Machine Design - I

Tutor:
Dr. Owaisur Rahman Shah
 Module – IIA
Week 5 – 7
Chapter 5: Mechanical Engineering Design
by Joseph Shigley, Charles Mischke, Richard Budynas
10th Edition.

• Fatigue Failure Resulting From Variable Load

– Fatigue in Metals
– Fatigue Failure in analysis and Design
– Fatigue Life Method
– Stress Life Method
– Strain Life Method
– Linear Elastic Fracture Mechanics Method
– Endurance Limit
– Fatigue Strength
– Stress Concentration and Notch Sensitivity
 Fatigue Failure
• In this case, some stress is
always present in any one
fiber, but now the level of
stress is fluctuating. These
and other kinds of loading
occurring in machine
members produce stresses
that are called variable,
repeated, alternating, or
fluctuating stresses.
Fatigue Failure
Fatigue Failure
Fatigue Failure
Fatigue Failure
 Quiz # 1 1/3 (10mins)
Q1: The design process is given by the following
flow chart, describe briefly the significance of
each step.
 Quiz # 1 2/3 (10mins)
Q2: What is the difference
between a code and a standard?
Q3: Explain the cost breakeven in
the figure-1
Q4: What is the difference
between Stress and Strength?
Figure - 1
Q5: Define design factor
 Quiz # 1 3/3 (5mins)
Q6: Say a load of 1000lb is causing failure but
the load is known within 15%. Calculate the
Loss-of-Function Parameter (load)
(1/1-Variance)
Q7: Say a load of 1000lb is causing failure and
the maximum load on the structure is known
within 25%. Calculate the Maximum Allowable
Parameter (load)
(1/1+Variance)
 Fatigue Failure
• Approach to fatigue failure in design
– Machine components need to be designed according to
the understanding of the fatigue phenomena taking
place in the material, even though they may not be fully
understood.

– Life of 1 < N < 103 cycles is generally classified as low-

cycle fatigue, whereas high-cycle fatigue is considered to
be N > 103 cycles.
 Fatigue Failure
• Fatigue life methods
– The Stress-Life Method
• The stress-life method, based on stress levels only, is the least
accurate approach, especially for low-cycle applications.
However, it is the most traditional method, since it is the easiest
to implement for a wide range of design applications, has ample
supporting data, and represents high-cycle applications
adequately.
 Fatigue Failure
• Fatigue life methods
– The Stress-Life Method
 Fatigue Failure
• Fatigue life methods
– The Stress-Life Method
 Fatigue Failure
• Fatigue life methods
– The Stress-Life Method
 Fatigue Failure
• Fatigue life methods
– The Strain-Life Method
• In 1910, Bairstow verified by experiment Bauschinger’s theory that
the elastic limits of iron and steel can be changed, either up or
down, by the cyclic variations of stress. In general, the elastic limits
of annealed steels are likely to increase when subjected to cycles of
stress reversals, while cold-drawn steels exhibit a decreasing elastic
limit.
• R. W. Landgraf has investigated the low-cycle fatigue behavior of a
large number of very high-strength steels, and during his research
he made many cyclic stress-strain plots. For the first few cycles of
controlled cyclic strain. In this case the strength decreases with
stress repetitions, as evidenced by the fact that the reversals occur
at ever-smaller stress levels. As previously noted, other materials
may be strengthened, instead, by cyclic stress reversals.
 Fatigue Failure
• Fatigue life methods
– The Strain-Life Method
 Fatigue Failure
• Fatigue life methods
– The Strain-Life Method
 Fatigue Failure
• Fatigue life methods
– The Strain-Life Method
 Fatigue Failure
• Fatigue life methods
– The Strain-Life Method
 Fatigue Failure
• Fatigue life methods
– The Strain-Life Method
 Fatigue Failure
• Fatigue life methods
– The Strain-Life Method
 Fatigue Failure
• Fatigue life methods
– The Strain-Life Method
• Now, from Fig. 6–12, we see that the total strain is the sum of the elastic and
plastic components. Therefore the total strain amplitude is half the total strain
range

• The equation of the plastic-strain line in Fig. 6–13 is

• The equation of the elastic strain line is

• Therefore, from Eq. (a), we have for the total-strain amplitude

• which is the Manson-Coffin relationship between fatigue life and total strain.