Chapter 6 - Fatigue Failure Theories - Part 2

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DESIGN OF MACHINE ELEMENTS:

Dr. Dinesh Kumar
Associate Professor
Dept. of Mech. Eng., MNIT Jaipur
Few major references are included here. Other references may be found in individual chapters.
1. Norton Robert L., “Machine Design: An Integrated Approach”,
Fourth Edition, Pearson Education Inc., New Jersey, 2011.
2. Shigley J. E. and Mischke C. R., Budynas R. G. and Nisbett K. J.,
“Mechanical Engineering Design“ McGraw Hill, 8th Edition, USA,
2008.
*It is impossible to write better than in the above mentioned references and paraphrasing any statements may lead to loss of technical
meanings /contents of the statements, and hence, many statements are quoted directly from these works.
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CHAPTER 6:
FATIGUE FAILURE THEORIES-PART II
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Estimating Fatigue Failure Criteria
• The best information

comes from-Testing
actual or prototype
assembly
• If not practical – next best information from tests of

specimen taken from the particular material as
manufactured (cast, forged ..)
• If not possible – from published data from literature
• In absence of all these, estimating the endurance limit/
fatigue strength of the material from Sut and Sy
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Estimating Fatigue Failure Criteria…
Material
with Knee
𝑆 ≅ 0.5𝑆 𝑓𝑜𝑟 𝑆 = 1400𝑀𝑃𝑎

𝑆𝑡𝑒𝑒𝑙:
𝑆 ≅ 700𝑀𝑃𝑎 𝑓𝑜𝑟 𝑆 ≥ 1400𝑀𝑃𝑎
𝑆 ≅ 0.4𝑆 𝑓𝑜𝑟 𝑆 < 400𝑀𝑃𝑎

𝐼𝑟𝑜𝑛𝑠:
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Estimating Fatigue Failure Criteria…
Material
without
Knee
𝑆 ≅ 0.4𝑆 𝑓𝑜𝑟 𝑆 < 330𝑀𝑃𝑎

𝐴𝑙 𝐴𝑙𝑙𝑜𝑦𝑠:
𝑆 @5𝐸8
𝑆 ≅ 0.4𝑆 𝑓𝑜𝑟 𝑆 < 280𝑀𝑃𝑎

𝐶𝑢 𝑎𝑙𝑙𝑜𝑦𝑠:
𝑆 @5𝐸8
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Fatigue failure: Correction factors

Correcting theoretical fatigue data
• Theoretical fatigue data must be modified to
account for physical differences between the
test specimen and the actual part being
designed.
• To take into account the effects of loading, size,
surface condition, temperature, reliability and
environment, various strength-reduction
factors are multiplied with the theoretical
estimate to obtain a corrected fatigue strength
or endurance limit for the particular application
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Fatigue failure: Correction factors…

• Materials with a “knee”
• Materials without a “knee”
at 5 x 108 cycles
 Correction factors:
Cload , Csize , Csurface , Ctemperature , Creliability
 Other factors may need to be added… depending on the type (& service)
of components being designed...
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•Loading effects (correction):
Note that a torsional fatigue strength is 0.577 the rotating fatigue strength.
Moreover, in the pure torsional case von Mises effective stress is calculated from
applied shear stresses. This effective alternating tensile stress value can be
compared directly to a rotating bending fatigue strength. Hence, Cload=1 for
torsional loading
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Size Effects (Gradient Factor):
• The rotating-beam and static test specimens are small
(about 0.3-in dia).
• For larger dimensions, a strength-reduction size factor is
applied to account for the fact that larger parts fail at
lower stresses due to the higher probability of a flaw
being present in the larger stressed volume.
Size effects (cylindrical parts): as per Shiegley & Mitchell
Derived from steel parts
Note: For axial loading there is no size effect, and hence:
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Size Effects (Gradient Factor)…:
Size effects (correction; non-cylindrical parts): as
per Kuguel suggestion
• A95 is the portion of the cross-sectional

area of the non-round part that is
stressed between 95% and 100% of its
maximum stress.
•Shigley and Mitchell[21] have found A95
for several common sections and their
results are shown in Figure 6-25 on next
page.
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Surface effects ( Csurface)

