Creating Estimated S-N Diagram

These equations are used to determine the corrected endurance limit Se

or the corrected fatigue strength Sf at a particular number of cycles N in
the high-cycle region of the S-N diagram. For the low-cycle region the
following estimates are found:
bending : ....................S m = 0.9 Sut
axial _ loading : .........S m = 0.75Sut

Sm material strength
at 103 cycles
The equation of the line from Sm to Sf (or Se) is: b
S n = aN
for materials that possess an endurance limit the coefficients (a, b)
can be calculated from the following two points:
for materials that do not possess an
endurance limit, use:

b
Note: S n = aN log(S n ) = log a + b log N
Boundary conditions: S n = S m _ at _ N = N1 = 103
Material with endurance limit S n = S e _ at _ N = N 2 = 106
Material without endurance limit S n = S f _ at _ N = N 2 = 5 ×108
N2 (106) z
1  Sm 
b = log .......where.....z = log N1 − log N 2 1.0 -3.000
z  Se  5.0 -3.699
10.0 -4.000
50.0 -4.699
Material with endurance limit
100.0 -5.000
N1=103 and N2=106
500.0 -5.699
 Problem: Create an estimated S-N diagram for a steel bar and define its equations.
How many cycles of life can be expected if the alternating stress is 100MPa.
Given: The Sut has been tested at 600MPa. The bar is 150mm square and has a hot
rolled finish. The operating temperature is 500oC maximum. The loading will be
fully reverse bending.
Assumptions: Infinite life is required (ductile steel with endurance limit). A
reliability factor of 99.9% will be used.

Solution:
'
S e = 0.5Sut = 300MPa
Loading factor is bending
kload = 1.0
The part is not round: A95 = 0.05bh = 0.05 × 150mm × 150mm = 1125mm 2
A95 1125mm 2
d equiv = = = 121.2mm
0.0766 0.0766

The size factor: −0.097

for _ 8mm ≤ d ≤ 250mm : .........k size = 1.189d equivalent
k size = 1.189(121.2) − 0.097 = 0.747
Surface Factor:

b −0.718
k Surface = A × S = 57.7 × (600)
ut = 0.584
Temperature Factor: kTemp = 1 − 0.0058(T − 450) = 1 − 0.0058(500 − 450) = 0.71

Reliability Factor
k reliability = 0.753

Corrected Endurance limit:

'
S e = kload × k size × k surf × kTemp × k reliability × S e
S e = 1.0 × 0.747 × 0.584 × 0.71× 0.753 × 300 = 70 MPa
 Creating the bending : ....................S = 0.9 S = 0.9 × 600 = 540 MPa
m ut
S-N diagram
1  Sm  1  540 
S n = aN b b = log  = − log  = −0.295765
z  Se  3  70 
log(S n ) = log a + b log N log(a) = log( S m ) − 3b = log(540) − 3 × ( −0.295765)

log a = log(S n ) − b log N a = 4165.7

100MPa = (4165.7) × N −0.295765
N = 3.0 ×105 cycles

N2 (106) z
1.0 -3.000
5.0 -3.699
10.0 -4.000
50.0 -4.699
100.0 -5.000
500.0 -5.699
Notches and Stress Concentrations
Kt is the theoretical stress concentration factor.
Notch sensitivity – q . Materials have different sensitivity
to stress concentrations, referred to as the notch sensitivity
of the material. In general, the more ductile a material is,
the less sensitivity to notches it is.
It depends on notch radius, the smaller the radius, the less
sensitive the material is
Neuber, Kuhn and Peterson have developed an
approach to notch sensitivity
Peterson’s equation

where a is Neubers constant and it is

solely a function of the material, and r
is the notch radius (both expressed in
inches).
Problem: A rectangular step steel bar (as shown below)
is to be loaded in bending. Determine the stress- r 0.25
= = 0.1388
concentration factor for the given dimensions. h 1.8
H 2
Given: H=2in, h=1.8in, r=0.25in. The material has = = 1.11
h 1.8
Sut=100kpsi. a = 0.062
1 1
Solution: Kt=1.56 q= = = 0.89
a 0.062
1+ 1+
r 0.25

