EMD Autumn 2016 Exam-2 Prep-B

Professor Bharat Bagepalli
Large Scale Yielding vs. Critical Crack length

F
F
B
B
Net Area
a
b
Large Scale Yielding over Net

Area
if S
Note: = Net Stress =
Critical Crack Length: Small Scale Yielding

@ Crack Tip
if K (= C ) KC or KIC Depending on
Plane Stress or Plane Strain
F
(ba)B
Note: = Nominal Stress =

Need to verify both!
F
bB
1
Fracture vs. General 3D Stress Assessment
General 3D Stress State
Fracture
Fracture Toughness
Plane Strain* KC = K
Compare With
(Material Property)
Plane Stress* KC = K
Units: MPa m
1.4 K
+
S
B
Principal Stresses 1 2 3
Von-Mises Stress EQ
Tresca Stress max
Units: MPa
Stress Intensity Factor

K = C
Units: MPa m
Calculate
Ultimate or Rupture Strength

SU or SR
Yield Strength SY
Shear Strength SY/2 or Sshear
Units: MPa
Fracture Constant (C or Q) vs. Stress Concentration Factor (KT )

Fracture Constant (C or Q): Leads to Stress Intensity Factor K
Stress Concentration Factor (KT ): Leads to Increased Stress
Design = KT*Nom
Crack is a Micro Feature: System is designed for its pre-existence
Notch is a Macro Feature: designed-into the System

3
Example: Plane Strain vs. Plane stress
Steel tension straps are use to reinforce a bulkhead structure. The manufacturer initially wanted to use
two (2) strips of A 538 Steel to carry a load total load F shared equally by each strip. They later came up
with the idea of using a single AISI 4340 Steel strap to carry the same load, to potentially save money.
The chances of finding a through crack, length 2a is the same in each case. The subscripts refer to the
steel used. There are two Design Cases to consider (next page)
F538
F538
F4340
Two Strips
A 538 Steel
Single Strip
AISI 4340 Steel
F538
F538
F4340
Assume Static loading, for each case, use Table below for Material property and Loading, and
Graph in Textbook Figure 5.17 for finding C to be used for Stress Intensity Factor K = C
Table below gives two Design Cases using A 538 and AISI 4340 Steels
Design Case #
Steel
Plate Width, 2b, m
Each Plate Thickness, B 538 or B4340, m
Through-Thickness Crack size, 2a, mm
Load per Strap, B 538 or B4340, N
Yielld Strength, Sy, MPa
Ultimate Strength, Su, MPa
Plane Strain Fracture Toughness, K1c, MPa-m^(1/2)
% Elongation on 50mm sample
1
2
A538
AISI 4340
0.15
0.15
0.01
0.025
3
3
550,000 1,100,000
1647
470
1696
745
3
AISI 4340
0.15
?
3
1,100,000
470
745
46.2
50
50
13
36
36
Mode-I Fracture
2 Straps
1 Thicker Strap
For the Design Cases 1 & 2 (two A 538 Straps) Find:
Factor Of Safety in Large Scale Yielding

Stress Intensity factor K
Appropriate Fracture Toughness to be used (Plane Stress KC
or Plane Strain KIC )
Factor Of Safety for Crack growth (as appropriate, Plane
Stress or Plane Strain)
Mode-I Fracture
2 Straps
1 Thicker Strap
Some Formulas and Approach
net = F/Anet use for FOS in Large Scale Yielding

nom = F/A use for FOS in Fracture
Must first confirm if Plane Strain

or Plane Stress Fracture
Stress Intensity Factor K = C nom (a) units MPa m

Figure 5.17 (Central Crack) or 5.19 (Edge Crack) in
Textbook to get C*
*C based on Crack geometry
Example,
Central Through Crack
Figure 5.17 gives
C (1a/b) for a/b
get C
Design Case-1: Two A 538 Straps, each sharing total load
FOS in Large Scale Yielding
Plane Strain despite being thinner

(because of high SY )
Design Case-1: Two A 538 Straps, each sharing total load (continued)
C (1a/b) = 0.98
Mode-I
a/b = 0.02
K = C Nom
Design Case-2: One AISI 4340 Strap bearing the load
FOS in Large Scale Yielding
Plane Stress despite being

thicker (because of low SY )
10
Design Case-2: One AISI 4340 Strap bearing the load (continued)
11
Edge Through Crack vs. Central Full Through Crack
Analysis is identical, Example, as before

