Fatigue Failure

It has been recognized that a metal subjected

to a repetitive or fluctuating stress will fail at a
stress much lower than that required to cause
failure on a single application of load. Failures
occurring under conditions of dynamic loading
are called fatigue failures.
Fatigue failure is characterized by three stages

Ken Youssefi

Crack Initiation

Crack Propagation

Final Fracture
MAE dept., SJSU

Jack hammer component,

shows no yielding before
fracture.

Crack initiation site

Fracture zone
Propagation zone, striation
Ken Youssefi

MAE dept., SJSU

VW crank shaft fatigue failure due to cyclic bending and torsional stresses

Propagation
zone, striations

Crack initiation site

Ken Youssefi

Fracture area

MAE dept., SJSU

928 Porsche timing pulley

Ken Youssefi

MAE dept., SJSU

Crack started at the fillet

Fracture surface of a failed bolt. The

fracture surface exhibited beach marks,
which is characteristic of a fatigue failure.

1.0-in. diameter steel pins from

agricultural equipment.
Material; AISI/SAE 4140 low
allow carbon steel

Ken Youssefi

MAE dept., SJSU

bicycle crank spider arm

This long term fatigue crack in a high quality component took a

considerable time to nucleate from a machining mark between the spider
arms on this highly stressed surface. However once initiated propagation
was rapid and accelerating as shown in the increased spacing of the 'beach
marks' on the surface caused by the advancing fatigue crack.
Ken Youssefi

MAE dept., SJSU

Crank shaft

Gear tooth failure

Ken Youssefi

MAE dept., SJSU

Hawaii, Aloha Flight 243, a Boeing 737, an upper part of the plane's cabin
area rips off in mid-flight. Metal fatigue was the cause of the failure.

Ken Youssefi

MAE dept., SJSU

Fracture Surface Characteristics

Mode of fracture

Typical surface characteristics

Ductile

Cup and Cone

Dimples
Dull Surface
Inclusion at the bottom of the dimple

Brittle Intergranular

Shiny
Grain Boundary cracking

Brittle Transgranular

Shiny
Cleavage fractures
Flat

Fatigue

Beachmarks
Striations (SEM)
Initiation sites
Propagation zone
Final fracture zone

Ken Youssefi

MAE dept., SJSU

Fatigue Failure Type of Fluctuating Stresses

a = max
max = - min

Alternating stress

a =
min = 0

Mean stress

a = m = max / 2

Ken Youssefi

min

max

m =
MAE dept., SJSU

max

+
2

min
10

Fatigue Failure, S-N Curve

Test specimen geometry for R.R. Moore
rotating beam machine. The surface is
polished in the axial direction. A constant
bending load is applied.

Typical testing apparatus, pure bending

Motor

Load

Rotating beam machine applies fully reverse bending stress

Ken Youssefi

MAE dept., SJSU

11

Fatigue Failure, S-N Curve

N > 103

N < 103

Infinite life

Finite life

Se

Se = endurance limit of the specimen

Ken Youssefi

MAE dept., SJSU

12

Relationship Between Endurance Limit

and Ultimate Strength
Steel

Steel

Se =

0.5Sut

Sut 200 ksi (1400 MPa)

100 ksi

Sut > 200 ksi

700 MPa Sut > 1400 MPa

Cast iron

Cast iron

Se =

0.4Sut

Sut < 60 ksi (400 MPa)

24 ksi

Sut 60 ksi

160 MPa Sut < 400 MPa

Ken Youssefi

MAE dept., SJSU

13

Relationship Between Endurance Limit and

Ultimate Strength
Aluminum

Aluminum alloys

Se =

0.4Sut

Sut < 48 ksi (330 MPa)

19 ksi

Sut 48 ksi

130 MPa Sut 330 MPa

For N = 5x108 cycle

Copper alloys

Copper alloys

Se =

0.4Sut

Sut < 40 ksi (280 MPa)

14 ksi

Sut 40 ksi

100 MPa Sut 280 MPa

For N = 5x108 cycle
Ken Youssefi

MAE dept., SJSU

14

Correction Factors for Specimens Endurance Limit

For materials exhibiting a knee in the S-N curve at 106 cycles
S = endurance limit of the specimen (infinite life > 106)
e

