UNIT-IL Design for Fatigue Strength Msc. @ STRESS CONCENTRATION A plate with a smoll civcular hole subjected to tensile stress is Shown in fig. The distyibution of stresses near the hole con be observed by using the Photo - elasticity technique. Tt ts ebsexved that there IS a sudden vise im the magnitude of stresses im the vidmily & the hele. aE nl se : i-F ws. © @ Fig- Stress Concontration + Stress concentration is defined ac the localization of high stregseo due to the ‘irregularities present in the component and a@brupt changes AP the cross-sections.” + The localized Stresses in the neighbourhood of the hele are fax greatev than the stvesses obtained by elementary equations. C oi , op = Med. ai e-%) & STRESS CONCENTRATION FACTOR: _+ tn ordey 40 congider the effect of Gress concentration and find out localized Stresses, a factor cooled Stress concentration factor is used. Highest value of actual stress near diccontinurty nts calc ae nbc SSN Hommal ches obtamed by elementary equations for min? cress- section + Theovetical Stress = eect ion factor ee Cos s &- 2 -=eo Where oz and & ave stresses determined elementa: equations and Cina, and Tmo. are Localized Etresses ab the digentinuities, = Whe mognitude of stress concentration factor depends “pen the geometry of the component. the causes of Streas concentration are as follows. ) Varialion in Pwpevties ef Materials. In design, material is assumed homegeneovs Abrroughout the component but ‘mn wactice , There is variation in material popes tie from one end to another due to the following factors f@) ‘mternal cratks and flaws like blow holes, (&) Cavities in welds, These variations act as discontinuities in the component and cause Gress concentration. we subjected to force Giy Lead Application’ Machine components a ata pemt or over a syral) avea on th hese foress ach either component, Since the area 's gmoll, the pressure af these pomts Is excessive. This veaulls in chress concentration, Exe & Contact between the Cam and follower, ® contact between the meshing teeth of the driving and the driven gear. Abrupt Changes in Sections’ Jn order to moun} gears, bearings on q ‘eamsmission sprockels , pulleys amd. ball dywSt sheps are cut on the chaltand choulders ave ‘provided i Gress concent— Lom assembl considexalions. This vesults in gation af these cross-sections change: Gi)liv) Digcontinvibies tw the Components Cevtein features Af as : \ conponente euch as oil holes oy oi) qroowes , keywoys and spi and gcrew threads yesult in discontinuities m the cass -seel cechion ef the component. This vesults stress concentra finn Ww Mashivigscradhes : Machining scratches, clamp rarks or- \nspeation mavks ave cusface jwrequtenities , which eanae he concentration, ation of Stress Concentration Feators een tention factors are determined by 400 methods on the Anesty of elasheity simple geomet * Determin the Gress © 0 Mathemadical Method - Based (iy Experimental Method dike phote-elashaty,C Fer chepes) 3 The charts for strees concettsahion fachors for different geom- eric Shapes and conditions & \oading were originally develo ed by RE Peterson. > At present, FEA packages ave used to find out the Stree concentration factors for ana geometric chapes. nal StredPaletation for Various Cases. Nomi @ Fer Rectangular Plate with a transverse hele loaded in tensior or comprescion dice ples e os ENominal Gress) = Gaye ajo .O%9 Cue m Pig-S2) (li) Fer a flee plate with ghouldey fillet subjected 4 tensile oF compressive force rin ai So ae (Re for this case im Pig-53)= the Stress Concentration factor for A flat fate eat os elliptical hele ond subjected to tensile force [e283] vehere Q= half width (or semi-major axis) of the ellipse 1 te the div? ef lead Bone b = half width (or cemm ptinar ants) of the ellipse in the divetion of load aseg ose-t rf b=o Ky = o> Qse-2 tf (a=) means ellipse becemes 4 circde ee ale ae & Reduction of Stress Concentvakion — Although it 1s net possible jo completely eliminate the effect of chreas “concentration, there ave smethods to veduce Eres concentrations. “This !s achieved by providing a specific geo- metic shape to the component. Th practice , reduction