Strain-Life Vs.

Stress-Life

Low Cycle High Cycle Fatigue

Fatigue (LCF) (HCF)
Stress

Strain-Life
Approach Stress-Life
Approach

100 103 106 N

 Nominal Vs Local Stress

nominal
stress n  
L
Local
Stress n Unloading (Local)
•
L Unloading (Nominal)
 
Loading Unloading

• Even though nominal stress is within the elastic range,

the local stress at notches may be higher than the yield
stress.
• Notch region experiences permanent deformation upon
unloading.
 Material Behavior

A0 A

d0 l0 l
d

Before loading After loading

Eng. Stress S = P/A0

Stress
True stress  = P/A
 Material Behavior
A0 A

d0 l0 l
d

Before loading After loading

l - l 0 l
Engineering strain e   l
l0 0
Strain l
dl  l 
True or Natural strain     ln 
l0
l  l0 
 Engineering & True Stress-Strain
  ln1  e
True -
Engineering Stress, S

A0
True Stress, 

  S  S 1  e f x
A f
Engineering S-e

Necking Occurs x
Sy
at Su
Failure
E=S/e

Engineering Strain, e
True Strain, 

Figure 2.3 Comparison of engineering and true stress-strain

 Monotonic Stress-Strain Relations

Total strain t
 P
• Elastic strain e

Elastic
Plastic strain p
Unloading
 t =  e+  p
E E e=/E
e 
p
t
 Plastic Strain
Log True Stress, (log)

K
  K  
n

 K
1

or p  
n

n
log   log K  nlog  p
1.0
Log Plastic Strain, (logp)

K - Strength coefficient
n - Strain hardening exponent
 Elastic, Plastic & Total Strain

Elastic  e  
E

 K
1

Plastic  p  
n

Total    
t e p

   
n

 t     Ramberg-Osgood
E  K  stress-strain relationship
 Elastic, Plastic & Total Strain

Example: K=70 ksi, E=10,000 ksi, n=0.5

(i) Given  = 40 ksi

1

   n
 t    
E  K  Elastic Plastic Total

40  0.5
1
40
t      0.004 + 0.3265 = 0.3305
10000 70 
ii   ? for  t  101
1

   
  0.49  490  0
0.5 2
101    
10000  70
  21.89 or - 22.38 ksi
 Example On Monotonic Stress-Strain Relation

Test Data for 7075-T651 Al

 (MPa) 430 450 470 490 510

Total t () 7350 8950 12850 22950 45750

Given E = 71 GPa,
A) Determine K and n in Ramberg-Osgood
stress-strain relationship for 7075-T651 Al alloy
B) Plot the experimental and Ramberg-Osgood
Predictions of and  on the same graph
 Ex. On Monotonic Stress-Strain Relation (Cont’d)

 K
1

   ,   , p  
n
Solution t e p e
E

 K
1

   
n

t
E
or   K p  log   log K  n log p
n

 t e=/E p= t- e

430 7.3510-3 0.006056 0.001294
450 8.9510-3 0.006338 0.002612
470 12.8510-3 0.006620 0.006230
490 22.9510-3 0.006901 0.016049
510 45.7510-3 0.007183 0.038567
Elastic Part
Given Exptl. Data
 Example (Cont’d)

 P
•

0.022950

490

E E

e 
p
t
0.016049
0.006901
 Example (Cont’d) - Stress Vs. Plastic Strain

• Plot  Versus p on log scale

K*
K=600.9 MPa
n=0.04937
n

log 

log p 1.0

1
    0.04937
So that     
71000 600.9
 Ex. (Cont’d) Comparison of Experimental Data
with Ramberg-Osgood Predictions

Data Points
Ramber-Osgood Equation

   0.04937
1


  t    
71000 600.9
t
 Cyclic Behavior – Bauschinger Effect

 
max max
y y
2
y Unload
 
Loading -y Load in
compression

• Yield at y during tensile loading

• Yield before -y during compressive loading
 Transient Behavior – Hardening

1 3 5
+
 5
 Time
3
1
- 2 4
(a) constant strain amplitude
3 5 
+ 1


Time 2
-
2 4 4
(b) stress response (c) cyclic stress-strain
(increasing stress level) response.
 Transient Behavior – Softening
1 3 5
+ 1

 3
Time
- 5
2 4
(a) constant strain amplitude
1 
3 5
4

Time 2
4
2
(c) cyclic stress-strain
(b) stress response response.
(decreasing stress level)
 Cyclic Material Behavior
Hysteresis Loop:
Material response to cyclic inelastic loading

/2 strain amplitude

 /2 stress amplitude

e - elastic part


p - plastic part

E
  e  p
  ;
p e 2 2 2
  e  
E
 Strain Hardening Vs. Softening
Manson Postulation: Based on experimental observation.
Using static material properties (ultimate and yield strength and
the strain hardening exponent, n), one can predict whether the
material is hardening or softening type.

