VARIABLE LOADING AND STRESS

CONCENTRATION
Elements of Theory of Machines and Machine Design

Md. Arif Mahmud Shuklo Shoshe

Fall 2020
Ahsanullah University of Science and Technology
Table of contents

1. Fatigue Failure due to Variable Loading

2. Endurance Limit of Rotating-Beam Specimen

3. The Fatigue Strength

4. The Marin equation

5. Stress Concentration

1
Fatigue Failure due to Variable
Loading
Fatigue Failure

• O ten, machine members are found to have failed under the

action of repeated or fluctuating stresses.

2
Fatigue Failure

• O ten, machine members are found to have failed under the

action of repeated or fluctuating stresses.
• Careful analysis reveals that the actual maximum stresses were
well below the ultimate strength of the material, and quite
frequently even below the yield strength.

2
Fatigue Failure

• The most distinguishing characteristic of these failures is that

the stresses have been repeated a very large number of times.

3
Fatigue Failure

• The most distinguishing characteristic of these failures is that

the stresses have been repeated a very large number of times.
• Hence the failure is called a fatigue failure.

3
Fatigue Failure

• Generally static failures give visible warning in advance.

4
Fatigue Failure

• Generally static failures give visible warning in advance.

• Fatigue failure is sudden and total, and hence dangerous.

4
Endurance Limit of
Rotating-Beam Specimen
 9 8 in R.
ength and at the
S − N diagrams or Wöhler diagrams
sed section at
t of the beam.

6–10 Low cycle High cycle

ram plotted from Finite life Infinite

f completely life
al fatigue tests.
Sut
NS G41300 steel,
Sut 5 116 kpsi;
100
t 5 125 kpsi.
Fatigue strength Sf , kpsi

NACA Tech.
December 1966.)

50 Se

100 101 102 103 10 4 10 5 106 107 108

Number of stress cycles, N

An S − N diagram plotted from the results of completely reversed axial

fatigue tests.
5
The Endurance Limit of Rotating-Beam Specimen, S′e

• The amplitude of cyclic stress that can be applied to the material

without causing fatigue failure is called the Endurance Limit, S′e .

6
The Endurance Limit of Rotating-Beam Specimen, S′e

• The amplitude of cyclic stress that can be applied to the material

without causing fatigue failure is called the Endurance Limit, S′e .
• {
0.5Sut Sut ≤ 1400 MPa
S′e =
700 MPa Sut > 1400 MPa
The prime mark on S′e in this equation refers to the
rotating-beam specimen itself.

6
The Fatigue Strength
The Fatigue Strength

• For the actual mechanical component, the fatigue strength, Sf

can be written in the form,

Sf = aNb

7
The Fatigue Strength

• For the actual mechanical component, the fatigue strength, Sf

can be written in the form,

Sf = aNb

• Where,
(f × Sut )2
a=
Se

7
The Fatigue Strength

• For the actual mechanical component, the fatigue strength, Sf

can be written in the form,

Sf = aNb

• Where,
(f × Sut )2
a=
Se

• And,
1 (f × S )
ut
b = − log
3 Se

7
The Marin equation
Endurance Limit Modifying Factors

• The rotating-beam specimen used in the laboratory to

determine endurance limits is prepared very carefully and
tested under closely controlled conditions.

8
Endurance Limit Modifying Factors

• The rotating-beam specimen used in the laboratory to

determine endurance limits is prepared very carefully and
tested under closely controlled conditions.
• It is unrealistic to expect the endurance limit of a mechanical or
structural member to match the values obtained in the
laboratory.

8
Endurance Limit Modifying Factors

• The rotating-beam specimen used in the laboratory to

determine endurance limits is prepared very carefully and
tested under closely controlled conditions.
• It is unrealistic to expect the endurance limit of a mechanical or
structural member to match the values obtained in the
laboratory.
• For an actual mechanical component, S′e is reduced to Se .

8
Marin equation

• Joseph Marin identified factors that quantified the effects of

surface condition, size, loading, temperature, and miscellaneous
items.

