Aerostructure-Fatigue Analysis

By

Dr. Mahdi Damghani

2022-2023

1
Suggested Readings

Reference 1 Reference 2

Chapter 6 of Ref [1], Chapter 4 of Ref [2]

2
 Topics

• Familiarisation with fatigue of metals

• Life estimates
• Endurance limit
• Fluctuating stresses
• Stress concentration and Notch sensitivity

3
 Scope
• Safe-life design (developed in the early • Damage tolerant design (developed
60s)
• Scope of this lecture.
• The structure is assumed to be
flaw free.
• Is not adequate due to in-
service damage and
manufacturing defects.
• Is based on uncertainty that
crack will not initiate at some
time during the aircraft life and
these crack must be detected
before the strength drops
below a certain level.
in the early 70s)
• Formation of crack (nucleation)
and monitoring its progression
and grow th up to the point of
part rupture.
• Is based on fracture
mechanics, to size structure so
that crack grow s at a stable,
slow rate and not achieve a
size large enough to fail the
structure before detection.
• Determination of inspection
intervals.
• Requires understanding
structural performance in the
presence of damage.
4
 Introduction

• In most testing of those properties of materials that relate to the

stress-strain diagram, the load is applied gradually, to give
sufficient time for the strain to fully develop;
• Furthermore, the specimen is tested to destruction, and so the
stresses are applied only once;
• Testing of this kind is applicable, to what are known as static
conditions;
• The condition frequently arises, however, in which the stresses
vary with time or they fluctuate between different levels.
• For example, a particular fiber on the surface of a rotating shaft
subjected to the action of bending loads undergoes both tension
and compression for each revolution of the shaft.

5
 Introduction
Climbing to
cruising altitude Descending and
Push back from Manoeuvring to Aligning the
Speeding down plane with
the gate, taxi to the destination
the runway runway
the runway
Landing, taxis to the
gate and parking at
terminal

Taken from:
http://science.how stuffworks.com/transport/flig
ht/modern/air-traffic-control1.htm

6
Overall process of fail safe fatigue
design for primary structures

I w ill explain all

these aspects in
this lecture

7
 Introduction

• Some cyclic loads in aircrafts;

• Push back (on landing gear)
• Turning (high stresses on landing gear)
• Taxi
• Take off
• Cabin pressurisation
• Landing impact
• Undercarriage loading
• Global/local turbulence
• Gust and manoeuvre

8
 Introduction

• Often, machine members are found to have failed

under the action of repeated or fluctuating stresses;
• The most 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;
• 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.

9
 Introduction

• Fatigue failure;
• Gives no warning (no large deflection etc) and it is very
sudden=brittle fracture;
• Dangerous (because it is sudden);
• Complicated phenomenon (partially understood);
• Life of a component must be obtained based on empirical
methods.

10
Introduction

Grow th of surface micro-

cracks of aircraft tow bar
as the result of fatigue
loading leading to failure

11
Introduction

12
Introduction

Fatigue crack at stress

raiser (discontinuity, i.e.
hole) due to stress
concentration

13
 Introduction

• The incidence of fatigue failure dominates the distribution

in aircraft;
• Fatigue is the predominant failure mode in service.
Frequency of failure mechanisms since 1980s

% of failures

Engineering components Aircraft components

Corrosion 29 16
Fatigue 25 55
Brittle fracture 16 -
Overload 11 14
High temperature corrosion 7 2
SCC/Corrosion fatigue/HE 6 7
Creep 3 -
Wear/abrasion/er osi on 3 6

14
 Introduction

• Micro-cracks formation on the surface of part due to

cyclic plastic deformations;
• During cyclic loading, these cracked surfaces open
and close, rubbing together;
• The beach mark appearance depends on the
changes in the level or frequency of loading and the
corrosive nature of the environment;
• Cracks keep growing up to a critical length and
suddenly part fails.

15
 Fatigue analysis approaches
• Stress-life method;
• Will be covered in the lecture
• Strain-life method;
• Beyond the scope of this lecture
• Linear elastic fracture mechanics method;
• Beyond the scope of this lecture

• Generally speaking we have;

• Low cycle fatigue (1<=N<=10 3)
• High cycle fatigue (N>10 3)

16
 Stress-life method

• The least accurate method;

• Specially for low cycle fatigue.
• Good approximation for high cycle fatigue;
• Assumes little plastic deformation due to cyclic loading;
• The most widely used since mid-1800s;
• A lot of data and understanding is available;
• Good predictions for high cycle fatigue;
• Easy to perform.

