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Fatigue Failure
2.1
Endurance Limit
d
motor
(a)
weights
Weights
mg
Se
(b)
a test specimen without failure, Fig. 1(b). The symbol for endurance limit
is Se0 . The S-N diagram becomes horizontal at the endurance limit as shown
in Fig. 2.
S
Se
10
10
10
106
107
=
0.50 Su
700 MPa
(2.2)
The endurance limit of the test specimen, Se0 , can be different from the
endurance limit, Se , of the machine part subjected to different loadings. The
endurance limit Se is affected by a number of factors called modifying factors.
Some of these factors are the surface factor kS , the gradient (size) factor kG ,
the load factor kL , the temperature factor kT , and the reliability factor kR .
Thus, the endurance limit of a member can be related to the endurance limit
of the test specimen by the following relationship: Se = kS kG kL kT kR Se0 .
Surface factor, kS
The surface modification factor, kS , depends on the tensile strength of
the material, Sut and on the part surface finish. The surface factor formula
2
is given by [5]
b
.
kS = a Sut
(2.3)
The factor a and the exponent b depends upon the quality of the surface
finish [5]:
1.58
4.51
for (MPa) a =
57.7
272
for
for
for
for
(2.4)
1.34
2.70
for (kpsi) a =
14.4
39.9
for
for
for
for
(2.5)
0.085
0.256
b=
0.718
0.995
for
for
for
for
(2.6)
(2.8)
For 2 in. < d < 4 in. or 50 mm < d < 100 mm the factors are reduced by
0.1.
For 4 in. < d < 6 in. or 100 mm < d < 150 mm the factors are reduced
by 0.2.
3
Load factor, kL
For the load factor the following
0.85
1
kL =
0.59
(2.9)
1
for 50% reliability,
0.897
for 90% reliability,
(2.11)
(2.13)
For 106 -cycle strength (endurance limit) for axial, bending, and torsional
loads:
Se = kS kG kL kT kR Se0 .
4
(2.14)
2.2
Fluctuating Stresses
The components of the time varying stresses are depicted in Fig. 3, where
min is minimum stress, max the maximum stress, a the stress amplitude
or the alternating stress, m the midrange or the mean stress, and r the
stress range. The mean stress and the alternating stress are
max + min
,
(2.15)
m =
2
max min
.
(2.16)
a =
2
The stress ratios are defined by
min
a
R=
and A =
.
(2.17)
max
m
The steady stress or static stress, s , has any value between min and max
and exists because of a fixed load. Figure 3(a) shows a sinusoidal fluctuating
stress, Fig. 3(b) represents a repeated stress, and Fig. 3(c) is a completely
reversed sinusoidal stress. A fluctuating stress is a combination of static plus
completely reversed stress.
2.3
A graphical representation of mean and alternating stress in relation to yielding and various fatigue life is shown in Fig. 4. The horizontal axis, a = 0, corresponds to static loading. The vertical axis is given by m = 0. The points
on the vertical axis, ordinate axis, (0, Se ), (0, S103 ), (0, S104 ), (0, S105 ), ... are
selected from the S-N diagram. The point (Su , 0) represents the ultimate tensile strength. The lines (0, Se )(Su , 0), (0, S105 )(Su , 0), (0, S104 )(Su , 0)
and (0, S103 ) (Su , 0) are the estimated lines of constant life. The diagram,
m a , is called the constant life fatigue diagram because it has lines corresponding to a constant 106 cycle or infinite life, constant 105 cycle, constant
104 cycle, and so forth. These lines are called the Goodman lines.
The point (Sy , 0) represents the yield strength and for ductile materials the point (Sy , 0) represents the compressive yield strength. At the
point (0, Sy ) the stress fluctuates between +Sy and Sy . The points on line
(Sy , 0) (0, Sy ) correspond to fluctuations having a tensile peak of Sy . The
points on line (Sy , 0) (0, Sy ) correspond to fluctuations having a compressive peak of Sy . Within the area defined by the lines (Sy , 0) (0, Sy ),
(Sy , 0) (0, Sy ) there is no yielding.
