Fatigue Failure

It has been recognized that a metal subjected

to a repetitive or fluctuating stress will fail at a
stress much lower than that required to cause
failure on a single application of load. Failures
occurring under conditions of dynamic loading
are called fatigue failures.

Fatigue failure is characterized by three stages

 Crack Initiation
 Crack Propagation
 Final Fracture
Ken Youssefi MAE dept., SJSU 1
 Jack hammer component,
shows no yielding before
fracture.

Crack initiation site

Fracture zone
Propagation zone, striation
Ken Youssefi MAE dept., SJSU 2
 VW crank shaft – fatigue failure due to cyclic bending and torsional stresses

Propagation
zone, striations

Crack initiation site Fracture area

Ken Youssefi MAE dept., SJSU 3

 928 Porsche timing pulley

Ken Youssefi MAE dept., SJSU Crack started at the fillet 4

 Fracture surface of a failed bolt. The
fracture surface exhibited beach marks,
which is characteristic of a fatigue failure.

1.0-in. diameter steel pins from

agricultural equipment.
Material; AISI/SAE 4140 low
allow carbon steel

Ken Youssefi MAE dept., SJSU 5

 bicycle crank spider arm

This long term fatigue crack in a high quality component took a

considerable time to nucleate from a machining mark between the spider
arms on this highly stressed surface. However once initiated propagation
was rapid and accelerating as shown in the increased spacing of the 'beach
marks' on the surface caused by the advancing fatigue crack.
Ken Youssefi MAE dept., SJSU 6
 Crank shaft

Gear tooth failure

Ken Youssefi MAE dept., SJSU 7

 Hawaii, Aloha Flight 243, a Boeing 737, an upper part of the plane's cabin
area rips off in mid-flight. Metal fatigue was the cause of the failure.

Ken Youssefi MAE dept., SJSU 8

 Fracture Surface Characteristics

Mode of fracture Typical surface characteristics

Ductile Cup and Cone
Dimples
Dull Surface
Inclusion at the bottom of the dimple

Brittle Intergranular Shiny

Grain Boundary cracking

Brittle Transgranular Shiny

Cleavage fractures
Flat

Fatigue Beachmarks
Striations (SEM)
Initiation sites
Propagation zone
Final fracture zone

Ken Youssefi MAE dept., SJSU 9

 Fatigue Failure – Type of Fluctuating Stresses

Alternating stress
max min
a = 2

Mean stress
max + min
m 2
=
Ken Youssefi MAE dept., SJSU 10
 Fatigue Failure, S-N Curve

Test specimen geometry for R.R. Moore

rotating beam machine. The surface is
polished in the axial direction. A constant
bending load is applied.

Typical testing apparatus, pure bending

Motor

Load

Rotating beam machine – applies fully reverse bending stress

Ken Youssefi MAE dept., SJSU 11

 Fatigue Failure, S-N Curve

N < 103 N > 103

Finite life Infinite life

S′e

Se′ = endurance limit of the specimen

Ken Youssefi MAE dept., SJSU 12

 Relationship Between Endurance Limit
and Ultimate Strength
Steel
Steel
0.5Sut Sut ≤ 200 ksi (1400 MPa)
Se′ = 100 ksi Sut > 200 ksi
700 MPa Sut > 1400 MPa

Cast iron Cast iron

0.4Sut Sut < 60 ksi (400 MPa)

Se′ = 24 ksi Sut ≥ 60 ksi
160 MPa Sut < 400 MPa
Ken Youssefi MAE dept., SJSU 13
 Relationship Between Endurance Limit and
Ultimate Strength
Aluminum
Aluminum alloys
0.4Sut Sut < 48 ksi (330 MPa)
Se′ = 19 ksi Sut ≥ 48 ksi
130 MPa Sut ≥ 330 MPa

For N = 5x108 cycle

Copper alloys
Copper alloys
0.4Sut Sut < 40 ksi (280 MPa)
Se′ = 14 ksi Sut ≥ 40 ksi
100 MPa Sut ≥ 280 MPa
For N = 5x108 cycle

Ken Youssefi MAE dept., SJSU 14

 Correction Factors for Specimen’s Endurance Limit
For materials exhibiting a knee in the S-N curve at 106 cycles
S ′ = endurance limit of the specimen (infinite life > 106)
e

Se = endurance limit of the actual component (infinite life > 106)

S Se

103 106 N

For materials that do not exhibit a knee in the S-N curve, the infinite
life taken at 5x108 cycles

Sf′ = fatigue strength of the specimen (infinite life > 5x108)

Sf = fatigue strength of the actual component (infinite life > 5x108)

S Sf

Ken Youssefi
103 5x108
MAE dept., SJSU
N 15
 Correction Factors for Specimen’s Endurance Limit

Se = Cload Csize Csurf Ctemp Crel (S′e)

• Load factor, Cload

Pure bending Cload = 1

Pure axial Cload = 0.7
Pure torsion Cload = 1 if von Mises stress is used, use
0.577 if von Mises stress is NOT used.
Combined loading Cload = 1

Ken Youssefi MAE dept., SJSU 16

 Correction Factors for Specimen’s Endurance Limit

• Size factor, Csize

Larger parts fail at lower stresses than smaller parts. This is
mainly due to the higher probability of flaws being present in
larger components.

