Mechanical

Design of Machine Elements

Complete a"er to watching Module 44 and Worksheet 14

Quiz 4: Fluctua0ng Fa0gue and Miner’s Rule

1) The steel bar with the geometry shown below has an axial fluctua3ng load applied from -5000 lbf to 12000 lbf.
The bar has a hole with a 0.25 inch diameter, is 0.25 inches thick, a fillet radii of 0.175 inches, and a notch sensi3vity
factor q = 0.95. The fully adjusted endurance limit of the bar is 40 ksi, the bar has an ul3mate strength of 185 ksi,
and a fa3gue strength frac3on f = 0.78. Using the Goodman criteria, determine the most conserva3ve N to design
to, where N is the life of the bar in terms of cycles to failure. (Most conserva3ve N to design to= worst case
scenario).
0.25“ 0.25“
0.175“

1.50“

+ 1.00“

0.75“

2.00“

4.00“

Step 1) Determine nominal stresses at the cri3cal points. There are two cri3cal
points on this bar: at the fillet radius where the bar transfers from a large height
to a smaller height, and at the hole.

Stress at the hole:
Fmin −5000lbf
σnom_min_hole = = = −16000 psi = −16ksi
[ H − d ][ t ] [1.50in − 0.25in ][ 0.25in ]

σnom_max _hole= Fmax = 12000lbf
= 38.4ksi
[ H − d ][ t ] [1.50in − 0.25in ][ 0.25in ]

Stress at the fillet:

F −5000lbf
σnom_min_fillet = min = = −20ksi
[ h ][t ] [1in ][ 0.25in ]


σnom_min_fillet = Fmin = 12000lbf = 48ksi
[ h ][t ] [1in ][ 0.25in ]
 Mechanical Design of Machine Elements
Complete a"er to watching Module 44 and Worksheet 14

Quiz 4: Fluctua0ng Fa0gue and Miner’s Rule

1) The steel bar with the geometry shown below has an axial fluctua3ng load applied from -5000 lbf to 12000 lbf.
The bar has a hole with a 0.25 inch diameter, is 0.25 inches thick, a fillet radii of 0.175 inches, and a notch sensi3vity
factor q = 0.95. The fully adjusted endurance limit of the bar is 40 ksi, the bar has an ul3mate strength of 185 ksi,
and a fa3gue strength frac3on f = 0.78. Using the Goodman criteria, determine the most conserva3ve N to design
to, where N is the life of the bar in terms of cycles to failure. (Most conserva3ve N to design to= worst case
scenario).
0.25“ 0.25“
0.175“

1.50“

+ 1.00“

0.75“

2.00“

4.00“

Step 2) Add in stress concentra3on factors to find actual max stresses at these
loca3ons.

Kt at hole
d/H = 0.25/1.5 = 0.167. From graph, Kt = 2.6.
Kf = 1+0.95(2.6-1) = 2.52

σmin_hole = -16.00 ksi * 2.52 = -40.32 ksi
σmax _hole = 38.40 ksi * 2.52 = 96.77 ksi


Kt at fillet
H/h = 1.5/1 = 1.5
r/h = 0.175/1 = 0.175. From graph, Kt = 1.8
Kf = 1+0.95(1.8-1) = 1.76

σmin_fillet = -20.00 ksi * 1.76 = -35.20 ksi
σmax _fillet = 48.00 ksi * 1.76 = 84.48 ksi

 Mechanical Design of Machine Elements
Complete a"er to watching Module 44 and Worksheet 14

Quiz 4: Fluctua0ng Fa0gue and Miner’s Rule

1) The steel bar with the geometry shown below has an axial fluctua3ng load applied from -5000 lbf to 12000 lbf.
The bar has a hole with a 0.25 inch diameter, is 0.25 inches thick, a fillet radii of 0.175 inches, and a notch sensi3vity
factor q = 0.95. The fully adjusted endurance limit of the bar is 40 ksi, the bar has an ul3mate strength of 185 ksi,
and a fa3gue strength frac3on f = 0.78. Determine the most conserva3ve N to design to, where N is the life of the
bar in terms of cycles to failure. (Most conserva3ve N to design to= worst case scenario).

0.25“ 0.25“
0.175“

1.50“

+ 1.00“

0.75“

2.00“

4.00“

Step 3) At the hole and fillet loca3on, determine alterna3ng and midrange
stresses, and if there is infinite life or not using the Goodman criteria.

At the hole:

σ hole _ a = σ max − σ min = 68.54ksi n=
1
=
1
= 0.54
2 σ σ 68.54 28.22
a
+ m
+
σ hole _ m = σ max + σ min = 28.22ksi Se Sut 40 185
2

Infinite life is not projected.

At the fillet:
σ − σ min 1 1
σ fillet _ a = max = 59.84ksi n= = = 0.61
2 σ a σ m 59.84 24.64
σ max + σ min + +
σ = = 24.64ksi Se Sut 40 185
fillet _ m
2
Infinite life is not projected.


 Mechanical Design of Machine Elements
Complete a"er to watching Module 44 and Worksheet 14

Quiz 4: Fluctua0ng Fa0gue and Miner’s Rule

1) The steel bar with the geometry shown below has an axial fluctua3ng load applied from -5000 lbf to 12000 lbf.
The bar has a hole with a 0.25 inch diameter, is 0.25 inches thick, a fillet radii of 0.175 inches, and a notch sensi3vity
factor q = 0.95. The fully adjusted endurance limit of the bar is 40 ksi, the bar has an ul3mate strength of 185 ksi,
and a fa3gue strength frac3on f = 0.78. Determine the most conserva3ve N to design to, where N is the life of the
bar in terms of cycles to failure. (Most conserva3ve N to design to= worst case scenario).