Se = endurance limit of the actual component (infinite life > 106)

S

103

Se
N

106

For materials that do not exhibit a knee in the S-N curve, the infinite
life taken at 5x108 cycles

Sf = fatigue strength of the specimen (infinite life > 5x108)

Sf = fatigue strength of the actual component (infinite life > 5x108)
S

Ken Youssefi

103

Sf
5x108

MAE dept., SJSU

15

Correction Factors for Specimens Endurance Limit

or

Ken Youssefi

Se = Cload Csize Csurf Ctemp Crel (Se)

Sf = Cload Csize Csurf Ctemp Crel (Sf)

Load factor, Cload

(page 326, Nortons 3rd ed.)

Pure bending

Cload = 1

Pure axial

Cload = 0.7

Pure torsion

Cload = 1 if von Mises stress is used, use

0.577 if von Mises stress is NOT used.

Combined loading

Cload = 1

MAE dept., SJSU

16

Correction Factors for Specimens Endurance Limit

Size factor, Csize

(p. 327, Nortons 3rd ed.)

Larger parts fail at lower stresses than smaller parts. This is

mainly due to the higher probability of flaws being present in
larger components.

For rotating solid round cross section

d 0.3 in. (8 mm)

Csize = 1

0.3 in. < d 10 in.

Csize = .869(d)-0.097

8 mm < d 250 mm

Csize = 1.189(d)-0.097

If the component is larger than 10 in., use Csize = .6

Ken Youssefi

MAE dept., SJSU

17

Correction Factors for Specimens Endurance Limit

For non rotating components, use the 95% area approach to calculate
the equivalent diameter. Then use this equivalent diameter in the
previous equations to calculate the size factor.
A95 = (/4)[d2 (.95d)2] = .0766 d2
d95 = .95d

dequiv = (

0.0766

)1/2

Rectangular parts

Solid or hollow non-rotating parts

dequiv = .37d
Ken Youssefi

A95

MAE dept., SJSU

dequiv = .808 (bh)1/2

18

Correction Factors for Specimens Endurance Limit

I beams and C channels

Ken Youssefi

MAE dept., SJSU

19

Correction Factors for Specimens Endurance Limit

surface factor, Csurf

(p. 328-9, Nortons 3rd ed.)

The rotating beam test specimen has a polished surface. Most

components do not have a polished surface. Scratches and
imperfections on the surface act like a stress raisers and reduce
the fatigue life of a part. Use either the graph or the equation with
the table shown below.

Csurf = A (Sut)b

Ken Youssefi

MAE dept., SJSU

20

Correction Factors for Specimens Endurance Limit

Temperature factor, Ctemp

(p.331, Nortons 3rd ed.)

High temperatures reduce the fatigue life of a component. For

accurate results, use an environmental chamber and obtain the
endurance limit experimentally at the desired temperature.
For operating temperature below 450 oC (840 oF) the
temperature factor should be taken as one.

Ctemp = 1

Ken Youssefi

for T 450 oC (840 oF)

MAE dept., SJSU

21

Correction Factors for Specimens Endurance Limit

Reliability factor, Crel (p. 331, Nortons 3rd ed.)

The reliability correction factor accounts for the scatter and
uncertainty of material properties (endurance limit).

Ken Youssefi

MAE dept., SJSU

22

Fatigue Stress Concentration Factor, Kf

Experimental data shows that the actual stress concentration factor is not as
high as indicated by the theoretical value, Kt. The stress concentration factor
seems to be sensitive to the notch radius and the ultimate strength of the
material.
Notch sensitivity factor
Fatigue stress
Kf = 1 + (Kt 1)q
concentration factor
rd
(p. 340, Nortons 3 ed.)

Steel

Ken Youssefi

MAE dept., SJSU

23

Fatigue Stress
Concentration Factor,
Kf for Aluminum
(p. 341, Nortons 3rd ed.)

