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Mechanical Engineering
Intelligent Structure & Integrated Design Laboratory
9. Fatigue of Materials:
Introduction and Stress-Based Approach
Objectives
(i) Explore the cyclic fatigue behavior of materials
(ii) Review laboratory testing in fatigue
(iii) Applied engineering methods to estimate fatigue life
9.1 Introduction
Fatigue:
Cyclic stress
(well below ultimate
stress)
Failure
Microphysical
damage
Cracks or other
microscopic damage
9.1 Introduction
3 approaches for failure:
(i) Stress-based approach: Based on nominal(average) stress in
the affected region of engineering
components
(ii) Strain-based approach: More detailed analysis of localized
yielding that may occur at stress
raisers during cyclic loading
(iii) Fracture mechanics approach: Treats growing cracks by the
methods of fracture mechanics
9.1 Introduction
9.2.1
Description of Cyclic Loading
Alternating stress
(i)
(ii)
(iii) Stress ratio:
(v) Relationships;
(vi) Specification
(a)
(b)
Zero-to-tension cycling;
9.2.2
Point Stress versus Nominal Stress
Unnotched
Notched
where : elastic stress concentration factor
Actual and nominal stresses for (a) simple tension, (b) bending, and (c) a
notched member. Actual stress distributions vs. are shown as solid
lines, and hypothetical distributions associated with nominal stresses S
as dashed lines. In (c), the stress distribution that would occur if there
were no yielding is shown as a dotted line
(log-linear plot)
(log-log plot)
Constants
for stress-life curves for various ductile engineering
metals, from tests at zero mean stress on unnotched axial
specimens ()
Fatigue strength:
A specific stress amplitude value from S-N curve at a
particular life of interest
High cycle fatigue:
Low stress & yielding are not dominated
Low cycle fatigue:
High stress & yielding are dominated (strain based
approach)
Fig. E9.1
9.2.4
Safety factors for S-N Curves
Example
2
For the AISI 4340 steel of Table 9.1, a stress amplitude of will be
applied in service for What are the safety factors in stress and in
life?
or
Notched specimen
Damage intensification
- Ductile: Crystal grains slip bands (intense deformation
due to shear motion between crystal planes)
cracks within grains joining with other similar
cracks propagates to failure
Fatigue
crack origin in an unnotched axial test specimen of AISI 4340
steel having 780 MPa, tested at 440 MPa with 0. The inclusion that
started the crack can be seen at the two higher magnifications.
9.7.2
Normalized Amplitude-Mean Diagrams
9.7.3
Additional Mean Stress Equations
Gerber parabola
Walker equation
)
: special fitting constant (more than one Rs)
9.7.4
Life Estimates with Mean Stress
Example
4
Sol)
(a) For
For
Sol)
(b)
because
* SWT equation is used
Sol)
curve
9.7.5
Safety Factor with Mean Stress
since
Morrows equation
STW equation
when
Example
5
Sol)
(a)
Sol)
(b)
because
Octahedral
shear stress criterion compared with cycle fatigue
strengths for completely reversed biaxial loading.
Example
6
(R=0)
Sol)
since
Sol)
9.9.1
The Palmgren-Miner Rule
Use of the Palmgren-Miner rule for life prediction for variable amplitude
loading which is completely reversed.
Life prediction for a repeating stress history with mean level shifts.
Homework
Problems
9.3, 9.10, 9.23, 9.29, 9.37, 9.41, 9.45