Fatigue Analysis of shafts

For solid shaft with round cross section, appropriate geometry terms can be
introduced for C, I and J resulting in

32 Ma 32 Mm
=σ a K=f σm Kf
I I
16Ta 16Tm
=τ a K=
fs τ m K fs
J J
Mm: Midrange bending moment, σm: Midrange bending stress
Ma : alternating bending moment, σa: alternating bending stress
Tm: Midrange torque, τa: alternating shear stress
Ta : alternating torque, τm: Midrange shear stress
Kf: fatigue stress concentration factor for bending
Kfs: fatigue stress concentration factor for torsion
 Fatigue Analysis of shafts
Combining these stresses in accordance with the DE failure theory the von-
Mises stress for rotating round, solid shaft, neglecting axial loads are given by

σ xa 2 + 3τ
σ 'a = xya  1/2 =
2
16 / π d 3  4(K f Ma )2 + 3(K fsTa )2  1/2 =16 A / π d 3
(1-9)
σ xm 2
σ 'm = + 3τ xym 2  1/2 =16 / π d 3  4(K f Mm )2 + 3(K fsTm )2  1/2 =16B / π d 3
where A and B are defined by the radicals in Eq. (1-9) as

=A  4(K f Ma )2 + 3(K fsTa )2  1/2

=B  4(K f Mm )2 + 3(K fsTm )2  1/2
The Gerber fatigue failure criterion
2 2 2
Sa  Sm  nσ 'a  nσ 'm  16nA  16nB 
+  = +  = 3 +  3  =1
Se  Sut  Se  Sut  π d Se  π d Sut 
 Fatigue Analysis of shafts

The critical shaft diameter is given by

1/3
  1/2

 2BSe  
2
8nA  
=
d 1 + 1 +     (1-10)
π Se    ASut   
   
or, solving for 1/n, the factor of safety is given by

  2

1/2

1 8A   2BSe  
= 
1 + 1 +     (1-11)
n π d Se    ASut   
3

   
 Fatigue Analysis of shafts

where

=A 4(K f Ma )2 + 3(K fsTa )2

=B 4(K f Mm )2 + 3(K fsTm )2 (1-12)

σ 'a A
=r =
σ 'm B
 Fatigue Analysis of shafts
Particular Case
A = 2K f Ma
For a rotating shaft with constant bending and torsion, the
bending stress is completely reversed and the torsion is
steady. Previous Equations can be simplified by setting Mm
B = 3 KfsTm
= 0 and Ta = 0, which simply drops out some of the terms.
1/3
  1/2

 K fsTmSe  
2
16nK f Ma  
=
Critical Shaft d 1 + 1 + 3     (1-13)
Diameter π Se    K f MaSut   
   
  2

1/2

1 16K f Ma    K fsTmSe   
Safety Factor= 1 + 1 +   
(1-14)

n π d Se    K f MaSut   
3

   
Fatigue Analysis of shafts

σ 'a 2K f Ma
=r = (1-15)

σ 'm 3K fsTm
 Shaft Diameter Equation for the DE-Elliptic
Criterion
Remember

σ xa 2 + 3τ
σ 'a =  1/2 =
xya
2
16 / π d 3  4(K f Ma )2 + 3(K fsTa )2  1/2 =16 A / π d 3
σ xm 2
σ 'm = + 3τ xym 2  1/2 =16 / π d 3  4(K f Mm )2 + 3(K fsTm )2  1/2 =16B / π d 3

where A and B are defined by

=A  4(K f Ma )2 + 3(K fsTa )2  1/2

=B  4(K f Mm )2 + 3(K fsTm )2  1/2
The Elliptic fatigue-failure criterion is defined by
2 2 2 2 2 2
 Sa   Sm   nσ 'a   nσ 'm   16nA   16nB 
  +   =   +   =  3  +  3  = 1
 Se   Sy   Se   Sy   π d Se   π d Sy 
 Shaft Diameter Equation for the DE-Elliptic
Criterion
Substituting for A and B gives expressions for d, 1/n and r:
Critical Shaft Diameter
1/3
   K M 2 2 2 2