If  ult /  y   1.4

 material cyclically hardens
or n  0.2 


If  ult /  y   1.12

 material cyclically softens
or n  0.1 

1

   n
Where, n is given by  t    
E  K 
 Strain Hardening/Softening

Cyclic (C) and monotonic (M) stress-strain curves


 C C

M M

7075-T6
2024-T4 Aluminum
Aluminum

(a)  (b)
 Strain Hardening/Softening
Cyclic (C) and monotonic (M) stress-strain curves

C

 M
M

C
Man-Ten
Steel 4340 (350 BHN)
Steel

 
(d)
(c)
 Cyclically Stable Condition

• Transient (hardening/softening) occurs during early

cycles of fatigue life.
• Eventually material reaches cyclically stable condition.

Transient Transient
Stable


Stable
t
t
 Effect of Heat Treat Condition on Hysteresis
Response

Annealing= ricottura
 Hysteresis Response of copper

Stabilized Hysterisis Loop

at  =0.0084

Material Exhibits Cyclically

Hardening Behavior
in fully Annealed
condition.
 Hysteresis Response of copper

Stabilized Hysterisis Loop

at  =0.0078

Material Exhibits Cyclically

Softening Behavior
in Partially Annealed
condition.
 Hysteresis Response of copper

Stabilized Hysterisis Loop

at  =0.0099

Material Exhibits Cyclically

Softening Behavior
in cold worked
condition.
 Cyclic Stress-Strain Curve
- Apply cyclic strain of amplitude
/2.
- Transient stress is followed by a
stabilized hysteresis loop
- Establish the stabilized
hysteresis loop for this strain level
- Repeat the procedure with
a different strain amplitude
- Connect the tips of the above
stabilized hystereis loops
- CYCLIC STRESS STRAIN
CURVE for the Material.


 CYCLIC STRESS-STRAIN RELATIONS

Total Strain     
t e p

Elastic Strain,  e  
E

 K 
1

Plastic Strain,  p  
n 

  K  
n

p 1
 n

So that  t    
E K 

K' - Cyclic Strength coefficient

n' - Cyclic Strain hardening exponent
 CYCLIC STRESS-STRAIN RELATIONS

  K  
Log Cyclic Stress, (log)

K' p

 K
1

or p  
n 

n' log   log K  nlog  p

1.0
Log Cyclic Strain, (logp)
 STABILIZED HYSTERESIS CURVE

Massing’s Hypothesis:
- For materials exhibiting symmetric behavior in
tension and compression.

- Hysteresis curve can be ESTIMATED from the

stabilized Cyclic Stress-Strain Curve.

- Doubling the stress and strain value from the

stabilized Cyclic Stress-Strain Curve
 STABILIZED HYSTERESIS CURVE
Following Massing’s Hypothesis:Obtain point B on the
Hysterisis curve by doubling the values corresponding
to point A on the Cyclic Stress-Strain Curve

 
B
540
Stabilized
A Stabilized Cyclic Hysteresis
270 Stress-Strain Curve
Curve

0.002  0 0.004 
(a) (b)
 Stabilized
B
Hysteresis
Loop
 = 540

0
=0.004 (c)
 EQUATION FOR HYSTERESIS LOOP
1

  n
Recall    t    
E K 
Following Massing’s Hypothesis:

2 /2
2 /2
1

   n
So that    
2 2E 2K 
1
Hysteresis
   n 
Equations
  2  
E 2 K 
 Example 2.1(Text)
Given test specimen with the following properties: E = 30000 ksi,
Cyclic strain hardening exponent = n´= 0.202,
Cyclic strength coefficient = K´=174.6 ksi.
The specimen is subjected to fully reversed
cyclic strain with a strain range,  = 0.04.

• Establish the stress-strain

response of the material.
• Plot the stress-strain response
on a plane.
0.02 1 3

 0o  = 0.04
t
-0.02
2 44
(a)

Figure E2.1 (a) Applied Strain history

 Example 2.1(Text)

Figure E2.1 (a) Applied Strain history

0.02 1 3
(b) Stress-strain response
 0o  = 0.04 
t
-0.02 77.1 ksi 1, 3
2 4
(a)
4

-0.02 o 0.02 
1

  n
  t     2 -77.1 ksi
E  K 

(b)
 Strain-Life Curves

Using true stress amplitude (/2), stress-life (S-N) data

could be plotted linearly on a log-log scale,

 
  f 2Nf 
b
(2.37)
2
1
2Nf  reversals to failure ( one reversal  cycle)
2
 
 f  fatigure strength coeff.  Material Fatigue
 Properties
b  fatigue strength exponent 


 f
 True fracture strength,  f
 Strain-Life Curves

Manson & Coffin found that plastic strain-life (p-N)

data could also be linearized on log-log coordinates

 p   
c

  f 2N  (2.38)
2  f 

 p
 plastic strain amplitude
2
1
2Nf  reversals to failure ( one reversal  cycle)
2
 f   fatigue ductility coeff. 
 Material
c  fatigue ductility exponent 
 Fatigue properties


  
f f
 Strain-Life Curves

How can we relate life to Total Strain Amplitude /2?

 e  p
Recall,  
2 2 2
 e 
 (2.39)
2 2E
From 2.37 & 2.39

 e  f
2Nf 
b
 (2.40)
2 E

 f 
2Nf    f 2Nf 
b c
 (2.41)
2 E
plastic Strain-Life
elastic
Relation
 Log-Linear Life Relations

