3 DESIGN FOR FATIGUE STRENGTH INTRODUCTION In static loading, the load is applied gradually and there is sufficient time for elongation of ‘The failure due to static load is explained by simple tension test. Due to static loading a ical component may fail by any one of the following modes, i) Failure by elastic deformation ) Failure by general yielding and ‘Failure by fracture. In fatigue loading, the load is repeated cyclically. The fatigue failure begins with a small ‘The crack will more likely to develop in the following regions : Regions of discontinuity such as holes, notches, grooves, keyways etc. | Regions of irregularities in machining operations such as inspection marks, stamp mark, ‘soraiches, etc., ‘Internal defects such as voids, cracks, non metallic inclusions, etc. en machine parts fail statically, they usually develop very large deflection, and thus static five visible indication in advance. But a fatigue failure gives no indication, It is sudden hence dangerous. It is relatively simple to design a component for static load, Since the failure depends on factors such as number of cycles, mean stress, stress amplitude, stress n, residual stresses, corrosion and creep, the design of components subjected to fatigue lis more complex.4388 —_—<$§&@&—= i@<—_—_—_—_—_ Design of Machine Elements: 3.2 DEFINITIONS a. Fatigue or variable load When a load or stress on a machine part changes in is known as variable load or fatigue load. ‘The variations are as follows = (i) Stress variation only on positive side (Fig. 3.1) Gi) Stress variation only on positive side with zero minimum stress. (Fig. negative direction (Fig. 3.3) magnitude or direction ot both, the I 3.2) (iii) Stress variation both in positive and PAP Time —= Fig. 3.1 Fig. 3.2 Fig. 3.3 both in positive and negative direction i.e., completely reversed Suess —— Stress —— ° Stress —— Time —= Time —= (iv) Equal stress variation (Fig. 3.4) (v) Stress variation on ne; (vi) Stress variation only on negative side (Fig. 3.6) ative side with zero maximum. stress. (Fig, 3.5) + ! 0 Stress —— ° ~ Time —— 7 Time —— pe Tene Fig. 3.4 Fig. 3.5 Pig. 3.6 b, Stress cycle '\ stress eycle is the smallest portion of the stress time plot whieh is repeated periodis identically.rt 189 Design for fatigue strength: c, Fluctuating stresses ‘The stresses which vary froma minimum to maximum value of same nature (j.e., Tensile or Compressive) are called fluctuating stresses. It is shown in Fig. 3.1 or Fig. 3.6. With reference to Fig. 3.7, the following terms are important d. Maximum stress (9,,,.) | It is the largest algebraic stress in a stress cycle. Tensile stress is taken as positive and compressive stress as negative. e. Minimum stress (G,,,,) Itis the smallest algebraic stress in a stress cycle. f, Mean stress (o,,) Itis the algebraic mean of the maximum and minimum stresses in one cycle OR hn ‘. 2 g. Range of stress (¢,) It is the algebraic difference between the maximum and minimum stresses in a stress cycle, 1 h, Stress amplitude or variable stress (o,) It is equal to one half of the range of stress 9 9, Time — Fig. 3.7 i, Stress ratio (r) Itis defined as the ratio of minimum stress to maximum stress in a stress cycle nin +: Stress ratio r = Fin, _j Amplitude ratio (A) It is defined as the ratio of variable stress to the mean stress in a stress cycle Repeated stresses The stresses which vary from zero to a certain maximum value are called repeated stresses. It ywn in Fig, 3.2 or Fig. 3.5.190 1 Alternating or completely reversed stresses ‘The stresses which vary from a minimum value to a maximum of the opposite nature [i minimum compression to maximum tensile vice versa] are called completely reversed or alternati or cyclic stresses as shown in Fig. 3.4. Design of Mactine Elements} 3.3. S.N. DIAGRAMS AND ENDURANCE LIMIT Design of a machine part that is subjected to fatigue load is based on the results of f tests. The following are the usual fatigue tests, (i) Completely reversed bending stress (Rotating beam test) (ii) Completely reversed axial stress (Push-Pull test) (iii) Repeated torsional stress (iv) Oscillating stress and super imposed static stress. REVOLUTION COUNTER WEIGHTS Fig. 3.8 : RR. Moore rotating beam fatigue testing machine The most widely used fatigue testing device is the R.R. Moore high-speed rotating machine and is shown in Fig. 3.8. The specimen is very carefully machined and polished wit final polishing in an axial direction to avoid circumferential scratches. Self-aligning ball bearit are used toensure that only radial loads are applied to the specimen. The test specimen is subj to pure bending moment and the magnitude of bending stresses is adjusted by means of wei ‘As the beam rotates, the fibres of the surface of the specimen undergo reversal of stress [i maximum tension when at bottom and maximum compression when at the top position]. ‘To determine the endurance limit stress of a material, a large number of tests are out. Each test consists of applying a constant bending load and the number of revolutions or st cycles before the appearance of first fatigue crack is measured. The results of these tests plotted by means of an SN curve. The 5-N curve is a graphical representations of the maxi applied stress versus logarithm of the number of cycles (log N), With a decrease in the stress, number of cycles necessary to cause failure will increase, Each test gives one failure point on S-N curve. For ferrous materials such as steel, the S-N curve becomes horizontal after the has been stressed for a certain number of cycle as shown in Fig. 3.9191 i Design for fatigue strength: j [Low eyele —-}=———High eyele ———- = ++ Finite life t——#€$€<=4 ptinite Fatigue strength — | a rT (nC Number of cycles (N) —= 10° 10’ 10? tor 10? toto?" Number of stress cycles (N) —= Fig. 3.9 Fig. 3.10 ‘The ordinate of the S-N diagram is called the fatigue strength, a statement of this strength must always be accompanied by a statement of the number of cycles N to which it corresponds. The portion of the curve up to 10° cycles is known as low cycle fatigue and beyond 10* cycles as the high cycle fatigue. Fatigue strength at 10° cycles of reversible loading is termed as endurance limit and is designated by 6 ,. It is defined as the maximum value of completely reversed bending stress which a polished standard specimen can withstand without failure for infinite number of cycles [usually 10° cycles]. In order to avoid confusion the term ‘endurance limit’ will be used only for reversed bending. For other types of loading the term endurance strength will be used. For non-ferrous metals the $-N curve slopes gradually even after 10° cycles as shown in Fig. 3.10. Thus there is no fatigue limit for such alloys. In such a case the endurance limit stress is always expressed as a function of number of stress cycles. 