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ME 307

Machine
Design I

Chapter 7
Fatigue Failure
Resulting from
Variable Loading
Dr. A. Aziz Bazoune

Dr. A. Aziz Bazoune

King Fahd University


of Petroleum &
Minerals
Mechanical
Chapter 7: Fatigue Failure Resulting from Variable Loading
Engineering

ME 307
Machine
Design I

LECTURE
26

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 2

ME 307
Machine
Design I

Modified Goodman
Diagram

It has midrange stress plotted along the


abscissa

and all other components of

stress plotted on the ordinate, with


tension in the positive direction.
The endurance limit, fatigue strength,
or

finite-life

strength

whichever

applies, is plotted on the ordinate above


and below the origin.
The midrange line is a 45o line from the
origin to the tensile strength of the
part.
Figure 7-24
Modified Goodman diagram showing all the strengths
and the limiting values of all the stress components for
a particular midrange stress

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 3

ME 307
Machine
Design I

Plot of Fatigue Failures for Midrange Stresses in both Tensile


and Compressive Regions.

Figure 7-25
Plot of fatigue failures
for midrange stresses
in both tensile and
compressive regions.
Normalizing the data
by using the ratio of
steady strength
components to tensile
strength Sm/Sut,
steady strength
component to
compressive strength
Sm/Suc, and strength
amplitude component
to endurance limit
Sa/Se enables a plot
of experimental
results for a variety of
steels.
Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 4

ME 307
Machine
Design I

Master Fatigue Diagram.

Figure 7-26
Master fatigue
diagram for AISI
4340 steel with
Sut = 158
Sy = 147 kpsi.
The stress
component at A
are
min = 20,
max = 120,
m = 70,
o = 50
all in kpsi
Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 5

ME 307
Machine
Design I

Fluctuating Stresses

Mean Stress Effect (R -1)

2. Representing mean
stress effect using
modified Goodman
Diagram

S is for strength

Failure data for Sm in tension and in


compression
COMPRESSIVE mean stresses
are BENEFICIAL (or have no effect) in fatigue

TENSILE mean stresses are DETRIMENTAL for fatigue behavior


Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 6

ME 307
Machine
Design I

In Fig. 7-27, the tensile side of Fig. 7-25 has been redrawn in terms of
strengths, instead of strength ratios, with the same modified Goodman criterion
together with four additional criteria of failure.
Such diagrams are often constructed for analysis and design purposes; they are
easy to use and the results can be scaled off directly.
The early viewpoint expressed on a diagram was that there existed a locus
(sa, sm) diagram was that there existed a locus which divided safe from
unsafe combinations of (sa, sm) .
Ensuing proposals included:
1. The parabola of Gerber (1874),
2. The Goodman (1890) (straight) line,
3. The Soderberg (1930) (straight) line.
Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 7

ME 307
Machine
Design I

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 8

ME 307
Machine
Design I

As more data were generated it became clear that a fatigue criterion,


rather than being a fence, was more like a zone or band wherein the
probability of failure could be estimated. We include the failure criterion
of Goodman because
It is a straight line and the algebra is linear and easy.
It is easily graphed, every time for every problem.
It reveals subtleties of insight into fatigue problems.
Answers can be scaled from the diagrams as a check on the
algebra.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 9

ME 307
Machine
Design I

Either the fatigue limit Se or the finite-life strength Sf

is plotted

on the ordinate of Fig. 7-27.


These values will have already been corrected
using the Marin factors of Eq.(7-17).
Note that the yield strength is plotted on the
ordinate too.
This serves as a reminder that first-cycle
yielding rather than fatigue might be the
criterion of failure.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 10

ME 307
Machine
Design I

The criteria of failure are diagrammed in Fig.7-27:


1.

The Soderberg,

2.

The modified

3.

Goodman

4.

The Gerber

5.

The ASME-elliptic

6.

Yielding

. The diagram shows that only the Soderberg criterion guards against any yielding,
but is biased low.
. Considering the modified Goodman line as a criterion, point A represents a
limiting point with an alternating strength Sa and midrange strength Sm . The slope
of the load line shown is defined as

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 11

ME 307
Machine
Design I

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 12

ME 307
Machine
Design I

FAILURE CRITERIA (mean stress)

1- Modified Goodman Theory (Germany, 1899)


Factor of Safety

For infinite life Failure Occurs When:

a m 1

Se Su n

Sa S m
1
Se Su

n = OA/OB

Load Line slope

Sa
r
Sm
Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 13

ME 307
Machine
Design I

FAILURE CRITERIA (mean stress)

2- The Soderberg Theory (USA, 1933)


Factor of Safety

For infinite life Failure Occurs When:

a m 1

Se S y n

Sa S m
1
Se S y

n = OC/OB
F
D

For finite life fatigue

strength Sf = a

replaces Se
Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 14

ME 307
Machine
Design I

FAILURE CRITERIA (mean stress)

3- The Gerber Theory (Germany, 1874)


Failure Occurs When:

