Professional Documents
Culture Documents
Gola
Costruzione di macchine - Machine Design
Fatigue - Chapter 4
a
ol
Chapters
.g
1 History and problem overview
2 Stress-life: material properties
m
3 Stress-life: component - infinite life
4 Stress-life: finite life io
5 Strain-life
6 Crack propagation and fracture
uz
m
Pierluigi Lenoci
These slides are a support to the Machine Design, and related, classes held by prof. M.M. Gola at POLITO, Technical University of Torino – For educational purposes and classroom use only
Chapter 2 - Stress-life: finite life
m.gola
2011
2014
Finite life
1. Linear Damage or Miner's Rule
a
2. Cycle counting
ol
3. Finite life and stress spectra
4. Finite life and the exceedance diagram
.g
5. Appendix: the Haibach extension
m
io
uz
m
a
produce a failure, i.e. life is finite.
ol
Section 1 defines the Miner’s rule for cumulative damage at multiple
.g
stress levels applied during the component life. A numerical example
is worked out for better clarity.
m
First the concept of “equivalent stress amplitude” is introduced.
Then it is shown how the simplified interpolation formulas
io
introduced in Ch. 2 Sect. 8 can extend the power of this concept.
uz
Section 2 shows one “cycle counting” method (the bath-tub version
of the rain-flow), and its practical application when a stress
m
a
The linear damage rule is based on the concept of cumulative
ol
damage.
.g
* A. Palmgren, “Die Dauerhaftigkeit der Kugellager,” Z. Ver. Deutsch. Ing.,
68 (1924)
** M. A. Miner, “Cumulative damage in fatigue,” J. Appl. Mech., 12 (1945)
m
Read also: io
M. A. Miner, “Estimation of fatigue life with Particular Emphasis on
uz
Cumulative Damage , ch. 12 in ” Metal Fatigue”, G. Sines and J.L.
Waisman editors, Mc Graw Hill, USA, (1959)
m
a
the sum of the wi ’s reaches the limit W: ∑ wi = W
ol
i
i : index of each set of applied load cycles at constant stress
.g
level σi
wi : damage fraction accumulated during the load cycles of
m
interval i at constant stress level σi
W : total damage constant
io
uz
The linear damage rule states that the damage fraction at a given
constant stress level σi is equal to a mathematical fraction:
m
a
i i
ol
When there is only one level σi , i=1, final failure occurs for ni = Ni
(of course...what else?): then, according to Miner, the damage
.g
constant W is assumed to be equal to 1.
m
The results of Miner's original tests showed that the damage
constant W corresponding to failure ranged from 0.61 to 1.45,
io
other researchers have shown variations as large as 0.18 to 23.0,
uz
with most results tending to fall between 0.5 and 2.0,
it seems to be true that the average value is close to Miner's
m
By far the largest effort in this respect, however, was spent by Kotte
and Eulitz of the Technical University of Dresden … who collected
hundreds of test programmes, i.e. many thousands of variable-
amplitude and corresponding constant-amplitude tests and carried
a
out new Miner calculations.
ol
One outstanding result of all these checks was that Miner's rule
.g
generally proved wildly unconservative; that is, the specimens -- in
the case of the IABG programme, the components -- failed long
m
before their predicted lives; factors of 10 and more on the
unconservative side were not uncommon.
io
from: Walter Schütz, A History of Fatigue, Engineering Fracture
Mechanics Vol. 54, No. 2, pp. 263-300, 1996
uz
a
4 50 1,7E+05 3,5E+05
We shall employ non dimensional
ol
5 43 2,0E+05
values sa=σa/Rm*100 for stresses. 6 38 1,6E+06
.g
7 29 8,0E+06
100
sa 8 25 2,0E+07
90
m
80
70
60
io sa,3 The cycles to
50 be taken into
account are
uz
40
30
20
only the blue
ones, i=1 to 4
m
10
n3 N3 Log N
0 for which Ni
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
exists.
Version Muzio M. Gola - DIMEAS 8
March 2014 Politecnico di Torino - Italia
1. Linear Damage or Miner's Rule (6/11)
m.gola
2011
2008
a
4 50 1,7E+05 3,5E+05 0,47
Then no failure should occur.
ol
Σ=0,93
.g
100
sa
90
m
80
70
60
50
io
uz
40
30
20
m
10
Log N
0
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
a
ni 4 50 1,7E+05 0,829
αi =
ol
n TOT nTOT= 2,05E+05 Σ=1,000
.g
100
ssaa,i
90
m
80
The aim is to
70
60
50
io obtain an
“equivalent stress
uz
40
30
amplitude” acting
for the total
20
m
10
Log N
0 number of cycles
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
nTOT.
