Design of Machine Elements

Design against fluctuating load

Lecture: 3
Presented By:
Jagdip Chauhan
Assistant Professor
MED, GJUS&T, Hisar
NOTCH:

• NOTCH : it is defined as a purposely introduced defect (usually U-shaped or V-

shaped or circular shaped) on a planar machine component which causes stress
concentration on its own region.
• Due to this, presence of Notch plays an important role in designing components
in conditions of fluctuating/ fatigue loading.
Fatigue stress concentration factor:

• The actual reduction in endurance limit due to stress

concentration came out to be less than the values analyzed by the
Theoretical stress concentration factor (Kt).
=
• Therefore, an alternate factor came in introduction to account this
reduction; called Fatigue stress concentration factor (K f).
Fatigue stress concentration factor:

• Fatigue stress concentration factor (Kf)

• Kf = (Endurance limit of the notch free specimen) /(Endurance limit of
the notched specimen)

• Kf or Fatigue stress concentration factor has a practical significance and

therefore observed in all actual materials. Value of Kf depends on the grain
size of the material. Fine grained materials experience greater reduction in
endurance limit than Coarse grained materials due to stress concentration.
 NOTCH SENSITIVITY:

• Defined as the susceptibility of a component to succumb to the

damaging effects of stress causing notches in fatigue loading
conditions.
• Factor governing this effect came to be known as Notch Sensitivity
Factor (q).

• q = (Increase of Actual stress over Nominal stress)/(Increase of

Theoretical stress over Nominal stress)
 NOTCH SENSITIVITY:
• Now,
σ0= Nominal stress (As obtained from elementary equations)
Actual Stress = Kf σ0
Theoretical Stress = Kt σ0
• Increase of Actual stress over Nominal stress= Kf σ0 – σ0
• Increase of Theoretical stress over Nominal stress= K t σ0 – σ0

• q = (Kf σ0 – σ0) / (Kt σ0 – σ0) = σ0 (Kf – 1) / σ0 (Kf – 1)= (Kf – 1)/(Kt – 1)

• Above equation can be modified as:

• Kf = 1+ q(Kt – 1)
 NOTCH SENSITIVITY:
• When the material has no sensitivity to notches :
q = 0 and Kf=1
• When the material fully sensitive to notches :
q=1 and Kf= Kt
• So, the value of q varies from 0 to 1.
• The experimental values of q for Reversed axial & bending stresses & Reversed
torsional shear stresses can be taken from the design charts

• In case of doubt in values, For safe design , we should always take q=1 and Kf= Kt.
 Endurance limit – Approximate Estimation:

•For design purpose two separate notations are used for endurance
limit, viz, S’e and Se where,
•S’e = Endurance limit stress of a rotating beam specimen subjected to
reversed bending stress (N/mm2)
•Se = Endurance limit stress of a particular component subjected to
reversed bending stress (N/mm2)
 Endurance limit – Approximate Estimation:

•Endurance limit for the different materials

•Endurance limit of steel

•S’e = 0.5 × Sut

•Endurance limit of Cast Iron, Cast Steel and wrought Aluminium Alloy

•S’e = 0.4 × Sut

•For cast Aluminium Alloy

•S’e = 0.3 × Sut

 Factors Affecting Endurance Limit:

•The endurance limit we have found experimentally cannot be used as such in design even
for the similar shaped components as that of specimen. Experiments reveal that even if an
actual mechanical component tested for endurance limit, the both values of endurance
limits for actual member and test specimen would be entirely different. This is because of
the precautions and conditions which we have followed while experimentation. In
practical situation these experimental condition cannot be possible and that is why the
endurance limit were found different for mechanical component and the test specimen of
same material. So, we can say that the endurance limit is not a true material property as it
is found that endurance limit is affected by many factors such as surface finish, reliability,
temperature, size etc. The value obtained experimentally (S­e) is thus modified on the basis
of the prevailing conditions in actual practice where the component is employed.
 Factors Affecting Endurance Limit:

Se ​= ka.​kb.​kc.​kd.​S’e
•Se = Endurance limit of the component, N/mm 2
•S’e = Endurance limit for rotating beam specimen, N/mm2
•ka = Surface finish factor
•kb = Size factor
•kc = Reliability factor
•kd = Modifying factor to account for stress concentration
Surface finish factor (Ka):
Surface finish and Reliability factor Kb and Kc :
Surface finish and Reliability factor Kb and Kc :

Kd =
 Endurance limit for different loading:
•The Endurance limit (Sse) of a component subjected to fluctuating torsional shear stresses is
onbtained from the Endurance limit in reversed bending (Se) using Theorries of failures.
•According to the maximum shear stress theory,
• Sse = 0.5 Se
•According to distorsion energy theory,
• Sse = 0.577 Se
•When the component is subjected to an axial fluctuating load, the conditions are different. In
axial loading the entire cross-section is uniformly stressed to the maximum value.
•For axial loading,
• (Se)a = 0.8 Se
 REVERSED STRESSES-DESIGN FOR FINITE AND
INFINITE LIFE:
•There are two types of problems in fatigue design
(i) components subjected to completely reversed stresses, and
(ii) components subjected to fluctuating stresses.
• As already discussed earlier the mean stress is zero in case of completely reversed
stresses. The stress distribution consists of tensile stresses for the first half cycle and
compressive stresses for the remaining half cycle and the stress cycle passes through
zero.
• In case of fluctuating stresses, there is always a mean stress, and the stresses can be
purely tensile, purely compressive or mixed depending upon the magnitude of the mean
stress. Such problems are solved with the help of the modified Goodman diagram.
 REVERSED STRESSES-DESIGN FOR INFINITE
LIFE:
•The design problems for completely reversed stresses are further divided into two groups-(i)
design for infinite life, and (ii) design for finite life.
•Case I: When the component is to be designed for infinite life, the endurance limit becomes the
criterion of failure. The amplitude stress induced in such components should be lower than the
endurance limit in order to withstand the infinite number of cycles. Such components are
designed with the help of the following equations:

•where (σa) and (τa) are stress amplitudes in the component and Se and Se are corrected
endurance limits in reversed bending and torsion respectively.
 REVERSED STRESSES-DESIGN FOR FINITE Life:
•Case II: When the component is to be designed for finite life, the S-N curve can be used. The
curve is valid for steels. It consists of a straight-line AB drawn from (0.9 S ut) at 10³ cycles to (Se)
at 106 cycles on a log-log paper. The design procedure for such problems is as follows:
(i) Locate the point A with coordinates [3, log10 (0.9Sut)] since log10 (10³) = 3
(ii) Locate the point B with coordinates [6, log10 (Se)] since log10 (106) = 6
(iii) Join AB, which is used as a criterion of failure for finite-life problems.
(iv) Depending upon the life N of the component, draw a vertical line passing through log10 (N)
on the abscissa. This line intersects AB at point F.
(v) Draw a line FE parallel to the abscissa. The ordinate at the point E, i.e., log10 (S f), gives the
fatigue strength corresponding to N cycles. The value of the fatigue strength (S f) obtained by the
REVERSED STRESSES-DESIGN FOR FINITE Life:

• S-N Curve
Thanks