Design Stress & Fatigue

MET 210W
E. Evans
Parts Fail When?
Crack initiation site
P
P
This crack in the part is very small.
If the level of stress in the part is
SMALL, the crack will remain stable
and not expand. If the level of stress
in the part is HIGH enough, the
crack will get bigger (propagate)
and the part will eventually fail.
Design Factor
Analysis



Design
o
=
=
y
S
N : Example
Stress Applied
Strength Failure
Safety of Factor
N
S
: Example
Factor Design
Strength Failure
Stress Allowable
y
ALLOW
= o
=
Factors Effecting Design Factor
Application
Environment
Loads
Types of Stresses
Material
Confidence
Factors Effecting Design Factor
Application
Environment
Loads
Types of Stresses
Material
Confidence
How many will be produced?
What manufacturing methods will
be used?
What are the consequences of
failure?
Danger to people
Cost
Size and weight important?
What is the life of the component?
Justify design expense?
Factors Effecting Design Factor
Application
Environment
Loads
Types of Stresses
Material
Confidence
Temperature range.
Exposure to electrical voltage or
current.
Susceptible to corrosion
Is noise control important?
Is vibration control important?
Will the component be protected?
Guard
Housing
Factors Effecting Design Factor
Application
Environment
Loads
Types of Stresses
Material
Confidence
Nature of the load considering all
modes of operation:
Startup, shutdown, normal
operation, any foreseeable
overloads
Load characteristic
Static, repeated & reversed,
fluctuating, shock or impact
Variations of loads over time.
Magnitudes
Maximum, minimum, mean
Factors Effecting Design Factor
Application
Environment
Loads
Types of Stresses
Material
Confidence
What kind of stress?
Direct tension or compression
Direct shear
Bending
Torsional shear
Application
Uniaxial
Biaxial
Triaxial

Factors Effecting Design Factor
Application
Environment
Loads
Types of Stresses
Material
Confidence
Material properties
Ultimate strength, yield strength,
endurance strength,
Ductility
Ductile: %E > 5%
Brittle: %E < 5%
Ductile materials are preferred for
fatigue, shock or impact loads.
Factors Effecting Design Factor
Application
Environment
Loads
Types of Stresses
Material
Confidence
Reliability of data for
Loads
Material properties
Stress calculations
How good is manufacturing
quality control
Will subsequent handling, use
and environmental conditions
affect the safety or life of the
component?
Design Factor
Adapted from R. B. Englund
Design Factor
Predictions of Failure
Static Loads
Brittle Materials:
Maximum Normal Stress - Uniaxial
Modified Mohr - Biaxial

Ductile Materials:
Yield Strength - Uniaxial
Maximum Shear Strength - Biaxial
Distortion Energy - Biaxial or Triaxial
Predictions of Failure
Fluctuating Loads
Brittle Materials:
Not recommended

Ductile Materials:
Goodman
Gerber
Soderberg
Maximum Normal Stress
Uniaxial Static Loads on Brittle Material:

In tension:
K
t
o s o
d
= S
ut
/ N

In compression:
K
t
o s o
d
= S
uc
/ N
45 Shear Diagonal
Modified Mohr
Biaxial Static Stress on Brittle Materials
o
1
o
2
Stress concentrations
applied to stresses before
making the circle
o
1
o
2
S
ut
S
ut
S
uc
S
uc
o
1,
o
2
Often brittle materials have
much larger compressive
strength than tensile strength
Yield Strength Method
Uniaxial Static Stress on Ductile Materials

In tension:
o s o
d
= S
yt
/ N
In compression:
o s o
d
= S
yc
/ N
For most ductile materials, S
yt
= S
yc

Maximum Shear Stress
Biaxial Static Stress on Ductile Materials
Ductile materials begin to yield when the maximum shear
stress in a load-carrying component exceeds that in a tensile-
test specimen when yielding begins.
t
max
s t
d
= S
ys
/ N = 0.5(S
y
)/ N

