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The maximum stress values are less than the ultimate tensile
stress limit, and may be below the yield stress limit of the
material.
The basis of the Stress-Life method is
the Wohler S-N diagram, shown
schematically for two materials in Figure
below.
Repeated
Reversed
Fully Reversed
Random/Iregular
The fatigue strength σe or Se
is the stress level that a
material can sustain for ‘N’
number of cycles
The stress level that a
material can withstand an
infinite number of cycles is
called endurance limit
Most of available S - N fatigue data has been obtained from fully reversed
rotational bending tests. However, material behavior and the resultant S - N curves
are different for different types of loading. It concerns in particular the fatigue
limit Se.
0.5
Bending
0.3 Axial
Torsion
0.1
103 104 105 106 107
Number of cycles, Log(N)
11
The stress endurance limit, Se, of steels (at 106 cycles) and the fatigue strength, S103
corresponding to 103 cycles for three types of loading can be approximated as (ref. 1, 23, 24):
S103= 0.90Su and Se = S106 = 0.5 Su - bending
Wrought Steel & alloy steel Ssu ≈ 0.75 x Su Ssyp = Approx 0,58 x Syp
Aluminum & alloys Ssu ≈ 0.65 xSu Ssyp = Approx 0,55 x Syp
Estimating Se´ From Static Data
Se 0.5Sut for Sut 200 ksi
steels Se 100 ksi for Sut 200 ksi
Se 0.4 Sut for Sut 60 ksi
irons
Se 24 ksi for Sut 60 ksi
S f @ 5 E 8 0.4 Sut for Sut 40 ksi
aluminums
S f @ 5 E 8 19 ksi for Sut 40 ksi
BUT, these are all for highly polished, circular rotating beams of a certain size
• Fatigue behavior and properties are calculated from the data
gathered through fatigue test on specimen
• Applied stress is of fully reversed nature
• These specimen are carefully prepared and are tested under
closely controlled conditions
• It is un – realistic to expect the endurance limit or fatigue
strength of a mechanical or structural member to match
values obtained in the laboratory
• Joseph Marine classified some of the factors that modify the
endurance limit and these are known as Marine Factors
• To account for most of these conditions, we employ a variety of these Marine Factors,
each of which is intended to account for a single effect
• If σ’e (S’e) is the endurance limit or fatigue strength of a specimen, and σe (Se) is the
fatigue strength of the mechanical component ( both made of same material), then
σe = ka kb kc kd ke kf σ’e
Where
ka , kb , kc , kd , ke , kf are Marine Factors
Description - a limit below which repeated stress does not induce
failure, theoretically, for an infinite number of cycles of load. The
limit of a material is affected by different factors.
o Endurance Limit Factors:
Equivalent diameter
0.0766d e2 0.05Ft
F d e 0.808 Ft
27
The size factor for bending and torsion may be
expressed as
(7-25)
kc
kpsi MPa Average
Bending 1 1 0 1
𝑺𝒖, 𝑻 𝑺𝒖, 𝑻
𝑺𝒆,𝑻 = 𝑺𝒆, 𝑹𝑻 × 𝒌𝒅 = 𝑺𝒆, 𝑹𝑻 × ; 𝒌𝒅 =
𝑺𝒖, 𝑹𝑻 𝑺𝒖, 𝑹𝑻
33
Temperature Factor kd
𝒇𝒂𝒕𝒊𝒈𝒖𝒆 𝒔𝒕𝒓𝒆𝒏𝒈𝒕𝒉 𝒂𝒕 𝒂𝒏𝒚 𝒕𝒆𝒎𝒑𝒆𝒓𝒂𝒕𝒖𝒓𝒆 ′𝑻′
𝒌𝒅 =
𝑭𝒂𝒕𝒊𝒈𝒖𝒆 𝒔𝒕𝒓𝒆𝒏𝒈𝒕𝒉 𝒂𝒕 𝒓𝒐𝒐𝒎 𝒕𝒆𝒎𝒑𝒆𝒓𝒕𝒂𝒖𝒓𝒆 ′𝑹𝑻′
kd = 0.975 + 0.432(10-3 ) TF - 0.115(10-5 ) (TF)2 + 0.104(10-8 ) (TF)3 - 0.595(10-3 )(TF )4
where 70 ≤ TF ≤ 1000o F
This may include
• Residual stresses
• Corrosion
• Electroplating
• Metal spraying
• Cyclic frequency
• Frettage corrosion
•?
