You are on page 1of 46

The Local Stress-Strain Fatigue Method ( -N)

© 2010 Grzegorz Glinka. All rights reserved. 1


Introduction
Although most engineering structures and machine components are designed such that
the nominal stress remains elastic (Sn< ys) stress concentrations often cause
plastic strains to develop in the vicinity of notches where the stress is elevated due
to the stress concentration effect. Due to the constraint imposed by the elastically
stresses material surrounding the notch-tip plastic zone deformation at the notch
root is considered strain controlled.
The basic assumption of the strain-life fatigue analysis approach is that the fatigue
damage accumulation and the fatigue life to crack initiation at the notch tip are the
same as in a smooth material specimen (see the Figure) if the stress-strain states in
the notch and in the specimen are the same. In other words:
The local strain approach relates deformation occurring in the immediate vicinity of a
stress concentration to the remote or local pseudo-elastic stresses and strains using
the constitutive response determined from fatigue tests on simple laboratory
specimens (i.e. the cyclic stress-strain curve and the strain-life curve.
From knowledge of the geometry and imposed loads on notched components, the local
stress-strain histories at the tip of the notch must be determined (Neuber or ESED
method).
Fatigue damage must be calculated for each cycle of the local stress-strain history
(hysteresis loops, linear damage summation)

© 2010 Grzegorz Glinka. All rights reserved. 2


The Basic Concept of the -N Method

/2)
a) Specimen '
f f b
x 2N f '
2N f c

log (
f
yy yy 2 E

y
z f/E

yy log (2Nf)
0
b) Notched component

The Similitude Concept states that if


yy the local notch-tip strain history in the
notch tip and the strain history in the
test specimen are the same, then the
Plastic zone
fatigue response in the notch tip region
and in the specimen will also be the
same and can be described by the
material strain-life ( -N) curve.
Fi

© 2010 Grzegorz Glinka. All rights reserved. 3


The principal idea of the local stress strain
S approach to fatigue life prediction method; M
peak
y y
Stress a)

Stress
peak peak

y
x
x x
z

S b)
M
peak

a) smooth specimen
representing the state of affairs
at he notch tip of a notched
body; b) smooth specimen
representing the state of affairs
at the weld toe in a weldment

© 2010 Grzegorz Glinka. All rights reserved. 4


Main Steps in the Strain-Life Fatigue Analysis
of Notched Bodies
1,1'
s 5,5'
Plastic
Fi 7,7' 3
Zone
a, a 1
ij ij n' 0
'
E K
8
2,2'
6
0 4

2
Kt S
Neuber :
S = f(Fi)

1 1' E
3
5
/2)
7 t
f
'
b
0 f '
log (

2N f f 2N f c
2 8 2 E
6 m

4 sf/E 0
Fatigue damages:
se/E
1 1 p e=
D1 ; D2 ;
N1 N2
1 1 1 0
D3 ; D4 ; D5 ; 2N log (2Nf) 2Ne
N3 N4 N5

Total damage: D D1 D2 D3 D4 D5 ; Fatigue life: NT = N blck=1/D

© 2010 Grzegorz Glinka. All rights reserved. 5


The stepwise - N procedure for estimating fatigue life (can
be summarised as follows - see the Figure below).

• Analysis of external forces acting on the structure and the component in question (a),
• Analysis of internal loads in chosen cross section of a component (b),
• Selection of critical locations (stress concentration points) in the structure (c),
• Calculation of the elastic local stress, peak, at the critical point (usually the notch tip, d)
• Assembling of the local stress history in form of the form of peak and valley sequence (f),
• Determination of the elastic-plastic response at the critical location (h),
• Identification (extraction) of cycles represented by closed stress-strain hysteresis loops (h, i),
• Calculation of fatigue damage (k),
• Fatigue damage summation (Miner- Palmgren hypothesis, l),
• Determination of fatigue life (m) in terms of number of stress history repetitions, Nblck, (No. of
blocks) or the number of cycles to fatigue crack initiation, N.
The details concerning many other aspects of that methodology are discussed below.

