103 cycles is the starting point of the high-cycle region (for all materials)
and 106 is the limit for finite life for steels. The Manson’s rule states no change in log(138) − log(0.8Sut )
log(Se1 ) = log(0.8Sut ) − 3
tensile strength of the part, i.e. (103,0.8(Sut)) point stays same after each loading. 3 − log(355000)
Se1 ≅ 110MPa

METU – ME 307 Machine Elements I – Fall 2008

 10
logS N r 2 = N 2 − n 2 = 107000 − 50000 = 57000 cycles
Similar to what is done after the first loading, the new endurance limit after the second
log(0.8Sut) loading, Se2, can be obtained by re-plotting the S-N diagram. The new S-N line passes
through (103,0.8(Sut)), (Nr2,Sf2) and (106,Se2) as shown in Figure 3.
log(Sf1) The Final endurance limit is:
S = Se2 and N = 106
log(Se)
log(0.8Sut ) − log(Sf 2 )
log(Se1) log(Se2 ) = log(0.8Sut ) − [3 − log(106 )]
3 − log(N r 2 )
n1=200000
N1=555000 log(0.8Sut ) − log(179)
log(Se2 ) = log(0.8Sut ) + 3
Nr1=N1-n1=355000 3 − log(57000)
Se2 ≅ 87 MPa
log(103 ) 1) log(106 ) logN
)

)
(n1

(N1
(Nr
logS
log

log
log

Figure 2. Life reduction after first loading

log(200)
Second loading:
In this period, the mean and alternating stresses become 100MPa and 150MPa, log(Sf2)
respectively. log(Se)
As seen in Figure 1, the second loading is also in the finite life region (comparing
with the line joining Se1 and Sut). Similar to what is done for the first loading, the log(Se1)
corresponding fatigue strength for the second loading, Sf2, is obtained from the
modified Goodman diagram as: log(Se2)
σa 2 150 n2=50000
Sf 2 = = N2=107000
σ 100
1 − m2 1 − Nr2=N2-n2=57000
Sut 620 N3=36800
Sf 2 = 179 MPa

log(N3)

log(Nr2)
log(103 )

log(n2)

log(N2)
To find the corresponding lifetime, N2, from the S-N diagram, this time life equation log(106 ) logN
is used. It is the same as using log(S)-log(N) equation.
The life equation is:
1
 S b (0.8(Sut )) 2 (0.8(620)) 2 Figure 3. Life reduction after second loading and remaining life for third loading
N 2 =  f 2  where a = = = 2239
 a  Se1 110
b)
1  0.8(Sut )  1  0.8(620)  For a final completely reversed loading until failure, the fatigue strength is equal to the
b = − log   = − log   = −0.218
3  S e1  3  110  applied stress because of zero mean stress.
N 2 ≅ 107000 cycles Sf 3 = σa3 = 200 MPa
The Remaining life for the part at 179 MPa loading is From the last modified S-N diagram, the remaining life, N3, is found as:

METU – ME 307 Machine Elements I – Fall 2008

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S = Sf 3 = 200 MPa and N = N 3 S = Sf 2 = 179 MPa and N = N 2
log(Sf 3 ) − log(0.8Sut ) log(N 3 ) − 3 log(Sf 2 ) − log(0.8Sut ) log(N 2 ) − 3
= =
log(Se2 ) − log(0.8Sut ) 3 log(Se ) − log(0.8Sut ) 3
log(200) − log(0.8(620)) log(N 3 ) − 3 log(179) − log(0.8(620)) log(N 2 ) − 3
= N 3 ≅ 36800 cycles = N1 ≅ 153000 cycles
log(87) − log(0.8(620)) 3 log(122) − log(0.8(620)) 3
S = Sf 3 = 200 MPa and N = N 3
c) log(Sf 3 ) − log(0.8Sut ) log(N 3 ) − 3
The part has already completed 250000 cycles in the first and second loadings. There =
is 100000 cycles left for third loading. The Maximum possible completely reversed log(Se ) − log(0.8Sut ) 3
stress can be found by finding the limit stress for n3=N3. log(200) − log(0.8(620)) log(N 3 ) − 3
From the last modified S-N diagram, the maximum completely reversed stress, σa3max, = N1 ≅ 88200 cycles
log(122) − log(0.8(620)) 3
is found as:
So, according to Miner’s rule:
S = Sf 3 max = σa3 max and N = N 3 = n 3 = 100000 cycles
n n n n
log(σa3 max ) − log(0.8Sut ) log(N 3 ) − 3 ∑ Ni = N1 + N2 + N3 = 1
= i 1 2 3
log(Se2 ) − log(0.8Sut ) 3
200000 50000 n3
5−3 + + =1
log(σa3 max ) = log(0.8(620)) + [ log(87) − log(0.8(620))] 555000 153000 88200
3 n 3 ≅ 27600 cycles
σa3 max ≅ 155 MPa Although it does not consider the order of cumulative damage, the Miner’s rule estimated
a lower remaining life than the Manson’s rule does for the third loading. This makes the
d) Miner’s rule a more conservative approach for this problem. If the second loading had
The Miner’s rule does not consider the order of cumulative damage effect introduced infinite life according to the initial S-N diagram, and finite life according to the first
by different loadings. So, the order of loading is not important for The Miner’s rule. modified S-N curve (of Manson’s rule), the Miner’s rule would estimate life of the second
However, for The Manson’s rule, the order of application of the loadings is taken into loading as infinite, whereas the Manson’s rule would estimate a finite life since it
account. This is because The Manson’s rule takes the damage of the part after each considers reduced endurance limit.
loading into account by considering the new damaged material line after each loading.
It can be a nice practice to solve the problem again by changing the order of It is worth to note that, it is not possible to estimate the life of the part exactly. These two
application of the loadings. By this way, it is possible to see the order of damage estimation methods only give an idea to the engineer about the order of magnitude of the
effect. The final endurance limit would be 82 MPa, if the second loading was applied remaining life. So, it is not possible to state which model gives the best estimate, always.
firstly, and first was applied secondly. 5 MPa difference is because of the more
damaging effect of high loading.
If the Miner’s rule is used, all lifetimes are found according to the initial S-N diagram
as:
S = Sf 1 = 138 MPa and N = N1
log(Sf 1 ) − log(0.8Sut ) log(N1 ) − 3
=
log(Se ) − log(0.8Sut ) 3
log(138) − log(0.8(620)) log(N1 ) − 3
= N1 ≅ 555000 cycles
log(122) − log(0.8(620)) 3

