Introduction

Professor Darrell F. Socie

Department of Mechanical Science and Engineering
University of Illinois at Urbana-Champaign
2011 Darrell Socie, All Rights Reserved
Fatigue and Fracture
( Basic Course )
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Contact Information
Darrell Socie
Department of Mechanical Science and Engineering
University of Illinois at Urbana-Champaign
1206 West Green
Urbana, Illinois 61801
Office: 3015 Mechanical Engineering Laboratory
dsocie@uiuc.edu
Tel: 217 333 7630
Fax: 217 333 5634
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Failure Modes
Elastic Deformation
Plastic Deformation
Buckling
Fracture
Fatigue
Surface Damage
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Stress-Strain Response
S
t
r
e
s
s

(
M
P
a
)
Strain (%)
0.1 10 100
ceramics
metals
polymers
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Strain Energy
S
t
r
e
s
s
,

o
(
M
P
a
)
Strain,c (%)
E 2
U
2
o
=
Strain energy
per unit volume
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Ashby
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Strength vs Modulus
From M F Ashby, Materials Selection in Mechanical Design, 1999, pg 424
E
2
f
o
High energy
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Component Stiffness
E A
L F
y=
L 4
E d
L
E A
y
F
k
2
axial
t
= = =
I E 3
FL
y
3
=
3
4
3
bending
L 64
E d 3
L
I E 3
y
F
k
t
= = =
L
F
L
F
d
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Relative Stiffness
L
F
2
2
3
4
2
bending
axial
d 3
L 16
L 64
E d 3
L 4
E d
k
k
=
t
t
=
500
k
k
10
d
L
bending
axial
~ ~
L
F
d
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Relative Stresses
L
F
L
F
d
2
axial
d
F 4
t
= o
3
bending
d
L F 32
t
= o
L 16
d
d
L F 32
d
F 4
3
2
bending
axial
=
t
t
=
o
o
006 . 0 1 . 0
L
d
bending
axial
=
o
o
~
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Critical Speed ( whirling )
L
y
F = mye
2
Instability occurs when the deflection due
centrifugal force exceeds the deflection
due to bending stiffness
3
L
y I E 192
F=
3
L
y I E 48
F=
Fixed ends
Free ends
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Spinning Tubular Shaft

=
t
t
=
t =
t =
E
L 2
r
3 . 94 n
L 2
r
L t r 2
t r
m
I
density L t r 2 m
t r I
4
2
cr
2 3
3
Consider a tube of length L, radius r, and thickness t
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Materials Selection
From M F Ashby, Materials Selection in Mechanical Design, 1999, pg 419
CFRP
Al
Ti
Fe
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Failure Modes
Elastic Deformation
Plastic Deformation
Buckling
Fracture
Fatigue
Surface Damage
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Kansas City Hyatt Regency
www.sgh.com/expertise/investigations/
kchyatt/kchyatt.htm
http://ethics.tamu.edu/ethics/hyatt/hyatt2.htm
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Kansas City Hyatt Regency
http://www.rose-hulman.edu/Class/ce/HTML/publications/momentold/winter96-97/hyatt.html
Proposed design Actual design
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Failure Modes
Elastic Deformation
Plastic Deformation
Buckling
Fracture
Fatigue
Surface Damage
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Buckling
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Buckling
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Buckling Theory
L
P
P
y
L
P
P
y
M
Equilibrium
M = Py
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Euler Buckling
2
2 2
cr
L
I E n
P
t
=
2
2
cr
L
I E C
P
t
=
C
Fixed-Free 0.25
Round_Round 1
Fixed_Round 2
Fixed-Fixed 4
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Delamination Buckling
o
o
c
o
o
c
h
L
( )
2
2
2
c
L
h
1 3
E
|
.
|

\
|
v
t
= o
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Plastic Buckling
2
2
cr
L
I E C
P
t
= 2
t
2
cr
L
I E C
P
t
=
E
E
t
strain
Elastic
Elastic - Plastic
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Fire Design of Steel Members
www.civil.canterbury.ac.nz/fire1/pdfreports/KLewis.pdf
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Standard Fire ISO 834
0
200
400
600
800
1000
0 10 20 30 40 50 60 70 80 90
T
e
m
p
e
r
a
t
u
r
e
,

C
Time, minutes
) 1 t 8 ( log 345 T
10
+ =
Steel melts at 1493 C
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Elastic Modulus of Steel
0
0.2
0.4
0.6
0.8
1
0 200 400 600 800 1000
Temperature, C
) 25 ( E
) T ( E
600 T
1100
T
ln 2000
T
1
) 25 ( E
) T ( E
<
|
.
|