3.4 EFFECT OF FACTORS ON ENDURANCE LIMIT ‘The endurance limit of a material strongly depends on the following factors. (i) Type of load (ii) Surface condition and corrosion (iii) Size of the section (iv) Grain size and direction {v) Discontinuties in the section (holes, notches, fillets, ete.,) (vi) Operating temperature (vii)Heat treatment (viii) Residual stresses (ix) Type of cycle (x) Type of stress, (i) Surface condition ‘The surface of the rotating beam specimen is highly polished, but most of the machine elements will not have such a high quality finish, Rough machining, scaly surface due to hot rolling and corrosion from water and acids badly affect the fatigue strength. Fig. 3.11, shows the surface finish factor for various surface conditions.192. x_—A$ $< w“—e Design of Machine Elements - Mirror Polished ent factor (¢,) Surface coeffi 6, 1500 MPa Fig. 3.10 ‘When the surface correction coefficient is known, then the endurance limit for the mat ‘of the machine member may be obtained by multiplying the endurance limit and the st correction coefficient (c,). Fora mirror polished specimen, the surface. correction coefficient ( is equal to unity, (Lee, = 1) +. Endurance limit for specimen other than mirror polished = 6, ¢,, whi Endurance limit for a polished specimen, o,, (ii) Size effect ‘The standard test specimen used in rotating beam method has a nominal diameter of 7.5 mm. Therefore if the nominal diameter is not equal to 7.5 mm, a size correction coeffi (¢.) should be considered, Fatigue strength has been observed to decrease with increase in part size because of the following reasons, (i) With the increase in size of the part the probability of increase in internal defects are because of greater volume. (ii) ‘There is higher probability of initiation of fatigue crack because of larger arca. (iii) Difficulties in obtaining uniform strength and heat treatment throughout the whole section of large parts. The size correction coefficient (c,,) is the ratio of fatigue strength of a given part 101 fatigue strength of a standard specimen. Fig. 3.12 shows the variation of size coefficient with! size of specimen.193 Design for fatigue strength: 40 80) 120) 160 200 mm Size Fig. 3.12 The following table gives the size coefficient e,,) for different diameter ranges. ‘The endurance limit decreases with increase in size of the components. «=. Endurance limit for specimen other than standard diameter = 0, ¢,. where o , = Endurance limit for a standard diameter (7.5 mm) specimen. Diameter (d), mm 75 Considering the stress concentration for the reversed stress the Sede rberg's equation used fa axial load is, &.c, Sm 2 --- 5.40 (DDH Ca Oya Guy 6 5.19 (DDHE197 5.13 (DDHB) Design for fatigue strength = Actual or Given factor of safety o. Substituting in Equation 5.19 (DDHB), o,, = same as that of given in equation (iii) so, o,= — ~~ 5.16 (DDHB) wy 4, RK, 0, --- 5.12 (DDHB) L = —K, nwhere n= n,,= Actual or given factor of safety. yOu Substituting in Equation 5.16, (DDHB) 0,, = 4, Neglecting the stress concentration for static Ioad in ductile material and size effect for yielding —- same as that of given in equation (ii) ‘The Soderberg's equation for the bending load is, | Ren Sy. | ee --- 5.52 (DDHB) ---- 5.64 (DDHB) If specific informations are not available then take 6, =056, T, = 0.66, for fatigue loading. Surface coefficient in case of torsion = = 0.425 + 0.575e,, --- 5.8 (DDHB) (i) Goodmancriterion According to Goodman criterion, the failure line is taken as the straight line joining the endurance limit (¢_,) and the ultimate strength (6,) as shown in Fig, 3.15. Here as the line connects the endurance limit to ultimate strength, it can be used for both ductile and brittle materials. The line198 ——_$______ Deesign of Machine Elements + AB is termed as "Modified Goodman failure line". Considering suitable factor: ‘of safety, the line Cl can be drawn parallel to the line AB. This line is termed as "Modified Goodman safe stress line’, Stress Amplitude, o Mean Stress of Pig. 3.15 [Fig 5.8 New DDHB] Consider a point P on the modified Goodman safe stress line as shown and let 6, and 6, the mean and amplitude stress at this point respectively. Now draw PE perpendicular to OB. From similar triangles PED and COD. PE _ ED _ OD-OE _ | _OE oc > 0D OD ~~ OD So, Se siege [Neglecting stress concentration K, ,, PE=0,] n where n = Factor of safety. a For ductile material, stress concentration may be ignored under steady loads, but suit stress concentration factor must be considered under fatigue load. Therefore for ductile mat equation (i) becomes, Fm L Oy o, 1 a However, forbrittle materials, the stress concentration factors should be applied to both stress and variable stress, K, for mean stress and K. for variable stress. Therefore for bi material, equation (i) becomes.for fatigue strength £$ ——_——_______________ 199 Considering the important three modifying factors for the endurance limit, the equation (ii) (ii) becomes, K_,o, 1 " ' ‘ = For ductile material ty) 4.0, n ee | orbri ‘ .0,6,.c, 1 3, For rittle material sen (9) Size effect in the ultimate stress is neglected. Equation (iv) and (v) are modified Goodman's equations. (Considering the stress concentration for the reversed stress, the Goodman's equation used for loading