Sa
Se

Sm
1
Su

Factor of Safety

n = OF/OB

D E
C

Factor of Safety
2

n a n m

1
Se Su

For finite life a replaces Se


Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 15

ME 307
Machine
Design I

FAILURE CRITERIA (mean stress)

4- The ASME Elliptic


Failure Occurs When:
Factor of
Safety
2

Sm
Sa
1

Se
S y

n a
n m


1
Sy
Se

Dr. A. Aziz Bazoune

D E

n = OE/OB

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 16

ME 307
Machine
Design I

FAILURE CRITERIA (mean stress)

4- The ASME Elliptic


Failure Occurs When
2

Sm
Sa
1

Se
S y
Factor of Safety
2

For finite life sa


Dr. A. Aziz Bazoune

D E

replaces Se

n m
n a
1

Se
Sy
n = OE/OB

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 17

ME 307
Machine
Design I

FAILURE CRITERIA

5- The Langer (1st Cycle) Yield Line


Failure Occurs When

Sa S m

1
S yt S yt

Factor of
Safety

a m 1

S yt S yt n

F
D

B
n = OD/OB

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 18

ME 307
Machine
Design I

Criteria Equations
(7-43)

(7-44)

(7-45)

(7-46)

(7-47)

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 19

ME 307
Machine
Design I

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 20

307
ME
The stresses
Machine
Design I

na and nm can replace Sa and Sm, where n is the design

factor or factor of safety. Then, Eqs. (7-43) to (7-46) become:

(7-48)

(7-49)

(7-50)

(7-51)

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 21

ME 307
Machine
Design I

We will emphasize the Gerber and ASME-elliptic for fatigue failure


criterion and the Langer for first-cycle yielding. However, conservative
designers often use the modified Goodman criterion. The design
equation for the Langer first -cycle-yielding is

(7 *)

The failure criteria are used in conjunction with a load line,


Principal intersections are tabulated in Tables 7-9 to 7-11. Formal
expressions for fatigue factor of safety are given in the lower panel of
Tables 7-9 to 7-11. The first row of each table corresponds to the
fatigue criterion, the second row is the static Langer criterion, and
the third row corresponds to the intersection of the static and fatigue
criteria.
Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 22

ME 307
Machine
Design I

The first column gives the intersecting equations and the second
column the intersection coordinates.
There are two ways to proceed with a typical analysis:
1. One method is to assume that fatigue occurs first and use one
of Eqs. (7-48) to (7-51) to determine n or size, depending on
the task. Most often fatigue is the governing failure mode.
Then follow with a static check. If static failure governs then
the analysis is repeated using Langer Static yield equation.
2. Alternatively, one could use the tables. Determine the load
line and establish which criterion the load line intersects first
and use the corresponding equations in the tables.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 23

ME 307
Machine
Design I

Fatigue
Criterion

Static
Langer
Criterion
Intersection
of the Static
and Fatigue
Criteria
TABLE (7-9)
Amplitude and Steady
Coordinates of Strength and
Important Intersections in
First Quadrant for Modified
Goodman and Langer Failure
Criteria.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 24

ME 307
Machine
Design I

Gerber

Langer

Intersection
of Gerber
and Langer
TABLE (7-10)
Amplitude and Steady
Coordinates of Strength and
Important Intersections in
First Quadrant for Gerber
and Langer Failure Criteria.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 25

ME 307
Machine
Design I

ASME
Elliptic

Langer

Intersection
of ASME
Elliptic and
Langer

TABLE (7-11)

Amplitude and Steady


Coordinates of Strength
and Important
Intersections in First
Quadrant for ASME Elliptic
and Langer Failure
Criteria.
Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 26

ME 307
Machine
Design I

Special Cases of Fluctuating


Stresses

Case 1: m fixed

Sa
n
a
Case 2: a fixed

Sm
n
m
Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 27

ME 307
Machine
Design I

Case 3: a / m fixed

Sa Sm
n

a m
Case 4: both vary arbitrarily

1 a m

n Se Sut
Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 28

ME 307
Machine
Design I

EXAMPLE 7-11 (Textbook)

Solution

(7-18)

Dr. A. Aziz Bazoune

(7-4), p. 329

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 29

ME 307
Machine
Design I

EXAMPLE 7-11 (Textbook)


(7-25), p. 331

(7-8), (7-17), p. 325, p. 328

(7-10)

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 30

ME 307
Machine
Design I

(7-*)

(7-28)
(7-10)

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 31

ME 307
Machine
Design I

Figure 7-28
Principal points
A, B, C, and Don
the designers
diagram drawn
for Gerber,
Langer and load
line.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 32

ME 307
Machine
Design I

(7-28)

Dr. A. Aziz Bazoune

7-10

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 33

ME 307
Machine
Design I

7-11
7-29

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 34

ME 307
Machine
Design I

Figure 7-29
Principal points
A, B, C, and Don
the designers
diagram drawn
for ASME Elliptic,
Langer and load
lines.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 35

ME 307
Machine
Design I

7-11

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 26

Slide 36

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