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# DESIGN OF FATIGUE FAILURE PREVENTION

The solution is based on the data and approach from the book of
Shigley's Mechanical Engineering Design, Ninth Edition in SI Units.

(a)
STATIC STRENGTH AISI 1020 HR

## Sut = 380 MPa * Ultimate Tensile Strength

Sy = 210 MPa * Yield Strength 1 mark

## ENDURANCE LIMIT MODIFYING FACTORS

Factor of Surface, k a (Refer to page 287-288, Table 6-2 and equation 6-19)
* For this case the finishing is ground-finished.
a = 4.51 b = −0.265

b −3
ka = a⋅ ( Sut) ka = 934.402× 10
1 mark

## Factor of Size, k b (Refer to page 288-289, equation 6-20)

* Refering to the most critical point location and choose the bigger size.

d = 20 mm

de = 0.370 ⋅ d de = 7.400 mm
− 0.107
kb = 1.24⋅ de kb = 1.001
2 marks
* Bending load, set k c = 1.

kc = 1

## Factor of Temperature, k d (Refer to page 290-292)

* If nothing said about k d, set kd =1. Otherwise its depend on the information given. Hence,
kd = 1

ke = 1

## Factor of Miscellaneous-Effects, k f (Refer to page 293-294)

* If no data support for any miscellaneos effects which affecting the fatigue
strength limit, set k f = 1. Hence,

kf = 1

ENDURANCE LIMITS
Uncorrected Endurance Limit, S e' (Refer to equation 6-8 at page 282)
* The Sut is less than 1400 MPa. Hence,

## Corrected Endurance Limit, S e (Refer to equation 6-18 at page 287)

Se = ka⋅ kb⋅ kc⋅ kd⋅ ke⋅ kf ⋅ Se' Se = 177.706 MPa 1 mark

(b)
M = 50000 Nmm

T = 50000 Nmm

d
c = c = 10.000 mm
2
d
r = r = 10.000 mm
2
4
π⋅ d 3 4
I = I = 7.854 × 10 mm
64
4
π⋅ d 3 4
J = J = 15.708 × 10 mm
32

M⋅ c
σ = σ = 63.662 MPa
I

T⋅ r
τ = τ = 31.831 MPa
J

## τao = 0.4⋅ τ τao = 12.732 MPa 1 mark

1 mark
σmo = σ σmo = 63.662 MPa

1 mark
τmo = τ τmo = 31.831 MPa

## * Determination of Fatigue Stress Concentration Factor (Refer to page 1026-1034)

ra = 5 mm d = 20 mm D = 30 mm
ra −3 D
= 250.000 × 10 = 1.500
d d
* K t for bending loading refers to Figure A-15-9 (page 1028). Hence,
Kt = 1.55

## * q for bending loading refers to Figure 6-20 (page 295). Hence,

q = 0.8
* K f for bending loading is calculated using equation 6-32 (page 295) . Hence,
Kf = 1 + q ⋅ ( Kt − 1 ) Kf = 1.440 1 mark

* K ts for bending loading refers to Figure A-15-9 (page 1028). Hence,
Kts = 1.3

## * qs for bending loading refers to Figure 6-20 (page 295). Hence,

qs = 0.84
* K fs for bending loading is calculated using equation 6-32 (page 295) . Hence,
Kfs = 1 + qs ⋅ ( Kts − 1 ) Kfs = 1.252
1 mark

1 mark

## Combine the Stress:

2 2
Von Mises Stress for Alternating Component: σav = ( σa) + 3 ⋅ ( τa)

1 mark
σav = 45.902 MPa

2 2
Von Mises Stress for Midrange Component: σmv = ( σm) + 3 ⋅ ( τm)

## σmv = 114.755 MPa 1 mark

*** In this calculation, σ av and σ mv are σ'a and σ' m respectively. v stands for Von Mises
CHECKING FIRST CYCLE YIELDING USING LANGER CRITERION

σav σmv 1
+ =
Sy Sy nl1
1 mark
nl1 = 1.307
nl1 = Langer's safety factor

## CHECKING SAFETY FACTOR REFERING TO THE MODIFIED GOODMAN CRITERION

σav σmv 1
+ =
Se Sut ng1
1 mark
ng1 = 1.785
*Hence, the shaft save. Infinite life cycle! 1 mark
ng1 = Modified Goodman's safety factor

(c)
P = 3500 N
2
A = π⋅ r

P
σax = σax = 11.141 MPa Constant Stress 1 mark
A

σmo2 = σax

* K ta for bending loading refers to Figure A-15-9 (page 1028). Hence,
Kta = 1.7

## * qa for bending loading refers to Figure 6-20 (page 295). Hence,

qa = 0.8
* K fa for bending loading is calculated using equation 6-32 (page 295) . Hence,
Kfa = 1 + qa⋅ ( Kta − 1 ) Kfa = 1.560 1 mark

Kf ⋅ σmo = 91.673
Kfa⋅ σmo2 = 17.380 1 mark

## σm2 = ( Kfa⋅ σmo2) + ( Kf ⋅ σmo) σm2 = 109.053 MPa 1 mark

2 2
Von Mises Stress for Midrange Component: σmv2 = ( σm2) + 3 ⋅ ( τm)

## σmv2 = 129.063 MPa 1 mark

CHECKING FIRST CYCLE YIELDING USING LANGER CRITERION

σav σmv2 1
+ =
Sy Sy nl2
1 mark
nl2 = 1.200
1 mark
No localized yielding
nl2= Langer's safety factor

σav σmv2 1
+ =
Se Sut ng2
1 mark
ng2 = 1.672

## The shaft save.

Infinite life cycle! 2 marks

(d)

5 marks