Design Stress & Fatigue

MET 210W
E. Evans
 Parts Fail When?
P

Crack initiation site

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)
P and the part will eventually fail.
 Design Factor
Analysis Failure Strength
Factor of Safety
Applied Stress
Sy
Example : N

Design
Failure Strength
Allowable Stress
Design Factor
Sy
Example : ALLOW
N
Factors Effecting Design Factor
Application
Environment
Loads
Types of Stresses
Material
Confidence
 Factors Effecting Design Factor
Application How many will be produced?
Environment What manufacturing methods will
Loads be used?
Types of Stresses What are the consequences of
Material failure?
Confidence Danger to people
Cost
Size and weight important?
What is the life of the component?
Justify design expense?
 Factors Effecting Design Factor
Application Temperature range.
Environment Exposure to electrical voltage or
Loads current.
Types of Stresses Susceptible to corrosion
Material
Is noise control important?
Confidence
Is vibration control important?
Will the component be protected?
Guard
Housing
Factors Effecting Design Factor
Application Nature of the load considering all
Environment modes of operation:
Startup, shutdown, normal
Loads operation, any foreseeable
Types of Stresses overloads
Material
Load characteristic
Confidence Static, repeated & reversed,
fluctuating, shock or impact
Variations of loads over time.
Magnitudes
Maximum, minimum, mean
 Factors Effecting Design Factor
Application What kind of stress?
Environment Direct tension or compression
Loads Direct shear
Bending
Types of Stresses Torsional shear
Material
Application
Confidence Uniaxial
Biaxial
Triaxial
 Factors Effecting Design Factor
Application Material properties
Environment
Ultimate strength, yield strength,
Loads endurance strength,
Types of Stresses
Ductility
Material Ductile: %E 5%
Confidence Brittle: %E < 5%
Ductile materials are preferred for
fatigue, shock or impact loads.
 Factors Effecting Design Factor
Application Reliability of data for
Environment Loads
Loads Material properties
Types of Stresses Stress calculations
Material How good is manufacturing
quality control
Confidence
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:
Kt d = Sut / N

In compression:
Kt d = Suc / N
 Modified Mohr
Biaxial Static Stress on Brittle Materials
2
45 Shear Diagonal Sut
2 1
Suc Sut
1 Stress concentrations
applied to stresses before
1, 2 making the circle

Often brittle materials have

much larger compressive
strength than tensile strength
Suc
 Yield Strength Method
Uniaxial Static Stress on Ductile Materials

In tension:

d = Syt / N
In compression:

d = Syc / N

For most ductile materials, Syt = Syc

 Maximum Shear Stress
Biaxial Static Stress on Ductile Materials

tmax td = Sys / N = 0.5(Sy )/ N

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.

Somewhat conservative use Distortion

Energy for more precise failure estimate
 Distortion Energy
Static Biaxial or Triaxial Stress on Ductile Materials
Shear
Diagonal 2 Best predictor of failure for
Sy ductile materials under static
loads or completely
reversed normal, shear or
combined stresses.
Sy
1
Sy
' 12 22 12
= von Mises stress
Failure: > Sy
Sy
Design: d = Sy/N
Distortion Energy
 von Mises Stress
Alternate Form

' 2x 2y x y 3t 2xy

For uniaxial stress when y = 0, ' 3t

2
x
2
xy

Triaxial Distortion Energy (1 > 2 > 3)

2
' ( 2 1 ) (3 1 ) (3 2 )
2 2 2
2

 Fluctuating Stress
Varying stress with a nonzero mean.

alternating = a max min

mean
2
max
max min
a
2
Stress

mean Stress Ratio,

min
R
max
Time -1 R 1
min
 Fluctuating Stress Example
Bending of Rocker Arm
Valve Spring Force
Valve Open

Valve
Closed

Tension in Valve Stem

Valve
Valve Spring Force
Closed

Valve
RBE
Open
2/1/91

Adapted from R. B. Englund

 Fatigue Testing
Bending tests
Spinning bending elements most common
Constant stress cantilever beams

Top View

Front View Applied Deformation

Fixed Support Fully Reversed, R = -1
 Fatigue Testing Test Data
Stress, (ksi)

