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Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide1
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide2
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide3
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide4
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide5
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide6
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide7
ME 307 Machine Design I
Crack Initiation
Fatigue always begins at a crack
Crack may start at a microscopic
inclusion (<.010 in.)
Crack may start at a "notch", or
other stress concentration
Crack Propagation
Sharp crack creates a stress
concentration
Each tensile stress cycle causes
the crack to grow
(~10-8 to 10-4 in/cycle)
Fracture
Sudden, catastrophic failure
with no warning.
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide8
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide9
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide10
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide11
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide12
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide13
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide14
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide15
ME 307 Machine Design I
Figure 7-5
Fatigue fracture surface
of a forged connecting
rod of AISI 8640 steel.
The fatigue crack origin
is at the left edge, at the
flash line of the forging,
but no unusual roughness
of the flash trim was
indicated. The fatigue
crack progressed halfway
around the oil hole at the
left, indicated by the
beach marks, before final
fast fracture occurred.
Note the pronounced shear lip in the final fracture at the right edge. (From ASM Handbook,
Vol. 12: Fractography, ASM International, Materials Park, OH 44073-0002, fig 523, p. 332.
Reprinted by permission of ASM International® , www.asminternational.org.)
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide16
ME 307 Machine Design I
Figure 7-6
Fatigue fracture surface of a 200-
mm (8-in) diameter piston rod of
an alloy steel steam hammer used
for forging. This is an example of
a fatigue fracture caused by pure
tension where surface stress
concentrations are absent and a
crack may initiate anywhere in
the cross section. In this instance,
the initial crack formed at a
forging flake slightly below
center, grew outward
symmetrically, and ultimately
produced a brittle fracture
without warning. (From ASM
Handbook, Vol.12: Fractography,
ASM International, Materials Park,
OH44073-0002, fig 570, p. 342.
Reprinted by permission of ASM
International,
www.asminternational.org.)
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide17
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide18
ME 307 Machine Design I
Figure 7-6
Fatigue failure of an ASTM A186 steel double-flange trailer wheel caused by stamp marks.
(b) Stamp mark showing heavy impression and fracture extending along the base of the lower
row of numbers. (From ASM Handbook, Vol.11: Failure Analysis and Prevention, ASM
International, Materials Park, OH 44073-0002, fig 51, p. 130. Reprinted by permission of ASM
International , www.asminternational.org.)
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide19
ME 307 Machine Design I
Figure 7-8
Aluminum alloy 7075-T73 landing-
gear torque-arm assembly redesign
to eliminate fatigue fracture at a
lubrication hole. (a) Arm
configuration, original and
improved design (dimensions given
in inches). (From ASM Handbook,
Vol. 11: Failure Analysis and
Prevention, ASM International,
Materials Park, wall
OH 44073-0002, fig 23, p. 114.
Reprinted By permission of ASM
International,
www.asminternational.org.)
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide20
ME 307 Machine Design I
Figure 7-8
Aluminum alloy 7075-T73 landing-
gear torque-arm assembly redesign
to eliminate fatigue fracture at a
lubrication hole. (b) Fracture
surface where arrows indicate
multiple crack origins.
(From ASM Handbook, Vol. 11:
Failure Analysis and Prevention,
ASM International, Materials Park,
wall OH 44073-0002, fig 23, p.
114. Reprinted By permission of
ASM International,
www.asminternational.org.)
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide21
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide22
ME 307 Machine Design I
Fatigue-Life Methods
Fatigue Strength and the Endurance Limit
Endurance Limit Modifying Factors
Stress Concentration and Notch Sensitivity
Fluctuating Stresses
Combinations of Loading Modes
Varying, Fluctuating Stresses; Cumulative Fatigue Damage
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide23
ME 307 Machine Design I
Three major fatigue life methods used in design and analysis for safe
life estimation:
1. Stress life method (S-N Curves)
2. Strain life method (ε-N Curve)
3. Linear elastic fracture mechanics method
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide24
ME 307 Machine Design I
1. Stress-Life Method
based on stress levels only
It is the least accurate approach, especially for low-cycle
applications.
Most traditional method:
easiest to implement for a wide range of design applications
ample supporting data
represents high-cycle applications adequately
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide25
ME 307 Machine Design I
2. Strain-Life Method
Involves more detailed analysis of the plastic deformation at localized
regions where the stresses and strains are considered for life
estimates.
Good for low-cycle fatigue applications.
Some uncertainties exist in the results.
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide26
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide27
ME 307 Machine Design I
To determine the strength of materials under the action of fatigue loads, specimens are
subjected to repeated or varying forces of specified magnitudes while the cycles or
stress reversals are counted to destruction. The most widely used fatigue-testing device
is the R. R. Moore high-speed rotating-beam machine. The specimen, shown in
Fig.6-9, is very carefully machined and polished, with a final polishing in an axial
Direction to avoid circumferential scratches.
Figure 7-9
Test-specimen geometry for
the R. R. Moore rotating-
beam machine. The bending
moment is uniform over the
curved at the highest-stressed
portion, a valid test of
material, whereas a fracture
elsewhere (not at the highest-
stress level) is grounds for
suspicion of material flaw.
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide28
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide29
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide30
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide31
ME 307 Machine Design I
There are essentially two types of fatigue:
Semi-Log Scale
1. High Cycle Fatigue (HCF) (Elastic Strain)
2. Low Cycle Fatigue (LCF) (Plastic Strain)
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide32
ME 307 Machine Design I
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
Figure 7-11
S-N bands for representative aluminum alloys, excluding
wrought alloys with Sut< 38 kpsi.
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide33
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide34
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide35
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide36
ME 307 Machine Design I
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading CH-7 LEC 20 Slide37