Note Eqns 2.37 and 2.38 are linear on a log-log plane

 p
 e e f '
 2 N f b  p   f ' 2 N f c
2 E 2
2 2
f '
f ' b
c
E

100 2Nf 100 2Nf

Elastic Strain - Life Plastic Strain - Life

 Total Strain-Life Relation

 p
  f ' 2 N f c
2
e/2  f '
 2 N f b  f ' 2 N f c
2 E
p/2
/2

e f '  e
 2 N f b 
2 E  p 2
2
2
2Nf
 Transition Life

Plastic
Dominant
Elastic
e/2
Dominant
p/2
/2 Total
Elastic

Plastic

2Nt 2Nf

 e  p
At 2Nf  2Nt : 
2 2
 f ' E  bc
1
 f'
2N t    f ' 2N t   2Nt   
b c

E   f ' 
 Transition Life

Total
Strain 106
Steels
e/2

2Nt
p/2
Elastic
/2 Plastic
Strain
Strain
100
2Nt 100 600
BHN

Hard  2Nt is small – most of 2Nf is elastic

Soft  2Nt is large – most of 2Nf is plastic
 Strength and Ductility

100
Normalized (soft material)
Soft has better life @ high 

Quenched (hard material)

/2, log

Hard has better life @ low 

10-4
100 108
2Nf , log
 Fatigue Properties
b, c, f´, f´: Empirical constants
1. Not all materials may be represented by 4-parameter strain-
life equations (e.g., Al & Ti alloys)
2. Parameters obtained by curve fit -Therefore, accuracy
depends on the number of data points used/available.
3. Parameters applicable over a given range – Outside this
range may give large errors
4. Strictly mathematical convenience – no physical basis.
1
       f'
   
n
    2 N
b
  ' 2 N
c

2 
2E  2K  E
f f f

1
  f '   
 2 N f b 

n
   f ' 2 N f c

2E E  2 K 
Relationships: K´ = f´/( f´)n’ Cyclic stress-strain
n´ = b/c
 Fatigue Properties

In the absence of “cyclic data”, the fatigue parameters can be

obtained as rough estimates from “monotonic properties”

 f´   f f  Su + 50 ksi for steels with BHN < 500

b varies from – 0.05 to – 0.12 with an average of – 0.085

(same as what we had in stress-life model)

1
 f´   f where  f  ln RA=(Ai-Af)/Ai
1 - RA

c varies between – 0.5 to – 0.7

For fairly ductile metals c  - 0.6
For strong metals c  - 0.5
 Examples

Example 2.2

Given monotonic and cyclic strain-life data. Determine

the cyclic stress-strain & strain-life constants

Monotonic data: Sy=158 ksi E = 28.4103 ksi

Su=168 ksi f = 228 ksi
%RA = 52 f = 0.734

Cyclic data see the table on next slide

 Example 2.2 (Cont’d)
Total Strain Stress Plastic Strain
Reversals to
Amplitude, Amplitude, Amplitude,
Failure, 2Nf
/2 /2 (ksi) p/2*
0.0393 162.5 0.0336 50
0.0393 162 0.0336 68
0.02925 155 0.0238 122
0.01975 143.5 0.0147 256
0.0196 143.5 0.0145 350
0.01375 136.5 0.00894 488
0.00980 130.5 0.00521 1,364
0.00980 126.5 0.00534 1,386
0.00655 121 0.00229 3,540
0.00630 119 0.00211 3,590
0.00460 114 0.00059 9,100
0.00360 106 0.00000 35,200
0.00295 84.5 0.00000 140,000

  p   e  
   
2 2 2 2 2E
 Example 2.2 (Cont’d)

log /2

  f ' 2N f 
b

2 b
 '  222 ksi b  - 0.076
f

log 2Nf

 p
  f ' 2N f  log p/2
c

2
c
 '  0.811 c  - 0.732
f

log 2Nf
 Example 2.2 (Cont’d)

To determine K´ and n´ (Two methods)


(A) Fit a power law between stress amplitude, and
2
 p
plastic strain amplitude,
2
  p 
n'

 K'   K´ = 216 ksi n´=0.094

2  2 
 f'
(B) Recall K' 
f

n'
'
-0.076
n' b/c   0.104
-0.732
222
K'  227 ksi
0.811 0.104
 Example 2.2 (Cont’d)

1
Elastic Strain
Plastic Strain
Strain Amplitude, /2

Total Strain
0.1
Power (Plastic Strain)
Power (Elastic Strain)

0.01

0.001

0.0001
1 100 10000 1000000
Reversals to Failure, 2Nf
 MEAN STRESS EFFECTS IN STRAIN-LIFE
APPROACH

Compressive Mean Stress

Fully Reversed (zero mean stress)
Tensile Mean Stress
Log /2

LCF

Mean Stress effects are

significant at longer lives, HCF
HCF
At high strain amplitudes, LCF,
mean stress relaxation occurs
Log 2Nf
and eventually mean stress tends
towards zero.
 MEAN STRESS RELAXATION UNDER
CONSTANT STRAIN AMPLITUDE

 
1
1 3 5 7 3
 m1 5
7
m
m4 
2
4
2 4 6 8 Time 6
8
Mean stress Relaxation is

not due to strain softening.

