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On the Bridge!
Cyclic Stresses
Mean stress:
Compression Tension
Stress
m =
1 cycle
mmax
ma m
0
mmin
max + min
2
Stress range:
r
mm
Time
r = max min
Stress amplitude:
a =
r
max min
=
2
2
Stress ratio:
R=
min
max
Conditiona
1015
Normalized
4340
Tempered
1045
Q&T 306$ F
1045
Q&T 500$ F
1045
Q&T 600$ F
4142
Q&T 400$ F
4142
Q&T 600$ F
4142
Q&T 700$ F
4142
Q&T 840$ F
Aluminum
1100
Annealed
2014
T6
2024
T351
5456
H311
7075
T6
Titanium
Ti-6Al-4V Solution treated+aged
Nickel
Inconel X
Annealed
a Q&T - Quenched and tempered.
Yield
strength
Sy ,
MPa
Fracture
strength
f,
MPa
Fatigue
ductility
coefFLHQW,
f
Fatigue
strength
exponent,
a
Fatigue
ductility
exponent,
_
228
1172
1720
1275
965
1720
1340
1070
900
827
1655
2720
2275
1790
2650
2170
2000
1550
0.95
0.73
0.07
0.25
0.35
0.07
0.09
0.40
0.45
-0.110
-0.076
-0.055
-0.080
-0.070
-0.076
-0.081
-0.080
-0.080
-0.64
-0.62
-0.60
-0.68
-0.69
-0.76
-0.66
-0.73
-0.75
97
462
379
234
469
193
848
1103
724
1317
1.80
0.42
0.22
0.46
0.19
-0.106
-0.106
-0.124
-0.110
-0.126
-0.69
-0.65
-0.59
-0.67
-0.52
1185
2030
0.841
-0.104
-0.69
700
2255
1.16
-0.117
-0.75
Table 7.1: Cyclic properties of some metals. Source: After Shigley and Mitchell
[1983] and Suresh [1998].
7
__
3 16
0.30
9 78 R
6m1
6m2
dlc
dN
Number of cylces, N
(a)
10-2
Kc
Regime A
10
Regime B
1 mm/min
-4
dlc
= C(6K)m
dN
m
1
10-6
one lattice
spacing
per cycle
10
1 mm/hr
1 mm/day
Regime C
1 mm/week
Crack length, lc
-8
log 6K
(b)
Figure 7.4: Illustration of fatigue crack growth. (a) Size of a fatigue crack for two
dierent stress ratios as a function of the number of cycles; (b) rate of crack growth,
illustrating three regimes.
=
(2N ) + f (2N )
2
E
Regimes of Crack Growth:
1. Regime A is a period of very slow crack growth. Note that the crack
growth rate can be even smaller than an atomic spacing of the
material per cycle.
2. Regime B is a period of moderate crack growth rate, often referred to
as the Paris regime
3. Regime C is a period of high-growth rate, where the maximum stress
intensity factor for the fatigue cycle approaches the fracture
toughness of the material.
Fatigue Striations
Smooth
(burnished)
surface
Microscopic
striations
Striations
(visible)
Rough
(fracture)
surface
Fatigue
Fracture
Surfaces
Reversed
bending
Unidirectional
bending
Tension-tension
or tension-compression
No stress
Mild stress Severe stress
concentration concentration concentration
Rotational
bending
Fracture surface
0.9
0.8
O
O
O
O
O
O
O
O
O
O
0.7
O
O
O
O
O
O
O
O
0.6
O
O
O O
O
O
O
OO O
O
O
O O O
O O
OO
O
O
O OO
O O
O
O
O
O
O
OO
OO O O O O O
OO
O
O
O O
O
O O OO
O
O
O
O O
0.5
For steels:
Not broken
O
O O
O
O OO
OO
O
0.4
103
104
105
106
bending :
axial :
torsion :
Se = 0.5Su
Se = 0.45Su
Se = 0.29Su
107
Aluminum Alloys
60
40
Wr
ou
Pe
gh
t
rm
an
en
tm
old
c
30
20
16
12
10
8
7
6
5
103
Sa
nd
c
104
105
ast
ast
106
107
108
109
8x103
50
Phenolic
Epoxy
40
Alkyd
Diallylphthalate
30
20
Nylon (dry)
10
PTFE
0
103
60
Polycarbonate
104
105
106
107
160
Carbon steels
Alloy steels
V Wrought irons
120
0.5
6
0.