17
 Strain-life method

• Detailed analysis of the plastic deformation at

localized regions where the stresses and strains are
considered for life estimates;
• Good for low-cycle fatigue;
• Several idealizations must be compounded, and so
some uncertainties will exist in the results.

18
 Fracture mechanics method

• The fracture mechanics method assumes a crack is

already present and detected;
• It is then employed to predict crack growth with
respect to stress intensity;
• It is most practical when applied to large structures in
conjunction with computer codes and a periodic
inspection program;
• Currently Airbus uses this method in combination with
stress-life method.

19
 Stress-life method

• To determine the strength of materials under the

action of fatigue loads, specimens are subjected to
repeated or varying forces of specified magnitudes
while the cycles or stress reversals are counted to
destruction;
• Therefore, graphs of subsequent slides (S-N
diagrams) can be produced.

20
Watch (https://w ww.youtube.com/watch?v=LhUclxBUV_E)

21
 Fatigue machine (for R = -1 only)

• R. R. Moore high-speed
rotating-beam machine;
• Specimen is subjected
to pure bending (no
transverse shear) by
means of weights;

• The specimen is very carefully machined and

polished, with a final polishing in an axial direction to
avoid circumferential scratches and minimize surface
roughness.

22
 R. R. Moore machine

• When rotated one half

revolution, the stresses in
the fibers originally below
the neutral axis are
reversed from tension to
compression and vice
versa;
• Upon completing the
revolution, the stresses
are again reversed so that
during one revolution the
test specimen passes
through a complete cycle
of flexural stress (tension
and compression).

23
Electro-hydraulic axial fatigue
machine (for all R values)

24
Output from fatigue test (see Ref [2])
Stress in the component some
Stress books use symbol σ instead
Each cycle is equal
to two reversals

time

The number of cycles to failure is called

fatigue life N f

25
 Fluctuating stresses

S min = minimum stress

S max = maximum stress
Sa = amplitude component
S m = midrange stress
S r = range of stress

S max − S min S r
Sa = =
2 2 S min Sa 1 − R
R= A= =
S max + S min S max Sm 1 + R
Sm =
2
S r = S max − S min Amplitude
Stress ratio
ratio

26
S-N/Wohler diagram (see Ref [1])

Results of completely
reversed axial fatigue tests.
Material: UNS G41300 steel,
normalized; S ut = 116 kpsi;
maximum S ut = 125 kpsi.

Often plotted in log-log or semi-log graphs. If

plotted in log-log, y axis is in terms of stress
amplitude or stress range and x axis in terms
of number of reversals or cycles to failure

27
How SN curve is established
My I =0.25r 4 , y = r 2nw1a
 max = ⎯⎯ ⎯ ⎯⎯→  max = − min =
I r 3

w1
w1
w1

28
S-N bands for Aluminium alloys for
completely reversed cycling

29
Fatigue strength in log-log S-N curve
(Sf) a is fatigue
S a = a (N f )
strength when N f b a and b are
is 1 cycle only constants for
cycles 10 3-10 7
Cycles to
the failure

S1000

log S1000 − log S e 1 S 

b= = − log 1000 
log 103 − log 107 3  Se 

Se Endurance limit

107 Fatigue life, i.e. life

required to nucleate
and grow a small
crack to visible crack
length
30
Note

• S-N curve in the

previous slide was for
one load ratio only
(R=Smin /Smax) but in
practice we have so
many load ratios (R) so
we need more graphs.

31
 Note

• Real S-N curve for

various load ratios
for un-notched
plate of Aluminium
7050-T7451
tested in long
transverse
direction.

Source:
Metallic Materials Properties Development and Standardization (MMPDS)

32
 Endurance limit of steel vs aluminium (Se)

• Endurance limit;
• The maximum
stress which can
be applied to a
material for an
infinite number of
stress cycles
without resulting in
failure of the
material.