K f = 1 + q(K t − 1)
K f = 1 + 0.89(1.56 − 1)
K f = 1.50
Design of a Cantilever Bracket for Fully Reversed Bending
Problem: Design a cantilever bracket to support a fully reversed bending load of 500-
lb amplitude for 109 cycles with no failure. Its dynamic deflection can not exceed
0.01in.. Calculate the safety factor.
Given: Beam width (b) = 2in ; beam depth over length (d) = 1in ; beam depth in wall
(D) = 1.125in ; fillet radius (r) = 0.3in ; applied load amplitude at point (F) = 500-lb ;
beam length (l) = 6in ; distance to load (a) = 5in ; distance for deflection calculation
(lx) = 6in ; Modulus of elasticity (E) = 3x107psi ; ultimate tensile strength (Sut) =
80kpsi for a steel. The cantilever has been machined and operates at a temperature of
120oF
 Famplitude = 500lb R = Fa = 500lb
Solution: M = Fa × a = 2500lb − in
Fmean = 0lb
bd 3 2 × 13
I= = = 0.1667
12 12
d 1
c = = = 0.5
2 2

Bending at the root

Mc 2500 × 0.5
σ a ,nom = = = 7500 psi
I 0.1667
D 1.125
= = 1.125
d 1
r 0.3
= = 0.3
d 1

K t = 1.33
 a = 0.080 K f = 1 + q(K t − 1)
= 0.87 K f = 1 + 0.87(1.33 − 1)
1 1
q= =
a 1 + 0.080
1+ K f = 1.29
r 0 .30

σ a = K f σ a , nom = 1.29 × 7500 = 9675 psi

The stress is a principal stress as there is no shear
stress at the top surface and there are no other
stresses present.
σa 9675
τ ab = = = 4832 psi
2 2
σ 1a ,σ 3a = 9675 psi,0 psi
σ VM , a = 9675 psi
Creating the S-N diagram.

'
S = 0.5S ut = 0.5 × 80000 = 40000 psi
e
A95 = 0.05db = 0.05 × 1× 2 = 0.1in 2
A95
d equivalent = = 1.14in
0.0766
Size factor: A95 = 0.05db = 0.05 × 1× 2 = 0.1in 2
A95
d equivalent = = 1.14in
0.0766
for _ 0.3in ≤ d ≤ 10.in : .........k size = 0.869d −0.097
− 0.097
k size = 0.869 × (1.14) = 0.86

Load Factor: Pure bending

kload = 1

Surface factor:

−0.265
k surf = ASutb = 2.7 × (80) = 0.845
Temperature factor: kTemp = 1.0
Reliability factor: As only ten of these parts are required, a high %
reliability is chosen (99.9%)
k reliability = 0.753
Corrected endurance limit: S e = kload k size k surf kTemp k reliability S e'
S e = 1× 0.86 × 0.845 ×1× 0.753 × 40000 psi
S e = 21843 psi

Predicted Safety factor: Se 21843

nsf = = = 2.26
σ VM , a 9675

The beam deflection y is calculated

F 3 500
y=
6 EI
[ ] (
3
x − 3ax 2 − ( x − a ) = 7
)
6 3 ×10 (0.1667 )
[ ] 3
63 − 3 × 5 × 6 2 − (6 − 5) = −0.005in
Designing for fluctuating Uniaxial Stresses
Many repeating and fluctuating stresses have non-zero mean
components and these must be taken into account.
 σm 
Modified-Goodman line σ a = S e 1 −
 S 
(for design)  ut 

 σ m2 
σ a = S e 1 − 2 
 S 
 ut 
Gerber Parabola (for
analysis of failed parts)
Design of a Cantilever Bracket for Fluctuating Bending
Problem: Design a cantilever bracket to support a fluctuating bending load of 100 to
1100-lb amplitude for 109 cycles with no failure. Its dynamic deflection can not exceed
0.02in.. Calculate the safety factor.
Given: Beam width (b) = 2in ; beam depth over length (d) = 1in ; beam depth in wall
(D) = 1.125in ; fillet radius (r) = 0.3in ; maximum applied load amplitude at point (F)
= 1100-lb ; minimum applied load amplitude at point (F) = 100-lb ; beam length (l) =
6in ; distance to load (a) = 5in ; distance for deflection calculation (lx) = 6in ; Modulus
of elasticity (E) = 3x107psi ; ultimate tensile strength (Sut) = 80kpsi for a steel; yield
strength (Sy) = 60kpsi. The cantilever has been machined and operates at a temperature
of 120oF
 FMax + FMin 1100 + 100
Solution: Fm = = = 600 lb
2 2
F − FMin 1100 − 100
Fa = Max = = 500 lb
2 2
Ra = Fa = 500 lb....... Rm = Fm = 600 lb..... RMax = FMax = 1100 lb
M a = Fa a = 500 lb × 5in = 2500 lb − in
M m = Fm a = 600 lb × 5in = 3000 lb − in
M Max = FMax a = 1100 lb × 5in = 5500 lb − in

