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
Factor of Loading, k c (Refer to page 290)
* 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

Factor of Reliability, ke (Refer to page 292-293 and equation 6-29)

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,

Se' = 0.5⋅ Sut Se' = 190.000 MPa

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

σao = 0.4⋅ σ σao = 25.465 MPa 1 mark

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

Investigate the stress concentration effect .

* 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
Bending Loading:
* 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

Torsion Loading:
* 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

σa = Kf ⋅ σao σa = 36.669 MPa 1 mark

τa = Kfs⋅ τao τa = 15.941 MPa 1 mark

σm = Kf ⋅ σmo σm = 91.673 MPa

1 mark

τm = Kfs⋅ τmo τm = 39.852 MPa 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

Axial Loading:
* 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

CHECKING SAFETY FACTOR REFERING TO THE MODIFIED GOODMAN CRITERION

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

The shaft save.

Infinite life cycle! 2 marks

ng2 = Modified Goodman's safety factor

(d)

- No localized yielding at the notch.

5 marks