See how steel (graph A)

has pronounced endurance
limit whereas aluminium
(graph B) does not have a
very clear endurance limit

33
 Endurance limit (Se)

• For example for steel material the endurance limit can

be obtained by the following relationship;

• Note that this is achieved from experiments and is for

fatigue test specimen not real life loading.

34
 Endurance limit (Se)

• In real life endurance limit can be different due to

many factors (see Ref [1] for more details);

35
 Fatigue prone locations

• The following locations in the structure are prone to

fatigue failure (formation of crack) due to stress
concentration and therefore illustrated in subsequent
slides;
• Holes
• Notches
• Lugs
• Pins
• Fillets
• Joints

36
 Stress Concentration and Notch
Sensitivity

• Any discontinuity in a machine part alters the stress

distribution in the immediate vicinity of the
discontinuity;
• Elementary stress equations no longer describe the
state of stress in the part at these locations;
• Such discontinuities are called stress raisers;
• Regions in which they occur are called areas of stress
concentration.

37
Stress concentration

Hole Hole Notch

38
Stress concentration in aircraft

39
Stress Concentration around a circular hole subjected to
remote loading in an infinite composite panel

40
 Stress concentration factor

• A theoretical, or geometric, stress-concentration

factor Kt or Kts is used to relate the actual maximum
stress at the discontinuity to the nominal stress
(remote stress);

• Stress concentration factor depends on;

• The geometry of structure
• Type of loading (uni-axial, bi-axial, bending moment etc)

41
 How to get stress concentration value?

• Experimental procedures;
• Photoelasticity;
• grid methods;
• brittle-coating methods;
• Electrical strain-gauge methods.
• Finite element analysis;
• Not exact.
• Analytical approaches based on conformal mapping
and complex algebra.

42
Stress concentration value

43
Stress concentration value

44
Stress concentration for a shaft under
bending load and axial load

45
Stress concentration for a notched shaft
under bending load and axial load

46
Stress concentration for a prismatic bar
under bending load and axial load

47
Stress concentration for a plate with a central
hole under bending load and axial load

48
 Fatigue Stress Concentration Factor

Fatigue stress Fatigue stress concentration

concentration factor factor is lower than elastic stress
concentration factor

0  q 1
Notch sensitivity

In analysis or design work, find K t

first, from the geometry of the part.
Then specify the material, find q, and
solve for K f from the equation

49
Notch sensitivity

50
Notch sensitivity

51
 Note

• In using these charts it is well to know that the actual

test results from which the curves were derived
exhibit a large amount of scatter;
• It is always safe to use Kf = Kt if there is any doubt
about the true value of q;
• Often q is not far from unity for large notch radii.

52
Industrial examples of fatigue critical
locations (lugs in flap track)

53
Industrial examples of fatigue critical
locations (fillets in flap track)

Fillet A

54
Industrial examples of fatigue critical
locations (buttstraps)

55
Industrial examples of fatigue critical
locations (buttstraps)

56
Industrial examples of fatigue critical
locations (buttstraps)

Cover

Buttstrap

Panel

57
Industrial examples of fatigue critical
locations (strut brackets)

58
Industrial examples of fatigue critical
locations (baffle panels)

59
Industrial examples of fatigue critical
locations (baffle panels)

60
Industrial examples of fatigue critical
locations (joints)

61
 Example 1

• A steel shaft in bending has an ultimate strength of

690MPa and a shoulder with a fillet radius of 3mm
connecting a 32mm diameter with a 38mm diameter.
Estimate Kf .

62
 Solution

D / d = 38 / 32 = 1.18
r / d = 3 / 32 = 0.093
K t = 1.65

63
 Solution

q = 0.84

K f = 1 + q(K t − 1)
K f = 1 + 0.84(1.65 − 1) = 1.55

64
 Example 2

• A plate with thic kness h=4 mm is subjected to an

alternating load P. The plate is subjected to a load cycle
Pmin=10 kN and Pmax=80 kN. Considering the notch
sensitivity factor of q = 0.9 calculate the life of panel.
Assume a=1600 MPa and b=-0.2 and material ultimate
strength is 600 MPa.
400mm

P 50mm 250mm
P

65
 Solution
We know :
S a = a (N f )
b

S max − S min S r
Sa = =
2 2 d = 50 = 0.2 → K t = 2.5
S + S min w 250
S m = max K f = 1 + 0.9(2.5 − 1) = 2.35
2

K f Pmax 80000 K f Pmin 10000

S max = = 2.35 = 188MPa → Smin = = 2.35 = 23.5MPa →
A 4  250 A 4  250

82.25 = 1600 ( N f )
188 − 23.5 −0.2
Sa = = 82.25MPa → N f = 2785610cycles
2

66
 Solution

• Solve the same question assuming that the hole

exists on a plate with infinite length and width;
• What is the difference between this situation and
previous situation?

