Multiaxial Fatigue

Other SAE books of interest:

Fatigue Design Handbook (Order No. AE-22) Recent Developments in Fatigue Technology Edited by Russell A. Chernenkoff and John J. Bonnen (Order No. PT-67)

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Multiaxial Fatigue
Darrell F. Socie Gary B. Marquis

Society of Automotive Engineers, Inc. Warrendale, Pa.

Library of Congress Cataloging-in-Publication Data Socie, Darrell. Multiaxial fatigue / Darrell F. Socie, Gary B. Marquis. p. cm. Includes bibliographical references. ISBN 0-7680-0453-5 1. MaterialsFatigue. 2. Axial loads. I. Marquis, G. (Gary) II. Title. TA418.38.S64 2000 620.1' 126dc21 99-32460 CIP

Copyright 2000

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ISBN 0-7680-0453-5 All rights reserved. Printed in the United States of America. Permission to photocopy for internal or personal use, or the internal or personal use of specific clients, is granted by SAE for libraries and other users registered with the Copyright Clearance Center (CCC), provided that the base fee of $.50 per page is paid directly to CCC, 222 Rosewood Dr., Danvers, MA 01923. Special requests should be addressed to the SAE Publications Group. 0-7680-0453-5/00-$.50. SAE Order No. R-234

Contents
Preface Acknowledgments Nomenclature Chapter 1State of Stress and Strain 1.1 Introduction 1.2 Stresses and Strains Acting on a Plane 1.3 Maximum Stress and Strain 1.4 Common States of Stress and Strain 1.5 Effective, Hydrostatic, and Deviatoric Stresses 1.6 Cyclic Stresses 1.7 Using the Ideas 1.8 Summary 1.9 References Chapter 2Stress-Strain Relationships 2.1 Introduction 2.2 Elastic Stress and Strain 2.3 Plastic Stress and Strain 2.4 Cyclic Deformation 2.5 Cyclic Plasticity Models 2.6 Using the Ideas 2.7 Summary 2.8 References Chapter 3Fatigue Damage Mechanisms 3.1 Introduction 3.2 Crack Nucleation and Early Growth 3.3 Tensile MechanismsMode I Growth 3.4 Shear MechanismsMode II Growth 3.5 Damage Maps 3.6 Summary 3.7 References ix xiii xv 1 1 2 8 11 17 21 24 31 33 35 35 35 37 44 53 67 72 75 77 77 78 82 90 92 98 99

Multiaxial Fatigue

Chapter 4Multiaxial Testing 4.1 Introduction 4.2 Torsion-Bending 4.3 Plates 4.4 Disks 4.5 Cruciform 4.6 Tubes 4.7 Fracture Mechanics Specimens 4.8 Summary 4.9 References Chapter 5Stress-Based Models 5.1 Introduction 5.2 Models 5.3 Comparison of Models 5.4 Using the Ideas 5.5 Summary 5.6 References Chapter 6Strain-Based and Energy-Based Models 6.1 Introduction 6.2 Static Yield Criteria 6.3 Energy Models 6.4 Critical Plane Models 6.5 Combined Critical Plane and Energy Models 6.6 Comparison of Models 6.7 Using the Ideas 6.8 Summary 6.9 References Chapter 7Fracture Mechanics Models 7.1 Introduction 7.2 Plastic Zones in Multiaxial Loading 7.3 Mode I Growth 7.4 Crack Growth in Torsion 7.5 Mixed Mode I and Mode II Crack Growth 7.6 Mixed-Mode Growth Rate Models 7.7 Using the Ideas

101 101 101 105 109 111 114 121 125 126 129 129 130 146 151 167 169 171 171 171 173 181 190 197 209 226 230 233 233 233 236 238 245 248 256

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Contents

7.8 7.9

Summary References

268 270 273 273 273 282 294 313 325 334 336 341 341 341 356 360 379 387 405 407 411 411 415 416 422 425 426 444 445 447 483

