6a Fatigue Strength Example

Fatigue Strength-Example
Héctor Enrique Jaramillo Suárez, Ph.D.

Example
A pulley (B) of 60 cm of diameter take 30 CV at 3600 rpm from
down and 45º (Figure 1). A C gear of 46 cm of diameter transmit
horizontally toward right the 40% of the total power. Another gear
(E) transmit the remaining power toward down and left according
an angle of 60o measured respect to the horizontal axel. The
pressure angle for both gears is 20o. The material used to made
the shaft was C1137 steel (Sut=597.6 MPa, Sy=351.5 MPa) using
the sled runner keyseat. The loads are time-constant.
a.Which is the diameter of the shaft using a safety factor of 1.8 and
the Soderberg criterion to the design?
a.Suppose that the diameter of the shaft decrease into D bearing,

so calculate the diameter necessary from D to E.
Prof. Héctor Enrique Jaramillo, Ph.D.

Resistencia de Materiales 2
Ingeniería Mecánica
Gear (E)
Diameter=30 cm
E
D
B
Gear (C)
A Diameter=46 cm
Pulley (B)
Diameter=60 cm

60o
45o
30 cm 45 cm 25 cm 25 cm

Answer
The moments transmitted by pulleys are:
P
P = Tw Þ T = 7018.7(30)
w TB = = 58.5 N.m
3600
1CV = 735 Watts
7018.7 P 7018.7(12)
2p T= TC = = 23.4 N.m
w= n n 3600
60 7018.7(18)
TE = = 35.1 N.m
3600

Calculating the forces:
B Pulley:
When the information is not complete, you can assumed that:
F1
F1 + F2 = 2( F1 - F2 ) F2 =
3
FB = F1 + F2 = 2( F1 - F2 )
TB = ( F1 - F2 )rB
FB 2TB 2(58.5 N.m)
TB = rB FB = =
2 rB 0.3 m
FB = 390 N
The forces produced by the gears are:
C Gear:
TC 23.4 N.m
FC = = FC = 101.7 N
rC 0.23 m
N C = FC tan a N C = 101.7 tan 20 N C = 37.0 N

E Gear:
TE 35.1 N.m
FE = = FE = 234.0 N
rE 0.15 m
N E = FE tan a N E = 234.0 tan 20 N E = 85.2 N

B Pulley: C Gear: E Gear:
y
y y
NC=37 N x
w
x FC=101.7 N 60°
w
45°
4 N
w x = 23
NE
FE
FB
=8
5.2
Fx = FB cos 45 = 390cos 45
N
Fx = 234sen60 − 85.2cos60
Fx = 275.8 N Fx = 101.7 N
Fx = 160.1 N
Fy = FB sen45 = 390sen45 Fy = 37.0 N Fy = 234cos60 + 85.2sen60
Fy = 275.8 N Fy = 190.8 N

Shear force and moment diagrams :
x-z Plane: y-z Plane:
x Ax=258.5 N 160.1 N y Ax=250 N 190.8 N
z z
275.8 N 101.7 N Dx=41.1 N 275.8 N 37 N Dx=128 N
0.30 0.45 0.25 0.25 0.30 0.45 0.25 0.25
Vx 258.5 Vy 250
[N] [N]
17.3 25.8
119 62.8
160.1 Mx 75
190.8
77.6
[N.m]
63.3
My 69.8
[N.m] 40 47.7
A B C D A B C D

Torque and resultant flexural moment diagrams
x Ax=258.5 N 160.1 N
275.8 N 101.7 N Dx=41.1 N

0.30 0.45 0.25 0.25
58.5
T
[N.m] 35.1
107.9
M R = ( M x2 + M y2 ) MR
[N.m]
94.2
62.2
A B C D

Critical section: B
M R = 107.9 N.m
T = 58.5 N.m
T=58.5 N.m
MR=107.9 N.m
The torque is constant, then the shear stress is time-constant and their behavior is:
t
τ max − τ min τ max + τ min
τa = =0 τm = =τ
t 2 2

Although the force is constant, the normal stress is time-varies. This is due
to the spin of the shaft that produces the change of position of the fibers.
So the stress time-behavior is:
σ Maximum σ max − σ min

σa = =σ
2
σ max + σ min
σ Minimum σm = =0
2

Stress calculation
For B keyseat:
K f = 1.6 Bending K fs = 1.3 Torsion
17585
s max =+
d3
Mc 32 M R 32(1079) 17585
s = Kf = Kf = 1.6 s=
I pd 3
pd 3 d3 17585
s min = -
d3
3873
t max = 3
Tc 16T 16(585) 3873 d
t = Kf = Kf = 1.3 t= 3
J pd 3
pd 3 d 3873
t min = 3
d

