Fatigue II

Lecture 11

Engineering 473
Machine Design
 Finite Life Estimates

How can the life

of a part be
estimated if the
Alternating S yt
Finite Life mean stress-
Stress, σ a
(Cycles to failure?) alternating stress
Se pair lie above the
Goodman line?
Infinite Life
Stress State

S yt Sut
Mean Stress, σ m

Goodman Diagram
 S-N Curve

The S-N curve gives

the cycles to failure
for a completely
reversed (R=-1)
uniaxial stress state.

What do you do if
the stress state is not
completely
reversed?
Completely reversed cyclic
stress, UNS G41200 steel

Shigley, Fig. 7-6

 Definitions
Stress Range
σ r = σ max − σ min

Alternating Stress
σ max − σ min
σa =
2
Mean Stress
σ max + σ min
σm =
2
Stress Ratio Amplitude Ratio
Note that R=-1 for a
σ min σa completely reversed
R= A=
σ max σm stress state with zero
mean stress.
Fluctuating-Stress Failure
Interaction Curves
The interaction curves
provide relationships between
alternating stress and mean
stress.
When the mean stress is
zero, the alternating
component is equal to the
endurance limit.

The interaction curves are

for infinite life or a large
number of cycles.
Shigley, Fig. 7-16
 Goodman Interaction Line
Any combination of mean and
k f Sa S m alternating stress that lies on or
+ =1 below Goodman line will have
Se Sut infinite life.

Factor of Safety Format

k f Sa Sm 1
+ =
Se Sut N f
Note that the fatigue stress
concentration factor is applied
only to the alternating
component.
Master Fatigue Plot

Constant
cycles till
failure
interaction
curves.

Shigley, Fig. 7-15

 Equivalent Alternating Stress

σa Alternating stress at zero

σ m =0 mean stress that fails the part
Alternating S yt in the same number of cycles
Stress, σ a as the original stress state.
Se
105 cycles

106 cycles

S yt Sut
Mean Stress, σ m

The red and blue lines are estimated fatigue interaction curves
associated with a specific number of cycles to failure.
Number of Cycles to
Failure

Once the equivalent

alternating stress is
found, the S-N curve
may be used to find
the number of cycles
to failure.
 Equivalent Alternating Stress
Formula
k f σa σm 1
+ = Goodman Line
Se Sut N f

σa ≡ Equivalent completely reversed

k f σa σm 1 σ m =0
+ = (R = -1) stress that causes fatigue
σ a σ =0 Sut N f
m
failure in the same number of cycles
as the original σ a and σ m pair.
k f σa
σa =
σ m =0 1 σm
−
N f Sut
 Example
5 in 5 in Pmax = 3000 lb
Pmin = 2000 lb
1 2

Material UNS
1.5 in. dia. 0.875 in. dia. G41200 Steel
0.125 in. rad. Notch sensitivity
q=0.3

π 4 π I1 0.249 in 4
D 1 = (1.5) = 0.249 in 4 S1 = = = 0.332 in 3
4
I1 =
64 64 c1 0.75 in
π 4 π I 2 0.088 in 4
D 2 = (0.875) = 0.088 in 4
4
I2 = S2 = = = 0.201 in 3
64 64 c 2 0.438 in
 Example
(Continued)
5 in 5 in Pmax = 3000 lb
Pmin = 2000 lb
1 2

Material UNS
1.5 in. dia. 0.875 in. dia. G41200 Steel
0.125 in. rad. Notch sensitivity
q=0.3

kf −1 D 1.5 in k t = 1.61
q= = = 1.71
k t −1 d 0.875 in k f = 1 + q(k t − 1)
r 0.125
k f = 1 + q(k t − 1) = = 0.143 = 1 + 0.3(1.61 − 1)
d 0.875
= 1.18
Ref. Peterson
 Example
(Continued)
Pmax = 3000 lb
5 in 5 in
Pmin = 2000 lb
1 2

Material UNS
1.5 in. dia. 0.875 in. dia. G41200 Steel
0.125 in. rad. Notch sensitivity
q=0.3
Section 1 (Base)

M1 (3000 lb )(10 in ) σ max − σ min

σ max = = 3
= 90.4 ksi σa = = 15.1 ksi
S1 0.332 in 2
M1 (2000 lb )(10 in ) σ max + σ min
σ min = = = 60.2 ksi
S1 0.332 in 3 σm = = 75.3 ksi
2
 Example
(Continued)
5 in 5 in Pmax = 3000 lb
Pmin = 2000 lb
1 2

Material UNS
1.5 in. dia. 0.875 in. dia.
G41200 Steel
0.125 in. rad. Notch sensitivity
Section 2 (Fillet) q=0.3

M1 (3000 lb )(5 in ) σ max − σ min

σ max = = 3
= 74.6 ksi σa = = 12.4 ksi
S1 0.201 in 2
M1 (2000 lb )(5 in ) σ max + σ min
σ min = = 3
= 49.8 ksi σm = = 62.2 ksi
S1 0.201 in 2
 Example
(Continued)

