Dowling Chapter 9: Test 1

Question 1
Which of the following is true for fatigue notch factors, 𝑘𝑓 & 𝑘𝑓′ , used to quantify the effect of a notch
with theoretical stress concentration factor, 𝑘𝑡 .

a) At 1 000 cycles the notch has less than the expected effect calculated 𝑘𝑡 𝑆𝑎𝑟 , due to ductility in
the notch
b) At 1 million cycles the notch effect is modelled accurately by the theoretical stress concentration
factor 𝑘𝑡
c) For notches with a large radius, 𝜌, at its tip, the fatigue notch factor at 1 million cycles become
almost equal to 𝑘𝑡
d) For notches with small radius, 𝜌, 𝑘𝑓 is smaller than 𝑘𝑡
e) Cracks in the notched member will grow into a region of rapidly increasing stress, whereas this
does not occur in the smooth member. As a result, the crack in the notched member will require
less cycles to grow than the one in the smooth member.
f) For high stresses at 1 000 cycles (short life) plastic strains in the notch cause the actual stress
amplitude 𝜎𝑎 < 𝑘𝑡 𝑆𝑎 due to yielding

Answers

a, c, d, f

Question 2
You have a quenched at tempered steel bar with 𝜎𝑢 = 1 900 𝑀𝑃𝑎 that is subjected to completely
reversed rotating bending. The notch radius is 5 mm with theoretical stress concentration factor 1.5.
What is the fatigue notch factor at 1 million cycles when using the Peterson approach (with small margin
of error) that makes provision for the variation in notch sensitivity for 𝜎𝑢 ? Round your answer to the
nearest hundredth.

Solution
According to Peterson for axial or bending:

𝑘𝑓 = 1 + 𝑞(𝑘𝑡 − 1)
1
𝑞= 𝛼
1+
𝜌
log 𝛼 = 2.654 × 10−7 𝜎𝑢2 − 1.309 × 10−3 𝜎𝑢 + 0.01103
𝛼 = 10log 𝛼 𝑚𝑚 𝑓𝑜𝑟 345 ≤ 𝜎𝑢 ≤ 2 070 𝑀𝑃𝑎

With values taken through, the answer is 𝑘𝑓 = 1.50 to the nearest hundredth.

If rounding was done on log 𝛼 and 𝛼, the answer to the nearest hundredth is still 𝑘𝑓 = 1.50.
Question 3
You have a structural steel bar with 𝜎𝑢 = 600 𝑀𝑃𝑎 that is subjected to completely reversed rotating
bending. The notch radius is 5 mm with theoretical stress concentration factor 1.5. What is the fatigue
notch factor at 1 million cycles when using the Peterson approach (with small margin of error) that
makes provision for the variation in notch sensitivity for 𝜎𝑢 ? Round your answer to the nearest
hundredth.

Solution
The answer to the nearest 100th is 𝑘𝑓 = 1.48. Even when rounding is done during calculations.
Question 4
You have a structural steel bar with 𝜎𝑢 = 700 𝑀𝑃𝑎 that is subjected to completely reversed rotating
bending. The notch radius is 5 mm with theoretical stress concentration factor 1.5. What is the fatigue
notch factor at 1 000 cycles when using the Peterson approach (with small margin of error) that makes
provision for the variation in notch sensitivity for 𝜎𝑢 ? Round your answer to the nearest hundredth.

Solution
The answer is 𝑘𝑓 = 1.10, even with rounding in the answers and the use of different approaches.

What if the student used the following function:

300 1.8
𝛼=[ ] × 10−3 𝑖𝑛.
𝜎𝑢 [𝑘𝑠𝑖]
300 × 6.89 1.8
=[ ] × 10−3 × 25.4 𝑚𝑚
𝜎𝑢 [𝑀𝑃𝑎]
= 0.1783
𝑘𝑓 = 1.48
Question 5
Table 10.1 of Dowling lists the parameters for estimating fatigue limits for completely reversed rotating
bending for a variety of parameters, from which S-N curves can be constructed for 50% probability of
survival. The load type factor refers, and specifically the Budynas factors. Is the following statement
correct: ‘The load factor for axial loading is 0.85 because in the axial load condition a larger volume of
material is subject to high stress compared to the rotating bending specimen, which increase the
probability of crack initiation and reduce the fatigue strength’.

Solution
Table 10.1 from Dowling is given below. The answer to the question above is YES.

Source: (Dowling, 2013, p. 505)

Question 6
You have a mirror polished round bar of diameter 30 mm that is subject to nonrotating bending. What
size factor shall be used to estimate the endurance limit at 1 million cycles for this application according
to Budynas? Round your answer to the nearest hundredth.

Solution
From Dowling Table 10.1, in the notes below the table, the following is given:

• For non-rotating bending, the diameter for the round section is:

𝑑𝑒 = 0.37𝑑
= 0.37 × 30
= 11.1 𝑚𝑚

• The following answers are possible with 𝑑𝑒 = 0.37𝑑:

1.0, 𝑑𝑒 ≤ 8
o 𝑚𝑑 = 𝐶𝑠𝑖𝑧𝑒 = { −0.097 = 0.94
1.189𝑑𝑒 , 8 < 𝑑𝑒 ≤ 250
1 𝑑𝑒 < 3
o 𝑚𝑑 = 𝐶𝑠𝑖𝑧𝑒 = {1.24𝑑 −0.107 3 ≤ 𝑑𝑒 ≤ 51 = 0.96 from Dowling Table 10.1
1.51𝑑 −0.157 51 < 𝑑𝑒 ≤ 254

Source: (Dowling, 2013, p. 505)

If the student used the first equation and did not take 𝑑𝑒 = 0.37𝑑, then the answer is 0.85 to 0.86.
Give 100% of the mark in this case.
Question 7
Consider Dowling Tables 10.1 and 10.2. The Budynas approximation refers. Calculate the endurance
for 50% probability of crack initiation, for a stress range of 500 MPa and mean stress zero, for a mirror
polished steel part, subject to axial loading. The ultimate tensile stress of the steel is 700 MPa.

In which range is your answer:

a) [0; 105)
b) [105; 5x105)
c) [5x105; 106)
d) [106; 108)
e) ≥108

Solution
The endurance limit of the material is at 350 MPa. The stress amplitude is 250 MPa, which is less
than the endurance limit. Therefore, infinite life applies for 50% probability of survival in this case.
The correct answer is e.

Question 8
A stress history is cyclic with nominal mean 100 MPa and nominal amplitude 80 MPa. What is the SWT
mean stress compensated completely reversed nominal stress amplitude in MPa? Round your
answer to the nearest tens.

Solution
According to Smith, Watson and Topper (Dowling, 2013, p. 455):

𝜎𝑎𝑟 = √𝜎𝑚𝑎𝑥 𝜎𝑎

1−𝑅
= 𝜎𝑚𝑎𝑥 √
2
= √180 × 80
= 120 𝑀𝑃𝑎