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Clase 3
Clase 3
2 primary classifications of
fatigue
Alternating – no DC component
Fluctuating – non-zero DC
component
Analysis of alternating stresses
As the number of cycles
increases, the fatigue strength
Sf (the point of failure due to
fatigue loading) decreases
For steel and titanium, this
fatigue strength is never less
than the endurance limit, Se
Our design criteria is:
S f (N )
a
As the number of cycles
approaches infinity (N ∞),
Sf(N) = Se (for iron or Steel)
Method of calculating fatigue strength
Seems like we should be able to use graphs
like this to calculate our fatigue strength if
we know the material and the number of
cycles
We could use our factor of safety equation
as our design equation
S f (N )
a
Se
a
Se
a
Estimating Se’ – Aluminum and Copper
Alloys
For aluminum and copper alloys, there is no endurance limit
Eventually, these materials will fail due to repeated loading
To come up with an “equivalent” endurance limit, designers
typically use the value of the fatigue strength (Sf’) at 108 cycles
Aluminum alloys
Se’ (Sf at 108 cycles) = 0.4 Sut for Sut < 48 ksi (330 MPa)
= 19 ksi (130 MPa) for all other values of Sut
Copper alloys
Se’ (Sf at 108 cycles) = 0.4 Sut for Sut < 35 ksi (250 MPa)
= 14 ksi (100 MPa) for all other values of Sut
Constructing an estimated S-N diagram
For steel and iron S 'f N aN b For 103 < N < 106
5.7
Correction factors
Now we have Se’ (infinite life)
We need to account for differences between the lab specimen and a real
specimen (material, manufacturing, environment, design)
We use correction factors
Strength reduction factors
Marin modification factors
These will account for differences between an ideal lab specimen and real life
Se = ka kb kc kd ke kf Se’
ka – surface factor
kb – size factor
kc – load factor
kd – temperature factor
ke – reliability factor
Kf – miscellaneous-effects factor
Modification factors have been found empirically and are described in section 6-9 of
Shigley-Mischke-Budynas (see examples)
If calculating fatigue strength for finite life, (Sf), use equations on previous slide
Endurance limit modifying factors
Surface (ka)
Accounts for different surface finishes
Ground, machined, cold-drawn, hot-rolled, as-forged
Size (kb)
Different factors depending on loading
Bending and torsion (see pg. 280)
Axial (kb = 1)
Loading (kc)
Endurance limits differ with Sut based on fatigue loading (bending, axial, torsion)
Temperature (kd)
Accounts for effects of operating temperature (Not significant factor for T<250 C [482 F])
Reliability (ke)
Accounts for scatter of data from actual test results (note ke=1 gives only a 50% reliability)
Miscellaneous-effects (kf)
Accounts for reduction in endurance limit due to all other effects
Reminder that these must be accounted for
Residual stresses
Corrosion
etc
Surface Finish Effect on Se
Temperature Effect on Se
Reliability Factor, ke
Steel Endurance Limit vs. Tensile Strength
Compressive Residual Stresses
Now what?
= kfnom+ = kfo
t = kfstnom = kfsto
kf = [1 + q(kt – 1)]
kfs = [1 + qshear(kts – 1)]
kt or kts and nominal stresses
Table A-15 & 16 (pages 1006-1013 in Appendix)
q and qshear
Notch sensitivity factor
Find using figures 6-20 and 6-21 in book (Shigley) for steels
and aluminums
Use q = 0.20 for cast iron
Brittle materials have low sensitivity to notches
As kf approaches kt, q increasing (sensitivity to notches, SC’s)
If kf ~ 1, insensitive (q = 0)
Property of the material
Example
Design Equation:
= Se / ’
Se because infinite life
Example, cont.
= Se / ’
What do we need?
Se
’
Considerations?
Infinite life, steel
Modification factors
Stress concentration (hole)
Find ’nom (without SC)
P P F
nom
2083F
A b - d h 60 - 12 10
Example, cont.
Now, estimate Se
Steel:
Se’ = 0.5 Sut for Sut < 1400 MPa (eqn. 6-8)
700 MPa else
AISI 1020 As-rolled
Sut = 448 MPa
Se’ = 0.50(448) = 224 MPa
Constructing an estimated S-N diagram
Modification factors
Surface: ka = aSutb (Eq. 6-19)
a and b from Table 6-2
Machined
ka = (4.45)(448)-0.265 = 0.88
Example, cont.
Size: kb
Axial loading
kb = 1 (Eq. 6-21)
Load: kc
Axial loading
kc = 0.85 (Eq. 6-26)
Example, cont.
Temperature:
kd = 1 (no info given)
Reliability:
ke = 1 (no info given)
Miscellaneous:
kf = 1
Endurance limit:
Se = kakbkckdkekfSe’ = (0.88)(0.85)(227) = 177 MPa
P
m
A
Mr
a
I
Alternating Stresses
Mean Stress
max min
'm
2
Stress amplitude
max - min
'
a
2
Together, m and a
characterize fluctuating
stress
Alternating vs. Fluctuating
Modified Goodman Diagram
Fluctuating Stresses in Compression and
Tension
Failure criterion for fluctuating loading
Soderberg
Modified Goodman
Gerber
ASME-elliptic
Yielding
Goodman Line
Safe design region a m
(for arbitrary fluctuations
1
Sf Sut
in m and a )
a m 1
Sf Sut
(safe stress line)
Important point: Part can fail because of fluctuations in either a, m, or both.
Design for prescribed variations in a and m to get a more exact solution.
Special cases of fluctuating stresses
Case 1: m fixed
Sa
a
Case 2: a fixed
Sm
m
Special cases of fluctuating stresses
Case 3: a / m fixed
Sa Sm
a m
1 a m
Sf Sut
Example
Given:
Sut = 1400 MPa
Syt = 950 MPa
Heat-treated (as-forged)
Fmean = 9.36 kN
Fmax = 10.67 kN
d/w = 0.133; d/h = 0.55
Find:
for infinite life, assuming
Fmean is constant
Example, cont.
My
Find m and a I
I bh 3 w - d h 3 75 - 10183 3.16x10 -8 m 4
1 1 1
12 12 12
h
ymax 0.009 m
2
M m m Fm L 9.36x103 0.3 702 Nm
F L 1 1
2 2 4 4
Find strength
Eqn. 7-8: S’e = .504Sut
Se ~ 700 MPa since Sut 1400 MPa
Modification factors
Surface : Size : Load :
ka aSut
b
Equation (7 - 19) : Bending
a 271 2.8 d eq 51 mm kc 1 (Eq. 7 - 25)
b -0.995
d eq 0.808hb
1
2
ka 0.201
- 0.107
kb 1.24d eq
kb 0.86
Se 0.2010.86700 121 MPa
Example, cont.
Design criteria
Goodman line:
a m
1/ n
Se S ut
1.25
Example, cont.