Fatigue Failure

It has been recognized that a metal subjected to a repetitive or fluctuating stress will fail at a stress much lower than that required to cause failure on a single application of load. Failures occurring under conditions of dynamic loading are called fatigue failures.
Fatigue failure is characterized by three stages

Crack Initiation
Crack Propagation Final Fracture
MAE dept., SJSU

Ken Youssefi

Jack hammer component, shows no yielding before fracture.

Crack initiation site

Fracture zone

Propagation zone, striation

Ken Youssefi MAE dept., SJSU

VW crank shaft fatigue failure due to cyclic bending and torsional stresses

Propagation zone, striations

Crack initiation site

Fracture area

Ken Youssefi

MAE dept., SJSU

928 Porsche timing pulley

Ken Youssefi

MAE dept., SJSU

Crack started at the fillet

Fracture surface of a failed bolt. The fracture surface exhibited beach marks, which is characteristic of a fatigue failure.

1.0-in. diameter steel pins from agricultural equipment. Material; AISI/SAE 4140 low allow carbon steel

Ken Youssefi

MAE dept., SJSU

bicycle crank spider arm

This long term fatigue crack in a high quality component took a considerable time to nucleate from a machining mark between the spider arms on this highly stressed surface. However once initiated propagation was rapid and accelerating as shown in the increased spacing of the 'beach marks' on the surface caused by the advancing fatigue crack.
Ken Youssefi MAE dept., SJSU

Crank shaft

Gear tooth failure

Ken Youssefi

MAE dept., SJSU

Hawaii, Aloha Flight 243, a Boeing 737, an upper part of the plane's cabin area rips off in mid-flight. Metal fatigue was the cause of the failure.

Ken Youssefi

MAE dept., SJSU

Fracture Surface Characteristics Mode of fracture

Ductile

Typical surface characteristics

Cup and Cone Dimples Dull Surface Inclusion at the bottom of the dimple Shiny Grain Boundary cracking

Brittle Intergranular

Brittle Transgranular

Shiny Cleavage fractures Flat

Beachmarks Striations (SEM) Initiation sites Propagation zone Final fracture zone
MAE dept., SJSU

Fatigue

Ken Youssefi

Fatigue Failure Type of Fluctuating Stresses

a = max max = - min

Alternating stress

a =

max min
2

min = 0
a = m = max / 2

Mean stress

m
=
MAE dept., SJSU

max + min
2
10

Ken Youssefi

Fatigue Failure, S-N Curve

Test specimen geometry for R.R. Moore rotating beam machine. The surface is polished in the axial direction. A constant bending load is applied.

Typical testing apparatus, pure bending

Motor

Load

Rotating beam machine applies fully reverse bending stress

Ken Youssefi MAE dept., SJSU

11

Fatigue Failure, S-N Curve

N < 103 N > 103

Finite life

Infinite life

Se

= endurance limit of the specimen Se

Ken Youssefi

MAE dept., SJSU

12

Relationship Between Endurance Limit and Ultimate Strength

Steel Steel 0.5Sut

Sut 200 ksi (1400 MPa) Sut > 200 ksi

= Se

100 ksi

700 MPa Sut > 1400 MPa

Cast iron
0.4Sut = Se 24 ksi

Cast iron

Sut < 60 ksi (400 MPa)

Sut 60 ksi

160 MPa Sut < 400 MPa

Ken Youssefi MAE dept., SJSU

13

Relationship Between Endurance Limit and Ultimate Strength

Aluminum
Aluminum alloys

= Se

0.4Sut

Sut < 48 ksi (330 MPa) Sut 48 ksi

19 ksi

130 MPa Sut 330 MPa

For N = 5x108 cycle

Copper alloys
Copper alloys

= Se

0.4Sut

Sut < 40 ksi (280 MPa) Sut 40 ksi

14 ksi

100 MPa Sut 280 MPa

For N = 5x108 cycle

Ken Youssefi MAE dept., SJSU

14

Correction Factors for Specimens Endurance Limit

For materials exhibiting a knee in the S-N curve at 106 cycles S = endurance limit of the specimen (infinite life > 10 6)
e

