ME 307 Machine Design I

Dr. A. Aziz Bazoune

King Fahd University of Petroleum & Minerals Mechanical Engineering Department

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

ME 307 Machine Design I

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 2

ME 307 Machine Design I

7-11 Characterizing Fluctuating Stresses

Fluctuating stresses in machinery often take the form of sinusoidal

pattern because of the nature of the nature of some rotating machinery. Other patterns some quite irregular do occur.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 3

ME 307 Machine Design I

7-11 Characterizing Fluctuating Stresses

In periodic patterns exhibiting a single maximum and single minimum of force, the shape of the wave is not important. The peaks on both sides (maximum, minimum) are important. Fmax and Fmin in a cycle can be used to characterize the force pattern. A steady component and an alternating component can be constructed as follows:

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 4

ME 307 Machine Design I

Stress Range

Mean (Midrange Stress)

(R>0 )

Stress Amplitude (Alternating Stress)

(R =0)

Stress Ratio

Stress Amplitude (R =-1)

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 5

ME 307 Machine Design I

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 6

ME 307 Machine Design I

Any varying stress with a nonzero mean is considered a fluctuating stress.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 7

ME 307 Machine Design I

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 8

ME 307 Machine Design I

The steady, or static, stress is not the same as the midrange stress. The steady stress may have any value between

min and min .

The steady stress exists because of a fixed load or preload applied to a part. The steady load is independent of the varying portion of the load.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 9

ME 307 Machine Design I

A helical compression spring is always loaded into a space shorter than the free length of the spring. The stress created by this initial compression is called the steady, or static, component of the stress.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 10

ME 307 Machine Design I

Equations (7-39) use symbols a and m as the stress components at the location of scrutiny. In the absence of a notch, a and m are equal to the nominal stresses

ao and mo induced by loads Fa and Fm , respectively.

With a notch they are a = Kf ao and m = Kf mo , respectively.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 11

ME 307 Machine Design I

When the steady stress component is high enough to induce localized notch yielding, the designer has problem. The first-cycle local yielding produces plastic strain and strainstrengthening. This is occurring at the location where fatigue crack nucleation and growth are most likely.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 12

ME 307 Machine Design I

Possible ways of quantifying the problem:

Residual Stress Method All stresses (both mean and alternating) are multiplied by the fatigue stress concentration factor Kf , and correction is made for yielding and resultant residual stresses if the calculated peak stress exceeds the material yield strength. Nominal Mean Stress Method In this method, stress concentration factor is applied only to alternating stress. Reduction in mean stress from not multiplying it by Kf , might be about the same as the reduction in mean stress achieved with the residual stress method by taking yielding and residual stress into account.
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from Variable Loading CH-07 LEC 25 Slide 13

ME 307 Machine Design I

7-12 Fatigue Failure Criteria for Fluctuating Stress

After having defined the various components of stress associated with a part subjected to fluctuating stresses, we want to vary both the midrange stress and the stress amplitude or alternating component, to learn about the FATIGUE RESISTANCE of parts when subjected to such situations. Many machine elements involve fluctuating stresses about a non-zero mean. The influence of non-zero mean stress is estimated by using one of several empirical relationships that determine failure at a given life when both alternating and mean stresses are nonzero.

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 14

ME 307 Machine Design I

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 15

ME 307 Machine Design I

Modified Goodman Diagram

It has midrange stress plotted along the abscissa and all other components of stress plotted on the ordinate, with tension in the positive direction. The endurance limit, fatigue strength, or finite-life strength whichever applies, is plotted on the ordinate above and below the origin. The midrange line is a 45o line from the origin to the tensile strength of the part.
Figure 7-24
Modified Goodman diagram showing all the strengths and the limiting values of all the stress components for a particular midrange stress

Dr. A. Aziz Bazoune

Chapter 7: Fatigue Failure Resulting from Variable Loading

CH-07

LEC 25

Slide 16

ME 307 Machine Design I

Plot of Fatigue Failures for Midrange Stresses in both Tensile and Compressive Regions.
Figure 7-25 Plot of fatigue failures for midrange stresses in both tensile and compressive regions. Normalizing the data by using the ratio of steady strength components to tensile strength Sm/Sut, steady strength component to compressive strength Sm/Suc, and strength amplitude component to endurance limit Sa/Se enables a plot of experimental results for a variety of steels.
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from Variable Loading CH-07 LEC 25 Slide 17

ME 307 Machine Design I

Master Fatigue Diagram.

Figure 7-26 Master fatigue diagram for AISI 4340 steel with Sut = 158 Sy = 147 kpsi. The stress component at A are min = 20, max = 120, m = 70, o = 50 all in kpsi
Dr. A. Aziz Bazoune Chapter 7: Fatigue Failure Resulting from Variable Loading CH-07 LEC 25 Slide 18