bd 3 2 ×13 M a c 2500 × 0.5

I= = = 0.1667 σ a ,nom = = = 7500 psi
12 12 I 0.1667
d 1 M m c 3000 × 0.5
c = = = 0.5 σ m,nom = = = 9000 psi
2 2 I 0.1667
D 1.125
= = 1.125
d 1
K t = 1.33
r 0.3
= = 0.3
d 1
 a = 0.080 K f = 1 + q(K t − 1)
q=
1
=
1
= 0.87 K f = 1 + 0.87(1.33 − 1)
a 1+ 0 . 080
1+ K f = 1.29
r 0.30
Verify that the stress concentration are below yield strength of the
material.
if .....K f σ Max < S y ....then.....K fm = K f
M Max c 5500 × 0.5
K f σ Max = K f = 1.29 = 21281 psi < S y = 60000 psi
I 0.1667
σ a = K f σ a , nom = 1.29 × 7500 psi = 9675 psi
σ m = K f , mσ m , nom = 1.29 × 9000 psi = 11610 psi
 Calculate the Von Mises for the alternating stress and the mean stress

σ a' = σ x2, a + σ y2, a − σ x , aσ y , a + 3τ xy2 , a = 96752 + 02 + 9675 × 0 + 3 × 0 2 = 9675 psi

σ m' = σ x2, m + σ y2, m − σ x , mσ y , m + 3τ xy2 , m = 116102 + 02 + 11610 × 0 + 3 × 02 = 11610 psi

Generating a S-N : Size factor:

A95 = 0.05db = 0.05 × 1× 2 = 0.1in 2 for _ 0.3in ≤ d ≤ 10.in : .........k size = 0.869d −0.097
A95 − 0.097
d equivalent = = 1.14in k size = 0.869 × (1.14) = 0.86
0.0766

Load Factor: Pure bending kload = 1

−0.265
Surface factor: k surf = ASutb = 2.7 × (80) = 0.845
Temperature factor: kTemp = 1.0
Reliability factor: As only ten of
these parts are required, a high % k reliability = 0.753
reliability is chosen (99.9%)
 '
S
Corrected endurance limit: e = k k k k k S
load size surf Temp reliability e

S e = 1× 0.86 × 0.845 × 1× 0.753 × 40000 psi

S e = 21843 psi

Various safety factors can be calculated:

It assumes that the alternate and mean
component will have a constant ratio.
1
nf = = 1.70
9675 11610
+
21883 80000
Sy 60000
ny = = = 2.82
σa +σm 9675 + 11610

The beam deflection y is calculated

FMax 3 1100
y=
6 EI
[ 3
] (
x − 3ax 2 − (x − a ) =
)
6 3 ×107 (0.1667 )
6 [
3
− 3 × 5 × 6 2
− (6 − 5 )3
]= −0.012in
 Applying Stress-
Concentration Effects with
Fluctuating Stresses

if ....K f σ Max < S y .....then.....K fm = K f

S y − K f σ a , nom
if ...K f σ Max > S y ....then....K fm =
σ m , nom
if ....K f σ Max, nom − σ Min , nom > 2 S y ....then....K fm = 0
Multiaxial Fluctuating Stresses
Problem: Determine the safety factors for the brackets tube shown.
Given:
Material: 2024-T4 aluminum with Sy=47ksi and Sut=68ksi.
Tube length (l) = 6in. ; arm (a) = 8in. ;
Tube outside diameter (OD) = 2in ; Tube inside diameter (ID) = 1.5in
The applied load varies sinusoidally from F=340 to -200lb
Assume finite life design 6x107 cycles.
The component has been machined. It
operates at RT and with 99.9% reliability.