1. K = C nom ( )
2. Use a/b to get C from Figure 5.19
3. Compare B with .
(test for Plane Stress vs. Plane Strain)

F
is based on Net Area: (b-a)*B
4. Net Stress Max

5. Nominal Stress Nom is based on total area b*B
Etc.
Note a and b as shown
Edge Crack
Figure 5.19
12
For a Thumbnail Surface Crack, Stress Intensity Factor K =
1.12
Q
Q from Text Book Figure 5.22
Thumbnail
Surface Crack
a/2C
Shape Parameter Q
Note: read-off Q on X-axis
Caution: 2c in figure is actually crack width

It has little to do with
C in K = C (Stress Intensity Factor for Through Cracks)
13
Example: Edge Crack Growth Iterative Design
An Aircraft Stringer made of 7075-T651 Aluminum alloy plate is 10mm thick, 8 cm wide and 70 cm long. Tests indicate that 7075-T651 has a
Plane Strain Fracture Toughness kIC = 28MPa m and a Yield Strength SY = 530MPa. From FEM analysis, the maximum load in a typical
mission is found to be 140 kN tension along the length.
During operation, due to fatigue loading, through-thickness Edge Cracks perpendicular to the loading arise. Failure will occur when these
cracks reach a critical length.
An on-board Sensor is being installed. The Sensor is to be designed to detect any crack that has a length = half the Critical length, early
enough to replace/fix the problem. What is Half the Critical Crack Length that the Sensor must be designed to?
Edge Crack
Figure 5.19
CI (1-a/b)3/2
Edge Through Crack
Critical crack aCR

propagates
Sensor can
detect this
a/b
Stringer
Undetected
initial crack
14
Example: Edge Crack Growth Iterative Design
Geometry
B = 10mm thick, b = 8 cm wide and L = 70 cm long.
Material
Tests 7075-T651 Aluminum Alloy,
Plane Strain Fracture Toughness kIC = 28MPa m
Yield Strength SY = 530MPa.
Loading: F = 140 kN tension
Find aCR and () aCR for Sensor
Figure 5.19
Edge Crack
a/b = 0.084
CI (1-a/b)3/2 = 1.04
15
Homework 9a: Prosthetic Hip Joint Fracture Mechanics in Contacts Autumn 2016
Recall class Contact Mechanics example on a Ball-and-Socket prosthetic hip joint design,
evaluate if the Al2O3 Femur Ball to Socket Edge contact will grow a 0.1mm (=2a) undetected
Crack, i.e, find FOS (KIC/K) Base your analysis on the Maximum Tensile Stress at the edge
of the Contact Patch, and data below
Contact Load = 50N
Material Properties of Al2O3 (both Liner and Ball)
Youngs Modulus E = 350GPa; Yield/Rupture Strength = 375MPa
Poissons Ratio = 0.25
Fracture Toughness KIC = 5MPa*m1/2
The liner has a Rounded Edge Radius = 4.5 mm. The Thigh Ball diameter is 28.4 mm
Contact between the Edge Radius and the Ball a Taurus-to-Sphere .. But for simplicity, can
be assumed to be Sphere-to-Sphere. Formulas given next page.
Assume a Central Through-Crack formed at the edge of the Contact Patch, and approximate
the local crack zone on the edge of contact patch to be a rectangular slab as shown
(2b=1mm, B=2mm). Use Figure 5.17 if necessary.
Socket/Linter Edge to Ball contact
16
Exam-2 Prosthetic Hip Joint Fracture Mechanics in Contacts Autumn 2016
Ceramics Fracture Easily: Very Low KIC
MPa m
17
Homework 9a: Prosthetic Hip Joint Fracture Mechanics in Contacts Autumn 2016
1. What is the radius c of the Contact Patch?