is, ---- 5.39 (DDHB) G_,, —Asexplained earlier, Su Owe a -~- 5.15 (DDHB) at a #k, Kym ——~ 5.10 (DDHB) where n, = n = Actual or given factor of safety 1 = —.K,, .n For brittle material K, Substituting in Equation 5.15(DDHB) Neglecting the size effect for ultimate stress o,, ==> nha sla Same as that of given in equation (v) for the brittle material. For ductile material the effect of stress concentration on ultimate stress or steady load is neglected oO, Gy = —* > same as that of given in equation (iv) for the ductile material,200 ——_— mm Design of Machine Elements ‘The Goodman's relation used for bending load is K, Gry Sm ey --- 5,51 (DDI Fig Fa The Goodman's relation used for torsional load is, K_,t, Ta” Te + —- 5.63 (DD! 3.6 STRESSES DUE TO COMBINED LOADING "The problem of fatigue behaviour under the action of different types of loads i... Be Axial and Torsion is still not fully discussed. However, the behaviour under biaxial load [i bending and axial or bending and torsion ctc.,) has been discussed in detail. The i theory of failure is used after converting the load into equivalent static load, For ductile either maximum shear stress or maximum distortion energy theory is'used, For brittle mat the maximum normal stress theory is used. (i) According to maximum shear stress theory Tn = VOTae +A To WHEE Ta n = Factor of safety a 1 -) where 7, = 0.6.6, Mon, 1 9, =p where 2, = — For bending load A" 6 for bending load where Z, = : For torsional load For torsional load For axial load For axial load,201 gn for fatigue strength According to distortion energy theory Gag = YG oq +3T cy Where 6, According to maximum normal stress theory a= i [oan Von tse | &y ae and n = Factor of safety 4 From Design Data Hand Book oe ot ee ---- 5,65 (DDHB) M Forbending loadd,, = Oy, = --~- 5.46 (DDHB) ee S.a* Ty = --- 5.18 (DDHB) ‘Neglect the size effect for yielding and stress concentration for static load since the effects are negligible. I 6. oy Sit rlip ay al Moy For bending load 0, = 6,, = “7 --- 5.45 (DDHB) » ba t, =tytoot --- $.66 (DDHB) us Bi Ena Mu omen --- 5.58 (DDHB) ? M c= oe =. 5.57 (DDHB) P rome tas , tee =~ Tikey = 0.6 o, for fatigue loading. ec a y yDesign of Machine Elements Considering the stress concentration for reversible stress equation 5.65 and 5,66 becomes. 202 i Ti oy On = St Gg Fy m = Sat gi, Sos Tat ty Ht t TK m= Tet ey G_,, and T_,, can be obtained as explained earlier For ductile material according to maximum shear stress theory LSS 85... Oy Ree ZG, +4 where T= > = 3, (DDHB) According to distortion energy theory 2 7 By = al = -- 5,69 (DDI 6, 6, +3, Where 6, = — 5.69 (DI For brittle material according to maximum normal stress theory, t fs = 7 6. G=> [ou + oq +4, | wher o, = = ~~ 5.67 (DDI 2 3.7 CUMULATIVE FATIGUE DAMAGE : MINER'S RULE When more than one stress level exists in a working cycle, the load cycle should be divided shown in Fig. 3.16 into a number of intervals in each of which the mean and alternating stress be considered constant. The equivalent completely reversed stress should be calculated for position, Fig, 3.17 shows the failure curve for completely reversed stress.Tor fatigue strength: 203 Let N, be the number of stress cycles before fatigue failure if only o, is acting. One stress 1 “eycle will take \ of the fatigue life and as there are n, cycles at this stress level, the proportional N ; a, a damage is jy. Similarly the proportional damage for stress level , will be 3 and so on, 1 2 Nowadding, a ® a, . N, Tie *N, toh 1 fi) Equation (i) is called Miners equation. Let 'N’ be the total life of the component. Then n, = o,N, n, =, N, n, =a, Nete,, where ct, 0,0, etc., are proportion of the total life _ that will be ‘Cones by the stress levels 6,, 6, 0,, etc. Substituting these values in equation (i) mo Oy a, iSiaaad feast cake Also 0, + 0, +O, + +01, = The life of a component subjected to different stress level can be determined by using these equations, ie N 1 HIGHLIGHTS i K = 1+q(K,-1) where K, = Actual stress concentration factor due to static load K, = Theoretical stress concentration factor due to static load q, = Notch sensitivity index due to local yielding For metal with excellent ductility q, is zero and therefore. K,, = 1. ie., the effect of stress concentration can be neglected For brittle materials, q, = 1 and therefore Ky, Be K) = 144 (K,=1) Where K_, = Fatigue or Endurance stress concentration factor, q = Notch sensitivity index, It is a measure of sensitivity to the discontinuities. It is very difficult to specify the usual values of 'q' as it depends on the chemical composition of the material, heat treatment and nature of cycle, If the yalue of q is not available then take K =204 Design of Machine Elernents. ii, Although size effect (e,,) reduces the yield stress, it is considered only for heavily s machine parts and the effect is neglected for the design of ordinary parts. Any other modifying factors like temperature effect, corrosion, etc., are given, then should be considered for calculating the endurance strength. y. Normally brittle materials are not used for fatigue load. vi For fatigue load ¢, = 0.6 6, . vii, According to maximum shear stress theory t, = —j- = 0.5 6,. 