od chress concentration is achieved by the fellow methods @) Adsitional “Notches amd Holes in Tension Member Tis observed that a ingle porch resists im O Nigh degree of eress concentyation. “The severity o® dress concentration 1S yeduced by three methods @ Use ef multiple notches Cnet page fg D ww) Danlling additena) holes Pre £13 © Removal ef tndesived material (—'— fa)1 Maltiple Natches © (® Foniginall Notch Drilling wo Be soVee- Holes emoval of yroderial ce) (ad (ii) Fillet Radius, Underautling and Notch for Member in Bonding + Take a bar ef circular cls with a Chovlder and subjected te bending ampment (Fig). There are 4hvee metheds to ~sodwce. chress concentrafion at the bose oP this Choulder. whichas @ Provide fillet aadivs © Provide andereut © Providing additional Notch Fillet whos vi Q in ee © Neth inndavent : nahn Me a4 LM @ © fig- Reduction af Gress concentration due fo Abrupt Change in cls Holes for Shaft with a key way \s chown results in chress concentsation ot the d reduces tovsional éhear ctrength (iii) Deilling Additional A trangmission aot is a discontinwiht and cormore of the keysory an fig. The KeyorQo Fq- seoeaed of stress Gncentsation in shaft with Koyconys (a) Original Chaft © Drilled Holes © Fillet radiva (iw Reduction of Stress Concentration in Theo Threaded Members : A threaded component Is chown in fig. Tb Is observed that force {iow Sine Is bent as id passes from the shank portion to threaded portion ef the component, This results in stress corcentwation j ; Lane. in the transition Plane poset Reduction india. wppopy (CPA (GA. A — @ sedis * Wo) © ments Fig- Reduction of Gress Gncentration in Threaded Gmpo wm Shank dia. © Original components © Undercutting © Reduction | finuities found in machine components cannet be —» Many discon ion cannot be totally aveided. Therefore, stress concentrat eliminates. Boblen® A flat glaie subjected to a tensile force of SKN is shown in Fig. ‘The plate material is grey cash in FG 200 and the factor of safely is &S, Determine the thickness of Plate. feo Uy [For Fillet sechion) = +8 em it Ky (for hole section) =26 t iseFLUCTUATING STRESSES ® + Th mong applications, the components are subjected to forces, which are net static, but versy in magnitude with respect to Lime, “The stresses Mduced due to such forces ate called Fluctuating Gresses, -» Th te observed that about 80% eof failures of mechanical components are due to ‘faligque. failure’ vesulting from Fluctuating 6lvesses, —» There ase three types of mathematica) models for cyclic stray @ Fluctuating Stresses © Repeated ctreues © Reversed Chreaceg Time (® Fluctuating Strexaav or © Repeated Strenes © Reversed Chresces Avternatiny Gresses eo Heve Cra 2nd Grin ATE Yhakimum and minimum shressee, cohile ave called mean Ghress and cress amplitude, vespect om and o% Snag — rin Og = % FATIGUE FATLURE -e Tt has been observed that moperials fail under fluctuabing, stresses at a Stress mmagnitede. which Is lower than the ultimate tensile strength of the material. => Some}imes, the. mognitude ts even lower than the strength, yield_x Farther, it has been found that the i © vmognitude, of the cbres causing fatigue failure decresses as the number of Areas cycles increases, —» “This phenomensn of decreased vesictance of the ynaterial to fluduating tresses is the main chamelerishic of fatigue failure, wy Failure became of cyclic is called fatigue failure. ee Fahigue failure 1S defined as =time. delayed fracture. undey cyclic Leading. Examples of paris im which fatigue failures ase common ave transmission shafts, connecting ryeds, Genrs, vehicle, suspension Springs amd ‘eal bearings. ewe fatigue failure is sudden and total. ressea oF Nuatsaling rresges ENDURANCE LIMIT -» The fahgue or endurance Lined of a material is defined ae the ‘maximum amplitude of completely reversed Stress hat th standard Specimen cn sustain for an unlimited number of cycles without fatigue failure, -» since the fatigue Jest cannet be conducted for unlivated 07 infinite no, of cycles, 10 cycles are considered 08 A cufficien mo. of cycles, to define the endurence Samat. tne no: oF life * \ife is defined as w+ falgue Life