Chapter 8Nonproportional Loading 8.1 Introduction 8.2 Definition of Nonproportionality 8.3 Nonproportional Loading Histories 8.4 Variable Amplitude Multiaxial Loading 8.5 Comparison of the Methods 8.6 Using the Ideas 8.7 Summary 8.8 References Chapter 9Notches 9.1 Introduction 9.2 Stresses and Strains in Notches 9.3 Stress-Based Approaches 9.4 Strain-Based Approaches 9.5 Crack Growth Approaches 9.6 Using the Ideas 9.7 Summary 9.8 References Chapter 10Applications 10.1 Introduction 10.2 Nonproportional Stressing and Loading 10.3 Analysis Guidelines 10.4 Recognizing Nonproportional Stressing 10.5 Stress and Strain Concentration Factors 10.6 Case Studies and Applications 10.7 Summary 10.8 References Index About the Authors

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Preface
Fatigue evaluation of components and structures has become an integral part of the design process in many industries. However, multiaxial fatigue continues to be largely the domain of a limited number of specialists. During the analysis of components subject to multiaxial loading, the problem often is reduced to an "equivalent" uniaxial fatigue case without thought as to whether the simplifying assumptions are valid for the specific load sequence or component being considered. Several international conferences on multiaxial fatigue have been held in recent years, and these have provided a wealth of test data and insight into the challenge of fatigue under multiaxial load conditions. However, for the nonexpert in the field, these volumes often are difficult to digest and complex to apply. We have written this book primarily for practicing engineers, researchers, and students. Our goal was to provide working knowledge of the fatigue damage processes and models under multiaxial states of stress and strain. Readers are introduced to the important considerations of multiaxial fatigue that differentiate it from uniaxial fatigue. We assumed that the reader has a basic background in engineering mechanics and is familiar with the fatigue damage process under uniaxial loading, but expertise in these fields is not required. In some cases, those wishing to implement the ideas should refer to other resources. Example problems are included in most chapters to illustrate how to use the ideas and concepts. This book is not intended to be a comprehensive summary of all published research in the field of multiaxial fatigue. Instead, an interpretive summary of various classes of models is presented and compared. We attempted to lend physical interpretation to observed results and provide an explanation as to why certain models work for one type of problem and not for another. Our focus is on a complete treatment of the subject from many perspectives. The reference lists at the end of each chapter, while complete, are by no means exhaustive and admittedly are biased by our own experiences. Several excellent surveys give other historical perspectives of the field.

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Multiaxial Fatigue

Models and test data in this book were generated primarily for metallic materials for which the vast majority of test data is available. However, many of the concepts are material independent and will be useful in designing test programs or analysis procedures for ceramic, composite, or other materials. The first four chapters provide the background for the subsequent chapters. Chapter 1 reviews states of stress and strain. Terms, definitions, and equations for multiaxial stresses and strains are included. This is followed in Chapter 2 by a description of stress-strain relationships, with emphasis placed on describing cyclic plastic deformation. Constitutive equations are reviewed briefly. Chapter 3 lays the foundation for later chapters by providing a review of fatigue damage mechanisms, especially those under multiaxial loading. Fatigue damage models are an attempt to describe mathematically the complex fatigue damage behavior discussed in this chapter. Chapter 4 surveys various test methods and specimens used in multiaxial fatigue research. Each type of specimen and test technique has a limited number of stress and strain states that can be produced; therefore, a comprehensive view of multiaxial fatigue requires many testing methods. The next three chapters describe fatigue damage models. Stress-based models common for high-cycle fatigue analysis are discussed in Chapter 5. The lowcycle fatigue strain and energy-based models are covered in Chapter 6. Crack growth-based approaches are described in Chapter 7. As in uniaxial fatigue, no single analysis method is appropriate for all component and loading situations. These chapters present a comprehensive treatment of all basic analysis methods. Chapter 8 presents some of the additional complications introduced into fatigue analysis when the loading is nonproportional. Nonproportionality first is defined; then, topics of nonproportional hardening, multiaxial cycle counting, and damage models are discussed. Regions of stress concentrations cannot be avoided in real structures; therefore, Chapter 9 gives attention to combining stress-strain analysis, damage models, and nonproportionality effects to analyze fatigue of components containing notches. The final chapter, Chapter 10, presents several case studies and illustrates how and when multiaxial fatigue analysis should be used in the design or optimization of engineering components.

