1

8. Cumulative Damage Theories:

In every Engineering, applications fatigue is an important failure mode. Fatigue is defined as
when a material is subjected to repeated stresses; it fails at stresses below yield point stresses.
The objective of all fatigue analysis, calculation testing is to be the acceptable combination of
load & life.
French was 1
st
person to suggest specimen may be called damaged, when it shows a reduction in
its endurance limit.
8.1. Classification of Damage theories:
Predictive methods which predicts the fatigue strength such variable stresses using S-N curves
for constant mean stress conditions called damage theories or hypothesis.
8.1.1. Linear Damage Theory:
i. Palmgren Minor damage theory
8.1.2.Non - Linear Cumulative Theories:
i. Marco Starkey theory
ii. Henry theory
iii. Corten-Dolan theory
8.2 Minors Damage Theory
The 1
st
cumulative damage theory was proposed by palmgren in 1924 & latter developed by
minor in 1945. This linear theory, which is still widely used, is referred to as the Palmgren-Miner
hypothesis or the linear damage rule. The theory may be described using the S-N plot shown in
the figure.
By definition of the S-N curve, operation at a constant stress amplitude S
1
will produce complete
damage, or failure, in N
1
cycles. Operation at stress amplitude S
1
for a number of cycles n
1
smaller than N
1
will produce a smaller fraction of damage, say D
1
. D
1
is usually termed the
damage fraction. Operation over a spectrum of different stress levels results in a damage fraction
D
1
for each of the different stress levels S
1
in the spectrum. When these damage fractions sum to
unity, failure is predicted.
2
8.2.1 Assumptions:-
1. Complete absence of work hardening during the cycle load is sinusoidal type
2. Beginning of first crack is responsible for the failure
3. No effect of sequence of stress cycles applied.
Fig 8-1: S-N curve
Here, S = stress amplitude
n
i
= Number of cycles of operation
N
i
= Total number of cycle that causes failure
It states that:-
1. Stress S
1
will cause failure in N
1
nos. of cycles.
2. When operation is carried out for n
1
nos. of cycles which is less than N
1
, it will cause a small
damage fraction D
1
3. Parallely if operating over a large range of operating stress levels say S
1
, S
2
, S
3
, ---S
i
cycles
for n
1
, n
2
, ---n
i
respectively will cause damage fractions as D
1
, D
2
,D
3
, ---D
i
4. The failure will occur when ,

D reaches unity
i.e. B
j
= B
1
+B
2
+B
I
I
j=1
1 [8-1]
3
According, to Minor damage fraction (D
i
) is directly proportion to the ratio of nos. of cycles of
operation to the total nos. of cycles that causes failure.
i.e. B
I
=
n

putting in equation [8-1]

n
1
N
1
+
n
2
N
2
+
n
i
N
i
1 [8-2]
Fig 8-2: Fatigue damage as a function of cycle ratio
1. It shows only linear relationship
2. Damage fraction of 0.4 would be predicted by Palmgren for same cycle ration [
n
N
=0.4
3. But same cycle ratio actually produces a damage fraction 0.78 for curve 1 & 0.08 for curve 2
4. It shows
1
>
2
>
3
4
8.3 Non Linear Theory
Joehnk developed this cumulative damage theory based on testing done on welded tees with the
superimposed sine wave stress histories. The results of his testing indicated that minor cycles
produce more fatigue damage than Miner's linear damage theory predicted. This indicated that
the relation between stress range and fatigue damage was not linear for the minor cycles. Joehnk
made a modification in Miner's theory according to the test results to account for the non-linear
behavior and labeled it non-linear Miner's damage theory.
8.3.1 Marco Starkey Cumulative damage theory:
One of the first nonlinear cumulative damage theories was proposed by Marco and Starkey. A
similar hypothesis was also proposed by Richart and Newmark. The Marco-Starkey theory is
based on the following postulates:
8.3.1.1 Assumptions:
1. Damage curve is given by
D = [
n
N

