Multiaxial Fatigue Damage

Multiaxial Fatigue
Professor Darrell Socie
© 2008-2014 Darrell Socie, All Rights Reserved

Outline
Stresses around holes

Crack Nucleation
Crack Growth
Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 1 of 85

Multiaxial Fatigue Problems
Uniaxial loading that produces multi

stressesund stress concentrators
Multiaxial loading that produces uniaxial
stresses around stress concentrators
Multiaxial loading that produces multiaxial
Multiaxial loading that causes mixed mode
long crack growth

3D stresses
Longitudinal Tensile Strain
0 0.004 0.008 0.012
Transverse Compression Strain
Thickness x
0.001 50 mm
y
0.002 30 mm z
100
0.003 15 mm
0.004
0.005 7 mm

Notch Stresses
t x z x z
x
7 0.01 -0.005 63.5 0
y
15 0.01 -0.003 70.6 14.1
z
30 0.01 -0.002 73.0 21.8
50 0.01 -0.001 75.1 29.3

Uniaxial loading that produces multi

stressesund stress concentrators
long crack growth

Hole in a Plate
a r
r r
r
r

Stresses at the Hole
4
3
=1
2
1 =0
0
30 60 90 120 150 180
-1
Angle
-2
= -1
-3
-4
Stress concentration factor depends on type of loading

Combined Loading

Maximum Tensile Stress Location
32 45
Kt = 3 Kt = 3.41 Kt = 4
1 = 1 = 1.72 1 =

In and Out of Phase Loading
In-phase Out-of-phase
Kt = 3 Kt = 4
Damage location changes with load phasing

Uniaxial loading that produces multiaxial

long crack growth

Notched Shaft Loading
MT
MX
MY

Torsion Loading
MX
T 1
t1 t3
MT z z
T
MX
T T
t2 t4
MT
z
T 1 T
t1 t2 t3 t4
Out-of-phase shear loading is needed to produce

nonproportional stressing
Uniaxial loading that produces multiaxial

long crack growth

Shear Stresses Around Hole =0
1.5
=0
1.0
r
xy
0.5
0
1 2 3 4 5
r
a

Torsion Experiments

Shear Stresses Around Hole r = 1.33
r
1.33
1.4 a
=0
1.0
r
xy
0.6
0.2
0 20 40 60 80 100 120 140 160 180

Angle

Stress Intensity Factors
1.50
1.25
1.00
F 0.75
R
0.50
a
0.25
0.00
1.00 1.50 2.00 2.50 3.00
a
R
da m
C K eq KI F a
dN
Cracks from Holes
Crack nucleates Mixed mode Tensile mode

in shear growth? growth?

Summary
Cracks nucleate in a uniaxial stress field and

then grow in a mixed tensile/shear stress field

Outline

Crack Nucleation
Stress Based Models
Strain Based Models
Crack Growth

Fatigue Mechanisms Summary
Fatigue cracks nucleate in shear

Fatigue cracks grow in either shear or tension
depending on material and state of stress

Stress Based Models
Sines
Findley
Dang Van

Bending Torsion Correlation
1.0 Shear stress

1/2 Bending fatigue limit
Shear stress in bending
Octahedral stress
Principal stress
0.5
0
0 0.5 1.0 1.5 2.0
Shear stress in torsion

Test Results
Cyclic tension with static tension

Cyclic torsion with static torsion
Cyclic tension with static torsion
Cyclic torsion with static tension

Cyclic Tension with Static Tension
1.5
Fatigue strength
Axial stress
1.0
0.5
-1.5 -1.0 -0.5 0 0.5 1.0 1.5

Mean stress
Yield strength

Cyclic Torsion with Static Torsion
1.5
Shear Stress Amplitude
Shear Fatigue Strength
1.0
0.5
0
0.5 1.0 1.5
Maximum Shear Stress
Shear Yield Strength
Cyclic Tension with Static Torsion
1.5
Bending Fatigue Strength
Bending Stress
1.0
0.5
0 1.0 2.0 3.0

Static Torsion Stress
Torsion Yield Strength
Cyclic Torsion with Static Tension
1.5
Shear fatigue strength
Torsion shear stress
1.0
0.5
-1.5 -1.0 -0.5 0 0.5 1.0 1.5

Axial mean stress
Yield strength

Conclusions
Tension mean stress affects both tension

and torsion
Torsion mean stress does not affect tension
or torsion

Sines
oct
(3 h )
2
1
( x y )2 ( x z )2 ( y z )2 6( 2
xy
2
xz
2
yz )
6
mean mean mean
( x y z )

Findley
k n f
2 max
tension torsion
Bending Torsion Correlation
1.0 Shear stress

Shear stress in bending
Octahedral stress
Principal stress
0.5
0
0 0.5 1.0 1.5 2.0
Shear stress in torsion