'
e
_
S__ =
Su
0.4
80
100 ksi
40
VV
VV
V
VV
0
0
60
120
180
Tensile strength, Sut, ksi
240
300
Figure 7.8: Endurance limit as function of ultimate strength for wrought steels.
Source: Adapted from Shigley and Mitchell [1983].
Staircase Approach
Applied stress, MPa
475
Failure
Survival
450
425
400
375
350
0
10
15
20
25
Test number
ini
c. Obtain the quantity An from
An =
A
1
n
ni
2
Number
of
cycles
10 8
10 8
10 8
10 7
5 10 8
Relation
S e = 0 .35S u
0.25S u < S e < 0.5S u
0.35S u < S e < 0.5S u
0.45S u < S e < 0.65S u
S e = 0 .40S u (S u < 48 ksi)
S e = 19 ksi (S u 48 ksi)
Table 7.2: Approximate endurance limit for various materials. Source: Adapted
from Juvinall and Marshek [1991].
Sl = 0.9Su
Sl = 0.75Su
Sl = 0.72Su
log Sf = bs log Nt + C
where
1
Sl
bs = log
3
Se
2
Sl
(Sl )
C = 2 log
+
log
S
=
log
.
e
Se
Se
Notch Sensitivity
Use these values with bending and axial loads
Use these values with torsion
20
1.0
Notch sensitivity, qn
0.8
7 9)
(13
0
14
(9
65 )
9)
(68
0
2)
10
(55
80 414)
(
60 45)
(3
0
5
0.6
180 (1241)
)
120 (827
5 2)
80 (5
4)
60 (41
Fatigue stress
concentration
factor:
Steel,
Su, ksi (MPa)
as marked
Kf = 1 + (Kc 1) qn
0.2
0
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0.10
0.12
0.14
0.16
Notch radius, r, mm
0
0.02
0.04
0.06
0.08
Notch radius, r, in.
Figure 7.10: Notch sensitivity as function of notch radius for several materials
and types of loading. Source: Adapted from Sines and Waisman [1959].
Manufacturing
process
Grinding
Machining or
cold drawing
Hot rolling
As forged
Factor e
MPa
ksi
1.58
1.34
4.51
2.70
57.7
272.0
14.4
39.9
Exponent f
-0.085
-0.265
-0.718
-0.995
Machi
ned, c
o
Ta
p
0.4
wa
ter
co
rro
de
d
Hot
rol
ed, c
o ld r
olled
led
Hot f
orged
Salt w
ater cor
roded
0.2
ld for
g
0.8
0.6
1.0
Fine polishing
60
100
140
180
220
16
32
0.8
63
125
250
0.7
500
1000
2000
0.6
0.5
260
0.9
0.4
40
Surface finish
Ra, +in.
80
120
160
200
240
Figure 7.11: Surface nish factors for steel. (a) As function of ultimate strength
in tension for dierent manufacturing processes; Source: (a) Adapted from
Norton [2011] and data from the American Iron and Steel Institute.
(b) As function of ultimate strength and surface roughness as measured with a
stylus prolometer. Source: (b) adapted from Johnson [1967].
Reliability
factor,
kr
1.00
0.90
0.87
0.82
0.75
0.70
Size Factor:
0.869d0.112
1
ks =
1.248d0.112
d depends on manufacturing
process, but one approach allows
estimation from the equivalent area
where the stress is above 95% of the
maximum stress:
A95
d=
0.0766
Temperature Factor:
kt =
Sut
Sut,ref
300
200
150
Peened - smooth
or notched
100
690
Not peened - smooth
345
50
Not peened - notched
(typical machined surface)
690
1380
2170
Ultimate tensile strength, Sut, (MPa)
(a)
483
70
414
Al 7050-T7651
Ti-6Al-4V
60
Shot peened
345
50
276
40
207
Machined
30
Polished
20
138
104
ksi
1035
100
1380
ksi
ksi
105
106
107
Number of cycles to failure, N'
108
(b)
Figure 7.12: The use of shot peening to improve fatigue properties. (a) Fatigue strength
at 2 x 106 cycles for high-strength steel as a function of ultimate strength; (b) typical S-N
curves for non-ferrous metals. Source: Courtesy of J.~Champaigne, Electronics, Inc.
r=2
41
M
45
45
50
Haigh Diagram
ma
Sut
mm
Sut
8
0.
0.6
4
0.
0.2
0.0
-1.0
- 0.
0.
0.4
0.