Version Muzio M. Gola - DIMEAS 10
March 2014 Politecnico di Torino - Italia
1. Linear Damage or Miner's Rule (8/11)
m.gola
2011
2012
The “equivalent stress amplitude” σ a,eq when applied for the total
number of nTOT (valid) cycles would produce the same damage of all
the single stress σ a levels applied each for its own n cycle number.
a
k
n ≤ σDk −1 106 is here written in the
Wöhler equation σ a N
ol
alternative form s ka N k
n ≤ sD −1 10
6
with: sa=σa/Rm*100 .
.g
100
sa σ a,eq The developments
90
N in the example of
m
80
next slide are valid
70
io only for the
60
simplest case,
50
where σm is the
uz
40
same for all σa
30
20 (in the example
m
10 σm=0; it could be
0 σm=any but equal
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08 for all )
k
In cases when σm is the same for all σa,i , 6 s
formula (6 for the “equivalent stress” Ni = 10 D − 1 (1
s a ,i
s a,eq holds; it is the stress amplitude
ni
which would produce the same damage ∑ N ≡ ∑ wi ≤ 1 (2
a
if applied for all nTOT cycles, as stated in i i i
ol
formula (5 written for the case σm=0 ∑ ni = n TOT (3
.g
i
100
sa σ a,eq = 0,52 ⋅ R m
ni = αi n TOT (4
N = 2,19 E + 5
90
m
80
70 Put 1) and 4) in 2):
60
50
io s ka,eq n TOT ≤ sDk −1 106 (5
uz
40
30
with: 1/k
20
k
m
10 s a,eq = ∑ αi s a,i
(6
0 i
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
When, instead, each σa,i or sa,i has a different σm,i or sm,i , then:
[s a ,i (s m ,i )] Ni = [s D (s m ,i )]
k k
106 (1
a
[ (sm,i )] 106 (1'
ol
k
s
ni N = D
∑ N ≡ ∑ w i ≤ 1 (2 [s a ,i (s m ,i )]
.g
i k
i i i
m
∑ ni = n TOT (3 In this case the formulation of an
i io equivalent stress amplitude
ni = αi n TOT (4 acting for the total number of
cycles nTOT is not possible
uz
1’) and 4) in 2): because a term s ka,eq in:
[ (sm,i )]
k
m
a
60
Sect. 8 of Ch. 2, the formula of sl. 9 of N
ol
40
~
30 sD
sa s (s )
.g
= a m which for the level i : 20
sD −1 sD (s m ) 10
sm
~ s (s )
0
sa,i 0 10 20
sm
30 40 50 60 70 80 90 100
m
= a,i m,i (6
sD −1 sD (s m,i )
io ~
sak,i 1
Eq. (6 put in eq. (5 gives: n TOT ∑ αi k 6
= 1 (7
sD −1 10
uz
i
Now the denominator is no longer dependent on sm,i then:
α ~
m
n TOT ∑ s k = s k 106 (8
i a,i D −1
i
~
sak,eq
Version Muzio M. Gola - DIMEAS 14
March 2014 Politecnico di Torino - Italia
2. Cycle counting (1/8)
m.gola
2011
2008
a
ol
50
.g
30 σ3 illustrates a very simple
σ4 case of a “block”
20
σ1 σ5
m
10 spectrum, which is of
stress (ksi)
0
io course a gross
-10 simplification of reality
-20 for educational
uz
-30 purposes.
-40
m
number of cycles
from: http://www.engrasp.com/doc/etb/mod/fm1/miner/miner_help.html
a
ol
60
50
.g
40
30
stress (ksi)
20
m
10
0
-10
-20
io
uz
-30
-40
-50
m
0 5 10 15 20 25 t (s)
from: http://www.engrasp.com/doc/etb/mod/fm1/miner/miner_help.html
a
A section of the time history must be isolated so that it begins and
ends at the maximum value, points • .
ol
300 • •
.g
250 σ (MPa)
200
m
150
100 io
50
uz
0
-50
m
-100
-150
t
-200
a
ol
300
.g
σσ(MPa)
(MPa)
250
200
m
150
100 io
50
uz
0
-50
m
-100
-150
tt
-200 •1
Version Muzio M. Gola - DIMEAS 18
March 2014 Politecnico di Torino - Italia
2. Cycle counting (5/8)
m.gola
2011
2008
… the total level descent at point 1 (from +300 to –200 MPa , i.e.
