Chapter 6: Fatigue Failure

Introduction, Basic Concepts

Fatigue: failure under applied cyclic stress.
- can cause part failure, even though σ max < S y .
R R R R

- responsible for ~ 90% of mechanical engineering failures.

Process of fatigue failure:

1) Crack initiation at points of high stress concentration
2) Crack propagation during which crack advances
incrementally with each stress cycle
3) Final failure which is rapid

Static failure produces large deflections:

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- visible warning for part replacement

Fatigue failure:
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- no visible warning

Fatigue test: Standard test involves the use of well-polished test piece in a
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rotating test machine that produces pure bending -reversed stresses. (R.R. Moore
rotating beam fatigue testing)
Fatigue strength: stress causing failure
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for
steels titanium Alloys

after a given number of cycles.

For laboratory rotary steel specimen, endurance limit is estimated as:

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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Estimate a) fatigue strength S f of a rotating steel specimen with N = 12.5 x 103

R R P P

cycles of stress reversals b) N for σ rev = 36 ksi R R

[S ut = 66.2 ksi, σ 0 = 115 ksi, m = 0.22, ϵ f = 0.9]

b biffs
R R R R R R

ff
Solution:
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6

sf 47cl
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0.08426
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assumption
correct

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 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.

103 I 150pool106 highcyclefatiger

fs
Sf a a ff be Ibs
g MatProfsNot Known
US Camewe otten een
also of came be estimated
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graph
f 0.79 from
2
a40.79460 194 Ksi
79
b Islog 401 0.06622

o 6622
Sf 199.7 Iso y ksf
Sf
Endurance Limit Modifying Factors:

S′ e is determined under controlled laboratory conditions. In reality, machine parts

R R

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 round rotating bending and torsion:

For non-rotating round section (of diameter d): d e =0.370 d

R R

For non-rotating rectangle section (of height h and base b): d e = 0.808 (hb)0.5
R R P

For axial loading (pull-push fatigue):

kb = 1
R R

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

drawn steel with a diameter of 1.5”, operating at a temperature of 70oF, 95%

P P

reliability is desired. Torsion dominates and S ut =76 ksi. What is the max. stress
R R

a) for infinite life? endurance limit Se

b) If it must run for at least 104 cycles?
P P

FiniteLife
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Endurancelimit of Iabtestspecimen

ka ascab 2.717650265 0BS7

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ki I 121inRT
ke o863 as1reliable

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104cycles 106 Hisncyclefatigued

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 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

- push-pull fatigue by axial force F a uniformly distributed across width

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

Gomm fizmm Se KuKbKoKdKeKfSe

Se_asSot o.s 4407 220MM
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ka asutb 4si o
l o.B Kb
PushPullfatigue

Kc ass axialbae

ki l assume RT
assumesoloreliatiliey
ke 1

see163Mea
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kf
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110.8125 D

kfe2. KfCoj
sen sO snITf_l
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Example (P6-17):
Given: - 1040 cold-drawn steel (S ut = 85 ksi, S y = 71 ksi)
R R R R

- rotates at 1600 rpm, F 1 =2500 lbf, F 2 =1000 lbf

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.

Effect of Fluctuating Stress – Fatigue Failure Criteria:

Reverse stag
fuk
 Fatigue Failure Criteria:

mostconservation
SodenBerg
use if feildingis Notallowed
0
TOIT th a so if ultimate
stunstm is unknown

passes thrasn Experimental tats

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these fit for failure data
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recommended criterion
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Fatigue Criteria for Brittle Materials
• For many brittle materials, the first quadrant fatigue failure criteria follows
a concave upward Smith-Dolan locus

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):

2) Obtain Kt (Geometry stress concentration)

3) Obtain q and/or qs (notch sensitivity for bending/axial and shear) see Figures 6-
20 and 6-21.
4) Calculate Kf and/or Kfs fatigue stress concentration factors for bending/axial
and shear.
Bending and Axial: Kf= 1 + q( Kt – 1)
Shear: Kfs= 1 + qs( Kt – 1)

5) Find 𝜎𝑚 and 𝜎𝑎 (apply Kf)

No Plastic Strain: Kf should be applied to both alternating and midrange stress
components.
𝜎𝑚 = 𝐾𝑓 𝜎𝑚0 𝜎𝑎 = 𝐾𝑓 𝜎𝑎0
Plasticity: The Dowling method recommends 𝜎𝑎 = 𝐾𝑓 𝜎𝑎0 and 𝜎𝑚 = 𝐾𝑓𝑚 𝜎𝑚0 ,
where Kfm is:

6) Use Fatigue failure theory (e.g., Modified Goodman) to calculate fatigue factor
of safety