Mechanical Behavior of Materials

Review of Chapter 4: Notches

Submitted by: Muhammad Murtaza 04-6-1-008-2018

Submitted to: Dr. M. Javed Hyder DME, PIEAS
Table of Contents
1. Introduction
2. Stress Life Approach
3. Strain Life Approach
1. Notch Root Stresses and Strains
2. Example of Notch Analysis.
4. Fracture Mechanics Approach
1. Introduction
2. Transition Crack Length
3. Stress Intensity Factors near Notch
4. Short Crack Growth at Notches
5. Combination Methods
2
1. Introduction
• Chapter 1 the stress-life approach was presented as a
means of determining the fatigue life of a smooth
specimen subjected to an applied alternating stress.
• Chapter 2 the strain-life approach was developed to
account for notch root plasticity and the influence of
load sequence effects on local mean and residual
stresses.
• Chapter 3 the fracture mechanics concepts can be
extended to account for fatigue crack growth at a
notch.
• This Chapter is the review of using the above
mentioned three principles to analyze the notch
members.
3
2. Stress-Life Approach
𝑲𝒕 :
• ln ideally elastic members the ratio of these
stresses is theoretical stress concentration factor:
𝜎𝑚𝑎𝑥
𝐾𝑡 =
𝑆
• This theoretical stress concentration factor is
solely dependent on geometry and mode of
loading.
• ln the stress-life approach the effect of notches is
accounted for by the fatigue notch factor 𝐾𝑓 .

4
2. Stress-Life Approach (Continue)
𝑲𝒇 :
• The unnotched fatigue strength of a member to
its notched fatigue strength at a given life :
(𝑢𝑛𝑛𝑜𝑡𝑐ℎ𝑒𝑑)
𝑆𝑒
𝐾𝑓 = (𝑛𝑜𝑡𝑐ℎ𝑒𝑑)
𝑆𝑒
• Considerable effort has been spent trying to
relate 𝐾𝑓 to 𝐾𝑡 . In general, 𝐾𝑓 is less than 𝐾𝑡 .
• ln the stress-life approach the effect of notches is
accounted for by the fatigue notch factor 𝐾𝑓 .
• Theoretically, 𝐾𝑓 is dependent on material type.

5
2. Stress-Life Approach (Continue)
𝒒:
• The additional effects, a notch sensitivity factor q, was
developed which relates the stress concentration value in
fatigue to theoretical value:
𝐾𝑓 − 1
𝑞=
𝐾𝑡 − 1
• As defined, values of q range from zero (no notch effect,
𝐾𝑓 = 1) to unity (full theoretical effect, 𝐾𝑓 = 𝐾𝑡 ). As
mentioned above, 𝐾𝑓 will always be less than or equal to
𝐾𝑡 .
• From the tests of Peterson, the proposed formula for q is:
1
𝑞= 𝑎
(1 + )
𝑟
where r is the notch root radius and a is a material constant.
6
2. Stress-Life Approach (Continue)
𝑵𝒐𝒕𝒄𝒉 𝑺𝒆𝒏𝒊𝒕𝒊𝒗𝒊𝒕𝒚 𝑪𝒖𝒓𝒗𝒆𝒔:

7
2. Stress-Life Approach (Continue)
𝑪𝒐𝒎𝒃𝒊𝒏𝒊𝒏𝒈 𝒕𝒉𝒆 𝒂𝒃𝒐𝒗𝒆 𝒆𝒒𝒖𝒂𝒕𝒊𝒐𝒏𝒔:
𝐾𝑡 − 1
𝐾𝑓 = 1 + 𝑎
(1 + 𝑟 )

