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Fatigue Note:
There are fatigue strength coefficients listed for several types of materials in table A-23 in
Shigley. If you are dealing with steel and you do not have specific data available for fatigue
strength coefficient, you can use the SAE estimations cited in equation 6-11 in Shigley (as I
did in the example in this video). If you have an experimental SN curve for the specific type
of material in question, you can use equation 6-9 in Shigley as a model and do a curve fit
to find the fatigue strength coefficient and the fatigue strength exponent. I'm not sure what
you are starting with, but these are some possible answers. Thanks for watching!

Fracture Mechanics Note:

Flaw Size (a) is an important parameter in fracture mechanics approach

•Fracture Toughness replaces strength of material

𝜎≫𝐹𝐴

– For Linear-Elastic Fracture Mechanics (LEFM), fracture toughness of a material is

determined from “Stress Intensity Factor”

– For Elastic-Plastic Fracture Mechanics(EPFM), fracture toughness is determined via

energy required to grow a crack
– Effect of Temperature on Fracture Toughness
– Fracture Toughness of materials are affected by temperature
– Ships experiencing cold weather conditions may be prone to fracture type failures

Three Modes of Fracture

Mode I denotes a symmetric opening (opening or tension mode)

Mode II denotes an antisymmetric separation (In-plane shear mode)
Mode III denotes an antisymmetric separation (out-of-plane shear or tearing mode)

Crack growth usually takes place in mode I or close to it.

The crack “adjusts” itself such that the load is perpendicular to the crack faces.

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It requires that the fatigue mechanism in terms of fatigue crack nucleation and fatigue
crack growth must be understood, as well as the influence of relevant variables on the
fatigue mechanism. The prerequisites for the book are elementary knowledge of materials
(material structure and material properties) and linear-elastic structural analysis (stress
and strain distributions, tension, bending and torsion).
If participants are already acquainted with linear-elastic stress analysis and fracture
mechanics, Chapters 3 and 5 can be omitted or briefly summarized as a refreshment.
Chapter summaries compiled in the last section of Chapters 2 to 20 should be useful for
the evaluation of personal understanding.

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The important point is that the fatigue life

until failure consists of two periods: the
crack initiation period and the crack growth
period.
Differentiating between the two periods is
of great importance because several
surface conditions do affect the initiation
period, but have a negligible
influence on the crack growth period.
Surface roughness is just one of those
conditions as discussed in Section 2.5.
Corrosive environments can affect initiation
and crack growth, but in a different way for
the two periods.

It should already be noted here that fatigue

prediction methods are different for the two
periods. The stress concentration factor Kt
is the important parameter for predictions
on crack initiation. The stress intensity
factor K is used for predictions on crack
growth.

Cyclic slip requires a cyclic shear stress. On

a microscale the shear stress is not
homogeneously distributed through the
material. The shear stress on
crystallographic slip planes differs from
grain to grain, depending on the size and
shape of the grains, crystallographic
orientation of the grains, and
elastic anisotropy of the material.

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We will test this on FEPIPE > WRC107

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And test again on CESARII > same results

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And then find FSRF:

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We got SIF of 119, and that seems high. And now we will check the results with the
FEA program.

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In this calculation shown above, the penetration line stresses were not calculated as
recommended by AMSE sec VIII Div.2

But we will check the penetration line stresses.

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No we will look at the another method to evaluate SIFs using Nuclear code N318.

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Not recommended because it tends to be a high value.

What is recommended is for abnormally high loads thru supports > individual
evaluation of each support

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SIF of 2 is more of a reasonable value and Stress Engineer will help the Pipe support
engineer to do his job better in the future. If Stress guy use the SIF = 1, actually he
leaved it to pipe support guy.

When we have a fatigue condition and we know that the pipe supports will fail first,
we must use SIF at least 2.

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Make sure to evaluate all loads.

See the below figure. Bolt failure due to the thermal gradient.

Pipe Support failure due to the water hammer.

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t/T

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Pipe connections including connections on bend.

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Evaluate all loads and moments properly.

Also include thermal gradient, all direct forces and flattening

We need to assure that the m/z stress at the pipe support in the pipe is not greater
than m/z stress in the pipe in the beam analysis.

Friction loads can induce large bending stresses.

Plastic Bending: Theory and Applications

By Tongxi Yu, Liangchi Zhang

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In FEA, what is linear and nonlinear

analysis?

In this article we explain in short the differences

between linear and nonlinear structural analysis
and provide some examples of the latter.