© 2010 Grzegorz Glinka. All rights reserved. 6


Because the crack initiation period occupies major part of a fatigue life of a smooth
specimen the life of the specimen is assumed to be equal to the fatigue crack initiation life.
Therefore, only the fatigue crack initiation life at the notch tip can be estimated from the
fatigue data obtained form a smooth specimen subjected to the same stress-strain history
as that one occurring in the notch tip. The same history means the same magnitudes of all
stress and strain components. If such conditions are satisfied the equality of one stress or
strain component in the notch and the smooth specimen assures that the other
components are the same as well. Therefore, it is possible to use in such a case only one
strain or one stress component as a parameter for fatigue damage calculation and fatigue
life estimation. It means that one component characterizes in those cases the entire stress-
strain state.
However, if the stress-strain state in the notch tip and in the specimen are not the same
calculations based on only one stress or strain component might be inaccurate.
Therefore, it seems important to review the elastic plastic stress-strain behavior of
materials and their mathematical models used in fatigue applications. It is also important to
know the modifications, which should be applied before the uni-axial strain-life ( N)
properties can be used if the stress-strain state in the notch tip is not the same as that one
in the material specimen used for obtaining relevant material properties.

© 2010 Grzegorz Glinka. All rights reserved. 7


Information Path for Strength and Fatigue Life Analysis

Material Component Loading


Properties Geometry History

Stress-Strain
Analysis

Damage Analysis

Fatigue Life

© 2010 Grzegorz Glinka. All rights reserved. 8


Smooth Laboratory Specimens Used for the Determination
of the Curve under Monotonic and Cyclic Loading
yy
Stress and strain state in specimens used
for determination of material properties

y yy
y

y
x
x
x z
yy
33

xx zz yy 6-8mm
yy

0 0 0 xx 0 0
ij 0 yy 0 ij 0 yy 0
0 0 0 0 0 zz yy

© 2010 Grzegorz Glinka. All rights reserved. 9


Determination of the Stabilized Cyclic Stress-Strain Curve
Multiple Step Test Program

Strain,
Stabilized cyclic
stress-strain curve

0 Time, t

Incremental Step Test Program

0 0.02

0.01
Strain,

0
Time, t
- 0.01

- 0.02
20 cycles
© 2010 Grzegorz Glinka. All rights reserved. 10
Mathematical Expressions Describing the Stress-Strain Curve and
the Shape of the Hysteresis Lop
1
n'

2 2E 2K '

1
n'

E K'

0 0

E
1
n'

p e
2 2E 2K '

Equation of the cyclic stress-strain curve Equation of the hysteresis loop branch
1 1
n' n'
e p
e p
E K' 2 2 2 2E 2K '
© 2010 Grzegorz Glinka. All rights reserved. 11
The Massing Hypothesis
Massing’s hypothesis states that the stabilised hysteresis loop branch may be
obtained by doubling the basic material stress-strain curve.

1 / n1
a a -cyclic stress – strain curve (amplitudes)
a '
E K

1 / n1

- doubled stress – strain curve (ranges)


'
2 2E 2K
or
1 / n1

2
E 2K '
© 2010 Grzegorz Glinka. All rights reserved. 12
Monotonic and cyclic stress-strain curves for various
metallic materials
100
[ksi]

100

[ksi]
100

[ksi]
cyclic
cyclic
cyclic
monotonic
Stress,

Stress,
Stress,
50 50 50 monotonic
monotonic

2024-T4 7075-T6 Man-Ten Steel

0 0.01 0.02 0 0.01 0.02 0 0.01 0.02


Strain, Strain, Strain,

monotonic
cyclic
150 150 150 cyclic
[ksi]

cyclic monotonic

[ksi]
[ksi]

100 100 100


Stress,

monotonic

Stress,
Stress,

50 SAE 4340 50 50
350 BHn Ti - 811 Waspalloy A

0 0.01 0.02 0 0.01 0.02 0 0.01 0.02


Strain, Strain, Strain,

© 2010 Grzegorz Glinka. All rights reserved. 13


The stress-strain response of metals is often drastically altered due to
repeated loading. The material may:
– Cyclically harden
– Cyclically soften
– Be cyclically stable
– Have mixed behaviour (soften or harden depending on )
• The reason materials soften or harden appears to be related to the
nature and stability of the dislocation substructure of the material.
• For a soft material, initially the dislocation density is low. The density
rapidly increases due to cyclic plastic straining contributing to
significant cyclic strain hardening.
• For a hard material subsequent strain cycling causes a rearrangement
of dislocations, which offers less resistance to deformation and the
material cyclically softens
ult
If 1.4 the material will cyclically harden
y

