Mechanical Design of Machine Elements

Complete after watching Module 41: Fatigue Goodman Diagram Example (Life)

Worksheet 8: Fluctuating Loading in Fatigue

A steel rod is loaded as shown below with F, which fluctuates from 200 lbf to 800 lbf.
The rod is NOT rotating. The fillet radii at all points is r = 0.08 in. The fatigue strength
fraction is f = 0.80, the fully adjusted endurance limit has been determined to be 25
ksi, the ultimate strength is 150 ksi, and the yield strength is 110 ksi. The fatigue
stress concentration factor at point A is 1.72.
Determine the life of the component at point A, assuming there is no plastic localized
strain at point A.

F
16 in 8 in

A.
O.
1 in 1.5 in

12 in 12 in
R1 R2

Assumptions:
Isotropic, homogenous, pure bending, neglecting weight of bar.

Known: Se = 25 ksi, Sy = 110 ksi, Sut = 150 ksi, Kf = 1.72, f = 0.80, geometry and loading.

Analysis:

Step 1: determine fully reversible stresses at point A.

R1_min = 66.67 lbf R1_max = 266.67 lbf
R2_min = 133.33 lbf R2_max = 533.33 lbf

M_min at point A = 800 lbf*in

M_max at point A = 3200 lbf*in
Mc 32(800lbf *in) Mc 32(3200lbf *in)
s rev _ nom _min = = = 8.15ksi s rev _ nom _min = = = 32.60ksi
I p (1)3 I p (1)3

Step 2: add in stress concentration factors

Kf = 1.72
σrev-min = 8.15*1.72 = 14.02 ksi
σrev-max = 32.60*1.72 = 56.07 ksi

(Note- you can also add in the stress concentrations later, to the alternating or midrange stresses. As
long as there is no localized plastic yileding at point A, either is correct.)
 Mechanical Design of Machine Elements
Complete after watching Module 41: Fatigue Goodman Diagram Example (Life)

Worksheet 8: Fluctuating Loading in Fatigue

A steel rod is loaded as shown below with F, which fluctuates from -100 lbf to 400 lbf.
The rod is NOT rotating. The fillet radii at all points is r = 0.08 in. The fatigue strength
fraction is f = 0.80, the fully adjusted endurance limit has been determined to be 25
ksi, the ultimate strength is 150 ksi, and the yield strength is 110 ksi. The fatigue
stress concentration factor at point A is 1.72.
Determine the life of the component at point A, assuming there is no plastic localized
strain at point A.

F
16 in 8 in

A.
O.
1 in 1.5 in

12 in 12 in
R1 R2

Step 3) Determine alternating and midrange stresses. Note: these will include Kf, as we added Kf into
sigma_min and sigma_max.

æ s max - s min ö æ 56.07 -14.02 ö æ s max + s min ö æ 56.07 +14.02 ö

sa = ç
è ÷ø = çè ÷ø = 21.03ksi s m = çè 2
÷ø = çè
2
÷ø = 35.05ksi
2 2

Step 4: calculate factor of safety for langer static yield and Goodman criteria
Langer static yield:
æ Sy ö æ 110 ö
n=ç ÷ =ç ÷ = 1.96
è s a + s m ø è 21.02 + 35.04 ø
The component will not yield on the first cycle.
Alternating Stress (ksi)

æ ö æ ö
ç 1 ÷ ç 1 ÷
n=ç = = 0.93
s a s m ÷ ç 21.02 35.05 ÷
ç + ÷ ç + ÷
è Se Sut ø è 25 150 ø

The component has finite life.

25
2
1
35 150
Midrange Stress (ksi)
Mechanical Design of Machine Elements
Complete after watching Module 41: Fatigue Goodman Diagram Example (Life)

Worksheet 8: Fluctuating Loading in Fatigue

A steel rod is loaded as shown below with F, which fluctuates from -100 lbf to 400 lbf.
The rod is NOT rotating. The fillet radii at all points is r = 0.08 in. The fatigue strength
fraction is f = 0.80, the fully adjusted endurance limit has been determined to be 25
ksi, the ultimate strength is 150 ksi, and the yield strength is 110 ksi. The fatigue
stress concentration factor at point A is 1.72.
Determine the life of the component at point A, assuming there is no plastic localized
strain at point A.

F
16 in 8 in

A.
O.
1 in 1.5 in

12 in 12 in
R1 R2

To determine life, must first find a fully reversible stress that causes the same amount of damage as the
fluctuating stress. Use Goodman equation to do this.

æ ö æ ö
Alternating Stress (ksi)

ç s a ÷ ç 21.03 ÷
s rev _ eq =ç = = 27.44ksi
s ÷ ç 35.05 ÷
ç1- m ÷ ç1- ÷
è Sut ø è 150 ø

Can use this stress to estimate life of component.

1
æs ö b
N = ç rev ÷
è a ø

a=
( fSut )2 = ( 0.80 *150)2 = 576ksi
27.4
25
21
Se 25
1 æ fS ö 1 æ 0.80 *150 ö 35
b = - log ç ut ÷ = - log ç ÷ø = -0.2271
150
3 è e ø
S 3 è 25 Midrange Stress (ksi)
1
æ 27.4 ö -0.2271
N =ç =
è 576 ÷ø
Between 550,000 and 770,000 cycles