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FCF Notes

(i) There are four main design philosophies for fatigue: infinite life, safe life, fail-safe, and damage tolerant design. Infinite life aims for zero defects over the lifetime, while safe life designs for a finite lifetime with safety margins. Fail-safe ensures failure of one part does not cause overall system failure, and damage tolerant design assumes cracks will form and uses inspections to prevent failure. (ii) Mean stress significantly impacts fatigue life. Tensile mean stress reduces fatigue strength, while compressive mean stress increases it. Relationships like Goodman, Gerber and Soderberg relate alternating and mean stresses to predict high cycle fatigue failure. Morrow, SWT and Manson-Halford models

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81 views

FCF Notes

(i) There are four main design philosophies for fatigue: infinite life, safe life, fail-safe, and damage tolerant design. Infinite life aims for zero defects over the lifetime, while safe life designs for a finite lifetime with safety margins. Fail-safe ensures failure of one part does not cause overall system failure, and damage tolerant design assumes cracks will form and uses inspections to prevent failure. (ii) Mean stress significantly impacts fatigue life. Tensile mean stress reduces fatigue strength, while compressive mean stress increases it. Relationships like Goodman, Gerber and Soderberg relate alternating and mean stresses to predict high cycle fatigue failure. Morrow, SWT and Manson-Halford models

Uploaded by

PappuRamaSubramaniam
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© © All Rights Reserved
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FCF Notes

Design philosophy: (i) Infinite life, (ii) Safe life, (iii) Fail safe and (iv) Damage
tolerant design concepts.

(i) Infinite life: the Infinite life: Safe-Life methodology, a structure is


designed in such a way to remain free from defect for its whole life.
Unlimited safety is the oldest criterion.It requires local stresses or strains
to be essentially elastic and safely below the fatigue limit.For parts
subjected to many millions of cycles, like engine valve springs, this is still
a good design criterion. This criterion may not be economical (i.e. global
competitiveness) or practical (i.e. excessive weightof aircraft) in many
design situations.

(ii) Safe life: The practice of designing for a finite life is known as "safe-life"
design. It is used in many industries, for instance automotive industry, in
pressure vessel design, and in jet engine design. The calculations may be
based on stress-life, strain-life, or crack growth relations. Ball bearings and
roller bearings are examples of safe-life design. The safe life must include a
margin for the scatter of fatigue results and for other unknown factors. The
margin for safety in safe-life design may be taken in terms of life, in terms of
load, or by specifying that both margins must be satisfied, as in the ASME
Boiler and Pressure Vessel Code.

(iii) Fail safe: Fail-safe design requires that if one part fails, the system does
not fail. Fail-safe design recognizes that fatigue cracks may occur and
structures are arranged so that cracks will not lead to failure of the
structure before they are detected and repaired. Multiple load paths, load
transfer between members, crack stoppers built at intervals into the
structure, and inspection are some of the means used to achieve fail safe
design.

(iv) Damage tolerant design concept: This philosophy is a refinement of the


fail-safe philosophy. It assumes that cracks will exist, caused either by
processing or by fatigue, and uses fracture mechanics analyses and tests
to check whether such cracks will grow large enough to produce failures
before they are detected by periodic inspection. Three key items are
needed for successful damage tolerant design: residual strength, fatigue
crack growth behavior, and crack detection involving nondestructive
inspection.
Fatigue Design: Cyclic stress and stress reversals, Fatigue and progressive
fracture, Endurance limit.

Fatigue failure results from repeated plastic deformation. Without repeated plastic
yielding, fatigue failures cannot occur. For example bending a paper clip by bending
it back and forth is a case low cycle fatigue. Fatigue failures typically occur after
thousands or millions of cycles. Minute yielding that exists on the microscopic level.
Fatigue failures can occur at stress levels far below conventional i)Yield Point ii)
Elastic Limit because of Highly Localized Yielding, Vulnerable Locations Include
Holes, sharp corners, threads, keyways, surface scratches, material defects, and
corrosion. Strengthening vulnerable locations is often as effective as making the
entire part from a stronger material

Conditions that Accelerate Crack Initiation i) Residual Tensile Stress ii) Elevated
Temperatures iii) Temperature Cycling iv) Corrosive Environments vi) High
Frequency Cycling.

Small Global Deformations create Failure Surface Perpendicular to Load, generating


Brittle Looking Failure Surface causing Abrupt Final Propagation to Failure

Initial Crack Results in an increase in local stress concentration. Under reverse


cycling crack deepens at crack root,Cross section reduced, Increased Stress , Rate of
Propagation Increases leading to final Failure

Stages of fatigue failure: 1.crack initiation in the areas of stress concentration (near
stress raisers) 2.incremental crack propagation 3.final rapid crack propagation after
crack reaches critical size
The total number of cycles to failure is the sum of cycles at the first and the Second
stages: Nf = Ni + Np
Nf : Number of cycles to failure
Ni : Number of cycles for crack initiation
Np : Number of cycles for crack propagation
High cycle fatigue (low loads): Ni is relatively high. With increasing stress level, Ni
decreases and Np dominates
Influence of mean stress on fatigue

Structural members subjected to in-service cyclic loads exhibit a fatigue behavior that generally
depends on the mean stress values. Mean stress is generally taken as average of minimum stress
and maximum stress. Mean stress in cyclic loading plays important role. For a given fatigue load
range a tensile mean normal stress has a detrimental effect on fatigue strength, whereas, in general,
a compressive mean normal stress has a beneficial effect. For metals and alloys, various criteria
have been proposed to deal with the mean stress effect on fatigue life.

1) For stress based fatigue i.e. for high cycle fatigue we have different approaches to take account
effect of mean stress like Gerber relationship, Goodman relationship, Soderberg relationship, etc.
Relationship can be generated by doing number of experiment. Graph is plotted as alternating
stress Vs mean stress. If point lies inside the area of lines then component is safe for that stress
value. And if point is lies outside of line area then material fails.

2) For strain based fatigue:- For strain based fatigue life calculation or for low cycle fatigue we
need different types of relationships which can take account of the effect of mean stress during
fatigue calculation like Morrow, SWT, Manson and Halford.

a) Morrow Relationship: - Effect of mean stress is generally described by Morrow rule which states
that mean stress mostly affect during early stage of loading or for higher fatigue life. In such type of
life, elastic strain amplitude dominates the total life.

b) Manson and Halford:- Manson and Halford suggested that both the elastic and plastic terms of
the strain-life equation should be modified to account for the mean stress effects and maintain the
independence of the elastic to plastic strain ratio from the mean stress. This model over predict the
result of mean stress when fatigue is at low cycle i.e. where component goes into plastic region.

c) SWT Relationship:- According to Smith-Watson-Topper product of maximum tensile stress and


strain amplitude controls the effect of mean stress.

Mean stress affect the fatigue life of component. By using Morrow relation or SWT relation
or Manson and Halford relation, we can estimate the effect of mean stress on fatigue life of
component. It is clear that increased mean stress reduced the fatigue life of component. But if mean
stress is compressive then it will increase the fatigue life of component.

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