Notch radius at the wall = 0.25in

Stress concentration factor
for bending = 1.7
For shear = 1.35
 Solution:
Aluminum does not have an endurance limit. As Sut > 48kpsi then
Sf=19kpsi at 5x108 cycles
Calculation of the correction factors:
This value is used despite the fact that
Load Factor: Bending kload = 1 both bending and torsion are present.
Size factor: −0.097
for _ 0.3in ≤ d ≤ 10.in : .........k size = 0.869d equivalent

A95 = 0.010462d 2
A95 0.010462d 2
d equivalent = = = 0.74in
0.0766 0.0766
k size = 0.869 × (0.74in) −0.097 = 0.895
 −0.265
Surface factor: (machined) k surf = AS = 2.7 × (68)
b
ut = 0.883
Temperature factor: (room temperature) kTemp = 1.0
Reliability factor: As only ten of these parts are k reliabilit y = 0 .753
required, a high % reliability is chosen (99.9%)
S f = kload k size k surf kTemp k reliability S e'
Corrected endurance limit:
S f = 1× 0.895 × 0.883 ×1× 0.753 ×19000 psi
At 5x108 cycles S f = 11299 psi
bending : .....S m = 0.9 Sut = 0.9 × 68000 = 61.2ksi
The problem calls for a
1  S m  1  61200 
life of 6x107 cycles, so b = log =− log  = −0.1287
z   5.699  11299 
the strength value at that  Sf 
life must be estimated. log(a) = log( S m ) − 3b = log(61200) − 3 × (−0.1287)
a = 148929

S n = aN b S n = (148929) × N −0.1287 = (148929) × 6 ×107 ( )−0.1287

S n = 14846 psi
Notch sensitivity (for hardened aluminum Sut=68000psi)
a = 0.148
1 1
q= = = 0.773
a 1 + 0.148
1+
r 0.25

Bending Torsion
K f = 1 + q(K t − 1) K f , s = 1 + q(K t , s − 1)
K f = 1 + 0.773(1.7 − 1) K f , s = 1 + 0.773(1.35 − 1)
K f = 1.541 K f , s = 1.270
The bracket tube is loaded in bending (as a cantilever) and in
torsion. All the loading are maximum at the wall. Need to find the
alternating and mean components of the applied force, moment and
torque at the wall.
FMax − FMin 340 − (−200)
Fa = = = 270lb
2 2
FMax + FMin 340 + (−200)
Fm = = = 70lb
2 2
M a = Fa l = 270lb × 6in = 1620lb − in
M m = Fml = 70lb × 6in = 420lb − in
Τa = Fa a = 270lb × 8in = 2160lb − in
Τm = Fm a = 70lb × 8in = 560lb − in
The fatigue stress concentration factor for the mean stresses depends
on the relationship between the maximum local stress in the notch
and the yield strength

if .....K f σ Max < S y ....then.....K fm = K f

FMax lc 340 × 6 × 1
K f σ Max = K f = 1.541 = 5855 psi < S y = 47000 psi
I 0.5369
bending.......K fm = K f = 1.541
torsion.........K fm = K f = 1.270

The largest tensile bending stress will be at the top or bottom of

the cantilever. The largest torsional shear stress will be all around
the outer circumference of the tube.
Finding the amplitude and M ac 1620 × 1
σa = Kf = 1.541 = 4649 psi
mean components due to I 0.5369
bending and torsion. Ta r 2160 × 1
τ a ,torsion = K F , shear = 1.270 = 2556 psi
J 1.074
M mc 420 × 1
σ m = K fm = 1.541 = 1205 psi
I 0.5369
Tm r 560 × 1
τ m,torsion = K F , shear ,mean = 1.270 = 663 psi
J 1.074

Finding the alternating/amplitude and mean Von Mises stresses at A.

