Chapter 6: Fatigue Failure: Introduction, Basic Concepts
Chapter 6: Fatigue Failure: Introduction, Basic Concepts
Chapter 6: Fatigue Failure: Introduction, Basic Concepts
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Fatigue test: Standard test involves the use of well-polished test piece in a
U U
rotating test machine that produces pure bending -reversed stresses. (R.R. Moore
rotating beam fatigue testing)
Fatigue strength: stress causing failure
U U
for
steels titanium Alloys
For steels, From Fig. 6–17, S'e = 0.5 Sut is typical of the data and represents
50% reliability.
Fatigue Strength
1) High-cycle fatigue:
loseNEW
U
N
Fatigue strength fraction, f,
of S ut at 103 cycles for
R R P P
S e = S′ e = 0.5 S ut
R R R R R
2) Low-cycle Fatigue:
U
polishedSfecimen
Example:
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ff
Solution:
U
a
Sean's Se
Ot's OsSm
NE 106ones
8 Em41151576.9
Of
of 12 its
HBESOO
Were notprovided orNotavalible Nebulae
Note if Oo Efm
116
Of 5ottsolesi 66,2 tso IS
Se se 0SSut o.sCq.z7 zz Ks
bi 1051 433.1
008
426
105 2 106
8426
f offsGxb4b 1126 2 103
f 0.8949
a fo8949 66.2
106Ksi
33.1
8426
12.5103
Sf aNb
6
sf 47cl
933.1 se fairy
b AssumeHisncycle fatigue Oreo scales
Sf Onur 36 aNb
0.08426
36 106N N 3.68105
assumption
correct
103k3 6oxb.SE106
Example: A steel rotating test specimen has an ultimate tensile strength of S ut =
U U R R
1100 MPa (160 ksi). Estimate the fatigue strength corresponding to a life of
150,000 cycles of stress reversals.
o 6622
Sf 199.7 Iso y ksf
Sf
Endurance Limit Modifying Factors:
are not manufactured the same way. Therefore, modifying factors are applied to
laboratory generated endurance limit S′ e .
R R
Surface factor k a
U U R
Size factor k b
U U R
For non-rotating rectangle section (of height h and base b): d e = 0.808 (hb)0.5
R R P
Load factor k c
U U R
Temperature factor k d
U U R
Reliability factor k e
U U R
U
Miscellaneous-Effects Factor kf
Reminder to consider other possible factors.
Residual stresses
Directional characteristics from cold working
Case hardening
Corrosion
Surface conditioning, e.g. electrolytic plating and metal spraying
Cyclic Frequency
Fretting Corrosion
Limited data is available.
Likely Requires testing.
Machined component
Example: A solid round shaft: rotating at 500 rpm, machined from 1030 cold-
U
reliability is desired. Torsion dominates and S ut =76 ksi. What is the max. stress
R R
FiniteLife
a see kaKbkoko ke Iff se
Sj as sort OS 76 38Ksi
Endurancelimit of Iabtestspecimen
B 0.2263
b 3ios
o2268
Sf
322.2kST toy
If Iz
e
E
Notch Sensitivity:
mb Bn
mulestamelinmiddle
Mb In
f fad
Notch sensitivity factor = q =
where
2
Kt 1
concentrationfactor
kt staticstress
Kffatige
q indicates the effects of the notch on the fatigue strength of a machine element
when subjected to fatigue loading.
If K f = 1 then q = 0
R R : the material has no sensitivity to notches at all
K f = K t then q = 1
R R R R : the material has full sensitivity to notches
K f = 1 + q (K t – 1)
R R R R R
Appendix
Always fondin
q can be obtained from Fig. 6.20 and 6.21 for steels and Al 2024-T6.
For q with notch radius > 0.16” (4 mm) use q at 0.16” (4 mm).
bonding E Axial baes useto find
a
torsion
Example: A steel shaft loaded in bending has an ultimate strength of 690 MPa
and a shoulder with a fillet radius of 3 mm connects a 32 mm diameter with a 38
mm diameter. (Estimate K f using the figure below)
R R
38mm 3mm
Kf Itoh ke l 32mm
rye ftp.o.o937
fIz 1Ko7 Kt l6S 1.6
q o.ES fromgraph 6.20
1.55
kfelto.ES1.65 1
foasis
fully revisedstress
ox
for
tension
stress strain
Moseoase
omin N compassion
avi
Example:
Given: - 1018 cold-drawn flat sheet (S ut = 440 MPa, S y = 370 MPa)
R R R R
Find: The largest force F a that can be applied with a factor of safety of n=1.8.
R R
Fae Fa
as
sectionA
A kf Of
Se
n 1260 0.2
Kc ass axialbae
ki l assume RT
assumesoloreliatiliey
ke 1
see163Mea
kt 2
kf
ltqfke lyq o.rsfromfy 6 2
110.8125 D
kfe2. KfCoj
sen sO snITf_l
fIT.g
Fa OA 2 60 12 lo 20,002N
Example (P6-17):
Given: - 1040 cold-drawn steel (S ut = 85 ksi, S y = 71 ksi)
R R R R
Find: minimum factor of safety based on infinite life. If infinite life is not
predicted, estimate N to failure. Check for yielding
Notch Sensitivity for Cast Irons:
Cast irons are already full of discontinuities, which are included in the
strengths.
Additional notches do not add much additional harm.
Recommended to use q = 0.2 for cast irons.
Reverse stag
fuk
Fatigue Failure Criteria:
mostconservation
SodenBerg
use if feildingis Notallowed
0
TOIT th a so if ultimate
stunstm is unknown
elite
F
f
N
Sami n t LETT
Se oScout Saso SO
se kakoiteKd se tf
265
Ka a sub 2,70too 0.8
Kb l atrialloud
I Se 30.5Ksi
ke Esa
Kds 1 RT
ke 897 aoi
reliable
32924
Ama
EYE FILE.pe
144.0k
0mm
IIIT 9714
0s
I 77
Kf It91kt1 from A b b f
q 0.79 ke 2.6
kf It 792.61 2.267
Se kaKbse
Table A 24
In the second quadrant,
Just include Ke Kt Kc Kf
c 0.9 foraxial torsion
T
Fatigue Criteria for Brittle Materials ke l for landing
loads
Testing has found that the Mean Stress 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, to construct Goodman Diagram:
kc = 0.59 to convert normal endurance strength to shear endurance
strength.
Ssy 0.5577Sy
SUMMARY
1) Define stress level below which fatigue failure cannot occur (Endurance Limit
Method):
6) Use Fatigue failure theory (e.g., Modified Goodman) to calculate fatigue factor
of safety