8
2. Stress-Life Approach (Continue)
𝑬𝒇𝒇𝒆𝒄𝒕 𝒐𝒇 𝑵𝒐𝒕𝒄𝒉 𝑹𝒂𝒅𝒊𝒖𝒔:
The effect of notch root
radius, r, on 𝐾𝑓 for hard
and soft materials may
be illustrated. Figure
contains a qualitative
representation of this
effect. From this figure it 𝐾𝑡 − 1
is recognized that the 𝐾𝑓 = 1 +
𝜌
(1 + )
effect of changing r on 𝐾𝑓 𝑟
is greatest when r = a. On 1
𝑞=
the other hand, 𝐾𝑓 is 𝜌
(1 + )
affected very little when 𝑟
r is less than a/10 or
9
greater than 10a.
2. Stress-Life Approach (Continue)
𝑬𝒇𝒇𝒆𝒄𝒕 𝒐𝒇 𝑵𝒐𝒕𝒄𝒉 𝑹𝒂𝒅𝒊𝒖𝒔:
𝜌 is a material constant and it can be obtained from the
graph given below:

10
2. Stress-Life Approach (Continue)
𝑬𝒇𝒇𝒆𝒄𝒕 𝒐𝒇 𝑵𝒐𝒕𝒄𝒉 𝑹𝒂𝒅𝒊𝒖𝒔:
The relationship to ultimate
strength can be explained by
the blunting effect seen in soft
materials. Due to yielding at
the notch root the peak
stresses predicted by 𝐾𝑡 are
never attained as shown in the
figure. In high strength
materials the full effect of 𝐾𝑡 is
realized.
The size effect of notch root
radius can be attributed to the
volume effect.
11
2. Stress-Life Approach (Continue)
𝑬𝒇𝒇𝒆𝒄𝒕 𝒐𝒇 𝑵𝒐𝒕𝒄𝒉 𝑹𝒂𝒅𝒊𝒖𝒔:
For a given notch geometry
the shape of the stress
gradient is constant when
normalized by the dimension
of the notch radius in first
figure. As the size of the notch
increases, the volume of highly
stressed material near the
notch increases in second
figure. This results in a greater
probability of fatigue failure.
The size effect is also due in
part to the effect of stress
gradients on crack growth. 12
2. Stress-Life Approach (Continue)
𝑲𝒆𝒚 𝑷𝒐𝒊𝒏𝒕𝒔
• 𝐾𝑓 has limiting value dependent on material and it is
around 5 or 6.
• The limit on 𝐾𝑓 may be an empirical method to account
for this loss of initiation life in sharp notches.
• The fatigue notch factor, 𝐾𝑓 , and the notch sensitivity
factor, q, are usually developed to correct the
endurance limit, 𝑆𝑒 , for notched members
• A general trend is that the value of fatigue notch factor
decreases with increasing stress level. This trend is
material dependent.

13
2. Stress-Life Approach (Continue)
𝑨𝒍𝒕𝒆𝒓𝒏𝒂𝒕𝒆 𝑴𝒆𝒕𝒉𝒐𝒅 𝒐𝒇 𝑷𝒓𝒆𝒅𝒊𝒄𝒕𝒊𝒐𝒏
• An alternative method for predicting the S-N curve for
notched components is by below figure.
• The limit on 𝐾𝑓 may be an empirical method to account
for this loss of initiation life in sharp notches.
• This method uses a straight line to connect the corrected
endurance limit (𝑆𝑒 /𝐾𝑓 ) to the true fracture stress, 𝜎𝑓 , at
one cycle.

14
2. Stress-Life Approach (Continue)
𝑴𝒐𝒅𝒊𝒇𝒊𝒄𝒂𝒕𝒊𝒐𝒏 𝒊𝒏 𝑺 − 𝑵 𝒄𝒖𝒓𝒗𝒆:

Modification of S-N curve for Alternative modification of S-N

notched components: Juvinall curve for notched
approach. components.

• Although this method incorporates the trend that the

notch effect decreases with decreasing fatigue life, the
method tends to be conservative.

