Module-2b Fatigue strength

Dr. Bhaskara Rao Lokavarapu

School of Mechanical Engineering
VIT Chennai Campus
 Overview of the Presentation

 Variable and cyclic loads.

Fatigue strength.
S-N curve.
Continued cyclic stress.
Soderberg and Goodman equations.
Design of helical springs.
Design of leaf springs.
Design of disc springs under constant and
Variable loads.
Numericals..
 Introduction
The concept of fatigue is very simple,
when a motion is repeated, the object
that is doing the work becomes weak
 Introduction
Fatigue occurs when a material is
subject to alternating stresses, over a
long period of time. .
Examples of where Fatigue may occur
are: springs, turbine blades, airplane
wings, bridges and bones.
 Introduction
The significance of the fatigue limit is
that if the material is loaded below this
stress, then it will not fail, regardless of
the number of times it is loaded
Material such as aluminum, copper and
magnesium do not show a fatigue limit,
therefore they will fail at any stress and
number of cycles
 Introduction
 Fatigue limit: The stress below which fatigue
failure does not occur regardless of the
number of stress cycles
 Fatigue Strength: The stress at which failure
occurs for a given number of cycles is the
fatigue strength.
 Fatigue Life: The number of cycles required
for a material to fail at a certain stress in
fatigue life.
 Fatigue Failure – Type of Fluctuating Stresses
a = max
max = - min

Alternating stress
max min
a = 2
min = 0
Mean stress
a = m = max / 2 max min
+
m = 2
 Fatigue Failure, S-N Curve

Test specimen geometry for R.R. Moore

rotating beam machine. The surface is
polished in the axial direction. A
constant bending load is applied.

Typical testing apparatus, pure bending

Motor

Load

Rotating beam machine – applies fully reverse bending

stress
Fatigue Failure, S-N Curve

N < 103 N > 103

Finite life Infinite life

S′e

Se′ = endurance limit of the specimen

 The Effect of Mean Stress on Fatigue Life

Mean stress exist if the

loading is of a repeating
or fluctuating type.

a Mean stress is not zero

Gerber curve
Se
Alternating
stress Goodman line

Sy Sut m
Soderberg line
Mean stress
 Load Correction factor

 Kb = Load correction factor for the reversed or

rotating bending load.
 Its value is usually taken as unity.
 Ka = Load correction factor for the reversed axial
load.
 Its value may be taken as 0.8.
 Ks = Load correction factor for the reversed
torsional or shear load.
 Its value may be taken as 0.55 for ductile
materials and 0.8 for brittle materials.
Effect of Surface Finish on Endurance Limit—
Surface Finish Factor
[Ksur]
Effect of Size factor on Endurance Limit—Size
Factor [Ksz]

• The value of size factor is taken as unity for

the standard specimen having nominal
diameter of 7.657 mm.

• When the nominal diameter of the specimen

is more than 7.657 mm but less than 50 mm,
the value of size factor may be taken as 0.85.

• When the nominal diameter of the specimen

is more than 50 mm, then the value of size
factor may be taken as 0.75.
Effect of Miscellaneous Factors on Endurance
Limit, [Ksur]

 In addition to the surface finish factor (Ksur), size

factor (Ksz) and load factors Kb, Ka and Ks, there
are many other factors such as reliability factor (Kr),
temperature factor (Kt), impact factor (Ki) etc. which
has effect on the endurance limit of a material.

 Considering all these factors, the endurance limit

may be determined by using the following
expressions
 Considering all these factors, the endurance
limit may be determined by using the following
expressions
 For the reversed bending load, endurance limit, σ'e
= σeb.Ksur.Ksz.Kr.Kt.Ki

 For the reversed axial load, endurance limit, σ'e =

σea.Ksur.Ksz.Kr.Kt.Ki

 For the reversed torsional or shear load, endurance

limit, σ'e = τe.Ksur.Ksz.Kr.Kt.Ki

 Fatigue stress concentration factor =

Ktf =1+q(Kt – 1)
 The following relations may be followed:

For steel :
σe = 0.5 σu ; σy = 0.55 σU ; τy = 0.5 to 0.6 σy
For Cast Iron :
σe = 0.4 σu ;
For non-ferrous metals and alloys
σe = 0.3 σU ;
 The Effect of Mean Stress on Fatigue Life

Mean stress exist if the

loading is of a repeating
or fluctuating type.

a Mean stress is not zero

Gerber curve
Se
Alternating
stress Goodman line

Sy Sut m
Soderberg line
Mean stress
Soderberg, Goodman and
Gerber Equations
 Problems-Fatigue strength-Axial Loads
 Example: 1. A rod of circular cross-section is
subjected to an alternating tensile force, varying
from 30 kN to 80 kN. Determine the diameter of the
rod, according to (i) Gerber method, (ii) Goodman
method, and (iii) Soderberg method; using the
following material properties. Ultimate tensile
strength = 1000 MPa and Yield strength = 550 MPa.
Take factor of safety as 2.5. Neglect stress
concentration effect and other correction factors.
 Given : FMin = 30 kN; FMax = 80 kN
σu = 1000 MPa
σy = 550 MPa
N = 2.5
TO Find: Diameter of the rod = d

Ans: The diameter of the rod (i) d = 10.4 mm;

