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For the following R=-1 AISI 1090 steel test data, plot two S-N curves, one using log-
linear coordinates and the other using log-log coordinates. a) Use linear regression to
estimate the best fit curves for the two coordinate systems. Show these lines on the
same graphs with the data b) Estimate the fatigue limit for the material, c) estimate the
fatigue strength at 5x105 cycles to failure, d) estimate the expected fatigue life at 200
MPa, e) Sketch upper and lower bounds for the data and comment on the observed
scatter.
Solution
The equations of the least square method for fitting of the straight line y A B
are,
The power function y=AxB is by taking logarithms transformed to log y = log A+Blog x and
the previously given equations for A and B are used. Hence, in the diagram with log-log
scales, y=AxB becomes a straight line. In this case, n = 24 because the two non-failed data
points should be excluded from the analysis. We compute the needed values and sums to
obtain the constants A and B. It MUST be noted that in linear regression, the dependent
variable y is Log(cycles to failure)
Y=19.94 -6.48X
Va
Nf
Linear-log plot with regression lines for Va =1202(Nf)-0.154 (green line) and Va = 536+(-
66.0)Log(Nf)(violet line)
'()
220
200
180
Va
160
140
120
&f
Log-log plot with regression lines for Va =1202(Nf)-0.154 (green line) and Va = 536+(-
66.0)Log(Nf)(violet line)
The exact fatigue limit cannot analytically be defined; it is, however, Va 130 MPa,
because two of five specimens did not fail with this stress.
The figures show that these curves nearly intersect at 500 000 cycles
e
! "d #$
! %#"d #!
data and comment on the observed scatter.
Scatter was found especially at longer fatigue lives. A standard deviation for all data could
be estimated.
Example 2
E
Example 2
An unnotched member fabricated from AISI 4142 steel (see table) is subjected to the
load history shown below. Use the Gerber mean stress correction equation and a)
perform a rainflow count of the load history, b) estimate the number of cycles to failure
and c) estimate the number of (blocks) repetitions to failure.
Rainflow counting yield 3 large amplitude cycles and 200 small amplitude cycles
2
Va Vm
1 ,
V ar V u
V 2 V 2
Va 1 m V 1 m AN b
V u ar V u f
A 1
MPa b 0.0
u 1757 MPa
600 2
1 1837 N f 0.0762 , which gives Nf =
1757
600
880 2
1 1837 N f 0.0762 , which gives Nf =
1757
320
j Nj ! a N fj N j / N fj
203 8,18E-06
The Palmgren-Miner rule:
j j
N N
Nj Nj
" Bf 1, where B f is the number of repetitions.
k 1 fj k 1 fj
1
j Nj
Bf | #$$%%% repetitions = 24 800 000 cycles
k 1 N
fj
Example 2b
An aircraft component is fabricated from Ti-6Al-4V solution treated and aged titanium
alloy (see table with Problem 3). At the critical point in the component, the stress history is
determined to be
Develop a rainflow table of for the history shown. Estimate the number of repetitions of the
given history necessary to cause fatigue failure.
j j
N N
Nj Nj
1 Bf 1, where B f is the number of repetitions.
k 1 fj k 1 fj
max min
Stress amplitude: a
2
Equivalent completely reversed stress for the cases where mean levels are involved:
V ar V maxV a V f 2 N f b
, V ar V maxV a is known as SWT-equation (Smith, Watson & Topper).
1 V max V a b
Nf
2 V 'f
j Nj m m N j N / N
1,35E-03
1
j
Nj
Bf | 7 repetitions.
N fj
k 1
Example 3
A stepped shaft has a diameter D = 50mm, d = 30mm and r = 3mm. determine and
compare Kt for a) axial loading and b) bending and c) torsion. Estimate the fatigue
notch factor, Kf for R=-1 axial loading if the shaft is made of the following steels: 1)
normalized 1038 (HB 163), 2) quenched and tempered 1038 (HB 195), 3) hot rolled
4340 (HB 243)
and 4) quenched and tempered 4340 (HB 409).
r 3 D 50
0.1 1.6
d 30 d 30
The elastic stress concentration factor Kt for axial loading is defined from Figure:
K t | 1.9
K t | 1.7
Kt for torsion loading is defined from Figure:
K t | 1.4
A value of fatigue notch factor k f could be obtained according to Peterson for R = -1 loading from
1.8
kt 1
kf 1 , where a 0.0254 2070 (for steels).
a Su
1
r
1.8
2070
The value of a can be obtained for 1038 (HB 163), Su = 582 MPa, 0.0254 0.2
.
582
1.90 1
We obtain k f 1 1.
0.249
1
3
1.8
2070
For 1038 (HB 195), Su = 649 MPa, 0.0254 0. .
649
1.90 1
We obtain k f 1 1.
0.205
1
3
1.8
2070
For 4340 (HB 243) Su = 827 MPa, 0.0254 0. .