15
2. Stress-Life Approach (Continue)
𝑳𝒊𝒎𝒊𝒕𝒂𝒕𝒊𝒐𝒏𝒔
• The stress-life method is best suited for high cycle
fatigue (HCF), where the notch strains are
predominantly elastic and loading is essentially
constant amplitude.
• This approach does not account for inelastic
behavior at the notch and cannot properly account
for changes in notch mean or residual stresses.
• Nevertheless, this method is still widely used in
fatigue analyses. It is especially useful for long lives,
where surface finish and other processing variables
have a large effect.
16
3. Strain-Life Approach
𝑰𝒏𝒕𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏:
• The strain-life method accounts for notch-root
plasticity.
• The basic concepts and background of the strain-
life method were presented in Chapter 2.
• In the following section we discuss how those
concepts may be applied in a fatigue analysis of a
notched component for constant amplitude
loading.
• It can be explained by two things:
1. Notch Root Stresses and Strains

2. Example of Notch Analysis.

17
3. Strain-Life Approach
1. Notch Root Stresses and Strains
𝑰𝒏𝒕𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏:
• The strain-life method requires that notch root
stresses and strains be known. These may be
determined by the following methods:
– Strain gage measurements
– Finite element analyses
– Methods that relate local stresses and strains to
nominal values
Often the least time-consuming and least
expensive method of determining these values is
by relating the local stresses and strains to nominal
values
18
3. Strain-Life Approach
1. Notch Root Stresses and Strains (Continue)
Effect of Yielding:
After yielding occurs, the local stress concentration,
𝐾𝜎 , decreases with respect to 𝐾𝑡 and 𝐾𝜖 increases
with respect to 𝐾𝑡 . In other words, after yielding, the
actual local stress is less than that predicted using 𝐾𝑡 ,
while the actual local strain is greater than that
predicted using 𝐾𝑡 .
𝜎
𝐾𝜎 =
𝑆
𝜖 For 𝜎 > 𝜎𝑦
𝐾𝜖 =
𝑒

19
3. Strain-Life Approach
1. Notch Root Stresses and Strains (Continue)
Effect of Yielding:
• The actual local strain is greater than that predicted
using 𝐾𝑡 .
• The local stress-strain response at the notch root
may vary from the nominally applied loading.

𝐾𝑡 = 𝐾𝜎 𝐾𝜖

𝜎𝜖
𝐾𝑡2 =
𝑆𝑒

𝐾𝑡2 𝑆𝑒 = 𝜎𝜖

20
3. Strain-Life Approach
1. Notch Root Stresses and Strains (Continue)
Neuber's rule:
• The theoretical stress concentration is the
geometric mean of the stress and strain
concentration or the square root of the product of
𝐾𝜎 and 𝐾𝜖 .
• This seems intuitively reasonable since after
yielding occurs, 𝐾𝜎 decreases while 𝐾𝜖 increases.
• Three versions of above equations termed
Neuber's rule, are often used in the local strain
approach to relate nominal stresses and strains to
local values.

21
3. Strain-Life Approach
1. Notch Root Stresses and Strains (Continue)
Three versions of Neuber's rule:
1. Nominally Elastic Behavior
For nominally elastic behavior, the remote strain, e,
can be related to the remote stress, S, using Hooke’s
Law:
𝐾𝑡2 = 𝐾𝜎 𝐾𝜖
𝜎 𝜖𝐸
𝐾𝑡2 =
𝑆 𝑆
(𝐾𝑡 𝑆)2
= 𝜎𝜖
𝐸
Applied Load = Notch Response