2 viii, According to distortion energy theory t, = 0.5776, ix. For ductile material the effect of stress concentration on the yield or ultimate strength neglected. For brittle material the effect of stress concentration on the ultimate strength considered, x. Ifthe value of modifying factor is given as more than one, then consider the given me factor.as correction factor and if the given value is less than one, then consider it as c¢ coefficient, Eg: If the surface modifying factor is given as 1.1, then k, = 1.1. If the surface modifying factor is given as 0.9, then e, = 0.9. Similarly if the modifying factor for size is 1.25 then k,, = 1.25 and if it is 0.8, then &, =! and soon, xi, Combined loading numericals can be solved by any one of the following three methods. Method I - Combined stress by equivalent stress method. Method II - Combined stress by Soderberg/Goodman relation method. Method III - Combined stress in terms of Load method. Example : 3.1 ‘Astuet rod (SAK 9260 oi! quenched, =L0B9.5 MPa, 5, = 689.4 MPa, o_, = 427.61 is subjected to.a tensile load which varies from 120 KN to 40 kN. Design the safe diameter of the red: “Soderberg Diagram". Adopt factor of safety as 2, stress concentration factor as unity and factors for load, size and surface a5 0.75, 0.85 and 0.9 respectively. (B.U, Aug, 1995, VTU, Dee 071 Data: Material -SAE 9260 Oil Quenched; 6,, = 1089.5 MPa, ©,,= 689.4 MPa, o_, = 427. [From Table 1.7 Old 120kN = 120% 10°N=12% 10'N (Tensile) 40KN = 40 10°N=410°N (Tensile) 2 1 0.75; ©, =O85; ¢, =0.91re | Design for fatigue strength 208 | Soation [Asthe steel rodiis subjected to variable axial load, Soderberg's relation for axial load is, a +oe ef ~ saoqppee) For axial load Eos +E, Enum + Fini _ 12210" +410" _ gy Ot N -—--5.33 (DDHB) Mean load F,, = 4 ‘Load amplitude F, = 4x 10'N 5,32 (DDHB) F, _ 4x10* ys Stress amplitudes, = == = peggescti ls ws-- §:34.a (DEB) * i thtuceds nd* 4 F, 8x10" — 32x104 Mean stress @,, = <8 =~ = 5 == 5.34 b (DDHB) aA Rad nd? 4 Design stress based on endurance limit o,, = —> -— 5.19 (DDHB) Design factor of safety based on endurance Himit n,, = k,K,.K,.0.,, -—-$.13 (DDHB) = no: “}f : ) 2) = 3.4475 oat) (ors) O= * 2 = 124.03 Nimm? Gy Design stress based on yield strength 6, = —~ —-5,16(DDHB) " Nya Design factor of safety based on yield strength n,, = k,.Ko,.m, —5.12(DDHB) 1 = 5 -Ke,.n Gs n,.=n= Given oractual FOS) e, Neglecting the size effect for yielding and stress concentration for static loading in ductile material 0,2 =? 689.4 Gq =a = 344.7 Némm? —5.40(DDHB)206 —_A Design of Machine Elements 1x16x10" 22x01 _ _ (na? 124.03) © (nd? \344.7) . Diameter of rod d= 26.57 mm, say 30. mm Note : For axial load endurance limit = ac, where ¢, = Load correction coefficient Example : 3.2 A piston rod is subjected to a maximum reversed axial load of HOKN, Itis made of steel having ultimate stress of 900 N/mm? and the surface is machined. The average endurance limit is 50% of ultimate strength. Take the size correction coefficient as 0.85 and factor of safety = 1.75. Determine! dimmeter of the rod. Data: Reversed axial load F = 110KN = 11x 10'N By, = +Hx1ON& FL, 3, = 900 Némm* 0, = 50% o, = 0.5% 900 = 450.N/mm! Ny FOS = n=1.75; ¢, = 085 x LON Solution : ‘As the piston rod is subjected to completely reversed axial load, Goodman's relation for axial | K. Keo, , Sm 2} ~~ 5.39 (DD O., Sud For axial load, load correction coefficient ¢, = 0.7 From Fig 5.3 (DDHB) for ¢, = 900 N/mm’, and machined surface (rough finish), surface coefficient ¢, = 0.78 For axial load 11x10* Mean load F,, = Load amplitude F, = 2 2 = Lx 10°N ; ixio* 44x10" Stress amplitudes, = a i = (078 4 ef Mean stress 6,Beason for fatigue strength: —$ $A 207 = (as) (ea) (4) (1.75) = 3,771 = ee = 119.34Nimm Design stress based on ultimate strength G_, = a --—5.15 (DDHB) Design factor of safety based on ultimate strength n,,= k,-Ko, .0,, --~5.10(DDHB) ian, .Kg,.n (: n,,=n= Actual FOS) Neglecting the size effect for yielding and stress concentration for static loading in ductile material (> Steel) 900 “ Oy = Tag = 514.286 Nien? Considering the stress concentration for variable or fatigue loading, Goodman's relation for axial load ‘is (ductile material) Kgs | Oy O_ig Guy 39(DDHB) x44 x1ot xd? 119.34 +. Diameter of piston todd = 34.26mm, say 35 mm ie., 0 = 1 (K,=1,sincenot given) Example : 3.3 Accantilever beam made of cold drawn carbon steel (0, =550MPa; 0, = 470 MP: circular cross-section shown in Fig, 3.18 is subjected to load which varies from - F to 3F, Determine the ‘maximum load that the cantilever can withstand for an infinite life, using a factor of safety of 2. (VTU. Jan/Feb. 2004, July 2007, Jan/Feb 2006, June 2012) Data: o, = 530MPa; ¢, = 470MPa; 0, = 275MPa D= 20mm; d= 13mm; r=3mm FOS n=2 Solution : [+——— 150 __ As the cantilever is subjected to variable bending load, Soderberg’s RB F Pte ‘ relation for bending load is, Kobe, Sim - 5.52 (DDHB) 40 gis Cua One At f Size correction coefficient ¢, = 0.85 (-. 7.5 = 16.298 x 10 W ~-+5.46 (DDHB) b Byso} Design factor of safety based on endurance limit n ,, =k, k, k,n, 5.13 (DDHB) ican = 5, 320 “Design stress based on endurance imit@.,, = "1° =yge> = 172.8Nimm* ——5.19(DDHB) Design factor of safety based on yield strength n= k.Ko, n, 5.12(DDHB) jen), = 2 Koon Neglecting the size effect for yielding, stress concentration for static loading in ductile material ay, = n=1.25 524 Design stress based on yield strength 6,, = > = 22 _ 416 symm? —5.16(DDHB) ) gh Oy, = T= 55 Considering the stress concentration for variable load, Soderberg’s relation for bending load is, Kg. Se, Se a ~5.52(DDHB) oi Tyg 1x8149x 107 W ¢ 16.298 x10 W 172.8 416 ce W = 11S82.6N,i.c., ILGKN 2 Wes LL6OKN and 3W = 34.8kN = I[Asthe stress concentration factor is not given, take Kg = 1]-| Design for fatigue strength 211 Esample : 3.5 Astepped shaft of circular cross-section shown in Fig. 3.20 is. subjected to variable load which is completely reversed with a value equal to 100 KN. It is made of SAE 1045 stecl annealed 19, =586.4 MPa ;¢, = 309.9 MPa ; a, = 289.3 MPa). Determine the diameter 'd' and radius ‘r’, so that themaximum stress will be limited to a value corresponding to.a factor of safety of 2, Notch sensitivity index = 1 Data; — Material - SAE 1045 steel annealed [From Table 1.4 Old DDHB] 100 m G, = 586.4 MPa ; 0, = 309.9 MPa ; 0, = 289.3 MPa \~ 4 -100 kN +100KN = +10°N teat F,,, = ~L00kN = -105N n FOSn = %q=1 Solution : Fig. 3.20 Asthe given stepped shaft is subjected to completly by reversed bending load, Soderberg's relation for K bending loud is, 2H + Som —-552(DDHB) Oy Oy Load correction coefficient e, = 1 (., Bending load) Assume size correction coefficiente,, =0.85 From Fig. 5.3 (DDHB) foro, = 586.4 MPa and rough finish, Surface correction coefficiente, = 0.82 1 D isd cB From Fig4.26 (Old DDHB): 4.21/4.21A (New DDHB)for-> === =18; 5 = a7 3012s Stress concentration factor K, = 1.585 K =K, = 1:585(--q=1) As the