FATIGUE 2013a PDF

ADVANCED STRENGTH OF COMPONENTS (P04710)
FATIGUE
http://www.youtube.com/watch?v=TH9k9fWaFrs
http://www.youtube.com/watch?v=nVw5g1s06ow
http://vimeo.com/24925550
PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 1

FATIGUE FAILURES ARE CAUSED BY
FLUCTUATING LOADS SLIP INTRUSION AND EXTRUSION
FAILURE OCCURS IN 4 STEPS
1. LOCAL MICROSCOPIC DAMAGE INITIATE.
DAMAGE OCCURS AT POINTS OF HIGH STRESS:
i. SURFACE NOTCHES – FILLETS, GROOVES, SCRATCHES, WELDS
ii. DEFECTS WITHIN THE MATERIAL
SEVERAL DAMAGE SITES MAY DEVELOP SIMULTANEOUSLY.

2 MICROCRACKING (STAGE 1 CRACKING)
3 MACROCRACKING (STAGE 2 CRACKING)
MICROCRACKS (< 100M) GROW ON PLANES
OF MAXIMUM SHEAR AT THE DAMAGE MACROCRACKS, EXTENDING ACROSS MANY
SITES GRAINS, DEVELOP WITH AN ORIENTATION
NORMAL TO THE MAXIMUM PRINCIPAL STRESS.
ONE CRACK WILL DOMINATE AND GROW
4 FAST FRACTURE OCCURS

FINAL FRACTURE MAY BE EITHER BRITTLE OR
DUCTILE, BUT IS OFTEN BRITTLE IN STRONGER
MATERIALS.

BLUNT CRACKS ESTABLISHED BY WELDING AND OTHER MANUFACTURING
PROCESSES ARE CHANGED DIRECTLY INTO SHARP MACROCRACKS.

BEHAVIOUR OF MATERIAL SPECIMENS
1 TYPE OF TEST TYPICAL STRESS-TIME RELATIONS

PUSH-PULL
F
s  Z 
A
PLANE BENDING
M
s  Z  yˆ
I
ROTATING BENDING
STRESS RANGE  2S a

M S
s  Z  yˆ STRESS RATIO  R 
http://www.youtube.com/watch?v=52knsY5AWIc
I Ŝ
PART II FATIGUE 5
2 STRESS – LIFE RELATIONSHIPS
a) b)
a) LINEAR – LINEAR
b) LOG – LINEAR
c)
c) LOG - LOG

MATERIALS HAVING A FATIGUE LIMIT
FATIGUE LIMIT HAS A STRONG

FATIGUE LIMIT
RELATIONSHIP TO THE ULTIMATE
TENSILE STRENGTH (EXCEPT WHERE u
IS HIGH)
STEEL Sao (106) = 0.4 u - 0.6u

TITANIUM Sao (107)  0.5 u
CAST IRON Sao (107)  0.4 u
OTHER MATERIALS
EXAMPLES FOR ROTATING BENDING
ALUMINIUM (WROUGHT) Sao (108) = 0.35 – 0.4 u

MAGNESIUM (WROUGHT) Sao (108)  0.35 u

Fatigue Strength, (MPa)
Ultimate Tensile Strength, UTS, (MPa) Ultimate Tensile Strength, UTS, (MPa)
STEEL WROUGHT COPPER ALLOYS
THE RELATIONSHIP BETWEEN FATIGUE STRENGTH AND ULTIMATE TENSILE STRENGTH APPLIES
FOR A WIDE RANGE OF LOW AND MEDIUM STRENGTH VERSIONS OF MATERIALS ( R W Hertzberg).

FATIGUE STRENGTH (MPa)
FATIGUE LIMIT (MPa)
STEEL ALUMINIUM
FOR A WIDE RANGE OF LOW AND MEDIUM STRENGTH VERSIONS OF MATERIALS. WHERE THE
MONOTONIC STRENGTH IS HIGH THE FATIGUE LIMIT IS A LOWER % OF u.

TYPICAL S-N CURVES FOR STEEL AND ALUMINIUM
u < 1400 MPa

STEEL
LOADING: ROTATING BENDING
ALUMINIUM u < 330 MPa
LOADING: ROTATING BENDING

EQUATIONS FOR S-N CURVES
Sa = a N b
Log Sa = b Log N + Log a
b = SLOPE =
 
Log S a 10e - Log S a 103  
Log 10e  Log 103

1
Log 
 
 S a 103
e - 3  
 S a 10
e
  
  Log 10e  Log 10o 
    
Log a  Log S a 10e   LogSa 103  Log S a 10e    
  Log 10e  Log 103 
  
 e 
 Log S 10e      Log S 103   Log S 10e  
a   e 3  a  a 

     
 e   e 
 
Log a  Log S a 10  Log S a 10
e 3  e - 3 
   Log S a 10 e  
 e -3 
 1 
   
 
 3   S 10 3 e  e  3
     
 e   
3  e 3   e 3   Log  a
 Log S a 10  Log S a 10
   
e
  3
 S a 10e
 1 
 
   
 e  3
 S 103 e
a  a
 a    
 S 10e 3
e.g. STEEL, STANDARD CURVE
 
S a 103  0.9 u   S a 106  0.5 u
1  S 10   3
1  0.9 
 Log     Log  
 S 10  
a u
b
e  3 a6  3
e
 0.5 u 
  0.085
 1 
  