Preface

References
Conferences Multiaxial Fatigue, ASTM STP 853, K.J. Miller and M.W. Brown, eds., American Society for Testing and Materials, West Conshohocken, PA, 1985, 741 pp. Advances in Multiaxial Fatigue, ASTM STP 1191, D.L. McDowell and R. Ellis, eds., American Society for Testing and Materials, West Conshohocken, PA, 1993, 455 pp. Multiaxial Fatigue and Deformation Testing Techniques, ASTM STP 1280, S. Kalluri and P.J. Bonacuse, eds., American Society for Testing and Materials, West Conshohocken, PA, 1993, 309 pp. Biaxial and Multiaxial Fatigue, European Group on Fracture, EGF Publication 3, M.W. Brown and K.J. Miller, eds., Mechanical Engineering Publications, London, 1989, 686 pp. Fatigue Under Biaxial and Multiaxial Loading, European Structural Integrity Society, ESIS Publication 10, K.F. Kussmaul, D.L. McDiarmid, and D.F. Socie, eds., Mechanical Engineering Publications, London, 1991, 480 pp. Multiaxial Fatigue and Design, European Structural Integrity Society, ESIS Publication 21, A. Pineau, G. Cailletaud, and T.C. Lindley, eds., Mechanical Engineering Publications, London, 1996, 532 pp. Proceedings of the Fifth International Conference on Biaxial/Multiaxial Fatigue and Fracture, E. Macha and Z. Mrz, eds., Technical University of Opole, Poland, Sept. 58, 1997, 1411 pp. Literature/Historical Surveys Krempl, E., "The Influence of State of Stress on Low-Cycle Fatigue of Structural Materials: A Literature Survey and Interpretive Report," ASTM STP 549, American Society for Testing and Materials, West Conshohocken, PA, 1974, 46 pp. Garud, Y.S., "Multiaxial Fatigue: A Survey of the State of the Art," Journal of Testing and Evaluation, Vol. 9, No. 3, 1981, pp. 165178.

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Multiaxial Fatigue

Jordan, E.H., "Fatigue-Multiaxial Aspects," Pressure Vessel and Piping: Design Technology1982A Decade of Progress, S.Y. Zamrik and D. Dietrich, eds., American Society of Mechanical Engineers, New York, 1982, pp. 507518. Brown, M.W., and Miller, K.J., "Two Decades of Progress in the Assessment of Multiaxial Low-Cycle Fatigue," Low-Cycle Fatigue and Life Prediction, ASTM STP 770, C. Amzallag, B.N. Leis, and P. Rabbe, eds., American Society for Testing and Materials, West Conshohocken, PA, 1982, pp. 482499. Ellyin, F. and Valaire, B., "Development of Fatigue Failure Theories for Multiaxial High Strain Conditions," Solid Mechanics Archives, Vol. 10, Martinus Nijhoff Publishers, Dordrecht, 1985, pp. 4585.

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Acknowledgments
This book started as a set of seminar notes for the Fracture Control Program at the University of Illinois at Urbana-Champaign. The first portion of the book was completed when Prof. Socie was a Visiting Professor at VTT Manufacturing Technology, Finland. Financial support from VTT during this time is gratefully acknowledged. The second portion of the book was completed when Dr. Marquis was a Visiting Scientist at the University of Illinois at Urbana-Champaign. His research work was supported by the U.S. Air Force Office of Scientific Research and VTT Manufacturing Technology. The final portion of the book was completed when Prof. Socie was a Visiting Professor at Kyushu University under a Japan Society for the Promotion of Science Fellowship. During this period, many colleagues and friends helped with copies of original pictures, data, and reviews of the manuscript. Dr. Chin-Chan Chu of Ford Motor Company and Prof. Ali Fatemi deserve special mention for their extensive reviews of the text and the equations.