• Rotating-beam specimen is polished to a mirror finish
• This requires a costly laboratory procedure but serves to
minimize
– (1) surface scratches and other geometric irregularities
acting as points of stress concentration,
– (2) any differences in the metallurgical character of the
surface layer of material and the interior, and
– (3) any residual stresses produced by the surface finishing
procedure.
• Commercially finished parts have lower fatigue
strengths.
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Surface effects ( Csurface)…
• Real components is not so psi6894.8=Pa
polished
• Rougher surface will have lower
fatigue strength due to stress
concentration introduced due
to surface irregularities
• Corrosive environments
drastically reduce strength
• Csurf=1 for Grey Cast Iron.
Surface discontinuities due to
graphite flakes in the cast-iron
matrix, and that adding even
rather severe surface scratches
does not make the situation
much worse, if any.
• So mirror polishing does not
make any improvement
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Given by Shigley and Mischke:
=1.0
(Use this model in the required units, as indicated in Table 6-3)
This approach has advantage of being computer programmable.
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Electroplating with chrome and nickel is generally not recommended for
parts stressed in fatigue if they are not in corrosive environment
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Temperature effects (Ctemp):
• When operating temperatures are below room
temperature, brittle fracture is a strong possibility and
should be investigated first.
• When the operating temperatures are higher than room
temperature, yielding should be investigated first because
the yield strength drops off so rapidly with temperature.
• At temp above 50% of MP, creep becomes a significant
factor and Stress-Life approach is no longer valid, and
strain-life approach should be used.
• Shigley and Mitchell suggest the following:
These criteria are based on data for steel and should not be used for other metals
such as Al, Mg, and Cu alloys
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Reliability effects: Crelab
• Reported data are based on mean values. There is
considerable scatter in multiple tests of the same
material under the same test conditions.
For example, if you wish to have

99.99% probability that your samples
meet or exceed the assumed
strength, multiply the mean strength
value by 0.702.
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Environment effects
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Creation of estimated S-N diagrams
• Once fatigue strength/endurance limit has been

corrected…construct estimated (corrected) S-N diagram
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Creation of estimated S-N diagrams…

Curve fitting of model (HCF-high cycle fatigue): S(N) = aNb
Use corrected values for Sf or Se

Fatigue strength at 103 cycles: Sm
0.9𝑆 𝑏𝑒𝑛𝑑𝑖𝑛𝑔
𝑆 = 𝑁 = 10 𝑐𝑦𝑐𝑙𝑒𝑠
0.75𝑆 𝑎𝑥𝑖𝑎𝑙 𝑙𝑜𝑎𝑑𝑖𝑛𝑔
For a material with knee:
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Creation of estimated S-N diagrams…

For a material without knee:
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Example 6.1
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Solution (Example 6.1)

(1)
(2)
(3)
(4)
(5)
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Solution (Example 6.1)…

(6)
(7)
(8)
(9)
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Solution (Example 6.1)…

(10)
(11) Life for alternating stress level of 100 MPa:
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Notches and Stress Concentrations

• A notch can be a hole, a groove, a fillet, an abrupt change
in cross section, or any disruption to the smooth contours
of a part.
• Notches are deliberately introduced to obtain engineering
features such as O-ring grooves, fillets on shaft steps,
fastener holes, etc.
• A notch creates a stress concentration that raises the
stresses locally and may even cause local yielding.
• Under static loading, the effects of stress concentrations
were only of concern for brittle materials. Ductile
materials would yield at the local stress concentration
and lower the stress to acceptable levels.
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Notches and Stress Concentrations…

• With dynamic loads, the situation is different, since
ductile materials behave as if brittle in fatigue failures
• Geometric or theoretical stress-concentration factors,
discussed earlier, have been determined for various
loadings and part geometries and are published in
various references.
• For dynamic loading, the theoretical stress-
concentration factor is modified based on the notch
sensitivity of the material to obtain a fatigue stress-
concentration factor, Kf, which can be applied to the
nominal dynamic stresses.
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• Theoretically, we might expect Kf to be equal to the