1/2

16n   K T   K M   K T  
d  4 
f a
 + 3 
fs a
 + 4 
f m
 + 3 
fs m
  
π  S S  S   S  
   e   e   y   y   
 
Safety Factor

1/2
 2 2
 K f Mm 
2
 K fsTm 
2

1 16   K f Ma   K fsTa 

4  + 3  + 4   + 3   (1-16)
n π d   Se 
3
 Se   Sy   Sy  
 
 Shaft Diameter Equation for the DE-Elliptic
Criterion

( ) ( )
2 2
σ 'a A 4 K f Ma + 3 K fsTa
=
r = =
σ 'm B 4 (K M ) + 3 (K T )
2 2
f m fs m
 Shaft Diameter Equation for the DE-Elliptic
Criterion

Particular Case
For a rotating shaft with constant bending and torsion,
the bending stress is completely reversed and the
A = 2K f Ma
torsion is steady. Previous Equations can be simplified
by setting Mm = 0 and Ta = 0, which simply drops out B = 3 KfsTm
some of the terms.
1/3
   K M 2 2

1/2

 1 6 n  K T  
=
Critical Shaft Diameter d   4  f a  + 3  fs m    (1-17)
 S  
 π   Se   y   
 
1/2
 K M  2
 K fsTm 
2

1 16 4  f a

=
Safety Factor  + 3   (1-18)
n π d   Se 
3
 Sy  
 
 Shaft Diameter Equation for the DE-Elliptic
Criterion

( )=
2
σ 'a A 4 K f Ma 2K f Ma
=
r = =
σ 'm B 3 (K )
2
T
fs m
3K fsTm

 At a shoulder Figs. A-15-8 and A-15-9 provide information about Kt and

Kts.
 For a hole in a solid shaft, Figs. A-15-10 and A-15-11 provide about Kt and
Kts .
 For a hole in a solid shaft, use Table A-16
 For grooves use Figs. A-15-14 and A-15-15
 Shaft Diameter Equation for the DE-Elliptic
Criterion

 The value of slope at which the load line intersects the junction of
the failure curves is designated rcrit.
 It tells whether the threat is from fatigue or first cycle yielding
 If r > rcrit, the threat is from fatigue
 If r < rcrit, the threat is from first cycle yielding.
 Shaft Diameter Equation for the DE-Elliptic
Criterion

 For the Gerber-Langer intersection the strength components Sa and

Sm are given in Table 7-10 as

 2 
S  2
 2Se   Sy 
S= 1− 1+ 
ut
  1− 
m
2Se   Sut   Se 
  (1-19)

S=
a Sy − Sm
Sa Sy − Sm Sy
= =
rcrit = −1
Sm Sm Sm
 Shaft Diameter Equation for the DE-Elliptic
Criterion

 For the DE-Elliptic-Langer intersection the strength components Sa

and Sm are given by

2Sy Se2
Sa =
S +S
2
e
2
y

Sm= Sy − Sa (1-20)

Sa Sa
= =
rcrit
Sm Sy − Sa
Note that in an analysis situation in which the diameter is known and the
factor of safety is desired, as an alternative to using the specialized equations
above, it is always still valid to calculate the alternating and mid-range
stresses using the following Eqs.

and substitute them into the one of the equations for the failure criteria ,
Eqs. (1-9) to (1-20) and solve directly for n.
 In a design situation, however, having the equations pre-solved for
diameter is quite helpful.
 It is always necessary to consider the possibility of static failure in
the first load cycle.
 The Soderberg criteria inherently guards against yielding, as can
be seen by noting that its failure curve is conservatively within the
yield (Langer) line on Fig. 6–27, p. 397.
 The ASME Elliptic also takes yielding into account, but is not
entirely conservative throughout its range. This is evident by
noting that it crosses the yield line in Fig. 6–27.
 The Gerber and modified Goodman criteria do not guard against
yielding, requiring a separate check for yielding. A von Mises
maximum stress is calculated for this purpose.
 To check for yielding, this von Mises maximum stress is compared to the
yield strength, as usual

 For a quick, conservative check, an estimate for σ’max can be obtained by

simply adding σ’a and σ’m as (σ’a + σ’m ) will always be greater than or
equal to σ’max, and will therefore be conservative.
 Example

Solution

6- 6-
20 21
Figure 7-20

Figure 7-21
18-
22

18- 18- Sold

14 24 erbe
rg