Linear static analysis

A linear static analysis is an analysis where a linear relation holds
between applied forces and displacements. In practice, this is
applicable to structural problems where stresses remain in the
linear elastic range of the used material. In a linear static analysis
the model’s stiffness matrix is constant, and the solving process is
relatively short compared to a nonlinear analysis on the same
model. Therefore, for a first estimate, the linear static analysis is
often used prior to performing a full nonlinear analysis.

Nonlinear analysis
A nonlinear analysis is an analysis where a nonlinear relation holds
between applied forces and displacements. Nonlinear effects can
originate from geometrical nonlinearity’s (i.e. large deformations),
material nonlinearity’s (i.e. elasto-plastic material), and contact.
These effects result in a stiffness matrix which is not constant
during the load application. This is opposed to the linear static
analysis, where the stiffness matrix remained constant. As a

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result, a different solving strategy is required for the nonlinear
analysis and therefore a different solver.

Modern analysis software makes it possible to obtain solutions to

nonlinear problems. However, experienced skill is required to
determine their validity and these analyses can easily be
inappropriate. Care should be taken to specify appropriate model
and solution parameters. Understanding the problem, the role
played by these parameters and a planned and logical approach
will do much to ensure a successful solution.

The source of this nonlinearity can be attributed to multiple

system properties, for example, materials, geometry, nonlinear
loading and constraints. Here are some examples…

Geometric Nonlinearity
In analyses involving geometric nonlinearity, changes in geometry
as the structure deforms are considered in formulating the
constitutive and equilibrium equations. Many engineering
applications such as metal forming, tire analysis, and medical
device analysis require the use of large deformation analysis
based on geometric nonlinearity. Small deformation analysis based
on geometric nonlinearity is required for some applications, like
analysis involving cables, arches and shells.

Material Nonlinearity
Material nonlinearity involves the nonlinear behavior of a material
based on a current deformation, deformation history, rate of
deformation, temperature, pressure, and so on. Examples of
nonlinear material models are large strain (visco) elasto-plasticity
and hyperelasticity (rubber and plastic materials).

Constraint and Contact Nonlinearity

Constraint nonlinearity in a system can occur if kinematic
constraints are present in the model. The kinematic degrees-of-
freedom of a model can be constrained by imposing restrictions on
its movement.
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Fatigue analysis for combined loading

Advanced mechanics of materials

Here some conceptual approaches are presented for evaluating questions of fatigue in various modes in which a mechanical
component may experience dynamic loading. When stress peaks from all of the types of stress (i.e. bending, torsion, axial)
align in-phase and at the same frequency, a method based on von-Mises stress is particularly useful. An example problem is
solved for a component loaded in such a way. Equivalent midrange and alternating stresses are computed for this example,
and the ASME Elliptic criterion is used to evaluate a fatigue factor of safety. When it is discovered that this factor of safety is

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less than 1 (implying a finite predicted life) the number of cycles expected before failure is estimated. Playlist for MEEN361
(Advanced Mechanics of Materials): https://www.youtube.com/playlist?list... Playlist for MEEN462 (Machine Element
Design): https://www.youtube.com/playlist?list... This lecture was presented on February 16, 2018. All retainable rights are
claimed by Michael Swanbom. Please subscribe to my YouTube channel and follow me on Twitter: @TheBom_PE Thank you
for your support!

Torsion causes torsional stress

Flexure stress

Axial load > axial stress

Possibility 1: All stresses applied at same frequency with peaks in phase

Use formulas in Shiegly > 6-55, 6-56

Possibility 2: same frequency and different phase

Von mises calculation> merge all three as a function of time

You can find the extremes of stress from von mises equations

Possibility 3: different frequency

Example: fins ASME elliptic factor of safety for a bent rod where deflections are known

Find factor of safety against fatigue

1st action: find SCFs – find torsional and bending fatigue SCFs

We need some graphs out of the book, fig. A-15-9, fig. A-15-8

Use D/d=3 (the highest value) in this case if you don’t know the actual size of the rod

Find r/D ratio = 0.5 > Kt=2

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Equation 6-32

Fig 6-20 > if you want a dirty and quick answer then use the chart

Best to do is to calculate sensitivity

2nd: Translate deflections into stresses

Table A-1 > delta = FL/3EI … due to BC flexing

How about twisting …. ø

Find normal stress due to flexure … bending

Find torsion

Equation 6-55 and 6-56 …

Find Midrange stress and alternating component of normal stress

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Find Midrange stress and alternating component of shearing stress