σa=250, σm=50 MPa) is the cycle n. 1 detected.
This leaves a number of secondary basins to empty by spilling at the
a
bottom point of each: 2 through 12 .
ol
300
.g
250 σB (MPa)
200
m
150
100 io
50
9
uz
0
2 4 8 12
-50
10
m
-100
5 7 11
-150
3 6 tt
-200
a
ol
300
.g
250 σB (MPa)
200
m
150
100 io 18
50
19 21
uz
0
17 20 22 23
-50
13
m
-100
14 15
-150
16 tt
-200
a
ol
300
.g
250 σB (MPa)
200
m
150
100 io
50
27
uz
0
-50
24 25 26
m
-100
-150
tt
-200
a
2 0 200 200 100 100 23 0 200 200 100 100
24 -50 50 100 50 0
ol
3 -150 200 350 175 25
25 -50 0 50 25 -25
4 0 100 100 50 50
26 -50 50 100 50 0
5 -100 100 200 100 0
.g
27 50 150 100 50 100
6 -150 100 250 125 -25
7 -100 100 200 100 0 These cycle counts can be grouped in
8 0 150 150 75 75 blocks. See colours: in this example
m
9 50 200 150 75 125
10 -50 250 300 150 100 they are not numerous, but in the real
11 -100 250 350 175 75 cases and with digit rounding they may
12 100 250 150 75
io 175 number up to thousands. One group is
13 -50 100 150 75 25
14 -100 100 200 100 0 missing: which one?
uz
15 -100 50 150 75 -25
16 -150 100 250 125 -25
To each block a “total occurrence”
17 0 50 50 25 25 number will be associated:
m
a
life at fatigue, deepening the tool presented in Section 1.
ol
Section 4 introduces advanced matters on the exceedance diagram.
.g
m
io
uz
m
a
1,5E+04
18 50 61
ol
6,7E+03
We shall not use the results from the cycle 40 35 58
6,7E+03
.g
30 30 43
2,3E+05
have a smaller and more treatable, yet
20 32 1,2E+06
representative of the concept, number of
m
0 25 25
1,3E+07
points.
io 30 20 29
5,3E+07
80
sm sa ni
70
0 50 50
1,1E+05
a
60
15 47 55
1,5E+04
ol
50 10^4 18 50 61
6,7E+03
10^5
.g
40 35 58
6,7E+03
40 10^6
10^7 30 30 43
2,3E+05
30 10^8
m
20 32 1,2E+06
20
0 25 25
1,3E+07
10
io 30 20 29
5,3E+07
uz
0
0 10 20 30 40 50 60 70 80 90 100 sx = σx / Rm
m
80 ni
70 0 50 50
15 47 55
60
0 18 50 61
15 50 40 35 58
18 30 30 43
40
20
30 30 20 32
40 0 25 25
20
30 20 29
10
0
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
Wöhler curves are traced for each sm, and ni’s represented for
each sa . Mind the colour code coupling each sa to its sm
Version Muzio M. Gola - DIMEAS 26
March 2014 Politecnico di Torino - Italia
3. Finite life and stress spectra (4/9)
m.gola
2011
2008
1,3 E+5
80 sm sa ni
sa = σa / Rm
70 0 50 50
1,1E+05
15 47 55
1,5E+04
60
18 50 61
6,7E+03
sm 50 40 35 58
6,7E+03
15 40 30 30 43
2,3E+05
30 20 32 1,2E+06
0 25 25
1,3E+07
20
30 20 29
5,3E+07
10
0
1,E+03
ni,15
1,E+04 Ni,15
1,E+05 1,E+06 1,E+07 1,E+08
40 35 58
6,7E+03
This is not terribly inconvenient, but there is a
30 30 43
better way, in that it simplifies the graphics, and 2,3E+05
makes use of the only Wöhler curve for the life 20 32 1,2E+06
106 cycles. 0 25 25
1,3E+07
30 20 29
5,3E+07
sm sa ~
sa
80
sa ~
sa sa
70 0 50 50
sD −1 sD 15 47 55
60 *
18 50 61
61
50 10^4
10^5 40 35 58
40 10^6 30 30 43
10^7
30 20 30 38
10^8
0 25 25
20
30 20 29
10
0 sm sx = σx / Rm
0 10 20 30 40 50 60 70 80 90 100
~ 6
As shown in sl.7-Sect.8-Ch.2, s a / sD = sa / sD −1 = 10 / N
1/k
( )
so for the same life N we can use ~ sa at sm=0 instead of s a .