5
fluctuating stress
a
r
(a)
max
m
min
repeated stress
(b)
max
r
a
O min = 0
reversed stress
max a
(c)
r
m = 0
min a
S
S-N diagram
S103
S104
S105
Se
10 3
10
10
10
N
10
S103
103
S104
S105
Sy
S106 = Se
104
Se
105
106
a
m
Sy
m (compression)
Sy
m (tension)
Su
The shaded area in Fig. 5(a) corresponds to a life of at least 106 cycles
and no yielding. The shaded area in Fig. 5(b) corresponds to a life of at
least 106 cycles and yielding. The shaded area in Fig. 5(c) corresponds to
less than 106 cycles of life and no yielding.
For torsional loads Ssy and Sus are used instead of Sy and Su with
Ssy 0.58 Sy
for steel.
(2.18)
S103
103
S104
S10 5
S106 = Se
Sy
(a)
104
Se
105
106
Sy
Sy
Su
O
a
S103
103
S104
S10 5
S106 = Se
Sy
104
Se
Sy
(b)
105
106
Sy
Su
S103
103
S104
S10 5
Sy
104
S106 = Se
Se
(c)
5
10
6
10
Sy
Sy
Su
2.4
(2.19)
2.5
There are various techniques for plotting the results of the fatigue failure test
of a part subjected to fluctuating stress.
A stress state can be described by the mean and the alternating components. This stress state is characterized by a point and if the point is
situated below the constant-life line then safety is suggested. A point on the
constant-life line gives the strength Sm as the limiting value of m . In a similar way the corresponding strength Sa is the limiting value of a , as shown
in Fig. 6. The alternating strength Sa as a limiting value of a is plotted
on the ordinate. The mean strength is Sm as a limiting value of m and is
plotted on the abscissa. The fatigue limit Se is plotted on the ordinate. The
tensile yield strength Sy is plotted on both coordinate axes. The ultimate
tensile strength Su is plotted on the abscissa.
Four criteria of failure are shown in the diagram in Fig. 6 that is, Soderberg, the modified Goodman, Gerber, and yielding. The Soderberg criterion
protects against yielding.
The equation for the Soderberg line is
Sm Sa
+
= 1.
Sy
Se
(2.20)
Sy
yield line
Soderberg line
modified Goodman line
Gerber line
Se
Sa
d
loa
lin
Sm
Sy
Su
(2.21)
(2.22)
The Gerber criterion is also called the Gerber parabolic relation because the
curve can be modeled by a parabolic equation of the form
2
Sa
Sm
+
= 1.
(2.23)
Se
Su
If SF is a design or safety factor then
Sa = SF a
and Sm = SF m .
10
(2.24)
(2.25)
11
(2.26)
(2.27)
tensile strength
ultimate
yield
Sut (MPa) Sy (MPa)
AISI 1006 Steel, cold drawn
330
285
AISI 1006 Steel, hot rolled bar, 19-32 mm round
295
165
AISI 1006 Steel, cold drawn bar, 19-32 mm round
330
285
AISI 1008 Steel, hot rolled bar, 19-32 mm round
305
170
AISI 1008 Steel, cold drawn bar, 19-32 mm round
340
285
AISI 1010 Steel, cold drawn
365
305
AISI 1010 Steel, hot rolled bar, 19-32 mm round or thickness
325
180
AISI 1010 Steel, cold drawn bar, 19-32 mm round or thickness
365
305
AISI 1012 Steel, cold drawn
370
310
AISI 1012 Steel, hot rolled bar, 19-32 mm round or thickness
330
185
AISI 1012 Steel, cold drawn bar, 19-32 mm round or thickness
370
310
AISI 1015 Steel, cold drawn
385
325
AISI 1015 Steel, cold drawn, 19-32 mm round
385
325
AISI 1015 Steel, hot rolled, 19-32 mm round
345
190
AISI 1015 Steel, as rolled
420
315
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13
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15
% fatigue
% S-N diagram
clear all; clc; close all
% alternating stresses are torsional
% steel bar, d<2in., fine ground surface
Su = 110; % ultimate strength (kpsi)
Sy = 77; % yield strength
(kpsi)
%
%
%
%
S
Su = 110.000 (kpsi)
Sy = 77.000 (kpsi)
10^3 cycle strenght S = 79.200 (kpsi)
Sep = 55.000 (kpsi)
kS = 0.899
kG = 0.900
kL = 0.577
10^6 cycle strenght Se = 25.667 (kpsi)
S = 79.200(kpsi) -> log(S) = 1.899
Se = 25.667(kpsi) -> log(Se) = 1.409
Su = 110.000 (kpsi)
Sy = 77.000 (kpsi)