ME 307 Machine Design I

Dr. A. Aziz Bazoune

Mechanical Engineering Department

King Fahd University of Petroleum & Minerals

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

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ME 307 Machine Design I

7-1 Introduction to Fatigue in Metals 306 7-2 Approach to Fatigue Failure in Analysis and Design 312 7-3 Fatigue-Life Methods 313 7-4 The Stress-Life Method 313 7-5 The Strain-Life Method 316 7-6 The Linear-Elastic Fracture Mechanics Method 319 7-7 The Endurance Limit 323 7-8 Fatigue Strength 325 7-9 Endurance Limit Modifying Factors 328 7-10 Stress Concentration and Notch Sensitivity 335 7-11 Characterizing Fluctuating Stresses 344 7-12 Fatigue Failure Criteria for Fluctuating Stress 346 7-13 Torsional Fatigue Strength under Fluctuating Stresses 360 7-14 Combinations of Loading Modes 361 7-15 Varying, Fluctuating Stresses; Cumulative Fatigue Damage 364 7-16 Surface Fatigue Strength 370 7-17 Stochastic Analysis 373
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-07 LEC-21 Slide - 2

ME 307 Machine Design I

7-7 7-8 7-9

The Endurance Limit Fatigue Strength Endurance Limit Modifying Factors

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

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ME 307 Machine Design I

7-7 The Endurance Limit

A quick method of estimating endurance limits is needed: for preliminary and prototype design for some failure analysis

Experimental results for rotating-beam tests simple tension tests of specimens taken from the same bar are shown in Figure 7.18.
Figure 7-18 Graph of endurance limits versus tensile strengths from actual test results for a large number of wrought irons and steels.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

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Figure 7-18 Graph of endurance limits versus tensile strengths from actual test results for a large number of wrought irons and steels. Ratios of Se/Sut of 0.60, 0.50, and 0.40 are shown by the solid and dashed lines. Note also the horizontal dashed line for of Se=107 kpsi. Points shown having a tensile strength greater than 214 kpsi have a mean endurance limit of Se=107 kpsi and a standard deviation of 13.5 kpsi.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

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ME 307 Machine Design I

For steels, the relationship between the tensile strength and the endurance limit is given by

(7-8)

where

S 'e : is the minimum tensile strength. The prime mark on S 'e in this
equation refers to the rotating-beam specimen itself. The unprimed symbol S e is for the endurance limit of any particular machine element subjected to any kind of loading.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

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ME 307 Machine Design I

The endurance limits for various classes of cast irons, polished or machined, are given in Table A-24. Aluminum alloys do not have an endurance limit. The fatigue strengths of some aluminum alloys at 5(108 ) cycles of reversed stress are given in Table A-24.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

LEC-21

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ME 307 Machine Design I

7-7 Fatigue Strength

Region of low cycle fatigue:
The fatigue strength strength .

S f is only slightly smaller than the tensile Sut

Region of high Cycle Fatigue

The purpose of this section is to develop methods of approximation of the S-N diagram in the high-cycle region, when information may be as sparse as the results of a simple tension test. Experience has shown high-cycle fatigue data are rectified by a logarithmic transform to both stress and cycles-to-failure.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

LEC-21

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ME 307 Machine Design I

7-8 Fatigue Strength

In the region of high cycle fatigue, the equation relating the fatigue strength

S f to the number of cycles to failure N may be given by the

(7-12)

empirical curve fit equation:

where

N is the number of cycles to failure and a and b are given by

(7-13)

(7-14)

where

f is found from Figure 7-19.

Chapter 7: Fatigue Failure Resulting from variable Loading CH-07 LEC-21 Slide - 9

Dr. A. Aziz Bazoune

ME 307 Machine Design I

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

LEC-21

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ME 307 Machine Design I

If a completely reversed stress

is given, setting

S f a in Eq. (7-12),

the number of cycles-to-failure can be expressed as

(7-15)

Low-cycle fatigue is often defined (see Fig. 7-10) as failure that occurs in a
range of

1 N 103 cycles.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

LEC-21

Slide - 11

ME 307 Machine Design I

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

LEC-21

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ME 307 Machine Design I

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

LEC-21

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ME 307 Machine Design I

Example
Given a 1050 HR steel, estimate a) The rotating-beam endurance limit at 106. b) The endurance strength of a polished rotating beam specimen corresponding to 104 cycles to failure. c) The expected life of a polished rotating-beam specimen under a completely reversed stress of 55 kpsi.

SOLUTION:
a) From Table A-20, From Eq. (7-8) b)

Sut 90 kpsi Sut 90 kpsi, f 0.86

S 'e 0.5 90 45 kpsi

From Fig. (7-19) for

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

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ME 307 Machine Design I

Example (Cont.d)
From Eq. (7-13)

and (7-14) ==

Thus Eq. (7-12) is: for

N 104

cycles to failure, the above equation becomes

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

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ME 307 Machine Design I

Example (Cont.d)
c) From Eq. (7-15), with

a 55 kpsi

Keep in mind that these are only estimates.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

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ME 307 Machine Design I

7-9

Endurance Limit Modifying Factors

The rotating-beam specimen used in the laboratory to determine endurance limits is prepared very carefully and tested under closely controlled conditions. It is unrealistic to expect the endurance limit of a mechanical or structural member to match the values obtained in the laboratory. Some differences include Material: composition, basis of failure, variability Manufacturing: method, heat treatment, fretting corrosion, surface condition, stress concentration Environment: corrosion, temperature, stress state, relaxation times Design: size, shape, life, stress state, stress concentration, speed, fretting, galling

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

LEC-21

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ME 307 Machine Design I

Marins Equation
Marin identified factors that quantified the effects of surface condition, size, loading, temperature, and miscellaneous items. Marins Equations is therefore written as:

(7-17)

Se :
S 'e :

Endurance limit at the critical location of a machine part in geometry and condition of use rotary-beam test specimen endurance limit

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

LEC-21

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ME 307 Machine Design I

When endurance tests of parts are not available, estimations are made by applying Marin factors to the endurance limit.
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-07 LEC-21 Slide - 19

ME 307 Machine Design I

(7-18)

where

Sut

is the minimum tensile strength and

and

are to be found in

Table 7-4.

Table 7-4
Parameters for Marin surface modification factor, Eq. (7-18)

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

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ME 307 Machine Design I

The size factor

kb

for bending and torsion may be given by:

(7-19)

For axial loading there is no size effect, so

(7-20)

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

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ME 307 Machine Design I

QUESTION:
What to do with Eq.(7-19) if a round bar in bending is not rotating or when a

non-circular cross-section is used?

ANSWER:
Use effective dimension

d e where
(7-23)

as the effective size of a round corresponding to a non-rotating solid or hollow round. Table 7-5 provides areas of common structural shapes undergoing non-rotating bending
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-07 LEC-21 Slide - 22

ME 307 Machine Design I

Table 7-5
Areas of common nonrotating structural shapes

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

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ME 307 Machine Design I

Average values for the load factor are given by

(7-25)

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from variable Loading

CH-07

LEC-21

Slide - 24