Socie 3.0 Multiaxial Fatigue

Professor Darrell F.
Socie
Department of Mechanical and Industrial Engineering
University of Illinois at Urbana-Champaign
2001 Darrell Socie, All Rights Reserved
Multiaxial Fatigue
Multiaxial Fatigue 2001 Darrell Socie, University of Illinois at Urbana-Champaign, All Rights Reserved 1 of 125
Contact Information
Darrell Socie
Mechanical Engineering
1206 West Green
Urbana, Illinois 61801
USA
d-socie@uiuc.edu
Tel: 217 333 7630
Fax: 217 333 5634
Outline
State of Stress ( Chapter 1 )
Fatigue Mechanisms ( Chapter 3 )
Stress Based Models ( Chapter 5 )
Strain Based Models ( Chapter 6 )
Fracture Mechanics Models ( Chapter 7 )
Nonproportional Loading ( Chapter 8 )
Notches ( Chapter 9 )
State of Stress
Stress components
Common states of stress
Shear stresses
Stress Components
X
Z
Y
zy
zx
xz
xy
yx
yz
Six stresses and six strains
Stresses Acting on a Plane
Z
Y
X
Y
X
Z
xz
xy
Principal Stresses
3
-
2
(
X
+
Y
+
Z
) + (
X
Y
+
Y
Z
-
2
XY
-
2
YZ
-
2
XZ
)
- (
X
Z
+ 2
XY
YZ
XZ
-
X
2
YZ
-
Y
2
ZX
-
Z
2
XY
) = 0
13
12
23
Stress and Strain Distributions
80
90
100
-20 -10 0 10 20
%

o
f

a
p
p
l
i
e
d

s
t
r
e
s
s
Stresses are nearly the same over a 10range of angles
Tension
x

/2
1

2
2
=
3
= 0
2
=
3
=
1
Torsion

xy
2
/
2
3
X
Y
1
=
xy
1
/
2
2
=
y
1
=
x
1
=
2
1
=
2
=
1
2
3
Biaxial Tension
3
3
1
Maximum shear stress Octahedral shear stress
Shear Stresses
2
3 1
13

=
( ) ( ) ( )
2
3 2
2
2 1
2
3 1 oct
3
1
+ + =
oct
2
3
=
Mises:
13 13 oct
94 . 0
2 2
3
= =
State of Stress Summary
Stresses acting on a plane
Principal stress
Maximum shear stress
Octahedral shear stress
Fatigue Mechanisms
Crack nucleation
Fracture modes
Crack growth
State of stress effects
Crack Nucleation
Slip Bands
Loading Unloading
Extrusion
Undeformed
material
Intrusion
Slip Bands
Mode I
opening
Mode II
in-plane shear
Mode III
out-of-plane shear
Mode I, Mode II, and Mode III
Stage I Stage II
loading direction
free
surface
Stage I and Stage II
Case A and Case B
Growth along the surface Growth into the surface
5 m
c
r
a
c
k

g
r
o
w
t
h

d
i
r
e
c
t
i
o
n
Mode I Growth
crack growth direction
10 m
slip bands
shear stress
Mode II Growth
1.0
0.2
0
0.4
0.8
0.6
1 10 10
2
10
3
10
4
10
5
10
6
10
7
Nucleation
Tension
Shear
304 Stainless Steel - Torsion
Fatigue Life, 2N
f
D
a
m
a
g
e

F
r
a
c
t
i
o
n

N
/
N
f
304 Stainless Steel - Tension
1 10 10
2
10
3
10
4
10
5
10
6
10
7
1.0
0.2
0
0.4
0.8
0.6
Nucleation
Tension
Fatigue Life, 2N
f
D
a
m
a
g
e

F
r
a
c
t
i
o
n

N
/
N
f
Nucleation
Tension
Shear
1.0
0.2
0
0.4
0.8
0.6
1 10 10
2
10
3
10
4
10
5
10
6
10
7
Inconel 718 - Torsion
Fatigue Life, 2N
f
D
a
m
a
g
e

F
r
a
c
t
i
o
n

N
/
N
f
Inconel 718 - Tension
Shear
Tension
Nucleation
1 10 10
2
10
3
10
4
10
5
10
6
10
7
1.0
0.2
0
0.4
0.8
0.6
Fatigue Life, 2N
f
D
a
m
a
g
e