For solid round cross section

d ≤ 0.3 in. (8 mm) Csize = 1

0.3 in. < d ≤ 10 in. Csize = .869(d)-0.097
8 mm < d ≤ 250 mm Csize = 1.189(d)-0.097

If the component is larger than 10 in., use Csize = .6

Ken Youssefi MAE dept., SJSU 17

 Correction Factors for Specimen’s Endurance Limit
For non rotating components, use the 95% area approach to calculate
the equivalent diameter. Then use this equivalent diameter in the
previous equations to calculate the size factor.

A95 d95 d
dequiv = ( )1/2
0.0766

Ken Youssefi MAE dept., SJSU 18

 Correction Factors for Specimen’s Endurance Limit
• surface factor, Csurf
The rotating beam test specimen has a polished surface. Most
components do not have a polished surface. Scratches and
imperfections on the surface act like a stress raisers and reduce
the fatigue life of a part. Use either the graph or the equation with
the table shown below.

Csurf = A (Sut)b

Ken Youssefi MAE dept., SJSU 19

 Correction Factors for Specimen’s Endurance Limit

• Temperature factor, Ctemp

High temperatures reduce the fatigue life of a component. For
accurate results, use an environmental chamber and obtain the
endurance limit experimentally at the desired temperature.

For operating temperature below 450 oC (840 oF) the

temperature factor should be taken as one.

Ctemp = 1 for T ≤ 450 oC (840 oF)

Ken Youssefi MAE dept., SJSU 20

 Correction Factors for Specimen’s Endurance Limit

• Reliability factor, Crel

The reliability correction factor accounts for the scatter and

uncertainty of material properties (endurance limit).

Ken Youssefi MAE dept., SJSU 21

 Fatigue Stress Concentration Factor, Kf
Experimental data shows that the actual stress concentration factor is
not as high as indicated by the theoretical value, Kt. The stress
concentration factor seems to be sensitive to the notch radius and the
ultimate strength of the material.
Notch sensitivity
Kf = 1 + (Kt – 1)q factor

Ken Youssefi MAE dept., SJSU 22

 Fatigue Stress
Concentration Factor,
Kf for Aluminum

Ken Youssefi MAE dept., SJSU 23

Design process – Fully Reversed Loading for Infinite Life
• Determine the maximum alternating applied stress, a, in terms of
the size and cross sectional profile
• Select material → Sy, Sut
• Choose a safety factor → n

• Determine all modifying factors and calculate the endurance

limit of the component → Se

• Determine the fatigue stress concentration factor, Kf

• Use the design equation to calculate the size

Se
Kf a =
n
• Investigate different cross sections (profiles), optimize for size or weight

• You may also assume a profile and size, calculate the alternating stress
and determine the safety factor. Iterate until you obtain the desired
safety factor
Ken Youssefi MAE dept., SJSU 24
 Design for Finite Life

Sn = a (N)b equation of the fatigue line

A A

S B S B
Se Sf

103 106 N 103 5x108 N

Sn = .9Sut Sn = .9Sut
Point A Point A
N = 10 3
N = 103

Sn = Se Sn = Sf
Point B Point B
N = 10 6 N = 5x108
Ken Youssefi MAE dept., SJSU 25
 Design for Finite Life
Sn = a (N)b log Sn = log a + b log N

Apply conditions for point A and B to find the

two constants “a” and “b”
2
(.9Sut)
3
a=
log .9Sut = log a + b log 10 Se
log Se = log a + b log 106 1 .9Sut
b= log
3 Se

Se
⅓ log ( .9S )
N ut
Sn = Se ( 106 )

Calculate Sn and replace Se in the design equation

Sn
Kf a = Design equation
n
Ken Youssefi MAE dept., SJSU 26
 The Effect of Mean Stress on Fatigue Life

Mean stress exist if the

loading is of a repeating or
fluctuating type.

a
Sy Yield line

Gerber curve
Se
Alternating
stress Goodman line

Sy Sut m
Soderberg line
Mean stress
Ken Youssefi MAE dept., SJSU 27
 The Effect of Mean Stress on Fatigue Life
Modified Goodman Diagram

a
Sy Yield line

Se
Alternating
stress Goodman line
C
Safe zone

Sy Sut m
Mean stress

Ken Youssefi MAE dept., SJSU 28

 The Effect of Mean Stress on Fatigue Life
Modified Goodman Diagram

a
Sy Yield line

Se

Goodman line
C
Safe zone Safe zone

- m - Syc Sy Sut +m

Ken Youssefi MAE dept., SJSU 29

 The Effect of Mean Stress on Fatigue Life
Modified Goodman Diagram

Fatigue, m ≤ 0 Fatigue, m > 0

a a m 1
+ = Infinite life
Se Sut nf
Se a m
a = n + = 1 Finite life
f Sn Sut
Yield Se
Sy Yield
a + m = n Sy
y
C
a + m = n
y
Safe zone Safe zone