2. What is the Tensile Stress at the Edge of the Contact Patch* ? (*consider this as Nominal NOM for Crack
analysis)
3. Based on the Crack and vicinity geometry model assumed, is it a Plane Strain or Plane Stress situation?
4. What is the Stress Intensity Factor K at the Crack due to the Contact Patch Edge stress?
5. What is the Factor of Safety in Fracture?
Stress Intensity factor K = C
C (1a/b)
1.0
2
= 0.836
2 4
Modes I & II
0.8
Mode III
2
= 0.637
0.6
0
0.2
0.4
0.6
0.8
1.0
a/b
18

Answers & Homework 9a: Prosthetic Hip Joint Fracture Mechanics in Contacts Autumn 2016
Equivalent Modulus, Ec, GPa
Equivalent Contact Radius Rc

(Sphere to infinite plate), mm
Contact Patch Radius, c mm
1.
2.
3.
Edge/Liner radius is 4.5mm = R1

The Ball diameter is 28.4mm; R2 = 14mm
Contact Load of 50N
Ceramic-on-Ceramic Al2O3 properties are:
Youngs Modulus, E1 = E2 = 350GPa
Poissons Ratio, 1 = 2 = 0.25
Rupture Strength Sy1 = Sy2 = 375MPa
Maximum Contact Pressures
Maximum Tensile Stress, MPa

at radius = c
19

Answers & Homework 9a: Prosthetic Hip Joint Fracture Mechanics in Contacts Autumn 2016
1.0
C (1a/b)
0.95
Modes I & II
0.8
Mode III
0.6
0
0.2
a/b = 0.1
0.4
0.6
0.8
1.0
a/b
20

Example: Edge Thumbnail Crack - Analysis
A high performance aerospace vehicle uses a a Titanium Aluminum alloy (Ti-6Al-4V)
plate stock with dimensions shown. A semicircular Thumbnail crack has been found
on inspection (4.5mm radius). The material properties of Ti-6Al-4V are: Yield Strength
SY = 820MPa, Plane Strain Fracture Toughness KIC = 106MPam . Find the Factors of Note: Differences
Safety in Large Scale Yielding and in Fracture. Elongation of standard 50mm sample between Thumbnail vs
= 14%
through Edge Crack
F = 750kN
Thumbnail Crack
21
Answer to Example: Edge Thumbnail Crack - Analysis
22

Text Book Figure 5.22
NOM /SY = 0.85
a/2c = 0.5
2c
a/2c
Plane Stress
Shape Parameter Q
Q = 2.1
Stress Intensity Factor K =
1.12
Q
Compare With .
Stress Intensity Factor K =
1.12
Q
Stress Intensity Factor K = C

24

General Approach: Fracture
1. Find Material Constants from internet even if supplied: E (Youngs Modulus). Syp (Yield Strength), SU (Ultimate
Strength), KIC (Plane Strain Stress-Intensity Factor), etc.
Check % elongation, e - if >5%, treat it as Ductile (or look up Table 3.10 in book). If Brittle, check against SU
2. Large Scale Yielding Check: net area to find net stress confirm net < Syp .. FOS = Syp / net etc.
3. For Fracture assessment:
Find Nominal Stress (ignoring cracks) nom
Confirm if
Plane Strain B> 2.5
Plane Stress B< 2.5
- use Fracture Toughness = K
- use Fracture Toughness = K = K
1.4 K
1+ 2
S
B
4. Find constant C for Stress Intensity Factor: need some crack geometry ratios (eg. a/b), read off graph to get
C (1a/b) vs (a/b) for example for a through crack (Text book Figure 5.17 Central Through, or Figure 5.19 Edge Through) for specific Fracture Mode (I, II or III) . Other geometries have similar approaches
For Thumbnail Crack, use Figure 5.22 to get Q given a/2C, Nom/SY
5. Calculate Stress Intensity Factor
Mode I, II, or III K = C Nom ( )
Thumbnail K =
FOS = KIC /K (Plane Strain) or KC /K (Plane Stress)
1.12
Q
Nom
Crack Propagation: Paris Equation for Crack Growth*
Integrating
aCR n/2
{a
da}
=
ao
NP
{
CPE [C ]n dN }
0
The # Load Cycles NP for Crack to grow from

Initial ao
to
Critical aCR
a(1n/2)
(1n/2)
aCR
ao
= {CPE [C ]n NP}
Concept of Fatigue
26
Example a
a) Estimate and plot Idealized S-N curve for AISI 1020 (CD) steel compare to
data in Figure 5.31 (convert to MPa)
Note: 100ksi = 689MPa
For AISI Steel Table 3.3 gives SU = 421MPa or 61ksi

