Design Stress & Fatigue

MET 210W
E. Evans

Predictions of Failure
Fluctuating Loads
Brittle Materials:
Not recommended

Ductile Materials:
Goodman
Gerber
Soderberg

Fluctuating Stress
Varying stress with a nonzero mean.
alternating = a

Stress

max

max min
mean
2
max min
a
2
Stress Ratio,

mean

min

min
R
max
Time

-1 R 1

Fluctuating Stress Example

Bending of Rocker Arm
Valve Open

Valve Spring Force

Valve Closed

Tension in Valve Stem

Valve Closed

RBE
2/1/91

Valve Spring Force

Valve
Open
Adapted from R. B. Englund

Endurance Strength
The stress level that a material can survive
for a given number of load cycles.
For infinite number of cycles, the stress
level is called the endurance limit.
Estimate for Wrought Steel:
Endurance Strength = 0.50(Su)
Most nonferrous metals (aluminum) do not
have an endurance limit.

Typical S-N Curve

Estimated Sn of Various Materials

Actual Endurance Strength

Sn = Sn(Cm)(Cst)(CR)(CS)
Sn

= actual endurance strength (ESTIMATE)

Sn

= endurance strength from Fig. 5-8

Cm

= material factor (pg. 174)

Cst

= stress type:

1.0 for bending

0.8 for axial tension
0.577 for shear

CR

= reliability factor

CS

= size factor

Actual Sn Example
Find the endurance strength for the valve stem.
It is made of AISI 4340 OQT 900F.
From Fig. A4-5.
Su = 190 ksi
From Fig. 5-8.
Sn = 62 ksi
(machined)

62 ksi

Actual Sn Example Continued

Sn = Sn(Cm)(Cst)(CR)(CS)
= 62 ksi(1.0)(.8)(.81)(.94) = 37.8 ksi
Sn,Table 5-8
Wrought Steel
Axial Tension

Actual Sn
Estimate

Reliability, Table 5-1

Size Factor, Fig. 5-9
99% Probability
Sn is at or above the
Guessing: diameter .5
calculated value

Goodman Diagram
a
Sy

Yield Line
Sn

NO FATIGUE
FAILURE REGION
-Sy

FATIGUE
FAILURE REGION
Goodman Line
a m

1
Sn S u
Sy

Su

Goodman Diagram
Safe Stress Line

K t a
Sn

m 1

Su N

Sy

Yield Line
Sn

FATIGUE
FAILURE REGION
Goodman Line
a m

1
Sn S u

Sn/N
SAFE ZONE
-Sy

Su/N

Sy

Su

Safe Stress Line

Example: Problem 5-53.

Find a suitable titanium alloy. N = 3
1.5 mm Radius
30 mm
DIA

42 mm DIA

F varies from 20 to 30.3 kN

FORCE

MAX = 30.3

30.3 20
5.15 kN
2
30.3 20
mean
25.15 kN
2
alt

MIN = 20

TIME

Example: Problem 5-53 continued.

Find the mean stress:
25,150 N
m
35.6MPa

(30 mm )2
4

Find the alternating stress:

a

5,150 N

(30 mm )2
4

7.3MPa

Stress concentration from App. A15-1:

D 42 mm

1.4;
d 30 mm

r 1.5 mm

.05
d 30 mm

Kt 2.3

Example: Problem 5-53 continued.

Sn data not available for titanium so we will guess!
Assume Sn = Su/4 for extra safety factor.

TRY T2-65A, Su = 448 MPa, Sy = 379 MPa

K t a
Sn

m
1

Su
N

(Eqn 5-20)

2.3(7.3 MPa)
35.6 MPa 1

.297
.8(.86)( 448 MPa / 4) 448 MPa N
Size
1
N
3.36
Reliability 50%
Tension
.297
3.36 is good, need further information on Sn for titanium.

Example:
Find a suitable steel for N = 3 & 90% reliable.
3 mm Radius
50 mm DIA

30 mm
DIA

T varies from 848 N-m to 1272 N-m

TORQUE

MAX = 1272 N-m

1272 848
212 N m
2
1272 848
mean
1060 N m
2

alt
MIN = 848 N-m

TIME

T = 1060 212 N-m

Example: continued.
Stress concentration from App. A15-1:
D 50 mm

1.667;
d 30 mm

r
3 mm

.1 Kt 1.38
d 30 mm

Find the mean shear stress:

)
Tm 1060 N m(1000 mm
m
m

200MPa

Zp
(30 mm )3
16

Find the alternating shear stress:

Ta 212000 N mm
a

40MPa
3
Zp
5301 mm

Example: continued.
So, = 200 40 MPa. Guess a material.
TRY: AISI 1040 OQT 400F
Su = 779 MPa, Sy = 600 MPa, %E = 19%

Verify that max Sys:

Ductile

max = 200 + 40 = 240 MPa Sys 600/2 = 300MPa

Find the ultimate shear stress:

Sus = .75Su = .75(779 MPa) = 584 MPa

Example: continued.
Assume machined surface, Sn 295 MPa
Find actual endurance strength:

(Fig. 5-8)

Ssn
= Sn(Cm)(Cst)(CR)(CS)
= 295 MPa(1.0)(.577)(.9)(.86) = 132 MPa

Sn
Wrought steel
Shear Stress

Size 30 mm
90% Reliability

Example: continued.