Se = endurance limit of the actual component (infinite life > 10 6)

S
103

Se
106

For materials that do not exhibit a knee in the S-N curve, the infinite life taken at 5x108 cycles

Sf = fatigue strength of the specimen (infinite life > 5x10 8) Sf = fatigue strength of the actual component (infinite life > 5x10 8)
S
103

Sf
5x108

Ken Youssefi

MAE dept., SJSU

15

Correction Factors for Specimens Endurance Limit Se = Cload Csize Csurf Ctemp Crel (Se)
or

Sf = Cload Csize Csurf Ctemp Crel (Sf)

Load factor, Cload (page 326, Nortons 3rd ed.)

Pure bending Pure axial

Cload = 1 Cload = 0.7

Pure torsion
Combined loading

Cload = 1 if von Mises stress is used, use 0.577 if von Mises stress is NOT used.
Cload = 1

Ken Youssefi

MAE dept., SJSU

16

Correction Factors for Specimens Endurance Limit

Size factor, Csize (p. 327, Nortons 3rd ed.)
Larger parts fail at lower stresses than smaller parts. This is mainly due to the higher probability of flaws being present in larger components.

For rotating solid round cross section

d 0.3 in. (8 mm)

0.3 in. < d 10 in. 8 mm < d 250 mm

Csize = 1 Csize = .869(d)-0.097 Csize = 1.189(d)-0.097

If the component is larger than 10 in., use Csize = .6

Ken Youssefi

MAE dept., SJSU

17

Correction Factors for Specimens Endurance Limit

For non rotating components, use the 95% area approach to calculate the equivalent diameter. Then use this equivalent diameter in the previous equations to calculate the size factor.
A95 = (/4)[d2 (.95d)2] = .0766 d2

d95 = .95d

dequiv = (
Solid or hollow non-rotating parts

A95 0.0766

)1/2

Rectangular parts

dequiv = .37d
Ken Youssefi MAE dept., SJSU

dequiv = .808 (bh)1/2

18

Correction Factors for Specimens Endurance Limit

I beams and C channels

Ken Youssefi

MAE dept., SJSU

19

Correction Factors for Specimens Endurance Limit

surface factor, Csurf (p. 328-9, Nortons 3rd ed.)
The rotating beam test specimen has a polished surface. Most components do not have a polished surface. Scratches and imperfections on the surface act like a stress raisers and reduce the fatigue life of a part. Use either the graph or the equation with the table shown below.

Csurf = A (Sut)b

Ken Youssefi

MAE dept., SJSU

20

Correction Factors for Specimens Endurance Limit

Temperature factor, Ctemp (p.331, Nortons 3rd ed.)
High temperatures reduce the fatigue life of a component. For accurate results, use an environmental chamber and obtain the endurance limit experimentally at the desired temperature. For operating temperature below 450 oC (840 oF) the temperature factor should be taken as one.

Ctemp = 1

for T 450 oC (840 oF)

Ken Youssefi

MAE dept., SJSU

21

Correction Factors for Specimens Endurance Limit

Reliability factor, Crel (p. 331, Nortons 3rd ed.)
The reliability correction factor accounts for the scatter and uncertainty of material properties (endurance limit).

Ken Youssefi

MAE dept., SJSU

22

Fatigue Stress Concentration Factor, Kf

Experimental data shows that the actual stress concentration factor is not as high as indicated by the theoretical value, Kt. The stress concentration factor seems to be sensitive to the notch radius and the ultimate strength of the material. Notch sensitivity factor Fatigue stress Kf = 1 + (Kt 1)q concentration factor rd
(p. 340, Nortons 3 ed.)

Steel

Ken Youssefi

MAE dept., SJSU

23

Fatigue Stress Concentration Factor, Kf for Aluminum

(p. 341, Nortons 3rd ed.)