R=
mmax/Sut
0.8
-0.6
-0.4
-0.2
6
0.
4
0.
2
0.
-0.8
8
0.
.0
1.
0
4 ycles
10 c
les
5 c yc
0
1
l es
6 cy c
10
-1
0.5
R=
R = 0.0
1.0
0.0
0.2
0.4
0.6
0.8
1.0
mmin/Sut
Figure 7.15: A typical Haigh diagram showing constant life curves for dierent
combinations of mean and alternating stresses.
Gerber:
Alternating stress, ma
Yield line
Kf ns a
+
Se
Se
Gerber line
Goodman
line
Soderberg line
0
Syt
Sut
Mean stress, mm
ns m
Sut
=1
Goodman:
Kf a
m
1
+
=
Se
Sut
ns
Soderberg:
Kf a
m
1
+
=
Se
Syt
ns
Equation
max =
Se
+ m
Kf
1<
Se
Su K f
0)
Sy
BC
max = S y
1<
Sy
CD
min = 2 m < S y
1<
Se
K f Su
DE
min =
EF
min = m <
FG
min = < S y
GH
max = 2 m + S y
HA
max = m +
1+
Se
Kf
Se
Kf
m <
Se
Kf
0)
Range
S y < S e /K f
m )
Se
1<
K f Su
Se
<
Kf
) m ) S y
Se
K f Su
Se
<
Kf
) m ) S y
Se
K f Su
Se
Sy <
Kf
m )
Se
1<
K f Su
Se
< S y ) m )
Kf
Se
< S y ) m )
Kf
Se
< S y ) m )
Kf
Se
< S y ) m )
Kf
0
< Sy
< Sy
0
Su
+S
B
Sy
C
Sy Smax
N
Se /Kf
Smax
Sm
D
45
Smin
H
0
Sm
Sy
Su
Sm
Smin
E
Se /Kf
S
G
a
45
Sy
b
Failure
equation
max < 2 m = S y /n
max < m =
max + m
max =
Validity limits
of equation
< S y ) m )
Se
ns K f
Se
K f Su
< 1 =
Sy
ns
Se
ns K f
Se
< Sy
Kf
Se
< S y ) m ) 0
Kf
Se
Sy <
Kf
0 ) m )
Se
1<
K f Su
Se
Sy <
Kf
) m ) S y
Se
1<
K f Su
Table 7.6: Failure equations and validity limits of equations for four regions of
complete modied Goodman relationship
Alternating stress
ratio, ma/Su
Se
(0.4)(0.9) = 0.36
Su
3.0
2.0
1.0
1.0
Figure 7.18: Alternating stress ratio as function of mean stress ratio for axially
loaded cast iron.
PVC
10-2
Epoxy
PET
10-3
10-4
10-5
Nylon 66
PC
Nylon
ST 801
300M Steel
10-6
0.2 0.4
0.8 1.0
2024-T3 Al
Al 2219-T851
PMMA PSF
10-1
8 10
20
40
80
6K (MPa m)
(a)
7075-T6 Al
10
Mo
-5
10-6
Mg
A36 steel
10-7
Ti-6Al-4V
10-8
10
4340 steel
20
50
100
6K (MPa m)
(b)
Figure 7.19: Fatigue crack growth data for a variety of materials. (a) Selected
polymers in comparison to aluminum and steel; (b) selected metal alloys. {\it
Source:} From Bowman [2004].
mm/cycle
( MPa m)m
in/cycle
m
ksi in
6.89 10 9
1.36 10 7
5.61 10 9
3.6 10 10
6.6 10 9
3.0 10 10
3.0
2.25
3.25
5.88 10 8
1.6 10 11
3.1 10 9
8.4 10 11
3.17
3.59
Paris law:
dlc
m
= C (K)
dN
100
80
80
/S u
th S u
Ratio S y
eng
r
t
s
e
Ultimat
60
Total elongation
40
20
0
106
60
Sy
Yield strength
10
10
40
20
10
Sy/Su, percent
100
Elongation, percent
s1
Example 7.11
y
V
40 mm
0.6 m
M
P
x
1.5 m
(a)
450 mm
(b)
(c)
Figure 7.21: Diver impacting diving board, used in Example 7.11. (a) Side view;
(b) front view; (c) side view showing forces and coordinates.
D-Check
(a)
(b)
Figure 7.22: (a) Exterior view of Boeing 747-400 during a D check; (b)
inspection of landing gear component for structural integrity. Source: Courtesy
of Lufthansa Technik.