Beruflich Dokumente
Kultur Dokumente
By
2016-2017
1
Suggested Readings
2
Topics
3
Your Questions
4
Introduction
5
Introduction
Climbing to
cruising altitude Descending and
Push back from Manoeuvring to Aligning the
Speeding down the destination plane with
the gate, taxi to
the runway runway
the runway
Landing, taxis to the
gate and parking at
terminal
Taken from:
http://science.howstuffworks.com/transport/flig
ht/modern/air-traffic-control1.htm
6
Introduction
7
Introduction
8
Introduction
• Fatigue failure
• Gives no warning (no large deflection etc) and it is very
sudden=brittle fracture
• Dangerous (because it is sudden)
• Complicated phenomenon (partially understood)
• Life of a component must be obtained based on empirical
methods
9
Introduction
10
Introduction
11
Introduction
12
Introduction
13
Fatigue analysis approaches
• Stress-life method
• Will be covered in the lecture
• Strain-life method
• Beyond the scope of this lecture
• Linear elastic fracture mechanics method
• Beyond the scope of this lecture
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Stress-life method
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Strain-life method
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Fracture mechanics method
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Stress-life method
18
Watch
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Fatigue machine (for R=-1 only)
• R. R. Moore high-speed
rotating-beam machine
• Specimen is subjected to
pure bending (no
transverse shear) by
means of weights
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R. R. Moore machine
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Electro-hydraulic axial fatigue
machine (for all R values)
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Output from fatigue test (see Ref [3])
Stress in the component some
Stress books use symbol σ instead
Each cycle is equal
to two reversals
time
23
Fluctuating stresses
S max S min S r
Sa
2 2 S min Sa 1 R
R A
S max S min S max Sm 1 R
Sm
2
S r S max S min Amplitude
Stress ratio
ratio
24
S-N/Wohler diagram (see Ref [2])
Results of completely
reversed axial fatigue tests.
Material: UNS G41300 steel,
normalized; Sut = 116 kpsi;
maximum Sut = 125 kpsi.
25
How SN curve is established
My I 0.25r 4 , y r 2nw1a
max max min
I r 3
w1
w1
w1
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S-N bands for Aluminium alloys for
completely reversed cycling
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Fatigue strength in log-log S-N curve
(Sf) a is fatigue
S a a N f
strength when Nf b a and b are
is 1 cycle only constants for
cycles 103-107
Cycles to
the failure
S1000
Se
Endurance limit
29
Note
Source:
Metallic Materials Properties Development and Standardization (MMPDS)
30
Endurance limit of steel vs aluminium (Se)
• Endurance limit
• The maximum
stress which can
be applied to a
material for an
infinite number of
stress cycles
without resulting in
failure of the
material
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Endurance limit (Se)
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Endurance limit (Se)
33
Fatigue prone locations
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Stress Concentration and Notch
Sensitivity
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Stress concentration
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Stress concentration in aircraft
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Stress Concentration around a circular hole subjected to
remote loading in an infinite composite panel
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Stress concentration factor
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How to get stress concentration value?
• Experimental procedures
• Photoelasticity
• grid methods
• brittle-coating methods
• Electrical strain-gauge methods
• Finite element analysis
• Not exact
• Analytical approaches based on conformal mapping
and complex algebra
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Stress concentration value
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Stress concentration value
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Stress concentration for a shaft under
bending load and axial load
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Stress concentration for a notched shaft
under bending load and axial load
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Stress concentration for a prismatic bar
under bending load and axial load
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Stress concentration for a plate with a central
hole under bending load and axial load
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Fatigue Stress Concentration Factor
Fatigue stress
concentration factor
0 q 1
Notch sensitivity
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Notch sensitivity
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Notch sensitivity
49
Note
50
Industrial examples of fatigue critical
locations (lugs in flap track)
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Industrial examples of fatigue critical
locations (fillets in flap track)
Fillet A
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Industrial examples of fatigue critical
locations (buttstraps)
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Industrial examples of fatigue critical
locations (buttstraps)
54
Industrial examples of fatigue critical
locations (buttstraps)
Cover
Buttstrap
Panel
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Industrial examples of fatigue critical
locations (strut brackets)
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Industrial examples of fatigue critical
locations (baffle panels)
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Industrial examples of fatigue critical
locations (baffle panels)
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Industrial examples of fatigue critical
locations (joints)
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Example 1
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Solution
D / d 38 / 32 1.18
r / d 3 / 32 0.093
K t 1.65
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Solution
q 0.84
K f 1 qK t 1
K f 1 0.841.65 1 1.55
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Example 2
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Solution
We know:
S a a N f
b
S max S min S r
Sa
2 2 d 50 0.2 K t 2.5
S S min w 250
S m max K f 1 0.92.5 1 2.35
2
64
Solution
65
Example 3
25 12.5
33 11.5
11 29.5
60 20
90 25
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Solution
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Example 4
log N 20.83 9.09 log S max 1 R
0.52
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Solution
• Let’s calculate for one entry only;
20 0.52
20.839.09 log 40 1
40
N 10 48998554
0 25 0.0 132655518
-5 28 -0.18 21779524
24 35 0.69 1480700983
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Tutorial 1
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Solution for Tutorial 1
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Solution for Tutorial 1
Kt _ B ?
K f _ B 1 qK t 1 ?