σ a' = σ x2, a + σ y2, a − σ x , a × σ y , a + 3τ xy2 , a

σ a' = 46492 + 02 − 4649 × 0 + 3 × 25562 = 6419 psi
σ m' = σ x2, m + σ y2, m − σ x , m × σ y , m + 3τ xy2 , m
σ m' = 12052 + 02 − 1205 × 0 + 3 × 6632 = 1664 psi
Various safety factors can be calculated:
It assumes that the alternate and mean
component will have a constant ratio.
1
nf = = 2.2
6419 1664
+
14846 68000
Sy 47000
ny = = = 5.82
σa +σm 6419 + 1664

We need to check the shear due to transverse loading at point B in

the neutral axis where the torsional shear is also maximal.
2Va 2 × 270
τ a,transverse = K f , shear = 1.270 = 499 psi
A 1.374
VQ 2V 2 × 70
τ= τ m,transverse = K f , shear, mean m = 1.270 = 129 psi
Ib A 1.374
τ a,total = τ a,transverse + τ a,torsion = 499 + 2556 = 3055 psi
τ m,total = τ m,transverse + τ m,torsion = 129 + 663 = 729 psi
 σ a' = σ x2, a + σ y2, a − σ x , a × σ y , a + 3τ xy2 , a
σ a' = 0 2 + 02 − 0 × 0 + 3 × 30552 = 5291 psi
σ m' = σ x2, m + σ y2, m − σ x , m × σ y , m + 3τ xy2 , m
σ m' = 02 + 0 2 − 0 × 0 + 3 × 7922 = 1372 psi

It assumes that the alternate and mean

Safety factors:
component will have a constant ratio.
1
nf = = 2.7
5291 1372
+
14846 68000
Sy 47000
ny = = = 7.05
σa +σm 5291 + 1372

Both points A and B are safe against fatigue failure.

We have a rotating shaft, as
shown, made of AISI 1040 hot
rolled (Sy = 290MPa; Sut =
524MPa; E = 210GPa).
Determine the Moment it can
support for 100,000 cycle life.

D 6
= = 1.5
d 4
r 0.2
= = 0.05
d 4

K t = 2.03
for _ d ≤ 0.3in _(8mm) : .....k size = 1
− 0.097
for _ 0.3in ≤ d ≤ 10.in : .........k size = 0.869d equivalent
for _ 8mm ≤ d ≤ 250mm : .........k size = 1.189d − 0.097
Determine the Fatigue Stress Concentration
a − 0.080 0.093 − 0.080
=
76 − 80 70 − 80
 0.093 − 0.080 
a = (76 − 80 ) + 0.080
 70 − 80 
TS=524MPa=76ksi
a = 0.085

a = 0.085
1 1
q= = = 0.768
a 1+ 0 . 085
1+
r 2 / 25.4

K f = 1 + q(K t − 1)
K f = 1 + 0.768 × (2.03 − 1)
K f = 1.791
Determine the S-N Diagram
Se ' = 0.5 × SUT = 0.5 × 524MPa = 262 MPa
kload −bending = 1 A95 = 0.0766d 2 = 0.0766 × 402 = 122.56mm 2
A95 122.56
d equivalent = = = 40mm
0.0766 0.0766
k size = 1.189 × d − 0.097 = 1.189 × (40mm) − 0.097 = 0.831
−0.718
k surf = ASutb = 57.7 × (524) = 0.6437
kTemp = 1.0 k reliabilit y = 0 .753

'
S f = S × kload × k size × k surf × kTemp × kreliability
e

S f = 262 × 1 × 0.831 × 0.6437 × 1 × 0.753

S f = 105.5MPa
 0.9x524=471.6MPa S n = aN b 1 S  1  471.6 
b = log m  = − log  = −0.21677
z  Se  3  105.5 

105.5MPa
N2 (106) z
1.0 -3.000
5.0 -3.699

105 10.0 -4.000

log(S n ) = log a + b log N log(a) = log(S m ) − 3b = log(471.6) − 3 × (−0.21677) 50.0 -4.699
log a = log(S n ) − b log N a = 2108 100.0 -5.000
500.0 -5.699
log(S f ) = b × log( N ) + log(a )
log(471.6) − log(105.5)
log(S f ) = 3 6
× log(105 ) + log(2108)
log(10 ) − log(10 )
log(S f ) = 2.24
S f = 173.8MPa
 πr 4 π × (0.024 )
Calculate the stress I= = = 0.1257 × 10− 6
4 4
(amplitude and mean)
My M × 0.02 5
σ Max = = −6
= 1 .5915 × 10 ×M
I 0.1257 × 10
My M × 0.02 5
σ Min = − =− −6
= −1 .5915 × 10 ×M
I 0.1257 × 10
σ Mean = 0
σ Amplitude = 1.5915 × 105 × M