@ N=1 i.e., Log(N)=0
SN=421MPa
@N= 106 or Log(N)=6
SF = 0.5SU = 210MPa
Figure 5.31
Professor Bharat Bagepalli, 2015
S-N Curve for AISI 1020 Cold Drawn Steel Pristine Sample
500
SU= 421
Figure 5.31 AISI 1020 (CD) Steel
300
S F
SF = 210
200
SU
100
SN
SN MPa
400
3
Log (N)
SF
Log (N)
28
Figure 5.31
AISI 1020 (CD) Steel
Figure 5.31 for 1020 Steel (cleaned up)
Alternating Stress Amplitude, Ksi
80
60
1020 Steel
40
20
0
104
105
107
106
Cycles to Failure
108
109
29
AISI 1020 (CD) steel
Comparing Constructed with Measured S-N curves (Figure 5.31)
30
Example b
b) Estimate and plot S-N curve for AISI 1020 (CD) steel part that is lathe-turned, no welds, will operate at 250
cycles/min (cpm), at a Reliability of 99.9%
Solution to b)
kgr = 1
kwe = 1 (no weld)
SU = (machine finish) = 421MPa
ksz = 0.9 (typical value)
ksr = 0.8 (Lathe Turned Surface Finish)
kfr = 1
kcr = 1
ksp = 1 (operating speed > 200 cpm and < 7000 cpm)
kr = 0.75 (Table 5.4 for 99.9% Reliability)
SF =
*210MPa
Gives SF = (0.8)(0.75)(0.9)(210) = 113MPa
Professor Bharat Bagepalli, 2015
S-N Curve for AISI 1020 Cold Drawn Steel For Design, using Knockdowns
500
SU= 421
SN MPa
400
Figure 5.31 AISI 1020 Steel
300
S
200 F
SF = 210
100
SF = 113
Apply Knockdown Factors
SF = KSF
0
0
3
Log (N)
32
Example: S-N curves with Completely Reversed loading Zero Mean Stress
1.
2.
3.
4.
a1 = 41ksi for n1 = 10 cycles

How many GAG sorties

can it fly before the
Stringer fails in fatigue?
80
Alternating Stress SN ksi
A Jet Fuselage Stringer is made of 2024 T4 Aluminum

Alloy (Su =68ksi, Syp = 47ksi). Graph shows its fatigue
behavior (from Fig 5.31 in Book). A typical Ground-AirGround (GAG) sortie subjects this critically stressed
stringer to the following alternating fully reversed
alternating stresses @ zero mean.
60
2024 T4 Aluminum Alloy

40
Fatigue Strength S5*108
20
0
4
N = 104
7
6
Log (N)
9
5*108
108
105
106
107
109
33
# Completely Reversed Stress Cycles to Failure
Solution:
80
60

41 40
33
25
20
8.69897
15
0
Log (N) = 4
5
105.2
N = 104
6
105.8
7
106.8
9
5*108 =108.69897
108
105
106
107
109
34
Example: S-N curves with Completely Reversed loading Zero Mean Stress
1.
2.
3.
4.
a1 = 35ksi, m1 = 10ksi for n1 = 10 cycles

a3 = 25ksi, m3 = -10ksi for n3 = 40 cycles
80
The Jet from earlier with a Fuselage Stringer made of

2024 T4 Aluminum Alloy (Su =68ksi, Syp = 47ksi) as in
Graph shows its fatigue behavior (from Fig 5.31 in
Book). The actual Ground-Air-Ground (GAG) sortie
subjects this critically stressed stringer to the following
alternating and mean stresses.
60

40
20
0
How many GAG sorties
can it fly before the
Stringer fails in fatigue?
4
N = 104
7
6
Log (N)
9
5*108
108
105
106
107
109
35
Example: Fatigue Life with Non-Zero Mean Stress
1.
2.
3.
4.