   1 
 0.9 u  
 
 S 10 3 e
  e 3  6  6 3 
 a    
  
a 3 
 S 10e  0.5 u  
3 
 a 
 1.62 u Sa = 1.62u N-0.085

ALUMINIUM, STANDARD CURVE
Sa (103) = 0.9u Sa (108) = 0.4u
1  0.9 u 
b Log     0.0704
8  3  0.4 u 
 1 
 0.9  u 8   8 3 
 
a     1.464 u
 0.4 u 3 

Sa = 1.464uN-0.0704

BEHAVIOUR OF COMPONENTS
FOR N ≥ 103 CYCLES OF ALTERNATING
CONSTANT AMPLITUDE LOAD
C L C D C S CO
  Sao
Sao
Kf
S'ao FATIGUE STRENGTH OF COMPONENT } At N

Sao FATIGUE STRENGTH OF SPECIMEN }
CL LOADING FACTOR
CD DIMENSION (SIZE) FACTOR
CS SURFACE FINISH FACTOR
Kf NOTCH FACTOR
Co OTHER E.G. SURFACE TREATMENTS ENVIRONMENT

Life /
Factor 103 cycles 106 or 108 cycles
CL Bending  Bending CL = 1.00 Bending  Bending CL = 1.00

Bending  Axial CL = 0.85 Bending  Axial CL = 0.85
Axial  Bending CL = 1.00 Axial  Bending CL = 1.00
Axial  Axial CL = 1.00 Axial  Axial CL = 1.00
CD CD = 1 Bending  CD = 1 for d < 8 mm

Bending  CD = 0.61d-0.097 for 8 < d < 200 mm
Axial  CD = 1 for d < 50 mm
CS CS = 1 Find CS from charts or data tables
For steel use graph of CS  u

(or graphs in ESDU 74027 based on Kt)
Co CO = 1 CO = 1
Unless data shows otherwise Unless data shows otherwise
Kf Kf = 1 (for ductile material) Kf = Kf

Kf = Kt (for brittle material)

SURFACE FINISH FACTORS – STEEL SPECIMENS AT N = 106

CO
(i) SURFACE TREATMENTS GIVING CO < 1
SEVERE GRINDING (TENSILE RESIDUAL STRESS) 0.9 – 0.75
COATINGS (METAL AND CERAMIC) 1 – 0.3
THE EFFECTS ARE GREATEST ON STRONG SUBSTRATES
DECARBURIZATION 0.6 – 0.3
FRETTING 0.6 – 0.3
WEAR
CORROSION 0.8 – 0.1
WELDING (COATINGS AND JOINING) 0.7 – 0.2
(ii) SURFACE TREATMENTS GIVING CO > 1(1)

GENTLE GRINDING (COMPRESSIVE RESIDUAL STRESS) 1.1
PEENING(2) - SHOT 1.3 – 2
GLASS BEAD
ROLLING (2) - GENERAL 1.3 – 2
- THREADS 1.3 –
SURFACE HARDENING(3) 1.3 – 2.5
(1) Ĉo  1.1 FOR UNIFORM TENSION BARS (NO INTERNAL DEFECTS)
(2) COMPRESSIVE RESIDUAL STRESSES IN SURFACE
(3) COMPRESSIVE RESIDUAL STRESS AND HIGHER u IN THE CASE. SUBSTRATE IS UNCHANGED.

OTHERS FACTORS FOR SURFACE TREATMENTS – STEEL SPECIMENS AT N = 106

MATERIAL: STEEL, u = 1100 MPa
DETERMINE:
SHAFT DIAMETER SO THAT IT WILL SURVIVE 106 CYCLES
S – N EQUATION
LIFE IF F = 8kN
u OF THE STEEL FOR LIFE OF 2.5 X 105 CYCLES WHEN F = 8kN.

1. USING STANDARD S-N CURVE FOR ROTATING BENDING SPECIMENS
Sao (106) = 0.5 x 1100

= 550 MPa
S'ao (106) = Sao (106) CL CD CS CO

CL = 1
CD = 0.61 d-0.097 (ASSUMING THAT 8 < d < 200mm )
CS = 0.9 (FROM GRAPH)

CO = 1 (IGNORING WEAR IN THE BEARING)
CD = 0.61 d-0.097 (ASSUMING THAT 8 < d < 200mm )
S'ao(106) = 550 x 106 x 1 x (0.61 d-0.097 ) x 0.9 = 302 x 106 x d-0.097 Pa

SHAFT LOADING
AT SUPPORT
M 1200 x 64 d 12223
REF = ŷ = x = (Pa )
4
I πd 2 d3
FOR N = 106  (106 )

 REF  S ao
12223
3
 302 106  d 0.097
d
d 2.903  12223 / (302 106 )


d  31mm
2.
2.
S'ao(106) = Sao(106) CLCDCsCo / Kf S’ao(103) = Sao(103) CL
CD = 0.61 x d-0.097 = 0.61 x (31 x 10-3)-0.097 = 0.85 = 0.9 u x 1
CS = 0.9; = 0.9 u
Co = CL = Kf = 1
S'ao(106) = (0.5x u)x 1 x 0.85 x 0.9 x 1 / 1
= 0.382u
S'ao = a Nb

