Dr. A. Aziz Bazoune Dr. A.

Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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Dr. A. Aziz Bazoune
King Fahd University of Petroleum &
Minerals
Mechanical Engineering Deartment
C%&"7 LC&'( )lide & (
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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7&( $ntrodu#tion to Fatigue in Metals !"+ 7&( $ntrodu#tion to Fatigue in Metals !"+
7&' Approa#h to Fatigue Failure in Anal,sis and Design !(' 7&' Approa#h to Fatigue Failure in Anal,sis and Design !('
7&! Fatigue&Life Methods !(! 7&! Fatigue&Life Methods !(!
7&- .he )tress&Life Method !(! 7&- .he )tress&Life Method !(!
7&/ .he )train&Life Method !(+ 7&/ .he )train&Life Method !(+
7&+ .he Linear&lasti# Fra#ture Me#hani#s Method !(0 7&+ .he Linear&lasti# Fra#ture Me#hani#s Method !(0
7&7 .he nduran#e Limit !'! 7&7 .he nduran#e Limit !'!
7&1 Fatigue )trength !'/ 7&1 Fatigue )trength !'/
7&0 nduran#e Limit Modif,ing Fa#tors !'1 7&0 nduran#e Limit Modif,ing Fa#tors !'1
7&(" )tress Con#entration and 2ot#h )ensitivit, !!/ 7&(" )tress Con#entration and 2ot#h )ensitivit, !!/
7&(( Chara#terizing Flu#tuating )tresses !-- 7&(( Chara#terizing Flu#tuating )tresses !--
7&(' Fatigue Failure Criteria for Flu#tuating )tress !-+ 7&(' Fatigue Failure Criteria for Flu#tuating )tress !-+
7&(! .orsional Fatigue )trength under Flu#tuating )tresses !+" 7&(! .orsional Fatigue )trength under Flu#tuating )tresses !+"
7&(- Combinations of Loading Modes !+( 7&(- Combinations of Loading Modes !+(
7&(/ 3ar,ing4 Flu#tuating )tresses5 Cumulative Fatigue Damage !+- 7&(/ 3ar,ing4 Flu#tuating )tresses5 Cumulative Fatigue Damage !+-
7&(+ )urfa#e Fatigue )trength !7" 7&(+ )urfa#e Fatigue )trength !7"
7&(7 )to#hasti# Anal,sis !7! 7&(7 )to#hasti# Anal,sis !7!
7&( $ntrodu#tion to Fatigue in Metals !"+ 7&( $ntrodu#tion to Fatigue in Metals !"+
7&' Approa#h to Fatigue Failure in Anal,sis and Design !(' 7&' Approa#h to Fatigue Failure in Anal,sis and Design !('
7&! Fatigue&Life Methods !(! 7&! Fatigue&Life Methods !(!
7&- .he )tress&Life Method !(! 7&- .he )tress&Life Method !(!
7&/ .he )train&Life Method !(+ 7&/ .he )train&Life Method !(+
7&+ .he Linear&lasti# Fra#ture Me#hani#s Method !(0 7&+ .he Linear&lasti# Fra#ture Me#hani#s Method !(0
7&7 .he nduran#e Limit !'! 7&7 .he nduran#e Limit !'!
7&1 Fatigue )trength !'/ 7&1 Fatigue )trength !'/
7&0 nduran#e Limit Modif,ing Fa#tors !'1 7&0 nduran#e Limit Modif,ing Fa#tors !'1
7&(" )tress Con#entration and 2ot#h )ensitivit, !!/ 7&(" )tress Con#entration and 2ot#h )ensitivit, !!/
7&(( Chara#terizing Flu#tuating )tresses !-- 7&(( Chara#terizing Flu#tuating )tresses !--
7&(' Fatigue Failure Criteria for Flu#tuating )tress !-+ 7&(' Fatigue Failure Criteria for Flu#tuating )tress !-+
7&(! .orsional Fatigue )trength under Flu#tuating )tresses !+" 7&(! .orsional Fatigue )trength under Flu#tuating )tresses !+"
7&(- Combinations of Loading Modes !+( 7&(- Combinations of Loading Modes !+(
7&(/ 3ar,ing4 Flu#tuating )tresses5 Cumulative Fatigue Damage !+- 7&(/ 3ar,ing4 Flu#tuating )tresses5 Cumulative Fatigue Damage !+-
7&(+ )urfa#e Fatigue )trength !7" 7&(+ )urfa#e Fatigue )trength !7"
7&(7 )to#hasti# Anal,sis !7! 7&(7 )to#hasti# Anal,sis !7!
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Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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7&7 7&7 .he nduran#e Limit .he nduran#e Limit
7&1 7&1 Fatigue )trength Fatigue )trength
7&0 7&0 nduran#e Limit Modif,ing Fa#tors nduran#e Limit Modif,ing Fa#tors
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Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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A 6ui#7 method of estimating enduran#e limits is needed:
for preliminar, and protot,pe design
for some failure anal,sis
C%&"7 LC&'( )lide & -
7&7
7&7
.he nduran#e Limit
.he nduran#e Limit
8perimental results for
rotating&beam tests
simple tension tests
of spe#imens ta7en from
the same bar are sho9n in
Figure 7.(1.
Figure 7&(1
:raph of enduran#e limits versus
tensile strengths from a#tual test
results for a large number of
9rought irons and steels.
Figure 7&(1
:raph of enduran#e limits versus
tensile strengths from a#tual test
results for a large number of
9rought irons and steels.
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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Figure 7&(1
:raph of enduran#e limits versus tensile strengths from a#tual test results for a large number of 9rought irons and
steels. Ratios of );
e
<)
ut
of ".+"4 "./"4 and ".-" are sho9n b, the solid and dashed lines. 2ote also the horizontal
dashed line for of );
e
=("7 7psi. >oints sho9n having a tensile strength greater than '(- 7psi have a mean enduran#e
limit of );
e
=("7 7psi and a standard deviation of (!./ 7psi.
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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For steels4 the relationship bet9een the tensile strength and the enduran#e
limit is given b,
?7&1@
9here