Stress Concentration
σ Amplitude − Corrected = K f × σ Amplitude = 1.791 × 1.5915 × 105 × M
σ Amplitude − Corrected = 0.28504 × 106 × M
σ Amplitude − Corrected = S f = 173.8MPa
Moment = 609.7 N − m
Problem: Determine the safety factor for the component shown below.
Consider all stress concentration factors at the wall equals to 1.0 and all
notch radius of 0.25in. At 1in from the wall the stress concentration
factors are Kbending=1.8; K torsion=1.6; Kshear=1.3; Kaxial=1.5

Given: The load P varies between Pmax=8000lb

and a Pmin=-4000lb
The load R varies between
+/-1000lb
AISI 4340 Oil Quenched
R at 855oC and Temper at
230oC 4hours
P
(Sy=200ksi; Sut=260ksi)
Machined component
working at room
temperature and a
reliability of 99.99%
 A95 = 0.05 × 1.5 × 2.4 = 0.18in 2
Determine the S-N Diagram
S e ' = 100 Ksi kTemp = 1.0 A95 0.18
d equivalent = = = 1.53in
0.0766 0.0766
kload −bending = 1 k reliabilit y = 0 .702 k = 0.869 × d − 0.097 = 0.869 × (1.53mm) − 0.097 = 0.833
size
−0.265 '
k surf = ASutb = 2.7 × (260) = 0.619 S f = Se × kload × ksize × ksurf × kTemp × kreliability
S f = 100 × 1 × 0.833 × 0.619 × 1 × 0.702
S f = 36.197 Ksi
Determine the Fatigue Stress
Concentration
a = 0.005
1 1
q= = = 0.99
a 0.005
1+ 1+
r 0.25

K f = 1 + q(K t − 1)
K f ,bending = 1 + 0.986 × (1.8 − 1)...........K f ,bending = 1.788
K f , axial = 1 + 0.986 × (1.5 − 1)..............K f , axial = 1.493
K f , shear = 1 + 0.986 × (1.3 − 1)..............K f , shear = 1.296
 Area = A = 1.5 × 2.4 = 3.6in 2
(6 2
)
+ 1.752 = 6.25
Ix =
1 .5 × 2 .4 3
= 1.728in 4
12
2.4 × 1.53
Iz = = 0.675in 4
12
R At the wall:
P
 6.00   1.75 
Ry = R ×   Vx = R ×  
 6 . 25   6.25 
Mx = P×5
Vz = P

 1.75   6.00 
Mz = R× ×6 + R×  × 3.25
 6 .25   6 . 25 
 y Point A:  2.4   6 
Mx ×  R× 
σy =  2 
−  6.25  P × 5 × 1.2
= − 0.2666R = 3.472P − 0.266R
Ix A 1.728
 1.75 
1 .5 × R  
B 3 × Vx  6 . 25  = 0.0583 R
x τ yx = =
2× A 2 × 3 .6
A
PMax = 8000lb.......PMin = −4000lb
z PMean = 2000lb........PAmplitude = 6000lb

σ y = 3.472 P − 0.266 R RMax = 1000lb......RMin = −1000lb

RMean = 0 Lb..........RAmplitude = 1000lb
τ yx = 0 .0583 R
σ y , Mean = 3.472 × 2000 = 6944 psi
σ y , Amplitude = 3.472 × 6000 − 0.266 × 1000 = 20566 psi
τ yx , Mean = 0
τ yx , Amplitude = 0 .0583 × 1000 = 58 .3 psi
 Finding the amplitude and mean Von Mises stresses at A.