Mean stress Relaxation can

occur in cyclically stable materials.
 MORROW’s MODEL FOR
MEAN STRESS EFFECTS
Recall
  f
 2Nf    f 2Nf 
b c
(2.41)
2 E

elastic plastic
Recognizing the effect of mean stress effects
predominantly at long lives, Morrow modified
the elastic component only

  
2N   2N 
b c
 f 0
f f f
(2.49)
2 E
 MORROW’s MODEL FOR
MEAN STRESS EFFECTS

f´   
 2N   2N 
b c
f  f 0
f f f
E 2 E
Log /2

 0
Zero Mean Stress
E Tensile Mean Stress

Log 2Nf
 MORROW’s MODEL FOR
MEAN STRESS EFFECTS

  
2N   2N 
b c
 f 0
f f f
(2.49)
2 E

elastic plastic

Model incorrectly predicts the ratio (e)/ (p) to be

a function of the mean stress.
 MORROW’s MODEL FOR
MEAN STRESS EFFECTS

1

+

p


p The two small Hysteresis loops
have the same (e)/ (p) ratio
+ but different Mean stresses.
1 The ratio (e)/ (p) is Independent
of the applied mean stress.
 Manson & Halford MODEL FOR
MEAN STRESS EFFECTS
Manson and Halford modified both elastic and plastic
terms of the strain-life relation so that the ratio (e)/ (p)
is Independent of the applied mean stress.

 
c

    
2Nf   f  2Nf 
b
b c
 f 0 f 0
(2.50)
2 E  f 

No Mean Stress
Log /2

Tensile Mean Stress

2Nt Log 2Nf

 Smith, Watson & Topper MODEL FOR
MEAN STRESS EFFECTS

 f
2

 2Nf   f
f
2Nf 
2b bc

max
 (2.52)
2 E


Where  max
 0 (2.53)
2

All mean stress models are empirically based and

apply in the ranges from which they are developed.

Their validity outside such ranges should be

Questioned.
 Problem# - 2.13

A metal has the following monotonic and cyclic tension

properties:
E=193 GPa Sy (0.2% offset)=325 MPa
Su=650 MPa f =1400 MPa
f =1.731 %RA=80% n=0.193
K’=1660 MPa n’=0.287

A) Calculate the strain reached on the first half-cycle for a

stress amplitude of 200 MPa.
B) Determine the stable total strain and plastic
strain amplitude for a stress amplitude of 200 MPa.
C) Repeat the calculation above, but now determine the
stress response for amplitude (/2) of 0.01
 Problem - 2.13 - Solution
Part A)

 C? M? Do we use monotonic (M)

or cyclic properties (C) for the
first half of the cycle?

If we know for sure that the material

had no prior loading  Use Monotonic
If we are not sure  Use Cyclic
 Problem - 2.13 - Solution

 K
1

   
n
Using Monotonic Stress-Strain
f 1400
M
E
K n   1259MPa
 f 1.7310.193

 200  0.193
1

200
M      0.001109
193000 1259

 K
1

   
n 

Using Cyclic Stress-Strain C

E
 200  0.287
1

200
C      0.001664
193000 1660
 Problem - 2.13 - Solution

Part B) b) Given /2 = 200 MPa

/2 = ?

Using Hysteresis Eqn.

   
1
n 

   
2 2E 2K 

  0.00207  0.00125

 e
elastic ,  0.001035
2
 p
plastic ,  0.000625
2

total ,  0.001663
2
 Problem - 2.13 - Solution

Part C) Given Strain  calculate stress response

C?
M? Initial half-cycle

 
1
Using Monotonic Properties    n
E K
 1  0.193
1

1
0.01       1M  489.4 MPa
193000  1259

 
1
Using Cyclic Properties     n
E K
 1  0.287
1

1
0.01       C
 413.3 MPa
193000  1660 1
 Problem - 2.13 - Solution
Stable Stress-Strain
 1M  489.4 MPa
 1 3 1,3
0   1C  413.3 MPa
 0
t 
2 4 2,4
Using Hysteresis 
   
1
n 

     0.01  solve for     826.6 MPa

2 2E 2K 

      We get different answers depending

2 1

      on whether we use 1M or 1C
 for the initial half-cycle
3 2

     
4 3
 Problem - 2.13 - Solution
Stable Stress-Strain

Ref No. Strain,  Stress (MPa) Stress (MPa)

Using M Using C
0 0 0 0
1 +0.01 489.4 413.3
2 -0.01 -337.2 -413.3
3 +0.01 489.4 413.3
4 -0.01 -337.2 -413.3
Mean Stress 76.1 0

M - Monotonic; C - Cyclic
 Problem - 2.13 Solution

Stable Stress-Strain
500 500
max=489.4 1,3 max=413.3 1,3
STRESS,  (MPa)