F
r
a
c
t
i
o
n

N
/
N
f
Fatigue Life, 2N
f
D
a
m
a
g
e

F
r
a
c
t
i
o
n

N
/
N
f
f
Nucleation
Shear
Tension
1 10 10
2
10
3
10
4
10
5
10
6
10
7
1.0
0.2
0
0.4
0.8
0.6
1045 Steel - Torsion
1045 Steel - Tension
Nucleation
Shear
Tension
1.0
0.2
0
0.4
0.8
0.6
1 10 10
2
10
3
10
4
10
5
10
6
10
7
Fatigue Life, 2N
f
D
a
m
a
g
e

F
r
a
c
t
i
o
n

N
/
N
f
Fatigue Mechanisms Summary
Fatigue cracks nucleate in shear
Fatigue cracks grow in either shear or tension
depending on material and state of stress
Stress Based Models
Sines
Findley
Dang Van
1.0
0
0
0.5
1.0 1.5 2.0
Shear stress
Octahedral stress
Principal stress
0.5
S
h
e
a
r

s
t
r
e
s
s

i
n

b
e
n
d
i
n
g
1
/
2

B
e
n
d
i
n
g

f
a
t
i
g
u
e

l
i
m
i
t
Shear stress in torsion
1/2 Bending fatigue limit
Bending Torsion Correlation
Test Results
Cyclic tension with static tension
Cyclic torsion with static torsion
Cyclic tension with static torsion
Cyclic torsion with static tension
1.5
1.0
0.5
1.5 -1.5 -1.0 1.0 0.5 -0.5 0
A
x
i
a
l

s
t
r
e
s
s
F
a
t
i
g
u
e

s
t
r
e
n
g
t
h
Mean stress
Yield strength
Cyclic Tension with Static Tension
1.5
1.0
0.5
1.5
1.0 0.5
0
S
h
e
a
r

S
t
r
e
s
s

A
m
p
l
i
t
u
d
e
S
h
e
a
r

F
a
t
i
g
u
e

S
t
r
e
n
g
t
h
Maximum Shear Stress
Shear Yield Strength
Cyclic Torsion with Static Torsion
1.5
1.0
0.5
3.0
0 2.0
1.0
B
e
n
d
i
n
g

S
t
r
e
s
s
B
e
n
d
i
n
g

F
a
t
i
g
u
e

S
t
r
e
n
g
t
h
Static Torsion Stress
Torsion Yield Strength
Cyclic Tension with Static Torsion
1.5
1.0
0.5
1.5 -1.5 -1.0 1.0 0.5 -0.5 0
T
o
r
s
i
o
n

s
h
e
a
r

s
t
r
e
s
s
S
h
e
a
r

f
a
t
i
g
u
e

s
t
r
e
n
g
t
h
Axial mean stress
Yield strength
Cyclic Torsion with Static Tension
Conclusions
Tension mean stress affects both tension
and torsion
Torsion mean stress does not affect tension
or torsion
Sines
= =

) 3 (
2
h
oct
= + +
+ + + + + +
) (
) ( 6 ) ( ) ( ) (
6
1
mean
z
mean
y
mean
x
2
yz
2
xz
2
xy
2
z y
2
z x
2
y x
Findley
2
+
|
\
|
.
| = k
n
max
f
tension torsion
Bending Torsion Correlation
1.0
0
0
0.5
1.0 1.5 2.0
Shear stress
Octahedral stress
Principal stress
0.5
S
h
e
a
r

s
t
r
e
s
s

i
n

b
e
n
d
i
n
g
1
/
2

B
e
n
d
i
n
g

f
a
t
i
g
u
e

l
i
m
i
t
Shear stress in torsion
1/2 Bending fatigue limit
Dang Van
( ) ( ) t a t b
h
+ =
m
V(M)
ij
(M,t) E
ij
(M,t)
ij
(m,t)
ij
(m,t)
h
Loading path
Failure
predicted
(t) + a
h
(t) = b
Dang Van ( continued )
Stress Based Models Summary
Sines:
Findley:
Dang Van: ( ) ( ) t a t b
h
+ =
= =