theoretical or geometric factor Kt. But, tests show that Kf is
often less than Kt.
• This is apparently due to internal irregularities (internal
notches) in the structure of the actual material.
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Notch Sensitivity
• Materials have different sensitivity to stress concentrations,
which is referred to as the notch sensitivity of the material.
• Ductile materials are lesser notch sensitive than brittle materials .
• Since ductility and brittleness in metals are roughly related to
strength and hardness, low-strength, soft materials tend to be
less notch sensitive than high-strength, hard ones.
• Notch sensitivity is also dependent on the notch radius (notch
sharpness). As notch radii approach zero (as they approach the
imperfection size), the notch sensitivity of materials decreases
and also approaches zero.
• Influence of notch at 103 cycles is considerably less that at 106
cycles. But for hard and stronger alloys effect of the notch at 103
cycles can be nearly as great as at 106 cycles.
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• Notch sensitivity q is defined as:
Or
Where Kt is the theoretical (static) stress-concentration factor for the

particular geometry and Kf is the fatigue (dynamic) stress-concentration
factor and actually it represent a reduced value of Kt
• The notch sensitivity q varies between 0 and 1.
• The Kt for the particular geometry and loading is determined
first, then establish the appropriate notch sensitivity for the
chosen material and use them in above equation to find the
dynamic stress-concentration factor Kf.
• The nominal dynamic stress is then increased by the factor Kf
for tensile stress (Kfs for shear stress) in the same manner as
was done for the static case:
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• The notch sensitivity q can also be defined from the
Kuhn-Hardrath formula in terms of Neuber’s constant
a and the notch radius r,
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Example 6-3
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Solution: Example 6-3

(1) where A and b are given in
the figure 4.36 as a function
of the D/d ratio
(2) The Neuber factor from Table 6-6 for Sut = 100 kpsi is 0.062.
(3)
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Designing for High-Cycle Fatigue

Four categories of Fatigue situations
Columns define the presence or absence of a mean stress
Rows define
presence of
of applied
stress in one
or more
than one
axes
Uniaxial: pure axial or pure bending

Multi-axial: normal-stress components on all axes with shear stress
on any face
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Designing for Fully Reversed

Uniaxial Stresses
Application: Fully reversed –torsional, -rotating bending, or -axial loading
1. Determine number of load cycles N & amplitude of load

2. Create a tentative geometry and find Kt & minimize it through good design
practice
3. Choose a tentative material for the part and its properties: Sut, Sy, Se’ (or Sf’) & q
4. Find Kf
5. Compute nominal alternating stress a (or a) at critical locations and apply Kf
6. Compute principal stress amplitudes and find the von Mises effective stress (’)
7. Correct the Se’ by applying correction factors for type of loads, size, surface,
temp, reliability, etc.
8. Create S-N diagram to find Sn for required life
9. Calculate factor of safety: Nf=Sn/’
10. Iterate by changing geometry and material
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1 Information given (very little):
• the required performance of the device,
• some limitations on size, and
• the required cycle life
So, we will have to make some basic assumptions about
part geometry, materials, and other factors as we go.
2 The load amplitude and the number of cycles are defined in
the problem statement. We will begin at the second step of
the design process, creating a tentative part-geometry
design.
3 A tentative design configuration
• A rectangular cross section cut out of a piece of cold-rolled
bar stock from the mill could be chosen because of:
ease in mounting and clamping, simple to cut the
length and drill holes, and little machining required.
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Solution: Example 6-4….
But, this design has some disadvantages:

• Mill tolerances on the thickness are not tight enough to give the required
accuracy on thickness, so the top and bottom would have to be machined or
ground flat to dimension.
• The sharp corners at the frame where it is clamped provide stress concentrations
of about Kt = 2 and also create a condition called fretting fatigue due to the slight
motions that will occur between the two parts as the bracket deflects.
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4 A better design configuration
• Larger mill stock is chosen and then finally machined to the
desired final shape and dimension, as shown in Fig.
• A fillet radius r is provided at the clamp point to reduce
fretting fatigue and achieve a lower Kt.
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5 Start with some trial dimensions for b, d, D, r, a, and l.
Assume (guess) values of
b = 1 in, d = 0.75 in, D = 0.94 in, r = 0.25, a = 5.0, and l = 6.0 in
6 Choose a material :
• for infinite life, low cost, ease of fabrication,
• to be used in a controlled, indoor environment, and
• that provide required stiffness (i.e., keep deflection
within limit)
Favorable Material: Low- to Medium-carbon, ductile steel
possessing
• requisite endurance-limit knee for infinite life,
• low notch sensitivity, and
• required high stiffness.
Chosen Material: SAE 1040 normalized steel with Sut = 80 000 psi, and E = 30 Mpsi
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7 Evaluate reaction forces and moment, and sectional
properties required to calculate nominal stress
8 Find the geometric stress-concentration factor Kt for the

