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Stress-Life/Strain-Life
Cyclic Loading
Definitions
max min
1
Stress amplitude: a max min
2
1
Mean stress: m max min
2
min
Load ratio: R
max
4
S - N Curve
If a plot is made of the applied stress amplitude
versus the number of reversals to failure (S-N curve)
the following behavior is typically observed:
S - N Curve
Endurance Limit
Stress-Life Approach
a f 2 N f
2
10
11
a a 0 1
Soderberg
m
y
m
a a 0 1
Goodman
m
TS
a a 0 1 m
m
TS
Gerber
12
Different Amplitudes
14
ni
i N 1
f i
It is assumed that the sequence in which the loads
are applied has no influence on the lifetime of the
component. In fact, the sequence of loads can have
a large influence on the lifetime of the component.
15
Reversals at ai
2 ni
d
2 N fi Reversals to failure at ai
16
In this case,
can be less than 1. During the
first loading (a1 ) numerous microcracks can be
initiated, which can be further propagated by the
second loading (a2 ).
17
In this case
can be greater than 1. The first
loading (a2) is not high enough to cause any
microcracks, but it is high enough to strain
harden the material. Then in the second loading
(a1), since the material has been hardened it is
more difficult to initiate any damage in the material.
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Strain-Life Approach
p
Under these conditions, if a plot is made of log 2
20
p
2
f 2 N f
General Approach
e p
2
2
2
The Coffin-Manson expression may used to express the
term p / 2 . What about e / 2?
22
f 2 N f
2
2
E
and we may write that:
f
2 N f
2
E
2 N
b
23
24
HCF/LCF
2 N t
f 2 N t
25
f E
2Nt
f
1
b c
27
Shot-Peening
29
30
Shot-Peening
Fatigue Crack Inhibition
Applications
Blades, buckets, disks and shafts for aircraft jet
engines; (e.g., blade roots are peened to prevent
fretting, galling and fatigue).
Crank shafts used in ground vehicles.
Shot peening of plasma-spray-coated components
before and after spraying.
Shot peening of gears used in automotive and heavy
vehicle components, marine transmissions, small
power tools and large mining equipment.
Compression coil springs in automobiles.
Peening and peen forming of wing skin for aircraft.
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Shot-Peening
32
33
34
Importance of Fatigue
Cyclic Loading
Definitions
1
a max min
2
1
Mean stress: m 2 max min
min K min
Load ratio: R K
max
max
LEFM approach
C K
N
dN
7
Three Regimes
Terminology
Slow-growth rate
(near-threshold)
Mid-growth rate
(Paris regime)
High-growth rate
Microscopic failure
mode
Additional static
modes
Fracture surface
features
Faceted or serrated
Additional cleavage
or microvoid
coalescence
High
Low
--
Microstructural
effects
Large
Small
Large
Large
Small
Large
Environmental
effects
Large
Small
--
Large
Large
Near-tip plasticity
rc dg
rc dg
rc dg
* large influence on crack growth for certain combinations of environment, load ratio and frequency.
r and d refer to the cyclic plastic zone size and the grain size, respectively.
10
c
g
Regime A
11
12
Regime B
K Y a
Where Y depends the specific specimen geometry.
13
da
C Y a
dN
af
a0
Nf
da
m
m
m/2
CY
dN
m/2
0
a
14
For m > 2:
Nf =
m 2CY
For m = 2:
m/2
1
1
m 2 / 2
m 2 / 2
a f
a 0
af
1
Nf
n
1
2
2
CY a 0
15
K max K c
or
Y max a f K c
18
2
K
1
c
2
Y 2 max
Fatigue Striations
An advancing fatigue crack leaves characteristic
markings called striations in its wake. These can
provide evidence that a given failure was caused by
fatigue. The striations on the fracture surface are
produced as the crack advances over one cycle, i.e.
each striation corresponds to da.
20
K
da
t
dN
y E
striation spacing
Important: This implies that the Paris Exponent m is
equal to 2.
22
u y x , 0 dx
*
0
dN
u
23
da
K
2 *
dN y u
4
25
Stage I
26
27
Fatigue Striations
Stage II
28
29
Fatigue Striations
30
31
32
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Fatigue Design
Safe-Life Approach
35
Case Study
HCF
Example Problem
11
12
0.