) 3 (
2
h
oct
2
+
|
\
|
.
| = k
n
max
f
Strain Based Models
Plastic Work
Brown and Miller
Fatemi and Socie
Smith Watson and Topper
Liu
10 10
2
10
3
10
4
10
5
0.001
0.01
0.1
Cycles to failure
P
l
a
s
t
i
c

o
c
t
a
h
e
d
r
a
l
s
h
e
a
r

s
t
r
a
i
n

r
a
n
g
e
Torsion
Tension
Octahedral Shear Strain
1
10
100
10
2
10
3
10
4
A
Fatigue Life, N
f
P
l
a
s
t
i
c

W
o
r
k

p
e
r

C
y
c
l
e
,

M
J
/
m
3
T
Torsion
Axial
0
o
90
o
180
o
135
o
45
o
30
o
T
A
T
T
T
T
T
T
A
A
A
A
A
Plastic Work
0.005 0.01 0.0
10
2
2 x10
2
5 x10
2
10
3
2 x10
3
F
a
t
i
g
u
e

L
i
f
e
,

C
y
c
l
e
s
Normal Strain Amplitude,
n
= 0.03
Brown and Miller
Case A and B
Growth along the surface Growth into the surface
U
n
i
a
x
i
a
l
E
q
u
i
b
i
a
x
i
a
l
Brown and Miller ( continued )
Brown and Miller ( continued )
( )
$
max

= + S
n
1
max
'
,
'
( ) ( )
2
2
2 2 + =

+ S A
E
N B N
n
f n mean
f
b
f f
c

Fatemi and Socie
C F G
H I J
/ 3
Loading Histories
0
0.5
1
1.5
2
2.5
0 2000 4000 6000 8000 10000 12000 14000
J-603
F-495 H-491
I-471
C-399
G-304
Cycles
C
r
a
c
k

L
e
n
g
t
h
,

m
m
Crack Length Observations
Fatemi and Socie
co
f
'
f
bo
f
'
f
y
max , n
) N 2 ( ) N 2 (
G
k 1
2
+
=
|
|
.
|
\
|
+

Smith Watson Topper
SWT
c b
f
'
f
'
f
b 2
f
2
'
f 1
n
) N 2 ( ) N 2 (
E 2
+
+
Liu
W
I
= (
n

n
)
max
+ ( )
b 2
f
2
'
f
c b
f
'
f
'
f I
) N 2 (
E
4
) N 2 ( 4 W

+ =
+
W
II
= (
n

n
) + ( )
max
bo 2
f
2
'
f
co bo
f
'
f
'
f II
) N 2 (
G
4
) N 2 ( 4 W

+ =
+
Virtual strain energy for both mode I and mode II cracking
Cyclic Torsion
Cyclic Shear Strain Cyclic Tensile Strain
Shear Damage Tensile Damage
Cyclic Torsion
Cyclic Torsion
Static Tension
Shear Damage
Tensile Damage
Cyclic Torsion with Static Tension
Tensile Damage
Shear Damage
Cyclic Torsion
Static Compression
Cyclic Torsion with Compression
Cyclic Torsion
Static Compression
Hoop Tension
Cyclic Shear Strain
Cyclic Tensile Strain
Tensile Damage Shear Damage
Cyclic Torsion with Tension
and Compression
Test Results

Load Case
/2
hoop
MPa
axial
MPa
N
f

Torsion 0.0054 0 0 45,200
with tension 0.0054 0 450 10,300
with compression 0.0054 0 -500 50,000
with tension and
compression
0.0054 450 -500 11,200

Conclusions
All critical plane models correctly predict
these results
Hydrostatic stress models can not predict
these results
0.006 Axial strain
-0.003
0.003
S
h
e
a
r

s
t
r
a
i
n
Loading History
Model Comparison
Summary of calculated fatigue lives

Model Equation Life
Epsilon 6.5 14,060
Garud 6.7 5,210
Ellyin 6.17 4,450
Brown-Miller 6.22 3,980
SWT 6.24 9,930
Liu I 6.41 4,280
Liu II 6.42 5,420
Chu 6.37 3,040
Gamma 26,775
Fatemi-Socie 6.23 10,350
Glinka 6.39 33,220
Strain Based Models Summary
Two separate models are needed, one for
tensile growth and one for shear growth
Cyclic plasticity governs stress and strain
ranges
Mean stress effects are a result of crack
closure on the critical plane
Separate Tensile and Shear Models
1
=
xy
1
Inconel 1045 steel stainless steel
Cyclic Plasticity
Mean Stresses
eq
f mean
f
b
f f
c
E
N N =