1  S ao
LOG 
 103  
b
e  3  10e
 S ao   
1  0.9  u 
 LOG     0.124
6  3  0.382 u 
 1 
   
 
 S  10 3 e  e 3 
  ao S’ao = 2.12 uN-0.124
   
a )
 S  10e 3
 ao ) --------(1)

0.9 u 
2
 2.12 u
= 2332 N-0.124 (MPa) )
0.382 u

3
M̂
REF = ŷ
I
1600 x 64 0.031
 x  547 MPa
 x 0.0314 2
FOR FAILURE IN N CYCLES

REF = S'ao (N)
Using (1)
547 = 2332 N-0.124
N = 1.2 x 105 cycles

4. FOR A SIMILAR STEEL WITH HIGHER U, OR THE SAME STEEL WITH HIGHER
HARDNESS, THE S-N CURVE IS PARALLEL TO THE ORIGINAL CURVE.
USING (1) FOR FAILURE IN 2.5 x 105 CYCLES
REF = S'ao (2.5 x 105)
547 = 2.12 u (2.5 x 105)-0.124
u = 1205 MPa
A 10% INCREASE IN u DOUBLES THE LIFE
+ 5% VARIATION IN U CAN BE EXPECTED, GIVING 2:1 VARIATION IN LIFE

Kf FOR NOTCHED COMPONENTS
Kf 
FATIGUESTRENGTH OF UNNOTCHEDBAR

 
Fao 106 (1)

S 'ao 106 (1)  
FATIGUESTRENGTH OF NOTCHED BAR  
Fao 106 (2) S ' ao 106 (2)  
Kf IS USUALLY IN THE RANGE 0.7 Kt - 0.95 Kt
AND CAN BE CALCULATED FROM Kf = 1 + q (Kt – 1)
1
q = NOTCH SENSITIVITY FACTOR FOR THE MATERIAL q
  
1 
 r 

r = NOTCH RADIUS
  u  1624 x 106 
 - FROM GRAPH OF Log     6
 [ Dowling p 407]
 586 x 10 

NOTCH SENSITIVITY
CONSTANT - NEUBER
ULTIMATE TENSILE STRENGTH (MPa)

e.g.
MATERIAL: (1) STEEL, u = 500MPa

(2) STEEL, u = 1200MPa
CALCULATE Kf
Kt
Kt = 2.99 ESDU 69020 Fig. 5.4

  u  1624 x 106 
Log     6

 586 x 10 
(1)  = 237.4m GRAPH 203m

(2)  = 15.17m GRAPH 16.9m

q 1
q =
 
1  
 r 

(1) q = 0.744 OR 0.758

(2) q = 0.920 0.916
Kf
Kf = 1 + q (Kt - 1)
(1) Kf = 2.48 OR 2.51
(2) Kf = 2.83 2.82
Kf (2) = 1.12 Kf (1)
Kf (1) = 0.83 Kt Kf (2) = 0.95 Kt

SHOULDER: Kt = 2.1
MATERIAL: STEEL u = 1100 MPa, y = 950MPa,
Sao(106) = 550MPa ROTATING BENDING
CALCULATE:
F FOR SHAFT TO LAST FOR AT LEAST 106 REVOLUTIONS
FY FOR MONOTONIC LOADING,  = 0 REV/ MIN.

FATIGUE STRENGTH
C L C D CS
S’ao(106) = Sao(106) Kf
CL = 1 SAME TYPE OF LOADING AS SPECIMEN

CD = 0.61 d-0.097 = 0.61 x 0.03-0.097 = 0.86
CS = 0.69 FROM GRAPH
Kt = 2.1
Kf = 1 + q (Kt - 1)

  u  1624 x 106 
LOG     6

 586 x 10 
 1100  1624 
 
 586 
 = 22.5m
1
q  0.9
 22.5 x 10 6 
1  
 2 x 10 3 
 
 K f  
   0 .95 
Kf = 1 + 0.9 (2.1 - 1) = 1.99  K 
 t  
  S ao 106 
C L C D CS
S ao
Kf
1 x 0.86 x 0.69
 
 106
S ao
0.15
 550 x  164MPa u
1.99

FOR THE SHAFT TO LAST 106 CYCLES OR MORE
aREF < S1 ao (106) = 164 MPa

M
aREF = yˆ
I
200 x 103 F x 32
  75.5 x 103 F ( Pa )
 x 0.033
 75.5 x 103 F = 164 x 106

F = 2.17kN

2.
M 2.1 x 0.2 F x 32
ˆ Z  Kt yˆ   158.4 x 103 F ( Pa )
I  x 0.03 3
For yield
ˆ Z  y  950MPa
158.4 x 103 Fy = 950 x 106
Fy = 6kN F
 0.36
FY

