11/5/2009

Worked Example The application of S-N curve

M= 1200 Nm

A solid circular shaft made from mild

steel subjected to cyclic bending
moment of 1200 Nm
If a 107 cycles
y
life is expected
p
for the
shaft, determine the diameter of the
shaft. Consider a stress safety factor 2

Solution:

Worked example
Given that the g
growth rate of a fatigue
g crack,, da/dN,, occurs according
g to
the relationship:

da / dN = 4 10 38 K 4

for fatigue limit,

The fatigue limit of the steel is e = 414 MPa.Take a safety factor of 2, e= 207MPa
For a shaft diameter of D and cyclic bending moments:

M min ( D / 2)
D 4
I =
I
64
1
1 ( M max + M min )( D / 2)
m = ( max min ) =
=0
2
2
I
16 ( M max M min ) e
1
1 ( M max M min )( D / 2)
=

a = ( max min ) =
2
I
D 3
Sf
2

max =

M max ( D / 2)
I

207 106

and

1200 32
;
D 3

min =

hence : D 3 15.9 10 5 m,

or

K = Y ( ) a

And integration using conditions:

Nf =

2
C (Y ) m m / 2 (2 m)

N = 0, a=a0; N=Nf, a=af

(a f

(1 m / 2 )

a0

(Ans: 1.1x105 cycles)

Worked example:
An solid circular shaft of diameter 50mm is made of the Ti alloy. A zero-maximum
cyclic torque of 10kNm is applied together with a zero to maximum cyclic bending
moment of 7.5 kNm. The yield strength of the alloy is 1185 MPa. How many cycles
can be applied before fatigue failure is expected. The fatigue test of the alloy shows
the relation of:

a N 0f .104 = 1889

da
m
= C (K )
dN

Into
equation:

Estimate the number of cycles required for a crack in a steel component

to g
grow in depth
p from 2mm to 10mm when the component
p
is subjected
j
an reversed cyclic stress (mean stress zero) with a stress range of 225
MPa.

D 38.9 mm

Fracture mechanics for fatigue

Take equation:

where K = 1.12 a

(1 m / 2 )

Take a stress element at the shaft surface in time where both the
torque and the moment reach their maximum values of the, then y, z,
yz , zx are zero
x max =

Mr
Mr
4(0.0075MN .m)
= 4
=
= 611.2 MPa
r / 4
(0.025m) 3
I

xy

xy max

Tr
Tr
2(0.010 MN .m
=
=
=
= 407.4 MPa
J r 4 / 2
(0.025m) 3

The principal stresses:

Where af is the maximum crack (final crack). a0 is initial crack.

Assume: m 2, and Y is constant

1
1
[( x y ) 2 + 4 xy2 ]
2
2
1
1
= (611.2 + 0)
(611 0) 2 + 4( 407.4) 2 = 814.9, 203.7 ( MPa)
2
2

2,3 = ( x + y )

x
z

11/5/2009

Maximum, minimum cyclic

stress (MPa)

Worked example

Stress amplitude
(MPa)

mean stress
(MPa)

1= 0, 0

1a = 0

1m = 0

2 = 814.8, 0

2a = 407.4

1m = 407.4

3 = -203.6,
203 6 0

3a = 101.8
101 8

1m = -101.8
101 8

Using strain energy criterion:

(0 407.4) 2 + (407.4 101.8) 2 + (101.8 0) 2 = 2 ae2

367.2

Insert the values to

Goodman relation for n:

367.2

n
n

Finally, the expected fatigue life:

466.7
=1
1185

n = 605.8 MPa

466.7
=1
1233

n = 590.9 MPa

4x10-7

6.2x10-7

21x10-7

17x10-7

29x10-7

0.42

0.53

0.63

0.79

0.94

1.17

If the material has a critical stress intensity factor of 1.8 MN m-3/2

and it is known that the moulding process produces defects 40 m
long, estimate the maximum repeated tensile stress, which could be
applied to this material for at least 106 cycles without causing
fatigue failure.

Similarly, me = 466.7 MPa

Insert the values to

Sodeberge relation for n:

2.25x10-7
da/dN
(m/cycle)
K
(MN m-3/2 )

( 1a 2 a ) 2 + ( 2 a 3a ) 2 + ( 3a 1a ) 2 = 2 ae2

ae = 367.2 MPa

A series of crack growth tests on a moulding

grade of polymethyl methacrylate gave the
following results:

Nf = 56071 or 71293
cycles

da
m
= C (K )
dN

da
log( ) = log C + m log(K )
dN

Since:

This is a linear equation. Use the data in the table we can find C
and m.
C = 1.965 x 10-6, m = 2.47
-5.4
-0.4

-0.3

-0.2

-0.1

-5.6

Log da/d
dn

-5.8
-6
6
-6.2
-6.4
-6.6
y = 2.4721x - 5.7067
R2 = 0.9997

0.1

Nf =

af =

But:
We
have:

2
(1 m / 2 )
(1 m / 2 )
(a f
a0
)
C (Y ) m m / 2 (2 m)

Nf =

1 K1c 2
(
)

1 K
(1 m / 2 )
{[ ( 1c ) 2 ](1 m / 2 ) a 0
}
C (Y ) m m / 2 (2 m)

Use excel we can calculate the Nf at different stress.

The results show when = 1.92 MPa, Nf = 106 cycles
the maximum repeated tensile stress is 2MPa

-6.8
Log K