Fatigue Failure Theories 1. Linear Elastic Fracture Mechanics 2. Strain Life Analysis 3.

Stress Life Analysis Linear Elastic Fracture Mechanics Assumptions A crack exist in the part Around the crack tip, the plastic zone is very small (negligibly small) When to use it: When load cycle is less than 1000 cycles When brittle fracture is most likely mode of failure Brittle fracture can occur in ductile parts!

How does it work? The fracture toughness of a material is compared to the stress intensity factor due to a crack, and if the fracture toughness is higher, the part will not fail.
fos = Kc K

Kc, the fracture toughness for many materials has been determined empirically and many values for Kc are published in design handbooks, material handbooks, vendor catalogs, etc. K must be determined by the engineer. In order to determine K, the stress intensity factor, the engineer must know the following: The dimensions of the part being analyzed (2b = plate width) The length of any existing cracks (or approximations of crack length) (2a = crack length) The location of the crack relative to the part edge s Is the crack an edge crack? Is the crack orientation perpendicular to the edge of the plate? s The stress induced on the part at the crack tip What is the nominal stress acting at the crack root? Are there stress risers in the vicinity of the crack? Stress intensity factor for an infinitely wide plate is given by:

K = ( )2 (center crack) a
1

K = 1.12 ( )2 (edge crack) a

1

K = ( )2 (if a is not considered << b) a

1

depends on the part geometry and the type of loading s

Example: A 10 mm bolt and a 200 mm nut are used to fasten down a plate that may be assumed to be infinitely wide (a<<b). A uniform stress of 50 N/mm2 is creating tension in the plate and the stress intensity factor due to the 10 mm hole in the plate, Kt, is 3.0. The fracture toughness,Kc, of the steel plate is 40 ksi (in.)1/2 Will the plate fail in brittle fracture?

What is the critical length that the crack can reach before brittle fracture?

Strain Life Analysis Assumptions A crack exist in the part and is growing When to use it: When load cycle is less than 1000 cycles When brittle fracture is most likely mode of failure Brittle fracture can occur in ductile parts! How does it work? Strain data are needed in order to use strain life analysis. The engineer needs to know total strain and elastic strain:

 = total elastic The engineer also needs to know the initial cross-sectional area of the machine part, Ao, and the final cross-sectional area at the part failure. s A C = ln o A The number of cycles to the part failure can now be calculated using this s formula:

N 2 = C
Example: A strip of mild steel, 10 mm thick, is bent successively about a cylinder of radius 100 mm. It is assumed that for all intents and purposes, the elastic strain may be safely disregarded. At failure the cross-sectional area of the strip had been reduced by 60%. How many cycles of bending before the strip will fail due to brittle fracture?

Stress Life Analysis: Assumptions: Cracks do not exist in the part When to use it: When load cycle is more than 1000 cycles When brittle fracture is not catastrophic (deadly!)

What the engineer needs to know: Part geometry and loading Part material properties and processing Operating conditions and environment of part