Kf AT N < 106 STEEL OR < 108 ALUMINIUM
AS THE LIFE DECREASES TOWARDS 103 CYCLES YIELDING OCCURS AT THE NOTCH AND
THE EFFECTIVE KT DECREASES FOR DUCTILE MATERIALS.
AT N = 103 USE Kf = 1 DUCTILE MATERIALS

Kf = Kt BRITTLE MATERIALS

103 < N < 106

MATERIAL: STEEL
u = 700MPa, Y = 540MPa
Sao (106) = 380MPa ROTATING BENDING
CALCULATE:
(i) Fa FOR ROD TO LAST AT LEAST 106 CYCLES
(ii) Fa FOR LIFE OF 103 CYCLES
(iii) Fa FOR LIFE OF 5 X 104 CYCLES
(iv) Fy FOR MONOTONIC LOADING
(v) FL FOR MONOTONIC LOADING
(vi) Fu FOR DUCTILE FRACTURE

S’ao(106) = Sao (106) C L C D CS
Kf
CL = 0.85 USING BENDING Sao
CD = 1
CS = 0.76 FROM GRAPH
 = 108.2 m , q = 0.82
Kf = 1 + q (Kt - 1) = 1 + 0.82 (2.4 - 1) = 2.15
S’ao (106) = 380 x 0.85 x 1 x 0.76  114.2MP

a
2.15

FOR THE ROD TO LAST 106 CYCLES
aREF = S’ao (106) = 114.2 MPa
aREF = Fa

Fa
 3183 Fa Pa 
A  x 0.012
3183 Fa = 114.2 x 106
Fa = 35.9 kN

(ii) N = 103
CL = 0.85
CD = 1 = CS = Co
Kf = 1 (DUCTILE)
S’ao(103) = Sao (103) CL = 0.9 CL
= 0.9 x 700 x 0.85 = 536 MPa
FOR THE ROD TO LAST 103 CYCLES
aREF = S’ao (103) = 536 MPa
3183 Fa = 537 x 106
Fa (103) = 168.2 kN

(iii) 103 < N < 106
  a Nb
S ao
b
1  S ao
LOG 
 103 

 
e  3  ao
S  10 e 
  
1  536 
 LOG     0.224
6  3  114.2 
 1 
   
 
 S  10 3 e  e 3 
a   ao
   
 S  10e
 ao
3
 1 
 
 
 536 x 106 6  63 
   2.515 x 109 ( Pa )

 114.2 x 106 3 
  

S’ao (N) = 2.515 x 109 N-0.224 (Pa)
FOR LIFE OF 5 x 104 CYCLES
S’ao (105) = 2.515 x 109 x (5 x 104) - 0.2224 = 223 MPa
aREF  S’as (5 x 104)
3183Fa = 223 x 106
Fa (5 x 104) = 70 kN
(iv) FY
ˆ Z  K t
F
 2.4 x
F
 7639 F Pa 
A  x 0.012
FOR YIELD
ˆ Z   y  540 M Pa
7639 Fy  540 x 106

Fy  70.7 kN

FL
(v) FL y  FL  540 x 106 x  x 0.012  170 kN
A
Fu
(vi) Fu u  Fu  700 x 106 x  x 0.012  220 kN
A
Fa (10 6 ) (
Fa 5 x 10 4 ) ( )
Fa 103 Fy FL
Fu Fu Fu Fu Fu
0.163 0.318 0.765 0.321 0.772

MATERIAL: ALUMINIUM
u = 330MPa
Cs = 0.8 UNMACHINED SURFACE
= 0.7 MACHINED SURFACE
q = 0.9
CALCULATE:
(i) Fa FOR 108 CYCLES TO FAILURE
(ii) Fa FOR 106 CYCLES TO FAILURE
(iii) Fu FOR DUCTILE FRACTURE

C C C C
(i) S’ao (108) = Sao (108) L D S O
Kf
Sao (108) = 0.4 σ u STANDARD CURVE FOR ROTATING BENDING
CL = 0.85
CD = 1
CS = 0.7 FOR CRACK INITIATION AT HOLE
CO = 1
Kt = 3.13 ESDU 69020 Fig 2.3
q = 0.9
Kf = 1 + q (Kt - 1) = 1 + 0.9 (3.13 - 1) = 2.92
0.4 x 330 x 0.85 x 1 x 0.7 x 1

S’ao (108) =  26.9MPa
2.92    0.08
 108
S ao
u

LOADING
F
 REF 
A
F
  2500 F ( Pa ) A = AREA OF UNDRILLED PLATE
50 x 8 x 106 (see ESDU 69020 Fig 2.3)
FOR A LIFE OF 108 cycles
aREF  S’ao(108) = 26.9 MPa 2500 Fa = 26.9 x 106 Fa (108) = 10.8kN
(ii) N = 103
CL = 0.85; CD = 1 = CS = CO
Kf = 1 (DUCTILE)
Sao (103) = 0.9u = 0.9 x 330 = 297 MPa
S’ao (103) = Sao (103) CL; = 297 x 0.85 = 252 MPa