STRESS,  (MPa)
mean
stress Using
Using
0=76.1 (K,n) (K’,n’)
0 0 0 mean
stress
0=0

min=-337.2 min=-413.3
2,4 2,4
-500 -500
-0.011 0 0.011 -0.011 0 0.011
STRAIN,  STRAIN, 
 Problem 2.17

The following stress-strain and strain-life properties are given for a steel:
E = 30103 ksi K’ = 137 ksi n’ = 0.22
f’ = 120 ksi b = -0.11 f’ = 0.95 c = -0.64
(a) Draw on log-log coordinates the elastic strain-life, plastic strain-life,
and total strain-life curves. Determine the transition life (2Nt).
(b) Draw the hysteresis loops corresponding to strain amplitude (/2 )
values of 0.05, 0.00125, and 0.0007. Determine the fatigue life in
reversals at these three strain levels.
(c) Determine the elastic, plastic, and total strain amplitude for a life (2Nf)
of 2 106 reversals.
(d) Determine the elastic, plastic, and total strain amplitude for a life (2Nf)
of 500 reversals.
(e) Determine the cyclic stress amplitude corresponding to fatigue lives
of 500 and 2 106 reversals.
(f) A component made from this materials is required to have a life of
no less than 104 reversals. The loading on the component causes
a total strain amplitude of 0.008. Determine if the component will
meet the life requirement.
 Problem 2.17 -Solution

• Draw on log-log coordinates the elastic strain-life, plastic strain-life,

and total strain-life curves. Determine the transition life (2Nt).
Recall from Lesson 7
 f
2Nf   
f
2Nf 
b c
 (2.41)
2 E
 e f
2Nf  
120
2Nf 
b -0.11

2 E 30000

Straight line with intercept of f at 2Nf  1
E
 p
 f2Nf  = 0.952Nf 
c -0.64

2
Straight line with intercept of  f
at 2Nf  1
 Problem 2.17 -Solution

2Nt = 30000
e/2
p/2
/2 Total
Elastic
Plastic

2Nt 2Nf
 e  p
At 2Nf  2N t : 
2 2
1
  E  bc  0.95(30000)  1 0.110.64
 2N t   f     30366
    120 
 f 
 Problem 2.17 – Solution
b1) To obtain initial stress response, use cyclic material
properties in

 
1
    n
E K

 
1

0.0007        18 ksi
0.22

30000 137

  
1

0.00125      24.8 ksi

0.22

30000 137

  
1

0.05      70.1 ksi

0.22

30000 137
 Problem 2.17 – Solution
b2) Hysteresis

 
1
     n
2 2E 2K 

 
1
     0.22
2 60000 274

/2  (ksi)

0.0007 36
0.00125 49.6
0.05 140.2
 Problem 2.17 – Solution

Hysteresis loop Hysteresis loop

for /2=.00125 for /2=.05
75 75

70.1
stress,  (ksi)

stress,  (ksi)
+24.8

0 0
-24.8
-70.1
2Nf=3.5105 rev. 2Nf=107 rev.
-75 -75
-0.05 0 0.05 -0.05 0 0.05
strain,  strain, 
 Problem 2.17 – Solution
b3) Life
 f
 2Nf    f 2Nf 

b c

2 E
 120
 2Nf 0.11  0.952Nf 0.64
2 30000

/2 2Nf (reversals)

0.0007 1.12107
0.00125 351400
0.05 107
 Problem 2.17 – Solution

2Nf  2  106    e  p
c & d)at  ? ? ?
2Nf  500  2 2 2
 f
 2Nf   f 2Nf 
b c

2 E
 e f p
 2Nf   f 2Nf 
b c

2 E 2

2Nf /2 e /2 p /2

2106 0.000899 0.000811 0.000088

500 0.019818 0.002019 0.017798
 Problem 2.17 – Solution

2Nf  2  106  
e) at  ?
2Nf  500   2
  e
Using (c&d) and  E
2 2
2Nf e /2 /2 (ksi)
2106 0.000811 24.33
500 0.002019 60.57

f) Life requirement @ /2=0.008 is 2Nf=10000. Is this met?

 f
 2Nf   f 2Nf   0.008 solve for 2Nf  2500
b c

2 E
No, life requirement is not met.
 More on Mean Stress and Initial Loading (Chapter 2)

Problem 2.38: Given the cyclic stress-strain and strain-life

parameters for a sheet E = 30103 ksi K’ = 174.6 ksi
n’ = 0.202 f’ = 133 ksi b = - 0.095 f’ = 0.26
c = - 0.47
Determine the life of this sheet material under the following
strain histories: Use Morrow relationship.
0.01 0.01
 
 0.002 0.002 0.002

-0.002 -0.002 -0.002

- 0.01 - 0.01
History A History B History C
 Problem 2.38 (Cont.)

General Steps for all three cases:

 1 3 0.002
• 0 to 1: Calculate stress at 1 using
0 cyclic stress-strain equation
1
2 4   1 n
History A -0.002  1    
1

E K 

• 1 to 2: Calculate stress range 12

using Hysteresis equation

    n
1

   
2 2E 2K 
 Problem 2.38 (Cont.)