Ken Youssefi

MAE dept., SJSU

24

Design process Fully Reversed Loading for Infinite Life

Determine the maximum alternating applied stress (a ) in terms of

the size and cross sectional profile

Select material Sy, Sut

Choose a safety factor n

Determine all modifying factors and calculate the endurance

limit of the component Se

Determine the fatigue stress concentration factor, Kf

Use the design equation to calculate the size

Se
Kf a =
n

Investigate different cross sections (profiles), optimize for size or weight

You may also assume a profile and size, calculate the alternating stress
and determine the safety factor. Iterate until you obtain the desired
safety factor

Ken Youssefi

MAE dept., SJSU

25

Design for Finite Life

Sn = a (N)b equation of the fatigue line

A

Sf

Se

Point A

Point B
Ken Youssefi

106

103

5x108

103

Sn = .9Sut

Point A

N = 10

Sn = Se

Point B

N = 10

MAE dept., SJSU

B
N

Sn = .9Sut
N = 103

Sn = Sf
N = 5x108
26

Design for Finite Life

Sn = a (N)b

log Sn = log a + b log N

Apply boundary conditions for point A and B to
find the two constants a and b

a=

log .9Sut = log a + b log 103

log Se = log a + b log 106

b=

Sn = Se ( 10 )

(.9Sut)

Se
1
3

log

.9Sut
Se

e
log ( .9S )
ut

Calculate Sn

and replace Se in the design equation

K f a =

Ken Youssefi

Sn
n

Design equation

MAE dept., SJSU

27

The Effect of Mean Stress on Fatigue Life

Mean stress exist if the
loading is of a repeating or
fluctuating type.

Mean stress is not zero

Gerber curve
Alternating
stress

Se
Goodman line

Soderberg line
Ken Youssefi

Sy

Sut

Mean stress
MAE dept., SJSU

28

The Effect of Mean Stress on Fatigue Life

Modified Goodman Diagram
a
Sy

Alternating
stress

Yield line

Se
Goodman line
C

Safe zone

Sy

Sut

Mean stress

Ken Youssefi

MAE dept., SJSU

29

The Effect of Mean Stress on Fatigue Life

Modified Goodman Diagram
a
Sy

Yield line

Se
Goodman line
Safe zone
- m

Ken Youssefi

Safe zone

Sy

- Syc

MAE dept., SJSU

Sut

+ m

30

The Effect of Mean Stress on Fatigue Life

Modified Goodman Diagram
Fatigue,

m 0

Fatigue,

a
Se

Se

a = n
f

Sn

+
+

m > 0

m
Sut

Sut

=
= 1

Se

Yield

a + m = n
y
- m

Ken Youssefi

nf

Infinite life

Finite life
Yield

Syc
Safe zone

Safe zone

a + m = n
y

Sy

- Syc

MAE dept., SJSU

Sy

Sut

+ m

31

Applying Stress Concentration factor to Alternating

and Mean Components of Stress

Determine the fatigue stress concentration factor, Kf, apply directly to

the alternating stress Kf a

If Kf max < Sy then there is no yielding at the notch, use Kfm = Kf

and multiply the mean stress by Kfm Kfm m

If Kf max > Sy then there is local yielding at the notch, material at the

notch is strain-hardened. The effect of stress concentration is reduced.

Calculate the stress concentration factor for the mean stress using
the following equation,

Sy

Kfm =
Fatigue design equation
Kf a
Kfmm
+

Se

Ken Youssefi

Sut

Kf a

m
1

nf

MAE dept., SJSU

Infinite life
32

Combined Loading
All four components of stress exist,

xa

alternating component of normal stress

xm

mean component of normal stress

xya

alternating component of shear stress

xym

mean component of shear stress

Calculate the alternating and mean principal stresses,

Ken Youssefi

1a, 2a = (xa /2)

(xa /2)2 + (xya)2

1m, 2m = (xm /2)

