MANE-4030: Elements of Mechanical Design: Worksheet #10

3/7/11: Fatigue
AISI 1060 hot-rolled steel (see Table 3.3) is to be used for a power plant application in which a cylindrical member is subjected to an axial load that cycles from 80,000 lbs tension to 40,000 lbs compression, repeatedly. The following manufacturing and operating conditions are expected: (i) The part is to be lathe-turned (ii) The cycle rate is 200 cycles/minute (iii) A life of 40 hours is required (iv) A strength reliability of 99 percent is required (v) A safety factor of 1.2 is required. In this problem you are to: (1) Determine what is the necessary rod diameter. (2) To verify that the shaft will have the necessary service life, the company wants to perform tests on some samples. However, the company would like to run 5 hour tests instead of 40 hour tests to save money. Thus, you must determine the test conditions (i.e. what should be the applied tension and compression forces (scaled up)) so that the 5 hour test is equivalent to a 40 hour service life with 80,000 lbs tension and 40,000 lbs compression cycles. (1a) Determine how many cycles correspond to a 40 hour service life. Is this on the high-cycle fatigue or the infinite life part of the S-N curve? (1b) Determine the fatigue limit for a small polished specimen, i.e. S f . (1c) Determine the fatigue limit for the actual part, i.e. Sf, by applying appropriate modifying factors. (1d) Write the equation for the line on semi-log scale that connects the strength at 1 cycle, i.e. Su, to the strength at 106 cycles, i.e. Sf. Calculate the fatigue strength corresponding to a 40 hour service life using this equation. (1e) Using the calculated fatigue strength and the safety factor, determine the allowable equivalent completely reversed ( eqCR ) stress level. (1f) Express the mean and alternating stresses in terms of the applied force (max and min) and the diameter (which you are solving for). For this application, is the mean stress greater than or less than 0? Choose the appropriate equation relating eqCR to a and m , set equal to the desirable level computed in (1e) and solve for the diameter required. (Assume maximum stress below yield) (1g) Compute the maximum stress and check that the safety factor against yielding is at least 1.2. If yes, everything is fine. If no, compute the diameter so that the safety factor against yielding is at least 1.2. (2a) Compute the fatigue strength using the equation found in (1d) at 5 hours. (2b) Using the safety factor and the fatigue strength at 5 hours, compute the allowable eqCR . Then using the diameter computed in (1f), determine the maximum and minimum forces for the 5 hour test assuming the same stress ratio for the 5 hour test and the 40 hour service life.

EMD worksheet #10 solutions

Mar. 7, 2011 (1a) N = 40 hr 60 min/hr 200 cycle/min = 4.8 105 cycles This is in the high cycle fatigue part of the curve. (1b) From p. 247, we nd for a wrought-ferrous alloy (hot-rolled steel is of this type), Sf 0.5Sut , and from Table 3.3 for AISI 1060 (HR), we nd Sut = 98 ksi. So S f (0.5)Sut = 49 ksi (1c) The modifying factors are: kgr = 1, typical value kwe = 1, no weld mentioned kf = 1, no stress concentration mentioned ksr = 0.76, p. 251 Figure 5.33, machined nish ksz = 0.9, typical value krs = 1, no info. given kf r = 1, no fretting mentioned kcr = 1, no corrosion mentioned ksp = 1, typical value kr = 0.81, 99% reliability, p. 247, Table 5.4 Sf = (0.76)(0.9)(0.81)(49ksi) = 27.15 ksi (1d) SN = b log(N ) + Sut S106 = 6b + 98 ksi = Sf = 27.15 ksi when N = 106 , log(N ) = 6 27.15 ksi 98 ksi b= = 11.8 ksi 6 SN = 11.8 ksi (log(N )) + 98 ksi S4.8105 = 11.8 ksi (log(4.8 105 )) + 98 ksi = 31 ksi (1e) nf = 1.2 = S4.8105 eqcr eqcr = 25.8 ksi

(1f) max = min = m = a = eqcr = 4Fmax (4)(80, 000 lb) = 2 d d2 4Fmin (4)(40, 000 lb) = 2 d d2 1 2 80, 000 lb (max + min ) = 2 (80, 000 lb 40, 000 lb) = >0 2 d d2 1 2 240, 000 lb (max min ) = 2 (80, 000 lb + 40, 000 lb) = 2 d d2 1 (240, 000 lb) 240, 000 lb a d2 = = 25, 800 psi = m 80 , 000 lb 80,000 lb 1 Su 1 d2 (98,000 psi) d2 98 ,000 psi

d = 1.8 in (1g) From Table 3.3, Syp = 54 ksi. ny = Syp (Syp )(d2 ) (54, 000 psi)( )(1.8 in)2 = = = 1.7 > 1.2 max 4Fmax (4)(80, 000 lb)

So yield is not predicted to occur, and the safety factor guarding against yield exceeds minimum allowed. (2a) N = 5 hr 60 min/hr 200 cycle/min = 6 104 cycles SN = (11.8 ksi) log(60, 000) + 98 ksi = 41.62 ksi (2b) Assuming the same stress ratio, then for the test, we want a /m = 3, and max = 2min . eqcr eqcr = = max = 41.62 ksi SN = = 34.68 ksi 1.2 1.2 3m a m = 34.68 ksi m = 1 98 1 Sut ksi 1 1 1 max m = 10.34 ksi = (max + min ) = (max max ) = 2 2 2 4 4Fmax 4Fmax = 41, 360 psi = d2 (1.8 in)2 Fmax = 105, 250 lb , Fmin = 0.5Fmax = 52, 625 lb