General Steps for all three cases:

 1 3 0.002
• At 2: Calculate stress 2 knowing
0 1 and 12
2 4 2 = 1 - 12
History A -0.002
• Beyond 2: Follow the two previous
steps to obtain stresses at 3,
4, and 5 etc.
• Calculate the mean stress knowing
the max and min stresses for
the stabilized stress cycle(s)
 Assignment #3, Problem #1

A metal has the following monotonic and cyclic tension

properties: E=193 GPa Sy (0.2% offset)=325 MPa
Su=650 MPa , f =650 MPa, f =1.731, %RA=80%
n=0.193, K’=1660 MPa n’=0.287
a) Material Hardens or Softens?
b) Calculate the strain reached on the first half-cycle for a
stress amplitude of 200 Mpa and monotonic properties.
c) Calculate the strain reached on the first half-cycle for a
stress amplitude of 200 Mpa and cyclic properties.
d) Determine the stable total strain and plastic
strain amplitude for a stress amplitude of 200 MPa.
e) Repeat the calculation above, but now determine the
stress response for amplitude (/2) of 0.01
 Assignment #3, Problem #1
b) Using Monotonic Stress-Strain

 K
1

   
n

M
E
 650
K  f
 584.7 MPa
 1.731
n 0.193
f

 200  0.193
1

200
M      0.00489
193000 584.7

 K
1

   
n 
c) Using Cyclic Stress-Strain
C
E
 200  0.287
1

200
C      0.001664
193000 1660
 Assignment #3, Problem #1

d) Given /2 = 200 MPa, /2 = ?

   
1
n 
Using Hysteresis Eqn.    
2 2E 2K 
 200  0.287
1

 200
   
2 193000 1660

 e
elastic amplitude ,  0.001035
2
 p
plastic amplitude ,  0.000625
2

total amplitude ,  0.001663
2

  0.00207  0.00125
 Problem - 2.13 - Solution
e) Given /2 = 0.01 /2 = ?

C?
M? Initial half-cycle

 K
1

   
n

Using Monotonic Properties

E
 
1

  0.193

0.01  1   1    1M  234.5 MPa

193000  584.7

 
1
Using Cyclic Properties     n
E K
 1  0.287
1

1
0.01       C
 413.3 MPa
193000  1660 1
 Problem - 2.13 - Solution
Stable Stress-Strain
 1,3   234.5 MPa
M

 1 3 1

0     413.3 MPa
C

 0 1

t 
2 4 2,4
Using Hysteresis 
   
1
n 

     0.01  solve for     826.6 MPa

2 2E 2K 

      We get different answers depending

2 1

      on whether we use 1M or 1C
 for the initial half-cycle
3 2

     
4 3
 STRAIN - LIFE APPROACH

METHODOLOGY:
• Establish notch-root strain history
• Relate nominal strain history to notch-root strain
history via stress/strain concentration factors
• Use the strain-life fatigue data of smooth specimens

ADAVANTAGES:
- Accounts for notch-root plasticity
- Accounts for changes in local mean stress
- Accounts for Residual stresses.
 STRESS & STRAIN CONCENTRATION FACTORS

Stress Concentration, K  
S
(4.11)

Strain Concentration, K  
e
K (concentration factor)

Strain Concentration, K Due to local yielding

K differs from K
Kt=K=K
Stress After yielding, local
Concentration, K strain is > that
yielding predicted by Kt
0 1.0 /y Stress
 local stress and strain predictions

A S
=KtS
A
=KS

S ,

S
e =Ke
=Kte
Differences between local stress and strain
predictions using Kt and K, K values.
Nominal & local stress/strain Response

S (nominal stress)
Nominal stress history
S
1 3

4
2 Time
,
 (local stress)

local stress-strain response

1,3
S

 (local
strain)
2,4
STRESS & STRAIN CONCENTRATION FACTORS -
Neuber’s Rule
Neuber’s Rule: Geometric mean of the stress and
strain concentration factors remains a constant
equal to Kt

K t  K K  (4.12)

So that K 2t  K  K 

Substituting for K and K


K 2t 
Se (4.13)
K 2tSe  
Notch Root Local
Nominal Stress/strain Stress/strain -
- Given To be determined
 Neuber’s Rule (Cont.)

K t Se  
2

 = K Se 2
t

- For a given component geometry and loading

mode Kt is a constant
- For a given loading, the nominal stress S can be
calculated
- For a know nominal Stress S, the nominal strain e
can be calculated via stress-strain law

 = K Se 2
t
Applied/Known
Notch Root Response
- Constant
- Needed for Life Calculation
 Neuber’s Rule (Cont.)

 = K Se   = Constant
2
t

- Constant, is a hyperbola on a stress-strain plane.

400
Constant
 MPa

200

0.02 0.06  0.1

 Neuber’s Rule and Local Response
,
Local and should satisfy both
S, e the Neuber’s Rule and the
stress-strain (or Hysteresis) law

Neuber’s Rule stress-strain law

Constant





 Neuber’s Rule and Local Response
For a given nominal stress S1and nominal strain e1,
the local stress and strain (1,1) values are given by
the “intersection” of the Neuber’s Rule and the
stress-strain (or Hysteresis) law.