(xm /2)2 + (xym)2

MAE dept., SJSU

33

Combined Loading
Calculate the alternating and mean von Mises stresses,

a = (1a2 + 2a2 - 1a2a)1/2

m = (1m2 + 2m2 - 1m2m)1/2

Fatigue design equation

a
Se

Ken Youssefi

m
Sut

MAE dept., SJSU

nf

Infinite life

34

Design Example
12

A rotating shaft is carrying 10,000 lb force

as shown. The shaft is made of steel with

D = 1.5d

Sut = 120 ksi and Sy = 90 ksi. The shaft

is rotating at 1150 rpm and has a
machine finish surface. Determine the
diameter, d, for 75 minutes life. Use
safety factor of 1.6 and 50% reliability.
Calculate the support forces,

10,000 lb.
6
6

R1
r (fillet radius) = .1d

R2

R1 = 2500, R2 = 7500 lb.

The critical location is at the fillet,

Calculate the alternating stress,

MA = 2500 x 12 = 30,000 lb-in

a =

Mc

32M

305577

m = 0

Determine the stress concentration factor

r = .1

d
D
= 1.5
d
Ken Youssefi

Kt = 1.7
MAE dept., SJSU

35

Design Example
Assume d = 1.0 in

Using r = .1 and Sut = 120 ksi,

q (notch sensitivity) = .85
Kf = 1 + (Kt 1)q = 1 + .85(1.7 1) = 1.6

Calculate the endurance limit

Cload = 1 (pure bending)

Crel = 1 (50% rel.)
Ctemp= 1 (room temp)
Csurf = A (Sut)b = 2.7(120)
0.3 in. < d 10 in.

-.265

= .759

Csize = .869(d)-0.097 = .869(1)-0.097 = .869

Se = Cload Csize Csurf Ctemp Crel (Se) = (.759)(.869)(.5x120) = 39.57

Ken Youssefi

MAE dept., SJSU

ksi
36

Design Example
Design life, N = 1150 x 75 = 86250 cycles
Se
(
)
log
.9Sut
N
86250
Sn = 39.57 ( 6
Sn = Se ( 6 )
10

a =

305577

d3

10

= 305.577 ksi

n=

Sn
Kfa

log (

39.57
)
.9x120
= 56.5 ksi

56.5
1.6x305.577

= .116 < 1.6

So d = 1.0 in. is too small

Assume d = 2.5 in
All factors remain the same except the size factor and notch sensitivity.

Using r = .25 and Sut = 120 ksi,

q (notch sensitivity) = .9

Kf = 1 + (Kt 1)q = 1 + .9(1.7 1) = 1.63

Csize = .869(d)-0.097 = .869(2.5)-0.097 = .795

Ken Youssefi

MAE dept., SJSU

Se = 36.2 ksi
37

Design Example
Se = 36.2 ksi

a =

305577

(2.5)

Sn = 36.20 (

86250
10

36.2

log ( .9x120 )
= 53.35 ksi

= 19.55 ksi

n=

Sn

Kfa

53.35
1.63x19.55

= 1.67 1.6

d = 2.5 in.

Check yielding

n=

Ken Youssefi

Sy
90
= 2.8 > 1.6 okay
=
Kfmax 1.63x19.55
MAE dept., SJSU

38

Design Example Observations

n=

Sn
Kfa

56.5
1.6x305.577

56.5
1.6x305.577/d

= 1.6

D = 1.5d
A

R1
r (fillet radius) = .1d

Calculate an approximate diameter

n=

So d = 1.0 in. is too small

Sn
K f a

12

= .116 < 1.6

d = 2.4 in.

R2 = 7500

So, your next guess

should be between
2.25 to 2.5

Check the location of maximum moment for possible failure

Mmax (under the load) = 7500 x 6 = 45,000 lb-in
MA (at the fillet) = 2500 x 12 = 30,000 lb-in
But, applying the fatigue stress conc. Factor of 1.63,
Kf MA = 1.63x30,000 = 48,900 > 45,000
Ken Youssefi

MAE dept., SJSU

39

Example
A section of a component is shown.
The material is steel with Sut = 620 MPa
and a fully corrected endurance limit of
Se = 180 MPa. The applied axial load
varies from 2,000 to 10,000 N. Use
modified Goodman diagram and find
the safety factor at the fillet A, groove B
and hole C. Which location is likely to
fail first? Use Kfm = 1
Pm = (Pmax + Pmin) / 2 = 6000 N
Pa = (Pmax Pmin) / 2 = 4000 N

