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Even if you design mechanical components satisfying mechanical strength criteria it may fail due to a phenomenon called fatigue. Historically many design disasters have happened by neglecting effect of Fatigue.In this video lecture we will learn how to predict and quantify fatigue effect.
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Beams are structural members, which are most commonly used in buildings. Beams have numerous other applications in case of bridges, automobi...
Fig.1 Two methods to break metal wire, Either bend it upward and downward repetitively or pull it
Your answer is obviously the second option. Because this method requires less effort compared to the first case. This is a well known example of fatigue failure. So how does material fail due to fatigue? To get answer for this question let us have a close look at stress variation in wire cross section.
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So if you trace stress induced at a point with respect to time it will vary like this. As a fluctuating stress with time.
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Initially the point will have positive stress, after that zero, then negative stress. The same cycle repeats again and again. Such fluctuating stress is root cause of fatigue failure. When such fluctuating load act on a material it will initiate something called micro crack. This crack will begin to grow with fluctuating load and over time it will cause an abrupt failure. Unlike failure due to static load failure due to fatigue happens without any warning, it does not make necking. And the failure is unpredictable.
Fig.4 Some practical cases which could result in fatigue failure, if not designed properly
The same phenomenon can happen for axle of this motor where it is undergoing fluctuating stress due to gravity effect of this mass. A rail wheel when it is in contact with with the track produces a high contact stress, but when the wheel rotates stress gets relieved. When it comes back to original position again contact stress arises. So this also is a case of fluctuating stress case. Again will lead to fatigue failure if we do not design it carefully. Same is the case with a gear pair. Here contact stress arised at contact point fluctuates with time.
So this will follow a trend like this, but not forever. You can see after particular stress amplitude, even with slight decrease in stress number of cycles required to make it fail increases drastically.
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Fig.6 Stress amplitude Vs number of cycles, green region represents safe design area
Or in short if you have stress amplitude below this limit number of cycles to make to fail jumps ton infinity. Or material never fails after this limit. the material never fails. This limit is known as endurance limit; below endurance limit it is safe to operate the material. Engineers always try to design their components by keeping stress amplitude below endurance limit. You can see that endurance limit is way below ultimate stress value.
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For this purpose we have to use something called Goodman diagram. Where mean value of stress is drawn on x axis. Amplitude of stress is drawn on y axis. When mean value of zero, we know safe stress limit is same as endurance limit. When amplitude of stress is zero, it is same as a static loading condition. So safe limit for tension is ultimate tensile stress at tension and safe limit for compression is ultimate tensile stress for compression. According to Goodman analysis safe stress amplitude limits for other cases lie on straight lines connecting this points. So for a particular stress mean value, we can find whats the maximum allowable safe stress limit from this diagram. It will be here.
Fig.8 Use of Goodman diagram to find safe stress amplitude when stresmm mean value is not zero
Similar analysis can be done considering, safe limit of amplitude zero condition as yield strength of material. This is known as Soberberg diagram. Generally Goodman analysis is the most preferred one.
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