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Problem 5: A machine part, made of hot-rolled AISI 1030 steel with a diameter of 30 k a = 0.8 For Sut = 0.47 GPa and machined surface finish
mm, has been run for 2 years and 100 cycles each day. The stress at the most critical k b = 0.85 given in the problem
section on the part is observed to have mean and alternating components of 80 MPa
and 150 MPa, respectively. The part at this section is machined. Assume there is no k c = 0.814 for 99 percent reliability
stress concentration at the critical section. The value of the size factor is known kd = 1 nothing mentioned
as k b = 0.85 and reliability is 99 percent. ke = 1 given in the problem
a) Determine the remaining life in years for the same loading conditions. kf = 1 nothing mentioned
b) Estimate the maximum alternating stress at the critical section if the part is
to be run for another 2 years, 100 cycles each day and the mean stress value remains Se = 0.8 ⋅ 0.85 ⋅ 0.814 ⋅1 ⋅1⋅1 ⋅ 235 = 130 MPa
the same, using the Miner’s Rule.
As fatigue strength fraction, f, 0.8 is taken for this problem (as an average value). Figure
Solution: 6-18 in the 8-th edition of textbook gives more accurate value, it suggests to take f=0.9 for
a) Sut=470 MPa. For this problem, it is taken as f=0.8.
The material properties from Table A-18 (8-th edition of textbook):
Sut = 470 MPa, Sy = 260 MPa The life can be found by the following equation:
(0.8 ⋅ Sut )2 (0.8 ⋅ 470)
1 a= = = 1087.5
Total cycles that the part has been run for 2 years:  Sf  b Se 130
N1 =   where
n1 = 2 years ⋅
365 days 100 cycles
⋅ = 73000 cycles  a  1 0.8 ⋅ Sut 1 0.8 ⋅ 470
b = − log = − log = −0.154
1 year 1 day 3 Se 3 130
The cyclic stress has two components, mean and alternating. We have to find the 1

corresponding completely reversed stress Sf for these components.  180.8  −0.154

N1 =   = 114800 cycles
σa Sut − σ m Sut ⋅ σa 470 ⋅150  1087.5 
= Sf = = = 180.8 MPa
Sf Sut Sut − σ m 470 − 80
The remaining life:
N1 − n1 = 114800 − 73000 = 41800 cycles
Sy 1 day 1 year
41800 cycles = 1.15 years
100 cycles 365 days
Sf
σa b)
From part a) N1 = 114800 cycles and n1 = 73000 cycles
Se
n 2 is the same as n1 , n 2 = 73000 cycles
Using the Minor’s Rule:
n1 n 2
+ = 1 , N 2 can be solved.
N1 N 2
σm Sy Sut
73000 73000
+ =1
114800 N2
The endurance limit of the part at the critical section is also needed in the calculations. N 2 = 200500 cycles
Se ' = 0.5 ⋅ Sut = 0.5 ⋅ 470 = 235 MPa

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The Maximum completely reversed stress corresponding to this life can be found
from the life equation:
1
 S b
N2 =  f 2  Sf 2 = a ⋅ (N 2 ) b = 1087.5 ⋅ 200500−0.154 = 165.9 MPa
 a 
The maximum alternating component of the stress at the critical section can be found
using the following relation:
σa 2 Sut − σm2
=
Sf 2 Sut
Sut − σ m2 470 − 80
σa 2 = Sf 2 ⋅ = 165.9 ⋅ = 137.7 MPa
Sut 470

METU – ME 307 Machine Elements I – Fall 2008