67
Example 3

• Calculate maximum and minimum stresses and the

load ratios for the following set of cycles, expressed
as a stress range and mean stress.
S (ksi) S m (ksi)
20 30

25 12.5

33 11.5

11 29.5

60 20

90 25

68
 Solution

S = S max − S min , R = S min → S = S max − RS max = S max (1 − R ) → S max = S (1 − R )

S max

S max + S min S max (ksi)

S = S max − S min , S m = → S min (ksi)
2
20 40
S + S min = S max
 → 2S m = S + S min + S min →
2 S m = S max + S min
0 25

-5 28
2S m = S + 2S min → S m − 0.5S = S min
24 35
• Let’s calculate for one entry only; -10 50
S min = 30 − 0.5  20 = 20ksi
-20 70
S max = S + S min = 20 + 20 = 40ksi

69
 Example 4

• Use the following equation to calculate the number of

cycles to failure for the maximum stress and load
ratios calculated in Example 3. Note that the equation
is for Aluminium 2024-T3 material for Kt=1.


log N = 20.83 − 9.09 log S max (1 − R )
0.52


70
 Solution
• Let’s calculate for one entry only;
  20  0.52 
20.83−9.09 log  40  1−  
  40  
N = 10 = 48998554

S min (ksi) S max (ksi) R Nf

20 40 0.5 48998554

0 25 0.0 132655518

-5 28 -0.18 21779524

24 35 0.69 1480700983

-10 50 -0.2 102823

-20 70 -0.29 3485

71
 Tutorial 1

• A rotating shaft simply supported in ball bearings at A

and D and loaded by a nonrotating force F of 6.8 kN.
Estimate the life of the part assuming;
• All shoulder fillets have radius of 3mm
• Sut = 690MPa and Sy = 580MPa (ultimate and yield strength)
• Se = 236MPa (endurance limit)
• q=0.84
• a=1437MPa
• b=-0.1308

72
 Solution for Tutorial 1

• The first task is to see where the fatigue failure could

potentially happen
• We know fatigue usually happens at discontinuity,
notches, fillets etc where stress is high
• In this problem potential places are points B and C
• So we investigate these locations

73
Solution for Tutorial 1
Kt _ B = ?
K f _ B = 1 + q(K t − 1) = ?

We solved this in
previous example,
see below

K f _ B = 1 + q(K t − 1) =
1 + 0.84(1.65 − 1) = 1.55

74
 Solution for Tutorial 1

• Let’s calculate fatigue stress concentration at point C,

too.

D / d = 38 / 35 = 1.08
r / d = 3 / 35 = 0.086
K t _ C = 1.6

75
 Solution for Tutorial 1

q = 0.84

K f _ C = 1 + q(K t − 1)
K f _ C = 1 + 0.84(1.6 − 1) = 1.5

76
 Solution for Tutorial 1

Based on these
stresses w here does
fatigue likely to
happen?

225
R1 = 6.8 = 2.78kN R2 = 6.8 − 2.78 = 4.02kN
550

M B = 2.78  250 = 695.5( N .m)

M B = 4.02 125 = 502.5( N .m)
CB = I = d 3 / 32 =  323 / 32 CC = I = d 3 / 32 =  353 / 32
ymax ymax
= 3.217 103 (mm3 ) = 4.209 103 (mm3 )

MB 695.5 MC 502.5
SB = K f _ B = 1.55 10 −6 = 335.1MPa SC = K f _ C = 1.50 10 −6 = 179.1MPa
C 3.217 C 4.209

77
 Solution for Tutorial 1

Based
These on these
stresses are both
greater than endurance limit
stresses w here does
of 236MPa and lower than
fatigue
yield stresslikely to
of 580MPa.
What happen?
does this mean?

