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MMJ1133 FATIGUE AND FRACTURE MECHANICS

A - INTRODUCTION

INTRODUCTION

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Course Content:
A - INTRODUCTION
Mechanical failure modes; Review of load and stress analysis
equilibrium equations, complex stresses, stress transformation,
Mohrs circle, stress-strain relations, stress concentration; Fatigue
design methods; Design strategies; Design criteria.

B MATERIALS ASPECTS OF FATIGUE AND FRACTURE


Static fracture process; Fatigue fracture surfaces;
Macroscopic features; Fracture mechanisms; Microscopic features.

C FATIGUE: STRESS-LIFE APPROACH


Fatigue loading; Fatigue testing; S-N curve; Fatigue limit; Mean
stress effects; Factors affecting S-N behavior microstructure, size
effect, surface finish, frequency.

INTRODUCTION

M.N.Tamin, CSMLab, UTM

MMJ1133 FATIGUE AND FRACTURE MECHANICS

Failure Versus Fracture


Failure
Inability of a component to perform according to its intended function.
Fracture
Separation of a component into two or more parts.

INTRODUCTION

M.N.Tamin, CSMLab, UTM

MMJ1133 FATIGUE AND FRACTURE MECHANICS

Some modes of failure


Gross yielding
Ductile failure
Brittle fracture
Creep Rupture and relaxation
Buckling
Stress corrosion cracking
Wear
Fatigue fracture
Fatigue crack nucleation and growth
Uniaxial and multiaxial fatigue
Creep-fatigue
Corrosion fatigue
Constant and variable amplitude loading
INTRODUCTION

M.N.Tamin, CSMLab, UTM

MMJ1133 FATIGUE AND FRACTURE MECHANICS

REVIEW OF LOAD AND STRESS ANALYSIS


Mechanics of Materials
A branch of mechanics that studies the relationships between
external loads applied to a deformable body and the intensity of
internal forces acting within the body.

Load
Equilibrium equation
Complex stresses
Stress transformation
Mohrs circle
Stress-strain relations
Stress concentration

INTRODUCTION

M.N.Tamin, CSMLab, UTM

MMJ1133 FATIGUE AND FRACTURE MECHANICS

Types of Loading on Structures

INTRODUCTION

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Typical Engineering Structures

Applications involving combined loading


INTRODUCTION

M.N.Tamin, CSMLab, UTM

MMJ1133 FATIGUE AND FRACTURE MECHANICS

Equilibrium of a Deformable Body

A body is said to be in
equilibrium when the resultant
of all forces and moments
acting on the body is zero.

F 0
Mo 0

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M.N.Tamin, CSMLab, UTM

MMJ1133 FATIGUE AND FRACTURE MECHANICS

Equilibrium of a deformable body

Determine the internal load at


cross section marked C of each
structure.

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M.N.Tamin, CSMLab, UTM

MMJ1133 FATIGUE AND FRACTURE MECHANICS

Stress Under General Loading Conditions

Stress intensity of a force


acting at a material point

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Simple Stresses

Tr

J
INTRODUCTION

A
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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Complex Stresses

T
A

Shear stress
A

INTRODUCTION

Normal stress

What is the magnitude of stress and


strain on specific plane at A?
Does the stress and strain represent
critical / maximum values at A?
If not
what is the maximum & minimum
(principal) stresses and maximum
shear stresses?
What is the corresponding strain
values?
On which planes do these stresses
act?

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Stress Transformation Equations

x y x y
x

cos 2 xy sin 2
2
2
x y
xy
sin 2 xy cos 2
2
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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Mohrs Circle
Graphical visualization of the stress
states at a given material point

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Fracture Planes

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Engineering Stress-strain Curve

Necking

Fractured
Tensile failure in ductile material is
associated with large plastic
deformation.

Totalel + pl

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Engineering Stress-Strain Curve

SS316 steel
800

Non-linear /Power-law

= K(p)n
400

200

200

Linear

0
0.0

= E
0.1

150

0.2

0.3

STRAIN,

0.4

0.5

STRESS, (MPa)

STRESS, (MPa)

600

0.6
100

= E

50

0
0.0000

0.0002

0.0004

0.0006

0.0008

0.0010

STRAIN,

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Mechanical Properties of Some Materials

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Stress Concentration

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Stress Concentration

Stress concentration factor

Kt
INTRODUCTION

max
avg
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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Stress Concentration

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Stress Concentration Factors

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

FATIGUE
Deterioration of a material by initiation and
propagation of crack when subjected to
repeated load.

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

FATIGUE
Deterioration of a material by initiation and
propagation of crack when subjected to repeated load.

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M.N.Tamin, CSMLab, UTM

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Fatigue design
flow diagram

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Fatigue life models


Nominal stress-life (S-N) model
Local strain-life (-N) model

[1870s]

[1960s]
Fatigue crack growth (da/dN-K) model
[1960s]
2-stage model, combining -N and da/dN-K to
incorporate fatigue crack nucleation and growth

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Fatigue life models


Nominal stress-life (S-N) model
Local strain-life (-N) model

[1870s]

[1960s]
Fatigue crack growth (da/dN-K) model
[1960s]
2-stage model, combining -N and da/dN-K to
incorporate fatigue crack nucleation and growth

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MMJ1133 FATIGUE AND FRACTURE MECHANICS

Fatigue design criteria


Infinite-life design

Unlimited safety
criterion where local stresses and strains are essentially
elastic, and below fatigue limit.

Safe-life design

Designing for finite life


with consideration on margin for scatter in fatigue data.

Fail-safe design

Structures are
arranged so that cracks will not lead to failure before they are
detected and repaired. Requires that if one part fails, the
system does not fail.

Damage-tolerant design

Leak-beforeburst design. Fracture mechanics analysis and tests are used


to ensure that existing cracks will not propagate before they
are detected by periodic inspection

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