22
3. Strain-Life Approach
1. Notch Root Stresses and Strains (Continue)
Three versions of Neuber's rule:
2. Limited Yielding:
Neuber's rule, in the form of Eq. (4.13), is sometimes
used when yielding occurs in the nominal stresses or
strains. In this case, Hooke's law can no longer be
used to relate the two ( S ≠ 𝐸𝑒).
𝐾𝑡2 𝑆𝑒 = 𝜎𝜖
3. Seeger's Version:
Finally, a third form of Neubers rule is used when very
high strains are present such that general yielding
occurs in the component. For this case Seeger
proposed the following version of Neuber's rule:
𝐾𝑝2 𝑆 ∗ 𝑒 ∗ = 𝜎𝜖 23
3. Strain-Life Approach
1. Notch Root Stresses and Strains (Continue)
Three versions of Neuber's rule:
𝑆 𝑎𝑡 𝑜𝑛𝑠𝑒𝑡 𝑜𝑓𝑔𝑒𝑛𝑒𝑟𝑎𝑙 𝑦𝑖𝑒𝑙𝑑𝑖𝑛𝑔 𝑆𝐿
𝐾𝑝 = =
𝑆 𝑎𝑡 𝑓𝑖𝑟𝑠𝑡 𝑛𝑜𝑡𝑐ℎ 𝑦𝑖𝑒𝑙𝑑𝑖𝑛𝑔 𝜎𝑦 /𝐾𝑡
∗
𝐾𝑡
𝑆 = 𝑆
𝐾𝑝
• The values of S* and e* must lie on the cyclic stress-
strain curve.
• In all three versions of Neuber's rule, 𝐾𝑡 and S must
be defined consistently. They must both be defined
using the same cross-sectional area. either net
section or gross section.
• At lives below 103 cycles the most suitable is
Seeger's version.
(𝐾𝑓 𝑆)2
= 𝜎𝜖 24
𝐸
3. Strain-Life Approach
2. Example of Notch Analysis Using Neuber's Rule
𝑰𝒏𝒕𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏:
• In the following section we describe in detail how
Neuber's rule is applied in constant amplitude
fatigue analyses of notched components. In the
example. the following assumptions and values are
used:
– Assume nominally elastic behavior.
– Use 𝐾𝑓 instead of 𝐾𝑡 .
– Use net section properties 𝐾𝑡 𝑛𝑒𝑡 , and S based
on 𝐴𝑛𝑒𝑡 .

25
3. Strain-Life Approach
2. Example of Notch Analysis Neuber’s (Continue)
Step 1, Initial Loading:
A nominal stress, 𝑆1 , is
applied to a previously
unstressed component.
Using Neuber's rule, we
must satisfy equation. At
the same time the local
stress and strain must lie
on the cyclic stress-strain
curve of the material.
(𝐾𝑓 𝑆)2
𝜎𝜖 =
𝐸

26
3. Strain-Life Approach
2. Example of Notch Analysis Neuber’s (Continue)
Step 2, Nominal Stress Reversal ∶
The nominal stress is then reversed to some stress
value, 𝑆2 , resulting in a change of stress ∆𝑆 = 𝑆1 - 𝑆2 .
This results in a change of the local or notch root
stress, ∆𝜎, and strain, ∆𝜖 .

This strain-life method is more complicated than the stress-

life approach, yet provides more physical insight.
27
4. Fracture Mechanics Approaches
1. Introduction
• Use of fatigue life of a component using fracture
mechanics principles method results in an estimate of the
fatigue life spent in crack propagation. Fracture mechanics
approaches may also be used in the fatigue analysis of
notched components.
• Fracture mechanics approaches may also be used in the
fatigue analysis of notched components.
• Important aspects of the analysis include the
determination of the size of the region over which this
field is effective and the stress intensity factor in this
region.

