Task 6 - Safety Review and Licensing

On the Job Training on Stress Analysis

Static strength and High and Low-Cycle Fatigue

at room temperature 2/2
Davide Mazzini – Ciro Santus

Pisa (Italy)
June 15 – July 14, 2015
 Table of content – Class VI.a.2

Content

• Fatigue of metals
- Definitions

- Different approaches to fatigue, Stress/ Strain life

- Low/ High Cycle Fatigue

- Fatigue notch sensitivity

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 Books

Books on Metal fatigue

S. Suresh. Fatigue of Materials. Cambridge University Press 1998.

H. E. Boyer. Atlas of Fatigue Curves. ASM International 2003.

R. I. Stephens, A. Fatemi, R. R. Stephens, H. O. Fuchs . Metal Fatigue in

Engineering. Wiley 2001.

… and many many others

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 Fatigue - Intro

Cyclic load leading to fracture

Cyclic loading, repeated
thousands or even millions of times

Eventual
Fatigue Fracture

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 Fatigue – Evolution of the crack

Nucleation

Persistent Slip Bands, PSBs

These slip lines were termed 'persistent slip bands' (PSBs) by Thompson, Wadsworth
& Louat (1956) who found that in Cu and Ni, the bands persistently reappeared at the
same sites during continued cycling even after a thin layer of the surface containing
these bands was removed by electropolishing.

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 Fatigue – Evolution of the crack

Nucleation

“Embryo” crack formation from PSBs

Irreversibility of
the cyclic slip

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 Fatigue – Evolution of the crack

Nucleation

“Embryo” crack formation from PSBs

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 Fatigue – Evolution of the crack

Stage I – Stage II Stage I: propagation at 45°,

single path or “zig-zag”,
Forsyth ~1960 within a single grain (or
very few grains)

Single slip system

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 Fatigue – Evolution of the crack
Stage II: perpendicular
Stage I – Stage II propagation on many grains

Forsyth ~1960

Two slip systems

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 Fatigue – Evolution of the crack

Stage II propagation and striations (beachmarks)

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 Fatigue – Evolution of the crack

Stage I usually at Inclusions (or other defects) in commercial metals

Even subsurface
nucleation

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 Fatigue – Evolution of the crack

Different possible

nucleation scenarios

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 Fatigue – Evolution of the crack

Stage III is the final fracture, so called “Sudden” or “Unstable”

This can be
considered a
static fracture…

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 Nucleation/ Propagation

What is the transition point from Nucleation to Propagation?

Stage I to Stage II

1 mm

It does not matter

It depends on the inspection method

Crack size, a Load amplitude 

?
10 102 103 104 105 106 108
1
Number of cycles, N
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 Nucleation/ Propagation

Nucleation to Propagation percentage of the entire fatigue life

No crack evolution
below the Fatigue Limit
Design value

Crack size, a Load amplitude 

?
10 102 103 104 105 106 108
1
Number of cycles, N

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 Fatigue – Engineering viewpoint

Engineering approaches

Stress life (High Cycle Fatigue – HCF)

Strain life (Low Cycle Fatigue – LCF)

Fracture Mechanics (Damage Tolerant Design)

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 Stress life approach

Definitions

Amplitude and mean

stresses

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 Stress life approach

Definitions
 min
Load ratio: R 
 max

Ex.:Alternate load: R  1
(default for testing) Time


Repeated load: R  0
Time
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 Stress life approach

S-N curves – Testing machines (historical)

Homework:

Find the load cycle experienced

at the mid section of the specimen,
depending on the weight and sizes
of the specimen

Moore rotating bending machine

4-pont bending load scheme

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 Stress life approach

S-N curves – Testing machines

Hourglass
specimen
Very blunt notch,
Equivalent to a
plain specimen

Resonance based
Push-pull fatigue
testing machine
100-150 Hz
Ex.: RUMUL

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 Stress life approach

Specimen shape for fatigue testing

Hourglass
specimen
Gauge length
Very blunt notch, not required Stress
Equivalent to a concentration
plain specimen ---
Why is this
not a problem
for the Tensile
Test?

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 Stress life approach

S-N curves, or Wöhler curve

Alternate
Fit line, or S-N curve
stress, σ a
Each point is a specimen
Several points at single load level
Some load levels
Either Log or
linear scale

Runouts:
Specimens not broken,
Test stopped at a specified
Log scale !!! maximum number of cycles
Ex.: 10 millions (107)

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 Stress life approach

Endurance limit, only for steels

Fatigue
strength at 105

Fatigue
strength at 108

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 How many specimens are required?