827
1.90 1
We obtain k f 1 1.
0.132
1
3
1.8
2070
For 4340 (HB 409), Su = 1468 MPa, 0.0254 0.0 .
1468
1.90 1
We obtain k f 1 1.
0.047
1
3
The following summary and comparison of the values of Kt shows that axial is the most critical
loading type. Kt for bending loading is only slightly less critical. However for torsion, Kt is only
about 74 % compared to bending load.
Kt % 100 92 73,7
Kf a
The smooth specimen is subjected to cyclic loading. The required fatigue life is
100 000 cycles to failure. Compute the allowable stress amplitude for mean stress 0, 200,
400 and 800 MPa. Use the Goodman mean stress correction equation. Use this data to
construct a constant life diagram for Nf = 1X105. (see the sample constant life diagram
below taken from the lecture slides)
The Goodmans equation generally gives reasonable results:
a m
1 ,
ar Vu
Vm Vm
Va 1 V ar 1 A
N f b
Vu Vu
A 1 MPa b 0.0
u 1757 MPa
V 0.0762
Va 1 m 1837 100000 , at Nf = 100 000 cycles, we get
1757
a
MPa Nf cycles
801,19 1
Therefore:
0.0648
Va 801.19N f
For m = 0 MPa.
0.0648
Va 9382 N f
a MPa Nf cycles
896,8 1
Therefore:
0.0648
Va 896.8N f
Va
938 100 2 N f 0.0648
a
MPa Nf cycles
992,41 1
Therefore:
0.0648
Va 992.41N f
A stepped shaft with a diameter D = 30 mm, d = 24 mm and r = 1.3 mm. The required
fatigue life is 1 000 000 cycle and is loaded in bending. a) Determine Kt and Kf , b)
Compute the allowable stress amplitude for mean stress 0, 200, 400 and 800 MPa and c)
use this data to construct a constant life diagram for Nf = 1X106.
Kt | 1.9
A value of fatigue notch factor k f could be obtained according to Peterson for R = -1 loading from
1.8
kt 1
kf 1 , where a 0.0254 2070 (for steels).
a Su
1
r
1 .8
2070
The value of a can be obtained, 0.0254 0.0
.
1757
1.98 1
We obtain k f 1 1.
0.0341
1
2
Using the value of k f , the nominal stress amplitude corresponding to the fatigue limit is:
ar
S ar
k
Example 5
For RQC-100 steel and using the Morrow mean stress correction, obtain equations relating
stress amplitude(Va)vs. cycles to failure (Nf) in the cases where the mean stress(Vm)is a)
100 MPa tension, b) zero and c) 100 MPa compression. Plot the curves on the same graph
using log-log coordinates.
The Morrows equation generally gives reasonable results for ductile steels:
a m
1 ,
ar V'f
V ar V 'f 2 N f b
Va V 'f V m 2 N f b
Va
+938 100 , 2 N f 0.0648 , by substituting Nf = 1 cycle, we get
a
MPa Nf cycles
801,19 1
Therefore:
0.0648
Va 801.19-N f .
For 1/ = 0 MPa.
0.0648
Va 93822 N f 3
a MPa Nf cycles
896,8 1
Therefore:
0.0648
Va 896.84N f 5
Va
6938 100 7 2 N f 0.0648
a
MPa Nf cycles
992,41 1
Therefore:
0.0648
Va 992.41:N f ;
Sm = S @ ? ><==
S @ ? <==
Example 6
Sometestdatapointsforthestressstraincurveof2024T351aluminiumduringaxialstressare
given:
V,MPa H
317 0.00474
341 0.00607
366 0.00950
390 0.01910
414 0.03290
439 0.05230
TheelasticmodulusforthematerialisgivenasE=73100MPa.
a) determinetheplasticstrain,Hp,foreachpointandplotVvsHponalogloggraphand
determinetheconstantsHandnfortheRambergOsgoodmaterialmodel(seeslide13
page6fromlectureslideset5)
b) PlottheresultingH=f(V)lineandtestdata(usealinearlineargraph).Determinerthe0.2%
offsetyieldstrength.
Foreachpoint,Histhetotalstrain,He=V/EandHp=HHe
TheresultingloglogplotisshownandthevaluesHandnfortheequation
arefoundbylinearregression.H=528MPa,n=0.066
1000
H=528MPa
stress(MPa)
1/n
1
0,0001 0,001 0,01 0,1 1
pstrain
totalstrainisfromtheRambergOsgoodcurve
Theresultingcurvewiththedatapointsisshown
500
450 0 offsetyield
400
350
300
stress(MPa)
250
200
150
100
50
0 offset
0 0,01 0,02 0,03 0,04 0,05 0,06
s
The0.2%offsetyieldstrengthoccurswhenHp=0.2%=0.002.ThisisV=350.3MPa
Example 7
Anelastic,linearhardeningmaterialhaselasticmodulusE=200GPa,yieldstrengthV0=fy=500
MPaandavalueofG=0.1(seeslide11page5fromlectureslideset5).Assumethatthematerial
behavesaccordingtotheelasticlinearhardeningspringslidermodel(seelectureslideset4).
