CHAPTER 1 : WORKING STRESSES (PART 2)

Todays Objectives:
Students will be able to:
1. explain the concepts of endurance limit, fatigue stress
concentration, reversing stress.
2. Know how to used Goodman diagram and miners equation.

Topics:
Endurance limit
Fatigue, stress concentration
Reversing stress / alternating
stress
Goodman diagram
Miners equation
DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

ENDURANCE
LIMIT
Also known as fatigue limit, which is the
amplitude (or range) of cyclic stress that
can be applied to material without causing
fatigue failure.
Determined by fatigue testing.
Fatigue: a mode of failure of engineering
components subjected to dynamic stresses.
Failure can occur at stresses well below the
yield point and tends to initiate at sharp
changes in cross sectional area or other
stress raisers.
The endurance limit depend upon the type
of load, the stress and the material of the
component.

DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

STRESS
CONCENTRATION
Irregularity in stress distribution
caused by abrupt changes of
form.
It occurs in the present of fillets,
holes, notches, etc (stress
raisers).
Theoritical stress
concentration
max

t
factor,

nor min al

DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

EXAMPL
The transition in the E
cross sectional area of the
steel bar is achieved using shoulder fillets as
shown. If the bar is subjected to a bending
moment of 5 kN.m, determine the maximum
normal stress developed in the steel. The yield
stress is y = 500 Mpa.

DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

Alternating / reversing
stress

DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

Repeated
stress

DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

The maximum stress = max

The minimum stress = min

max=
The mean stress = mean

min

max

min

The stress amplitude = amp =2

The stress ratio R =

max
min

DEM 303 Design of Machine Elements 1

For Alternating stress R =

-1
For Repeated stress +ve R
= 0/max
For Repeated stress
ve
Norhaslina
binti R
Abdul Aziz

DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

COMBINATION OF MEAN STRESS AND

FLUCTUATING STRESS

DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

GOODMAN LINE / MODIFIED

GOODMAN LINE
If the point of the combined stress is below the relevant Goodman
line then the component will not fail .
This is a less conservative criteria based on the material Ultimate
strength Yield point Sut.
To establish the factor of safety relative to the Goodman Criteria

DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

GERBER
LINE

If the point of the combined stress is below the Gerber line then the
component will not fail .
This is a less conservative criteria based on the material Ultimate
strength Sut.
To establish the factor of safety relative to the Gerber Criteria.

Se = The modified fatigue strength

Sut = The ultimate tensile strength
Syt = The yield tensile strength
Nf = The factor of Safety applicable the
fatigue
DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz

Miners
Equation
Miners rule is a simple cumulative damage rule for irregular,
repeated loading.
In real practice, large % of mechanical and structural parts subjected
to randomly varying stress cycle intensity (e.g:automotive suspension,
aircraft structural components).
If a part is cyclically loaded at a stress level causing failure in 10 5
cycles, then each cycle of that loading consumes one life of the part.
On this basis, 100% of life has been consumed, fatigue failure is
predicted.
j k by:
Linear cumulative damage rule is expressed

n n
N N
1

..... n
N

n
1;
N
j 1

Where; n = number of cycles at specific stresses level.

N = life (in cycle) at these stresses level.
DEM 303 Design of Machine Elements 1

Norhaslina binti Abdul Aziz