Number of Cycles to Failure, N

Data from R. B. Englund, 2/5/93
 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(Su)

Most nonferrous metals (aluminum) do not

have an endurance limit.
Typical S-N Curve
Estimated Sn of Various Materials
Actual Endurance Strength
Sn = Sn(Cm)(Cst)(CR)(CS)

Sn = actual endurance strength (ESTIMATE)

Sn = endurance strength from Fig. 5-8
Cm = material factor (pg. 174)
Cst = stress type: 1.0 for bending
0.8 for axial tension
0.577 for shear
CR = reliability factor
CS = size factor
 Actual Sn Example
Find the endurance strength for the valve stem.
It is made of AISI 4340 OQT 900F.

From Fig. A4-5.

Su = 190 ksi

62 ksi
From Fig. 5-8.
Sn = 62 ksi
(machined)
 Actual Sn Example Continued

Sn = Sn(Cm)(Cst)(CR)(CS)
= 62 ksi(1.0)(.8)(.81)(.94) = 37.8 ksi
Sn,Table 5-8
Wrought Steel
Actual Sn
Axial Tension Estimate
Reliability, Table 5-1

99% Probability Size Factor, Fig. 5-9

Sn is at or above the Guessing: diameter .5
calculated value
 Goodman Diagram
a
Yield Line
Sy
FATIGUE
Sn
FAILURE REGION

Goodman Line
a m
NO FATIGUE 1
FAILURE REGION Sn S u

m
-Sy 0 Sy Su
 Goodman Diagram
Safe Stress Line a
K t a m 1
Yield Line
Sn Su N Sy
FATIGUE
Sn
FAILURE REGION

Goodman Line
Sn/N a m
1
Sn S u
SAFE ZONE
m
-Sy 0 Su/N Sy Su
Safe Stress Line
 Example: Problem 5-53.
Find a suitable titanium alloy. N = 3
1.5 mm Radius

42 mm DIA 30 mm
DIA

F varies from 20 to 30.3 kN

+
MAX = 30.3
30 .3 20
alt 5.15 kN
FORCE

2
30 .3 20
MIN = 20 mean 25 .15 kN
2
- TIME
Example: Problem 5-53 continued.
Find the mean stress:
25,150 N
m 35.6 MPa

(30 mm )2
4
Find the alternating stress:
5,150 N
a 7.3 MPa

(30 mm )2
4
Stress concentration from App. A15-1:
D 42 mm r 1.5 mm
1.4; .05 K t 2.3
d 30 mm d 30 mm
Example: Problem 5-53 continued.
Sn data not available for titanium so we will guess!
Assume Sn = Su/4 for extra safety factor.
TRY T2-65A, Su = 448 MPa, Sy = 379 MPa

K t a m 1
(Eqn 5-20)
Sn Su N
2.3(7.3 MPa) 35 .6 MPa 1
.297
.8(. 86 )( 448 MPa / 4) 448 MPa N
Size 1
Tension Reliability 50% N 3.36
.297
3.36 is good, need further information on Sn for titanium.
 Example:
Find a suitable steel for N = 3 & 90% reliable.
3 mm Radius

50 mm DIA
30 mm
DIA

T varies from 848 N-m to 1272 N-m

+
MAX = 1272 N-m
1272 848
TORQUE

alt 212 N m
2
1272 848
MIN = 848 N-m mean 1060 N m
2
- TIME
T = 1060 212 N-m
Example: continued.
Stress concentration from App. A15-1:
D 50 mm r 3 mm
1.667; .1 K t 1.38
d 30 mm d 30 mm

Find the mean shear stress:

Tm 1060 N m(1000 mm )
tm m
200 MPa
Zp
(30 mm)3
16

Find the alternating shear stress:

Ta 212000 N mm
ta 3
40 MPa
Zp 5301 mm
Example: continued.
So, t = 200 40 MPa. Guess a material.
TRY: AISI 1040 OQT 400F
Su = 779 MPa, Sy = 600 MPa, %E = 19%
Ductile
Verify that tmax Sys:
tmax = 200 + 40 = 240 MPa Sys 600/2 = 300MPa

