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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
VW crank shaft fatigue failure due to cyclic bending and torsional stresses
Fracture area
Ken Youssefi
Ken Youssefi
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
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
Ken Youssefi
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
Fracture Surface Characteristics Mode of fracture Ductile Typical surface characteristics Cup and Cone Dimples Dull Surface Inclusion at the bottom of the dimple Shiny Grain Boundary cracking Shiny Cleavage fractures Flat Beachmarks Striations (SEM) Initiation sites Propagation zone Final fracture zone
MAE dept., SJSU
Brittle Intergranular
Brittle Transgranular
Fatigue
Ken Youssefi
Alternating stress
Wa = Wmin = 0
Wmax Wmin
2
Mean stress
Wa = Wm = Wmax / 2 Wm
=
Ken Youssefi MAE dept., SJSU
Wmax + Wmin
2
10
Load
11
Finite life
Infinite life
Se
Ken Youssefi
12
100 ksi
Cast iron
Se =
24 ksi
13
0.4Sut
Se =
19 ksi
Copper alloys
Copper alloys
0.4Sut
Se =
14 ksi
14
Se = endurance limit of the specimen (infinite life > 106) Se = endurance limit of the actual component (infinite life > 106)
S
103
Se
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
103
Sf
5x108
Ken Youssefi
15
Correction Factors for Specimens Endurance Limit Se = Cload Csize Csurf Ctemp Crel (Se)
or
Cload = 1 Cload = 0.7 Cload = 1 if von Mises stress is used, use 0.577 if von Mises stress is NOT used. Cload = 1
Ken Youssefi
16
Larger parts fail at lower stresses than smaller parts. This is mainly due to the higher probability of flaws being present in larger components.
Ken Youssefi
17
dequiv = (
A95 0.0766
)1/2
Rectangular parts
dequiv = .37d
Ken Youssefi MAE dept., SJSU
18
Ken Youssefi
19
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
20
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
21
Ken Youssefi
22
Steel
Ken Youssefi
23
Ken Youssefi
24
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 Wa = 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
MAE dept., SJSU
Ken Youssefi
25
A B Se
106
S Sf N
103
B N
5x108
Point A
Sn = .9Sut
N = 10
3
Point A
Sn = .9Sut
N = 103
Point B
Ken Youssefi
Sn = Se
N = 10
6
MAE dept., SJSU
Point B
Sn = Sf
N = 5x108
26
a= b= log (
(.9Sut) Se
1 3
log
.9Sut Se
Sn = Se ( 106 )
Calculate Sn
Se ) .9Sut
Ken Youssefi
Wa
Soderberg line
Ken Youssefi MAE dept., SJSU
Sy Mean stress
Sut
Wm
28
Alternating stress
Sy Mean stress
Sut
Wm
Ken Youssefi
29
Wa
Sy Yield line
Sy
Sut
+Wm
Ken Youssefi
30
Wm 0
Fatigue,
Wm > 0 Sut
= =1 1 Infinite life
Wa
Se
Wa
Se
+ +
Wm Wm
Sut
nf
Finite life Yield
Wa = n f
Yield Se Syc Safe zone - Wm - Syc
Wa
Sn
Wa + Wm = n y
Safe zone
Wa + Wm = n y
Sy Sut +Wm
Sy
Ken Youssefi
31
If Kf Wmax < Sy then there is no yielding at the notch, use Kfm = Kf and multiply the mean stress by Kfm Kfm Wm
If Kf Wmax > Sy then there is local yielding at the notch, material at the Calculate the stress concentration factor for the mean stress using the following equation, Kfm =
Sy
Kf Wa
Wm
1 Infinite life
32
Se
Sut
nf
Ken Youssefi
Combined Loading
All four components of stress exist,
Wxa Wxm
Xxya Xxym
Combined Loading
Calculate the alternating and mean von Mises stresses,
Wa Wm
= =
Wa
Se
Wm
Sut
nf
Infinite life
Ken Youssefi
34
Design Example
A rotating shaft is carrying 10,000 lb force as shown. The shaft is made of steel with 12 d A
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,
Wa =
Mc
32M
305577
Wm = 0
r = .1
Kt = 1.7
35
Design Example
Assume d = 1.0 in
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
Design Example
Design life, N = 1150 x 75 = 86250 cycles Se log ( .9S ) N 86250 ut Sn = 39.57 ( 6 Sn = Se ( 6 )
10 10
log (
)
56.5
39.57 ) .9x120
= 56.5 ksi
Wa =
305577
= 305.577 ksi
n=
Sn KfWa
1.6x305.577
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 Csize = .869(d)-0.097 = .869(2.5)
Ken Youssefi
-0.097
= .795
Se = 36.2 ksi
37
Design Example
Se = 36.2 ksi
Sn = 36.20 (
= 19.55 ksi
86250
10
6
= 53.35 ksi
Wa =
305577
(2.5)
n=
Sn
KfWa
53.35 1.63x19.55
= 1.67 1.6
d = 2.5 in.
Check yielding
n=
Ken Youssefi
38
n=
Sn KfWa
56.5 1.6x305.577/d
3
= 1.6
d = 2.4 in.
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 Pa = (Pmax Pmin) / 2 = 4000 N Pm = (Pmax + Pmin) / 2 = 6000 N
Fillet
d D 35 = = 1.4 d 25
4 = .16 25
Kt = 1.76
Ken Youssefi
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 = 1.65 Wa = Kf A 25x5 Pm 6000 = 48 MPa = Wm = A 25x5 Fatigue design equation
Wa
Se
+
Wm
Sut
Infinite life
n = 2.7
Ken Youssefi
41
Example
n = 2.5
42
Ken Youssefi
Example
Groove
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 Wa = Kf A (35-6)5
3 = .103 29
Wm =
Pm A
6000
29x5
1
= 41.4 MPa
n = 2.57
MAE dept., SJSU
The part is likely to fail at the hole, has the lowest safety factor
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 Mm = 22.5 x 16 = 360 in - lb = 23178.6 psi = 69536 psi
Wa = Wm =
Mc
I
Mc
32Ma
d d
= =
32(120)
(.375)
32Mm
3
32(360)
(.375)
Ken Youssefi
44
Example
Csurf = A (Sut)b = 14.4(150)
2
Cload = 1 (pure bending) Ctemp= 1 (room temp) Crel= .814 (99% reliability)
-.718
= .394
dequiv = A95 / .0766 = .37d = .37 x.375 = .14 dequiv = .14 < .3 Csize = 1.0
ksi
Wm
Sut
n = .7 < 1
Finite life
Wa
Sn
Ken Youssefi
Wm
+
Sut
=1
23178.6
Sn
69536 =1 150000
Sn = 43207 psi
45
Example
Se log ( .9S ) ut
Sn = Se ( 106 )
43207 = 24077 (
N 10
6
log ( .9x150 )
24.077
N = 96,000 cycles
Ken Youssefi
46