We have finite life and

material does not
yield

MB 695.5 MC 502.5
SB = K f _ B = 1.55 10 −6 = 335.1MPa SC = K f _ C = 1.50 10 −6 = 179.1MPa
C 3.217 C 4.209

78
Solution for Tutorial 1

S a = a (N f ) →
b

1
 S b
Nf = a  →
 a 
−1
 335.1  0.1308
Nf =  = 68000(cycles)
 1437 

79
 Tutorial 2 (real industrial problem)

• Flap track of an aircraft undergoes 414 occurrences of

cyclic loading that brings about stresses at fillet locations.
Stresses are obtained from detailed finite element analysis
for unit load cases as shown in the next slide. Fatigue life
of component follows the relationship log N f = A − B log(S eq − C )
in which A=10.7, B=3.81, C=10 and
S max S
Seq = (1 − R ) , R = min , D = 0.64
D

KDF S max
It can be further assumed that minimum stresses are zero
and KDF=0.651 (knock down factor due to surface
treatment). Note that above equations are in ksi units.
Calculate the life of component assuming that the fatigue
load on flap is 8841.8 N

80
Tutorial 2 (real industrial problem)

Note: Stresses are in MPa

and obtained for flap load of
1000N (unit load)

81
 Solution for Tutorial 2
S min = 0

 16.4 →R=0
S max = 1000  8841.8 = 145MPa

• Note that max stress need to be adjusted based on

surface treatment
S eq =
145.0
(1 − 0)D = 222.7 MPa → Seq = 222.7 = 32.3ksi
0.651 6.89
• In this example we did not need to use Kf as we are
directly extracting max stresses from detailed FEA
log N f = A − B log(S eq − C ) → N f = 10
(
A− B log S eq −C )
→

N f = 1010.7 −3.81log (32.3−10 ) = 365559.83cycles

82
 Important Notes [3]

• Fatigue damage of components correlates strongly with;

• Applied stress amplitude/range
• Applied mean stress (mostly in high cycle fatigue region)
• In high cycle fatigue, direct (normal) mean stress is
responsible for opening and closing micro-cracks
• Normal tensile mean stresses are detrimental and
compressive mean stress are beneficial for fatigue
strength (why?)
• Shear mean stress has little effect on crack propagation
(see next slide)
• There is no/little effect of mean stress in low cycle fatigue
due to large amount of plastic deformation

83
Fatigue induced cracks and their
opening for various stresses

Opening In-plane shear Out-of-plane shear

84
 Important Notes [3]

• So far, what we have been doing was based on not taking

into account the effects of tensile normal mean stresses on
the high cycle fatigue strength of components
• We have been assuming Sm=0
• Therefore, below scientists proposed empirical equations
to take such effect into account;
• Gerber (1874)
• Goodman (1899)
• Haigh (1917)
• Soderberg (1930)

85
 Influence of tensile normal mean stress on
fatigue strength
• To compensate and understand the influence of tensile normal
mean stress on high cycle fatigue strength, several empirical
plots can be established (constant life plot as below and also see
next slide)

86
 Example of constant life diagrams
• This can be obtained from S-N diagram
This is SN curve for
various mean stress
values
S max − S min S r
Sa = =
2 2
S max + S min
Sm =
2

Increase in life

87
 Fatigue failure criteria for fluctuating
stresses (Haigh plot)
Effective alternating stress at
failure for a life time of Nf cycles
(modified fatigue strength)

Mid-range Yield Ultimate tensile

strength strength strength

88
Note

Unsafe

Safe
Infinite life

89
 Note

• Extension of previously mentioned fatigue criteria will

allow the use of Sar instead of Se

2
Sa  Sm 
2
Sa Sm   Sm 
2
Sa Sm  Sa
+ =1 +   = 1 + =1   +   = 1
S ar S y S ar Sut  
S ar  Sut   S ar   Sy 
• Sar is a fully reversed stress amplitude corresponding
to a specific life in the high-cycle fatigue region

90
General observations
Most actual test data tend to For most fatigue situations R~-1 ( i.e. small
fall betw een the Goodman mean stress in relation to alternating stress),
and Gerber curves there is little difference in the theories

In the range w here the theories show large

differences (i.e. R values approaching 1)
there is little experimental data

The Soderberg line is very conservative and

seldom used

91
 Complex loading and cycle counting

• Instead of a single fully

reversed stress history block
composed of n cycles,
suppose a machine part, at a
critical location, is subjected to
either of;
• A fully reversed stress S1 for n1
cycles, S2 for n2 cycles
• A “wiggly” time line of stress
exhibiting many and different
peaks and valleys

92
 Complex loading and cycle counting

Source: N.E. Dowling, Mechanical behaviour of

materials, 3rd edition, (Pearson / Prentice hall)

• What stresses are significant?