Find the ultimate shear stress:

Sus = .75Su = .75(779 MPa) = 584 MPa
Example: continued.
Assume machined surface, Sn 295 MPa
(Fig. 5-8)

Find actual endurance strength:

Ssn = Sn(Cm)(Cst)(CR)(CS)
= 295 MPa(1.0)(.577)(.9)(.86) = 132 MPa

Sn Size 30 mm
Wrought steel 90% Reliability
Shear Stress
Example: continued.
K t ta tm 1
Goodman: (Eqn. 5-28)
Ssn S su N
1.38( 40 MPa) 200 MPa 1
.7606
132 MPa 584 MPa N
1
N 1.31
.7606
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
Su = 1520 MPa, Sy = 1360 MPa, %E = 10%
Ductile
Find the ultimate shear stress:
Sus = .75Su = .75(779 MPa) = 584 MPa

Find actual endurance strength:

Ssn = Sn(Cm)(Cst)(CR)(CS)
= 610 MPa(1.0)(.577)(.9)(.86) = 272 MPa
Sn shear size
wrought reliable
Example: continued.
K t ta tm 1
Goodman: (Eqn. 5-28)
Ssn S su N
1.38( 40 MPa) 200 MPa 1
.378
272 MPa 1140 MPa N
1
N 2.64
.378
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 Sn does not improve much for Su > 1500 MPa
 Example: Combined Stress Fatigue

RBE
2/11/97
 Example: Combined Stress Fatigue Contd
PIPE: TS4 x .237 WALL
MATERIAL: ASTM A242
Equivalent
DEAD WEIGHT:
Reversed,
Repeated SIGN + ARM + POST = 1000#
(Compression)

45

Bending

RBE
2/11/97 Repeated one direction
Example: Combined Stress Fatigue Contd
Stress Analysis:
Dead Weight:
P 1000 #
2
315 .5 psi (Static)
A 3.17 in

Vertical from Wind:

P 200 #
2
63 .09 psi (Cyclic)
A 3.17 in

Bending:
M 500 # (60 in)
3
9345 .8 psi (Static)
Z 3.21 in
Example: Combined Stress Fatigue Contd
Stress Analysis:
Torsion:
T 200 # (100 in)
t 3
3115 .3 psi (Cyclic)
ZP 2(3.21 in )

Stress Elements: (Viewed from +y)

STATIC: 315.5 psi CYCLIC: 63.09 psi Repeated
9345.8 psi One Direction

z z
t = 3115.3 psi
x x Fully Reversed
 Example: Combined Stress Fatigue Contd
Mean Stress: Alternating Stress:
+
TIME
9345.8 Static

Stress
-315.5 m
-31.5 Repeated / 2
- MIN = -63.09 psi
8998.8 psi a t (CW)
tmax
t (CW) tmax (0,-3115.3)

(-31.5,-3115.3)
8998 .8 psi
tmax 4499 .4 psi tmax 3115 .34 psi
2
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: Su = 70 ksi, Sy = 50 ksi, %E = 21%
t 3/4 Ductile
 Example: Combined Stress Fatigue Contd
We must use Ssu and Ssn since this is a combined
stress situation. (Case I1, page 197)

Sus = .75Su = .75(70 ksi) = 52.5 ksi

Ssn = Sn(Cm)(Cst)(CR)(CS)
= 23 ksi(1.0)(.577)(.9)(.745) = 8.9 ksi
Hot Rolled
Surface Size 4.50 dia
Wrought steel 90% Reliability
Combined or Shear Stress
 Example: Combined Stress Fatigue Contd
Safe Line for Goodman Diagram:
ta = Ssn / N = 8.9 ksi / 3 = 2.97 ksi
tm = Ssu / N = 52.5 ksi / 3 = 17.5 ksi
K t ta tm 1

Ssn S su N
10
1.0(3115 .3 psi) 4499 .4 psi 1
Alternating Stress, ta

Ssn .426
8900 psi 52500 psi N
1
N 2.29
.426

5 Su
3115.3 Kttalt
Ssn/N

0
0 5 10 15 Su/N 20
tmean = 4499.4 Mean Stress, tm