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NT Fatigue G6.xmcd

Fatigue Analysis Pg 257

The Units used as standard:

in, kip, kpsi, sec, hp

in, kip, kpsi, sec/min, hp

Endurance Strength

Pg 274

Fatigue failure occurs when a machine element is subjected to fluctuating load. The
inherent strength of the material weaken at every cycle until eventually the structure is
overcome by the applied cyclic load.
To determine the strength of material under fatigue loading, specimens are subjected to
repeated loading of specified magnitude and counted to destruction. The most widely
used is the R. R. Moore machine fatigue test.

Above: Moores' Fatigue Test machine

Below: SN diagrams from Moores' experiment

NT Fatigue G6.xmcd

# S-N DIAGRAM: Endurance (fatigue) strength against number of cycles

of Moore's steel specimen. See Fig 6-10 Pg 266
# Below: SN graph of other metals under fatigue load.

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NT Fatigue G6.xmcd

Endurance Strength @ Infinite Life

Endurance Limit
Se' = 0.5Sut

if

Sut 1400MPa

(See Eqn 6-8 pg 274)

NB: Endurance limits found only in steel and titanium

Endurance Limit Modifying Factors

b

Surface factor,

ka = a Sut

Eg: If surface is machined:

ka = 4.51Sut

Size factor for round

and rotating shaft,

kb = 1.24d
kb = 1.51d

Load factor,

kc = 1

Pg 278

0.265

0.107
0.157

if

2.79 d 51mm

if

51 < d 254mm

==> bending load

kc = 1 0.85

(for bending and axial load combined)

Temperature factor, kd , Reliability factor, ke , Misc factor, kf = 1

Endurance Limits,

Se = ka kb kc kd ke kf Se'

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NT Fatigue G6.xmcd

CYCLIC LOADINGS Pg 292

Static
Load is applied slowly without shock and is held at constant value.

Repeated and Reversed

Reversed: when a load-carrying component is subjected to certain level of tensile load
followed by a same level of compressive load.
Repeated: when loading is repeated many thousand times.

max - maximum stress acting on the specimen

min - minimum stress acting on the specimen
max - maximum shear stress acting on the specimen
min - minimum shear stress acting on the specimen
Kf

- stress concentration factor

mean stress acting on the specimen

alternating stress acting on the specimen

max + min

m = Kf

max min

a = Kf

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NT Fatigue G6.xmcd

STRESS CONCENTRATION Pg 287

theoritical stress concentration factor Pg 105 See Table A-15 to A-16

Kt

Kf 1

q=

Kt 1

notch sensitivities. (concentration factor are less severe for some materials).
See Fig 6-20, 6-21 and eqn. 6-32 & 6-33.

For Cast Iron: q = 0.2

Kf = 1 + q Kt 1 actual stress concentration factor (reduced value of Kt due to

different material type ie different notch sensitivities)

t = Kf n

SC stress (at Stress Concentration region)

Sample Problem 1

Given :

P = 15kN
2

Cross section area :

An = ( 25mm) ( 25mm) = 625 mm

Normal stress (without notch) ,

n =

An

= 24 10 Pa

Stress concentration occurs at notch : See pg 1003 Fig A-13-3 :

r
d

2.5mm
25mm

= 0.1

30mm
25mm

= 1.2

rf = 2mm

Sut = 400MPa

Kt = 2.38

q = 0.73

Kf = 1 + q Kt 1 = 2.007
Cross section area at notch region :
Actual stress at notch :

At = ( 25mm) ( 25mm 5mm) = 500 mm

t = Kf

P
At

= 60.27 MPa

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NT Fatigue G6.xmcd

Fatigue Failure Criterion

Langer's eqn (for early cycle yielding) :

Sy

Modified Goodman equation:

Gerber equation:

Soderberg equation:

Se

a
Se

a
Se

Pg 297

Sy

m
Sut

[6-45]

m
+
=1
S
ut

[6-48]

m
Sy

[6-46]

[6-44]

If = 1.0 then the stress ( m , a) lies on the Langer line or the other fatigue curves.
Any points lower than the curves are safe i.e.

> 1.0.

To ensure the materials do not yield at the first cycle loading, the Langer's equation must
be applied against both stresses m , a . If the material is considered safe by Langer,
further analysis must done using any of the Fatigue equations as can be explained by the
figure below. The Soderberg lines is an exception to the above because it does need to
be accompanied by Langer's test.

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NT Fatigue G6.xmcd

Fatigue Strength @ Finite Life

Pg 276

Method 1: To find the finite life, we need the equation Sf = a Nx

Total numer. of cycles, Nx < 1000000

If Sut < 490MPa then f = 0.9
If 490 Sut 1400MPa get f from Fig 6-18 pg 277
a=

(f Sut)2

f Sut
1
b = log

S
3
e

Se

if m = 0
If m 0

then

a
Nx =
a

then do the following steps:

Apply modified Goodman equation:

a
Sf

m
Sut

=1

to get

Sf
1

Use the equation derived from Sf = a Nx

that is,

Sf
Nx =
a

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NT Fatigue G6.xmcd

Stress Concentration Factor at Finite Life

2
5
2
K3 = 1 Kf 1 0.18 0.43 10 Sut + 0.45 10
Sut

KN =

K3

Kf

Nx

1 Kf
log
3 K3

From the figure above, when the mean stress is compressive, failure occurs when a = Se
In a complete setup, the figure below shows the safe area for Goodman Fatigue life.