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Nomenclature
We have attempted to use a standard set of nomenclature throughout this book for stresses and strains. Many of the fatigue damage models contain adjustable constants and parameters. We have chosen to use the nomenclature of the original authors rather than inventing an entirely new set of symbols. This results in various constants and parameters (such as C, k, f, etc.) that are duplicated throughout the book. Each of these constants has a specific meaning when used with a particular model, and a detailed description of the constant or parameter is given in the text associated with the various models. Stresses, Strains, and Energy ij n n,max x, y, z 1, 2, 3 ij eq xy, yz, xz 13, 2 3 , 12 oct Nonproportional hardening coefficient Backstress tensor Normal strain range Shear strain range Normal strain range Shear stress range Normal strain Normal strain on a plane Maximum normal strain on a plane Normal strains in X-Y-Z coordinate system Principal strains Strain on a plane Strain tensor Equivalent strain Equivalent or effective strain Shear strain Shear strains in X-Y-Z coordinate system Principal shear strains Shear strain on a plane Octahedral shear strain Stress ratio 3/1 Strain ratio 3/1

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Multiaxial Fatigue

* x, y, 1, 2, h ij eq max n n,max xy, yz, 13, 23, oct Cijkl f q I1, I2, J1, J2, J 3 Sij Sijkl U WI
WII

z 3

xz 12

I3

W Wc

Residual stress tensor Normal stress Normal stresses in X-Y-Z coordinate system Principal stresses Stress on a plane Hydrostatic stress Stress tensor Equivalent stress Maximum stress Normal stress on a plane Maximum stress acting normal to a plane Equivalent or effective stress Shear stress Shear stresses in X-Y-Z coordinate system Principal shear stress Shear stress on a plane Octahedral shear stress Stiffness tensor Bending stress Shear stress Stress invariants Deviatoric stress invariants Deviatoric stress tensor Compliance tensor Strain energy Axial work Shear work Work Work per cycle

Many of these variables may be combined with superscripts e, p, and t to indicate elastic, plastic, and total, respectively.

Material Properties uts y Ultimate strength Yield strength

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Nomenclature

fl fl f f f b b c c C m E E* G H K K K* K n n t b tA,B KO K t h

np

Fatigue limit Shear fatigue limit Fatigue ductility coefficient Shear fatigue ductility coefficient Fatigue strength coefficient Shear fatigue strength coefficient Fatigue strength exponent Shear fatigue strength exponent Fatigue ductility exponent Shear fatigue ductility exponent Paris equation intercept Paris equation slope Elastic modulus Effective modulus Shear modulus Plastic modulus Strength coefficient Cyclic strength coefficient Effective strength coefficient Out-of-phase strength coefficient Strain hardening exponent Cyclic strain hardening exponent Poisson's ratio Fatigue limit in torsion Fatigue limit in bending Fatigue limit for Case A and Case B cracks Long crack threshold stress intensity Threshold stress intensity

Fracture Mechanics K e q KI, KII, KIII KI, K I I , KIII JI, J I I , JIII R S Equivalent stress intensity Cyclic stress intensity in Modes I, II, and III Stress intensity in Modes I, II, and III J integral for Modes I, II, and III Stress ratio Strain energy density

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Multiaxial Fatigue

a ao Y K() area

Flaw size Intrinsic flaw size Geometry factor Strain intensity factor Projected area of a flaw

General

Nf 2N f Kt Kf KBt K
T t eq

Cycles to failure Reversals to failure Stress concentration factor Fatigue notch factor Stress concentration in bending Stress concentration in torsion Equivalent stress concentration Yield function Vickers hardness

K t F HV

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