103 < N < 108
S’ao = a Nb
 
1  S ao

 103   
b
e  3
LOG
 S  10e
 ao   
1  252 
  LOG    0.194
8  3  26.9 
 1 
  
 
 S  103 e
  e 3 
  ao 
  
a
 S  10e 3 
 ao 
 1 
 
 
 252 x 10  6 8  83 
    965MPa

 26.9 x106 3 
  
 ( N )  965 N 0.194
S ao ( MPa )
FOR LIFE OF 106 cycles
S’ao (106) = 965 x (106)-0.194 = 66.1 MPa
aREF  S’ao (106)
2500 Fa = 66.1 x 106; Fa (106) = 26.4 kN

(iii) ULTIMATE MONOTONIC LOAD
Fu
u 
A
Fu = 330 x 106 x 40 x 8 x 10-6 = 105.6 kN
( )
Fa 108
= 0.1
Fu
Fa (10 6 )
= 0.25
Fu

PARTS WITH NON ZERO MEAN STRESS
SUBJECTED TO CYCLIC LOADING

EFFECT OF MEAN STRESS


1. UNNOTCHED SPECIMENS

THE CURVE FOR N = CONSTANT CAN BE APPROXIMATED BY:
  S n 
Sa 1   m  
=     
Sao   u 
WHEN Sm IS POSITIVE
FOR MOST STEELS n ~ 1.5
FOR ALUMINIUM AND THE STRONGER STEELS

n 1
n = 1 IS USED FOR MOST WROUGHT METALS
Sa ( N )  S 
 1  m       (1)
S ao ( N )  u 
(GOODMAN)
USE (1) FOR 103 < N < 106 STEEL

EFFECT OF Sm ON N
103 <N< 108 ALUMINIUM

EXAMPLE
MATERIAL: STEEL, u = 700 MPa
CALCULATE:
(i) M̂ FOR LIFE OF 106 CYLCES
(ii) LIFE WHEN M̂ = 26 Nm
i) Sao (106) = 0.5 x 700 = 350 MPa
Sa  S 
 1  m  Sm = Sa
S ao   u 
  
S a 10  350 1 
6 S a 106  

 700 
Sa (106) = 233 MPa

LOADING
 aREF
M  I
a y
 x 83
 x x 10 9
aREF 32
 50.26 x 10 9  (1)
aREF ( Nm)
FOR A LIFE OF 106 CYCLES
aREF  Sa (106) = 233 MPa
Ma = 50.26 x 10-9 x 233 x 106 = 11.7 Nm; M̂ = 23.4 Nm
(ii) N = 103
Sao (103) = 0.9 x 700 = 630MPa
Sa (103)=Sao(103) 1  Sm 
  u 

= 630

1  Sa 10  
3 
Sa (103)=332 MPa
 700 

103 < N < 106
(a) USING Sa
Sa = a Nb
b
1

 
 S a 103 

e  3
Log
 
e 
 S a 10 
1  332 
 Log     0.05126
3  233 
 1  1
     
 
 S 10  3 e  e  3  332 x 10 6 6 3
a  a    473 MPa
  
 [ S a 10 ] 
e 3
  
 233 x 106  
3
Sa = 473 N-0.05126
FOR LOADING OF Ma = 13 Nm FOR LIFE OF N CYCLES
aREF Ma from(1) aREF  Sa ( N)


50.26 x 10 9
259  473 N 0.05126
 259 MPa
N  1.27 x 105 cycles

2. NOTCHED COMPONENTS
BRITTLE AND DUCTILE MATERIALS BEHAVE DIFFERENTLY
2.1 BRITTLE MATERIALS IN TENSION

FATIGUE LOADING
MONOTONIC LOADING
S a  K S 
 1  t m 

S ao  u 

2.2 DUCTILE MATERIALS IN TENSION
MONOTONIC LOADING
FATIGUE LOADING
S a  S 
 1  m 
 
S ao u 

EXAMPLE
THICKNESS = 10
MATERIAL: STEEL ,  u  760 MPa

FATIGUE LOADING OF TENSION / COMP. SPECIMENS
Sao (103 )  573 MPa , Sao (106 )  360 MPa
CALCULATE LOAD AMPLITUDE FOR:
(i) LIFE OF 106 CYCLES
(ii) LIFE OF 105 CYCLES

(i)
CL CD CS CO
 (106 )  S ao (106 )
S ao
Kf K f  1  0.872 (1.87  1)  1.76
Sao (106 )
1 x 0.78 x 0.75 x 1
CL  1  (106 )  360 x
S ao
1.76
CD  0.61 d 0.097  0.61 x 0.080.097  0.78  119.7 MPa
USING DEPTH IN DIRECTION OF CRACK GROWTH
CS  0.75
CO  1
K t  1.87 ESDU 69020 Fig 5.8 S a (106 )  Sm 
 
1  
 (10 ) 
S ao 6
u 
   1624  760  1624
Log     u 
 586  586
  85.5 m
1 1
q   0.872
   85.8 
1   1  
 r   4000 
 

LOADING
M
REF  ŷ
I
Mx6
 2
 93750 M        (1)
0.01 x 0.08
MEAN STRESS
S m   REF  93750 x 4000

 375 MPa                  (2)
 375 
S a (106 )  119.7 1    60.6 MPa
 760 
FOR LIFE CYCLES OF 106 CYCLES
 a REF  S a (106 )
93750 M a  60.6 x 106
M a  646 Nm