: is the minimum tensile strength. .he prime mar7 on in this

e6uation refers to the rotating&beam spe#imen itself.

.he unprimed s,mbol is for the enduran#e limit of an, parti#ular

ma#hine element subAe#ted to an, 7ind of loading.
'
e
S
'
e
S
e
S
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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.he enduran#e limits for various #lasses of #ast irons4 polished or ma#hined4
are given in .able A&'-. Aluminum allo,s do not have an enduran#e limit.
.he fatigue strengths of some aluminum allo,s at /?("
1
@ #,#les of reversed
stress are given in .able A&'-.
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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7&7
7&7
Fatigue )trength
Fatigue )trength

Region of lo9 #,#le fatigue: Region of lo9 #,#le fatigue:

.he fatigue strength is onl, slightl, smaller than the tensile
strength .

Region of high C,#le Fatigue Region of high C,#le Fatigue

.he purpose of this se#tion is to develop methods of appro8imation of
the )&2 diagram in the high&#,#le region4 9hen information ma, be as
sparse as the results of a simple tension test. 8perien#e has sho9n
high&#,#le fatigue data are re#tified b, a logarithmi# transform to both
stress and #,#les&to&failure.
f
S
ut
S
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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7&1
7&1
Fatigue )trength
Fatigue )trength
$n the region of high #,#le fatigue4 the e6uation relating the fatigue
strength to the number of #,#les to failure ma, be given b, the
empiri#al #urve fit e6uation:
9here is the number of #,#les to failure and a and b are given b,
f
S
N
?7&('@
N
?7&(!@
?7&(-@
9here is found from Figure 7&(0. f
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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a

f a
S =
3
1 10 N
?7&(/@
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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8ample
8ample
:iven a ("/" %R steel4 estimate
a@ .he rotating&beam enduran#e limit at ("
+.
b@ .he enduran#e strength of a polished rotating beam spe#imen
#orresponding to ("
-
#,#les to failure.
#@ .he e8pe#ted life of a polished rotating&beam spe#imen under a
#ompletel, reversed stress of // 7psi.
:iven a ("/" %R steel4 estimate
a@ .he rotating&beam enduran#e limit at ("
+.
b@ .he enduran#e strength of a polished rotating beam spe#imen
#orresponding to ("
-
#,#les to failure.
#@ .he e8pe#ted life of a polished rotating&beam spe#imen under a
#ompletel, reversed stress of // 7psi.
)BLC.$B2: )BLC.$B2:
a@ From .able A&'"4
From 6. ?7&1@
b@ From Fig. ?7&(0@ for