•?
•?
• Any other parameter found in research
You may find ke as reliability factor in the literature
and kf as miscellaneous factor
σe = k a k b k c k d k e k f σ’
Reliability factor kf
The reliability factor accounts for the scatter of reference data such as the rotational
bending fatigue limit Se’.
The estimation of the reliability factor is based on the assumption that the scatter can be
approximated by the normal statistical probability density distribution.
𝒌𝒇 = 𝟏 − 𝟎. 𝟎𝟖 × 𝒁𝒂
The values of parameter za associated with various levels of reliability can be found in Table
7-7 in the textbook by Shigley .
37
Problem from “Shigley's Mechanical Engineering Design 9th edition”
>>Prob:- 6 -2 9th Estimate S’e in kpsi for the following
Estimate σ’e for the following materials materials:
a) AISI 1009 CD steel
(a) AISI 1035 CD steel.
b) AISI 1080 HR steel
c) 2024 T3 aluminum (b) AISI 1050 HR steel.
d) AISI 4340 steel heat treated (c) 2024 T4 aluminum.
(d) AISI 4130 steel heat-treated to a tensile
strength of 235 kpsi.
σ’e = 0.5 σu
σ’e = 34 kpsi
Prob:- 6 -2
Estimate σ’e for the following materials
a) AISI 1009 CD steel
b) AISI 1060 Annealed
c) 2024 T3 aluminum
d) AISI 4340 steel heat treated
σ’e = 0.5 σu
σ’e = 56 kpsi
Prob:- 6 -2
Estimate σ’e for the following materials
a) AISI 1009 CD steel
b) AISI 1060 Annealed
c) 2024 T4 aluminum
d) AISI 4340 steel heat treated
c) 2024 T4 aluminium
σ’e = 0.3 σu
σ’e = 0.5 σu
Given
Dia of rod = 3/16 inch
e k a kb k c k d k e k f
Machining = grinding /
Hardness = 490 Brinell
e
Asked
Fatigue strength of rod = ? so for e , we hav to find
k a kb kc k d ke k f and e/
for e/ we need u
Relation between hardness and ultimate strength
0.475 H B kpsi
u
3.41 H B MPa Eq 2-21
Prob:- 6 -1
A 3/16 – in drill rod was heat-treated and ground. The measured hardness was found to be 490 Brinell. Estimate the endurance strength if the
rod is used in rotating bending.
Dia of rod = 3/16 inch Machining = grinding, Hardness = 490 Brinell, Fatigue Limit of rod = ?
ka a ub Eq 6 - 19
u 242.6 Kpsi
for 'a' and 'b', from table 6-2
a 1.34
b -0.085 for ground surface finish
k a 1.34242.6
0.085
0.840
Ka = 0.85
Prob:- 6 -1
A 3/16 – in drill rod was heat-treated and ground. The measured hardness was found to be 490 Brinell. Estimate the endurance strength if the
rod is used in rotating bending.
Dia of rod = 3/16 inch Machining = grinding, Hardness = 490 Brinell, Fatigue Limit of rod = ?
d
0.107
0.107
0.3 0.897 d 0.11 d 2 in
0.91d 0.157 2 d 10 in
kb
0.107
d 1.24d 0.107 2.79 d 51 mm
7.62
1.51d 0.157 51 d 254 mm
Eq 6 - 20
0.3
0.107
kb d 0.897 d 0.107 0.11 d 2 in
Eq 6 - 20
0.107
0.897 3 / 16
0.107
kb 3 / 16
0.3
kb 1.05
Prob:- 6 -1
A 3/16 – in drill rod was heat-treated and ground. The measured hardness was found to be 490 Brinell.