mI
Where m
i
= function of stress level
2. Specimen subjected to any sequence of completely reversed sinusoidal stress will fail
when D reaches unity.
3. Failure occurs or 100% damage when [
n
N
reaches its critical value.
Fig 8-3: Fatigue damage as a function of cycle ratio
5
For Eg: Two sequence of stress
1
&
3
For 1
st
sequence,
1
is applied first for a cycle ratio [
n
N
= u.S and ,
3
applied until failure takes
place at D=1.0
From fig, the O-M-N-F represents the process & cycle ratio to produce failure may be computed
from curve as:
[
n
N
= [
n
N
1 + [
n
N
S
[
n
N
= u.S +(1 u.98)
[
n
N
= u.S2 [8-3]
For 2
nd
sequence,
3
is applied first for a cycle ratio [
n
N
= u.S and ,
1
applied until failure
takes place at D=1.0
From fig, the O-A-B-F represents the process & cycle ratio to produce failure may be computed
from curve as:
[
n
N
= [
n
N
S + [
n
N
1
[
n
N
= u.S +(1 u.uS)
[
n
N
= 1.47 [8-4]
From [8-3] and [8-4] we can say that recognizing that 1 > S
Analysis indicates that [
n
N
is less than unity in sequence (1) when higher stress level 1 is
applied first & [
n
N
is greater than unity in sequence (2) when lower stress level S is applied
first.
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8.3.2 Henry Cumulative Damage Theory:
The cumulative damage theory proposed by Henry is based on the concept that the S-N curve is
shifted as fatigue damage accumulates and that fatigue damage may be defined as the ratio of the
reduction in fatigue limit to the original fatigue limit of virgin material.
8.3.2.1 Assumption:
1. Damage is a ratio of loss in endurance limit to original endurance limit of sound or virgin
material.
i.e. D =
E
o
- E
E
o
[8-5]
Where, D = damage
E
o
= original fatigue limit
E = Fatigue limit after damage
2. He was further assumed that S-N curve could be represented by the equation of an
equilateral hyperbola referred to stress axis & line passing through E
0
parallel to cycle
axis as the asymptotes of hyperbola.
So, equation assumed for S-N curve,
N =
K
o

S-E
o

Where, N = Number of cycle to failure at stress amplitude S
S = Completely reversed amplitude of applied stress
Ko = Material constant
Eo = Original fatigue limit
3. Henry further assumed that the S-N curve after damage can be represented by equation of
equilateral hyperbola as:
Nr =
K
S-E
[8-6]
7
Where, Nr = number of remaining cycle to failure at stress S
S = completely reversed amplitude of applied stress
K = Material constant
E = Damage fatigue limit
Based on some heuristic argument Henry Further assumed that,
[
K
Ko
= [
E
Eo
[8-7]
According to Henry, If n cycle of stress amplitude S are applied to a specimen, the remaining life
Nr at that stress amplitude is given by
Nr = N n [8-8]
Where, N = total number of cycles required to produce failure of the virgin material when
subjected to amplitude S.
The above equation can be readily converted to a damage equation by utilizing equation [8-5]
D =
n
N
1 + [
E
0
5 - E
0
[ 1-
n
N

