10/29/2013

UTS

FRACTURE AND FATIGUE

2013 Spring Fracture & Fatigue assessment

Steven TRAN- 11228184 Neslon TRAN- 11025513 Danny DU- 11227966

Fracture and Fatigue 2013

TABLE OF CONTENT Problem 1:.............................................................................................................................. 3 Step 1: Estimating the actual endurance limit :.......................................................... 4 Step 2: Determine nominal bending stress ........................................................................ 5 Step 3: Fatigue factor of safety and check whether the infinite life is predicted .............. 7 Step 4: calculate the cycle to failure (finite life) ................................................................. 7 Problem 2: .............................................................................................................................. 9 Step 1: Estimating the actual endurance limit :........................................................ 10 Step 2: Determine the applied normal stresses ............................................................... 11 Step 3: Fatigue factor of safety and check whether the infinite life is predicted ............ 11 Step 4: Calculate the cycle to failure (finite life) .............................................................. 12 Appendix .................................................................................................................................. 13

Fracture and Fatigue 2013

Problem 1:
The shaft shown in the figure is machined from AISI 1040 CD steel. The shaft rotates at 1600-rpm and is supported in rolling bearings at A and B. the applied forces are and . Determine the minimum fatigue factor of safety based on achieving infinite life. If infinite life is not predicted, estimate the number of cycles to failure. Also check for yielding.

All calculations were taken to 4 decimal places to prevent error when rounding off. For all figures and tables mentioned, please refer to the appendix

Given:
Material: Cold-Drawn, AISI 1040 steel Type of stress: Bending stress Forces:

Fracture and Fatigue 2013

Step 1: Estimating the actual endurance limit
Using the formula: From table A-20 material property, AISI 1040 Cold-Drawn steel: , For actual endurance Using the property: : { , as For surface factor Using the formula: And the property for a machined surface finishes: Factor (a) = 4.51 and Exponent (b) = - 0.265 :

For material factor

, as the material is steel For stress factor : {

Using the property:

, as its bending stress For reliability factor :

, as reliability was not mentioned For size factor Using the property for circular section in rotating bending: For size range where D is in mm, , where D = 40mm as its the smallest diameter of the shaft For temperature factor :

, as temperature was not mentioned Therefore actual endurance limit is:

Fracture and Fatigue 2013

Step 2: Determine nominal bending stress

Reaction Force calculation ; (1) ; (2) Solve (1) and (2) , Shear Force calculation

Bending Moment calculation (LHS) (Hogging) (Hogging) (Hogging) (Hogging)

Check RHS (Check OK)

Fracture and Fatigue 2013 Shear Force Diagram (V, kN)

8

B 0

-2

-6

Bending Moment Diagram (M, kN.m)

1.536 1.416 1.152

0.504

A
0

B
0

The critical location occurs at point D, (the shoulder fillet) as this is where the bending moment is large, the diameter is small and the stress concentration exists. Determine the nominal bending stress at plane D.

Yielding is not predicted as

Fracture and Fatigue 2013

Step 3: Fatigue factor of safety and check whether the infinite life is predicted
Using the formula where : and

The notch sensitivity factor

Using figure 6-20 notch sensitivity chart for steel: For , an estimated value : under bending:

For stress concentration factor

Using figure A-15-9 stress concentration factor At Therefore the fatigue factor of safety: , Fatigue factor of safety as From this and

, It is estimated that

, thus infinite life doesnt exist.

Step 4: calculate the cycle to failure (finite life)

Using Shigleys S-N equation: , where For fatigue strength factor and :

Using figure 6-18 fatigue strength fraction: For ( ) : , an estimated value

For the equivalent fatigue stress corresponding to the applied loading Using Goodmans equation: Rearranging the equation: As

Fracture and Fatigue 2013

Rearranging Shigleys equation to obtain the number of cycles (N): ( ) Checking yield factor of safety Using the equation : , therefore it takes 7994 cycles to fail.

Fracture and Fatigue 2013

Problem 2:
The cold drawn AISI 1040 steel bar shown in the figure is subjected to a completely reversed axial loading fluctuating between 28KN in compression to 28KN in torsion. Estimate the fatigue factor of safety based on achieving infinite life, and the yield factor of safety. If infinite life is not predicted, estimate the number of cycles to failure.

All calculations were taken to 4 decimal places to prevent error when rounding off. For all figures and tables mentioned, please refer to the appendix

Given:
Material: Cold-Drawn, AISI 1040 steel Type of stress: Axial loading Forces:

Fracture and Fatigue 2013

Step 1: Estimating the actual endurance limit
Using the formula: From table A-20 material property, AISI 1040 Cold-Drawn steel: , For actual endurance Using the property: : { , as For surface factor Using the formula: And the property for a machined surface finishes: Factor (a) = 4.51 and Exponent (b) = - 0.265 :

For material factor

, as the material is steel For stress factor : {

Using the property:

, as the material is under axial loading For reliability factor :

, as reliability was not mentioned For size factor , as the material is under axial loading For temperature factor :

, as temperature was not mentioned Therefore actual endurance limit is:

10

Fracture and Fatigue 2013

Step 2: Determine the applied normal stresses
For maximum stress Using the formula For minimum stress Using the formula For amplitude: Using the formula :

For mean: Using the formula

Step 3: Fatigue factor of safety and check whether the infinite life is predicted
Using the formula where : and

The notch sensitivity factor

Using figure 6-20 notch sensitivity chart for steel: For , an estimated value : for bar in tension or simple compression with a

For stress concentration factor

Using figure A-15-1 stress concentration factor transverse hole: At Therefore the fatigue factor of safety: , Fatigue factor of safety as From this It is estimated that

, thus infinite life doesnt exist.

11

Fracture and Fatigue 2013

Step 4: Calculate the cycle to failure (finite life)
Using Shigleys S-N equation: , where For fatigue strength factor and :

Using figure 6-18 fatigue strength fraction: For ( ) : , an estimated value

For the equivalent fatigue stress corresponding to the applied loading Using Goodmans equation: Rearranging the equation: As

Rearranging Shigleys equation to get number of cycles (N): , therefore it takes 34041 cycles to fail. :

( ) Check for yield factor of safety Using the equation

12

Fracture and Fatigue 2013

Appendix
Material property:

Size factor for circular section in rotating bending:

13

Fracture and Fatigue 2013

Stress concentration factors under bending:

Notch sensitivity charts for steel:

Fatigue strength fraction :

14

Fracture and Fatigue 2013

Theoretical stress concentration factor:

15