Dang Van
(t) a h (t ) b
ij(M,t) Eij(M,t)
ij(m,t)
ij(m,t)
m
V(M)

Isotropic Hardening
Failure occurs when

the stress range is
stabilized stress range

not elastic

Multiaxial Kinematic and Isotropic
a) b)
3 3
Yield domain
expands and
translates
Co
Oo Oo
2 2
Ro
1 1
c) d)
CL
3 3
Loading
path
RL
OL
Oo Oo
1 2 1 2
* stabilized residual stress

Dang Van ( continued )
t a h t =b
Failure
predicted
h h
Loading path

Stress Based Models Summary
Sines: oct
(3 h )
2
Findley: k n f
2 max
Dang Van: (t) a h (t ) b

Model Comparison R = -1
10
Relative Fatigue Life
Goodman
1
0.1 Findley
0.01 Sines
0.001
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
Torsion Tension Biaxial Tension
Stress ratio,
Outline

Crack Nucleation
Stress Based Models
Strain Based Models
Crack Growth

Strain Based Models
Brown and Miller

Fatemi and Socie
Smith Watson and Topper

Brown and Miller
2 x103
Fatigue Life, Cycles = 0.03
103
5 x102
2 x102
102
0.0 0.005 0.01

Normal Strain Amplitude, n

Case A and B
Growth along the surface Growth into the surface

Brown and Miller ( continued )
ax i al
Uni
Equ
ibia
x ial

Brown and Miller ( continued )
max S n
'
max f 2 n , mean
S n A ( 2N f ) b B '
f ( 2N f ) c
2 E

Mohr’s Circle
max
1
n
ˆ max S n
x
Brown and Miller -

Cracks should be equally likely
on two planes 90° apart
max
n

Loading Histories
/ 3
C F G
H I J

Crack Directions

Hypothesis
Fatigue damage is planar in nature

The material finds a critical plane for
microcrack growth.
100
% of applied stress
90
80
-20 -10 0 10 20
Stresses are nearly the same over a 10° range of angles

Stresses on the Planes
Shear
Tension

Fatemi and Socie

Fatigue Lives
3 3 3
12,899 9,500 14,117

12,121 5,963 16,062
C F G
3 3 3
7,676 7,419 5,149

8,020 9,139 3,488
H I J

Crack Length Observations
2.5
F-495 H-491
J-603 I-471 C-399

2
Crack Length, mm
G-304
1.5
0.5
0
0 2000 4000 6000 8000 10000 12000 14000
Cycles
Fatemi and Socie
'
n,max
1 k f
(2Nf )bo '
f (2Nf )co
2 y G

Torsion Tests
1= xy

304 Stainless Steel
1
1

Smith Watson Topper

SWT
'2
n
1 f
(2Nf )2b ' '
f f (2Nf )b c
2 E

Loading Histories
0 1 2 3 4
5 6 7 8 9
10
11 12 13

Stress-Strain Response
300 300 300
Case 1 Case 2 Case 3
150 150 150
0 0 0
Shear Stress ( MPa )
-150 -150 -150
-300 -300 -300

-600 -300 0 300 600 -600 -300 0 300 600 -600 -300 0 300 600
300 300 300
Case 4 Case 5 Case 6
150 150 150
0 0 0
-150 -150 -150
-300 -300 -300

-600 -300 0 300 600 -600 -300 0 300 600 -600 -300 0 300 600

Maximum Stress
All tests have the same strain ranges
2000
Equivalent Stress, MPa
1000
200 2
10 103 104
Fatigue Life, Nf
Nonproportional hardening results in lower fatigue lives
Summary
Cracks nucleate in shear and then grow in

either shear or tension depending on the
material and state of stress

Separate Tensile and Shear Models
Cyclic shear strains Cyclic tensile strains
Normal stresses open and close microcracks

Shear Growth
shear stress
slip bands
10 m
crack growth direction
( From Murakami )

Tensile Growth
crack growth direction

5 m

Cyclic Torsion
Cyclic Shear Strain Cyclic Tensile Strain
Cyclic Torsion
Shear Damage Tensile Damage

Cyclic Torsion with Static Tension
Cyclic Torsion Shear Damage Tensile Damage

Static Tension

Cyclic Torsion with Compression

Static Compression

Cyclic Torsion with Tension
and Compression

Static Compression
Hoop Tension

Test Results
Load Case /2 hoop MPa MPa

axial Nf
Torsion 0.0054 0 0 45,200
with tension 0.0054 0 450 10,300
with compression 0.0054 0 -500 50,000
with tension and 0.0054 450 -500 11,200
compression

Conclusions
All critical plane models correctly predict
these results
Hydrostatic stress models can not predict
these results