Version Muzio M. Gola - DIMEAS 29
March 2014 Politecnico di Torino - Italia
3. Finite life and stress spectra (7/9)
m.gola
2011
2008
80 sm sa ~
sa *
sa
70 0 50 50
15 47 55
60 *
*
* 18 50 61
50 10^4
10^5 40 35 58
40 *
* 10^6 30 30 43
10^7
30 20 32 40
* 10^8
0 25 25
20
30 20 29
10
0 sm sx = σx / Rm
0 10 20 30 40 50 60 70 80 90 100
80 s m* ~
sa * ni
sa
70 0 50 50
1,1E+05
0 55 55
1,5E+04
60 *
*
*
50 * 10^4
0 61 61
6,7E+03
10^5 0 58 58
6,7E+03
40 *
* 10^6 0 43 43
2,3E+05
10^7
30 0 40 40
1,2E+06
* 10^8
20
* 0 25 25
1,3E+07
0 29 29
5,3E+07
10
0 sm sx = σx / Rm
0 10 20 30 40 50 60 70 80 90 100
All points to consider are now those listed and marked with *
sm ~
sa ni
80
~
sa
70 0 50 50
1,1E+05
0 55 55
1,5E+04
60
0 61 61
6,7E+03
~
sa
sm 50 0 58 58
6,7E+03
0 40 0 43 43
2,3E+05
0 40 40
1,2E+06
30
0 25 25
1,3E+07
20 0 29 29
5,3E+07
10
0
1,E+03 1,E+04 ni,50
1,E+05 Ni,50
1,E+06 1,E+07 1,E+08
80
~
s a,i ni Σ ni
~
sa 61 2,0E+04
1,4E+04 2,0E+04
1,4E+04
70 58 2,0E+04
1,4E+04 4,0E+04
2,8E+04
0
55 3,0E+04
2,1E+04 7,0E+04
4,9E+04
60
50 2,3E+05
3,3E+05 2,8E+05
4,0E+05
43 2,8E+05
4,0E+05 5,6E+05
8,0E+05
50
38 2,2E+06
3,2E+06 2,8E+06
4,0E+06
40 29 1,1E+07
1,6E+07 1,4E+07
2,0E+07
25 2,8E+07
4,0E+07 4,2E+07
6,0E+07
30
3,2E+06
3,3E+05
2,0E+04
3,0E+04
2,0E+04
4,0E+05
1,6E+07
4,0E+07
20
10
Log N
0
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
80
~
sa
70
0
•
60
50
40
30
3,2E+06
3,3E+05
2,0E+04
3,0E+04
2,0E+04
4,0E+05
1,6E+07
4,0E+07
20
10
6,0E+07
7,0E+04
8,0E+05
2,0E+04
4,0E+06
2,0E+07
4,0E+04
4,0E+05
0
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
80
~
s a,2 : value of stress at level 2
0 ~
sa n2 : number of cycles spent al level 2
N2 : max life at ~
70
s a,2 for σm=0
~
s a,2 60 o o o Log(n1 + n2 ): total cycles for levels 1+2
50
s D −1
40
s II
30
2,0E+04
2,0E+04
20
10
Log N
0 o o
4,0E+04
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
80
0 ~
sa
70
2,0E+04
60 2,0E+04
3,0E+04
50 3,3E+05
s D −1 4,0E+05
40
s II 3,2E+06
30 1,6E+07
4,0E+07
2,0E+04
20 2,0E+04
10
Log N
n
0 o
4,0E+04
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
From: k 0
80
~
sa
6
sD −1
70
Ni = 10 ~ ••
sa,i 60
•
we can ssDD−1−1
50 •
calculate Ni •
ssIIII
40
•
and then the 30
2,0E+04
2,0E+04
ratio ni/Ni i.e.
