Fatigue Part 1

Dr. Nuri Ersoy

Fatigue, Damage, Durability
Fatigue is the process where repeated variations
in loading cause failure even when the nominal
stresses are below the material yield strength;
Damage is the inverse of life for a given strain
amplitude and is cumulative until failure
Durability is the capacity of an item to survive its
intended use for a suitably long period of time,
so that good durability minimises the cost of
maintaining and replacing the item
Approaches to Analysing and
Designing Against Fatigue Failure
Stress Based Aproach: Analysis is based on the nominal
(average) stresses in the region of the component being
analysed. The nominal stresses that can be resisted
under cyclic loading is determined by considering mean
stresses and by making adjsutments for the effects of
stress raisers, such as grooves, holes, fillets, and
keyways
Strain Based Approach: involves more detailed analysis
of the localised yielding that may occur at stress raisers
during cyclic loading.
Fracture Mechanics Approach: treats growing cracks
using fracture mechanics approach
Definitions and Concepts
Constant Amplitude Stressing
2
: Stress g Alternatin
2
: Stress Mean
: Range Stress
min max
min max
o
o
o o
o
o o o
A
=
+
=
= A
a
mean
Fatigue Testing
Rotating Bending Testing
Fatigue Testing
Servohydraulic Testing
Metallurgical Fundamentals
Persistent Slip Band Formation
Stages of Fatigue
Initiation Stage I Stage II
Stages of Fatigue
Crack Initiation: Early development of fatigue
damage which can be removed by suitable
thermal annealing
Slip band crack growth: deepening of the initial
crack on planes of high shear stress Stage I
crack growth
Crack growth on planes of high tensile stress:
growth of well-defined crack in direction normal
to maximum tensile stress Stage II crack growth
Ultimate ductile failure: occurs when the crack
reaches a sufficient length so that the remaining
cross section cannot support the applied load.
Fatigue Stages and
Fatigue Surfaces
Fatigue Striations
Stage II Crack Growth
Low Cycle vs High Cycle Fatigue
Low Cycle
<10
4
cycles
o>o
Y
50% of life spent for initiation
Many cracks nucleate
High Cycle
>10
4
cycles
o<o
Y
90% of life spent for initiation
Single crack nucleates
Fatigue Testing
Rotating Bending Testing
Stress-Life Curve (S-N curve)
constants material
are and
) 2 (
b
N
f
b
f f a
o
o o
'
'
=
Prime indicates that it is obtained from rotating-bending tests
Stress level below which fatigue failure does not occur (plain
carbon and low alloy steels)
Fatigue Strength
Stress amplitude value from an S-N curve at a
particular life of interest
S-N Curve
S-N Curve
o
a
, MPa N
f
, cycles
948 222
834 992
703 6004
631 14130
579 43860
524 132150
Probabilistic Nature Of Fatigue
Scatter in rotating bending S-N data for an unnotched aluminum alloy
Distribution of fatigue lives for 57 small specimens of
7075-T6 aluminum tested at S
a
=207 MPa
Probabilistic Nature of Fatigue
Safety Factors
B -1/B X
N
for X
S
=2 X
S
for X
N
=10
-0.1 10 1024 1.26
-0.2 5 32 1.58
-0.333 3 8 2.15
o
a
=AN
f
B
Endurance Limit versus UTS
Endurance Limits
Wrought Steel
Cast Steel and Cast Iron
Aluminium Alloys
Wrought Aluminium Alloys
Magnesium Alloys
Copper and Nickel Alloys
Titanium Alloys

>
<
=
'
1400MPa for 700MPa
1400MPa for 5 . 0
u
u u
e
S
S S
S

>
<
=
'
MPa 40 3 for 130MPa
MPa 40 3 for 40 . 0
u
u u
e
S
S S
S

>
<
=
'
MPa 00 6 for 275MPa
MPa 600 for 45 . 0
u
u u
e
S
S S
S
u e
S S 35 . 0 =
'

=
'
mold permanent for 100MPa - 70
cast sand for 75MPa - 0 5
e
S
u u e
S S S 50 . 0 to 25 . 0 =
'
u u e
S S S 65 . 0 to 45 . 0 =
'
Generalized S-N Curve for
Wrought Steel
Factors Affecting the Endurance
Limit
factor notch fatigue
factor y reliabilit
factor loading
factor (Gradient) Size
factor surface
/
=
=
=
=
=
'
=
f
R
L
G
S
f R S G L e e
k
C
C
C
C
where
k C C C C S S
S-N Diagrams for Other Types
of Loading (Loading Factor, C
L
)
Influence of Surface Finish on Fatigue
Strength (Surface Factor,C
s
)
Influence of Size on Fatigue
Strength (Size Factor, C
G
)
Size Factor, C
G
in bending or torsion
in axial loads
independent of size
1
b
k ~
1 0.4 (10 )
.85 0.4 (10 ) 2 (50 )
.75 2 (50 )
b
for d mm
k for mm d mm
for d mm
''
s

'' ''
~ < <

''
>

Reliability Factor, C
R

Reliability
c
k
50%
90%
95%
99%
99.9%
99.99%
1.00
.90
.85
.80
.75
.70
Fundamentals of Machine Component Design, 4/E by Robert C. J uvinall and Kurt M. Marshek
Table 8.1a (p.
303)
Generalized Fatigue
Strength Factors for
Ductile Materials
(S-N curves).
(Continued on next
slide.)
Fundamentals of Machine Component Design, 4/E by Robert C. J uvinall and Kurt M. Marshek
Table 8.1b (cont.)
Effect of Mean Stress
Presentation of Mean Stress Data
Constant life Diagram
Presentation of Mean Stress Data
Normalized Amplitude-Mean Diagrams
0 for
stress g alternatin the is
stress mean any for
stress g alternatin the is
1
Parabola Gerber
) 0 ( 1
Line Goodman Modified
2
=
=
|
|
.
|

\
|
+
> = +
m
ar
m
a
u
m
er
e
m
u
m
ar
a
o
o
o
o
o
o
o
o
o
o
o
o
o
Life Estimates
Any combination of mean
stress o
m
and amplitude o
a
is
thus expected to produce the
same life as the stress
amplitude applied at zero
mean stress, o
ar
. Hence o
ar
may be thought of as an
equivalent completely
reversed stress, with respect
to the life produced.
b
f f
f
m
ar
b
f f ar
f
m
a
ar
f
m
ar
a
N
N
) 2 ( 1
) 2 (
1
1
Approach Morrow
o
o
o
o
o o
o
o
o
o
o
o
o
o
'
|
|
.
|

\
|
'
=
'
=
'

=
=
'
+
Life Estimates
) 0 ( ) 2 (
Approach (SWT) Topper - Watson - Smith
max max
max
>
'
=
=
o o o o
o o o
b
f f a
a ar
N