36

Spring 2015
Solution continued:
The equivalent # of fully reversed stress

cycles per GAG sortie using
80
1.
2.
3.
4.
60
41 40
33
20
8.69897
15
0
Log (N) = 4
5
105.2
N = 104
6
105.8
7
106.8
a1-eq-Cr = 41ksi for n1 = 10 fully reversed cycles

The Fully reversed stress

numbers are same as before!
The corresponding Ni = Cycles to failure
from S-N graph
1. a1-eq-Cr = 41ksi, N1 = ~105.2 = 1.6*105 cycles
2. a2-eq-Cr = 33ksi N2 = ~105.8 = 6.3*105 cycles
3. a3-eq-Cr = 25ksi N3 = ~106.8 = 6.3*106 cycles
4. a4-eq-Cr = 15ksi N4 > 109 = cycles
Then, the Part has reached End Of Life if
25
eq-CR
9
5*108 =108.69897
108
105
106
107
109
#GAG sorties NGAG

10
20
40
100
NGAG*
+
+
+
=1
1.6105 6.3105 6.3106
37
Giving NGAG = ~9,900 sorties as before
Robot arm non-zero mean fatigue
A Robot made of steel, operating on a Workpiece is pictured below. This requires that the Robot apply a
constant force FX when operating on the Workpiece over the range shown: the Arm moves from a mean
position at height H, up and down by h. The Robot Arm and Leg are made of hollow rectangular section,
b*a*t (width, height, thickness). Use the data in table next page.
38
Robot Fatigue Prof. Bharat Bagepalli
Oct-15
Design Attributes
Material
Young's Modulus, GPa
Ultimate Satrength, Su, MPa
Yield Strength, Sy, MPa
Fatigue Strength, S'f pristine sample, @ 10^6 cycles, MPa
K-infinity (knockdown factors multiplied)
Poisson's Ratio
Robot Elbow height, H, m
Robot Arm swing heignt, +/- h, m
Work piece Load, Fx, Newtons (N)
Rectanglurar section "a", mm
Rectanglurar section "b", mm
Rectangular Section wall thickness, t, mm
Notch Sensitivity, q (given)
Hole diameter, d, mm
Stainless steel
200
690
450
340
0.65
0.3
1.2
0.25
3000
This Affects Mean Stress

This Affects Alternating Stress
This affects Overall Stress magnitude
(both Mean and Alternating
100
80
1
0.8
10
39
Robot arm non-zero mean fatigue
Calculate the following:

a. Maximum, Minimum, Mean and Alternating stresses at the Base of
the Robot
b. Equivalent Completely Reversed Alternating Stress
c. The appropriate Fatigue Stress Concentration Factor KF from the
Theoretical Stress Concentration Factor KT for the Hole at the
bottom (meant for wiring) using the Chart, and the Notch Sensitivity
(only for the Alternating Stress) of 0.8 (given)
d. Knocked-down Fatigue Limit SF using the KInfinity and the Fatigue
Limit of a pristine sample SF provided
e. Factor Of Safety in Large Scale Yielding
f. Fatigue life of the Robot for the duty cycle shown, given Ultimate
Strength SU
40
Fatigue, Non-Zero Mean Stress Robot
41
2.68
= 1+ 0.8(2.68-1) = 2.36
= 2.36*130.9 = 307 MPa
42

Observe that, even though the thin-walled rectangular cross section is in bending, the face with
the hole sees uniform tensile/compressive stress due to the bending, being farthest away from
the Neutral Axis
Hence, we must use Kt for a Flat Plate under Axial Load/Stress (above) for d/W = 10/80 = 0.125
Stress Concentration Factor
bending
2.68
0.125
43
307 MPa
307
(690 - 307)
4.9
104.9
7.88*104 cycles
44
or SN
Fatigue, Non-Zero
Mean Stress Robot
700
Su = 690MPa
Alternating Stress, MPa to Failure SN
Pristine Samples
SF = 340MPa
EQ-CR =307MPa
SF = 221MPa
For Component Design
Log (N) = 0
N = 100
5
4.9
SF = KSF
106
107
104
105
102
103
101
104.9 = 7.88*104 cycles
45
Completely Reversed Stress Cycling
Fatigue, Non-Zero Tensile Mean Stress of an Actuator Bar
-20,955 Newtons (Compression) to 41,910 Newtons
Tensile Mean Stress
Alt
Mean
46
Lathe-turned (machined) Fig 5.33 gives