assumed part dimensions
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9 Calculate the notch sensitivity q of the chosen material based
on its ultimate strength and the notch radius
10 Calculate fatigue stress-concentration factor Kf, the local

alternating stress σa in the notch, the largest alternating
principal stress and the von Mises alternating stress σ'a
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11 Calculate uncorrected endurance limit Se’
12 Calculate the corrected endurance limit Se
For rectangular cross section
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13 Compute the safety factor and the beam deflection y:
The deflection of 0.026 inch is not within the stated

specification, and the design fails with a safety factor of less
than one, and hence require iteration.
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14 • To make design safe: dimensions can be changed, or the
material.
• Let the material is kept unchanged but the beam cross-
sectional dimensions and the notch radius are increased and
the model rerun
Let the dimensions are b = 2 in, d = 1 in, D = 1.125 in, r = 0.5, a =

5.0, and l = 6.0 in.
The safety factor is now 2.5 and the maximum deflection is

0.005 in.
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For Other Fully-reversed Stresses

• The above example demonstrate that designing
for fully reversed HCF loading is straight
forward, once the principles are understood.
• If the design called for fully reversed-torsional, -
rotating-bending, or -axial loading, the design
procedure would be the same as in this
example.
• The only differences would be in the choices of
stress equations and strength modification
factors as described in the previous sections.
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Effect of Mean Stress on Fatigue Strength
• When tensile mean component

of stress is added to the
alternating component, the
material fails at lower
alternating stresses than under
fully reversed loading
• Fig. 6-16 shows test results
made of steels at 107 to108
cycles (a) and aluminum alloys
at 5x108 cycles (b) for various
levels of mean and alternating
stresses in combination
• The plots are normalized by
diving a by Sf under fully
reversed stress ( at same no. of
cycles) and m by Sut
The best fitted line of the data is the Gerber line and the straight line connecting
the fatigue strength (1 on y-axis) with the ultimate strength (1 on x-axis) is the
Goodman line
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Effect of Mean Stress on Fatigue Strength
• Figure 6-17 shows the

effect of mean (ranging
from the compressive to
the tensile stress) on
failure
• It is clear from the data
that compressive mean
stress have a beneficial
effect and tensile mean
stresses are detrimental
• Hence, creating residual
compressive stress in the
material is beneficial to
mitigate effect of tensile
stresses
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Designing for Fluctuating Uniaxial Stresses
• While the Gerber parabola is a good fit to experimental data,

making it useful for the analysis of failed parts,
• The modified-Goodman line is a more conservative and commonly
used failure criterion when designing parts subjected to mean plus
alternating stresses.
• The Soderberg line is less often used, as it is overly conservative.
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Designing for Fluctuating Uniaxial Stresses…
These failure lines are defined by
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Modified Goodman-diagram
A schematic plot of 3-D surface formed by a, m, and N for a material having knee at
106 cycles
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Modified Goodman-diagram…
• Fig. 6-43(b) drawn on a-N plane shows
the projections lines that are S-N diagrams
for various levels of mean stress.
• Fig. 6-43(c) shows the projections on the
a- m plane for various values of N, called
constant-life diagram
• As each line on it shows the relationship
between mean and alternating stress at a
particular cycle life.
• The line connecting Se on a axis and Sut
on m axis is the modified Goodman line.
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Augmented modified Goodman-diagram

• The yield lines and compressive region are
included
Area in “gray” is the “safe-zone”
Extended based on
empirical data
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Augmented modified Goodman-diagram…