Ken Youssefi

MAE dept., SJSU

24

Design process Fully Reversed Loading for Infinite Life

Determine the maximum alternating applied stress ( a ) in terms of the size and cross sectional profile Select material Sy, Sut
Choose a safety factor n

Determine all modifying factors and calculate the endurance limit of the component Se
Determine the fatigue stress concentration factor, Kf

Use the design equation to calculate the size

Se Kf a = n
Investigate different cross sections (profiles), optimize for size or weight You may also assume a profile and size, calculate the alternating stress and determine the safety factor. Iterate until you obtain the desired safety factor
MAE dept., SJSU

Ken Youssefi

25

Design for Finite Life

Sn = a (N)b equation of the fatigue line

A S
103

A B S B

Se
106

Sf
N
103

5x108

Point A

Sn = .9Sut
N = 10
3

Point A

Sn = .9Sut
N = 103

Point B
Ken Youssefi

Sn = Se
N = 10
6
MAE dept., SJSU

Point B

Sn = Sf
N = 5x108
26

Design for Finite Life

Sn = a (N)b
log Sn = log a + b log N
Apply boundary conditions for point A and B to find the two constants a and b
3

log .9Sut = log a + b log 10 log Se = log a + b log 106

a= b=

(.9Sut) Se
1 3

log

.9Sut Se

Sn = Se ( 106 )
Calculate Sn

Se log ( .9S ) ut

and replace Se in the design equation

Kf a =

Sn n

Design equation
27

Ken Youssefi

MAE dept., SJSU

The Effect of Mean Stress on Fatigue Life

Mean stress exist if the loading is of a repeating or fluctuating type.

Mean stress is not zero

Gerber curve

Alternating stress

Se Goodman line

Soderberg line
Ken Youssefi MAE dept., SJSU

Sy Mean stress

Sut

m
28

The Effect of Mean Stress on Fatigue Life Modified Goodman Diagram

a
Sy Yield line

Alternating stress

Se Goodman line Safe zone

C

Sy
Mean stress

Sut

Ken Youssefi

MAE dept., SJSU

29

The Effect of Mean Stress on Fatigue Life Modified Goodman Diagram

a
Sy Yield line

Se Goodman line Safe zone - m - Syc Safe zone

C

Sy

Sut

+m

Ken Youssefi

MAE dept., SJSU

30

The Effect of Mean Stress on Fatigue Life Modified Goodman Diagram

Fatigue,

m 0

Fatigue,

m > 0 Sut Sut

=
= 1

a
Se

+ +

m
m

Infinite life

nf
Finite life Yield

a = n f
Yield Se Syc Safe zone - m - Syc

Se

a
Sn

a + m = n y

Safe zone

a + m = n y
Sy Sut +m

Sy

Ken Youssefi

MAE dept., SJSU

31

Applying Stress Concentration factor to Alternating and Mean Components of Stress

Determine the fatigue stress concentration factor, Kf, apply directly to
the alternating stress Kf a If Kf max < Sy then there is no yielding at the notch, use Kfm = Kf and multiply the mean stress by Kfm Kfm m If Kf max > Sy then there is local yielding at the notch, material at the

notch is strain-hardened. The effect of stress concentration is reduced.

Calculate the stress concentration factor for the mean stress using the following equation, Kfm =

Sy

m
1

Kf a

Fatigue design equation Kf a Kfmm = +

Se

Sut

nf

Infinite life

Ken Youssefi

MAE dept., SJSU

32

Combined Loading
All four components of stress exist,

xa
xm

alternating component of normal stress

mean component of normal stress alternating component of shear stress

xya

xym

mean component of shear stress

Calculate the alternating and mean principal stresses,

1a, 2a = (xa /2)

1m, 2m = (xm /2)
Ken Youssefi

(xa /2)2 + (xya)2

(xm /2)2 + (xym)2
33

MAE dept., SJSU

Combined Loading
Calculate the alternating and mean von Mises stresses,
2 1/2 a = (12 + ) a 2a 1a 2a 2 1/2 m = (12m + 2 ) m 1m 2m