(ii) d = 18.2818 mm & (iii) d = 21.85 mm
Problems-Fatigue strength-Bending Loads
 Example: 2. A cantilever rod of circular cross-section is
subjected to a cyclic transverse load; varying from -100 N
to +300 N, as shown in figure. Determine the diameter of
the rod, according to (i) Soderberg method, and (ii)
Goodman method, using the following material
properties. Factor of safety = 2, Theoretical stress
concentration factor = 1.4, Notch sensitivity factor = 0.9,
Ultimate tensile strength = 550 MPa, Yield strength = 320
MPa. Endurance limit = 275 MPa, Size correction factor =
0.85 and surface correction factor = 0.90
 Given : FMin = -100 N; FMax = + 300 N; N = 2
kt = 1.4; q = 0.9; σu = 550 MPa
σy = 320 MPa; σe = 275 MPa
B = 0.85; C = 0.90
TO Find: Diameter of the rod = d
Ans : The diameter of the rod (i) d = 15.774 mm &
(ii) d = 15.33 mm
Problems-Fatigue strength-Torsional Loads
 Example: 3. A 50 mm diameter shaft made from carbon
steel, hardened to 180 Brinnel, is subjected to a torque,
which fluctuates from + 2000 N-m to – 1000 N-m as
shown in figure. Determine the factor of safety, use the
following information. Ultimate tensile strength (U.T.S) =
33 x B.H.N kgf/cm2. Torsional endurance limit = 0.25 x
U.T.S; Yield strength = 0.6 x U.T.S; Yield strength in
shear = 0.5 x U.T.S
 Given : TMin = -1000 N-m; TMax = + 2000 N-m;
UTS = 33x B.H.N kgf/cm2
τe = 0.25 x U.T.S; τy = 0.6 x U.T.S
τu = 0.5 x U.T.S; assume; ktf=1.4,
B=0.8,C=0.9
TO Find: Factor of safety=N

Ans: Factor of safety N = 1.144

Problems-Fatigue strength-Axial and Bending loading

 Example: 4. A steel rod of circular section is subjected

to an axial load, varying from 20 kN to 50 kN; as the
bending moment varies from 500 N-m to 1000 N-m. The
maximum bending moment and maximum axial load
occurs at the same instant. Determine the diameter of
the rod. Use the following information. Factor of safety
= 2.25; Ultimate tensile strength (U.T.S) = 560 MPa; Yield
strength = 320 MPa.
 Given : FMin = 20 kN; FMax = 50 kN;
MMin = 500 N-m; MMax= 1000 N-m
N = 2.25
σu = 560 MPa
σy = 320 MPa
TO Find: Factor of safety=N

Ans: Diameter of the rod =d = 42 mm

 Problems-Fatigue strength
 Assume: σe = 0.5 σu =0.5x560 = 280 MPa
A = 0.7 for variable axial loading
= 1.0 for variable bending moment
B = 0.8
C = 0.85
Ktf = 1.4
 (i) Equivalent normal stress due to variable
axial load  y  v K tf
1   m 
 e ABC
 (ii) Equivalent normal stress due to variable
bending moment      y  v K tf   1   2 
y
 e ABC resul tant
2 m
N
Ans: Diameter of the rod =d = 42 mm
 Problems-Fatigue strength
 Example: 5. Determine the endurance strength of a steel
shaft, for a life of 106 cycles. The ultimate strength and
endurance limit of the shaft material is 425 MPa and 220
MPa respectively.

 Given : N = 10 6 cycles
σu = 425 MPa
σe = 220 MPa

TO Find: Endurance strength of steel = σef

Ans: Endurance strength of steel = σef = 190.1 MPa

• The endurance strength, for 106 cycles is given by
 ef  10 C N b

 0.8 u 2 
c  Log  
  e 

1  0.8 u  
b   Log  
3   e 
 Problems-Fatigue strength
 Example: 6. A component is subjected to completely
reversed stress cycle which vary over a 30 second time
period, as follows:
10 cycles at 500 MPa
5 cycles at 600 MPa
3 cycles at 700 MPa
The corresponding fatigue lives for the above stresses are:
105 , 4x104, and 1.5x104 cycles respecticivley. Determine the
fatigue life of the component.
 Given : N1‘ = 10 ; N1 = 10 5 cycles
N2‘ = 5 ; N2 = 4x10 4 cycles
N3‘ = 3 ; N3 = 1.5x10 4 cycles

TO Find: Fatigue life

Ans: Fatigue life = 19.6 hrs
   
N1 N 2 N 3
• Using the Miner’s rule,    1 for
N1 N 2 N 3
satisfactory operation.

4.25X10-4 corresponds to 30 seconds

1 corresponds to ???

(30x1)/ 4.25X10-4 =70588.235 seconds

=19.6078 hours
 Problems-Fatigue strength
 Example: 7. A machine component is subjected to a reversed
bending stress of 500 MPa for 10% of the time, a reversed
bending stress of 600 MPa for 50% of the time, and a
reversed bending stress of 700 MPa 40% of the time.
Determine the expected life of the component. The
endurance strength of the component material for various
stress levels are as follows:
500 MPa 2,60,00 cycles
600 MPa 55,000 cycles
700 MPa 21,000 cycles
 Given : α1 = 0.1 ; N1 = 2,60,000 cycles
α2 = 0.5 ; N2 = 55,000 cycles
α3 = 0.4 ; N3 = 21,000 cycles
TO Find: Expected life of the component

Ans: Expected life of the component = 42,086 cycles

• According to the Miner’s equation
1 2 31
  
N1 N 2 N 3 N C