\
|
+ =
600 T
5 . 53 T
1100
T
1 690
) 25 ( E
) T ( E
>

|
.
|

\
|

=
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Yield Strength of Steel
0
0.2
0.4
0.6
0.8
1
0 200 400 600 800 1000
Temperature, C
) 25 (
) T (
ys
ys
o
o
600 T
1750
T
ln 767
T
1
) 25 ( E
) T ( E
<
|
.
|

\
|
+ =
600 T
440 T
1000
T
1 108
) 25 (
) T (
ys
ys
>

|
.
|

\
|

=
o
o
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Design Loads
0
0.2
0.4
0.6
0.8
1
0 200 400 600 800 1000
Temperature, C
) 25 ( E
) T ( E
Safety factor of 5 is typically
used for column buckling
~ 850 C
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Design Loads
0
0.2
0.4
0.6
0.8
1
0 200 400 600 800 1000
Temperature, C
) 25 ( E
) T ( E
Safety factor of 5 is typically
used for column buckling
~ 850 C
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Time to Failure
0
200
400
600
800
1000
0 10 20 30 40 50 60 70 80 90
T
e
m
p
e
r
a
t
u
r
e
,

C
Time, minutes
~ 30 minutes before steel
columns will buckle in a
building fire
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Failure Modes
Elastic Deformation
Plastic Deformation
Buckling
Fracture
Fatigue
Surface Damage
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Fractures
1943 1972
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Griffith 1893-1963
Circa1920 studied scratches and
the effect of surface finish on
fatigue for the Royal Aircraft
Establishment
E 2 a = t o
Griffith (1920) The Phenomena of Rupture and Flow in Solids,
Philosophical Transactions of the Royal Society, A, 221, 163-198
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Failure Modes
Elastic Deformation
Plastic Deformation
Buckling
Fracture
Fatigue
Surface Damage
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Early steam engine
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Typical broken axle of the 1840s
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Expert opinions of the time
I never met one which did not present a
crystallization fracture
the principal causes are percussion, heat and
magnetism
the change may take place instantaneously
steam can speedily cause iron to become
magnetic
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Rankine 1820 - 1872
Trained as a civil engineer
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William Rankines second paper
Stated that deterioration of axles is gradual
the fractures appear to have commenced with a
smooth, regularly-formed, minute fissure, extending
all round the neck of the journal, and penetrating on
an average to a depth of half an inch. until the
thickness of sound iron in the center became
insufficient to support the shocks to which it was
exposed.
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Rankine ...
In all the specimens the iron remained fibrous;
proving that no material change had taken place in
the structure
He noted that fractures occurred at sharp corners
He recommended that the journals be formed with a
large curve in the shoulder (which is exactly right!)
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Aloha Flight 243
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Failure Modes
Elastic Deformation
Plastic Deformation
Buckling
Fracture
Fatigue
Surface Damage
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Alaska Airlines Flight 261
January 31, 2000
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Jackscrew
http://www.ntsb.gov/events/2000/aka261
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Gimbal Nut
http://www.ntsb.gov/events/2000/aka261
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Report
The threads of the gimbal nut from the accident aircraft are
stripped, and metal shreds made of the same material as that nut
were found on the jackscrew. There are also impact marks on the
outside of the gimbal nut and the lower stop nut; the Board will
try to determine if those impact marks - as well as the stripping
of both nuts threads - were made before the aircraft contacted
the water or after.
http://www.ntsb.gov/events/2000/aka261
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Adhesive Wear
Attractive force between atoms tend to pull
material from the asperity contacts
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Abrasive Wear
Hard particle microcuts a softer workpiece
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Surface Fracture
subsurface inclusion
Subsurface crack nucleation leads to spalling failures
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Fretting
Sliding with small displacements
nucleates fatigue cracks
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Wear Process
A typical junction will deform with a load AL until the
load and contact area reach the material strength.
AL
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Mechanisms
AL
Clean metal surfaces form a solid junction which shears
off to form a wear particle.
The formation of a particle is a rare event,
estimates are 1 in 10,000 contacts
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Adhesive Wear Law
P 3
x L k
V=
V - volume of material removed
x - sliding distance
P - hardness
L - load
k - wear coefficient
3 - hemispherical particle assumption
1 - cubic shaped particles
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Typical Values of k
k
Mild steel on mild steel 10
-2
Brass on hard steel 10
-3
Lead on steel 2x10
-5
PTFE on steel 2x10
-5
Stainless steel on hard steel 2x10
-5
Tungsten Carbide on Tungsten Carbide 10
-6
Polyethylene on steel 10
-7
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Lubrication
10
-6
10
-5
10
-4
10
-3
10
-2
W
e
a
r

c
o
e
f
f
i
c
i
e
n
t
clean poor
lubrication
average
lubrication
excellent
lubrication
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Failure Modes
Elastic Deformation
Plastic Deformation
Buckling
Fracture
Fatigue
Surface Damage
Fatigue and Fracture
( Basic Course )