Ksr =0.9 (650MPa = 94ksi)
Ksz = 0.9 typical value

Table 5.4
Reliability 99.9% - Table 5.4 gives Kr = 0.75
94ksi
47

AISI 4420 CD Steel
SU = 94ksi = 650MPa
SY = 85ksi = 586 MPa
Elongation of a 5cm bar = 22%
Find usable Fatigue Limit SF
KSR = 0.9
KSZ = 0.9
99.9%
KSR = 0.75
SF = (0.9)(0.9)(0.75)SF =0.6075*325
= 197MPa
48
650 - (5.778/6)*(650-197)
SN = 214MPa
SF
166MPa
214
49

Homework 9b: S-N Curve for AA 2024-T4 Aluminum Alloy Autumn 2016
Give your answers in Metric Units (100ksi = 689MPa)
a) Estimate and plot Idealized S-N curve for AA2024-T4 given Su = 75ksi, e=20%, compare to data in Figure 5.31.
b) Estimate and plot S-N curve for a AA2024-T4 part that is ground, welded to another part, and the load varied at
1500 cpm at a Reliability of 99.95%. Refer Textbook, eg. Table 5.3, 5.4, 5.33 and Fig 5.33 (has steel, but use this )
Note: this is an Aluminum alloy: Use appropriate relations
You may use the blank S-N
Grid provided
Figure 5.31
Figure 5.31 for AA 2024-T4 (Cleaned up)
Alternating Stress Amplitude, Ksi
80
60
Aluminum AA2024-T4
40
20
0
104
105
106
107
Cycles to Failure
108
109
50
Answers & Homework 8b: S-N Curve for AA2024-T4 Aluminum Alloy Autumn 2016
a) Estimate and plot Idealized S-N curve for AA2024-T4 given Su = 68ksi, e=20%, compare to data in Figure 5.31.
Give your answers in Metric Units (100ksi = 689MPa)
@ N=1 i.e., Log(N)=0 SN = SU = 75ksi = 517MPa
@N= 5*108 or Log(5*108) = 8.7 SN = 0.4SU = 30ksi = SF = 207 MPa
or SN
Figure 5.31
AA2024-T4
Aluminum AA2024-T4
SF = 138 measured
Log (N) = 0
Su
Idealized
SF
SF
Log(5*108)
51
Answers & Homework 8b: S-N Curve for AA2024-T4 Aluminum Alloy Spring 2016
b) Estimate and plot S-N curve for a AA2024-T4 part that is ground, welded to another part, and the load varied at
1500 cpm at a Reliability of 99.95%
Solution to b)
Ref: Tables 5.3 and 5.33
kwe = 0.8 (typical for welded)
Ksr = 0.7 (typical value, possibly lower, but Fig 5.33 has steel use this)
ksz = 0.9 (typical value)
ksp = 1 (operating speed > 200 cpm and < 7000 cpm)
kr = 1-0.08X = 0.736 (Table 5.4 for 99.95% Reliability)
@ N= 5*108 Cycles (Aluminum Alloy), SN = SF
SF =
*207MPa
Gives SF = (0.8)(0.7)(0.9)(0.736)(207) = 77MPa
52
Answers & Homework 8b: S-N Curve for AA 2024-T4 Aluminum Alloy Spring 2016
S-N Curve for AA2024-T4 Aluminum Alloy
SU= 517
500
Figure 5.31 AA2024-T4
400
SN MPa
300
200
SF = 207
SF
SF = 138 measured
100
SF = 77
0
0
N = 100
101
102
5
Log (N)
106
107
104
105
103
8.7
10
9
Log(5*108)
108
109
1010
53
2024-T4 Aluminum Alloy

Comparing Constructed with Measured S-N curves (Figure 5.31)
54

Example: Rainflow Cycle Counting
Using the Rainflow counting method, given the following stress-time spectrum and the S-N curve for the
stressed Automobile Steel part, how many such typical stress Blocks can the part sustain before failing in
fatigue?
Stress-Time Sequence
Stress, ksi
1 block
Time, Seconds
55
Rainflow Cycle Counting

Challenge is Cycle Counting under constantly varying amplitudes
Pages 268-273
Stress-Time Sequence
1 block
1 block
Stress, ksi
Stress, ksi
Peaks
Valleys
Time, Seconds
Time, Seconds
Starting with a High Peak, pick a Block that is representative of lifetime Duty Cycle (= k Blocks)
Can be Random Variation as well does not have to repeat!
56
Rainflow Cycle Counting