Static Design
æ 17585 3873 ö
17585 A = (s x ,t xy ) = ç , 3 ÷
sx = è d
3
d ø
d3
3873 æ 3873 ö
t xy = 3 B = (s y ,-t xy ) = ç 0,- 3 ÷
d è d ø
t
8792.5
3873 A sp =
d3 d3
2 1/ 2
éæ 8792.5 ö æ 3873 ö ù
2
t max = êç ÷ +ç 3 ÷ ú
17585 s êëè d
3
ø è d ø úû
d3
3873 9608
-
d3 B t max = 3
d
18400
s1 =
d3 1/2 18820
σ ʹ = ⎡⎣σ − σ 1σ 2 + σ ⎤⎦
2
1
2
2
= 3
815 d
s2 = -
d3
Using the Tresca criterion:
t max £ t adm
Sy 9608 351x106 d ≥ 0.037 m
2t max £ 3
£
N d 1.8 d ≥ 37 mm

Fatigue Design
17585 σ max − σ min 17585
s max =+ σa = =σ =
d3 2 d3
17585
s min =- σm =
σ max + σ min
=0
d3 2
τ max − τ min
τa = =0
3873 2
t max = 3
d
τ max + τ min 3873
3873 τm = =τ = 3
t min = 2 d
d3

Alternating Stresses
17585 æ 17585 ö
sa = 17585 A = (s x ,t xy ) = ç ,0 ÷
d3 sa = è d
3
ø
d3
ta = 0
B = (s y ,-t xy ) = (0,0 )
t
(t max )a = 87923 .5
d
A 17585
(s 1 )a
1/2
= σ ʹ = ⎡⎣σ 12 − σ 1σ 2 + σ 22 ⎤⎦
( )
B 17585 s d3 a
d3
17585
(s 2 )a = 0 ( )
σʹ =
a
d3

Midrange Stresses
sm = 0 æ 3873 ö
A = (s x ,t xy ) = ç 0, 3 ÷
è d ø
3873
tm = 3 3873 æ 3873 ö
d t xy = 3 B = (s y ,-t xy ) = ç 0,- 3 ÷
d è d ø
t
A
3873
3873
d3
(t max )m = 3
d
3873
(s 1 )m
1/2
s = 3 σ ʹ = ⎡⎣σ 12 − σ 1σ 2 + σ 22 ⎤⎦
( )
d m
6708
3873
- 3 (s 2 )m 3873
=- 3 ( )
σʹ = 3 s ¢ = 3t
d B d
m
d

Using Tresca criterion:
8792.5 17585
(t max )a = 3 s a = 2 *t a =
d3
d
3873 7746
(t max )m = 3 s m = 2 *t m = 3
d d
Using Soderberg criterion:
sa 1sm
+ =
Se Sy n

Endurance Limit Calculation
S e = k a kb kc k d ke k f S e¢
S e¢ = 0.5Sut = 0.5(597.6 MPa) S e¢ = 298.8MPa
Surface condition modification factor:
Source: C.J. Noll and C. Lipson, “Allowable Working Stresses,” Society for Experimental Stress Analysis, vol. 3, no. 2, 1946 p. 29. Reproduced by O.J. Horger
(ed.) Metals Engineering Design ASME Handbook, McGraw-Hill, New York. Copyright © 1953 by The McGraw-Hill Companies, Inc. Reprinted by permission.
k a = aS = 4.51(597.6)
b
ut
-0.265
k a = 0.828
Size modification factor:
The diameter obtained by static design (d=37 mm) allow to come near to the
fatigue design diameter. So the fatigue design diameter can be approach from
20% to 30% more than the static diameter: (37*1.25=46.25mm).
2.79 ≤ d ≤ 51 mm kb = 1.24d -0.107 = 1.24(48) -0.107

kb = 0.819
Load modification factor:
The flexion govern the design due their higher values: kc = 1.0
Temperature modification factor:
The shaft works to room temperature: k d = 1.0
Reliability factor:
For 90% of reliability: ke = 0.897
Source: Budynas−Nisbett, Shigley’s. Design of Mechanical Mechanical Engineering Elements, Eighth Edition
Miscellaneous-effects modification factor:

There are not special effects to take into account: k f = 1.0
Se = (0.828)(0.819)(1.0)(1.0)(0.897)(1.0)(298.8 MPa)
Se = 182 MPa
So:
17585 7746
sa = sm = 3
d3 d
Applying Soderberg criterion:
17585 7746
sa sm
1 d3 + d3 1
+ = =
Se Sy n 6 6
182 x10 351.5 x10 1.8
17585 7746 1
6 3
+ 6 3
=
182 x10 (d ) 351.5 x10 (d ) 1.8
1.187 x10 -4 1
3
= d = 0.060 m d = 60 mm
d 1.8
Doing a first iteration:
51< d ≤ 254 mm kb = 1.51d -0.157

kb = 1.51(60) -0.157 kb = 0.794
Se = (0.828)(0.794)(1.0)(1.0)(0.897)(1.0)(298.8 MPa) Se = 176.2 MPa

17585 7746
sa sm
1 d3 d 3 1
+ = + =
Se Sy n 6 6
176.2 x10 351.5 x10 1.8
d = 0.0603 m d = 60.3 mm

Part B
Suppose that the diameter of the shaft
decrease into D bearing, so calculate the
diameter necessary from D to E.

r Assuming a notch radius of 1.6 mm so d
should be at least of 60.3-2x1.6=57.1 mm.
D=50.2 d
If the diameter of the shaft is 50, we can
calculate Kt.
r 1.6 D 60.3
= = 0.032 = » 1.2
d 50 d 50
2.1
1.75

K f = 1 + q ( K t - 1) Flexion:
K f = 1+ 0.79(2.1−1)
0.79 K f = 1.87
Torsion:
K fs = 1+ 0.79(1.75−1)
Source: George Sines and J. L. Waisman (eds.), Metal Fatigue, McGraw-

K fs = 1.59
Hill, New York. Copyright 1969 by The McGraw-Hill Companies, Inc.