We solved this in
previous example,
see below
K f _ B 1 qK t 1
1 0.841.65 1 1.55
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Solution for Tutorial 1
D / d 38 / 35 1.08
r / d 3 / 35 0.086
K t _ C 1.6
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Solution for Tutorial 1
q 0.84
K f _ C 1 qK t 1
K f _ C 1 0.841.6 1 1.5
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Solution for Tutorial 1
Based on these
stresses where does
fatigue likely to
happen?
225
R1 6.8 2.78kN R2 6.8 2.78 4.02kN
550
CB I d 3 / 32 323 / 32 CC I d 3 / 32 353 / 32
ymax ymax
3.217 103 (mm 3 ) 4.209 103 (mm 3 )
MB 695.5 MC 502.5
SB K f _ B 1.55 10 6 335.1MPa SC K f _ C 1.50 10 6 179.1MPa
C 3.217 C 4.209
75
Solution for Tutorial 1
These stresses
Based are both
on these
greater than endurance
stresses where does
limit of 236MPa and
fatigue
yield stress likely to
of 580MPa.
happen?
What does this mean?
MB 695.5 MC 502.5
SB K f _ B 1.55 10 6 335.1MPa SC K f _ C 1.50 10 6 179.1MPa
C 3.217 C 4.209
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Solution for Tutorial 1
S a a N f
b
1
S b
Nf a
a
1
335.1 0.1308
Nf 68000(cycles)
1437
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Tutorial 2 (real industrial problem)
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Tutorial 2 (real industrial problem)
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Solution for Tutorial 2
S min 0
16.4 R0
S max 1000 8841.8 145MPa
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Important Notes [3]
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Important Notes [3]
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Influence of tensile normal mean stress on
fatigue strength
• To compensate and understand the influence of tensile normal
mean stress on high cycle fatigue strength, several empirical
plots can be established (constant life plot as below and also see
next slide)
83
Example of constant life diagrams
• This can be obtained from S-N diagram
This is SN curve for
various mean stress
values
S max S min S r
Sa
2 2
S max S min
Sm
2
Increase in life
84
Fatigue failure criteria for fluctuating
stresses (Haigh plot)
Effective alternating stress at
failure for a life time of Nf cycles
(modified fatigue strength)
85
Note
Unsafe
Safe
Infinite life
86
Note
2
Sa Sm
2
Sm
2
Sa Sm Sa Sm Sa
1 1 1 1
S ar S y S ar Sut
S ar Sut S ar Sy
• Sar is a fully reversed stress amplitude corresponding
to a specific life in the high-cycle fatigue region
87
General observations
Most actual test data tend to For most fatigue situations R<1 ( i.e. small
fall between the Goodman mean stress in relation to alternating stress),
and Gerber curves there is little difference in the theories
88
Complex loading and cycle counting
89
Complex loading and cycle counting
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Methods of cycle counting
• Beyond the scope of this lecture
• Interested readers are recommended to refer to
chapter 3 of Ref. [3];
• Level crossing cycle counting
• Peak-valley cycle counting
• Range counting
• Three-point cycle counting method
• Four-point cycle counting method
• Rain-flow counting technique
91
Output form cycle counting
• A typical result of cycle counting would look like;
After cycle counting it
becomes fairly straightforward
to calculate stress range and
mean stress values and
proceed as normal
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Cumulative damage
93
Cumulative damage
94
Note on cumulative damage
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Example 3
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Solution
ni n1 n2 n3 n4
D D
Ni N1 N 2 N 3 N 4
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Example 4
98
Solution
1.0 1.0
Repetitions Repetitions 2.56
Di 0.39
99
Example 5
100
Solution
• We know from solution that;
log N f A B logS eq C N f 1010.7 3.81log 32.310 365559.83cycles
101
Solution
102
Example 6
• The squared hollow box girder belongs to an aircraft and it is subjected
to a tensile force of 10P and a transverse shear force P at the beam’s
tip. The following cycles were recorded for the load P on the box girder
for one year of aircraft’s service:
The squared box girder has length L = 1000mm and the hollow squared
cross-section has an edge length of 100mm and uniform thickness of 2
mm.
• Calculate the second moment of area of the cross-section about the
horizontal axis passing through the centroid
• Assuming yield stress of material is 500MPa and using the Soderberg
fatigue criteria, determine the number of repetitions (years) to failure
due to fatigue.
(Note: consider the material parameters for the S−N curve as being A =
1800MPa and B = −0.2 and use the Miner’s rule for the most critical point
in the box girder).
103
Example 6
104
Solution
Sa Sm S
1 S a S ar 1 m 1
S ar S y S
y
105
Solution
S ar S f aN b
106
Tutorial 3
• A solid shaft of circular cross-section with a diameter of 40mm is subjected to an
eccentric axial load F at a distance of 10mm from the center of the cross-section
and it is also subjected to a torque T. The loads are applied repeatedly and, for
each repetition, the following load pulsations and number of cycles applies:
Tmin Cycles
Cycle ID Fmin (kN) Fmax (kN) Tmax (kNm)
(kNm) repetition
1 20 100 0 0 5000
2 10 50 0 2 1000
107
Tutorial 3
108
Solution for Tutorial 3
Cycle Tmin Tmax Cycles
Fmin (kN) Fmax (kN)
ID (kNm) (kNm) repetition
1 20 100 0 0 5000
109
Solution for Tutorial 3
110
Solution for Tutorial 3
Cycle Tmin Tmax Cycles
Fmin (kN) Fmax (kN)
ID (kNm) (kNm) repetition
2 10 50 0 2 1000
111
Solution for Tutorial 3
• Finally we get;
S ar S f aN b 231.6 1600 N 0.2 N 15.74 103 cycles
112
Solution for Tutorial 3
113