• What counts as a cycle?
• What is the measure of damage incurred?

93
 Methods of cycle counting
• Beyond the scope of this lecture
• Interested readers are recommended to refer to
chapter 3 of Ref. [3];
• Level crossing cycle counting
• Peak-valley cycle counting
• Range counting
• Three-point cycle counting method
• Four-point cycle counting method
• Rain-flow counting technique

94
 Output from cycle counting
• A typical result of cycle counting would look like;
After cycle counting it
becomes fairly straightforw ard
to calculate stress range and
mean stress values and
proceed as normal

95
 Cumulative damage

• Palmgren-Miner cycle-ratio summation rule (1924), also

called Miner’s rule

• where ni is the number of cycles at stress level Si and

Ni is the number of cycles to failure at stress level S i
• The parameter D has been determined by experiment
• Usually 0.7<D<2.2 with an average value near unity

96
Cumulative damage

97
 Note on cumulative damage

• Damage parameter (D), that is defined in previous

slide, is the ratio of instantaneous to critical crack
length, i.e. D = a / af
• There are other damage models in the literature that
are not linear such as those proposed by
Subramanyan (1976) and Hashin (1980) as below;

98
 Example 3

• A structural member is to be subjected to a series of

cyclic loads which produce different levels of
alternating stress as shown in table below. Determine
whether or not a fatigue failure is probable.

99
 Solution

• We use miner’s cumulative damage theory as below;

ni n1 n2 n3 n4
D=  D= + + + 
Ni N1 N 2 N 3 N 4

10 4 105 106 107

D= + 6+ + = 0.39  1
5 10 10 24 10 12 107
4 7

100
 Example 4

• Calculate the total number of repetitions required for

the loading of example 3 to reach the fatigue failure
point.

101
Solution

1.0 1.0
Repetitions = → Repetitions = = 2.56
 Di 0.39

102
 Example 5

• For the question of Tutorial 2 calculate damage for

the following cases;
• Damage calculation for a single cycle
• Damage calculation for all occurrences of each cycle (each
block)
• Damage calculation for 15000 hours (3000 hours per block)

103
 Solution
• We know from solution that;
log N f = A − B log(S eq − C ) → N f = 1010.7 −3.81log (32.3−10 ) = 365559.83cycles

• Damage is calculated for single occurrence;

ni
D=
1
 D= = 2.73 10 −6
Ni 365559.83

• Damage is calculated for all occurrences;

ni
D=
414
 D= = 1.13 10 −3
Ni 365559.83

• Damage is calculated for 15000 hrs flight;

ni  15000 
D=
414
 D=  = 5.66 10 −3
Ni  3000  365559 .83

104
 Scatter Factor

• Due to scattering of fatigue data and also unknowns,

it is common place to use a factor of safety known as
scatter factor
• This factor can sometimes reach values of 8
• If we assume scatter factor of 8 then we have for the
damage;
D=
ni
  15000  313
D = 8   = 4.53 10 − 2
Ni  3000  365559.83

105
 Example 6
• A square hollow box girder is subjected to a tensile force of 10P and a
transverse shear force P at the beam’s end. The following cycles were
recorded for the load P on the box girder for one year of aircraft’s
service:

• The girder has length L = 1000mm and the hollow squared cross-
section has an edge length of 100mm and uniform thickness of 2 mm.
• Calculate the second moment of area of the cross-section about the
horizontal axis passing through the centroid
• Assuming yield stress of material is 500MPa and using the Soderberg
fatigue criteria, determine the number of repetitions (years) to failure
due to fatigue for the most critical point in the girder.
• Consider the material parameters for the S−N curve as being A =
1800MPa and B = −0.2 and use Miner’s rule.