Standard ISO 12107

15 tests (minimum)

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 Large scatter of fatigue

Number of cycle/ Stress scatter

Very uncertain design values, especially in terms

of Finite life Number of cycles to failure

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 Large scatter of fatigue

Design curve

Fit line, 50% reliability

Standard deviation
Design curve,
higher reliability,
ex.: 99%, or even 99.9 %

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 The Staircase method

Testing procedure for Fatigue Endurance

Numerical procedure to calculate

Mean and Standard Deviation

Number of required
specimens: 15-20

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 Low Cycle/ High Cycle Fatigue

Different regions of the S-N curve HCF

Elastic
1 cycle = Tensile Test cyclic loading



LCF
Elastic-plastic
cyclic loading
 Fatigue Endurance/
Ultra-High Cycle Fatigue (UHCF)

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 Low Cycle/ High Cycle Fatigue

S-N curve values for Steels

R  1
SU
N f  1,  a  S U 0.9 S U
N f  103 ,  a  0.9 S U
N f  106 , S n  0.5 CSCG CR S U
 a  0.5 CSCG CR S U
Fatigue Endurance
CS : Surface factor
CG : Gradient factor
CR : Reliability factor

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 High Cycle Fatigue

Basquin’s law (HCF)

Different forms,same law:
 a   f (2 N f )b

 a  a ( N f )b

Fatigue
1
Endurance 
 a  a( N f ) k

k  1/ b

a, b are material properties

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 High Cycle Fatigue

Basquin’s law (HCF)

Exercise:

 a  a ( N f )b Find the a, b parameters for the

Steel HCF line as function of the
Ultimate Tensile Strength and the
correcting factors CX
Fatigue
Endurance

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 Low Cycle Fatigue

LCF requires the Strain life approach

LCF, Elastic-plastic cyclic loading:
Limited Stress sensitivity
Remarkable Strain variation



Fatigue
Endurance 
  2 a
  2 a
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 Low Cycle Fatigue

Manson-Coffin law
Composition of two asymptotes:
Plastic Elastic (Basquin)
predominant Plastic predominant

 p
Basquin’s
asymptote    e   p
In notched component,
Δε may be found through
Material parameters: the Neuber's rule...
 f , b,  f , c Pisa, June 15 – July 14, 2015 33
 High Cycle Fatigue

Mean stress effect, different models

Haigh’s diagram

Higher mean stress,

same alternate

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 High Cycle Fatigue

Goodman’s line
Values from S-N
curve at R = -1

“Modified”
Goodman’s line

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 Effect of Stress Concentration

Fatigue Stress Concentration Factor - Kf

Experimental
definition:

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 Effect of Stress Concentration

Kf < Kt

Same stress at the surface,

apparently equal fatigue load
Expected
trend Sn / K t

In fact, fortunately:
Sn / K t  Sn*

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 Effect of Stress Concentration

Why Kf < Kt ?

Process zone concept

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 Effect of Stress Concentration

How to calculate Kf

The notch sensitivity factor

Kf  1
q
Kt 1

K f  1  q( K t  1)

q ranges from 0 to 1 and it depends on the Notch radius

and on the material strength (Ultimate Tensile Strength)

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 Numerical example

Step 1:
Rotating shaft
AISI 4340, Calculate the material fatigue limit
SU = 1000 MPa r  1mm
d  30 mm CS  0.7
CG  0.8
CR  0.814
D  35 mm 
L  270 mm
SU
Sn  CSCG CR  228 MPa
F  300 N 2

Calculate the margin with

respect to the fatigue R.C. Juvinall, K.M. Marshek, Fundamentals of
endurance Machine Component Design - Wiley 2011

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 Numerical example

Step 2:
Rotating shaft
AISI 4340, Calculate the bending nominal stress
SU = 1000 MPa r  1mm
d  30 mm M  FL  81 103 N mm  81.0 N m

W d 3  2.65  103 mm
32
M
D  35 mm L  270 mm n   31MPa
W
F  300 N

Calculate the margin with

respect to the fatigue
endurance

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 Numerical example

Step 3:
Rotating shaft
AISI 4340, Calculate the Stress Concentration Factor
SU = 1000 MPa r  1mm
d  30 mm
r
 0.033
d
D
D  35 mm  1.167
L  270 mm d

F  300 N
K t  2.15
Calculate the margin with
respect to the fatigue
endurance
R.C. Juvinall, K.M. Marshek, Fundamentals of
Machine Component Design - Wiley 2011

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 Numerical example

Step 4:
Rotating shaft Calculate the Fatigue St. Conc. Factor
AISI 4340, S
r  1mm Bhn  U  290 (Brinell)
SU = 1000 MPa 3.45
d  30 mm q  0.85

Kf 
D  35 mm L  270 mm 1  q ( K t  1)
F  300 N  1.98

Calculate the margin with

respect to the fatigue
endurance
R.C. Juvinall, K.M. Marshek, Fundamentals of
Machine Component Design - Wiley 2011

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 Numerical example

Step 5:
Rotating shaft
AISI 4340, Calculate the Safety Factor
SU = 1000 MPa r  1mm
d  30 mm Sn
SF   3.8
 n Kf
SF  1, Ok!
D  35 mm L  270 mm
F  300 N

Calculate the margin with

respect to the fatigue
endurance

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 Singularity for vanishingly small radius

r 0

K f  q( 0)  K t ( )  ?

Kt  

q0
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 Singularity for vanishingly small radius

The limiting (r  0)
value for K f ,is finite,
but how to calculate?

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