•The line AG defines yielding in compression This ignores the beneficial effect of
compressive stress and considers that the
situation to be identical to the fully reversed
case
• Line BC defines fatigue failure in combination

with compressive mean stress
• Line CF defines fatigue failure in combination

with tensile mean stress
• Line GE defines yielding in tension
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Applying Stress-Concentration Effects with
Fluctuating Stresses
• The alternating component of stress σa is
treated the same way as it was for the case of
fully reversed stress. (i.e., Kt, q  Kf  σa= Kf
σnom).
• The mean component of stress σm is treated
differently depending on the ductility or
brittleness of the material and, if ductile, on
the amount of yielding possible at the notch.
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Fluctuating Stresses….
• If the material is brittle, then the full value of

the Kt is usually applied to the nominal mean
stress (σm)nom to obtain the local mean stress σm
at the notch using equation: σm= Kt (σm)nom .
• If the material is ductile, Dowling suggested the
approaches to compute mean stress fatigue-
concentration factor Kfm depending on the
relationship of the maximum local stresses to
the yield strength of the ductile material.
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Fluctuating Stresses….
then
 m = K fm nom
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Safety factors in fluctuating stresses
• Fig. 6-46 shows four views of the tension side of the augmented modified-
Goodman diagram.
• Point Z represents load (von Mises Stresses) on a part.
• The SF depends on the manner in σm and σa can vary w. r. t. one another in
service.
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Safety factors in fluctuating stresses….
Case 1
YQ
Nf =
YZ
  a' 
'
= S ut 1  ,
m@Q  S 
 f 
 m' @ Q Sut   a' 

Nf = ' = ' 1  .
 m @ Z  m  S f 
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Case 2
XP
Nf =
XZ
  m' 
'
= S y 1  ,
a@ P  S 
 y 
 a' @ P S y   m' 
Nf = ' = ' 1  .
 a @ Z  a  S y 

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Case 3 OR  '
 '
m@ R a@ R
Nf = = ' = '
OZ  m @ Z  a @ Z
 m' @ R Sy
Nf = ' = ' .
 m@ Z  m   a'
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Case 4
Line ZS  Line CF
OS ' OZ  ZS
Nf = = , where :
OZ OZ
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Design Steps for Fluctuating Stresses

1. Determine number of load cycles N & the load (amplitude of the applied
alternating load and the mean load) expected over the service life of the part.
2. Create a tentative geometry based on good engineering practice, and find Kt (try
to minimize it through good design practice).
3. Choose a tentative material for the part and its properties: Sut, Sy, Se’ (or Sf’) & q
4. Evaluate Kf and Kfm.
5. Compute nominal a and m at critical locations and apply Kf and Kfm.
6. Compute principal stress amplitudes and find the von Mises effective stresses (a’
and m’ ).
7. Correct the Se’ (or Sf’) by applying correction factors for type of loads, size,
surface, temp, reliability, etc. to find corrected Se (corrected Sf for required life N).
8. Create modified Goodman diagram and write equations for modified Goodman
line and Yield line.
9. Plot the von Mises effective stress (a’ and m’ ) on the diagram and calculate a
safety factor for the design.
10. Iterate by changing geometry and/or material or redesign for a shorter
acceptable part life.
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1 Information given (very little):
• the required performance of the device,
• some limitations on size, and
• the required cycle life
So, we will have to make some basic assumptions about
part geometry, materials, and other factors as we go.
2 The load amplitude and the number of cycles are defined in
the problem statement. We will begin at the third step of
the design process, creating a tentative part-geometry
design.
3 A tentative design configuration
Choose the same design configuration as finalized in
Problem 6-5 (refer Figure on next slide) to achieve a lower Kt
and reduce chances of fretting fatigue.
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Solution: Example 6-5…
The trial dimensions, taken from Problem 6-4 after the

successfully solution to the fully reversed case, are b = 2 in, d =
1 in, D = 1.125 in, r = 0.5, a = 5.0, and l = 6.0 in.
4 Choose a material :
• for infinite life, low cost, ease of fabrication,
• to be used in a controlled, indoor environment, and
• that provide required stiffness (i.e., keep deflection
within limit)
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Favorable Material: Low- to Medium-carbon, ductile steel
possessing
• requisite endurance-limit knee for infinite life,
• low notch sensitivity, and
• required high stiffness.
Chosen Material: SAE 1040 normalized steel with Sut = 80 000 psi, Sy = 60 kpsi and E
= 30 Mpsi
5 The mean and alternating components of the load and their

reaction forces can be calculated from the given maximum and
minimum loads.
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6 The mean and alternating moments, and the maximum
moment acting at the root of the cantilever beam can be
calculated.
7 The nominal bending stresses at the root are found for both
the alternating load and the mean load from:
8 Find the geometric stress-concentration factor Kt for the