For D section: TD=351 N.m MD=622 N.m
11848
σ max =+
d3
Mc 32M R 32(622) 11848
σ = Kf = Kf = 1.87 σ=
I πd 3
πd3 d3 11848
σ min = −
d3
2842
τ max =
Tc 16T 16(351) 2842 d3
τ = K fs = K fs 3 = 1.59 τ= 3
J πd πd3 d 2842
τ min =
d3

11848 σ max − σ min 11848
σ max =+ σa = =σ =
d3 2 d3
11848 σ max + σ min

σ min =− σm = =0
d3 2
τ max − τ min
τa = =0
2842 2
τ max = 3
d
τ max + τ min 2995
2842 τm = =τ = 3
τ min = 2 d
d3
Alternating Stresses
11848 ⎛ 11848 ⎞
σa = 11848 A = (σ x , τ xy ) = ⎜ 3 ,0 ⎟
d3 σa = ⎝ d ⎠
d3
ta = 0 B = (s y ,-t xy ) = (0,0 )
t
5924
( )
τ max = 3
a
d
A 11848 1/2
B 11848 s (σ 1 )a = d 3 σ ʹ = ⎡⎣σ 12 − σ 1σ 2 + σ 22 ⎤⎦
( )a
d3
11848
(s 2 )a = 0 ( )
σʹ =
a
d3

Midrange Stresses
⎛ 2842 ⎞
sm = 0 A = (σ x , τ xy ) = ⎜ 0, 3 ⎟
⎝ d ⎠
2842
τm = 2842 ⎛ 2842 ⎞
d3 τ xy = 3 B = (σ y ,−τ xy ) = ⎜ 0,− 3 ⎟
d ⎝ d ⎠
t
A
2842 2842
d3 ( m
)
τ max = 3
d
2842 1/2
s (σ 1 )m = 3 σ ʹ = ⎡⎣σ 12 − σ 1σ 2 + σ 22 ⎤⎦
( )
d m
2842 2842 4923

− 3
d B ( )σ2 = − 3 ( )
σʹ = 3
m
d
m
d
Endurance Limit Calculation
S e¢ = 298.8MPa
k a = 0.828
kb = 1.51d -0.157 = 1.51(50) -0.157 kb = 0.82
kc = 1.0
k d = 1.0
ke = 0.897
k f = 1.0

S e = (0.828)(0.820)(1.0)(1.0)(0.897)(1.0)(298.8MPa)
S e = 182 MPa
Knowing that:
12608 5990
sa = sm = 3
d3 d
Applying Soderberg criterion:
11848 4923
sa sm
1 d3 + d3 1
+ = =
Se Sy n 6 6
182x10 351.5x10 1.8
11848 4923 1
6 3
+ 6 3
=
182x10 (d ) 351.5x10 (d ) 1.8
7.91x10 1
−5
3
= d = 0.0522 m d = 52.2 mm
d 1.8


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6a Fatigue Strength Example

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Fatigue Strength-Example

Héctor Enrique Jaramillo Suárez, Ph.D.

a.Suppose that the diameter of the shaft decrease into D bearing,

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

N C = FC tan a N C = 101.7 tan 20 N C = 37.0 N

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

x Ax=258.5 N 160.1 N y Ax=250 N 190.8 N

275.8 N 101.7 N Dx=41.1 N 275.8 N 37 N Dx=128 N

0.30 0.45 0.25 0.25 0.30 0.45 0.25 0.25

Prof. Héctor Enrique Jaramillo, Ph.D.

275.8 N 101.7 N Dx=41.1 N

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

σ Maximum σ max − σ min

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

Using Soderberg criterion:

Prof. Héctor Enrique Jaramillo, Ph.D.

2.79 ≤ d ≤ 51 mm kb = 1.24d -0.107 = 1.24(48) -0.107

Load modification factor:

For 90% of reliability: ke = 0.897

Miscellaneous-effects modification factor:

51< d ≤ 254 mm kb = 1.51d -0.157

Se = (0.828)(0.794)(1.0)(1.0)(0.897)(1.0)(298.8 MPa) Se = 176.2 MPa

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

Source: George Sines and J. L. Waisman (eds.), Metal Fatigue, McGraw-

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

11848 σ max + σ min

Prof. Héctor Enrique Jaramillo, Ph.D.

2842 2842 4923

Prof. Héctor Enrique Jaramillo, Ph.D.

Prof. Héctor Enrique Jaramillo, Ph.D.

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