106
Example 6

107
 Solution

• Second moment of area of section:

• So the maximum stress from the axial and tranverse force is:
10 103  P P 103 1000  50
S max = + = 52.6 P( MPa)
100 2 − 96 2 1.255 106 (the minimum stress is zero)

108
 Solution
• So the mean and the amplitude is:

𝑆𝑎𝑟
The Soderburg line is: 𝑆𝑎 𝑆𝑚 𝑆𝑚
+ =1 → 𝑆𝑎 = 𝑆𝑎𝑟 1 −
𝑆𝑎𝑟 𝑆𝑦 𝑆𝑦

→
𝑆𝑦

109
Solution

𝑆𝑎𝑟 = 𝑆𝑓 = 𝑎𝑁 𝑏
→
→

110
 Tutorial 3
• A solid shaft of circular cross-section w ith a diameter of 40mm is subjected to an
eccentric axial load F at a distance of 10mm from the center of the cross-section
and it is also subjected to a torque T. The loads are applied repeatedly and, for
each repetition, the follow ing load pulsations and number of cycles applies:

Tmin Cycles
Cycle ID Fmin (kN) Fmax (kN) Tmax (kNm)
(kNm) repetition

1 20 100 0 0 5000

2 10 50 0 2 1000

Using the Soderberg fatigue criteria, calculate;

A) Damage to the component
B) Number of repetitions before the rod fails by fatigue
(Note: consider the material yield stress 420MPa and the follow ing material
parameters for the S-N curve: a = 1600MPa and b = -0.2)

111
Tutorial 3

112
 Solution for Tutorial 3
Cycle Tmin Tmax Cycles
Fmin (kN) Fmax (kN)
ID (kNm) (kNm) repetition
1 20 100 0 0 5000

Fmax M max y 100 103  4 100 103 10  20  64

 max = + = + = 238.9 MPa
A I   40 2   40 4
Fmin M min y 20 103  4 20 103 10  20  64
 min = + = + = 47.75MPa
A I   40 2   40 4
 −  min 238.9 − 47.75
 a = max = = 95.6 MPa
2 2
 max +  min 238.9 + 47.75
m = = = 143.3MPa
2 2
a m 95.6 143.3
+ =1 + =1 S ar = 145.11MPa
S ar Sy S ar 420

113
 Solution for Tutorial 3

• From S-N curve we remember;

S ar = S f = aN b  145.11 = 1600 N −0.2  N = 162.972 103 cycles

114
 Solution for Tutorial 3
Cycle Tmin Tmax Cycles
Fmin (kN) Fmax (kN)
ID (kNm) (kNm) repetition
2 10 50 0 2 1000

Fmax M max y 50 10  4 50 10 10  20  64

3 3
 max = + = + = 119.45MPa
A I   40 2   40 4
Fmin M min y 10 103  4 10 103 10  20  64
 min = + = + = 23.89 MPa
A I   40 2   40 4
D
Tr T 2 16T 16  2 106
 max = = = = = 159.15MPa  min = 0
J D 4 D 3   403
32
 max −  min 119.45 − 23.89 159.15 − 0
a = = = 47.78MPa a = = 79.6 MPa
2 2 2
 max +  min 119.45 + 23.89 159.15 + 0
m = = = 71.67 MPa m = = 79.6 MPa
2 2 2

115
 Solution for Tutorial 3

• Since we have both shear and direct stress we convert

then into equivalent von-Mises stress

 aeq =  x2 + 3 xy2 = 47.782 + 3  79.6 2 = 145.9MPa

 meq =  x2 + 3 xy2 = 71.67 2 + 3  79.6 2 = 155.4MPa

• Plug these into Soderberg criterion

 aeq  meq 145.9 155.4
+ =1 + = 1  S ar = 231.6MPa
S ar S y S ar 420

• Finally we get;
S ar = S f = aN b  231.6 = 1600 N −0.2  N = 15.74 103 cycles

116
 Solution for Tutorial 3

• Damage is calculated as;

ni
D= 
5000 1000
D= + = 0.094
Ni 162.97 103 15.74 103

• For part to fail we must have;

N repetition  D = 1 1
N repetition = = 10.614
D
• This means that the component can go through;
10.614  5000 cycles for Cycle 1
10.614 1000 cycles for Cycle 2

117