- m - Syc Sy Sut +m

Ken Youssefi MAE dept., SJSU 30

 Applying Stress Concentration factor to Alternating
and Mean Components of Stress
• Determine the fatigue stress concentration factor, Kf, apply directly to
the alternating stress → Kf a

• If Kf max < Sy then there is no yielding at the notch, use Kfm = Kf

and multiply the mean stress by Kfm → Kfm m

• If Kf max > Sy then there is local yielding at the notch, material at the
notch is strain-hardened. The effect of stress concentration is reduced.

Calculate the stress concentration factor for the mean stress using
the following equation,
Sy Kf a
Kfm =
m
Fatigue design equation
Kf a Kfmm 1
+ = Infinite life
Se Sut nf

Ken Youssefi MAE dept., SJSU 31

 Combined Loading
All four components of stress exist,

xa alternating component of normal stress

xm mean component of normal stress

xya alternating component of shear stress

xym mean component of shear stress

Calculate the alternating and mean principal stresses,

1a, 2a = (xa /2) ± (xa /2)2 + (xya)2

1m, 2m = (xm /2) ± (xm /2)2 + (xym)2

Ken Youssefi MAE dept., SJSU 32

 Combined Loading

Calculate the alternating and mean von Mises stresses,

a′ = (1a2 + 2a2 - 1a2a)1/2

m′ = (1m
2
+ 2m - 1m2m)1/2
2

Fatigue design equation

′a ′m 1
+ = Infinite life
Se Sut nf

Ken Youssefi MAE dept., SJSU 33

 Design Example 10,000 lb.
12˝ 6˝ 6˝
A rotating shaft is carrying 10,000 lb force
as shown. The shaft is made of steel with d D = 1.5d
Sut = 120 ksi and Sy = 90 ksi. The shaft A
is rotating at 1150 rpm and has a R1 R2
machine finish surface. Determine the r (fillet radius) = .1d
diameter, d, for 75 minutes life. Use
safety factor of 1.6 and 50% reliability.
Calculate the support forces, R1 = 2500, R2 = 7500 lb.

The critical location is at the fillet, MA = 2500 x 12 = 30,000 lb-in

Calculate the alternating stress, a = Mc

=
32M
=
305577
m = 0
I πd 3
d 3

Determine the stress concentration factor

r
= .1
d
Kt = 1.7
D
= 1.5
d
Ken Youssefi MAE dept., SJSU 34
 Design Example
Assume d = 1.0 in

Using r = .1 and Sut = 120 ksi,

q (notch sensitivity) = .85
Kf = 1 + (Kt – 1)q = 1 + .85(1.7 – 1) = 1.6

Calculate the endurance limit

Cload = 1 (pure bending)

Crel = 1 (50% rel.)
Ctemp= 1 (room temp)
-.265
Csurf = A (Sut)b = 2.7(120) = .759

0.3 in. < d ≤ 10 in. Csize = .869(d)-0.097 = .869(1)-0.097 = .869

Se = Cload Csize Csurf Ctemp Crel (S′e) = (.759)(.869)(.5x120) = 39.57 ksi
Ken Youssefi MAE dept., SJSU 35
 Design Example
Design life, N = 1150 x 75 = 86250 cycles
Se 39.57
N ⅓
log ( .9S )
ut 86250 ⅓ log ( .9x120 )
Sn = Se ( 6 )10
Sn = 39.57 ( 6 10
) = 56.5 ksi

305577 Sn 56.5
a = = 305.577 ksi n=
Kfa
=
1.6x305.577
= .116 < 1.6
d3
So d = 1.0 in. is too small

Assume d = 2.5 in
All factors remain the same except the size factor and notch sensitivity.

Using r = .25 and Sut = 120 ksi,

Kf = 1 + (Kt – 1)q = 1 + .9(1.7 – 1) = 1.63
q (notch sensitivity) = .9

Csize = .869(d)-0.097 = .869(2.5)-0.097 = .795 → Se = 36.2 ksi

Ken Youssefi MAE dept., SJSU 36

 Design Example
Se = 36.2 ksi → Sn = 53.35 ksi

305577
a = 3
= 19.55 ksi
(2.5)
Sn 53.35
n= = = 1.67 ≈ 1.6
Kfa 1.63x19.55

d = 2.5 in.

Check yielding

Sy 90
n= = = 2.8 > 1.6 okay
Kfmax 1.63x19.55

Ken Youssefi MAE dept., SJSU 37