Estimate the endurance strength if the rod is used in rotating bending.
Dia of rod = 3/16 inch Machining = grinding, Hardness = 490 Brinell, Fatigue Limit of rod = ?
e k a kb e/
e 0.8401.05 107 kpsi
e 94.4 kpsi
The rod is used at 450OC.
Prob:- 6 -1 (modified)
A 3/16 – in drill rod was heat-treated and ground. The measured hardness was found to be 490 Brinell. Estimate
the endurance strength if the rod is used in rotating bending.
Dia of rod = 3/16 inch Machining = grinding, Hardness = 490 Brinell, Fatigue Limit of rod = ?
e k a kb k c k d k e k f /
e
e k a kb k d e/
e 0.840 1.05 0.843107 kpsi
e 79.6 kpsi
Prob:- 6 -1 (further modified) The rod is used at 450OC with 90% reliability.
A 3/16 – in drill rod was heat-treated and ground. The measured hardness was found to be 490 Brinell. Estimate
the endurance strength if the rod is used in rotating bending.
Dia of rod = 3/16 inch Machining = grinding, Hardness = 490 Brinell, Fatigue Limit of rod = ?
𝒌𝒇 = 𝟎. 𝟖𝟗𝟕
e k a kb k c k d k e k f /
e
e k a k b k d k f e/
e 0.840 1.05 0.843 0.897 107 kpsi
e 71.4 kpsi
Example
A circular steel shaft rotates at 2500 rpm. It has a fixed lateral load of 500 N applied at the free end. It has a
machined finish and will be used for infinite life with a reliability of 99%. Find the Fatigue strength and factor of
safety. The shaft is made from G10800 steel HR.
𝝈𝒆 = ?
R 2.5 𝟇 25
𝝈𝒆
𝑭𝑶𝑺 = =?
𝝈𝒙𝒂
37.5
Factor of Safety Fatigue Srtength of the component
Applied Stress amplitude
e
F .O.S n
xa
e ka kb kc kd ke k f '
e
Find the fatigue strength of the material
Bending moment M = 500x0.25 = 125 N-m
load kc = ?
load kc = 1.0
𝒌𝒇 = 𝟏 + 𝒒 𝒌𝒕 − 𝟏
Giving Kt = 1.68
Kf = 1+0.85(1.68 – 1) = 1.58
𝑴 = ±𝟓𝟎𝟎 × 𝟐𝟓𝟎 𝑵 − 𝒎𝒎
𝟐𝟓
𝒄= 𝒎𝒎
𝟐
𝝅 𝟒 𝝅 𝟒
𝑰= 𝒅 = 𝟐𝟓 = 𝟏𝟗𝟏𝟕𝟓 𝒎𝒎𝟒
𝟔𝟒 𝟔𝟒
± 𝟓𝟎𝟎×𝟐𝟓𝟎 ×𝟏𝟐.𝟓 𝑵
𝝈𝒃 = = ±𝟖𝟏. 𝟒𝟗
𝟏𝟗𝟏𝟕𝟓 𝒎𝒎𝟐
𝑵
𝝈𝒃 = ±𝟖𝟏. 𝟒𝟗 𝝈𝒖 = 𝟕𝟑𝟏 𝑴𝑷𝒂
𝒎𝒎𝟐
𝟖𝟏.𝟒𝟗−𝟖𝟏.𝟒𝟗 𝑵
𝝈𝒎 = =𝟎 𝝈𝒆 = 𝟏𝟑𝟏 𝑴𝑷𝒂
𝟐 𝒎𝒎𝟐
𝟖𝟏.𝟒𝟗+𝟖𝟏.𝟒𝟗 𝑵
𝝈𝒂 = = 𝟖𝟏. 𝟒𝟗
𝟐 𝒎𝒎𝟐
𝝈𝒂 𝝈𝒎 𝟏
𝒌𝒇 + =
𝝈𝒆 𝝈𝒖 𝑵
𝟖𝟏.𝟒𝟗 𝟎 𝟏
+ =
𝟏𝟑𝟏 𝟕𝟑𝟏 𝑵
𝑵 = 𝟏. 𝟔
𝑓𝑜𝑟 2𝐷 𝛾𝑥𝑦 = 𝜀𝑥 − 𝜀𝑦
Data:-
I Beam Steel 1030 Normalised
Fully Reverse Load 10000N Surface Finish Lapping
Hole Radius at 750 mm 2.5 mm Opr Temp 300OC
Load Bending Reliability 90%
Find FOS = ?