possibility of failure is at the fillet, Maximum BMatthe fille. My, = +10°x 100 = + 107N-mm Minimum BM at the fillet My, = -10x 100 = — 107 N-nm For ending load My. ~My, _ 107-(-10") Bending moment amplitudeM,, = 7 RE 10'Nmm 5.43 DDH) My +M, 10’ -(-10") Mean bending moment M,,,= —"*->- Seo ~--5.44 (DDHB) 32x10" Bending stress amplitude p, = ae -—-5.45(DDHB) M, Mean bending stress 6, = >" —~546(DDHB) eDesign factor of safety based on endurance limit n,, =k, k_k,M.,, 5.13) ‘ all Sate es team = BS = (oasyoa2yy = 2:87 Design stress based on endurance limite, = = 100.82 Nimm? S19 Design factor of safety based on yield strength n,,= k,-Ko,.n,, 1 a Reet Neglecting the size effect for yielding and stress concentration for static loading in ductile ra n= n=2 Design stress based yield strength Oy, = ny, 2 Considering the stress concentration for variable load Soderberg’s relation for bending load is, Kio Gum Sb. 4 mel —552 OG yg 1.585% 32x10" i. > + “(pa )(100.82) Diameter of rod atthe filletd = 116.99 = 117 mm, say 120mm, + Fitetradiuse = 4g = 422 215mm 8 8 e,, Xe ‘ sss x.} 4 S864 MPa t 0 Fig. 5.3 (DDHB) Fig. 4.26 (Old DDHB); 4.214.214 (New,Dedign for fatigue strength — A A@A@A@@ ia @i@a@@ @a $$$ 213 Example : 3.6 A beam of SAE 2320 steel oil quenched (6, = 516.8 MPa ; 0, = 331.5 MPa; MPa) is subjected to a load causing a bending stress of 200 N/mm? (i) Find the factor of safety if the loads steady. (ii) Find the factor of safety if the stress is varying between - 150 N/mm? and 200 N/mm? and the stress concentration factor is 1.2. (iil) Find the factor of safety if the stress is completely reversed. ‘Take the load and size correction coefficients.as 1 and 01.9 respectively. 316.8 Data: Material-SAE 2320 oil quenched 0, = 516.8 MPa ; 6, = 331.5 MPa ; 316.8 MPa Bending stress = @, =200N/mm? e, = 09; e=1 Solution : From Fig. 5.3 (DDHB) fora, = 516.8 MPaand rough finished, Surface correction coefficient e, = 0.835 () Forsteady load G, y FOS n = oy (i) Fluctuating bending stress 55, = 200N/m Gy, = — 150 Nini? Bending stress amplitude 6), = a 516.8 MPa = - ei Fig. 5.3 (DDB) 0D os Nim 2 =k kk, (0.9)(0.835)0)) 3168 238.075 ny ~ 134680 ~ on Design stress based on endurance limit o.,, = Design factor of safety for yield strength n,, = k,-Ko, .n,, —5.12(DDHB)214 Design of Machine Elements - | Pym 9, 3315 j +. Design stress based yield strength 0,, = in —5.16(DDHB) | v4 From Fig 4.17 (Old DDHB); 4.13 (New DDHB) for quenched steel q = 1 .K, =k, Considering the stress concentration for variable load Soderberg’s relation for bending load is, 9 Kio Gre , Sh =1 =~ 5.52(DDEB) Oui Ove L2xI7S as mee) eee) “4 n n © FOSn = 104 (iil), Completely reversed stress Sy. = 200Nimm? Gy = ~ 200 N/mm? 200 -(~200) Bending stress amplitude Sy, = em) = 200N/mm? 200-200 Mean bending stress Oy, = 5 =0 Soderberg’s relation for bending load is, , 1 «200, = 1 [Neglect K_, since itis not given for completely reversed stress] 2 FOS n = 119 Example : 3.7 A cantilever beam shown in Fig. 3.21 is subjected to load variation from - F to 3F. Determine the maximum load that this member can withstand for an infinite life, using a factor of safety 2. The material of the beam is SAE 1025, water quenched steel (, = 620.8 MPa; o, = 400.1 MPa; 0, = 345.2 MPa). (VTU. July/Aug, 2002, Dec '06 /Jan'07)ll Design for fatique strength: Salution : ‘As the given cantilever beam is subjected to variable bending load, Soderberg's relation for bending 215 Kio, Son load is, Gaga AOE —-5.52(DDHB) Load correction coefficient e, Bending load) Size correction coefficient ¢,,= 0.85 (. 73.—"8* = —— 22,5 104 N-mm Mi, t+ Me, 35x 10% — 4 Mean torque M,, = —'™\>—s = tee = 12.5% 10'N-mm 225x104 — 36x10" Stress amplinde 1, = = _--5.57(DDHB) ry ad 16 M, 125x10" — 20x10° Mean stress t, = = =—=——— = =a -—5.58 (DDHB) OZ Te ad 16 Load correction coefficient for torsional load ¢, = 0.6 Assume size correction coefficient c,, = 0. From Fig. 5.3 (DDHB) fora, = 600 MPa Surface correction coefficient for torsion ©’ s. Design endurance stress for torsion 7.4, = Rough p 4 fa # 0.91 4 7 4 el & oe eas hee — (o-MesWeus Kew) ae 1 Fig. 5.3 (DDHB) = (le KE se) were, =(0.,)(@)=300% 0.6 = 180mm? 1" s esaxogsyoon = 77.35 Nimm? Design yield strength in shear Ty, = “5.17 (DDHB) Neglecting size effect for yielding and stress concentration for static loading in ductile material218 Design of Machine Elements. Ty _ 280 4 Ty, = oh =F =155.556Nimmi As specific information is not available, neglect notch sensitivity. . K ,=K, = 13 Considering the stress concentration for variable load, Saderberg's relation for torsional load is, yd 13x36 x108 20x 108 (na? (77.35) i (na )(55.556) +. Diameter of steel rod d = 28.58 mm, say 30 mm Example : 3.10 ‘The non rotating shaft shown in Fig. 3.23 is subjected to a load F varying from 4000 N to 12000.N. shaft material haso, = 600 MPa ando_, = 300 MPa. The correction coefficients for surface, size and k are 0.8, 0.85 and 0.9 respectively. Find the dimension 'D’, for a factor of safety of 3.5 and notch se index 0.9. All dimensions in mm Data: 6, = 600N/mm'; & , =300N/mm?* c,, = O08; ¢, =085;¢, = 09 n= 35; q=09 Solution : F As the distances are symmetrical, the reaction atthe bearings are —> ‘The possibility of failure is at the fillet 12000 Maximum B.M. atthe fillet My, 600 = 2 600 = 36x 10°N-mm 4000 x 600 Minimum B.M- at the fillet My, x 600 = = 12 10°N-mm| | Design for fatigue strength | Forbending load 219 Bending moment amplitude M, = --~5.43(DDHB) . : = DORM azo, ZEB = 12x10°'N-mm M,,, +My... Mean bending moment M, = —ms>—*ss —S.44 (DDHB) _ 365x105 +1210" - eee = 24x 10°N-mm 2x08 zx 3 32 «80 Bending stress amplitude Op, = 23.873 Nimm? ---5.45 (DDHB) 24 «10° Mean bending stress T= = 47,746 Némm? —5.46(DDHB) © eggs 9 «80 Design stress based on endurance limit 6_y = ~~ —-5.19(DDHB) 5 eg oinen erie © Kalksckytgg = MOOR 0808 252.457 Ninn? Design stress based on ultimate strength o,, = —* — 5.16 (DDHB) at Mea p eee oe © Kako ty ~ Ko, xe a Neglecting the size effect for yielding and stress concentration for static loading eed -—5.51 (DDHB) Kg x 23873 47.746 $2457” 171.429 ~ icy220 Design of Machine Elements 2K, = 1585 K, = 1+q(K-"] ie, 1585 = 14+0.9[K,-1] 2K, = 168 From Fig, 4.26 (Od DDHB); 4.21/4.21A (New DDHB) 145 r 8 - ot = — = 01 = 1.65 for | = gg = O-band K, = 16: x4 Dd — = 135 0 a 43: cD = 1.35x80 = 108mm. Fig. 4.26 (Old DDHB); 4.21/4.21A (New DDHB) Combined loading Example : 3.11 A steel member of circular section is subjected to a torsional stress that varies from Oto 35 MPa at the same time it is subjected to an axial stress that varies from - 14 MPa to +28 MPa. Neglecting concentration and column effect and assuming that the maximum stresses in torsion and axial load: the same time, determine (i) Maximum equivalent shear stress (ji) Factor of safety based upon yield in: ‘The material has an endurance limit ¢_, = 266 MPa and an yield strength o, = 480 MPa. diameter of the member is less than 12 mm. Take load correction factor = 1, Surface factor =1 (VTU. March. Data: 1... = 3SMPa; t,, =0; 0,,=28MPa; o,, =~14 MPa 3, = 206MPa; a, =480MPa; ¢,= = 1;d< 12mm Solution : ‘Combined stress by equivalent stress method (Method - 1) (a) () Consider torsional load ‘Torsional stress anmplitude t, = = 175N/mm Tru +Taiy _ 35+0 ; Mean torsional stress t, = "al. =" = 17.5 Némm? Ja Equivalent torsional stess t, = T= Tet yf 5.66)Design for fatigue strength where t ,, Neglecting stress concentration Tuy _ 288 Bo iy, 22) gp abe peal Gat nol Sig Bag Rg Be ky n 1, x1)x1X: « ar] pg POSED RUST met = Ge) n 0 2as an ty Cig Ty ka Ko,-Myy ~ Kg,.n for static loading and size effect for yield strength = —% = > [In fatigue or pure torsion, x, = 0.60, =0.6 480 = 288 N/mm] Considering stress concentration for fatigue loading (ii) Consider axial load ‘Axial stress amplitude 6, Mean axial stress o, Equivalent normal stress o',, wherea, Six —Smin _ 28-(-14) e " 2 2 2 21 Némm! Smut+ Sein’ 28-14 " 2 5 = 7 N/mm’ Sut arn ~-- 5.65 (DDHB) 14 ee SOE eerie mag Kekekniy 206 x1 bd 206 rei n rest n, ghey yy Re yd Neglecting the size effect for yield strength and stress concentration for static loading ree a222 —$ Aa Design of Machine Elements -| : 6 Considering the stress concentration far fatigue load c',, = 6, =9, +—"~ .0,K., “id ra sop Cale 55,932 Nimm? . Maximum equivalent shear stress according to maximum shear stress theory — {55.932 + 4x 41.9667 = 50.43 Nimm? 1 2 3 = 50.43 Nimm? y 6 (b) Wehave 7,,,= 2 = =* = n 2n soa = ven = On .. FOSn = 4.76 Example ; 3.12 A hot rolled steel shaft is subjected toa torsional load that varies from 330 Nm (cw) to 110 Nm (cew) as an applied bending moment at the critical section yarles from + 440 Nm to - 220 Nm. The shaft is uniform cross section and no keyway is present at the critical section. Determine the required st diameter. The material has an ultimate strength of 550 MN/nr and yield strength of 410 MN/m?. Factor safety = 1.5. Size and surface correction coefficients are 0.85 and 0.62 respectively. Take the endu: limit as half the ultimate strength. [B.U. Oct. 98 ; VTU. Jan/Feb. 2004, June/July 2009, May/June 2010, Dec. 2011 Data: My, = +330Nm = +3310! N-mm M,,,, = -110Nm = - 11x10" N-mm 440.Nm = +44 x 10" N-mm My_, = -220Nm = 22x 10* N-mm 9, = 550 MN/m? = 550N/mm?; 9, 110 MN/m? = 410 N/mm* = 0.62 n= FOS =15 36, = 0.85; tate e, 1 3 on 5% 550 = 275 MN/m? =275 Nimm?Design for fatigue strength: 223 Solution : Combined stress by equivalent stress method (Methed - 1) @ Consider torsional load M nn _ 332104 -(-11x10 Torque amplitude M,, = —**>——** agen s neeseee 22 10*N-mm +M, 3x10" — 4 Mean torque My, = st ae = 11<10'Nmm 22x10* — 11204510" Torsional stress amplitude t, See ~-57(DDHB) -—§ 16 M,, x10" $6,023x10" Mean torsional stress 7, = >" = qs = se —-5,58(DDHB) eae Lr d 16 —5.66(DDHB) Equivalent torsional stress 7, where t,, = BY nig Kee scKiMa n (For torsional load ¢, = 0.6) 5x0, ss 165X0.85 x 0.62 = 57.97 Nimm? Ty, = Neglecting size effect for yiclding and stress concentration for static load += where t, = 0.60, in fatigue for pure torsion 0.6% 410 = 246 Némm? ‘Considering stress concentration for fatigue loading 1 Get eee eeR - Toa224 Gi) Consider bending load: Bending moment amplitude Mi, Mean bending moment My = Bending stress amplitude 6, Mean bending stress 6,,, = Equivalent bending stress of, wheres, _ 56.023% 10" Design of Machine Elements - ise) 112.045%10* +\ 5797 a ay a _ | 373x100" Son = a M, -M 44x10' (22104 gg Mg 5 Mato! (2000) seine ti 2 2 +M, 22x10* ga ae, MIO S22 KIO i104 2 2 33x10" 336.135 x10* =. “a —5.45(DDEB) M,, _11x10* _ 112,045%10! = Moe ss 2 —5.46 (00) 32 --—5.65 (DDHB) _ 94 o — Fleury Sig KgeKgur tg a 275% 0.85% 0.62 x1 = 96617 Nha? 9, Ke Ky, thy Neglecting size effect for yielding and stress concentration for static load a, 410 = Ss == = 273.33 Nim n 15 Considering stress concentration for fatigue load g, = On = Sy +n, HK 112.045 x 10" (23) 336.135 10% “ #1 (96617 a a) 1063 104 oe— 225 Design for fatigue strength Now maximum equivalent shear stress based on maximum shear stress theory a T= Toe = 9 Vou + 4ty —~5,68(DDHB) 7 fe en ane 1 (ee) +f) _ 6493x108 2 ao a a All cnt $0 Tag, = at mes: eran) a 6.493% 10° 410 @ 2x15 «+. Diameter of shaftd = 36.22.mm,say40mm Example : 3.13 Around rod of diameter 1.2d is reduced toa diameter d witha fillet radius of 0.1d. This stepped rod is tosustain a twisting moment that fluctuates between + 2.5 kN-m and + 1.5 KN-m together with a bending moment that fluctuates between +1 kN-m and —1kN-m. The rod ismade of carbon steel C40 (6, = 328.6 MPa; 6, = 620 MPa), Determine a suitable value ford" (VTU, Jan/Feb. 2003) Data: D= 1.2d;r=O.1d +2.5kN-m = +2.5« 10° N-mm +L5kN-m = +15 x 10° N-mm +1kN-m= 1x 10 N-mm My, = -1kN-m = -1x 10° N-mm Material of rod C40 steel; 6, = 328.6 MPa ; 0, = 620 MPa [From Table 1.5 Old DDHB) Solution : Combined stress by equivalent stress method (Mehtod - 1) Assume factor of safety n= 2 6 ,=0.5, =0.5 620 =310MPa ) Consider torsional load From Fig, 4.23 (Old DDHB); 19/4.19 (New DDHB) D fory = 125 201 x4 Shear stress concentration factor K, = 1,335 t | Torque amplitudeM,, = 0 io Oo Fig. 4.23 (Old DDHB); 4.19/4.19A (New DDHB)226 Design of Machine Elements -| 6 mae X10" = 0.5% 10N-mm 2 M, +M. Sx 10% 0° Mean torque My, = ae # eee = 2x 10°N-mm M, _O5x10° 2.546510" Torsional stress amplitude T, ~~ 1.57 (DDHB) 10186 x Lo® Mean torsional stress, T, — .58 (DDHB) Equivalent torsional stress 1, ~-- 5.66 (DDHB) ‘ = Se 2 SS _ .,, Stet Whe Kkekity 7 Fatty sincet, =@ ,:¢, =310* 0.6 = 186 MPa Assume size correction coefficient ¢, = 0.85 From Fig. 5.3 (DDHB) foro, = 620 MPa and rough finish Surface correction coefficient for torsion e' =0.91 0.81 oat 186% 0.85% 0.91 4 = 879385 Niemi ay KyaKa,-My, 620 MPa a Ty.te © Kg, -0 Fig. 5.3 (DDB) ‘Neglecting size effect in yielding and stress concentration for static load. To where t, = 0.64, in fatigue for pure torsional = 0.6% 328.6 = 197.16 MPa Ty = 5 = 98SEMPHDesign for fatigue strength a ARa_J_€?