assumed part dimensions:
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9 The values of q and Kt are used to find the fatigue stress-
concentration factor Kf , and then Kfm is calculated:
10 Use these factors to find the local mean and alternating

notch stresses.
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11 The local stresses are used to compute the von Mises
alternating and mean stresses
12 The uncorrected endurance limit Se’ is determined as:
13 Calculate the corrected endurance limit Se
For rectangular cross section
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13 Calculate the corrected endurance limit Se….
14 The four possible safety factors are calculated and the smallest
or most appropriate one can be selected from those calculated,
and for Case III
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15 The maximum deflection is calculated using the maximum
applied force Fmax.
Note:
• Using the same cross-section dimensions and the same alternating load as
in Example 6-4 now gives a safety factor Nf3 = 1.9 and maximum deflection
ymax = 0.012 in for this fluctuating loading case, compared to Nf3 = 2.5 and
ymax = 0.005 in for the fully reversed loading situation of Example 6-4.
• The addition of a mean stress to the previous level of alternating stress

reduced the safety factor and increased the deflection, as expected.
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15 • Increasing the part’s cross-section dimensions slightly gives
the better design. The final dimensions are b = 2 in, d = 1.2 in,
D = 1.4 in, r = 0.5 in, a = 5 in, and l = 6.0 in.
• Nf3 becomes 2.6 as shown in the Goodman diagram of

Figure 6-48, and the maximum deflection becomes 0.007 in.
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Designing for Multiaxial Stresses in Fatigue
• Includes combined loads that create simultaneous

time-varying biaxial or triaxial stresses at the same
point. E.g., a rotating shaft subjected to both a BM
and a torque.
• There may be many possible loading combinations.
• The torque might be constant, fully reversed, or
fluctuating.
• If the torque is not constant, it could be synchronous,
asynchronous, in- or out-of-phase with the bending
moment.
• Researchers suggest that the assumption that loads
are synchronous and in-phase is usually accurate for
machine design and usually conservative
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Designing for Multiaxial Stresses in Fatigue….
• Simple mutiaxial stress: Cases of Periodic, synchronous,

in-phase loads that cause combined stresses whose
principal directions do not change with time. Example: A
rotating shaft in combined bending and constant torque
• Complex multiaxial stress: : Cases of asynchronous, out-
of-phase loads that cause combined stresses whose
principal directions vary with time. Example: A rotating
shaft in combined bending and time-varying torque
Note: According to the SAE Fatigue Design Handbook,
“Analysis of Second situation is, in general, beyond the
current state of the technology. The design process must
proceed by very approximate analyses supported by
extensive experimental studies simulating the material
and geometry as well as the loading.”
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Designing for Multiaxial Stresses in Fatigue….
Simple Multiaxial stresses (fully reversed or fluctuating)

• The von Mises Effective stresses for both alternating
and mean components of applied stresses are used in
modified Goodman diagram to find safety factor
For biaxial stress
(Take  m' = 0, for fully reversed case)

Note: Appropriate stress-concentration factors should be applied to the above
mentioned alternating and mean components of the applied stresses.
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A General Approach to HCF

• Fully reversed loading mode is a special case of
fluctuating mode
• We can treat all fatigue-loading cases as fluctuating
and consistently apply the modified-Goodman
diagram (MGD) criteria of failure
• As the MGD and S-N diagram are simply different
views of the same 3-D relationship between ’m, ’a
and N
• The MGD provides a universal tool to determine a
safety factor for any stress problem, whether static,
fully reversed fatigue, or fluctuating fatigue
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A General Approach to HCF…

A fully reversed stress state
Fluctuating loading stress state
A static loading stress state
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A General Approach To HCF Design
• Generate suitably the MGD from tensile

strength using generated S-N diagram. Apply
appropriate strength reduction factors
(correction factors)
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(1) Aluminum does not have an endurance limit. Its endurance
strength at 5E8 cycles can be estimated from equation:
Since the Sut is larger than 48 kpsi, the uncorrected Sf ’@5E8 =