+

'
'
( ) ( ) 2 2
[ ]
|
|
.
|
\
|
+ =
R 1
2
) ( ) ( W
max n n I
c
f
'
f
b
f
n
'
f
n
max
) N 2 ( ) S 5 . 0 5 . 1 ( ) N 2 (
E
2
) S 7 . 0 3 . 1 ( S
2
+ +

+ = +

co
f
'
f
bo
f
'
f
y
max , n
) N 2 ( ) N 2 (
G
k 1
2
+
=
|
|
.
|
\
|
+

c b
f
'
f
'
f
b 2
f
2
'
f 1
n
) N 2 ( ) N 2 (
E 2
+
+
Fracture Mechanics Models
Mode I growth
Torsion
Mode II growth
Mode III growth
Mode I, Mode II, and Mode III
Mode I
opening
Mode II
in-plane shear
Mode III
out-of-plane shear

Mode I
Mode II
Mode I and Mode II Surface Cracks
= -1
= 0
= 1
= -1
= 0
= 1
= 193 MPa = 386 MPa
10
-3
10
-4
10
-5
10
-6
d
a
/
d
N
m
m
/
c
y
c
l
e
10 100 200 20 50 10 100 200 20 50
K, MPa m
10
-3
10
-4
10
-5
10
-6
d
a
/
d
N
m
m
/
c
y
c
l
e
Biaxial Mode I Growth
K, MPa m
Mode II
Mode III
Surface Cracks in Torsion
Transverse Longitudinal Spiral
Failure Modes in Torsion
1500
1000
Y
i
e
l
d

S
t
r
e
n
g
t
h
,
M
P
a
40
30
50
60
H
a
r
d
n
e
s
s
R
c
200 300 400 500
Shear Stress Amplitude, MPa
No Cracks
Spiral
Cracks
Transverse
Cracks
Longi-
tudinal
Fracture Mechanism Map
10
-6
10
-5
10
-4
10
-3
d
a
/
d
N
,

m
m
/
c
y
c
l
e
5 10 100 50 20
K
I
, K
III
MPa
m
K
I
K
III
Mode I and Mode III Growth
1 10
100
10
-7
10
-6
10
-5
10
-4
10
-3
10
-2
d
a
/
d
N
,

m
m
/
c
y
c
l
e
m
Mode I R = 0
Mode II R = -1
7075 T6 Aluminum
Mode I R = -1
Mode II R = -1
SNCM Steel
Mode I and Mode II Growth
K
I
, K
II
MPa
Fracture Mechanics Models
( )
m
eq
K C
dN
da
=
[ ]
25 . 0
4
III
4
II
4
I eq
) 1 ( K 8 K 8 K K + + =
[ ]
5 . 0
2
III
2
II
2
I eq
K ) 1 ( K K K + + + =
[ ]
5 . 0
2
II II I
2
I eq
K K K K K + + =
a ) E F ( )
) 1 ( 2
E
F ( ) ( K
5 . 0
2
I
2
II eq

(
+
+
=
( ) a k 1 G F K
ys
max , n
eq

|
|
.
|
\
|
+ =
Fracture Surfaces
Bending Torsion
10
-9
10
-8
10
-7
10
-6
10
-5
10
-4
0.2 0.4 0.6 0.8 1.0
Crack length, mm
C
r
a
c
k

g
r
o
w
t
h

r
a
t
e
,

m
m
/
c
y
c
l
e
K = 11.0
K = 14.9
K = 10.0
K = 12.0
K = 8.2
Mode III Growth
Fracture Mechanics Models Summary
Multiaxial loading has little effect in Mode I
Crack closure makes Mode II and Mode III
calculations difficult
Nonproportional Loading
In and Out-of-phase loading
Nonproportional cyclic hardening
Variable amplitude
xy
y
t
t
t
t
x
=
o
sin(t)
xy
= (1+)
o
sin(t)
In-phase
Out-of-phase
xy
xy
x
=
o
cos(t)
xy
= (1+)
o
sin(t)

