MAE 4353 Mechanical Design II

Dr James A. Kidd
Module 3, Part 1: 8/25/14
Statistics & Fatigue
Statistics Review
Fatigue
Fatigue in Metals
Fatigue Failures
Fatigue Life Methods (Stress-Life, Strain-Life, Linear-Elastic Fracture Mechanics)
Endurance Limit
Fatigue Strength
Modifying Factors
Stress Concentration and Notch Sensitivity
Fluctuating Stress Characterization
Fatigue Failure Criteria
Loading Mode Combinations
Fluctuating Stresses and Cumulative Fatigue Damage
Problems
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Probability Distribution - Normal
Normal (Gaussian) Probability Density Function (PDF)
Shorthand:
Probability Distribution: Measure of uncertainty of a given quantity or measurement
Fatigue life and component wear data are noisy and must be treated accordingly for
good design and analysis
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Probability Distribution Normal, cont
Transforming into standard
variable z permits use CPD tables:
No closed form for Cumulative Probability
Distribution (CPD) for Gaussian:
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Empirical Distribution Rule
6
Weibull Distribution
Variable shape; Highly useful for reliability estimates based on experimental or field data
3-Parameter Weibull Distribution:
x
0
is the minimum guaranteed valued of x
Characteristic
Value of x below which lie 63.2%
of observations
Shape parameter b>0
Controls skew
(large to right, small to left)
Reliability is complement to CPD:
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Weibull Distribution, cont
Solving for x:
x - Value at which specified reliability could be expected
(given distribution defined by x
0
, and b)
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Error Propagation

Coefficient of Variation:
Table 20-6
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Error Propagation Example
Given force and area measurements of a rod under tension with normal
probability distributions and means of F = 20,000 psi and A = 0.5 in
2
and
coefficients of variation of C
F
= 0.05 and C
A
= 0.05, determine the mean and
standard deviation of the resulting direct stress. If the material has a yield stress
allowable of 43,000 psi, comment on the implications of the results.
Going further: What are the implications of material property statistical variation?
MMPS Handbook properties:
A Basis 99% samples exceed value to 95% confidence
B Basis 90% samples exceed value to 95% confidence
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Fatigue
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Fatigue in Metals
Failure - Under varying load
- Well below ultimate strength
- Possible with little structural deformation, i.e., suddenly
Cracks typically begin at discontinuities, for example:
Rapid cross section changes
Keyways
Stress concentration points
Tool marks, scratches, etc.
Surface pits from contact or corrosion
Material flaws
General fatigue classifications:
Low Cycle: N10
3
cycles
High Cycle: N>10
3
cycles
Progression:
Stage I: Micro-crack initiation and initial growth
Stage II: Micro-crack to macro-crack, beach mark bands
Stage III: Rapid growth to failure
http://youtu.be/DykiHVrVkKg
TWI Fatigue Testing
http://youtu.be/GPYw8hRkyVA
Fatigue Crack Propagation
Fatigue-Life Methods - Introduction
Stress-Life Method
Most traditional and represents high-cycle fatigue adequately
Least accurate for low-cycle fatigue
Strain-Life Method
More detailed analysis of localized plastic deformations
Better for low-cycle fatigue estimates
Multiple compounding idealizations so significant
uncertainties
Discuss due to insight into nature of fatigue
Linear-Elastic Fracture Mechanics (LEFM)
Fracture mechanics crack growth as function of stress
intensity
Typically implemented via computer codes
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Stress-Life Method
Fatigue strength from test data
Widely used method:
Moores rotating beam for pure bending of
close tolerance, highly polished specimens
Note statistical nature of the results
Testing of material and
components may be
required
Example with endurance
limit, S
e
If no clear endurance limit,
S
e
must include number of
cycles (say 10
8
)
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Endurance Limit Strength
Simplified relationship
for endurance limit
strength in steels:
For test specimen NOT actual component!
Fig 6-17
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Endurance Limit Modifying Factors
Marin Equation:
Endurance strength in real life can (will!) differ from lab test data using carefully
prepared specimens in controlled environments
Real effects include: Material, manufacturing, environment, design,
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Factors, cont.
Surface Factor k
a
:
Test specimens are highly machined, highly polished and in a protected environment
Real components may have a variety of finishes (ground, machined, etc.)
Finish a, kpsi b
Ground 1.34 -0.085
Machined or cold-drawn 2.70 -0.265
Hot-Rolled 14.4 -0.718
As-Forged 39.9 -0.995
S
ut
, kpsi
150
k
a
0.875
0.716
0.394
0.273
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Factors, cont.
Size Factor k
b
:
Real components vary in size from the test specimens
For bending and torsion:
For axial loading (no effect):
Equivalent diameters:
For non-rotating cylinders:
For rectangular cross-sections:
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Factors, cont.
Loading Factor k
c
:
Accounts for differences in component loading vs. test loading
When torsion is combined with bending or axial, use k
c
=1
Temperature Factor k
d
:
For reduced temperatures, brittle fracture is a higher risk
For elevated temperatures a model for a steel is:
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Factors, cont.
Reliability Factor k
e
:
Fatigue strength values usually expressed as means
Data indicates an 8% typical standard deviation
Reliabilty, % z
a
k
e
50 0 1
90 1.288 0.897
95 1.645 0.868
99 2.326 0.814
99.9 3.091 0.753
99.99 3.719 0.702
99.999 4.265 0.659
99.9999 4.753 0.620
Miscellaneous Effects Factor k
f
:
For anything else, like
Corrosion, coatings,
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Endurance Strength Example
What is the endurance strength of the machined shaft given below if a 99.99%
reliability is desired?
Assignments
Friday (8/22) by 2200:
Complete and submit Resume Slide Assignment to D2L Dropbox
By class time Monday (8/25):
Read Shigley Chapters 20 (stats) and 6 (Fatigue)
Complete online Stats & Fatigue Quiz
Download Stats/Fatigue Problem set (conditional on quiz)
Upload Problem Set #1 (Elasticity)
Wednesday (8/27):
Fatigue, continued + guest Speaker
Friday (8/29): Jet Engine Cutaway Assessment at DML
3 groups: 0900, 0945, 1030 sign up Wednesday
Monday (9/1): Labor Day No Class!
Wednesday (9/3): Finish Fatigue, Introduce Project Phase I
By class time Friday (9/5):
Review brainstorming videos on D2L project Phase I folder
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