Chap 1 Stress-Life

1.1 Introduction
1.2 S-N Diagram
1.3 Mean Stress Effects
1.4 Modifying Factors
1.5 Important Concepts
1.1 Introduction
S-N approach used to understand and quantify
metal fatigue.
applied stress is primarily within the elastic
range of material and the cycles to failure are
long.
The S-N method doesnt work well in low-
cycle applications.
1.2 S-N Diagram
Disadvantagetreats all strains as elastic.
S
e
endurance limita stress level below which
the material has an infinite life.

Most nonferrous alloys have no endurance limit.
8
10 5
Se/Su=fatigue ratio
Over 200Ksi carbide inclusions formed
A power relationship estimate the S-N curve for
steel b c
N S 10 =
6 3 085 . 0
10 10 62 . 1 < < =

N for N S S
u
1.3 Mean Stress Effects
=
max
-
min
= stress
range

a
=(
max
-
min
)/2= stress
amplitude

m
=(
max
+
min
)/2= mean
stress
R=
min
/
max
= stress
ratio
A=
a
/
m
= amplitude
ratio

a
o
m
o
max
o
min
o
o A
The result of a fatigue test are plotted on a
Haigh diagram.
Mean stress equations
Soderberg:

Goodman:

Gerber:

Morrow:
1 = +
y
m
e
a
S S
o o
1 = +
u
m
e
a
S S
o o
1 ) (
2
= +
u
m
e
a
S S
o o
1 = +
f
m
e
a
S o
o o
Infinite life
Compressive mean
stresses are very
benefincial.



compressive mean
stress has no effect for
notched components.
1.4 Modifying Factors
The variables include
1Size
2Type of loading
3Surface finish
4Surface treatments
5Environment
S
e
=S
e
C
size
C
load
C
surf.fin
.......
(S
e
by R.R.Moore test)

1.4.1 Size effects
Correlated with the thin
layer of surface material.
Less pronounced size
effect for axial loading
than for bending or
torsion.
In English units
in d if
in d in if
d
size
C
3 . 0
10 3 . 0
0 . 1
869 . 0
{
097 . 0
s
s s

=
d
1.4.2 Loading Effects
The ratio of endurance limits found using axial
and rotating bending test.


using torsion and rotating bending test.


(0.577 using von Mises failure criterion)
) ( 70 . 0 ) ( bending S axial S
e e
~
) ( 577 . 0 ) ( bending S torsion
e e
~ t
1.4.3 Surface Finish
1.4.4 Surface Treatment
Residual
stress
yield
Presetting(prestressing)
1Initial overload is favorable for the same
direction.
2Dont use in fully reversed loading.
PlatingSe
Alleviate the residual tensile stress
Nitride,Shot peen,bake,anneal.
The extra corrosion resistance offered by plating.
Thermal
Hot rolling and forging



Carburizing,nitriding,and induction hardening
produce residual compressive surface stresses.
Surface decarburization.

Produce residual tensile stresses.
Se
Mechanical
Cold rolling
Shot peening
Cold rolling
Se
Shot peening
advantageused on oddly shaped parts
disadvantageleave a rough dimpled surface
Fatigue ratio=0.5
Temperature
S
e
for steels increase at low temperature,but
reduction in fracture toughness.
At high temperature, S
e
for steels disapper due
to the mobilizing of dislocations.
At temperature beyond of melting point,creep
becomes important.
High temperature can cause annealing,which
remove residual compressive stress.

1.4.6 Environment
Corrosion-fatigue
Higher strength steels have no advantage
1.5 Important concepts
Increase S
e
:
1Carburization
2Nitriding
3Shot peening
3Cold rolling
4Flame
5Induction hardening
Reduce Se :
1 Decarburization(hot rolling)
2 Cr or Ni plating
3 Severe grinding
4 Rough surface finish
5 Large section size
6 Tensile mean stress