A cantilever I beam as shown in the figure is made of steel 1030 Normalised and
subjected to fully reversible load of 10000 N alone Z – axis . The beam was
manufactured by forging and its surface finish was attained through lapping process. A
hole of radius 2.5 mm had to be drilled in the web as shown. The beam is part of a car
engine area where temperature is expected to raise to 𝟑𝟎𝟎𝑶 𝑪. Estimate the endurance
strength for reliability 90%.
𝝈𝒖 = 𝟓𝟐𝟏 𝑴𝑷𝒂 𝒐𝒓 𝟕𝟓 𝒌𝒔𝒊
𝒂 = 𝟏. 𝟓𝟖 𝒃 = −𝟎. 𝟎𝟖𝟓
𝑨𝟗𝟓
𝒅𝒆 =
𝟎.𝟎𝟕𝟔𝟔
𝑨𝟗𝟓 𝟗𝟓𝟎
𝒅𝒆 = = ≅ 𝟏𝟏𝟐 𝒎𝒎
𝟎.𝟎𝟕𝟔𝟔 𝟎.𝟎𝟕𝟔𝟔
−𝟎.𝟏𝟓𝟕 −𝟎.𝟏𝟓𝟕
𝒌𝒃 = 𝟏. 𝟓𝟏 𝒅𝒆 = 𝟏. 𝟓𝟏 𝟏𝟏𝟐 = 𝟎. 𝟕𝟏𝟗𝟗 𝒊𝒊𝒊
Load = Bending
𝒌𝒄 = 𝟏 (𝒊𝒗)
𝒌𝒅 = 𝟏. 𝟐𝟐𝟏𝟒 𝒗
𝒌𝒆 = 𝟎. 𝟖𝟗𝟕 𝒗𝒊
𝒘 = 𝟑𝟎𝟎 𝒎𝒎
d= 𝟓 𝒎𝒎
h= 𝟐𝟓 𝒎𝒎
𝟓
D = d/h= = 𝟎. 𝟐
𝟐𝟓
𝟓
d/w= = 𝟎. 𝟎𝟏𝟔𝟕