If ult
1.2 the material will cyclically soften
y

© 2010 Grzegorz Glinka. All rights reserved. 14


Determination of the fatigue strain-life curve

1. Smooth laboratory specimens are used for the


determination of the and - N curves.
2. The data points are obtained at half life of
each specimen to assure that the material is
stabilized.
3. 80% -95% of the specimen life spent to create
a crack up to 0.5 -1 mm deep.
diameter: 6 - 8 mm 6-8mm

© 2010 Grzegorz Glinka. All rights reserved. 15


Determination of the Fatigue Strain-Life Curve
ae '
b
10-2 e f
2N f
Elastic strain amplitude

f’=938 MPa ea
2 E

Elastic a/E 0.0648


10-3

RQC-100 Steel
uts=758 MPa

10-4
10 102 103 104 105 106
Number of cycles, Nf

0
ap
Plastic strain amplitude

10-2
f ’=1.38 p c
'
pa f 2N f
2 E

Plastic
10-3

RQC-100 Steel 0.704 p e


uts=758 MPa

10-4
10 102 103 104 105 106
Number of cycles, Nf
© 2010 Grzegorz Glinka. All rights reserved. 16
Fatigue Strain – Life Properties
In 1910, Basquin observed that stress-life (S-N) data could be plotted linearly on a log-log scale.

'
f (2 N f )b
2
where: / 2 - true stress amplitude; 2 N f - reversals to failure (1 rev = ½ cycle);
'
f - fatigue strength coefficient, b - fatigue strength exponent (Basquin’s exponent)

Parameters f’ and b are fatigue properties of the material. The fatigue strength coefficient, f’, is
approximately equal to the true fracture strength at fracture f. The fatigue strength exponent, b,
varies in the range of 0.05 and –0.12.
Manson and Coffin, working independently (1950), found that plastic strain-life data ( p-N) could be
linearized in log-log co-ordinates.

p '
f (2 N f ) c
2
p ’
where: 2
- plastic strain amplitude; 2Nf - reversals to failure; f - fatigue ductility coefficient
c - fatigue ductility exponent
Parameters f’ and c are fatigue properties of the material. The fatigue ductility coefficient, f’, is
approximately equal to true fracture ductility (true strain at fracture), f’. The fatigue ductility exponent,
c, varies in the range of –0.5 and –0.7.

© 2010 Grzegorz Glinka. All rights reserved. 17


Fatigue Strain-Life Curve
'
f b c
'
a 2N f f 2N f
2 E

f’=1.38
/2

Total
10-4

/2 (log scale)
= a

f’
Strain amplitude,

f’=938 MPa

Elastic 0.0648 c
a/E

= a
10-4 f’/E
Total
Plastic

0.704 Strain amplitude, Elastic


b
RQC-100 Steel
uts=758 MPa

10-4
10 102 103 104 105 106 1 2Nt (log scale)
Number of cycles to failure, Nf Number of reversals to failure, 2Nf

© 2010 Grzegorz Glinka. All rights reserved. 18


The Strain-life and the Cyclic Stress-Strain Curve Obtained from
Smooth Cylindrical Specimens Tested Under Strain Control
(Uni-axial Stress State)

f Strain - Life Curve Stress -Strain Curve


/2)
log (

c
f/E
b

e/E

0 log (2Nf) 2Ne 0


1
' b c n'
f ' 2N
2N
2 E f f f E K'
© 2010 Grzegorz Glinka. All rights reserved. 19
CYCLIC PROPERTIES
K - cyclic strength coefficient
n - cyclic strain hardening exponent
ys - cyclic yield strength
E - modulus of elasticity

1/ n

The Ramberg-Osgood curve


E K
FATIGUE PROPERTIES
f - fatigue ductility coefficient
c - fatigue ductility exponent
f - fatigue strength coefficient
b - fatigue strength exponent
'
f b ' c
(2 N f ) f (2 N f ) The Manson-Coffin curve
2 E
© 2010 Grzegorz Glinka. All rights reserved. 20
The Mean Stress Effect
max,3