(ii) (a) USING Sa – N
103 < N < 106
N  103
CL  1 C D  C S  CO S a  a N b
K f  1 (DUCTILE)
b
1  S 103 
LOG  a 
 
e 
e  3  a
S (10 ) 
 (103 )  S ao (103 )  573 MPa
S ao 1  290.3 
  LOG     0.2268
S m  375 MPa (FROM (2)) 3  60.6 
 1 
 S 
  
 S  10
a   a e
3 e


 
 e  3

290.32
 1391 MPa
S a (103 )  S ao
1
(103 ) 1  m 
u 
  
 S a 10
3 
 60.6

 375 
 573 1   S a  1391 N 0.2268 ( MPa )
 760 
 290.3 MPa
FOR LIFE 105 CYCLES
Sa 102 MPa
 a REF  Sa (105 )  102 MPa

FROM (1)
5102 x 106
Ma (10 ) 
93750
= 1090 Nm

VARIABLE AMPLITUDE LOADING
WHEN THE LOADING CAN BE
SUMMARISED BY DISCRETE SETS OF
STRESS LEVELS, LIFE CAN BE ESTIMATED
USING A SIMPLE CUMULATIVE DAMAGE
CALCULATION.

MINER’S LAW
FAILURE OCCURS WHEN  Di  

WHERE
n Cycles applied at Sa , Sm
DAMAGE D = 
N Cycles to produce failures at Sa , Sm
THE VALUE OF  VARIES WITH CONDITIONS EG THE ORDER OF APPLICATION OF
THE LOADING CYCLES.
RANDOM LOADING GIVES 0.6 <  < 1.6
IT IS COMMON TO USE  = 1
ni
 Ni
1

EXAMPLE
THICKNESS = 10
MATERIAL: STEEL ,  u  760 MPa

FATIGUE LOADING OF TENSION / COMP. SPECIMENS
Sao (103 )  573 MPa , Sao (106 )  360 MPa
LOADING, VARYING CONTINUOUSLY
Ma (Nm) 646 3097 1088
% OF LIFE 60 10 30
CALCULATE THE LIFE

FROM PREVIOUS ANALYSIS
n
 Ni 1
i
0.6 N 0.1 N 0.3 N

  1
106 103 105
0.6 x 106  100 x 106  3 x 106  N  1

N  9652 cycles
60.6 290.3 102

Sa ( MPa )
ni ACTUAL CYCLES APPLIED 0.6 N 0.1 N 0.3 N
Ni FOR FAILURE AT CONSTANT 106 103 105

AMPLITUDE (CYCLES)

TWO AND THREE DIMENSIONAL STATES OF STRESS
FOR DUCTILE MATERIALS FAILING AT A FREE SURFACE USE VON MISES
OR TRESCA EQUIVALENT UNIAXIAL STRESSES IN THE USUAL FATIGUE CALCULATIONS.
EG TORSION LOADING
VON MISES
1  2 2  2  3 2  3  1 2  2 2

  3 z
TRESCA

ˆ    
 z    z  
  2 z
FOR CAST MATERIALS CONTAINING INCLUSIONS USE THE MAXIMUM PRINCIPAL STRESS.

RESULTS FROM TORSION FATIGUE TESTS
TORSION FATIGUELIMIT, 
ROTATINGBENDING FATIGUELIMIT, S a
MATERIAL
TORSION FATIGUELIMIT, A
ROTATINGBENDING FATIGUELIMIT,Sa
VON MISES TRESCA ̂

PLAIN CARBON STEEL 0.55 0.95 1.10
ALLOY STEELS 0.58 1.00 1.16
NON-FERROUS ALLOYS 0.52 0.9 1.04

(N = 108) 0.60 1.04 1.20
CAST IRONS 0.9 0.9

1.0 1.0
GENERAL COMPONENTS
PREDICTIONS ARE NOT AS GOOD AS THE PREDICTIONS FOR TORSION.

IMPROVING FATIGUE STRENGTH
1 IMPROVE SHAPE IE REDUCE Kf
2 IMPROVE SURFACE FINISH
3 INCREASE MATERIAL STRENGTH EG HARDEN, CHANGE MATERIAL
4 INDUCE COMPRESSIVE RESIDUAL STRESS

EG PEENING,
SURFACE HARDENING,
PRE-LOADING BEYOND YIELD
5 IMPROVE ENVIRONMENT
6 REDUCE FRETTING
FOR 3 AND 4 CHANGES AT THE SURFACE ARE SUFFICIENT EXCEPT WHERE THE STRESS IS
UNIFORM