Loading History
0.003
Shear strain
Axial strain 0.006
-0.003

Model Comparison
Summary of calculated fatigue lives
Model Equation Life

Epsilon 6.5 14,060
Garud 6.7 5,210
Ellyin 6.17 4,450
Brown-Miller 6.22 3,980
SWT 6.24 9,930
Liu I 6.41 4,280
Liu II 6.42 5,420
Chu 6.37 3,040
Gamma 26,775
Fatemi-Socie 6.23 10,350
Glinka 6.39 33,220

Outline

Crack Nucleation
Crack Growth

Mode I and Mode II Surface Cracks
Mode II
Mode I

Biaxial Mode I Growth
10-3 = 193 MPa 10-3 = 386 MPa
= -1 = -1
=0 =0
=1 =1
da/dN mm/cycle
da/dN mm/cycle
10-4 10-4
10-5 10-5
10-6 10-6
10 20 50 100 200 10 20 50 100 200
K, MPa m K, MPa m

Mode I and Mode III Growth
10-3
da/dN, mm/cycle
10-4 KI
10-5 KIII
10-6
5 10 20 50 100
KI , KIII MPa m
Mode I and Mode II Growth
7075 T6 Aluminum
10-2 Mode I R = 0
Mode II R = -1
10-3
da/dN, mm/cycle
10-4
10-5
10-6
SNCM Steel
10-7 Mode I R = -1
Mode II R = -1
1 10 100
KI , KII MPa m
Fracture Surfaces
Bending Torsion
Mode III Growth
K = 14.9
10-4 K = 12.0
Crack growth rate, mm/cycle

K = 11.0
K = 10.0
10-5 K = 8.2
10-6
10-7
10-8
10-9
0.2 0.4 0.6 0.8 1.0
Crack length, mm

Fracture Mechanics Models
da m
C K eq
dN
4 4 4 0.25
K eq K 8 K
I II 8 K III (1 )
2 2 2 0. 5
K eq K I K II (1 ) K III
2 2 0.5
K eq K I K I K II K II
0.5
E
K eq ( ) (FII )2 (FIE )2 a
2(1 )
n,max
K eq FG 1 k a
ys

Growth of Inclined Cracks
25 1010 Steel
20 tensile growth
15 K
KII 10
K
5 shear
no growth growth
0 5 10 15 20 25
KI
Cracks grow in either tension or shear

From: Otsuka et.al. Engineering Fracture Mechanics, Vol 7, 1975
Otsuka
Tensile growth:
2 3
K cos K I cos K II sin
2 2 2
Shear growth:
1
K cos K I sin K II 3 cos 1
2 2 2

Strain Energy Density
Strain energy density at the crack tip:
S a11K I2 2a12K IK II a22KII2 a33KIII2
Necessary and sufficient conditions for crack growth:
S
0 at o
2
S
2
0 at o
Cyclic strain energy density:
S 2 [a 11 ( o ) K Imean K I a 12 ( o ) ( K II
mean
KI K Imean K II )
mean mean
a 22 ( o ) K II K II a 33 ( o ) K III K III ]
Sih, G.C and Barthelemy, B.M. “Mixed Mode Fatigue Crack Growth Predictions” Engineering Fracture Mechanics, Vol. 13, 1980
Summary
Many models but no experimental verification

for out-of-phase spectrum loads

Multiaxial Fatigue

Multiaxial Fatigue Damage

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Multiaxial Fatigue Damage

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Multiaxial Fatigue

Professor Darrell Socie

© 2008-2014 Darrell Socie, All Rights Reserved

Stresses around holes

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 1 of 85

Uniaxial loading that produces multi

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 2 of 85

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 3 of 85

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 4 of 85

Uniaxial loading that produces multi

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Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 6 of 85

Stress concentration factor depends on type of loading

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 8 of 85

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 9 of 85

Damage location changes with load phasing

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 10 of 85

Uniaxial loading that produces multiaxial

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 11 of 85

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 12 of 85

Out-of-phase shear loading is needed to produce

Uniaxial loading that produces multiaxial

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Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 15 of 85

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0 20 40 60 80 100 120 140 160 180

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Crack nucleates Mixed mode Tensile mode

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Cracks nucleate in a uniaxial stress field and

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Stresses around holes

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Fatigue cracks nucleate in shear

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1.0 Shear stress

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Cyclic tension with static tension

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-1.5 -1.0 -0.5 0 0.5 1.0 1.5

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0 1.0 2.0 3.0

-1.5 -1.0 -0.5 0 0.5 1.0 1.5

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Tension mean stress affects both tension

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1.0 Shear stress

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Failure occurs when

stabilized stress range

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 35 of 85

* stabilized residual stress

Multiaxial Fatigue © 2008-2014 Darrell Socie, All Rights Reserved 37 of 85

Dang Van: (t) a h (t ) b

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Stresses around holes

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Brown and Miller

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0.0 0.005 0.01

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