Stress
Stress
max,2 m,3 m,3> 0

min,3
max,
1
m,2 Time m,2 =0
Strain
m,1 m,1< 0

f
min,
/2)

2
min,1
Strain amplitude, log(

m,1 < 0;

m,2 = 0;

m,3 > 0;

100 102 104 106


Number of reversals, log(2Nf)

© 2010 Grzegorz Glinka. All rights reserved. 21


Mean Stress Effect Correction Models

Morrow
'
f m b c
'
2Nf f 2Nf
2 E
Manson-Halford
c/ b
' '
f m b f m c
'
2Nf f '
2Nf
2 E f

Smith-Watson-Topper (SWT)
2
'
f 2b b c
' '
max 2N f f f 2N f
2 E
© 2010 Grzegorz Glinka. All rights reserved. 22
Comparison of Constant Life a - m Curves According to Morrow’s
and the SWT Mean Stress Correction Model;
SAE 8620 Alloy Steel; at Nf =106 cycles
SAE 8620 Alloy Steel
a - m diagrams for N=106 cycles
140

120

Morrow
100
SWT
(ksi)

80
a
Stress Amplitude

60

40

20

0
-350 -300 -250 -200 -150 -100 -50 0 50 100 150 200 250 300 350
Mean Stress m
(ksi)

© 2010 Grzegorz Glinka. All rights reserved. 23


Limitations and Physical Interpretation of Mean
Stress Correction Models
Morrow’s model
• The predictions made with Morrow’s mean stress correction model
are consistent with the observations that mean stress effects are
significant at low values of plastic strain, where the elastic strain
dominates. The correction also reflects the trend that mean
stresses have little effect at shorter lives, where plastic strains are
large.
• However Morrow,s mean stress model incorrectly predicts that the
ratio of elastic to plastic strain range is dependent on mean stress.
This is clearly not true, because the shape of the stress-strain
hysteresis loop does not depend on the mean stress.
• Although Morrow’s mean stress correction model violets the
constitutive relationship, it generally correctly predicts mean stress
effects.

© 2010 Grzegorz Glinka. All rights reserved. 24


Limitations and Physical Interpretation of Mean
Stress Correction Models
Manson and Halford model
• Manson and Halford modified both the elastic and plastic terms of the
strain-life equation to maintain the independence of the elastic-plastic strain
ratio from mean stress.

• This equation tends to predict too much mean stress effect at short lives or
where plastic strains dominate. At high plastic strains, mean stress
relaxation occurs.

Smith, Watson, and Topper (SWT) model


• Since SWT parameter is in the general form of

max f Nf 0
it becomes undefined when max is negative ( max < 0). The physical
interpretation of this approach assumes that no fatigue damage occurs
when the maximum stress is compressive.

© 2010 Grzegorz Glinka. All rights reserved. 25


Stress States in a Notched Body

n = F/Anet M peak = max = Kt n


22
22 T

F
C 12
2 C
peak
C

22

22 33 n 22

A, B 11 A, B 23
A
D 0 B 1

33
3 33
22 22

D
11 F D 11

T
M
33 33

Stresses in axisymmetric notched Stresses in axisymmetric notched body


body under axial loading under axial, bending and torsion loading

© 2010 Grzegorz Glinka. All rights reserved. 26


The localized plasticity phenomenon

Fi Linear elastic body

e
e
e
e, e
ij ij
E
E

Fi Non-linear elastic-plastic body


Plastic
a
Zone

a, a
ij ij a
a a
E
f( )
E
a
© 2010 Grzegorz Glinka. All rights reserved. 27
The Neuber Rule and material stress-strain curve

1
n'
for 0
E K' E
P ? for 0

e
0
22
2 E
a
22 0 0
n

1
2
Kt n a a e e a a
22 22 or 22 22 22 22
E
2L
a
a 22 a
22 f 22
E
P

© 2010 Grzegorz Glinka. All rights reserved. 28


Neuber’s Rule The ESED Method

e B
22
e
22 B
a a
22
22
A AA

0 22
a 0 a
e 22 e 22
22

2 2 e e
a

n Kt e e a a n Kt 22 22
22
a a
22 22 22 22 22 d 22
E 2E 2 0
a
a
a 22 a
22 f 22
a 22
f a
E 22
E
22