28
4. Fracture Mechanics Approaches
2. Transition Crack Length
• Near the notch, the local notch stress-strain field
dominates the stress intensity solution. The notch
produces a stress gradient. As the distance from the notch
increases, the elevation of the stresses due to the notch
decreases.
• Once the crack length is larger than this value, the
effective crack length, a. can then be assumed to be the
sum of the notch width, D, and the actual crack length, /,
growing out of the notch.
𝐾𝑠ℎ𝑜𝑟𝑡 = 1.12𝐾𝑡 𝑆 𝜋𝑙
𝐾𝑠ℎ𝑜𝑟𝑡 = 𝑆𝑡𝑟𝑒𝑠𝑠 𝑖𝑛𝑡𝑒𝑛𝑠𝑖𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑠ℎ𝑜𝑟𝑡 𝑐𝑟𝑎𝑐𝑘
𝑆 = 𝑅𝑒𝑚𝑜𝑡𝑒 𝑜𝑟 𝑁𝑜𝑚𝑖𝑛𝑎𝑙 𝑆𝑡𝑟𝑒𝑠𝑠
𝐾𝑡 = 𝐸𝑙𝑎𝑠𝑡𝑖𝑐𝑠 𝑆𝑡𝑟𝑒𝑠𝑠 𝐶𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟
𝑙 = 𝑓𝑟𝑒𝑒 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑐𝑟𝑎𝑐𝑘 𝑙𝑒𝑛𝑔𝑡ℎ
𝐾𝑙𝑜𝑛𝑔 = 𝑆 𝜋𝑎 ∴𝑎 =𝑙+𝐷
29
 4. Fracture Mechanics Approaches
2. Transition Crack Length (Continue)
• When the crack is small,
it behaves like a crack
growing from the edge of
2. Plate subjected to the
nominal stress of K,S. As
the crack becomes longer
it grows out of the notch
stress-strain field and
behaves like a crack
whose length includes
the notch width.
• where f (g) depends on
the specific geometry of
the component being 𝐾𝑙𝑜𝑛𝑔 = 𝑓(𝑔)𝑆 𝜋𝑎
analyzed.
30
𝐾𝑙𝑜𝑛𝑔 = 𝑓(𝑔)𝑆 𝜋𝑎 = 𝐾𝑠ℎ𝑜𝑟𝑡 = 1.12𝐾𝑡 𝑆 𝜋𝑙𝑟
4. Fracture Mechanics Approaches
2. Transition Crack Length (Continue)

31
4. Fracture Mechanics Approaches
3. Stress Intensity Factor Near a Notch
• Stress intensities for a crack growing in the notch stress-
strain field, when 𝑙 < 𝑙𝑟 must be obtained in order to use
standard LEFM approaches. A limited number of
theoretical solutions have been developed for the stress
intensity factor near a notch.

32
4. Fracture Mechanics Approaches
3. Stress Intensity Factor Near a Notch (Continue)

Another expression that has been proposed for

approximating the stress intensity factor near a notch is
simply to multiply the bulk stress by the theoretical stress
concentration factor. 𝐾𝑡 and by 1.12, the free surface
(edge) correction factor.
∆𝐾𝑠ℎ𝑜𝑟𝑡 = 1.12𝐾𝑡 ∆𝑆 𝜋𝑙 33
4. Fracture Mechanics Approaches
4. Short Crack Growth at Notches
• A plastic zone often develops in the notch root due to the
stress concentrations associated with the notch.
• This region is, in turn, surrounded by the bulk stress-strain
field.
• Even in situations where the strains surrounding the notch
remain elastic, the plot is often nonlinear.
• The three types of anomalous crack growth behavior for
cracks at notches are:
– Short crack growth only in a plastic field
– Short crack growth in both plastic and elastic fields
– Short crack growth only in an elastic field

34
4. Fracture Mechanics Approaches
4. Short Crack Growth at Notches (Continue)

Three types of deviation

from the normal crack
growth rate curve are shown
in figure below.