𝟑𝟎𝟎
𝒌𝒕 ≅ 𝟐. 𝟕
𝒌𝒕 ≅ 𝟐. 𝟕
𝒒 ≅ 𝟎. 𝟖
𝒌𝒇 = 𝟏 + 𝟎. 𝟖 𝟐. 𝟕 − 𝟏 = 𝟐. 𝟑𝟔 (𝒗𝒊𝒊)
𝝈ƴ 𝒆 = 𝑺ሖ 𝒆 = 𝟐𝟔𝟎. 𝟓 𝑴𝑷𝒂 (𝒊)
𝒌𝒂 = 𝟎. 𝟗𝟐𝟖 𝒊𝒊
𝒌𝒃 = 𝟎. 𝟕𝟏𝟗𝟗 𝒊𝒊𝒊
𝒌𝒄 = 𝟏 (𝒊𝒗)
𝒌𝒅 = 𝟏. 𝟐𝟐𝟏𝟒 𝒗
𝒌𝒆 = 𝟎. 𝟖𝟗𝟕 𝒗𝒊
𝟏
𝝈𝒆 = 𝟎. 𝟗𝟐𝟖 × 𝟎. 𝟕𝟏𝟗𝟗 × 𝟏 × 𝟏. 𝟐𝟐𝟏𝟒 × 𝟎. 𝟖𝟗𝟕 × × 𝟐𝟔𝟎. 𝟓 = 𝟖𝟎. 𝟔 𝑴𝑷𝒂 𝒗𝒊𝒊𝒊
𝟐. 𝟑𝟔
𝑴𝑪
𝝈𝒃𝒆𝒏𝒅𝒊𝒏𝒈 𝒂𝒕 𝑯𝒐𝒍𝒆 =
𝑰
𝑴 = 𝟏𝟎𝟎𝟎𝟎 × 𝟕𝟓𝟎 𝑵 − 𝒎𝒎
𝟐𝟓
𝒄= 𝒎𝒎
𝟐
𝑵
𝝈𝒃𝒆𝒏𝒅𝒊𝒏𝒈 𝒂𝒕 𝒉𝒐𝒍𝒆 = ±𝟏. 𝟓𝟓
𝒎𝒎𝟐
𝟏.𝟓𝟓+𝟏.𝟓𝟓 𝑵
𝝈𝒂 = = 𝟏. 𝟓𝟓
𝟐 𝒎𝒎𝟐
𝟏.𝟓𝟓−𝟏.𝟓𝟓 𝑵
𝝈𝒎 = =𝟎
𝟐 𝒎𝒎𝟐
𝝈𝒂 𝝈𝒎 𝟏
𝒌𝒇 + =
𝝈𝒆 𝝈𝒖 𝑵
𝟏.𝟓𝟓 𝟎 𝟏
+ =
𝟖𝟎.𝟔 𝟓𝟐𝟏 𝑵
𝑵 = 𝟓𝟐
𝒆𝒒𝒂𝒖𝒕𝒊𝒐𝒏 𝒐𝒇 𝒍𝒊𝒏𝒆 𝒃𝒆𝒕𝒘𝒆𝒆𝒏 𝟏 𝒙𝟏 , 𝒚𝟏 𝒂𝒏𝒅 𝟐 𝒙𝟐 , 𝒚𝟐
𝒙 − 𝒙𝟏 𝒚 − 𝒚𝟏
𝒆𝒒𝒂𝒖𝒕𝒊𝒐𝒏 𝒐𝒇 𝒍𝒊𝒏𝒆 𝒃𝒆𝒕𝒘𝒆𝒆𝒏 =
𝒙𝟐 − 𝒙𝟏 𝒚𝟐 − 𝒚𝟏
𝝈𝒎 − 𝝈𝒖 𝝈𝒂 − 𝟎
𝒆𝒒𝒂𝒖𝒕𝒊𝒐𝒏 𝒐𝒇 𝑮𝒐𝒐𝒅𝒎𝒂𝒏 𝒍𝒊𝒏𝒆 =
𝟎 − 𝝈𝒖 𝝈𝒆 − 𝟎
𝝈𝒂 𝝈𝒎 𝝈𝒂
𝒆𝒒𝒂𝒖𝒕𝒊𝒐𝒏 𝒐𝒇 𝑮𝒐𝒐𝒅𝒎𝒂𝒏 𝒍𝒊𝒏𝒆 − +𝟏=
𝝈𝒖 𝝈𝒆
𝟎, 𝝈𝒆 𝝈𝒂 𝝈𝒎
𝒆𝒒𝒂𝒖𝒕𝒊𝒐𝒏 𝒐𝒇 𝑮𝒐𝒐𝒅𝒎𝒂𝒏 𝒍𝒊𝒏𝒆 + =𝟏
𝝈𝒆 𝝈𝒖
𝝈𝒎
𝝈𝒖 , 𝟎