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Ken Youssefi
Crack Initiation
Crack Propagation
Final Fracture
MAE dept., SJSU
Fracture zone
Propagation zone, striation
Ken Youssefi
VW crank shaft fatigue failure due to cyclic bending and torsional stresses
Propagation
zone, striations
Ken Youssefi
Fracture area
Ken Youssefi
Ken Youssefi
Crank shaft
Ken Youssefi
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
Ductile
Brittle Intergranular
Shiny
Grain Boundary cracking
Brittle Transgranular
Shiny
Cleavage fractures
Flat
Fatigue
Beachmarks
Striations (SEM)
Initiation sites
Propagation zone
Final fracture zone
Ken Youssefi
Alternating stress
a =
max min
2
Mean stress
m
=
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max + min
2
10
Load
11
N < 103
Finite life
Infinite life
Se
Ken Youssefi
12
Se =
0.5Sut
100 ksi
Cast iron
Cast iron
Se =
0.4Sut
24 ksi
Sut 60 ksi
13
Se =
0.4Sut
19 ksi
Sut 48 ksi
Copper alloys
Copper alloys
Se =
0.4Sut
14 ksi
Sut 40 ksi
14
Se
106
For materials that do not exhibit a knee in the S-N curve, the infinite
life taken at 5x108 cycles
Ken Youssefi
103
Sf
5x108
15
Ken Youssefi
Pure bending
Cload = 1
Pure axial
Cload = 0.7
Pure torsion
Combined loading
Cload = 1
16
Csize = 1
Csize = .869(d)-0.097
8 mm < d 250 mm
Csize = 1.189(d)-0.097
Ken Youssefi
17
dequiv = (
Ken Youssefi
A95
0.0766
)1/2
d95
18
Csurf = A (Sut)b
Ken Youssefi
19
Ctemp = 1
Ken Youssefi
20
Ken Youssefi
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Ken Youssefi
22
Fatigue Stress
Concentration Factor,
Kf for Aluminum
Ken Youssefi
23
Se
Kf a =
n
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
Ken Youssefi
24
B
Sf
Se
106
103
Point A
Point B
Sn = .9Sut
Point A
Sn = .9Sut
N = 10
N = 103
Sn = Se
Sn = Sf
Point B
N = 10
Ken Youssefi
5x108
103
N = 5x108
25
a=
b=
Sn = Se ( 106 )
Calculate Sn
Se
1
3
log
.9Sut
Se
Se
log ( .9S )
ut
Ken Youssefi
(.9Sut)
Sn
n
Design equation
26
a
Sy
Yield line
Gerber curve
Alternating
stress
Se
Goodman line
Sy
Soderberg line
Sut
Mean stress
Ken Youssefi
27
Alternating
stress
Yield line
Se
Goodman line
C
Safe zone
Sy
Sut
Mean stress
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28
Yield line
Se
Goodman line
Safe zone
- m
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Safe zone
Sy
- Syc
Sut
+ m
29
m 0
Fatigue,
a
Se
Se
a = n
f
Sn
+
+
m > 0
m
Sut
m
Sut
=
= 1
Se
Yield
a + m = n
y
nf
Finite life
Sy
Safe zone
Ken Youssefi
Infinite life
Yield
Sy
- m
Safe zone
a + m = n
y
Sy
- Syc
Sut
+ m
30
If Kf max > Sy then there is local yielding at the notch, material at the
Kfm =
Sy
Se
Ken Youssefi
Sut
Kf a
m
1
nf
Infinite life
31
Combined Loading
All four components of stress exist,
xa
xm
xya
xym
Ken Youssefi
32
Combined Loading
Calculate the alternating and mean von Mises stresses,
a
Se
Ken Youssefi
m
Sut
nf
Infinite life
33
Design Example
12
D = 1.5d
10,000 lb.
6
6
R1
r (fillet radius) = .1d
R2
a =
Mc
32M
=
3
305577
m = 0
Kt = 1.7
34
Design Example
Assume d = 1.0 in
-.265
= .759
ksi
35
Design Example
Design life, N = 1150 x 75 = 86250 cycles
Se
log ( .9S )
86250
N
ut
Sn = 39.57 ( 6
Sn = Se ( 6 )
10
a =
305577
d3
10
= 305.577 ksi
n=
Sn
Kfa
39.57
log ( .9x120 )
= 56.5 ksi
56.5
1.6x305.577
Assume d = 2.5 in
All factors remain the same except the size factor and notch sensitivity.
Se = 36.2 ksi
36
Design Example
Se = 36.2 ksi Sn = 53.35 ksi
a =
305577
(2.5)
= 19.55 ksi
n=
Sn
Kfa
53.35
1.63x19.55
= 1.67 1.6
d = 2.5 in.
Check yielding
n=
Ken Youssefi
Sy
90
= 2.8 > 1.6 okay
=
Kfmax 1.63x19.55
MAE dept., SJSU
37