Fatigue Failure MATERIALS
Fatigue Failure MATERIALS
Fatigue Failure MATERIALS
Crack Initiation
Crack Propagation
Final Fracture
Ken Youssefi MAE dept., SJSU 1
Jack hammer component,
shows no yielding before
fracture.
Fracture zone
Propagation zone, striation
Ken Youssefi MAE dept., SJSU 2
VW crank shaft – fatigue failure due to cyclic bending and torsional stresses
Propagation
zone, striations
Fatigue Beachmarks
Striations (SEM)
Initiation sites
Propagation zone
Final fracture zone
Alternating stress
max min
a = 2
Mean stress
max + min
m 2
=
Ken Youssefi MAE dept., SJSU 10
Fatigue Failure, S-N Curve
Motor
Load
S′e
Copper alloys
Copper alloys
0.4Sut Sut < 40 ksi (280 MPa)
Se′ = 14 ksi Sut ≥ 40 ksi
100 MPa Sut ≥ 280 MPa
For N = 5x108 cycle
S Se
103 106 N
For materials that do not exhibit a knee in the S-N curve, the infinite
life taken at 5x108 cycles
S Sf
Ken Youssefi
103 5x108
MAE dept., SJSU
N 15
Correction Factors for Specimen’s Endurance Limit
A95 d95 d
dequiv = ( )1/2
0.0766
Csurf = A (Sut)b
• You may also assume a profile and size, calculate the alternating stress
and determine the safety factor. Iterate until you obtain the desired
safety factor
Ken Youssefi MAE dept., SJSU 24
Design for Finite Life
S B S B
Se Sf
Sn = .9Sut Sn = .9Sut
Point A Point A
N = 10 3
N = 103
Sn = Se Sn = Sf
Point B Point B
N = 10 6 N = 5x108
Ken Youssefi MAE dept., SJSU 25
Design for Finite Life
Sn = a (N)b log Sn = log a + b log N
Se
⅓ log ( .9S )
N ut
Sn = Se ( 106 )
a
Sy Yield line
Gerber curve
Se
Alternating
stress Goodman line
Sy Sut m
Soderberg line
Mean stress
Ken Youssefi MAE dept., SJSU 27
The Effect of Mean Stress on Fatigue Life
Modified Goodman Diagram
a
Sy Yield line
Se
Alternating
stress Goodman line
C
Safe zone
Sy Sut m
Mean stress
a
Sy Yield line
Se
Goodman line
C
Safe zone Safe zone
• If Kf max > Sy then there is local yielding at the notch, material at the
notch is strain-hardened. The effect of stress concentration is reduced.
Calculate the stress concentration factor for the mean stress using
the following equation,
Sy Kf a
Kfm =
m
Fatigue design equation
Kf a Kfmm 1
+ = Infinite life
Se Sut nf
m′ = (1m
2
+ 2m - 1m2m)1/2
2
′a ′m 1
+ = Infinite life
Se Sut nf
305577 Sn 56.5
a = = 305.577 ksi n=
Kfa
=
1.6x305.577
= .116 < 1.6
d3
So d = 1.0 in. is too small
Assume d = 2.5 in
All factors remain the same except the size factor and notch sensitivity.
305577
a = 3
= 19.55 ksi
(2.5)
Sn 53.35
n= = = 1.67 ≈ 1.6
Kfa 1.63x19.55
d = 2.5 in.
Check yielding
Sy 90
n= = = 2.8 > 1.6 okay
Kfmax 1.63x19.55