13
1
d
2
ij
ij
Solution
The strain energy density is given as 1/2( i j i j),
i.e 1/2( x x x x + y y y y + etc). The only
nonzero term in this expansion will be
1/2( y y y y ). We know that y y = /H, so
we need to solve for y y . We know that
14
yy
yy
xx
zz
xx
0
E
xx
yy
and thus
xx
yy
15
so
yy
1 v
2
yy
and finally
yy
E
E
yy
2
1 v
1 v2 H
so
BbHE
1
d
2
2 v
21 v H
16
If the crack grows all the way across the plate and
the plate separates into two pieces, the system will
have zero strain energy. So the strain energy
decreases as the crack grows. Calculate the change
in strain energy d of the plate if the crack grows
by some amount da. Use the same assumptions used
previously to calculate the total strain energy. Then
use the result that
1
B a u
fixed
17
Solution
Following the same assumptions above, if the
crack grows by an amount da we lose an amount
of strain energy equal to (calculated above)
times the volume BHda (volume that previously
contained strain energy but is now unstressed,
due to crack growth). So that
18
BHE
d
da
2
2 1 v H
and thus
1
B a u
fixed
2
HE
( )
2
2 1 v H
So
1
K E , K E
2
2H 1 v
2
Solution
To find the critical value of for crack advance,
simply set K (determine above) equal to KIc and
solve for :
K Ic
E
2H 1 v
21
Evaluate K
Blister Test
The interface toughness of an adhesive is to be
estimated on the basis of a proposed method which
entails the bonding of a thin elastic disk with the
adhesive on a rigid substrate. Pressure is applied
to the bonded side of the disk through a tiny hole
in the substrate, by pumping a fluid. This
pressurization results in partial debonding of the
disk and the formation of a bulge or blister in
the disk. This method is hence referred to as the
pressurized bulge test or blister test.
22
24
pl x
x
3
2Eh
2
2 2
25
wx dx qH
l
1 dc 2
Q
2 dl
26
Solution
The compliance of the system is defined as
q cl Q
Observe that (i) the pressurized fluid is
incompressible, (ii) the pressure under the blister
is equal to the pressure in the piston, and (iii) the
pressure in the piston is directly related to Q by
Q
p
H
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8 1 l
Q
q
3
2
15 E h H
8 1 l
c(l )
15 E h 3 H 2
per tip
1 dc 2 4 1 l
2
Q
Q
3
2
2 dl
6Eh H
29
12
12
75 2 h H 2
q ,
E
6
l
32
or
5 3 Hh h
qE
KI
3
4 2 l
30
HCF
2 l
Q
3 Hh h
33
CM
T CM P
.
C
The potential energy is given by
1
1
1 CM 2
2
W p CM P
2
2
2 C 2C
2
1
1 T
2 C 2 CM
34
da
a T 2
3. Show that
depends on the nature of
the loading system.
36
Solution
1. For fixed grip loading, T = . From this,we note
that CM/C = 0 and CM = 0. For dead-weight
loading, the rate of change of the load P with
time is zero, i.e.
0
P
C
T
0.
1 C M / C
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W P
2T
2 C C
dC
da
Note that
T
M
P
CT
CM
C
T M
From this equation, we note that CM +C = CT .
Thus it is seen that
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P 2 dC
2 da
3
a C C M
2
T
1
dC
2
2 C C M
da
2
T
P
P d C
dC
2
C C M da 2 da
2
d C
2
da
2
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Stress-Life
A circular cylindrical rod with a uniform crosssectional area of 20 cm2 is subjected to a mean axial
force of 120 kN. The fatigue strength of the material,
a =f s is 250 MPa after 106 cycles of fully reversed
loading and TS = 500 MPa. Using the different
procedures discussed in class, estimate the allowable
amplitude of force for which the shaft should be
designed to withstand at least one million fatigue
cycles. State all your assumptions clearly.
Solution
The different expressions we have to assess the
influence of mean stresses are :
42
m
a a | m 01
Soderberg
y
m
a a | m 01
Modified Goodman
TS
a a | m 01 m
TS
Gerber
60
a 2501
220 MPa, (Modified Goodman)
500
60 2
a 2501
246.4 MPa, (Gerber)
500
60
a 2501
207.1 MPa, (Soderberg)
350
As you can see, you get significantly different
answers depending on the model used. The
Soderberg gives the most conservative result,
while Gerber is the least conservative.
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