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3rd Year Design and Production

Fatigue Lecture 3
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2.1

Fatigue
Revision

Fatigue strength as obtained from R. R. Moore fatigue tests can be used to predict the fatigue strength of other components. We use modifying factors: Sn = Sn CL CG CS Sn is the actual (calculated) fatigue strength Sn is data from SN curve (experiment or estimate) CL modifying factor for loading type CD (a.k.a. CG ) modifying factor for gradient/size CS modifying factor for surface nish In general Sn < Sn

Endurance Limit Factors

Bending (a) Endurance Limit Sn = Sn CL CG CS CL Load Factor CS Surface Factor CD Dimension Factor (0 < < 10mm) CD Dimension Factor (10mm < < 50mm) (b) 103 Cycle Strength Sn 0.5 Su Su 0.5(Bhn)[ksi] Sus 0.8 Su for steel Sys 0.58 Sy Max distortion energy theory Sys 0.50 Sy Max shear stress theory 1 chart 1.0 0.9 0.9 Su Axial 1 chart 0.7 to 0.9 0.7 to 0.9 0.75 Su Torsion 0.58 chart 1.0 0.9 0.9 Sus

Dr. Michael Conry 2004

mconry@acronymchile.com

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4.1

Endurance Limit Factors

Surface Finish

Mean and Alternating Stress

We have been discussing Fully Reversed Stress States mean stress is zero. In many real situations, this is not the case. Some notation: m mean stress max maximum stress min minimum stress a amplitude of uctuating component A Mathematical example: = m + a sin(t) max = m + a and min = m a m = 0.5(max + min )

Dr. Michael Conry 2004

mconry@acronymchile.com

Mean and Fluctuating Stress

Presence of a Static Tensile Stress reduces the amplitude of Reversed Stress that can be applied Presence of a Static Compressive Stress slightly increases amplitude of Reversed Stress that can be applied (effect usually ignored)

Constant Life Fatigue Diagrams

To look at effect/interaction of m and a , we aim to draw a constant life fatigue curve. xaxis: mean stress m yaxis: uctuating amplitude a If a = 0, Static Failure (intersection of curve with xaxis) May use Sy or Su depending on application If m = 0, Totally Reversed Load (intersection of curve with yaxis) Data (maybe modied) from SN diagram: Sn (for innite life)

Dr. Michael Conry 2004

mconry@acronymchile.com

Constant Life Fatigue Diagrams

Su Sy

Yield Line Sn

Soderberg Line

Goodman Line Su

Sy m (Tension)

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9.1

Constant Life Fatigue Diagrams

Equations
Soderberg Line is based on Sy and Sn Sa /Sn + Sm /Sy = 1 Goodman Line is based on Su and Sn Sa /Sn + Sm /Su = 1 Gerber Locus is based on Su and Sn Sa /Sn + (Sm /Su )2 = 1 Parabolic Distortion Energy Locus is based on Su and Sn (Sa /Sn )2 + (Sm /Su )2 = 1 Elliptical

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Factor of Safety
Illustrated here for Goodman Criteria (can use Soderberg, etc., also). F S is the factor of safety Safe stress line is parallel to original Goodman line

Dr. Michael Conry 2004

mconry@acronymchile.com

Sa Sm 1 + = Sn Su FS

a
Sn Sn /FS Goodman Line Safe Stress Line Su /FS m (Tension) Su

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Summary of CLF Diagrams

Four lines relevant for innite life: Soderberg, Goodman, Yield-line, Load-line Two additional failure loci (less conservative) Gerber (parabolic), Distortion-Energy (elliptical) Which failure criteria to use?: If no yielding allowed, Soderberg will be conservative If we dont know Su , then use Soderberg If Su is known, and we want to nd innite life, with yielding permitted, then use Goodman line If Su is known, and we want to nd innite life, with yield onset permitted, then use Goodman line and yield line to dene the safe zone (Modied Goodman Criterion).

Two acetates

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Stress Concentration
Surface features and aws can lead to locally elevated stresses Tables/charts allow us to look up Kt Theoretical or Geometric stress concentration factors Materials have different notch sensitivities: q Material with a lot of aws not damaged much by one more low notch sensitivity

Dr. Michael Conry 2004

mconry@acronymchile.com

 Very perfect material is signicantly damaged by addition of a notch high notch sensitivity Calculate Fatigue Stress Concentration Factor Kf using Kt and q: Kf = 1 + q(Kt 1)

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Stress Concentration
What do we apply Kf to? Ductile Materials Nominal Mean Stress Method Apply Kf only to alternating stress Brittle Materials Residual Stress Method Apply Kf to both alternating stress and mean stress

Dr. Michael Conry 2004

mconry@acronymchile.com