Cyclic Stress/Strain Law

 
1 n 
 
    
E K 
 1,1 (Solution)


Neuber’s Rule, Constant


 Neuber’s Rule and Local Stress/Strain Response

Neuber’s Rule   = Constant = K f S e

2

Note, for fatigue K f is used instead of K t

 
1

Stress-Strain Law      n 

E K 
S  S 
1
n 

e    
E K 
S
e if S  S y known
E
Substitute for e and  in to Neuber’s rule
   n
1
  1n
 S S
      = K 2t S     
E K   E K  
   
 Neuber’s Rule and Local Stress/Strain Response-
Example
Given: S=50, K’ =154 ksi, E = 30 msi, Kt=2.0 and n’ =0.125
     
1 0.125   
1
0.125 
S S
      = K t S     
2


30000 154   30000 154 
 

  1.054485x10   1.132623x10
9 13 2 17

Solving for :  72.8 ksi.

Then, strain  can be obtained by substituting for

 in to Neuber’s rule or Stress-Strain law

  
1
n   72.8 72.8
1 0.125

          
E K  
30000 154  

 = 0.002427 + 0.002494 = 0.004921
 Methodology for Local Response
from Nominal Applied History

 (local stress)
S (nominal stress)

S1 Cyclic Stress
-Strain Curve Neuber’s
S=S1-S2 P1 Rule, =c1
Time

S2  (local strain)
Nominal stress P2
reversal Hysteresis Stress – Strain Curv
Neuber’s Rule,  =c2

Intersection of hysteresis stress-strain

curve and Neuber’s hyperbola ( ).
 Neuber’s Rule and Local Hysteresis Response

Neuber’s Rule   = Constant = K 2f S e

Note, for fatigue K f is used instead of K t
1
Hysteresis Law     n'
   
2 2E 2K' 
1
e S  S  n'
   
2 2E 2K' 
e S S
 if  Sy
2 2E 2
Substitute for e and  in to Neuber’s rule
  1 n'  S  S 1 n' 
      = K t S    
2

2E 2K'    
2E 2K'   
known
 Neuber’s Rule and Local HysteresisResponse-
Example
Given: S=100, K’ =154 ksi, E = 30 msi, Kt=2.0 and n’ =0.125
   1 0.125 
      = 0.71606
60000 308
 


( )  1.34975x10    5.79903x10

9 15 2 19

Solving for :  145.6 ksi.

Then, strain range  can be obtained by substituting for

 in to Neuber’s rule or Hysteresis law

   
1
n'  72.8 72.81 0.125 
         
2 2E 2K'  
30000 154  

= 0.002427 + 0.002494 = 0.004921    0.009842
 GROSS AND NET AREAS FOR SCF
P
Gross Area

Net Area KtGROSS

Kt
KtNET
a/W

a = hole radius, W = plate width, t = Plate Thickness

Gross Area = Wt, Net Area = (W-2a)t
SGROSS = P/Wt, SNET = P/(W-2a)t
KtGROSS = max/ SGROSS, KtNET = max/ SNET
 Problem 4.3

For a notched plate with a net stress concentration factor

Kt = 3, E = 200 GPa, K’ = 1400 MPa, Sy = 600 MPa,
n’ = 0.14

Determine the net stress, S, necessary to:

A) Reach yield, Sy at the notch root

B) Reach a strain of  = 1 % at the notch root

If a net section stress of 610 MPa is applied to the plate,

determine the resulting local notch root stress and strain
( and ).
 Solution

Solution: ,
a) Notch root yields at  = Sy = 600
S, e
Calculate local strain from local stress

   600 
1 1

 n 
600 0.14

         =0.00535
E K  200000 1400
Calculate net stress/strain (S, e) Solution
from known local
stress/strain (,)  Stress-Strain curve

Neuber’s Rule
Neuber’s Rule
  Kt S e
2   K 2tSe

 Solution 4.3 (Contd.)

 
S n 

3 SE  SK   6000.00535 

1
2

Substituting for e
S2 S8.1429
  0.356667 S= 266.5 MPa
200000 2.96718  10 22

b) Given  = 0.01 at notch root; Determine S & e

Calculate local stress from local strain

 
1
 
E  K 
n

1
    0.14
    0.01   693 MPa
200000 1400 
 Solution 4.3 (Contd.)
Calculate net stress/strain (S, e) from
known local stress/strain (,)
S  S 1n 
Neuber’s Rule K t S       6930.01
2

E K   
S2 S 8.1429
  0.77
200000 2.96718  10 22

Solving S=382.6 MPa

382.6 382 .6

1
0.14

e    e=0.00201
E  K  
Check if K2t S e   

9382.60.00201  6930.01
 Solution 4.3 (Contd.)

c) If S=610 MPa,  =?  =?
   K 2t S e   
1
n    
1
n 
 
    9S
  S S 
   
E K   E K  
   

2  8.1429
  31.2799
200000 2.96718  10 22

Solving for ,   864.19 MPa

1
864.19 864.19 n
Local Strain,      0.036196
E  K  
 Problem 4.21

A notched component has a theoretical stress concentration

factor, Kt= 3. The component is loaded to cause a nominal
stress, S = 200 MPa. Determine the resulting notch root
stress, , and strain, . The component is then unloaded to
a nominal stress S =0.
Determine the residual stress at the notch root.