STRAIN – LIFE FATIGUE ANALYSIS
APPROACH IS USED PRIMARILY FOR HIGHER ACCURACY OF FATIGUE LIFE

PREDICTION AT HIGH LOADING - LOW CYCLE COUNT SITUATIONS
THE METHOD IS NEVERTHELESS USED ACROSS LOW AND HIGH CYCLE

FATIGUE LIFE PREDICTION
STRAIN – LIFE FATIGUE EQUATIONS ARE BASED ON PARAMETERS

DETERMINED FROM THE STABILISED CYCLIC STRESS STRAIN CURVES OF
MATERIALS MONOTONIC
RELATIONSHIP
CYCLIC STRESS STRAIN CURVES ARE EXPRESSED IN RAMBERG OSGOOD
EQUATION FORM WHERE K’ IS THE CYCLIC STRENGTH COEFFICIENT AND 1 / n'
  
n’ IS THE STRAIN HARDENING COEFFICIENT     
E  K' 
CYCLIC
  e  p
CYCLIC
STRESS
 
STRAIN
2 2 2
1/ n'
CURVES
    
FROM   
STABLE 2 2E  2K ' 
HYSTERESIS
LOOPS

STRAIN – LIFE FATIGUE ANALYSIS
 
CYCLIC HARDENING
t
STRESS RESPONSE
t HYSTERESIS LOOPS
STRAIN CONTROL 

CYCLIC SOFTENING
t

STRAIN – LIFE RELATIONS
COFFIN – MASON’S EQUATION - BASED ON PLASTIC STRAIN RANGE
 p
  'f (2 N f )c --------------------------------------------------- (1)
2
BASQUIN’S EQUATION - BASED ON ELASTIC STRAIN RANGE
 e   f
'
  (2 N f )b --------------------------------------------------- (2)
2 2E E
MORROW EQUATION - BASED ON SUPERPOSITION OF EQUATIONS (1) AND (2) COVERS
BOTH ELASTIC AND PLASTIC REGIMES
  e  p  f
'
   (2 N f )b   'f (2 N f )c ------------------------------- (3)
2 2 2 E
HALF THE TOTAL NUMBER OF REVERSALS AT THE TRANSITION FROM PLASTIC TO
ELASTIC FATIGUE IS GIVEN BY EQUATION (4) 1
 '  c b
1  f 
Nt  N f   
------------------ (4)
2  E 'f
 

TERMS IN THE EQUATIONS
E – YOUNG’S MODULUS
 e  p
- ELASTIC STRAIN AMPLITUDE - PLASTIC STRAIN AMPLITUDE
2 2
 'f - FATIGUE DUCTILITY COEFFICIENT WHICH IS THE STRAIN INTERCEPT AT ONE LOAD
REVERSAL i.e. 2Nf = 1
2Nf - TOTAL STRAIN REVERSALS TO FAILURE
c - FATIGUE DUCTILITY EXPONENT WHICH IS A MATERIAL PROPERTY THAT RANGES

BETWEEN -0.5 AND -0.7
 'f - FATIGUE STRENGTH COEFFICIENT WHICH IS THE STRESS INTERCEPT AT ONE LOAD
REVERSAL i.e. 2Nf = 1
b - FATIGUE STRENGTH EXPONENT IS A MATERIAL PROPERTY
2Nt - THE NUMBER OF REVERSALS AT THE TRANSITION FROM PLASTIC TO ELASTIC FATIGUE

OVERALL STRAIN –LIFE CURVE

DETERMINATION OF FATIGUE DUCTILITY COEFFICIENT

DETERMINATION OF FATIGUE STRENGTHCOEFFICIENT

EFFECT OF MEAN STRESS IN STRAIN – LIFE FATIGUE PREDICTION
BY USING MINER’S RULE TO INCLUDE THE EFFECT OF MEAN STRESS, MORROW’S EQUATION
(3) BECOMES
c
  f
'     b
 1  m (2 N )b   ' 1   m  (2 N )c -------------------- (5)
2 E  '  f f
 '  f
 f   f 
ANOTHER FORM OF MORROW’S EQUATION (4) ABOVE WITH MODIFICATION ONLY TO THE
ELASTIC PART IS AS GIVEN IN EQUATION (6) BELOW
  f
'   
 1  m (2 N )b   ' (2 N )c
 '  f f f ---------------------------(6)
2 E
 f 
SMITH, WATSON AND TOPPER (SWT) RELATIONSHIP IS WRITTEN AS
  'f 
 max .   f (2 N f ) 
' b
(2 N f )   f (2 N f ) 
b ' c
------------------- (7)
2  E 
SWT APPEARS TO BE GOOD FOR A WIDE RANGE OF MATERIALS AND GOOD FOR
GENERAL USE

FATIGUE REDUCTION FACTORS OTHER APPROXIMATIONS IN THE STRAIN – LIFE APPROACH
INFORMATION FOR FATIGUE REDUCTION FACTORS FOR STRAIN – LIFE METHOD IS RATHER
LIMITED COMPARED TO THE STRESS – LIFE APPROACH
FOR LIFE BELOW THE TRANSITION LIFE FROM PLASTIC TO ELASTIC FATIGUE DOMINATED
REGIMES NO FACTORS ARE REQUIRED EXCEPT UNDER SEVERE ENVIRONMENTAL CONDITIONS.
CS , CD AND CL CAN BE APPROXIMATED AS 1
NOTE Kf IS NOT REQUIRED BECAUSE STRAINS FROM THE LOCAL POINT ON A COMPONENT IS
USED DIRECTLY, I.E. THERE IS NO NEED TO CONSIDER REFRENCE STRESS AS IN THE STRESS –
LIFE APPROACH
BEYOND THE TRANSITION POINT APPLY FOLLOWING FACTORS TO THE ELASTIC PARTS
OF THE STRAIN – LIFE EQUATIONS
CD = 0.71 d - 0.093 FOR 8 < d < 250 MM FOR BENDING PROBLEMS
 'f  UTS  345 (MPa );  'f  strain at fracture (tensile test)
1   f
'
  Ao 
b   log ;   ln
'   ln 100 