1 block
Highest Peak
Stress, ksi
1
Deepest Valley
Time, Seconds
Rules
1. Initiate the first raindrop at the highest (most +) peak
2. Initiate the second raindrop at the lowest (most -) valley
3. Continue down with next peak or valley in sequence
until it sees no peaks
4. Initiate other raindrops capturing next highest peak-tovalley range
5. Rain flows to next roof along Time axis, all the way
down, and stops when
- It comes to a Peak more positive than it started from
OR
- It comes to a Valley more negative than it started
from
6. Rain drop must stop if it meets rain from a roof above
7. Combine drops (pairs) to form cycles. A cycle consists
of 2 drops, 1 from a Peak and 1 from a Valley
8. Pair drops together such that
- Ether of these runoff (highest Peak)/(Lowest Valley)
OR
- End on some Roof
9. No double counting, or missed segments
Drops
Rainflow
1 -
form 1 cycle, max = 40ksi, min = - 40ksi,
Check: that none of the rules is violated
57
Rainflow Cycle Counting .. the rest of the Drops
(stretching Time axis for clarity)
1 block
6
Highest Peak
Stress, ksi
Next Highest Peak to

Lowest Valley Range
max = 25
10
Example
Drops 9-10
8
min = 0
4
9
Deepest Valley
Example
Drops 2-5
max = 20
min = -25
Time, Seconds
Rainflow
58
Stress Cycles per Block
Su
62
Drops
(Cycles)
Max
Stress
SigmaMax
40
5
20
15
25
1, 6
3,4
2,5
7,8
9,10
ksi
(Max + Min)/2
Min Stress Mean Stress

Sigma-m
Sigma-Min
For m >0, eq-CR =
0
-5
-2.5
0
12.5
-40
-15
-25
-15
0
a
=
SU
(Max - Min)/2
Alternating
Stress
Sigma-alt
40
10
22.5
15
12.5
Use this if S-N

Equivalent
# Cycles to
curve is not given
Completely Reversed Failure N, at this In this example, use
S-N curve below
Stress, Sigma-EQ-CR
Sigma-Eq-CR
1.3*104 cycles
40
13000
10.00
Infinity
4*105 cycles
22.50
400000
15
Infinity
15.66
Infinity
12.5
= 15.66 ksi
12.5
62
For 1 Block, fraction of Life used up is
L1-block =
+
= 7.9423*10-5
4
5
410
1.310
40
22.5
BF = # Blocks for fatigue failure

BF*L1-block = BF (7.9423*10-5) = 1
Gives BF = 12,590 Blocks to fail in fatigue
1.3*104 cycles
4*105 cycles 59

SN or SN
Su
Alternating Stress, MPa to Failure
Cycles to Failure @ eq-CR for Steel

eq-CR
SF
Log (N) =
N = 100
106
104
105
102
103
101
Cycles to Failure @ eq-CR N =
7
107
60
Example: Trading off Steel vs. AA2024-T4 Aluminum Alloy for given eq-CR
Professor Bharat Bagepalli,
SU-St500
= 500
SU-Al= 469
SN MPa
400
300
eq-CR
200
SF-St = 140
100
SF-Al = 70
0
0
N = 100
101
102
4
Log (N)
106
107
104
105
103
6*(SU-St Eq-CR)/(SU-St SF-St)
10
8.7
9
Log(5*108)
108
109
10
1010
8.7*(SU-Al Eq-CR)/(SU-Al SF-Al)
10
61
Robot arm non-zero mean Torsion and Bending fatigue
A Robot made of steel, operating on a Workpiece is pictured below. This requires that the Robot apply a constant
force FX when operating on the Workpiece over the range shown: the Arm moves at a constant height h above its
elbow (H above ground) in a horizontal plane while it machines a workpiece. The Arm swings in the horizontal plane
from a mean position along the X-axis, to a maximum position z1, and to a minimum position z2 along the Z-axis
as shown. There is a Hole, diameter d, near the bottom for cabling as shown. The forces FX & FZ need to be
constant at the Workpiece to produce consistent quality output. The Robot Arm and Leg are made of hollow
rectangular section, b*a*t (width, height, thickness). Use the data in table next page.
62
Design Attributes
Material
Stainless steel
Young's Modulus, 200GPa
Ultimate Strength, Su, 690MPa
Yield Strength, Sy, 450MPa
Fatigue Strength, S'f pristine sample, @ 10^6 cycles, 340MPa
K (knockdown factors multiplied)
0.65
Poisson's Ratio
0.3
Robot Elbow height, H, 1.2m
Robot Arm heignt, h, 0.25m
Work piece Load, Fx, Newtons 4000N
Work piece Load, Fz, Newtons 1000N
Offset L, 0.9m
Robot Arm lateral swing, z1, 0.3m
Robot Arm lateral swing, z2, 0.4m
Rectangular section "a", 100mm
Rectangular section "b", 80mm
Rectangular Section wall thickness, t, 2mm
Hole diameter, d, 10mm
Theoretical SCF, given Kt = 2.7
Notch Sensitivity Bending q-b (given)
0.8
Notch Sensitivity Torsion q-t (given)
0.9
63
FX
Workpiece
Moving Arm
Fixed Leg
L
H
b
FZ
Workpiece
FX
z1
FX
FZ
b
P
X
View P
Hole for Cabling,