9
Marin equation

• Joseph Marin identified factors that quantified the effects of

surface condition, size, loading, temperature, and miscellaneous
items.
• A Marin equation is therefore written as

Se = ka kb kc kd ke kf S′e

9
Marin equation

Where,

• Surface Factor, ka
• Size Factor, kb
• Loading Factor, kc
• Temperature Factor, kd
• Reliability Factor, ke
• Miscellaneous Factor, kf
• Rotary-Beam test specimen endurance limit, S′e
• Endurance limit at the critical location of a machine part in the
geometry and condition of use, Se

10
Factors of Marin equation

Surface Factor, ka
b
ka = aSut (6-19)
Values of a and b should be taken from from Table 6-2.

Size Factor, kb
For axial loading,
kb = 1 (6-20)

For bending and torsion may be expressed as,

{
1.24d−0.107 2.79 ≤ d ≤ 51 mm
kb = (6-21)
−0.157
1.51d 51 < d ≤ 254 mm

d here is the diameter of the sha t.

11
Factors of Marin equation

Loading Factor, kc 

1
 bending
kc = 0.85 axial (6-26)


0.59 torsion

Temperature Factor, kd
kd = 1 (6-28)

(Sut )T = (ST /SRT ) × (Sut )RT (6-28a)

Value of ST /SRT should be taken from Table 6-4.

12
Factors of Marin equation

Reliability Factor, ke
ke = 1 − 0.08za (6-29)
Value of ke can be taken found directly from Table 6-5 for standard
reliabilities.

Miscellaneous Factor, kf
kf = 1 (Assumed, if not given specifically)

13
Problem

Problem 1
For a 1050 hot rolled steel, estimate,

(a) Rotating beam endurance limit at 106 cycles.

(b) The endurance strength of a polished rotating beam specimen
corresponding to 104 cycles to failure.
(c) The expected life of a polished rotating-beam specimen under a
completely reversed stress of 385 MPa.

14
Problem

Problem 2
An AISI 1015 hot-rolled steel bar has been machined to a diameter of
25 mm. It is to be placed in reversed bending for 70,000 cycles to
failure in an operating environment of 300o C. Using ASTM minimum
properties, and a reliability of 99 percent, estimate the endurance
limit and fatigue strength at 70,000 cycles.

15
Stress Concentration
Stress Concentration

• Stresses at or near a discontinuity, such as a hole in a plate, are

higher than if the discontinuity did not exist.

16
Stress Concentration

• Stresses at or near a discontinuity, such as a hole in a plate, are

higher than if the discontinuity did not exist.
• A stress raiser is any discontinuity in a part that alters the stress
distribution so that the elementary stress equations no longer
describe the stress in the part.

16
Stress Concentration

P P

a
(a)

σmax
P

• (b)

(a) Plate with cross-sectional plane. (b) Half of plate showing stress
distribution.

17
Stress Concentration

P P

a
(a)

σmax
P

• (b)

(a) Plate with cross-sectional plane. (b) Half of plate showing stress
distribution.

• The stress concentration is the region where stress raisers are

present.

17
Stress Concentration

• The stress concentration factor, Kc, is the factor used to relate

the actual maximum stress at the discontinuity to the average or
nominal stress.

18
Stress Concentration

• The stress concentration factor, Kc, is the factor used to relate

the actual maximum stress at the discontinuity to the average or
nominal stress.
•
σmax
Kc =
σnom

18
Preferred Design

Fracture Toughness

P P P P

(a) (c)

P P P P

(b) (d)

Axially loaded flat plate with fillet showing stress contours: (a) square
corners, Kc = 3; (b) rounded corners, Kc = 1.5; (c) small grooves, (Preferred)
and (d) small holes, (Preferred).

19
Preferred Design

•
Preferred Design for Stepped Sha t.

20
Preferred Design

•
Preferred Design for Stepped Sha t.

•
Preferred Design for Screws.

20
Problem

Problem 3
An AISI 1060 hot-rolled steel bar has been machined into a shoulder
with a fillet radius of 5.25 mm connecting a 30 mm diameter with a 45
mm diameter as shown in the figure below. It is to be placed in
reversed axial loading for 50,000 cycles to failure in an operating
environment of 550o C. Using ASTM minimum properties, and a
reliability of 99.9 percent, estimate the endurance limit and fatigue
strength at 50,000 cycles. Consider fatigue stress-concentration
factor Kf .

21
Questions?

21