Goodman:

K t a
Ssn

m
1

S su N

(Eqn. 5-28)

1.38( 40 MPa) 200 MPa 1

.7606
132 MPa
584 MPa N
1
N
1.31
.7606
No Good!!! We wanted N 3
Need a material with Su about 3 times bigger than this
guess or/and a better surface finish on the part.

Example: continued.
Guess another material.
TRY: AISI 1340 OQT 700F
Su = 1520 MPa, Sy = 1360 MPa, %E = 10%
Ductile

Find the ultimate shear stress:

Sus = .75Su = .75(779 MPa) = 584 MPa

Find actual endurance strength:

Ssn = Sn(Cm)(Cst)(CR)(CS)
= 610 MPa(1.0)(.577)(.9)(.86) = 272 MPa
Sn

shear
wrought

size
reliable

Example: continued.

Goodman:

K t a
Ssn

m
1

S su N

(Eqn. 5-28)

1.38( 40 MPa) 200 MPa

1

.378
272 MPa
1140 MPa N
1
N
2.64
.378

No Good!!! We wanted N 3
Decision Point:
Accept 2.64 as close enough to 3.0?
Go to polished surface?
Change dimensions? Material? (Cant do much better in
steel since Sn does not improve much for Su > 1500 MPa

Example: Combined Stress Fatigue

RBE
2/11/97

Example: Combined Stress Fatigue Contd

PIPE: TS4 x .237 WALL
MATERIAL: ASTM A242
Equivalent
Reversed,
Repeated

DEAD WEIGHT:
SIGN + ARM + POST = 1000#
(Compression)

45
Bending

RBE
2/11/97

Repeated one direction

Example: Combined Stress Fatigue Contd

Stress Analysis:
Dead Weight:

P
1000 #

315.5 psi
2
A 3.17 in

(Static)

Vertical from Wind:

P
200 #

63.09 psi
2
A 3.17 in

(Cyclic)

Bending:
M 500 # (60 in)

9345.8 psi
3
Z
3.21 in

(Static)

Example: Combined Stress Fatigue Contd

Stress Analysis:
Torsion:
T
200 # (100 in)

3115 .3 psi
3
ZP
2(3.21 in )

Stress Elements:
STATIC:

315.5 psi

(Cyclic)

(Viewed from +y)

CYCLIC:

9345.8 psi

z
x

z
x

63.09 psi Repeated

One Direction

= 3115.3 psi

Fully Reversed

Example: Combined Stress Fatigue Contd

Mean Stress:
Static
Repeated / 2

8998.8 psi
(CW)

TIME

Stress

9345.8
-315.5
-31.5

Alternating Stress:
m
MIN = -63.09 psi

max

max

(CW)
(0,-3115.3)

1
(-31.5,-3115.3)

max

8998.8 psi

4499.4 psi
2

max 3115 .34 psi

Example: Combined Stress Fatigue Contd

Determine Strength:
Try for N = 3 some uncertainty
Size Factor? OD = 4.50 in, Wall thickness = .237 in
ID = 4.50 2(.237) = 4.026 in
Max. stress at OD. The stress declines to 95% at
95% of the OD = .95(4.50) = 4.275 in. Therefore,
amount of steel at or above 95% stress is the same
as in 4.50 solid.
ASTM A242: Su = 70 ksi, Sy = 50 ksi, %E = 21%
t

3/4

Ductile

Example: Combined Stress Fatigue Contd

We must use Ssu and Ssn since this is a combined
stress situation. (Case I1, page 197)
Sus = .75Su = .75(70 ksi) = 52.5 ksi
Ssn = Sn(Cm)(Cst)(CR)(CS)
= 23 ksi(1.0)(.577)(.9)(.745) = 8.9 ksi
Hot Rolled
Surface
Wrought steel
Combined or Shear Stress

Size 4.50 dia

90% Reliability

Example: Combined Stress Fatigue Contd

Safe Line for Goodman Diagram:
a = Ssn / N = 8.9 ksi / 3 = 2.97 ksi
m = Ssu / N = 52.5 ksi / 3 = 17.5 ksi
Alternating Stress, a

K t a
Ssn

10
Ssn

N=1F
Not Fai

ai l

Ssn/N

N=3
Safe

5
mean = 4499.4

1
2.29
.426

Su

Ktalt

m
1

S su N

1.0(3115 .3 psi) 4499.4 psi 1

.426
8900 psi
52500 psi N

5
3115.3

10
15
Mean Stress, m

Su/N

20