Where, D = damage fraction

n = no. of cycles applied at stress amplitude S
N = no. of cycles to failure
E
0
= original fatigue limit
S = applied stress amplitude
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8.3.3 Corten Dolan Cumulative Damage theory
The Corten-Dolan theory of the cumulative damage is based on six assumptions that are at least
qualitatively, well supported by data. These assumptions are
8.3.3.1 Assumptions :
1. A nucleation period may be required to initiate permanent fatigue damage.
2. The number of damage nuclei that are formed throughout the member increases as the stress is
increased.
3. Damage at a given stress amplitude propagates at an increasing rate with increased number of
cycles.
4. The rate of damage per cycle increases as the stress is increased.
5. The total damage that constitutes failure in a given member is a constant for all possible stress
histories that could be applied.
6. Damage will continue to be propagated at stress levels that are lower than the minimum stress
required to initiate damage.
8.3.3.2 Statement:
To simplify development of their hypothesis, Corten and Dolan initially assumed the nucleation
period to be zero , or
N = 0
Where, N = number of cycles of stress level S required to nucleate damage.
A power-law relationship was next assumed to exist between damage per nucleus and applied
cycles to give
D = m D = m r N
a
Where,m = number of damage nuclei
D = damage per nucleus
r = coefficient of damage propagation rate, a function of stress level
Then for two different constants stress amplitudes S
1
& S
2
, Damage D
f
can b expressed as
D
f
= m
1
r
1
N1
a1
= m
2
r
2
N2
a2
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8.4 Journal paper 1:
Title: Transient Stress Analysis and Fatigue Life Estimation of Turbine Blades
Published: Memorial University of Newfoundland,St. Johns, Newfoundland, Canada
Presented by: Deepak Dhar
Abstract:
This paper is concerned with life estimation of a turbine blade taking into account the
combined effects of centrifugal stresses, vibratory stresses and thermal stresses. The stresses are
determined by accounting for the rotor acceleration. The blades are subjected to aerodynamic
excitation force obtained from thin cambered aerofoil theory under incompressible flow.
The thermo-elastic forces are obtained from the three-dimensional non-linear heat transfer
equations using the finite element analysis. The fatigue life is estimated using two well known
theories, from the number of cycles in various blocks during start-up and shut-down periods of
the turbine operation when the stresses peak.
Conclusion:
Although there exists enormous literature regarding fatigue failure in materials, yet there is no
satisfactory theory to predict the onset of fatigue in most of the cases. This is because the fatigue
is based on numerous factors. One of the important factors was the effect of temperature on the
fatigue life. Studies of the past had not quantitatively calculated the temperatures in the blade in
the determination of the fatigue life. The same applies to the aerodynamic flows which create
vibratory stresses. The present study considered many such factors on a quantitative basis. The
next question that arises is the generality of the models. The present study is based on the general
three-dimensional model for a) Thermal heat transfer including the nonlinear radiation. b)
Aerodynamic vibratory and c) Centrifugal effects. The results showed that this study can be quite
useful in analyzing the fatigue phenomenon in turbine blades.
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8.5 Journal paper 2:
Title: Development and Validation of an S-N Based Two Phase Bending Fatigue Life
Prediction Model
Published: General Motors Corporation Wixom, MI 48393
Presented by: Avinash Singh
Abstract:
The stress-life S-N method along with the Palmgren-Miner cumulative damage theory is the
simplest and the most commonly used fatigue life prediction technique. Its main advantage is
that the material properties needed are easy to collect and life calculation is simple. However
under many variable amplitude loading conditions, life predictions have been found to be
unreliable. Various modifications have been proposed to the Palmgren-Miner theory, but they
have not lead to more reliable life predictions. In this paper, a two-stage cumulative damage
model will be developed and validated. This model divides fatigue life into two phasesa crack
initiation phase and a crack propagation phase. It will be shown that the proposed method results
in greatly improved life prediction capabilities. Also, the proposed method retains the simplicity
of the S-N based approach in that the material data is still relatively simple to generate and the
calculations are straightforward
Conclusion:
In this paper a new cumulative damage theory, based on the stresslife method, has been
proposed. The proposed theory recognizes that there are two phases in the life of a component
an initiation phase followed by a propagation phase. A method to generate initiation and
propagation S-N curves has also been outlined. It has been shown that the proposed method can
accurately predict bending fatigue life under two step loading conditions. The proposed method
also explains why sometimes preloaded parts fail while loaded below the endurance limit
observed in constant amplitude loading.