Find von mises midrange and alternating stress components

Find fully corrected endurance limit

Find cycles

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Solid Mechanics

Solid Mechanics I ---- bar

(Mechanics of Materials)
Solid Mechanics II ---- bar system
(Structure Mechanics)
bars
plates
Solid Mechanics III ---- blocks
(Theory of Elasticity) dams

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shells
Solid Mechanics VIII
(Theory of Plasticity)

Video Lecture 23

Midrange and Alternating Stress | Goodman Criteria

| Axial Fatigue Load

LECTURE 23: Here the concept of expressing fluctuating stresses in terms of

midrange and alternating components is presented and explained. The Goodman
failure criteria is presented as a simple technique of estimating the stress
thresholds at which the life of parts can no longer be expected to be infinite. An
example problem is completed in which an axially loaded connecting rod with a
pin-in-hole stress concentration is evaluated for a fatigue factor of safety using
the Goodman criteria for infinite life. Marin factors are used to estimate the fully
corrected endurance limit. The factor of safety guarding against first-cycle
yielding is also evaluated. The load line is plotted on midrange-alternating stress
axes along with the Goodman and Langer failure lines. The factors of safety
found are inspected relative to the graphical representation. Playlist for
MEEN361 (Advanced Mechanics of Materials): https://www.youtube.com/playlist?
list... Playlist for MEEN462 (Machine Element Design):
https://www.youtube.com/playlist?list... This lecture was presented on February
5, 2018. All retainable rights are claimed by Michael Swanbom. Please subscribe
to my YouTube channel and follow me on Twitter: @TheBom_PE Thank you for
your support!

Midrange and alternating stress – Goodman criteria ……. fig-6-24

- Fully reverse at the verge of failure

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- Static load at the verge of failure
- Repeated loading at the verge of failure

See fig 6-27 …. Representing the Goodman criteria on midrange and alternating stress axes

Goodman is not conservative

fig 6-25….

Gerber criterion (parabolic)

ASME elliptic criterion (elliptical)

MSS Static Failure Criterion (Maximum Shearing

Stress AKA Tresca or Guest)
Advanced Mechanics of Materials

Here the Maximum Shearing Stress static failure criterion is presented and
justified in the context of Mohr's circles. Use of this criterion is then
demonstrated in an example. The Tresca hexagon failure locus is plotted for the
material given in the example. The principal stresses are found for the state of
plane stress given in the example, then a load line representing this state of
stress is plotted on the failure locus diagram.

+ Why we often ignore stress concentration effects for ductile materials loaded
statically

+ 45 degree lines (slip planes) on tensile specimens: a clue that shearing stress
is an important factor in material failure mechanics

NOTE Criteria:
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When the maximum shearing stress on a part in service reaches the amount of
shearing stress in a tensile specimen that causes it to fail, we predict that the
part will fail.

The max. shearing stress failure criterion - Also known as Tresca or Guest
criterion

Case 1: both in-plane principal stresses are positive

Case 2: one in-plane principal stress is positive and one is negative

Case 3: both in-plane principal stresses are negative

plotting the failure locus for the MSS criterion (the Tresca hexagon)

Notes from Shigley:

Design Considerations
Sometimes the strength required of an element in a system is an important factor in
the determination of the geometry and the dimensions of the element. In such a situation
we say that strength is an important design consideration. When we use the
expression design consideration, we are referring to some characteristic that influences
the design of the element or, perhaps, the entire system. Usually quite a number of
such characteristics must be considered and prioritized in a given design situation.
Many of the important ones are as follows (not necessarily in order of importance):

1 Functionality 14 Noise
2 Strength/stress 15 Styling
3 Distortion/deflection/stiffness 16 Shape
4 Wear 17 Size
5 Corrosion 18 Control
6 Safety 19 Thermal properties
7 Reliability 20 Surface
8 Manufacturability 21 Lubrication
9 Utility 22 Marketability
10 Cost 23 Maintenance
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11 Friction 24 Volume
12 Weight 25 Liability
13 Life 26 Remanufacturing/resource recovery
Some of these characteristics have to do directly with the dimensions, the material,
the processing, and the joining of the elements of the system. Several characteristics
may be interrelated, which affects the configuration of the total system.

Breakeven Points

If the desired production is greater

than 50 parts, the automatic machine should be used.

strength is an inherent property of a part, a property built into the part because of the use
of a particular material and process.

S to denote strength, with appropriate subscripts to denote the type of strength. Thus, Sy
is a yield strength, Su an ultimate strength, Ssy a shear yield strength, and Se an
endurance strength.

Stress is a state property at a specific point within a body, which is a function of load,
geometry, temperature, and manufacturing processing.

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