σ a' = σ x2, a + σ y2, a − σ x , a × σ y , a + 3τ xy2 , a

σ a' = 02 + 205662 − 0 × 20566 + 3 × 58.32 = 20566 psi
σ m' = σ x2, m + σ y2, m − σ x , m × σ y , m + 3τ xy2 , m
σ m' = 02 + 69442 − 0 × 6944 + 3 × 02 = 6944 psi
Safety factors for Point A at the wall:
1
nf = = 1.46
20566 6944
+
31197 260000
Sy 200000
ny = = = 7.27
σa +σm 20566 + 6944
 y  1.5   6 
Mz ×  R × 
Point B:  2   6.25  4.8 × R × 0.75
σy = − = − 0.2666R = 5.066R
Iz A 0.675
3 × V z 1 .5 × P
τ yz = = = 0.208 P
B 2 × A 2 × 3 .6
x PMax = 8000lb.......PMin = −4000lb RMax = 1000lb......RMin = −1000lb
A PMean = 2000lb........PAmplitude = 6000lb RMean = 0 Lb..........RAmplitude = 1000lb

z σ y , Mean = 0 psi τ yz , Mean = 0 .208 × P = 416 psi

σ y , Amplitude = 5.066 × 1000 = 5066 psi τ yz , Amplitude = 0 .208 × 6000 = 1248 psi
σ y = 5.066 R σ a' = σ x2, a + σ y2, a − σ x , a × σ y , a + 3τ xy2 , a

τ yz = 0 .208 P
σ a' = 02 + 50662 − 0 × 5066 + 3 × 12482 = 5508 psi
σ m' = σ x2, m + σ y2, m − σ x , m × σ y , m + 3τ xy2 , m
σ m' = 0 2 + 02 − 0 × 0 + 3 × 4162 = 720 psi

1
nf = = 5.6 Sy 200000
5508 720 ny = = = 32.11
+ σa +σm 5508 + 720
31197 260000
 Area = A = 1.5 × 2.4 = 3.6in 2
At 1in from the wall: (6 2
)
+ 1.752 = 6.25
1 .5 × 2 .4 3
Ix = = 1.728in 4
12
2.4 × 1.53
Iz = = 0.675in 4
12
R
P
 6.00   1.75 
Ry = R ×   Vx = R ×  
 6 . 25   6.25 
Vz = P
Mx = P×4

 1.75   6.00 
Mz = R× ×5 + R×  × 3.25
 6 .25   6 . 25 
 y  2.4   6 
Point A: Mx ×  R× 
σ y = K f ,bending ×  2 −K  6.25 
f , axial ×
Ix A
P × 4 × 1.2
σ y = K f ,bending × − K f , axial × 0.2666R
1.728
B σ y = 1.7883× 2.78P − 1.493× 0.266R = 4.97P − 0.397R
x
A  1.75 
1 .5 × R  
τ yx = K f , shear ×
3 × Vx
= 1.296 ×  6 . 25  = 0.0755 R
z 2× A 2 × 3 .6
σ y = 4.97 P − 0.397 R PMax = 8000lb.......PMin = −4000lb RMax = 1000lb......RMin = −1000lb
PMean = 2000lb........PAmplitude = 6000lb RMean = 0 Lb..........RAmplitude = 1000lb
τ yx = 0 .0755 R
σ y , Mean = 4.97 × 2000 = 9940 psi
σ y , Amplitude = 4.97 × 6000 − 0.397 × 1000 = 29423 psi
τ yx , Mean = 0
τ yx , Amplitude = 0 .0755 × 1000 = 75 .5 psi
 Finding the amplitude and mean Von Mises stresses at A.
σ a' = σ x2, a + σ y2, a − σ x , a × σ y , a + 3τ xy2 , a
σ a' = 02 + 294232 − 0 × 29423 + 3 × 75.52 = 29423 psi
σ m' = σ x2, m + σ y2, m − σ x , m × σ y , m + 3τ xy2 , m
σ m' = 02 + 9940 2 − 0 × 9940 + 3 × 0 2 = 9940 psi
Safety factors for Point A at 1 in from the wall:
1
nf = = 1.02
29423 9940
+
31197 260000