Tee fallghe | a e}ress cycles Ahat the ‘ctandard specimen one ne fest before the ap pearance du fatigue enack. am is es The dimensions of the standard test specimen > q shown es 250R ‘oaeoe”— Tt 1s observed that the beam is subjected to completel reversed Geese usith tendle Gres in the fist half and compressive Gres in the second half, The distri bubien ts sinusoidal and one Gress cycle is completed ‘im one srevoludio > The amplitude a Wnis cycle Cog os ox) Is given by Av AG elo ) A @ ® . ding Bots Beam subjected to Bending Moment ® Beam G Stress cel at pent A, \ maohi A. schematic diagram eda rotating beam fat a Son te ghowninabove Fig. The Specimen aste ag a ‘votaling r 4o a bendi moment. . it ic sub oats toa completely weyersed ctreas cycle ahi ie bending moment by addition oF deletion of pet Cl can vary the Gtsess amplitede - ae ned smen is ToIated by an electsic . The ae oN speci ; a yevolutions before the appearance of the Fast falig end me a etalitian Counter~© Tn exch test, two weadings are token viz chess Vide > and number of Gress cycles (N). ea, Re + These readings are used as two co-ordinates for plotting a point on the ON diagram This point is called ‘failure Poet —> The &N Curve is the grephical vrepresentalion of tress amplitude (sp versus the number ef ress cydles(N) belbre the fatigue failure ona leq- leg graph paper +> The a is also called “Wohler diagram / oe a, > Failure Pointe ae fy SN curve fox Steels becomes peat matertals Mike Geels, the SN Curve scjootehe ob of cycles, which Indicates the Gress amplitude cle. Me nding to Infinite number af cy eae “4 this Chess amplitude at \0° cycles spapresods 1 niqule endurance imt of the material: The SN Curve Grown in above Tgure Is valid only for fermus wmelals. Fer ron-fervut metals Like Al alloys, S-N curves slopes gradually even after 10° gycles.ge LOW-CYCLE AND HIGH CYCLE PATIGUE ®

Key ic the “fatigue chress concent vation as fellows Endusance \iwat of the notch free specimen Doak of the notehed specimen factor,” which is define re : Endurance > Ky is applicable fo actual moterials.and depends upon the gr" ave ef the raterial. Notch Sensi#ivity ® Tr ts dePined ag the susceptibility fa material to succumb to the damaging offect: of stress mENA yotches in fatigue Aeading - @u also be defined as the degree fo which the theorilic 3 chress concentredion 1S actually ryeaghed - The rotch gensiti vity footer 4 1S defined as Tncerease cfactual Ghress_vver nominal Gress = Foxease of theoretical Elress over ominal Stress _ yomina) Stress obtained PY elementary equations = Actual chress = KeGo , theoritical etvess = Ke Oe of actual used to solve Hse sush pocblems ovland Endurance Limit CN Curve IS Geedman & Seierbperg dines becomes the failure omes uged te solve Criterion, cma Such problems Case Design for Tnfinite Wife t- The amplitude Gtress duced & such components Rrould be lower than the endwrance Dimid 1 orders to withstand the yafinite yunber of Cycles: Such compore ave designed by using following equations cycles +0 (> ak jee cydes on a log-log paper. Sats .¢ 4 Jogos-e The design pyccedure for such papblems is ac follews: © 1) Locate the pomt A with coosdinates [3 Jogo Con oil] W Locate the point & with coovdinates (6, Jogie ed] iii) Toin AB, which 18 used ae q criterion of Gillure for finite - Life problems. iv) Depending upon the Life N of the component, draw a vertical line passing through AegiolNd on the abscisca , This line inter- sects AGBat port F Vv) Draw a Mine FE parallel to the absciseq The otdinate. at jhe pot E, ie logic), giver the fatigue Grrength covsesper ding to N_ cyctes, ye SOME IMPORTANT RELATIONS @® The modifying factor Ka te account for the effeok of Ghress concert ration te defined as 5 ® The endurance Mrit CT.) of a component subjected to Fluctuating orsional Cheav Ghresses 1S clotained from the evdurant Jimat in nreversed bending (62) wing qheories 6 failures. According fo the max” QAhear ervess theory [q-05e | According to dutostion energy Terry i actuating lead, hon the co snent te cubjected to axial 1 "g ‘e © one ance Swit in ao Avading ie lower than ahe ‘volating beam ‘test. for axial Soading (2)4