19 kpsi.
(2) Find a corrected endurance strength at the standard 5E8
cycles
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(3) Strength value at the required life of 6E7 cycles
Note that Sm is calculated as 90% of Sut

because the loading is bending
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(4) Notch sensitivity of the material (hardened Aluminum)
assumed notch radius of 0.25 in
(5) Fatigue stress-concentration factors
(6) The alternating and mean components of the applied force,

moment, and torque at the wall
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(6) The fatigue stress-concentration factor for the mean stresses
In this case, there is no reduction in stress-concentration factors for the mean stress
because there is no yielding at the notch to relieve the stress concentration.
(7) Find the alternating and mean components of the normal

bending stress and of the torsional shear stress on point A
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(8) Find the alternating and mean von Mises stresses at point A
(9) Alternating and mean von Mises stresses are synchronous and in-phase
and any changes in them will be in a constant ratio. This is a Case 3
situation and the safety factor is found as below:
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Checking at Point B
(10) Stresses at Point B
• Consider shear due to transverse loading at point B on the neutral
axis where the torsional shear is also maximal
• The maximum transverse shear stress at the neutral axis of a hollow,
thin-walled, round tube was given as
• Point B is in pure shear. The total shear stress at point B is the sum of
the transverse shear stress and torsional shear stress which act on the
same planes of the element
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(11) Find the alternating and mean von Mises stresses for point B
(12) The safety factor for point B
So, Both points A and B are safe against fatigue

failure.
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Important Equations Used
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Important Equations Used…
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Fretting : A special wear process that occurs at the contact

area between two materials under load and subject to minute
relative motion by vibration or some other force
103

Chapter 6 - Fatigue Failure Theories - Part 2

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Chapter 6 - Fatigue Failure Theories - Part 2

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1/2/2022

DESIGN OF MACHINE ELEMENTS:

Estimating Fatigue Failure Criteria

• The best information

• If not practical – next best information from tests of

Estimating Fatigue Failure Criteria…

𝑆 ≅ 0.5𝑆 𝑓𝑜𝑟 𝑆 = 1400𝑀𝑃𝑎

𝑆 ≅ 0.4𝑆 𝑓𝑜𝑟 𝑆 < 400𝑀𝑃𝑎

Estimating Fatigue Failure Criteria…

𝑆 ≅ 0.4𝑆 𝑓𝑜𝑟 𝑆 < 330𝑀𝑃𝑎

𝑆 ≅ 0.4𝑆 𝑓𝑜𝑟 𝑆 < 280𝑀𝑃𝑎

Fatigue failure: Correction factors

Fatigue failure: Correction factors…

• Materials without a “knee”

Fatigue failure: Correction factors…

Fatigue failure: Correction factors…

Derived from steel parts

Note: For axial loading there is no size effect, and hence:

Fatigue failure: Correction factors…

• A95 is the portion of the cross-sectional

Fatigue failure: Correction factors…

Fatigue failure: Correction factors…

Surface effects ( Csurface)

Fatigue failure: Correction factors…

Fatigue failure: Correction factors…

Fatigue failure: Correction factors…

This approach has advantage of being computer programmable.

Fatigue failure: Correction factors…

Fatigue failure: Correction factors…

Fatigue failure: Correction factors…

Fatigue failure: Correction factors…

For example, if you wish to have

Fatigue failure: Correction factors…

Creation of estimated S-N diagrams

• Once fatigue strength/endurance limit has been

Creation of estimated S-N diagrams…

Use corrected values for Sf or Se

For a material with knee:

Creation of estimated S-N diagrams…

Solution (Example 6.1)

Solution (Example 6.1)…

Solution (Example 6.1)…

(11) Life for alternating stress level of 100 MPa:

Notches and Stress Concentrations

Notches and Stress Concentrations…

Notches and Stress Concentrations…

• Theoretically, we might expect Kf to be equal to the

Notches and Stress Concentrations…

Notches and Stress Concentrations…

Notches and Stress Concentrations…

Where Kt is the theoretical (static) stress-concentration factor for the

Notches and Stress Concentrations…

Notches and Stress Concentrations…

Notches and Stress Concentrations…

Notches and Stress Concentrations…

Notches and Stress Concentrations…

Solution: Example 6-3

Designing for High-Cycle Fatigue

Uniaxial: pure axial or pure bending

Designing for Fully Reversed

1. Determine number of load cycles N & amplitude of load

Solution: Example 6-4

Solution: Example 6-4….