1
+
1
+
In and Out-of-Phase Loading
xy
2
2
xy
xy
2
2
xy
In-Phase and Out-of-Phase
x

x
x

x
xy
/2

xy
/2
xy
/2
xy
/2
cross
diamond
out-of-phase
square
Loading Histories
in-phase
out-of-phase
diamond
square
cross
Loading Histories
Findley Model Results
/2
MPa

n,max
MPa
/2 + 0.3
n,max
N/N
ip
in-phase 353 250 428 1.0
90
out-of-phase
250 500 400 2.0
diamond 250 500 400 2.0
square 353 603 534 0.11
cross - tension cycle 250 250 325 16
cross - torsion cycle 250 0 250 216
xy
/2 cross
xy
/2
diamond
out-of-phase
xy
/2
square
in-phase
xy
/2
Nonproportional Hardening
t
t
t
t
x
=
o
sin(t)
xy
= (1+)
o
sin(t)
In-phase
Out-of-phase
xy
xy
x
=
o
cos(t)
xy
= (1+)
o
sin(t)
600
-600
300
-300
-0.003
-0.006
0.003
0.006
Axial Shear
In-Phase
Axial
600
-600
-0.003
0.003
Shear
-300
300
0.006
-0.006
90 Out-of-Phase
600
-600
-0.004
0.004
Proportional
-600
600
-0.004
0.004
Out-of-phase
Critical Plane
N
f
= 38,500
N
f
= 310,000
N
f
= 3,500
N
f
= 40,000
0 1 2 3 4
5 6 7 8 9
10
11 12 13
Loading Histories
-300
-150
0
150
300
-600 -300 0 300 600
-300
-150
0
150
300
-600 -300 0 300 600
-300
-150
0
150
300
-600 -300 0 300 600
-300
-150
0
150
300
-600 -300 0 300 600
-300
-150
0
150
300
-600 -300 0 300 600
-300
-150
0
150
300
-600 -300 0 300 600
Case 3 Case 2 Case 1
S
h
e
a
r

S
t
r
e
s
s

(

M
P
a

)
Stress-Strain Response
Stress-Strain Response (continued)
-300
-150
0
150
300
-600 -300 0 300 600
-300
-150
0
150
300
-600 -300 0 300 600
-300
-150
0
150
300
-600 -300 0 300 600
-300
-150
0
150
300
-600 -300 0 300 600
-300
-150
0
150
300
-600 -300 0 300 600
-300
-150
0
150
300
-600 -300 0 300 600
S
h
e
a
r

S
t
r
e
s
s

(

M
P
a

)
Axial Stress ( MPa )
1000
200
10
2
10
3
10
4
E
q
u
i
v
a
l
e
n
t

S
t
r
e
s
s
,
M
P
a
2000
Fatigue Life, N
f
Maximum Stress
Nonproportional hardening results in lower fatigue lives
All tests have the same strain ranges
Case A Case B Case C Case D
x

x

x

x
y

y

y

y
Nonproportional Example
Case A Case B Case C Case D
xy xy xy xy
Shear Stresses
-0.003 0.003
-0.006
0.006
x
y
-300 300
x
-150
150
x
y
Simple Variable Amplitude History
-0.003
0.003
x
-300
300
x
-0.005
0.005
xy
-150
150
x
y
Stress-Strain on 0 Plane
-0.003
0.003
30
-300
300
-0.003
0.003
-300
300
30 plane 60 plane
6
0
3
0
60
Stress-Strain on 30 and 60 Planes
Stress-Strain on 120 and 150 Planes
-0.003
0.003
-300
300
1
2
0
-0.003 0.003
-300
300
150 plane 120 plane
1
5
0
120
150
time
-0.005
0.005
S
h
e
a
r

s
t
r
a
i
n
,

Shear Strain History on Critical Plane

Fatigue Calculations
Load or strain history
Cyclic plasticity model
Stress and strain tensor
Search for critical plane
Nonproportional Loading Summary
Nonproportional cyclic hardening increases
stress levels
Critical plane models are used to assess
fatigue damage
Notches
Stress and strain concentrations
Nonproportional loading and stressing
Fatigue notch factors
Cracks at notches
z
M
T
M
X
M
Y
P
Notched Shaft Loading
0
1
2
3
4
5
6
0.025 0.050 0.075 0.100 0.125
Notch Root Radius, /d
S
t
r
e
s
s