© 2010 Grzegorz Glinka. All rights reserved. 29


Neuber’s Rule and the The ESED method and the
Ramberg-Osgood curve Ramberg-Osgood curve

e B
22
e
22 B
a a
22
22
A AA

0 22
a 0 a
e 22 e 22
22

2 1
2 a 2
nKt
e e a a
e e a a Kt n 22 22 22 22 22
n
22 22 22 22
E 1 2E 2 2E n 1 K
1
a a n a a n
a 22 22 a 22 22
22
E K 22
E K
© 2010 Grzegorz Glinka. All rights reserved. 30
Graphical solution to the Neuber rule and the equation
of the Stress-Strain curve

Cyclic stress-strain curve


a a f( 22a )
22 22
Stress

Elastic behavior

a
22

Neuber’s rule
2
Kt n e e a a
22 22 22 22
E

0 a Strain
22

© 2010 Grzegorz Glinka. All rights reserved. 31


P Load History Stress-Strain Response at the Notch Tip
P1
2
K t Smax

a
a e
max max
2

Notch tip stress,


Cyclic stress-strain
curve
P1
P2
O
time

Notched Body

P
0 Notch tip strain, a
e

2
Hysteresis stress-strain curve
a

S S
P1 2
1 K t Smax
Neuber’s hyperpola, a a

2
2L
Material Response at the Notch Tip
Due to Loading and Unloading
P
Reversals of Load P
© 2010 Grzegorz Glinka. All rights reserved. 32
- curve Simulation of Stress-Strain Response at the Notch
Tip (Neuber’s Rule) Induced by Cyclic Loading
2
Kt n2
1
1 1
n' 1 E
E K' 2
3
01, 03

Nominal stress history


n
Stress

peak
Nominal stress,

n
n1 n3
1
0
0 y
dn
T 3

0 n2 n4
time 02
2 1
1 n' 2
1
1 1 1 ' 2
E K Kt
1 n2
2
n' 2 2
2
2 2 E
2 2 2 '
E 2K
© 2010 Grzegorz Glinka. All rights reserved. 33
Simulation of Stress-Strain Response at the Notch
- curve Tip (ESED Method) Induced by Cyclic Loading
2
Kt n2
2

2 d 2
1 1 2E 0
n'
3
' 2
E K 01, 03

2
Kt n1
1

1 d 1
2E 0
Nominal stress history
n
Stress

peak
Nominal stress,

n 1
n1 n3 0

0 y
dn 3
T
02
0 n2
time
n4 2

1 1
1 2 2
' 1
1 1
n 2 2 2 2
n'
1 d 1
1
' ' 2 d 2
0
2E n 1 K 0
2E n' 1 2K '

© 2010 Grzegorz Glinka. All rights reserved. 34


Cyclic loading and cyclic stress-strain response
smooth component, non-linear elastic-plastic stress-strain curve
1
a a n'
a max max
max '
E K a
max

0
t
a a
max, max 0

a
a
min

1
a a n'
0 a max max

a
max '
E K
1
1
a a n' a a n'
a
2 a
E 2K ' 2
a
min , E 2K '
a
min
a a a
a
min max
a a a
min max
© 2010 Grzegorz Glinka. All rights reserved. 35
Cyclic loading and cyclic stress-strain response
notched component, non-linear elastic-plastic stress-strain curve
n
1
a a n' n,max
a max max
max '
E K

n
0 n,min
a
max,
0 t
a
max

F a F

0 n
a

2 2
1
Kt n ,max a a
Kt n a a
a a n' max max
a
2 E E
a
min, E 2K ' 1 1
a a a n' a a n'
min a max max a
max
2
a E K '
E 2K '

a a a a a a
min max ; min max

© 2010 Grzegorz Glinka. All rights reserved. 36


Notched component
P Elastic-perfectly plastic material
Nominal stress S

S Smax
Sa Material curve
S S
Sm ys
Smin
0 E
Kt
0

Stress-strain response at the notch tip

For K t Smax ys and For K t Smax ys and For K t S 2 ys


Kt S 2 ys
Kt S 2 ys
Notch tip stress

ys max
ys max ys
max

min
0 0 0
min
No yielding Yielding on the 1st cycle Reversed yielding
ys
min

© 2010 Grzegorz Glinka. All rights reserved. 37


The ‘erratic’ relationship between the nominal mean stress Sm
and the local (at the notch tip) mean stress m
For K t Smax ys and
Kt S 2 S Nominal stress history S
ys