Estimate(sketch)thematerialbehaviorfor:
a) completelyreversedcyclicstrainingatHa=0.006
b) strainingfrom H=0toH=0.012followedbydecreasingstraintoH=0.005andthenincreasing
straintoH=0.015.
Usingthespringslidermaterialmodelforelasticlinearhardeningmaterialandtheparameters
given,theresultingstressstrainresponseduringmonotonicloadingwouldbeasshown.
Forcompletelyreversedcyclicloading,thestressstrainresponseisasshown.Notethatoncethe
straincycleisreversed,thematerialyieldonlywhenthechangeinstrainattainstwicetheinitial
yieldstrength.Seethefigure.Forcompletelyreversedyieldingthecycleisalwaysperfectly
symmetric.
b)ThestraincycleforstrainingfromH=0toH=0.012followedbydecreasingstraintoH=0.005and
thenincreasingstraintoH=0.015isshown
Example 8
Anotchedcomponenthaskt=3.Thecomponentisloadeduntilnominalstress,S=200MPa.The
componentisthenunloadedtoanominalstressofS=0.Strainlifepropertiesofthematerialare:
E=100GPa,Vf=1000MPa,Hf=1.0,b=0.08andc=0.60.
a) determinethelocalstressandlocalstrainatthenotchatS=200MPa.
b) determinetheresiduallocalstressandlocalstrainatthenotchatS=0MPa
c) usetheNeuberanalysisandMorrowmeanstresscorrectiontoestimatethefatiguelifeof
thecomponent.
Findthefollowingequationsfromthelecturenotesfortheweek6andsolvethemissingconstants
forthecyclicstressstraincurve:
' f
H' 1000MPa
H ' f b / c
H'
10.08 / 0.60
1000MPa
b 0.08 2
n' n'
c 0.60 1
Neubers rule and the cyclic stressstrain curve are used to estimate both the maximums and
amplitudes of the local notch stress and strain. For the initial monotonic response, assumed to
followthecyclicstressstraincurve,wehave:
1 1
V max V nc V max V max 2 / 15
H max f V max
max
E Hc 100000MPa 1000MPa
Eliminationof betweenequationsgivesanequationinvolvingstressthatcanbesolvedbytrial
anderrororothernumericalprocedure.However,e.g.acalculatorwithanumericalsolvercanbe
suggestedtobeusedtosolve .
1
V nc
(k t S max ) 2 V 2 V E
H c ,Substituting intooriginalequationgives .
1
V 2 / 15
3 200MPa 2
V 2 V 100000 MPa
463.54166 ...M
1000 MPa max
max | 463.5M
then
0 0
3 3
D D
0 0
3 3
D D
1 1
Q
I
P
D(
[
P+
D
[
V V 463 5 2
V c 463 5
7 77 10 3
P
D
[
P
D
[
15
H
c 100000 1000
Forcyclicloading,itisconvenienttoworkinthetermsofamplitudesusingthecyclicNeuber`srule
andthesamestressstraincurve,butevaluatethesefor:
3
D
P
D
[
P
L
Q
' 200
Theneededequationsare:
1 1
Q
'V 'V c 'V 'V 2
(
0
3
D
0
3
D
'H 2 2
2 c 100000 2 1000
and
.
6
0 0
3 3
D D
2 3 0 200 2
W
'
(
'V'H .
100000
Solvingthesegives:
3 ,
3
D
Theminimumvaluesforcyclicloadingcanbeobtained:
0
3
D
3
D
P
L
Q
P
D
[
P
D
[
H H 'H
! !
3
D
3
D
P
L
Q
| 464 .
Theestimatedstressstrainresponseisshowninthefollowingfigure.Thiswasplottedbyequating
'& 2 f ('% / 2) forthebothbranchesofthehysteresisloop.
Morrow'smeanstresscorrectionestimateisknownas:
'H + ' f + m
,a (2 N f *b H ' f (2 N f *c
2 E
wehave:
0 3
3 D
D
1
-1000 168.
2 0 08 1 02 0 60
0
3 06 10 3
100000
1
I
| 4 4 10 5 cycles/
Exmpale 9
UsingthematerialpropertiesgiveninTableA.2,Constructthemonotonicandcyclicstresssrain
curvesforRQC100hotrolledsteelforstrainbetween0and2%.Doesthismaterialcyclically
hardenorsoften?
fromtable
m
cyclic
V / Va
H / a
Overthisrangeofstrain,themonotoniccurveisabovethecycliccurve,thereforethematerial
softens.