Endurance Strength,

Stress Transformation
and Prediction of Failure

Revision and Summary

Estimating Fatigue Failure Criteria

Fatigue is progressive failure that occurs due to

dynamic and fluctuating stresses.
Almost 90% of the metallic failures are due to
fatigue
Fatigue failures can occur at stress levels far below
the ultimate or yield strengths of a material.
To estimate the fatigue life, Endurance strength/
fatigue strength is necessary to be determined.

Endurance Strength

Endurance strength is a materials ability to

withstand the fatigue loading.
Several factors that could affect the
endurance strength.

Factors Affecting Endurance

strength
1.
2.
3.
4.
5.

Type of selected material

Type of stress on a component
Size of a part
Surface treatments
Reliability

Estimating actual endurance strength

Actual endurance strength, Sn

sn' = sn (Cm )(Cst )(C R )(C s )

where

Sn = modified endurance strength (depend on surface

treatment)
Cm = material factor,
Cst = type of stress factor,
CR = reliability factor, and
Cs = size factor

Estimating actual endurance strength

Try Example Problem 5-2

Stress Transformation

Refer to Stress Transformation.pdf

Examples (refer to Example Stress
Transformation.pdf)

Static Failure Theories

Static failure occurs due to the stresses

applied to a part exceed the materials
allowable stress.
Therefore, it is necessary to ensure the
operation stress subjected to a component is
less the allowable stress.
Machine components are always subjected to
uncertain load and varies of material
behavior.
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Static Failure Theories

A design factor, N (factor of safety) should

introduce to design of component to ensure it
is safe to use under a specific operation
condition.
Designer must determine a reasonable value
of design factor for a component to avoid
overdesign.

Static Failure Theories

Guidelines to select appropriate Design Factor, N

(proposed by Robert L. Mott)


For ductile materials:

 N = 1.25 to 2.0: Design of structures under static loads for which
there is a high level of confidence in all design data.
 N = 2.0 to 2.5: Design of machine elements under dynamic
loading with average confidence in all design data.
 N = 2.5 to 4.0: Design of static structures or machine elements
under dynamic loading with uncertainty about loads, material
properties, stress analysis or the environment.
 N = 4.0 or higher: Desire to provide extra safety to critical
components.
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Static Failure Theories

Several theories have been formulated to
predict failure of ductile materials

1.
2.
3.
4.
5.

The maximum normal-stress theory

Maximum normal-strain theory
Total strain-energy theory
The distortion-energy (von-Mises) theory
Maximum shear stress theory
Good predictor, most accurate and
commonly used in failure investigation
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Distortion Energy Theory

Refer to Distortion energy theory.pdf

Examples (refer to Example Distortion energy
theory.pdf)

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Shear stress due to torque

=

Tc
J

T = Torque, Nm
c = radius distance from center to point of interest, m

(For max , c always equal to r)

J = Polar moment of Inertia, m4
Exercise
Compute the torsional shear stress in a circular shaft with a diameter of
50mm that is subjected to a torque of 800 N.m.
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Normal stress due to Bending

(Bending stress)
=

Mc
I

M = moment, Nm
c = distance from center to point of interest, m
I = moment of Inertia, m4

Exercise
A circular shaft has diameter of 40mm
is subjected to forces as shown in the
figure. Calculate the maximum bending
stress at point B

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