Somewhat conservative use Distortion
Energy for more precise failure estimate
Distortion Energy
Best predictor of failure for
ductile materials under static
loads or completely
reversed normal, shear or
combined stresses.
Shear
Diagonal
o
1
o
2
2 1
2
2
2
1
o o o + o = o'
o = von Mises stress
Failure: o > S
y
Design:

o s o
d
= S
y
/N


Static Biaxial or Triaxial Stress on Ductile Materials
S
y
S
y
S
y
S
y
Distortion Energy
von Mises Stress
Alternate Form



For uniaxial stress when o
y
= 0,

Triaxial Distortion Energy (o
1
> o
2
> o
3
)

2 2 2
3
xy y x y x
' t + o o o + o = o
2 2
3
xy x
' t + o = o
2
2 3
2
1 3
2
1 2
2
2
) ( ) ( ) ( ' o o + o o + o o
|
|
.
|

\
|
= o
Fluctuating Stress
S
t
r
e
s
s

Time
o
min
o
mean
o
max
Varying stress with a nonzero mean.
o
alternating
= o
a
2
mi n max
mean
o + o
= o
2
mi n max
a
o o
= o
Stress Ratio,
max
mi n
R
o
o
=
-1 s R s 1
Fluctuating Stress Example
Valve Spring Force
Valve Spring Force
Valve Open
Valve
Closed
Valve
Closed
Valve
Open
Bending of Rocker Arm
Tension in Valve Stem
Adapted from R. B. Englund
RBE
2/1/91
Fatigue Testing
Bending tests
Spinning bending elements most common
Constant stress cantilever beams
Fixed Support
Applied Deformation
Fully Reversed, R = -1
Top View
Front View
Fatigue Testing
Number of Cycles to Failure, N
S
t
r
e
s
s
,

o

(
k
s
i
)

Data from R. B. Englund, 2/5/93
Test Data
Endurance Strength
The stress level that a material can survive
for a given number of load cycles.
For infinite number of cycles, the stress
level is called the endurance limit.
Estimate for Wrought Steel:
Endurance Strength = 0.50(S
u
)
Most nonferrous metals (aluminum) do not
have an endurance limit.

Typical S-N Curve
Estimated S
n
of Various Materials
Actual Endurance Strength
S
n
= S
n
(C
m
)(C
st
)(C
R
)(C
S
)

S
n
= actual endurance strength (ESTIMATE)
S
n
= endurance strength from Fig. 5-8
C
m
= material factor (pg. 174)
C
st
= stress type: 1.0 for bending
0.8 for axial tension
0.577 for shear
C
R
= reliability factor
C
S
= size factor

Actual S
n
Example
Find the endurance strength for the valve stem.
It is made of AISI 4340 OQT 900F.


62 ksi
From Fig. A4-5.
S
u
= 190 ksi
From Fig. 5-8.
S
n
= 62 ksi
(machined)
Actual S
n
Example Continued
S
n
= S
n
(C
m
)(C
st
)(C
R
)(C
S
)
= 62 ksi(1.0)(.8)(.81)(.94) = 37.8 ksi



Size Factor, Fig. 5-9
Wrought Steel
Axial Tension
Reliability, Table 5-1
99% Probability
S
n
is at or above the
calculated value
S
n
,Table 5-8
Actual S
n

Estimate
Guessing: diameter ~ .5
S
n

Goodman Diagram
o
m
o
a
-S
y
S
y
S
y
S
u
FATIGUE
FAILURE REGION
NO FATIGUE
FAILURE REGION
Goodman Line
0

Yield Line
1 =
o
+
'
o
u
m
n
a
S S
S
n
/N

S
n

Goodman Diagram
o
m
o
a
-S
y
S
y
S
y
S
u
FATIGUE
FAILURE REGION
Goodman Line
0

Yield Line
1 =
o
+
'
o
u
m
n
a
S S
S
u
/N
N S S
K
u
m
n
a t
1
=
o
+
'
o
Safe Stress Line
Safe Stress Line
SAFE ZONE
MAX = 30.3
Example: Problem 5-53.
Find a suitable titanium alloy. N = 3
42 mm DIA
30 mm
DIA
1.5 mm Radius
F varies from 20 to 30.3 kN
+
-
F
O
R
C
E