0.25“ 0.25“
0.175“

1.50“

+ 1.00“

0.75“

2.00“

4.00“

Step 4) As infinite life is not predicted, need a sigma equivalent. It is clear from
the alterna3ng and midrange stresses that the highest stress will be at the hole,
so that will be the worst case scenario.
At the hole:

σ rev _ eq = σ a = 68.54 = 80.88
σ 28.23
1− m 1−
Sut 185



1 1

a=
( fSut )2 [(0.78)(185)]2
= = 520.56 ⎛σ ⎞ b
⎛ 80.88 ⎞ −0.186
N = ⎜ rev ⎟ =⎜ = 22280
Se 40 ⎝ a ⎠ ⎝ 520.66 ⎟⎠
1 ⎛ fS ⎞
b = − log ⎜ ut ⎟ = −0.186
3 ⎝ Se ⎠

Answer: between 17000 and 29000 cycles (accoun3ng for rounding and Kt
selec3on)
 Theore3cal Stress Concentra3on Factor Kt
2.4 r
F D d F
2.2
σnom= d*t
D/d = 1.5 where t is the
Kt bar thickness
2.0

1.8

1.6
0.05 0.10 0.15 0.20
r/d

Theore3cal Stress-Concentra3on Factor Kt

By Cdang [CC0], via Wikimedia Commons

hgps://commons.wikimedia.org/wiki/File%3AKt_plaque_percee_symetrique_trac3on.svg
Mechanical Design of Machine Elements
Complete a"er to watching Module 44 and Worksheet 14

Quiz 4: Fluctua0ng Fa0gue and Miner’s Rule
The varying, fluctua3ng stresses shown to the below are found at the cri3cal loca3on
of a component. The material is steel, the fully adjusted endurance limit is 25 ksi, the
ul3mate strength is 200ksi. The fa3gue strength frac3on is f = 0.77.

1) What is the life of the part in hours if this 6 second stress pagern con3nues to
repeat for the remainder of the part’s life?

σ ksi
80

60

40

20
0 t (sec)
-20

-40

-60

-80
Mechanical Design of Machine Elements
Complete a"er to watching Module 44 and Worksheet 14

Quiz 4: Fluctua0ng Fa0gue and Miner’s Rule
The varying, fluctua3ng stresses shown to the below are found at the cri3cal loca3on
of a component. The material is steel, the fully adjusted endurance limit is 25 ksi, the
ul3mate strength is 200ksi. The fa3gue strength frac3on is f = 0.77.

1) What is the life of the part in hours if this 6 second stress pagern con3nues to
repeat for the remainder of the part’s life?
n sigma min sigma max sigma a sigma m

Cycle 1 2 -20 10 15 -5

Cycle 2 3 -20 40 30 10

Cycle 3 2 -40 60 50 10

( fSut )2 [(0.77)(200)]2
a = Se = 25
= 948.6
1 ⎛ fSut ⎞
b = − 3 log ⎜⎝ S ⎟⎠ = −0.26

e

Cycle 1 has two repe33ons. The alterna3ng and midrange stresses are both
below the endurance limit. Checking the Goodman factor of safety:

1 1
n = = = 1.74
σ a σ m 15 −5
+ +
Se Sut 25 200

Therefore, life is infinite for cycle 1.

Cycle 2 is fluctua3ng, with three total cycles. and to calculate the number of
cycles, a sigma equivalent is necessary
σa 30 1 1
σ rev _ eq = = = 31.58 ⎛ σ rev ⎞ b ⎛ 31.58 ⎞ −0.2632
σ N =⎜ =⎜ = 411506
1− m 1−
10 ⎝ a ⎟⎠ ⎝ 948.64 ⎟⎠
Sut 200


Mechanical Design of Machine Elements
Complete a"er to watching Module 44 and Worksheet 14

Quiz 4: Fluctua0ng Fa0gue and Miner’s Rule
The varying, fluctua3ng stresses shown to the below are found at the cri3cal loca3on
of a component. The material is steel, the fully adjusted endurance limit is 25 ksi, the
ul3mate strength is 200ksi. The fa3gue strength frac3on is f = 0.77.

1) What is the life of the part in hours if this 6 second stress pagern con3nues to
repeat for the remainder of the part’s life?
n sigma min sigma max sigma a sigma m

Cycle 1 2 -20 10 15 -5

Cycle 2 3 -20 40 30 10

Cycle 3 2 -40 60 50 10

( fSut )2 [(0.77)(200)]2
a = Se = 25
= 948.6
1 ⎛ fSut ⎞
b = − 3 log ⎜⎝ S ⎟⎠ = −0.26

e

Cycle 3 is fluctua3ng, with twototal cycles. and to calculate the number of

cycles, a sigma equivalent is necessary

σ 50
1 1
⎛ σ rev ⎞ b ⎛ 52.63 ⎞ −0.26
σ rev _ eq = σa = = 52.63 N =⎜ =⎜ = 59086
− −
10 ⎝ a ⎟⎠ ⎝ 948.64 ⎟⎠

m
1 1
Sut 200


n 2 3 2
D=∑ i = + + = 0.000041
N i inf inity 411406 59086

1 6sec 1min 1hr

time = * * * = 40.51hrs
0.000041 1cycle 60sec 60 min