6  0.5   UTS    100  % RA 
f
  Af 
ADDITIONAL APPROXIMATIONS IN THE STRAIN – LIFE APPROACH
n' 1
b ; c
1  5n ' 1  5n '
NO WIDE ACCEPTANCE YET
MORROW JD. CYCLIC PLASTIC STRAIN ENERGY AND FATIGUE OF METALS. INTERNAL FRICTION,
DAMPING, AND CYCLIC PLASTICITY—ASTM STP 378. AMERICAN SOCIETY FOR TESTING AND
MATERIALS, PHILADELPHIA, PA, 1964:45-87.
M.L. ROESSLE, A. FATEMI, STRAIN-CONTROLLED FATIGUE PROPERTIES OF STEELS AND SOME

SIMPLE APPROXIMATIONS, INTERNATIONAL JOURNAL OF FATIGUE 22 (2000) 495–511

ADDITIONAL APPROXIMATIONS IN THE STRAIN – LIFE APPROACH
n' 1
b ; c
1  5n ' 1  5n '
NO WIDE ACCEPTANCE YET
MORROW JD. CYCLIC PLASTIC STRAIN ENERGY AND FATIGUE OF METALS. INTERNAL FRICTION,
DAMPING, AND CYCLIC PLASTICITY—ASTM STP 378. AMERICAN SOCIETY FOR TESTING AND
MATERIALS, PHILADELPHIA, PA, 1964:45-87.
M.L. ROESSLE, A. FATEMI, STRAIN-CONTROLLED FATIGUE PROPERTIES OF STEELS AND SOME

SIMPLE APPROXIMATIONS, INTERNATIONAL JOURNAL OF FATIGUE 22 (2000) 495–511

Fatigue Strength, (MPa)
Ultimate Tensile Strength, UTS, (MPa) Ultimate Tensile Strength, UTS, (MPa)
STEEL WROUGHT COPPER ALLOYS
FOR A WIDE RANGE OF LOW AND MEDIUM STRENGTH VERSIONS OF MATERIALS ( R W Hertzberg).
PART II FATIGUE STRENGTH OF COMPONENTS 81

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ADVANCED STRENGTH OF COMPONENTS (P04710)

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 1

FAILURE OCCURS IN 4 STEPS

1. LOCAL MICROSCOPIC DAMAGE INITIATE.

DAMAGE OCCURS AT POINTS OF HIGH STRESS:

i. SURFACE NOTCHES – FILLETS, GROOVES, SCRATCHES, WELDS

ii. DEFECTS WITHIN THE MATERIAL

SEVERAL DAMAGE SITES MAY DEVELOP SIMULTANEOUSLY.

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 2

ONE CRACK WILL DOMINATE AND GROW

4 FAST FRACTURE OCCURS

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 3

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 4

1 TYPE OF TEST TYPICAL STRESS-TIME RELATIONS

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 6

FATIGUE LIMIT HAS A STRONG

STEEL Sao (106) = 0.4 u - 0.6u

EXAMPLES FOR ROTATING BENDING

ALUMINIUM (WROUGHT) Sao (108) = 0.35 – 0.4 u

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 7

STEEL WROUGHT COPPER ALLOYS

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 8

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 9

u < 1400 MPa

ALUMINIUM u < 330 MPa

LOADING: ROTATING BENDING

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 10

Log Sa = b Log N + Log a

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 11

e.g. STEEL, STANDARD CURVE

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 12

Sa (103) = 0.9u Sa (108) = 0.4u

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 13

FOR N ≥ 103 CYCLES OF ALTERNATING

CONSTANT AMPLITUDE LOAD

S'ao FATIGUE STRENGTH OF COMPONENT } At N

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 14

CL Bending  Bending CL = 1.00 Bending  Bending CL = 1.00

CD CD = 1 Bending  CD = 1 for d < 8 mm

For steel use graph of CS  u

Kf Kf = 1 (for ductile material) Kf = Kf

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 15

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 16

(ii) SURFACE TREATMENTS GIVING CO > 1(1)

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 17

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 18

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 19

Sao (106) = 0.5 x 1100

S'ao (106) = Sao (106) CL CD CS CO

CS = 0.9 (FROM GRAPH)

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 20

FOR N = 106  (106 )

d 2.903  12223 / (302 106 )

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 22

FOR FAILURE IN N CYCLES

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 23

A 10% INCREASE IN u DOUBLES THE LIFE

+ 5% VARIATION IN U CAN BE EXPECTED, GIVING 2:1 VARIATION IN LIFE

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 24

AND CAN BE CALCULATED FROM Kf = 1 + q (Kt – 1)

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 25

ULTIMATE TENSILE STRENGTH (MPa)

PART II FATIGUE ADVANCED STRENGTH OF COMPONENTS 26