@J>_J_$€_$_________ nd, 10.186x10° 98.56 (2.5465 10° hese 71.9355 é rae | =, 14.845 10° tee Gana ee : (ii) Consider bending load D From Fig. 4.26 (Ol DDHB);421/4.21A (New DDHB)for > = 12and + = 0.1 Stress concentration factor K, = 1,625 M, M, Ix10° Bendling moment amplitude My, = Taanoeh = ) =1x10°N-mm +My, Mean bending mement My, =0 ——5.44(DDHB) Tx1O® 10186 10° Bending stress amplimde o, ee ee —~5.45 (DDHB) ts mys a 32 6 eM , oe Mean bending stress 0},, tee e Equivalent bending stress ¢., = rt 6 Sake, eee er rr : 1 From Fig. 5.3 (DDHB) when 9, = 620 MPa and rough finished or q machined or cold drawn Fig. 4.26 (Old DDHB); Surfluce coefficient for bending e, = 0.81 4.21/4.21A (New DDHB) 0085x0811 = BOOB OSH = 106.7175 Nima? oy o, Sue By Derr sta Ke Ke, ty Ko,+n Neglecting size effect for yielding and stress concentration for static loading a, _ 3286 ay = Y= 8 = 164.3 N/mm? Neglectingq,K, = K, ° Considering stress concentration for fatigue, 0,,=0., =», +=" . oy, .K n= Om = 9, + G8, K,22 ——_—_______________ Dasign of Marchiine Elements - i 6 ( 1643 ) 10,186 10° = O+\ G06. 7175 oe (1.625) 5.4835 10° * Gey = Om = a Ip ¢. Maximum equivalent shear stress based on maximum shear stress theory i , re ; (Gy) +4{ Sage) —- 5.68 (DDHB) 1 [f254835%10°f14:84s210° )° alse Te \ 19,5634 x 10% =e a, 9; a thee AIO yy = = 5 Némm? 19.5634x10° 328.6 a’ 2x2 <. Diameter of red d = 61,98mm, say 65mm Example : 3.14 A steel cantilever member shown in Fig 3.24 is subjected to a transverse load at its end that vs from 45N up to 135 N downas an axial load varies from 110 N compression to 450.N tension, Determine the required diameter at the change of section for infinite life using a factor of safety of 2. The st properties of the material areo, = 550 MPa,, = 470 MPa ando,, = 275 MPa. Notch sensitivity qeL. [VTU, Dec.09/Jan.10, Dec.20 Fig. 3.24 Data: n=2; 6, = 550MPa, o, = 470MPa; 6, = 275 MPa Solution ; Combined stress by equivalent stress method (Method - 1) (i) Consider the axial load F,4, = 450.N (Tensile); F,,. = 1ON(Comp.);ee Design for fatigue strength 229 Ro +P 450-110 . Mean load F, = BA >—BS = = 170N 5.33 (DDHB) Load amplitude F, 230N ---5.32 (DDHB) Stress amplitude 6, —-5.34.a(DDHB) Mean stress 6, = == 5,34 b(DDHB) From Fig, 4.24 (Old DDHB); 4.20/4.20A (New DDHB) 2, for2 224 X cee eee 1.635 Stress concentration factor K, = 1,635 ‘Assume size correction coefficient e,, = 0.85 k,| For axial loading load correction coefficient e, = 0.7 From Fig. 5.3(DDHB) when, = 550MPa ‘ — Surface correction coefficiemte, = 0.83 Goahhn a Fig. 4.24 (Old DDHB); ‘Equivalent normal stress 6, =o, + eit 9, 4.20/4.204 (New DDHB) ta . = patie LI Yi t Mein fe, lta ge Reka 2750.85 X0.830.7 Note i c_, ¢, is the = ee ae endurance limit for axial load = 67.904Nimm? eis Dy Ka-Ka,my, Neglecting size effect for yielding and stress concentration size static load 9. 7 eo 222 @235Nmme ep 2 Considering stress concentration for fatigue loading, | wq=1K,=K, 6, Faia, = Sy 29g 457 5,K 216.451 ( 235 \ES) 233.683 5 (oe Bee 67.904) a? B= a230 ——— a Darsign f Machine Elements -| Gi) Consider bending load Since the possibility of failure is atthe fillet, ‘Maximum B.M. at the fillet Mj yyy = 135 % 125 = 16875 N-nm Minimum B.M. at the fillet My,,, = —45% 125 =- 5625 N-mm From Fig. 4.26 (Old DDHBY; 4:21/4.214 (New DDHB) D r fort = 2and7 = 02 350 MPa Stress concentration factor K, = 144 Fig. 5.3 (DDHB) From Fig. 5.3 (DDHB) Surface correction coefficient ¢, = 0.83 Sinceg= 1, K., = K, = h44 Load correction coefficient for bending e, M -M 16875 —(-5625) Bending moment amplitude My, = —""*5—"= = Jerns 5679) = 11250 Nemm M,_ +M 16875-5625 Mean bending moment My, = oo = 7 = $625 N-mm , ( 114.592 10° Bending stress amplitude Oy, a ~-- 5.45 (DDHB) 57.296% 10" Mean bending stress Sy, = Se — -—- $46 (DDHB) - Lan d 32 Equivalent bending stresso., O+ oe Oe, ~~ 5.65 (DDHB) Md Gb SA OOF were ay Kg kakin ag a 2 1.85. z TsxOSsx O89) agthanlt o,, = 235 N/mm’ same as that of axial A Considering stress concentration for fatigue loading, 9. el I a a 7 . 457.07 x10° + Fea scoung = a 5729610? (235) [114.592 10' Stapssto” , (2) (: jaa)ae | ¢. Maximum equivalent normal stress o,= cgay + Cec g Se 3 Y J 457.07 x 10 Also, = 2233,683 457.07 x 10° “238 Ta ‘serena he Lie 02 d 3 2233.683d +. 457.07 x10° Fig. 4.26 (Old DDHB); i a 4.214214 (New DDHB) ic, 235 d’~2233,683d - 457.07 x 10' =0 ie, d’—9,505d—1945 = 0 By trial and error method Diameter at the change of section d= 12,75 mm. Example : 3.15 Ashaft of circular section is subjected to a turning moment that fluctuates between 800 kNm and 600 kNm and also a bending moment that fluctuates between + 500 kNm and -300kNm. The material selected for the shaft has a shear stress value of 100 MPa at endurance limit and shear stress value of 120 MPa at the yield point. Determine the diameter of the solid circular shaft taking a value of 2.5 for the factor of safety. Surface factor, size factor and load factor can be taken as 0.9, 0.85 and 1.0 respectively. Shear stress concentration factor is 1.8 and the notch sensitivity is 0.95, (B.U. Feb, 96) Data: i. = 800KNm = 8x10 N-mm = 600kNm = 6% 10 N-mm My,., = 500kNm = 5x 10" N-mm My, = =-30kKNm = =3x 10" N-mm = 100 MPa; a= 20 MPa; FOS =n = 2.5 e, = 0.9; ¢, = 0.85; ¢, =1; K, = 1.8; q = 0.95 Solution : Combined stress by Soderberg/Goodman relation method (Method 2) Consider bending load in -My 5x10" =(-3x108) 7 a = 4x 10°N-mm Bending moment amplitude My, = Mi, +M, 5x108-3x10° Mean bending moment My, = Sea tties Qe 2 = 1x 10°N-mm232 Design of Machine Elements 4 4xto" 40744 x10" i i oO = = - — Bending stress amplitude 8p, =] =" = 45 (DDI 32 My, 1x10 — 10.186%10° oO =—* =—— =a —- 546 Mean bending stress Sp, Ze Ee a (DDI 32 Consider torsional load Torque amplitude = -~- 5.55 (DDI 2 exrat ie. My, = aa = 1x 10°N-mm M. +M, Mean torque = ts -—- 5.56 (DDI 6 8 ie Mi. = Seige = 7 LO°N-mm . 