Sut = 116 ksi

S′e = 30 ksi = Se

k f σa σm 1
+ =
Se Sult N f

Completely reversed cyclic

stress, UNS G41200 steel
Shigley, Fig. 7-6
 Example
(Continued)
Section 1 (Base)

M (3000 lb)(10 in ) = 90.4 ksi σ max − σ min

σ max = 1= σa = = 15.1 ksi
S1 0.332 in 3 2
M1 (2000 lb )(10 in ) σ max + σ min
σ min = = 3
= 60.2 ksi σm = = 75.3 ksi
S1 0.332 in
2

Sut = 116 ksi Nf = 1

S′e = 30 ksi = Se
1.0(15.1 ksi ) 75.3 ksi
k f σa σm 1 + = 1.15
+ = 30 ksi 116 ksi
Se Sult N f Part has finite life at base.
 Example
(Continued)

Section 2 (Fillet)

M1 (3000 lb )(5 in ) σ max − σ min

σ max = = 3
= 74.6 ksi σa = = 12.4 ksi
S1 0.201 in 2
M1 (2000 lb )(5 in ) σ max + σ min
σ min = = 3
= 49.8 ksi σm = = 62.2 ksi
S1 0.201 in 2

Sut = 116 ksi Nf = 1

S′e = 30 ksi = Se
1.18(12.4 ksi ) 62.2 ksi
+ = 1.02
k f σa σm 1 30 ksi 116 ksi
+ =
Se Sult N f Part has finite life.
 Calculation of Equivalent
Alternating Stress

k f σa
σa =
σ m =0 1 σm
−
N f Sut
Base Fillet
σ a = 15.1 ksi σ a = 12.4 ksi
σ m = 75.3 ksi σ m = 62.2 ksi

(1.0)15.1 (1.18)12.4
σ a σ =0 = σ a σ =0 =
1 75.3 m 1 62.2
−
m
−
1.0 116 1.0 116
= 43.0 ksi = 31.5 ksi
 Cycles to Failure Estimate

90
70

50 Base

30 Fillet
20

10
 Multi-axis Fluctuating
Stress States
Everything presented on fatigue has been based on
experiments involving a single stress component.

What do you do for problems in which there are

more than one stress component?
 Marin Load Factor, kc

Se = k a ⋅ k b ⋅ k c ⋅ k d ⋅ S′e
The endurance limit is a function of the
load/stress component used in the test.

ì0.923 Axial loading Sut ≤ 220 ksi (1520 MPa)

ï 1 Axial loading Sut > 220 ksi (1520 MPa)
ï
kc = í
ï 1 Bending
ïî0.577 Torsion and shear
 Alternating and Mean Von
Mises Stresses
1. Increase the stress caused by an axial force by
1/kc.
2. Multiply each stress component by the
appropriate fatigue stress concentration factor.
3. Compute the maximum and minimum von Mises
stresses.
4. Compute the alternating and mean stresses based
on the maximum and minimum values of the von
Mises stress.
5. Use the Goodman alternating and mean stress
interaction curve and S-N curve to estimate the
number of cycles to failure. Use the reversed
bending endurance limit.
 Complex Loads

A part is subjected
σ, F to completely reversed
σ2 stresses as follows
σ1 σ3 σ1 for n1 cycles,
σ 2 for n 2 cycles,
t, time σ 3 for n 3 cycles,
M
σ m for n m cycles,

What is the cumulative effect of these different load cycles?

 Minor’s Rule
Cumulative Damage Law

n1 n 2 n 3 nm
+ + +K + =C
N1 N 2 N 3 Nm
n i ≡ number of cycles for stress level i
N i ≡ cycles to failure at stress level i
C ≡ Constant ranging from 0.7 to 2.2.
C is usually taken as 1.0
Minor’s Rule is the simplest and most widely used
Cumulative Damage Law
 Example

Stress Cycles Life n

State (n) (N) N
1 1,000 2,000 0.5
2 5,000 10,000 0.5
3 10,000 100,000 0.1
1.1 Part will fail
 Assignment
(Problem No. 1)

A rotating shaft is made of 42 x 4 mm AISI 1020 cold-drawn

steel tubing and has a 6-mm diameter hole drilled transversely
through it. Estimate the factor of safety guarding against
fatigue failure when the shaft is subjected to a completely
reversed torque of 120 N-m in phase with a completely
reversed bending moment of 150 N-m. Use the stress
concentration factor tables found in the appendices, and
estimate the Marin factors using information in the body of the
text.
 Assignment
(Problem No. 2)

A solid circular bar with a 5/8 inch diameter is subjected to a

reversed bending moment of 1200 in-lb for 2000 cycles,
1000 in-lb for 100,000 cycles and 900 in-lb for 10,000
cycles. Use the S-N curve used in this lecture. Determine
whether the bar will fail due to fatigue. Assume all Marin
factors are equal to 1.0.
 Assignment
(Problem No. 3)

Same as Problem No. 2 except there is a constant

axial force of 5,000 lb acting on the bar in
addition to the completely reversed bending
moment.