Lesson No.

7 in Machine Design 1[Pick the date]

 Lesson No. 7 in Machine Design 1 – UNIAXIAL VARIABLE LOADING: INDEFINITE LIFE

DESIGN

 CHARACTERIZING FLUCTUATING LOADS AND STRESSES

 Direct Axial Loads (Tension or Compression)/Stresses

Pmax +¿ P
Midrange Load Pm: Pm = min
¿
2

Pmax −¿P
Amplitude Load Pa: P a= ¿ min

Pm
Midrange Stress σ m : σ m=¿
A

Pa
Amplitude Stress σ a σ a=
A

 Bending Loads/Stresses:

M max + M min
Midrange Moment M m : M m=
2

M max −M min
Amplitude Moment M a : M a=
2

Mmc
Midrange Stress σ m : σ m=±
I

Mac
Amplitude Stress σ a :σ a=±
I

 Torsional Loads/Stresses:

T max + T min
Midrange Torque T m :T m=¿
2

T max−T min
Amplitude Torque T a :T a=
2

T mc
Midrange Stress τ m : τ m=
J

T ac
Amplitude stress τ a : τ a=
J

 Direct Shear Loads/Stresses:

Pmax +¿ P
Midrange Direct Shear Force Pm : Pm= ¿min

Pmax −¿ P
Amplitude Direct Shear Force Pa : Pa= ¿ min

Pm
Midrange Direct Shear Stress τ m : τ m=
As

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Lesson No. 7 in Machine Design 1[Pick the date]

Pa
Amplitude Direct Shear Stress τ a : τ a=
As

 Transverse Shear Loads./Stresses:

V max+¿V
Midrange Transverse Load V m :V m= min
¿
2

V max−¿V
Amplitude Transverse Load V a :V a= min
¿
2

a. Solid Circular Section.

4 Vm
Midrange Transverse Shear Stress ( τ tr )m : ( τ tr )m =
3 A

4 Va
Amplitude Transverse Shear Stress ( τ tr )a : ( τ tr )a =
3 A

b. Solid Rectangular Section.

3 Vm
Midrange Transverse Shear Stress ( τ tr )m : ( τ tr )m =
2 A

3 Va
Amplitude Transverse Shear Stress ( τ tr )a : ( τ tr )a =
2 A

Researchers have done much work on the modes of failure of materials subjected to
different conditions of variable loading. These led to the formulation of failure criteria based
on sound analysis of observable occurrence. Referring to Factors of Safety obtained in the
preceding example problems and also from the succeeding illustrative examples, these will
confirm the literature provided from reference 3 (The Mechanical Design Process) that the
value of Factor of Safety is closely related with the Theories of Failure (or failure analysis)
employed.

 THE ENDURANCE LIMIT AND ENDURANCE STRENGTH OF DUCTILE

MATERIALS.

The endurance limit S'e is for a mirror-polished, rotating beam subjected to pure bending and its
value is closely related to the ultimate Strength.
Unless there are data from tests simulating the actual material shape, surface condition, size,
environment, temperature, loading conditions, and miscellaneous effects, this material’s
endurance limit will differ from the actual endurance strength Se . The endurance strength Se for
use in design equations may be estimated by the following procedure:

Step 1. Estimate the endurance limit S'e using the following equations:
'
 For Steels - - - - - - - - - - - - - - - - - - - Se =0.5 Su
'
 For Cast Steels - - - - - - - - - - - - - - - - - Se = 0.40 Su
'
 For nonferrous metals and alloys - - - - - Se = 0.30 Su
'
 For Cast Iron - - - - - - - - - - - - - - - - - - - Se = 0.35 Su

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Lesson No. 7 in Machine Design 1[Pick the date]

Step 2. Estimate the Endurance Strength Se by applying the Marin modification

Factors as follows:

Se =[ K sur K sz K L K T K R K misc ] S'e

Where, S'e =¿endurance limit for a mirror-polished rotating beam subjected to pure
Bending, with indefinite Life (or106 cycles ¿ failure), tested at normal
atmospheric conditions.
Se =¿ adjusted endurance strength of the material at the anticipated actual
conditions of use with minimum indefinite Life of 106 cycles to failure. This
value is for use in design fatigue equations.
K sur = Surface factor −¿ adjustment for deviation from the Mirror-polished surface test
condition.
= 1.0 for nonferrous metals
= aSbu

It is to be noted that the ultimate strength values are already corrected

Temperature deviations from room temperature. K sur = 1.0 for a mirror-
polished (or ground) surface condition.

K sz =¿Size factor−−¿ modification factor for the deviation from the rotating beam test
data. Practically, due to manufacturing or some processes undergone by a material,
homogeneity is decreased as the dimension increases and so the endurance strength is
somewhat reduced.
= 1.0 for axial loading.
For a rotating solid circular shaft,

For a non-rotating solid rectangular shaft, equivalent diameter to be

used is d e =0.808 √ bh

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Lesson No. 7 in Machine Design 1[Pick the date]

K L= Load factor−−¿adjustment to compensate for the deviation from rotating-

beam test’s completely reversed bending load conditions. For non- rotating
shafts or rectangular shafts, use

KL

K T =¿ Temperature adjustment factor. This factor takes care of the deviations

from the thermal environment conditions experienced by a rotating-
beam test specimen. The material’s strength tends to decrease with
increasing temperature while lowering the temperature increases the
brittleness of the material. The ductility is also increased up to some
point.

When the endurance limit as determined from the rotating- beam test
was taken at 70F or 20C temperature, use

KT =
( S T ) F ( ST )C
=
S 70 F S20 C

. In the absence of rotating-beam test data, use the followin equation (for steels
only):

K T = [0.975 + 0.432 x 10−3 T F −0.115 x 10−5 T 2F

−¿0.595 x 10−12 T 4F ¿

Where T F is the existing temperature of the material in degrees Fahrenheit

and 70oF≤ T F ≤1,000 oF. This factor need not be applied if the ultimate
strength was already corrected for temperature variation prior to estimation
of the Endurance Limit S'e .

K R=¿ A statistically determined

modification factor for a

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Lesson No. 7 in Machine Design 1[Pick the date]

desired degree of reliability.

K misc = A modification factor to take care of the miscellaneous

effects, such as corrosion and cyclic frequency.

In estimating the value of the endurance strength, it is suggested to use a

modification factor of unity for an unknown value of a Marin Factor.

The endurance limit of a material should be adjusted to a safer value equal to that
of the endurance strength in order to prevent failure of the part. However, for a
design category where costly material testing is permissible, it is recommended to
test the material based on the actual conditions of use. In this case the endurance
strength will equal the endurance limit obtained from the endurance test.

Future designers are encouraged to get abreast of the developments in the field of
engineering materials because the value of the factor of safety is greatly
influenced by the designer’s knowledge of the source of data and the process/es to
be employed in fabricating the part.

Knowledge of the processes a material went through can also play a great role in
the evaluation of a product’s performance and a ready reference as to what further
processes or treatment needs to be done to improve the design.

Prepared by: RBMAGAY, M. Engr.

ME Faculty

/rbm

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