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Definition of fatigue: evolution of properties occurring in a material subjected to repeated application of stresses or strains. Notes:
Fatigue affects a variety of applications Distinct materials have distinct damage mechanisms and distinctive fatigue 5/23/12 properties.
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Consider spokes on a motorcycle wheel. Will failure occur if (t) and if max < y ?
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Types of Fatigue
Mechanical Fatigue Multiaxial Fatigue Thermal Fatigue Creep-Fatigue Thermomechanical Fatigue Corrosion Fatigue
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Contact Fatigue
Material or component is subjected to isothermal mechanical cycling at room or elevated temperature conditions Mechanical strain rate is designed to avoid time dependent deformation (e.g. creep)
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Stages of Fatigue
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Safe-Life Design
Def: Safe-Life Design is an approach which designs components with no tolerance for failure during the course of the life of the part
Standards
Def: Standard - an accepted guide that governs concepts, procedure, definitions, etc. Ex: ASTM E606 Standard Practice for Strain-Controlled Fatigue Testing Ex: ISO 1099:2006 5/23/12 Metallic
materials --
Fatigue Journals
International Journal of Fatigue Engineering Materials & Structures Engineering Failure Analysis Materials Science and Engineering Journal of Mechanical Sciences
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Fatigue Texts
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Fatigue Analysis
can be used to determine each of the following:
Number of cycles to failure Effect of altering the component (e.g., material, processing, geometry) Effect of environment and temperature Effect of presences of stress concentrations and cracks on fatigue 5/23/12
Founders of Fatigue
Poncelet (1824) Rankine (1842) Wohler (1860s) Bauschinger (1885) Ewings and Humpries (1903) Coffin and Manson (1954) Paris (1961)
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Jean-Victor Poncelet
Coined the term fatigue Used the term to refer to tired metals that had been worn down via cyclic loading
Studied waterwheels
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and turbines
August Wohler
Systematically examined steel railway axles Sought to determine the existence of the endurance limit below the endurance limit of the material Developed S-N curves Concluded that cyclic stress range is more important than peak stress.
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August Wohler
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Using micrographs, they determined fatigue crack initiation is related to the evolution of the crystal structure
Versailles train crash (1842) Boston Molasses Disaster (1915) Liberty Ships of WWII (1940s) De Havilland Comet Jets (1953, 1954) The Point Pleasant/Silver Bridge Disaster (1967) China Airlines Flight 611 (2002) And more 5/23/12
Notes: Occurred on May 8th, 1842 Carriages behind piled into the wrecked engines and caught fire
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De Havilland Comet
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Disaster Summary
Fatigue damage affects Fatigue failure caused by a variety of factors: Stress concentrations Corrosion fatigue Prior damage
Fatigue damage can be deadly Current fatigue methods stop these 5/23/12
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Beach Marks
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Mechanical Cycling
Notes:
Cyclic stress (or strain) leads to fatigue failure The resistance of a material (or a component) to fatigue is measured in cycles, denoted by Nf, and connoted by fatigue life
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Notes:
Example Cycles
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Consider a critical location in component Consider the mechanical (and thermal) loads experienced by that component
Fatigue Regimes
Def: Low Cycle Fatigue (LCF) - when Nf is in the range of 101 to 103. Def: Infinite Life - when Nf is above 5/23/12 106.
Stress amplitude a = (max min)/2 Mean stress m = (max + min)/2 Stress range = (max - min) Stress ratio R = min/max Amplitude ratio A = a/m
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Stress-Life Approach
Strain range is dominated by elastic rather than plastic strain Peak and valley stresses are constant Only one component of loading 5/23/12 (e.g., axial,
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Relationship of Su and Se
strengths, fatigue
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The endurance limit is impacted by each of the following: Surface condition Presence of notches Fabrication defects Absolute size Environment Cyclic Rate 5/23/12
The unmodified endurance limit, Se, is based on the rotating bending tests Marin factors are unitless, positive, and have a
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Type of Load
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Environment, Cenv
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Reliability Factor, CR
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Miscellaneous Factor, Cm
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Cyclic Rate
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Discussion of Methods
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Finite Life
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Summary
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Stress Concentrations
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