Sy 200000
ny = = = 5.08
σa +σm 29423 + 9940
Examples of fatigue Failure

STRIATIONS INDICATING SLOW FATIGUE

CRACK GROWTH BEACH MARKS

OVERLOAD FAILURE MULTIPLE CRACK ORIGIN

Failure of a steam turbine blade from a
nuclear power plant due to fatigue
A fatigue crack that started at the site
of a lightning strike is shown below.
 Quiz
A rotating shaft loaded by the 5kN and 10kN forces is represented below. The grinding
relief groove at B is 2.5mm deep. The cylindrical surface AB is ground but the groove is
machined. The shaft is made of a steel hardened and tempered to SUT=1300MPa and a
SYield=1000MPa according to the BS 826M40 (EN26). The shaft transmit a power of
15kW at 900RPM between the loads. A safety factor (on load) of 2 corresponding to a life
of 0.35x106 cycles has been used for the shaft design. Is the design correct? If not
determine the new life for a S.F.=2. The shaft operates at room temperature with a
reliability of 99.9%.
 1300MPa=188.5ksi
Kbending=1.63……KTorsion=1.32
a = 0.0215
Determine the Fatigue Stress 1 1
q= = = 0.954
a 0.0215
Concentration 1+ 1+
r 5
25.4
K f = 1 + q(K t − 1)
K f ,bending = 1 + 0.954 × (1.63 − 1)...........K f ,bending = 1.601
K f ,torsion = 1 + 0.954 × (1.32 − 1)..............K f , shear = 1.305
 A95 = 0.0766d 2 = 0.0766 × 352 = 93.835mm 2
Determine the S-N Diagram
S e ' = 650MPa kTemp = 1.0 kload −bending = 1 A95 93.835
d equivalent = = = 35mm
0.0766 0.0766
k reliabilit y = 0 .753
k size = 1.189 × d − 0.097 = 1.189 × (35mm) − 0.097 = 0.8422
−0.265
k surf = ASutb = 4.51 × (1300) = 0.6745
S f = Se' × kload × ksize × ksurf × kTemp × kreliability
S f = 650 × 1 × 0.8422 × 0.6745 × 1 × 0.753
S f = 278MPa
N2 (106) z
1.0 -3.000
5.0 -3.699
S n = aN b 1 S  1  1170 
0.9x1300=1170MPa b = log m  = − log  = −0.208 10.0 -4.000
z S
 e 3  278  50.0 -4.699
log(S n ) = log a + b log N 100.0 -5.000
log a = log(S n ) − b log N 500.0 -5.699

log(a ) = log( S m ) − 3b = log(1170) − 3 × (−0.208)

345.95MPa log(a ) = 3.69218 ⇒ a = 4922.4
278MPa
log(S f ) = b × log( N ) + log(a )
log(1170) − log(278)
log(S f ) = 3 6
× log(3.5 × 105 ) + log(4922.4)
log(10 ) − log(10 )
log(S f ) = 2.539
S f = 345.95MPa
3.5x105
 ∑ M A = 0 = 5 × 100 + 250 × 10 − R2 × 350
R2 = 8.571N − m ⇒⇒ R1 = 6.428 N − m

2πnT
P= ....n(rpm)..T ( N − m)...P ( watts )
60
60 × 15000
T= = 159.15 N − m
2π × 900

6.428kN Critical point at B:

1.428kN MB=749.9N-m
TB=159.15N-m

8.571kN
642.8N-m Bending moment gives the stress amplitude,
857N-m while the Torque gives the mean stress.
M ×c
σ bending , amplitude = K bending ×
MA=160.7N-m MB=749.9N-m MC=214.3N-m I
T ×c
τ torque, mean = K torque ×
T=159.15N-m J
π
I= (0.035)4 = 7.366 × 10−8 m 4
64
π
J= (0.035)4 = 14.73 × 10−8 m 4
32
 M ×c T ×c
σ bending , amplitude = K bending × τ torque, mean = K torque ×
I J

σ amp = (1.601) ×
(
(749.9 N − m ) 0.035 )
2 = 285.23MPa τ (
(159.15 N − m ) 0.035 2 )
mean = (1.305) × = 24.68MPa
7.366 × 10−8 14.73 × 10− 8

Finding the Von Mises stresses Modified Goodman

σ VM , a = 285.23MPa 1 285.23 42.74
= + ⇒ S .F . = 1.17
S .F . 345.95 1300
σ VM , m = 3 × (24.68MPa )2 = 42.74MPa
Langer
σ Yield 1000MPa
LangerSF = = = 3.05
σ VM , mean + σ VM , amp 285.23MPa + 42.74MPa
Calculating the new life
1 285.23 42.74
= + ⇒ σ N = 574.2 MPa log(S f ) = b × log( N ) + log(a ) ⇒ log( N ) =
(log(S f ) − log(a ) )
2 σN 1300 b
log(574.2) − log(4922.4)
log( N ) = = 4.486
− 0.208
N = 30620cycles