Fatigue design equation

a
Se

m
Sut

nf

Infinite life

Ken Youssefi

MAE dept., SJSU

34

Design Example
A rotating shaft is carrying 10,000 lb force as shown. The shaft is made of steel with
12

10,000 lb. 6 6

d R1 r (fillet radius) = .1d A

D = 1.5d
R2

Sut = 120 ksi and Sy = 90 ksi. The shaft is rotating at 1150 rpm and has a machine finish surface. Determine the diameter, d, for 75 minutes life. Use safety factor of 1.6 and 50% reliability.
Calculate the support forces,

R1 = 2500, R2 = 7500 lb.

MA = 2500 x 12 = 30,000 lb-in

The critical location is at the fillet, Calculate the alternating stress,

a =

Mc

32M

= 3

305577

m = 0

Determine the stress concentration factor d D = 1.5 d

Ken Youssefi

r = .1

Kt = 1.7
35

MAE dept., SJSU

Design Example
Assume d = 1.0 in

Using r = .1 and Sut = 120 ksi, q (notch sensitivity) = .85

Kf = 1 + (Kt 1)q = 1 + .85(1.7 1) = 1.6

Calculate the endurance limit

Cload = 1 (pure bending) Crel = 1 (50% rel.) Ctemp= 1 (room temp) Csurf = A (Sut)b = 2.7(120)
0.3 in. < d 10 in.
-.265

= .759
-0.097

Csize = .869(d)-0.097 = .869(1)

= .869
ksi
36

Se = Cload Csize Csurf Ctemp Crel (Se) = (.759)(.869)(.5x120) = 39.57

Ken Youssefi MAE dept., SJSU

Design Example
Design life, N = 1150 x 75 = 86250 cycles Se log ( .9S ) 86250 N ut Sn = 39.57 ( Sn = Se ( 6 ) 6
10 10

log ( .9x120 )
= 56.5 ksi

39.57

a =

305577

d3

= 305.577 ksi

n=

Sn Kfa

56.5
1.6x305.577

= .116 < 1.6

So d = 1.0 in. is too small

Assume d = 2.5 in

All factors remain the same except the size factor and notch sensitivity.

Using r = .25 and Sut = 120 ksi, q (notch sensitivity) = .9

Csize = .869(d)-0.097 = .869(2.5)
Ken Youssefi

Kf = 1 + (Kt 1)q = 1 + .9(1.7 1) = 1.63

-0.097

= .795

Se = 36.2 ksi
37

MAE dept., SJSU

Design Example
Se = 36.2 ksi

Sn = 36.20 (

86250
106

log ( .9x120 )
= 53.35 ksi

36.2

a =

305577

(2.5)

= 19.55 ksi

n=

Kfa

Sn

53.35

1.63x19.55

= 1.67 1.6

d = 2.5 in.

Check yielding

n=

Sy 90 = 2.8 > 1.6 okay = Kfmax 1.63x19.55

MAE dept., SJSU

Ken Youssefi

38

Design Example Observations

n= Sn Kfa
= 56.5

1.6x305.577

= .116 < 1.6

d

12 A

6
D = 1.5d R2 = 7500

So d = 1.0 in. is too small Calculate an approximate diameter

R1 r (fillet radius) = .1d

n=

Sn Kfa

56.5

1.6x305.577/d

= 1.6

d = 2.4 in.

So, your next guess should be between 2.25 to 2.5

Check the location of maximum moment for possible failure

Mmax (under the load) = 7500 x 6 = 45,000 lb-in MA (at the fillet) = 2500 x 12 = 30,000 lb-in But, applying the fatigue stress conc. Factor of 1.63, Kf MA = 1.63x30,000 = 48,900 > 45,000
Ken Youssefi MAE dept., SJSU