20
the damage
10
0 Log
index. 1,E+03 1,E+04 4,0E+04
1,E+05 1,E+06 1,E+07 n
1,E+08
~
s a,i ni Σ ni Ni ni/Ni
It is easily seen that it is absolutely 61 2,0E+04 2,0E+04 4,8E+04 0,4173
values ~
25 4,0E+07 6,0E+07 7,1E+10 0,0006
sa< s II.
Version Muzio M. Gola - DIMEAS 37
March 2014 Politecnico di Torino - Italia
4. Finite life and the exceedance diagram (6/12)
m.gola
2011
2008
Both in numerical 80
~
sa
simulations and in 70
0
laboratory tests the 60
exceedance diagram
is truncated by
50
eliminating the 40
3,2E+06
3,3E+05
2,0E+04
3,0E+04
2,0E+04
4,0E+05
1,6E+07
4,0E+07
20
do not contribute to 10
damage.
0
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
It takes as much computer time (and testing time) to deal with one small cycle as
with one large cycle. Thus the small cycles at the lower end of the exceedance
diagram consume most of the time (cost) while their effect may be very small.
Therefore, it would be advantageous if their number could be reduced. This is
called truncation.
Quoted from: David Broek, The practical use of fracture mechanics, Kluwer
Academic Publishers, 1989 (a warmly suggested reading!)
Version Muzio M. Gola - DIMEAS 38
March 2014 Politecnico di Torino - Italia
4. Finite life and the exceedance diagram (7/12)
m.gola
2011
2008
0
80 The total
70
number of
•• effective cycles
•
60
10
0
1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
i.e. the ratio between applied 43 4,0E+05 8,0E+05 2,5E+06 0,1583 0,1
38 3,2E+06 4,0E+06 3,2E+07 0,1002 0,8
cycles ni and nTOT.
nTOT = total cycle number
80 80
nTOT=4*106 nTOT=1*106
70 70
60 60
50 50
0,0825
0,0075
0,0825
0,0075
40 40
0,005
0,005
0,005
α1 = 0,005
0,8
0,1
α6 = 0,8
0,1
30 30
20 20
10 10
0 0
1,0E+03 1,0E+04 1,0E+05 1,0E+06 1,0E+07 1,0E+03 1,0E+04 1,0E+05 1,0E+06 1,0E+07
max stress
principal stresses MPa
min stress
cumulated cycles
~
s a,i ni αi
Σ ni Ni ni/Ni
1 61 2,0E+04 2,0E+04 4,8E+04 0,417 0,005
2 58 2,0E+04 4,0E+04 7,5E+04 0,268 0,005
3 55 3,0E+04 7,0E+04 1,3E+05 0,235 0,0075
4 50 3,3E+05 4,0E+05 3,5E+05 0,946 0,0825
5 43 4,0E+05 8,0E+05 2,5E+06 0,158 0,1
6 38 3,2E+06 4,0E+06 3,2E+07 0,100 0,8
In the case shown here the sum ∑ ni / Ni 2,13
i
is much larger than 1.
n
Since all lives ni in the sum of damage fractions: ∑ i
i Ni
appear in linear form, to get a desired damage sum W it will be
sufficient to multiply all of them by the factor φ=W/2,13 .
W 106
n̂ TOT ≤ ≡W
αi ~ k ~ 2k −1
∑ Ni sa,i sa,i
∑ αi sD−1 + ∑ αi sD−1
i
i=1, j i= j,n
~
s a,i ni αi
Σ ni Ni ni/Ni
1 61 9,4E+03
2,0E+04 9,4E+03
2,0E+04 4,8E+04 0,196
0,417 0,005
2 58 9,4E+03
2,0E+04 1,9E+04
4,0E+04 7,5E+04 0,126
0,268 0,005
3 55 1,4E+04
3,0E+04 7,0E+04
3,3E+04 1,3E+05 0,111
0,235 0,0075
4 50 3,3E+05
1,6E+05 4,0E+05
1,9E+05 3,5E+05 0,946
0,445 0,0825
5 43 4,0E+05
1,9E+05 8,0E+05
3,8E+05 2,5E+06 0,158
0,074 0,1
6 38 3,2E+06
1,5E+06 1,9E+06 3,2E+07 0,100
0,047 0,8
∑ ni / Ni 1,00
i
80 s ka Ni = 106 sDk −1
70
0
60 s 2ak −1 Ni = 106 sD2k−−11
10 50
20
40
30
40 30
50
20
10
0
1,E+04 1,E+05 1,E+06 1,E+07 1,E+08