STRESS CYCLES

Repeated Stress Cycle

Completely Reversed Stress Cycle

m
= 0
R = -1
Random Stress Cycle
STRESS-LIFE DIAGRAM
(HIGH CYCLE FATIGUE)
Basquin Relation
N
F
(
a
)
p
= C
Stress Life Approach
Endurance Limit or Fatigue Limit
Yield Strength
There is a strong correlation between fatigue
strength and tensile strength.
(From Forrest, Fatigue of Metals, Pergamon Press, London, 1962)

e
0.5
u
for steels

e
(for 10
8
cycles) 0.35
u
for non-ferrous alloys
Statistical Nature of Fatigue
Ti6Al4V
Statistical Nature of Fatigue
Effect of mean stress on fatigue
GOODMAN DIAGRAM
(gives the maximum allowable stress amplitude
for a different mean stress)
GOODMAN DIAGRAM
x = 1 for Goodman line
x = 2 for Gerber parabola

u
=
o
for Soderberg line
Effect of mean stress on fatigue
EXAMPLE
SOLUTION
STRESS STRAIN LOOP FOR CONSTANT
STRAIN CYCLE
STRAIN-LIFE DIAGRAM
(LOW CYCLE FATIGUE)
Coffin- Manson Relation
(Low cycle fatigue)
STRAIN-LIFE EQUATION
(FOR ALL FATIGUE LIVES)
CUMULATIVE FATIGUE DAMAGE
CUMULATIVE FATIGUE DAMAGE
CUMULATIVE FATIGUE DAMAGE
A multipurpose traffic bridge has been in service for three years and
each day carries a large number of trains, trucks, and automobiles. A
subsequent highway analysis reveals a sharp difference between
expected actual traffic patterns that threatens to shorten the usefull life
span of the bridge. Fortunately, a nearby second bridge was recently
completed that can assume all of the train traffic. Given the following
fatigue information, estimate the remaining lifetime for the first bridge,
assuming that it will carry only truck and automobile traffic.
VEHICLE FATIGUE
LIFETIME
VEHICLES/
DAY
Automobiles 10
8
5000
Trucks 2x10
6
100
Trains 10
5
30
CUMULATIVE FATIGUE DAMAGE
Example
Trains
Trucks
a) First establish the amount of fatigue damage
accumulated during the initial 3-year service period:
Accumulated damage in initial 1095 days: 0.438.
That is 43.8% of the combined fatigue lifetime.
b) Remaining fatigue lifetime: 56.2% of the combined
fatigue lifetime.
D= remaining days of service
D= 5620 days(15.4 years) for automobile + truck traffic
only.
D= 3.85 years, if the train traffic were to be continued.
FRACTURE MECHANICS
APPROACH TO FATIGUE
(Damage Tolerant Design)
C-T SPECIMEN
Crack Growth Rate Measurement
1) Crack length, a is
measure against
number of cycles, N
2) a vs N diagram is
drawn
3) Crack growth rate,
da/dN is calculated
from the slope.
STUDY:
http://aluminium.matter.o
rg.uk/content/html/eng/d
efault.asp?catid=176&pa
geid=2144416584
a vs N DIAGRAM
Driving Force for Crack Growth
The driving force for crack growth is the in
the stress intensity factor range during
cycling.
0 R for
0 R for
a (a/W) K
< =
> =
=
max
min max
f
o o A
o o o A
t o A A
Crack Growth Rate Diagram
(da/dN vs K)
REMAINING FATIGUE LIFE
a
c
a
c
General Solution:
c
o
a
a
m
p
a (a/W) A
da
N
) f t o A
(
(

=
c o
3 3 2 3
p
a
1
a
1
Y A
2
N
) (
/
o A t
m=3;; constant Y= f(a/W) :
N
F
N
F
EXAMPLE PROBLEM
A relatively large sheet of steel is to be exposed to cyclic
tensile and compressive stresses of magnitudes +100
MPa and -50 MPa respectively. Prior to testing, it has
been determined that the length of the largest straight-
through center crack is 2.0 mm. Estimate the fatigue life
of this sheet if its plane strain fracture toughness is 25
MPa.m
1/2
and the values of m and A are 3 and 1X10
-12
respectively for in MPa and a in mm. Assume Y=1.
Answer: 2a
o
= 2 mm, so a
o
= 1 mm
a
c
= 0.01989 m = 19.89 mm
N
F
= 8.81 X 10
6
cycles
T
F
= 204 days (For a loading frequency of 0.5 Hz)
AN EXAMPLE FROM DIETER
AN EXAMPLE FROM DIETER
FACTORS AFFECTING THE
FATIGUE LIFE
Geometrical Design
Surface Roughness
Surface Strength
Residual Stresses
Size
Environment
Metallurgical Structure
GEOMETRICAL DESIGN
(Remove stress concentrators)
BAD
BETTER
EFFECT OF STRESS CONCENTRATION
SURFACE ROUGHNESS
Reduction factor for fatigue limit of steel due to
various surface treatments (Surface Finish)
Sensitivity to
surface condition
increases with
increasing
strength.
Corrosion has a
significant effect
on fatigue limit
SURFACE TREATMENT
Shot Peening
Carburizing, Nitriding, Induction Hardening, Electroplating
Decarburization?
COMPRESSIVE RESIDUAL STRESS
(Put surface into compression)
EFFECT OF CORROSION
TOPICS TO THINK ABOUT
1) Why does shot peening improve the fatigue life
of a metal component?
2) Why does carburizing increase the fatigue life of
a steel component?
3) What microstructure is the best for the optimum
fatigue properties in heat treated low alloy
steels?
4) What kind of fatigue (low cycle or high cycle)
should be considered for the ribbed steels in
steel reinforced concrete during an earthquake?
5) What effect will have the decarburization of a
steel component on the fatigue performance of
it?