School of Engineering EN334

M. Daniel K. Wood

Example 4.1
Problem:
An AISI 1020 CR steel bar is to withstand a tensile pre-load of
356kN and a fluctuating tensile load varying from 0 to 71.2kN. The
steel bar has a geometric stress-concentration factor of 1.995
corresponding to a fillet radius of 5mm. Assume the notch sensitivity
is 0.70, and the surface factor ksf = 0.78. Determine the bar
diameter for a factor of safety of 1.5 and an infinite life.

Solution:
From the appendix (material properties), the yield and ultimate
stresses for AISI 1020 CR steel are Sy = 414 x106 N/m2 and Su =
552 x106 N/m2 respectively.
 School of Engineering EN334
M. Daniel K. Wood

Sn= half of the ultimate strength of the material (Su/2) = 0.5552 106
N/m2 = 276 106 N/m2.

ksf = surface finish factor = 0.78 (given)

kr = reliability factor = 1 (assume since no information is given)
ks = size factor = 0.85 (mid-value assumed since initial diameter is
not known)
kt = temperature factor = 1 (assume since no information is given)
k f 1 q (k st 1) = fatigue stress concentration factor
= 1 + 0.7(1.995 1) = 1.6965
km = 1 / kf = the stress concentration modifying factor
= 1/1.6956 = 0.5894

Therefore, Se k sf k r k s kt k m S n = 0.7810.8510.5894276 106

= 107.85 106 N/m2 (Pa).

 School of Engineering EN334
M. Daniel K. Wood

The stress induced in the steel bar is:

Fs 35.6 x10 3 N 142.4 x10 3 N

s
A d 2
d 2
4
The stress range in the steel bar is:

Fr 71.2 x10 3 N 284.8 x10 3 N

r
A d 2
d 2
4
 School of Engineering EN334
M. Daniel K. Wood

The stress amplitude in the steel bar is:

r 142.4 x10 3 N
a
2 d 2
The mean stress in the steel bar is:

142.4 x10 3 N 142.4 x10 3 N 284.8 x10 3 N

m s a
d 2
d 2
d 2

We now use the Goodman diagram to find the stress range as

follows:
 School of Engineering EN334
M. Daniel K. Wood

The load line can now be drawn with a gradient of a m 0.5 .

Using basic knowledge of intersection of straight line, the points of
intersection can be found from the ultimate strength-endurance limit
line, and the superimposed design line-equations as follows:
Ultimate strength-endurance limit line:

107.85
Y1 X 107.85 0.195 X 107.85
552

Design line equation:

Y2 0.5 X

Where Y is the alternating stress and X is the midrange stress

 School of Engineering EN334
M. Daniel K. Wood

At the point of intersection, Y1 = Y2. Solving the simultaneous

equation leads to:

0.195X 107.85 0.5 X

We find the value of X = 155.179Pa. The value of Y1 is found as

follows:

Y1 0.195 X 107.85 0.195 155.179 107.85

77.59 x106 N / m 2

Using the relation

a
nf
S sr
 School of Engineering EN334
M. Daniel K. Wood

142.4 x10 3 N 1
1.5
d 2 6
77.59 x10 N

Solving for the diameter, Voila!

142.4 x10 3
d 6
0.0197m (19.7mm)
77.59 x10 *1.5