35
4. Fracture Mechanics Approaches
4. Short Crack Growth at Notches
• In the first case, the totally
elastic case, a major
reason the deviation from
linearity occurs is believed
to be due to the "short
crack problem".
• This "problem" is that
short cracks tend to grow
faster than long cracks at
the same ∆𝐾. In the notch
field, a major cause of this
"short crack" behavior is
the difference in residual
plastic deformation in the
wake of the crack.
36
5. Combination Methods
• This method combines the local strain approach to
predict initiation life and a fracture mechanics
approach to predict propagation life.
• When the crack is smaller than this length, crack
initiation or early growth from the notch can be
estimated using the strain-life approach.
• Use of this approach to estimate the initiation life
avoids the inherent difficulties of using LEFM
methods to describe short crack behavior at the
notch root.
• Once the crack is larger than this length
• (𝑙 > 𝑙𝑟 ), crack growth can be modeled with a standard
fracture mechanics approach with the initial crack size
taken to be 𝑙𝑟 .
𝑇𝑜𝑡𝑎𝑙 𝐿𝑖𝑓𝑒 = 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝐿𝑖𝑓𝑒 + 𝑃𝑟𝑜𝑝𝑎𝑔𝑎𝑡𝑖𝑜𝑛 𝐿𝑖𝑓𝑒 37
5. Combination Methods (Continue)
• This method requires that strain-life data be
available which report life as the number of cycles
required to develop a crack of length.
• Strain-life data are usually reported as life to
failure of a laboratory specimen.
• For sharp notches, Dowling states: "Propagation is
expected to dominate at all lives, so that crack
initiation data are superfluous.“
• Stated another way, a notch that looks like a crack
will behave like a crack and the initiation life is
negligible.

38
5. Combination Methods (Continue)
• A simple combined approach that has been
shown to yield very similar results to Dowling's
method has been proposed by Socie, the method
combines:
1. An initiation life estimate obtained using the
standard local strain approach that assumes that
the notch is fully effective 𝐾𝑓 = 𝐾𝑡 .
2. A propagation estimate obtained using a fracture
mechanics approach that assumes the initial
crack size is equal to the depth of the notch (𝑎𝑖
= 𝐷𝑒𝑝𝑡ℎ 𝑜𝑓 𝑁𝑜𝑡𝑐ℎ).

39
5. Combination Methods (Continue)
• A simple combined approach that has been
shown to yield very similar results to Dowling's
method has been proposed by Socie, the method
combines:
1. An initiation life estimate obtained using the
standard local strain approach that assumes that
the notch is fully effective 𝐾𝑓 = 𝐾𝑡 .
2. A propagation estimate obtained using a fracture
mechanics approach that assumes the initial
crack size is equal to the depth of the notch (𝑎𝑖
= 𝐷𝑒𝑝𝑡ℎ 𝑜𝑓 𝑁𝑜𝑡𝑐ℎ).
• These are combined to obtain a total fatigue life
estimate.
40
5. Combination Methods (Continue)
Key Points:
• This method predicts results very close to those
obtained from Dowling's method.
• An advantage of this approach is that it is simple and
easy to implement.
• Predictions using this approach tend to be
conservative.
• Use of the strain-life approach allows difficulties with
strain gradients, plasticity effects, and short crack
effects to be avoided when dealing with small cracks.
• Fracture mechanics methods allow additional life
from crack propagation to be included in the total life
estimates.

41
References
1. R. E. Peterson. Stress Concentration Factors, Wiley. New York, 1974.
2. J. E. Shigley, Mechanical Engineering Design, McGraw-Hill, New York. 1977.
3. R. E. Peterson, "Analytical Approach to Stress Concentration Effects in
Aircraft Materials," Technical Report 59-507, U.S. Air Force-WADC Symp.
Fatigue Metals, Dayton, Ohio, 1959.
4. H. Neuber, Theory of Notch Stresses: Principle for Exact Stress Calculations,
Edwards, Ann Arbor, Mich., 1946.
5. R. E. Peterson, "Relation between Life Testing and Conventional Tests of
Materials," Bulletin ASTM No. 133, Mar. 1945.
6. R. C. Juvinall, Engineering Considerations of Stress, Strain and Strength,
McGrawHill, New York, 1967.

42