1x10° 5.093210" Stress amplitude t, = at aaTgeO 16 M,, — 7x10® — 3565x108 Meansesst, = = nay tat 5.58 (DD) 16 According to maximum shear stress theory, , Sepa eee Combined mean shear stress 1), = 5 YO2, +4 gob aga ote 1 |froas6xi08 "| 35 olin yy! kivaats ay 7 Oe, +4% 2h Combined shear stress amplitude T= > 1 fdecassot y {3093x108 _ 2axi08 ay a a ae Now according to Soderberg’s straight line relation considering the stress concentration factor fatigue loading is,233 Design for fatigue strength: i ee Te yl ae lle Oy Mente iy Kyelig yy n 100 x 085% 0.91 : = Se = 90.6 Niemi? 235 tye _ Bye Te Ket Neglecting size effect for yielding and stress concentration for static loading, pol ae ke OBS mm? Fatigue stress concentration factor K , = 1 +q (K,=1)=1+0.95 [1.8~1] = 1.76 176x21x10" | 36x10" _ d’ x 30.6 x48 v+ Diameter of shaftd = 580.665 mm = 600 mm Bxample : 3.16 A cold drawn steel rod of circular cross-section is subjected to a variable bending moment of 565 ‘Nm to 1130 Nm as the axial load varies from 4500 N to 13500 N. The maximum bending moment occursat the same instant that the axial load is maximum. Determine the required diameter of the rod fora factor of safety = 2. Neglect stress concentration and column effect. Take o, = 550 MPa, 6, = 470 MPa, endurance limit as 50% of the ultimate strength and size, load and surface correction coefficients as 0.35, 1 and 0.85 respectively. (B.U, Aug. 99) Data: 1130 Nm = 113 x 10* N-mm 565. Nm = 56.5 x 10* N-mm 13500 N 4500 N 2 550 MPa; 6, =470 MPa; 0, = S0% @, = 0.5 « $50 = 275 MPa O85; 6, = 0.85,¢, =1 Soliton ; Combined stress by Soderberg/Goodman relation method (Method - 2) Consider bending toad 4 = 28.25 x LO*N-mm Bending moment amplitude My, 113x104 +565%10" 2 Mean bending moment My, = = 84.75 x 10"Nemm234 Design of Machine Elements ~ is My, 2825x10 — 287.752x10* Bending stress amplitude %, = a7 ey “a —5AS(DI ’ we 2 M,, — 84.75x10* — 863.2564210" Mean bending stress Oy, = = —5.46 'b raed n° B -F, 13500-4500 = =e = 4500N 5.320) E, Mean load F, = Fae * Faia, 200A 900 9 5301 F, 4500 5.73x10* it ats = > Stress amplitude o, Khe a 9000 | 11461 Mean stress 0, =f = 3 = gi 863.2564 x10" 11.46%10° ft oe Combined mean stress 7, = Sp, +0,.= * 287,752x10% | 5.73x10° Combined stress amplitude o, = g, +6,= yy + qr Now according to soderberg’s straight line equation neglecting the stress concentration for fat loading =1 —- §,83 (DDI oy G4.0y Cy ly WS Oe = ig gly yng 7 n 75 x 0.85% 0.851 a PERO nO = 99.344 N/mm? g, 6, 6,0 Sw = yg = Ka Ko.ty, ~ Kon Neglecting size effect for yielding and stress concentration for static load 9, 6, £ = 2 8 Las n 2Design for fatigue stength ——_— A A — — — 235 863.2564 x10° + — + 65700 S500) 9 d ie, f-106.44dd-65700 = 0 By trial and error method Diameter of steel rod d = 41.231 mmsay 45mm —_—_—____ Example : 3.17 [Asteel shaft is subjected toa bending moment varies from 100 Nm to 200Nm and transmits 10 kW at 150 rpm. The torque varies over arange of + 40%, The shaft is made of steel whose yield stress = 400 N/mm? and endurance stress = 300 N/mm?, Surface coefficient factor = 0.9. Size factor = 1.2. Factor of safety =5. | Stress concentration factor = 1.94, Determine the diameter of shaft for infinite life | Data: My = 200Nm = 2 10° N-mm My, = 100Nm = 1x 10° N-mm N = 10kW; n=150rpm ‘Solution : Combined stress by Soderberg/Goodman relation method (Method - 2) Consider bending load My -M $1108 Bending moment amplitude My, = —t=s—*m = eee = 0.5% 10° N-mm M, +M, s 5 Mean bending moment My, = Seale -ewane = 1.5% 10*N-mm Ms, 095x105 $.093x10° Bending stress amplitude Op, = i = 2210 5 SOPRRIO™ <== 5.45 (DDB) i eal eas d 32 1Sx10* — 15.279x10° Mean bendingstress Gy, = =p = OA ~~ 5.46 (DDEB) sg 32 Consider torsional load M = 93501000 wherein ¥-mm236 TT Design of Machine Elernents Oy = 9550%x 000x755 = 636,667 « 10° N-mm_ = 1.4xM, = 14% 636.667 « 10> = 8.913 10°N-mm. ‘a bay = 0.6XM, = 0.6% 636.667 x 10" = 82x 10°N-mm, M..- ‘Torque amplitude = —**5—* —555 (00) 8913 x10 ~3 08 ie.My, = said ae = 2.5465 10°N-mm M, +M, Mean torque = — 2" 5.661 13x10" f Le.M,, = porate" ssa = 636653 10°N-mm M, 25465108 _ 12.9692%10° Stress amplitude t, = = = Se = gedaan so” $57 01 Zy tg ad 16 6366510" 32.4243 10° Mean stress 1, = Z, T 93 7 a 5.580) 16. According to maximum shear stress theory, Combined mean stress On tate, 5.68! 666242410" a Combined stress amplitude o', = oz, +442 | sits yeety \ 4 26433676%10° =a_ Design for fatigue strength 237 Now according to Soderberg's straight line relation considering the stress concentration factor for fatigue load K.g6, 48a ; 5.83 Sad Sst me S., Gas Pye Cul whereo ,, = Ky Keekj 0 ~ kn 300%0.9%1 we SE Aa Ninict ing ¢, = cae 45.Nimm* (+: For bending ¢,= 1) Oe Sri ty, = keKe, ty, Neglecting size effect for yielding and stress concentration for static loading, a, — 400 eae ‘As specific information about notch sensitivity is not available, neglecting g.K_,=K, = 1.94 80 N/mm? , 194 2643.3676% 10" if 6662.424 x10" a x45 axso + Diameter ofshaftd = 58.2mim say 60mm Example : 3.18 Acomponent machined from a plate made of steel 45C'8 (6, = 630 N/mm’) is shown in Fig. 3.25. Itis subjected to a completely reversed axial force of 50 kN. ‘the expected reliability is 90% and the factor of safety is 2. Determine the plate thicknessé for infinite life, if the notch sensitivily factor is 0.8. Take the size correction coefficient as 0.85. (VTU, July 2007) Fig. 3.25 G, = 630N/mm?; F,., = +SOKN=+4 50x 10'N; F,,, ==50x10°V n = 23q=0.8; Reliability =90%