)BLC.$B2: )BLC.$B2:
a@ From .able A&'"4
From 6. ?7&1@
b@ From Fig. ?7&(0@ for


90 kpsi
ut
S =
( )
' 0.5 90 45 kpsi
e
S = =
90 0.86 kpsi,
ut
S f = =
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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8ample ?Cont.;d@
8ample ?Cont.;d@
From 6. ?7&(!@

and ?7&(-@ ==

.hus 6. ?7&('@ is:
for #,#les to failure4 the above e6uation be#omes

From 6. ?7&(!@

and ?7&(-@ ==

.hus 6. ?7&('@ is:
for #,#les to failure4 the above e6uation be#omes

4
10 N =
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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8ample ?Cont.;d@
8ample ?Cont.;d@
#@ From 6. ?7&(/@4 9ith
Deep in mind that these are onl, estimates.


#@ From 6. ?7&(/@4 9ith
Deep in mind that these are onl, estimates.


55kpsi
a
=
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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7&0
7&0
nduran#e Limit Modif,ing Fa#tors
nduran#e Limit Modif,ing Fa#tors




.he rotating&beam spe#imen used in the laborator, to determine enduran#e limits is
prepared ver, #arefull, and tested under #losel, #ontrolled #onditions. $t is
unrealisti# to e8pe#t the enduran#e limit of a me#hani#al or stru#tural member to
mat#h the values obtained in the laborator,. )ome differen#es in#lude

Material: #omposition4 basis of failure4 variabilit,

Manufa#turing: method4 heat treatment4 fretting #orrosion4 surfa#e #ondition4

stress #on#entration

nvironment: #orrosion4 temperature4 stress state4 rela8ation times

Design: size4 shape4 life4 stress state4 stress #on#entration4 speed4 fretting4 galling
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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Marin;s 6uation
Marin;s 6uation




?7&(7@
Marin identified fa#tors that 6uantified the effe#ts of surfa#e #ondition4 size4
loading4 temperature4 and mis#ellaneous items. Marin;s 6uations is therefore
9ritten as:
nduran#e limit at the #riti#al lo#ation of a ma#hine part in geometr,
and #ondition of use
rotar,&beam test spe#imen enduran#e limit
:
e
S
' :
e
S
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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Ehen enduran#e tests of parts are not available4 estimations are made b, appl,ing Marin
fa#tors to the enduran#e limit.
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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9here is the minimum tensile strength and and are to be found in
.able 7&-.
?7&(1@
ut
S
a b
.able 7&-
>arameters for
Marin surfa#e
modifi#ation
fa#tor4 6. ?7&(1@
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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.he size fa#tor for bending and torsion ma, be given b,:
?7&(0@
b
k
For a8ial loading there is no size effe#t4 so
?7&'"@
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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FC).$B2: FC).$B2:
Ehat to do 9ith 6.?7&(0@ if a round bar in bending is not rotating or 9hen a
non&#ir#ular #ross&se#tion is usedG
?7&'!@
A2)ER: A2)ER:
Cse effective dimension 9here
e
d
as the effe#tive size of a round #orresponding to a non&rotating solid or hollo9 round.
.able 7&/ provides areas of #ommon stru#tural shapes undergoing non&rotating bending
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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.able 7&/
Areas of #ommon non&
rotating stru#tural
shapes
Dr. A. Aziz Bazoune Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from variable Loading Chapter 7: Fatigue Failure Resulting from variable Loading
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Average values for the load fa#tor are given b,
?7&'/@