What is the fatigue life of the component if it is subjected to a

cyclic nominal stress of 0 to 200 MPa (R=0)?

Use a Neuber analysis and the Morrow mean stress-strain

life relationship [Eq. (2.49)]. The strain-life properties for this
material are: E=100 GPa, ´f=1000 MPa, b= - 0.08, ´f=1.0
and c= - 0.60.
 Problem 4.21 (Cont’d)


1, 3 1,3
Stress (S)

1 3
Nominal

200 MPa

0 2 4 Time 
2, 4 2,4
Segment 0-1: K t S1 e1   1 1
2

  
1
n     
1
n 
S S  
K 2t S1  1   1     1  1   1  
E K   E K  
Given:
   
Kt  3, S1  200, E  100000, K  1000 MPa, n  0.1333
 Problem 4.21 (Cont’d)

 12  18.5  200  200 7.5 

  9 200    
100000 1000 7.5 
100000 1000   
8.5 2
1  3.162278  1017 1  1.1416783  1023
1  463.9 MPa

Segment 1-2: K 2t S e   
  
1
n     
1
n 
S
 S  
 
K t S  2     2  
2

 E 2K    E 2K  

   
S  200 Solve for   589.6 MPa
 2  1     2  125.7
 Problem 4.21 (Cont’d)

Residual stress at notch root is when the nominal stress

is completely released, i.e. S2=0

Residual stress at notch root, 2= -125.7 MPa


463.9 1,3


-125.7 2,4


 Problem 4.21 (Cont’d)

1
      n
Life Calculation:    
2 2E 
2 K 

 589.6  589.6 
7.5

   
2 2100000  21000 


 0.00305
2

 
Mean Stress,  0  1 2
 169.1 MPa
2
 Problem 4.21 (Cont’d)

Using Morrow to account for the effect of mean stress on life,

 f  0
  b
 
2Nf   f 2Nf c
2 E
1000  169.1
0.00305  2Nf 0.08  1.02Nf 0.60
100000

0.00305  0.0083092Nf   2Nf 

0.08 0.60

Solving, 2Nf = 875,670

Life, N= 437,835 cycles

 Example on Mean Stress & Residual Notch Stress

Problem 4.30: Given the cyclic stress-strain and strain-life

parameters for a aluminum sheet E = 10.6103 ksi
K’ = 95 ksi n’ = 0.065 f’ = 160 ksi b = - 0.124
f’ = 0.22 c = - 0.59
Determine the life of this sheet material under the following
strain histories: Use Morrow relationship.

• Comment on the notch root response vs nominal response

• Comment on the mean stress effect
• Comment on the residual stress effects
 Problem 4.30 (Cont.)

1 480 kips
P 1 3
240 kips  240
3

0 2 4
4
2
History C
History A - 480
2
480 kips
P
4 240

0
3
1 History B
- 480
 Problem 4.30 (Cont.)

General Steps for all three cases:

• First determine the SCF, Kt

• 0 to 1:
• Given nominal stress S, calculate the notch root
stress using stress-strain equation and Neuber’s
Rule
 = K Se 2
t

 
1

 n 

    
E K 
S  S 
1
n 

e    
E K 
 Problem 4.30 (Cont.)

• 1 to 2
• 2 to 3
• 3 to 4
•Etc,

Knowing S, Calculate stress range  at the notch

root; Use Hysteresis eq. and Neuber Rule in terms of
stress and strain ranges.
  = K 2f S e
1
    n'
   
2 2E 2K' 
1
e S  S  n'
   
2 2E 2K' 
 Problem 4.30 (Cont.)

• Calculate the Strain Amplitude

• Calculate the mean stress

• Calculate the Life using one of the formulas

such as Morrow’s
 Effect of load sequence on fatigue life
S
Nominal Stress, S

40
20
12 in.
ksi

0
-20 Cycles, N
35 in.
-40
2 in. dia
History A: Has non-zero
Mean stress but no over
Or under load S
Notched Specimen
 Effect of load sequence on fatigue life

9-1/2 Cycles History B: High-Low Load

40 Sequence. The last overload
20 Is positive resulting in
Compressive residual stress
ksi

0
Nominal Stress, S

-20 Cycles, N at the Notch root. Has

non-zero Mean stress.
-40
History B
10 Cycles History C: High-Low Load
40 Sequence. The last overload
20 Is negative resulting in
ksi

0 tensile residual stress at the

-20 Cycles, N Notch root. Has non-zero
-40 Mean stress.
History C
 Effect of load sequence on fatigue life

9-1/2 Cycles
40 40
20 20
ksi

0 0
Nominal Stress, S

-20 Cycles, N -20 Cycles, N

-40 -40
History B: Nf= 460,000
10 Cycles History A: Nf=115,000
40
20
ksi

0
-20 Cycles, N
-40
History C: Nf=63,000