Fillet

4
= .16
25

d
D
35
=
= 1.4
d
25

Ken Youssefi

Kt = 1.76

MAE dept., SJSU

40

Example
Using r = 4 and Sut = 620 MPa,
q (notch sensitivity) = .85
Kf = 1 + (Kt 1)q = 1 + .85(1.76 1) = 1.65
Calculate the alternating and the
mean stresses,
Pa
4000
= 52.8 MPa
K
= 1.65
a = f
A
25x5
Pm
6000
= 48 MPa
=
m =
A
25x5
Fatigue design equation

Se

Ken Youssefi

Sut

Infinite life

MAE dept., SJSU

52.8
48
=
+
180
620

n = 2.7

41

Example

Hole
d
5
=
= .143
w
35

Kt = 2.6

Using r = 2.5 and Sut = 620 MPa,

q (notch sensitivity) = .82
Kf = 1 + (Kt 1)q = 1 + .82(2.6 1) = 2.3
Calculate the alternating and the
mean stresses,
Pa
4000
= 61.33 MPa
= 2.3
a = Kf
A
(35-5)5
Pm
6000
= 40 MPa
=
m =
A
30x5
61.33
40
=
+
180
620

Ken Youssefi

n = 2.5
MAE dept., SJSU

42

Example

Groove

3
= .103
29

d
Kt = 2.33
D
35
=
= 1.2
d
29
Using r = 3 and Sut = 620 MPa,

q (notch sensitivity) = .83

Kf = 1 + (Kt 1)q = 1 + .83(2.33 1) = 2.1
Calculate the alternating and the
mean stresses,
Pa
4000
= 58.0 MPa
= 2.1
a = Kf
A
(35-6)5

m =

Pm
A

6000

29x5

58.0
41.4
=
+
180
620

= 41.4 MPa

n = 2.57

The part is likely to fail at the hole, has the lowest safety factor
Ken Youssefi

MAE dept., SJSU

43

Example
The figure shows a formed round wire cantilever
spring subjected to a varying force F. The wire is
made of steel with Sut = 150 ksi. The mounting
detail is such that the stress concentration could
be neglected. A visual inspection of the spring
indicates that the surface finish corresponds
closely to a hot-rolled finish. For a reliability of
99%, what number of load applications is likely to
cause failure.
Fa = (Fmax Fmin) / 2 = 7.5 lb.
Fm = (Fmax + Fmin) / 2 = 22.5 lb.
Ma = 7.5 x 16 = 120 in - lb

a =

Mc

m =

Mc

Ken Youssefi

I
I

32Ma

d 3
32Mm

Mm = 22.5 x 16 = 360 in - lb

32(120)

(.375)
=

= 23178.6 psi

32(360)

(.375)

= 69536 psi

MAE dept., SJSU

44

Example

Calculate the endurance limit

-.718

Cload = 1 (pure bending)

Csurf = A (Sut)b = 14.4(150)

Ctemp= 1 (room temp)

A95 = .010462 d (non-rotating round section)

= .394

Crel= .814 (99% reliability)

dequiv =

95

/ .0766

= .37d = .37 x.375 = .14

dequiv = .14 < .3 Csize = 1.0

Se = Cload Csize Csurf Ctemp Crel (Se) = (.394)(.814)(.5x150) = 24.077

a
Se

m
Sut

23178.6
69536
=
+
24077
150000

ksi

n = .7 < 1
Finite life

Find Sn, strength for finite number of cycle

a
Sn
Ken Youssefi

m
Sut

=1

23178.6

Sn

69536
=1
150000

MAE dept., SJSU

Sn = 43207 psi

45

Example

Sn = Se ( 10 )
6

Se
log ( .9S )
ut

24.077

43207 = 24077

N
106

log ( .9x150 )

N = 96,000 cycles

Ken Youssefi

MAE dept., SJSU

46