C
o
n
c
e
n
t
r
a
t
i
o
n

F
a
c
t
o
r
T
o
r
s
i
o
n
B
e
n
d
i
n
g
2.20
1.20
1.04
D/d
D d
Stress Concentration Factors

a
r
r
Hole in a Plate
-4
-3
-2
-1
0
1
2
3
4
30 60 90 120 150 180
Angle
= 1
= 0
= -1
Stresses at the Hole
Stress concentration factor depends on type of loading
0
0.5
1.0
1.5
1
2 3 4 5
r
a
Shear Stresses during Torsion

Torsion Experiments
Multiaxial Loading
Uniaxial loading that produces multiaxial
stresses at notches
Multiaxial loading that produces uniaxial
stresses at notches
Multiaxial loading that produces multiaxial
stresses at notches
0.004 0.008 0.012 0
0.001
0.002
0.003
0.004
0.005
50 mm
30 mm
15 mm
7 mm
Longitudinal Tensile Strain
T
r
a
n
s
v
e
r
s
e

C
o
m
p
r
e
s
s
i
o
n

S
t
r
a
i
n
Thickness
100
x
z
y
Thickness Effects
M
X
M
Y
1 2 3 4
M
X
M
Y
Applied Bending Moments
A
B
C
D
A
C
A
C
B
D
B
D
Location
M
X
M
Y
Bending Moments on the Shaft
Bending Moments
M
A B C D
2.82 1 1
2.00 3 2
1.41 2 1
1.00 2
0.71 2
M M =
5 5
A B C D
M
2.49 2.85 2.31 2.84
t
1
t
2
t
3
t
4
M
X
M
T
t
1
T
t
2
T
t
3
1
=
z
t
4
1
=
T
Torsion Loading
Out-of-phase shear loading is needed to produce
nonproportional stressing
M
X
M
T
K
t
= 3 K
t
= 4
Plate and Shell Structures
0
1
2
3
4
5
6
0.025 0.050 0.075 0.100 0.125
Notch root radius,
S
t
r
e
s
s

c
o
n
c
e
n
t
r
a
t
i
o
n

f
a
c
t
o
r
K
t
Bending
K
t
Torsion
K
f
Torsion
K
f
Bending
D d
d
= 2.2
D
d
Fatigue Notch Factors
1.0
1.5
2.0
2.5
1.0
1.5 2.0 2.5
Experimental K
f
C
a
l
c
u
l
a
t
e
d

K
f
conservative
non-conservative
Fatigue Notch Factors ( continued )
bending
torsion
r
a
1
1 K
1 K
T
f
+
+ =
Petersons Equation
Fracture Surfaces in Torsion
Circumferencial Notch
Shoulder Fillet
1.00 1.50 2.00 2.50 3.00
0.00
0.25
0.50
0.75
1.00
1.25
1.50
F
= 1
= 0
= 1
R
a
a
R
Stress Intensity Factors
( )
m
eq
K C
dN
da
= a F K
I
=
0
20
40
60
80
100
0 2 x 10
6
C
r
a
c
k

L
e
n
g
t
h
,

m
m
4 x 10
6
6 x 10
6
8 x 10
6
= -1 = 0 = 1
Cycles
Crack Growth From a Hole
Notches Summary
Uniaxial loading can produce multiaxial
stresses at notches
Multiaxial loading can produce uniaxial
stresses at notches
Multiaxial stresses are not very important in
thin plate and shell structures
Multiaxial stresses are not very important in
crack growth
Final Summary
Fatigue is a planar process involving the
growth of cracks on many size scales
Critical plane models provide reasonable
estimates of fatigue damage
University of Illinois at Urbana-Champaign
Multiaxial Fatigue

Socie 3.0 Multiaxial Fatigue

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Shear Strain History on Critical Plane

Stress Concentration Factors

Shear Stresses during Torsion

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