diameter d
FZ
z2
FX
64
Calculate the following:

a. Maximum, Minimum, Mean and Alternating stresses at the Base of
the Robot
b. Equivalent Completely Reversed Alternating Stress
c. The appropriate Fatigue Stress Concentration Factor KF from the
Theoretical Stress Concentration Factor KT for the Hole at the
bottom (meant for wiring) using the Chart, and the appropriate Notch
Sensitivity q (only for the Alternating Stress). Assume that the hole is
located at highest stress point.
d. Knocked-down Fatigue Limit SF using the K and the Fatigue Limit
of a pristine sample SF provided
e. Factor Of Safety in Large Scale Yielding
f. Fatigue life of the Robot for the duty cycle shown, using the S-N
curve and suitable knock-downs for Fatigue assessment
65
Bending Moment about Z-Axis: MZ
Bending Moment about X-Axis: MX
FX
Workpiece
FZ
Workpiece
FZ
Z
FZ
MX
X
FZ
MZ
C
X
MX
MZ
MZ = FX*(H + h)
MX = FZ*(H + h)
66
Torque about Y-Axis: TY
FZ
Workpiece
FX
Z
z1
FX
z2
FZ
Torque
X
FZ
TY-Max
TY
FX
TY-Min
TY
X
TY Ranges from
TY-Max = {FZ*(L) + FX*(z1)}
to
TY-Min = {FZ*(L) - FX*(z2)}
Time
Torque Fluctuates!
67
Z
1
X
torsion
SF = Kinfinity *SF
68
=21.88 MPa
Z
1
X
M =21.88 MPa
>221MPa
Check out Chart 33, earlier
Equivalent Von-Mises Stresses
450
Mean
+3*21.882
(SU - SF)
02 +
Alternating
= 6.7*103
Cycles
69
Su = 690MPa
or SN
700
Pristine Samples
Actual Completely Reversed Alternating Stress
KF*EQ-CR =390.5MPa
SF = 340MPa
SF = 221MPa
Log (N) = 0
N = 100
4
3.83
SF = KSF
106
107
104
105
102
103
101
103.83 = 6.7*103 cycles
Actual Life of part
70
Completely Reversed Stress Cycling
FX
Workpiece
t
Z
MZ
5800
FZ
C
z1
FX
FZ
Torque
Workpiece
FX
X
MX
1450
TY
Hole for Cabling,

diameter d
TY-Max 2100
Time
FZ
z2
FX
TY-Min -700
71
Robot arm Max Mean and Alternating Stresses at Corner 4
349.6 MPa
Y
b
Equivalent Mean
Stress 351.6 MPa
Mean Stresses
t
Z
X
MZ
5800
Torque
21.88 MPa
MX
1450
TY
Hole for Cabling,

diameter d
TY-Max 2100
TY-Min -700
3
4
Alternating
Shear Stress
from w/o KF
Time
Conservative
assumption:
Hole is near 4
so apply KF
43.8 MPa
Equivalent
Alternating
Stress 75.8 Mpa
w/o KF 72

EMD Autumn 2016 Exam-2 Prep-B

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EMD Autumn 2016 Exam-2 Prep-B

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