MIN = 20
TIME
kN .
.
mean 15 25
2
20 3 30
=
+
=
kN .
.
alt 15 5
2
20 3 30
=

=
Example: Problem 5-53 continued.
Find the mean stress:


Find the alternating stress:


Stress concentration from App. A15-1:
MPa 35.6 =
t
= o
2
m
) mm 30 (
4
N 150 , 25
MPa 7.3 =
t
= o
2
a
) mm 30 (
4
N 150 , 5
2.3 K
t
= = = = = 05 .
mm 30
mm 5 . 1
d
r
; 4 . 1
mm 30
mm 42
d
D
Example: Problem 5-53 continued.
S
n
data not available for titanium so we will guess!
Assume S
n
= S
u
/4 for extra safety factor.
TRY T2-65A, S
u
= 448 MPa, S
y
= 379 MPa



3.36 = =
= = +
=
o
+
'
o
297 .
1
N
297 .
N
1
MPa 448
MPa 6 . 35
) 4 / MPa 448 )( 86 (. 8 .
) MPa 3 . 7 ( 3 . 2
N
1
S S
K
u
m
n
a t
(Eqn 5-20)
Tension
Size
Reliability 50%
3.36 is good, need further information on Sn for titanium.
MAX = 1272 N-m
Example:
Find a suitable steel for N = 3 & 90% reliable.
T varies from 848 N-m to 1272 N-m
+
-
T
O
R
Q
U
E

MIN = 848 N-m
TIME
m N 1060
2
848 1272
mean =
+
=
m N 212
2
848 1272
alt =

=
50 mm DIA
30 mm
DIA
3 mm Radius
T = 1060 212 N-m
Example: continued.
Stress concentration from App. A15-1:


Find the mean shear stress:



Find the alternating shear stress:


MPa 200 =
t

= = t
3
m
mm
p
m
m
) mm 30 (
16
) 1000 ( m N 1060
Z
T
MPa 40 =

= = t
3
p
a
a
mm 5301
mm N 212000
Z
T
1.38 K
t
= = = = = 1 .
mm 30
mm 3
d
r
; 667 . 1
mm 30
mm 50
d
D
Example: continued.
So, t = 200 40 MPa. Guess a material.
TRY: AISI 1040 OQT 400F
S
u
= 779 MPa, S
y
= 600 MPa, %E = 19%
Verify that t
max
s S
ys
:
t
max
=

200 + 40 = 240 MPa s S
ys
~ 600/2 = 300MPa
Find the ultimate shear stress:
S
us
= .75S
u
= .75(779 MPa) = 584 MPa

Ductile
Example: continued.
Assume machined surface, S
n
~ 295 MPa

Find actual endurance strength:
S
sn
= S
n
(C
m
)(C
st
)(C
R
)(C
S
)
= 295 MPa(1.0)(.577)(.9)(.86) = 132 MPa


S
n
Wrought steel

Shear Stress

90% Reliability

Size 30 mm

(Fig. 5-8)
Example: continued.
Goodman:



1.31 = =
= = +
=
t
+
'
t
7606 .
1
N
7606 .
N
1
MPa 584
MPa 200
MPa 132
) MPa 40 ( 38 . 1
N
1
S S
K
su
m
sn
a t
(Eqn. 5-28)
No Good!!! We wanted N > 3
Need a material with Su about 3 times bigger than this
guess or/and a better surface finish on the part.
Example: continued.
Guess another material.
TRY: AISI 1340 OQT 700F
S
u
= 1520 MPa, S
y
= 1360 MPa, %E = 10%
Find the ultimate shear stress:
S
us
= .75S
u
= .75(779 MPa) = 584 MPa
Find actual endurance strength:
S
sn
= S
n
(C
m
)(C
st
)(C
R
)(C
S
)
= 610 MPa(1.0)(.577)(.9)(.86) = 272 MPa



Ductile
S
n
wrought

shear

reliable

size

Example: continued.
Goodman:



2.64 = =
= = +
=
t
+
'
t
378 .
1
N
378 .
N
1
MPa 1140
MPa 200
MPa 272
) MPa 40 ( 38 . 1
N
1
S S
K
su
m
sn
a t
(Eqn. 5-28)
No Good!!! We wanted N > 3
Decision Point:
Accept 2.64 as close enough to 3.0?
Go to polished surface?
Change dimensions? Material? (Cant do much better in
steel since S
n
does not improve much for S
u
> 1500 MPa

Example: Combined Stress Fatigue
RBE
2/11/97
Example: Combined Stress Fatigue Contd
RBE
2/11/97
Repeated one direction
PIPE: TS4 x .237 WALL
MATERIAL: ASTM A242
Equivalent
DEAD WEIGHT:
SIGN + ARM + POST = 1000#
(Compression)
Reversed,
Repeated
45
Bending
Example: Combined Stress Fatigue Contd
Stress Analysis:
psi 5 . 315
in 17 . 3
# 1000
A
P
2
= = = o
Dead Weight:
psi 09 . 63
in 17 . 3
# 200
A
P
2
= = = o
Vertical from Wind:
(Static)
(Cyclic)
psi 8 . 9345
in 21 . 3
) in 60 ( # 500
Z
M
3
= = = o
Bending:
(Static)
Example: Combined Stress Fatigue Contd
Stress Analysis:
Torsion:
(Cyclic) psi 3 . 3115
) in 21 . 3 ( 2
) in 100 ( # 200
Z
T
3
P
= = = t
Stress Elements: (Viewed from +y)
CYCLIC:
STATIC:
315.5 psi
9345.8 psi
63.09 psi Repeated
One Direction
t = 3115.3 psi
Fully Reversed
x
z
x
z
Example: Combined Stress Fatigue Contd
Mean Stress:
9345.8
-315.5
-31.5
8998.8
psi
Static
Repeated / 2
Alternating Stress:
t
(CW)
o
1
o

t
max
psi 4 . 4499
2
psi 8 . 8998
max
= = t
+
TIME
-
S
t
r
e
s
s

MIN = -63.09 psi
o
m
o
a
t
(CW)
o

(-31.5,-3115.3)
(0,-3115.3)
t
max
psi 34 . 3115
max
= t
Example: Combined Stress Fatigue Contd
Determine Strength:
Try for N = 3 some uncertainty
Size Factor? OD = 4.50 in, Wall thickness = .237 in
ID = 4.50 2(.237) = 4.026 in
Max. stress at OD. The stress declines to 95% at
95% of the OD = .95(4.50) = 4.275 in. Therefore,
amount of steel at or above 95% stress is the same
as in 4.50 solid.
ASTM A242: S
u
= 70 ksi, S
y
= 50 ksi, %E = 21%

t s 3/4 Ductile
Example: Combined Stress Fatigue Contd

We must use S
su
and S
sn
since this is a combined
stress situation. (Case I1, page 197)

S
us
= .75S
u
= .75(70 ksi) = 52.5 ksi

S
sn
= S
n
(C
m
)(C
st
)(C
R
)(C
S
)
= 23 ksi(1.0)(.577)(.9)(.745) = 8.9 ksi
Hot Rolled
Surface

Wrought steel

Combined or Shear Stress

90% Reliability

Size 4.50 dia

Example: Combined Stress Fatigue Contd

Safe Line for Goodman Diagram:
t
a
= S
sn
/ N = 8.9 ksi / 3 = 2.97 ksi
t
m
= S
su
/ N = 52.5 ksi / 3 = 17.5 ksi

Mean Stress, t
m
0 15 10 5 20
0
5
10
A
l
t
e
r
n
a
t
i
n
g

S
t
r
e
s
s
,

t
a

2.29 = =
= = +
=
t
+
'
t
426 .
1
N
426 .
N
1
psi 52500
psi 4 . 4499
psi 8900
) psi 3 . 3115 ( 0 . 1
N
1
S S
K
su
m
sn
a t
S
u
/N
S
sn
/N
S
u
S
sn

t
mean
= 4499.4
3115.3
K
t
t
alt