39

Example
A section of a component is shown. The material is steel with Sut = 620 MPa and a fully corrected endurance limit of Se = 180 MPa. The applied axial load varies from 2,000 to 10,000 N. Use modified Goodman diagram and find the safety factor at the fillet A, groove B and hole C. Which location is likely to fail first? Use Kfm = 1
Pa = (Pmax Pmin) / 2 = 4000 N Pm = (Pmax + Pmin) / 2 = 6000 N

Fillet

d D 35 = = 1.4 d 25

4 = .16 25

Kt = 1.76

Ken Youssefi

MAE dept., SJSU

40

Example
Using r = 4 and Sut = 620 MPa, q (notch sensitivity) = .85
Kf = 1 + (Kt 1)q = 1 + .85(1.76 1) = 1.65
Calculate the alternating and the mean stresses, Pa 4000 1.65 = 52.8 MPa K = a = f A 25x5 Pm 6000 = 48 MPa = m = A 25x5 Fatigue design equation

Se

Sut

Infinite life

52.8 48 = + 180 620

n = 2.7

Ken Youssefi

MAE dept., SJSU

41

Hole
d 5 = = .143 Kt = 2.6 w 35

Example

Using r = 2.5 and Sut = 620 MPa, q (notch sensitivity) = .82

Kf = 1 + (Kt 1)q = 1 + .82(2.6 1) = 2.3 Calculate the alternating and the mean stresses, Pa 4000 = 61.33 MPa = 2.3 a = Kf A (35-5)5 Pm 6000 = 40 MPa = m = A 30x5
61.33 40 = + 180 620

n = 2.5
42

Ken Youssefi

MAE dept., SJSU

Example
Groove

d Kt = 2.33 D 35 = = 1.2 d 29 Using r = 3 and Sut = 620 MPa, q (notch sensitivity) = .83 Kf = 1 + (Kt 1)q = 1 + .83(2.33 1) = 2.1

3 = .103 29

Calculate the alternating and the mean stresses, Pa 4000 = 58.0 MPa = 2.1 a = Kf A (35-6)5

m =

Pm
A

6000

29x5
1

= 41.4 MPa

58.0 41.4 = + 180 620

Ken Youssefi

n = 2.57
MAE dept., SJSU

The part is likely to fail at the hole, has the lowest safety factor

43

Example
The figure shows a formed round wire cantilever spring subjected to a varying force F. The wire is made of steel with Sut = 150 ksi. The mounting detail is such that the stress concentration could be neglected. A visual inspection of the spring indicates that the surface finish corresponds closely to a hot-rolled finish. For a reliability of 99%, what number of load applications is likely to cause failure. Fa = (Fmax Fmin) / 2 = 7.5 lb. Fm = (Fmax + Fmin) / 2 = 22.5 lb. Ma = 7.5 x 16 = 120 in - lb Mm = 22.5 x 16 = 360 in - lb

a =

Mc

32Ma

d 3 d
3

32(120)

(.375)
=

= 23178.6 psi

c m = M I

32Mm

32(360)

(.375)

= 69536 psi

Ken Youssefi

MAE dept., SJSU

44

Calculate the endurance limit

Example
Csurf = A (Sut)b = 14.4(150)
2

Cload = 1 (pure bending) Ctemp= 1 (room temp) Crel= .814 (99% reliability)

-.718

= .394

A95 = .010462 d (non-rotating round section)

dequiv =

A95 / .0766

= .37d = .37 x.375 = .14

dequiv = .14 < .3 Csize = 1.0

Se = Cload Csize Csurf Ctemp Crel (Se) = (.394)(.814)(.5x150) = 24.077

a
Se
+

ksi

m
Sut

23178.6 69536 = + 24077 150000

n = .7 < 1
Finite life

Find Sn, strength for finite number of cycle

a
Sn
Ken Youssefi

m
Sut

=1

23178.6

Sn

69536 =1 150000

Sn = 43207 psi

MAE dept., SJSU

45

Example

Se log ( .9S ) ut

Sn = Se (

N 10

) 6

43207 = 24077

N 106

log ( .9x150 )

24.077

N = 96,000 cycles

Ken Youssefi

MAE dept., SJSU

46