Lecture 11 Endurance Limit Modifiers6-9 Endurance Limit Modifiers Pa te ot sete 2 CS) wee gohe The rotating-beam endurance limit is usually known. The actual endurance limit in a part is often not known. We introduce Marin factors to adjust the rotating-beam en ice limit to match the actual part dheting ee d a ren Vinh Se - actual endurance limit Se’ - rotating bearm endurance limit ka - surface condition factor kb - size factor ke - load factor kd - temperature factor ke - reliability factor kf- miscellaneous factorSurface Factor, K_a + Stresses tend to be high at the surface + Surface finish has an impact on initiation of crack at localized stress concentrations + Surface factor is function of ultimate strength. Higher strengths are more sensitive to rough surfaces. elec - on we ¢ J - aa Se For eal Tables? Past n ramet i) oe AZ b Curie conctels Example 6-3 A steel has a minimum ultimate strength of $20 MPa and a machined surface. Estimate kos Solution From Table 6-2, a = 4.51 and b =—0.265. Then, from Eg. (6-19) Answer 209-0265 = 0,860Size Factor, k_b * Large parts have greater surface area at high stress levels + Likelihood of crack initiation is higher + Size factor is obtained from experimental data with wide scatter + For Round and Rotating parts subject to Bending and/Torsion loads, tating parts ene the trend of the size factor data is... on 7 = ( 4f09°"E 9.9015” = 0.187 o.%d + For Non-Rotating round or hollow parts, Non Rota Ne To oF now [i-ovea]* + For! Non-Rotating rectangular parts, S20 fcamas]7 + Other common cross-sections are given in Table 6-3 Aw - Example 6-4 se Bead JAA ery Solution (a) From Eg, (6-20) ‘answer ton (GS) = (BY = ose (b) From Table 6-3, de = 0.374 = 0.3 From Eq, (6-203, — = (fyLoading Factor, kc + Accounts for changes in the endurance limit for different types of fatigue loading. * Only to be used for single load types. + Use Combination Loading method (sec. 6-14) when more than one load type is present. Temperature Factor, k_d + If the ultimate tensile strength is known at the operating temperature, use the strength and set k_d=1. + If the ultimate tensile is only known at room temperature, then use Table 6-4 to estimate the ultimate strength at the operating temperature and set k_d=1. Alternatively use the raom temperature strength and use the k_d given in the table. Sy = Ar gth sopety dap Sep + Another option is to use this fourth-order polynomial to find the k_d ata desired operating temperature. 0.975 + GUBE-BT, - OS E-G Ty OME Te — 9.595e-13 Te Teble 6-4 et of Opsaing the sigh a grating seperate Ser= ene wrength (0099 <5 ky = (Sr/Ser)asore= 1-018 + (0.995 — 1.018): = 1.007 From Eq. (6-8) then, (Se)asy- = 0.5 (Sur aso = 0.5(70.5) = 35.2 Kpst ese Part a gives the better estimate due to actual testing of the particular material.Reliability Factor, ke + When the endurance limit is plotted versus tensile strength for steels, scatter is observed. We take the average line through the data to find Se/Sut=0.5. * Statistical analysis, shows the standard deviation of the endurance limit is less than 8% (0.08). oe es Tet ea uch Cod When we plotted the stress-life curve, of materials we will also see scatter. a Ss FE 30% att SNe! ob Vay 2 we The reliabi iy oan be incorporated into design using the following equation and table. = TeeFerchwe Verte tale, Table 6-5 oes e eae Tronsformation Variate x, Reliability Factor ke 0 0 1.000 0 1.288 0897 98 65 0.868 99 i 2325 ————— 00814 %99 3.001 o7s3 9999 a9 02 99,999) 4.265 0689) 99,9909Miscellaneous-Effects Factor, k f There exist many other conditions that can modify the endurance limit. The k_f factor exists as a reminder that these conditions must be incorporated into the design process. The value of the k_f factor is not always available. Additional experiments may be required to characterize the behavior. + Residual stresses + Directional characteristis of the material * Corrosion + Surface condition e.g. electrolytic plating, metal spraying, coatings * Cyclic frequency « Frettage Corrosion + Radiation * and many more... The design engineer must carefully think about the environment and conditions the design will be subject to and identify the appropriate modification factors for the design.ExamplesExample 6-8 S, = Matte. Se A 1015 hot-rolled steel bar has been machined to a diameter of | in. It is to be placed in reversed axial Toading for 70 000 cycles to failure in an operating environment of 550°F. Using ASTM minimum properties, and a reliability of 99 percent, estimate the Eran iit and fatigue strength at 7O0WD eye. Sap" Lo) TEES Solution ° 3 — From Table A-20, Sq = 50 kpsi at 70°F, Since the rotating-beam speclifien endurance imit is not known at room temperature, we determine the ultimate strength at the ele- vated temperature first, using Table 6-4. From Table 64. Sr 0.995 + 0.963 a ——=0979 fi) ‘The ultimate strength at 580°F is then Coe (Sar)ssor = (Sr /Ster 530: (Sus > = 0.97950) = 49.0 kpsi ee The rotating-beam specimen endurance limit at 550°F is then estimated from Eg, (6-8) = Gf20.s-$, ) = 0.5(49) Next, we determine the Marin factors. For the machined surface, Eq. (6-19) with Table 6-2 gives a a> btu fen ky = aS, = 2.7049") = 0.963 u oe. For axial loading, from Eq. (6-21), the size factor ky = 1. and from Eq. (6-26) the load ing factor is ke = 0.85. The temperature factor kg = 1, since we accounted for the tem= perature in modifying the ultimate strength and consequently the endurance limit. For 99 percent reliability, from Table 6-5, ke =0.814. Finally, since no other conditions were given, the miscellaneous factor is Ar= 1. The endurance limit for the partis esti- mated by Eq. (6-18) as ih eer Ag c= bakohbabelyS, ee = 0,963(1)(0.85)(1 ee ii CO Sree = F Sux For the fatigue strength at 70 000 cycles we need to construct the S-N’ equation, From p. 293, since S,, = 49 < 70 kpsi, then f = 0.9. From Eq. (6-14) A GS" _ 10.9149) ie Ss 16.3 = 119.3 kpsi and Eq. (6-15) ve(G*) ml re (ae ara 3 Finally, for the fatigue strength at 70 000 cycles, Eq. (6-13) gives 16.3 5, = AN®= 119.3(70 000)"™"