max
Smax
max Sa
K tSmax S
max
a Sm
a K t Sa
Kt Sm 0 t
m

min Kt Smax 2Kt Sa


m
Local notch tip stress histories
min
0 t
Kt S 2 ys
max
ys
For K t Smax ys and max ys
Kt S 2 ys a ys
ys max
m 0
max ys min ys
a
a Kt Sa m=0
0 t
m ys K t Sa
m min ys 2K t Sa
0 t

min ys min
© 2010 Grzegorz Glinka. All rights reserved. 38
Strain,
Material Stress-Strain Response
Applied strain 2
1
b) Due to Variable Amplitude
history
Cyclic Loading
3

4 2’

5
6 7

7 1’

Resulting
Resulting stress history
stress-strain
path

Stress,

© 2010 Grzegorz Glinka. All rights reserved. 39


Strain-Stress Hysteresis Loops vs. “Rainflow Counted”
Cycles

© 2010 Grzegorz Glinka. All rights reserved. 40


Mathematical Description of Material Stress-Strain Response
Induced by a Variable Amplitude Stress or Strain History

Stress history

© 2010 Grzegorz Glinka. All rights reserved. 41


The linear hypothesis of Fatigue Damage accumulation (the Miner rule)

a '
b c
f '
2N f 2N f
a
a f
Strain amplitude,
a
2 E
a

2Nf1 2Nf4 2Nf2 2Nf3 2Nf5 Reversals

' b c 5
i f ' D Di D1 D2 D3 D4 D5
a ,i
2 N fi f
2 N fi N fi
2 E i 1

1 1 1 1 1 1 1 1
D1 ; D2 ; D3 ; ;
Nf1 Nf2 Nf3 N f1 Nf2 Nf3 Nf4 Nf5
1 1 if D 1Failure !!
D4 ; D5 ;
Nf4 Nf5 1 1
LR
D 1 N f1 1 Nf2 1 Nf3 1 Nf4 1 Nf5
© 2010 Grzegorz Glinka. All rights reserved. 42
The Loading Sequence Effect
P
S A e B
S
2
C E a D
t t
S S
0 0
D 1 C E

B 2L A

a A
P a B
C, E

S, a D
m

a
200 MPa
0 0

m
a
D
a

0.005
C, E
B A
© 2010 Grzegorz Glinka. All rights reserved. 43
Modeling the residual stress effect
2 2 E

Kt S r
Kt S r
22
E E
N
22
N
22
- Neuber’s 22 d 22
- ESED method
E rule 2E 0

e e

2
Kt S r
22 22 2
E Kt S r

2E

2
Kt S 2
22 22 r Kt S
r E
2E
E

e e
Kt S Kt S
E E

Kt S r Kt S r
E E
© 2010 Grzegorz Glinka. All rights reserved. 44
Nominal stress S
B
S Residual Stress Effect on
y peak the Stress-Strain Response

Stress
at the Notch Tip
C
Case 1 r> 0!
A Time x
B
Case 2 r< 0!
B max
r
A
r= 0!
S
B B r> 0!
max

m m
m
A A
m
0 0

r< 0! C min
C r= 0! C

min C

r A
© 2010 Grzegorz Glinka. All rights reserved. 45
Summary of the Local Strain-Life ( -N) Approach
Advantages:
• The method takes into account the actual stress-strain response of the material due
to cyclic loading.
• Plastic strain, and the mechanism that leads to crack initiation, is accurately
modeled.
• This method can model the effect of the residual mean stresses resulting from the
sequence effect in load histories and the manufacturing residual stresses. This
allows for more accurate damage accumulation under variable amplitude cyclic
loading.
• The -N method can be more easily extrapolated to situations involving complicated
geometries.
• This method can be used in high temperature applications where fatigue-creep
interaction is critical.
• In situations where it is important, this method can incorporate transient material
behavior.
• This method can be used for both low cycle (high strains) and high cycle fatigue (low
strains)
• There is only one essential empirical element in the method, i.e. the correction for
the mean stress effect.

© 2010 Grzegorz Glinka. All rights reserved. 46

You might also like