Fatigueload

Reduced material resistance under

fluctuating stresses or reversals,
which may culminate in cracks or
failure after a number of cycles.
Fatigueisthetendencyofamemberto
failatstresslevelsbelowyieldstress
whensubjecttocyclicalloading.
Thereforefailurecriterionisnotyield
stressorultimatetensilestress.Then
whatisthat?
 Completelyreversedcycleofstress:
Illustratesthetypeoffatigueloading
whereamemberissubjectedto
oppositeloadsalternately witha
meansofzero.
Forexamplebendingofsteelwire
continuouslyineitherdirectionleads
toalternatetensileandcompressive
stressesonitssurfacelayersand
failurefatigue.
 Repeated&ReversedStress
anelementsubjectedtoarepeatedand
alternatingtensileandcompressivestresses.

Continuoustotalloadreversalovertime
RepeatedandReversedStress

min
R 1
max
Theaverageormeanstressiszero.
 Definitions:
max min
a = Alternating stress
2 2

max min
m = Mean stress
2

min
R
max R = 0, repeated and one direction, i.e.
stress cycles from 0 to max value.
R =-1, Fully reversed
 FluctuatingStress
Whenanelementexperiencesalternating
stress,butthemeanstressisNOTzero.

LoadvariesbetweenPandQovertime
 FluctuatingStress

max min max min

a m
2 2

The average or mean stress is not zero.

 Fatigueproperties:
Fatiguelife(N): itistotalnumberof
cyclesarerequiredtobringaboutfinal
fractureinaspecimenatagivenstress.
Fatiguelifeforagivenconditionisa
propertyoftheindividualspecimen
andisarrivedataftertestinganumber
ofspecimensatthesamestress.
 Fatiguestrength(n)
Itisthemaximumstressatwhicha
materialcanwithstandrepeatedlyN
numberofcyclesbeforefailure.
ORitisthestrengthofamaterialfora
particularfatiguelife.
 FatiguelimitorEndurancelimit(Se ):
itisstressbelowwhichamaterialwill
notfailforanyunlimitednumberof
cycles.
Forferrous materialsitisapproximately
halfoftheultimatetensilestrength.
Thisvalueisobtainedwiththehelpof
standardrotatingbeamtest.
 Endurancelimit
Thecyclicstresslevelthatthematerialcan
sustainfor10millioncyclesiscalled
the EnduranceLimit (EL).DenotedbySe.
Rotatingbeamspecimen(Bending)
ForSteels,
Se=0.5Sut,Sut1400MPa
ForCastironandcaststeels,
Se=0.45SutMPa,Sut600MPa
 Theendurancelimitofarealmachine
componentislowerthantheestimatedof
experimentallydeterminedendurance
limitbecausethesize,shape,surface
finish,etcofacomponentsaregenerally
quitedifferentfromthoseofthe
specimensusedintesting.Assuchthe
followingrelationshipisgenerallyusedto
determineendurancestrengthofreal
component.
Se=KaKbKcKdKeSe
 Se=endurancestrengthofacomponent,MPa
Se=endurancelimitofastandardspecimenof
therespectivematerialinarotatingbeam
machine.
Ka=surfacefinishfactor
Kb=sizefactor
Kc=reliabilityfactor
Kd=modifyingfactorforstressconcentration
Ke=miscellaneousfactorliketemperature,
environmentaletc
FatigueFailure,SNCurve
N < 103 N > 103

Finite life Infinite life

Se

Se = endurance limit of the specimen

Generally, the region upto 1000 cycles is
low cycle fatigue .Some defense
equipment is designed for life in this
region.
Design of components subjected to fluctuating
stresses for infinite life

a
Sy Yield line

Gerber curve
Se
Alternating
stress Goodman line

Sy Sut m
Soderberg line
Mean stress
TheEffectofMeanStressonFatigueLife
ModifiedGoodmanDiagram
a
Sy Yield line

Se
Alternating
stress Goodman line
C
Safe zone

Sy Sut m
Mean stress
Exampleonreversedstress
1.Aplatemadeofsteel20C8Sut=440N/mm2.Itissubjectedtoa
completelyreversedaxialloadof30KN.Assumeka=0.67,
kb=0.85,kc=0.89,kd=0.45andfactorofsafetyas2.Determine
theplatethicknessforinfinitelife?
Sol.Se=0.5Sut=0.5x440=220N/mm2
Se=KaxKbxKcxKdxSe=0.67x0.85x0.89x0.45x220=50.9N/mm2
Allowablestress=Se/fs=50.9/2=25.45N/mm2
Alsoallowablestress=P/(wd)t=(30x1000)/(5010)t=25.45
t=29.47mm
Exampleonfluctuatingstress
1.Acircularrodmadeofductilematerialhasendurancestrengthof
280N/mm2andultimatestrengthof350N/mm2.Thememberis
subjectedtovariableaxialloadvaryingfrom300KN(tensile)and
70KN(compressive).AssumeKa=0.85,Kb=1.0,Kc=1,Kd=0.55and
factorofsafetyas2.Findsuitablediameteroftherod?
Sol.Se=280N/mm2
Sut=350N/mm2
UsingGoodmanlineequation:
Sm/Sut+Sa/Se=1/fs(1)
Se=KaxKbxKcxKcxKdxSe=0.85x1x1x0.55x280=132.3MPa
Sm=(Pmax+Pmin)/2A=[300+(70)]/2A=115/AN/mm2
Sa=(PmaxPmin)/2A=[300(70)]/2A=185/AN/mm2
Putvaluesineqn.1weget:A=3456mm2
NowA=/4d2=3456ord=66.3mm