Ken Youssefi

MAE dept., SJSU

1
It has been recognized that a metal subjected
to a repetitive or fluctuating stress will fail at a
stress much lower than that required to cause
failure on a single application of load. Failures
occurring under conditions of dynamic loading
are called fatigue failures.

Fatigue Failure
Fatigue failure is characterized by three stages
Crack Initiation
Crack Propagation
Final Fracture
Ken Youssefi
MAE dept., SJSU
2
Jack hammer component,
shows no yielding before
fracture.
Crack initiation site
Fracture zone
Propagation zone, striation
Ken Youssefi
MAE dept., SJSU
3
VW crank shaft fatigue failure due to cyclic bending and torsional stresses
Fracture area
Crack initiation site
Propagation
zone, striations
Ken Youssefi
MAE dept., SJSU
4
928 Porsche timing pulley
Crack started at the fillet
Ken Youssefi
MAE dept., SJSU
5
1.0-in. diameter steel pins from
agricultural equipment.
Material; AISI/SAE 4140 low
allow carbon steel
Fracture surface of a failed bolt. The
fracture surface exhibited beach marks,
which is characteristic of a fatigue failure.
Ken Youssefi
MAE dept., SJSU
6
This long term fatigue crack in a high quality component took a
considerable time to nucleate from a machining mark between the spider
arms on this highly stressed surface. However once initiated propagation
was rapid and accelerating as shown in the increased spacing of the 'beach
marks' on the surface caused by the advancing fatigue crack.
bicycle crank spider arm
Ken Youssefi
MAE dept., SJSU
7
Gear tooth failure
Crank shaft
Ken Youssefi
MAE dept., SJSU
8
Hawaii, Aloha Flight 243, a Boeing 737, an upper part of the plane's cabin
area rips off in mid-flight. Metal fatigue was the cause of the failure.
Ken Youssefi
MAE dept., SJSU
9
Cup and Cone
Dimples
Dull Surface
Inclusion at the bottom of the dimple
Ductile
Fracture Surface Characteristics
Shiny
Grain Boundary cracking
Brittle Intergranular
Shiny
Cleavage fractures
Flat
Brittle Transgranular
Beachmarks
Striations (SEM)
Initiation sites
Propagation zone
Final fracture zone
Fatigue
Mode of fracture Typical surface characteristics
Ken Youssefi
MAE dept., SJSU
10
Fatigue Failure Type of Fluctuating Stresses

a
=

max

min
2
Alternating stress
Mean stress

m
=

max

min
2
+

min
=0

a
=

max
/ 2

m
=

a
=

max

max
=

-
min
Ken Youssefi
MAE dept., SJSU
11
Fatigue Failure, S-N Curve
Test specimen geometry for R.R. Moore
rotating beam machine. The surface is
polished in the axial direction. A constant
bending load is applied.
Motor
Load
Rotating beam machine applies fully reverse bending stress
Typical testing apparatus, pure bending
Ken Youssefi
MAE dept., SJSU
12
The standard machine operates at an
adjustable speed of 500 RPM to
10,000 RPM. At the nominal rate of
10,000 RPM, the R. R. Moore machine
completes 600,000 cycles per hour,
14,400,000 cycles per day.
Bending moment capacity
20 in-lb to 200 in-lb
Ken Youssefi
MAE dept., SJSU
13
Fatigue Failure, S-N Curve
Finite life Infinite life
N < 10
3
N > 10
3
S
e

= endurance limit of the specimen

S
e


Ken Youssefi
MAE dept., SJSU
14
Relationship Between Endurance Limit
and Ultimate Strength
Steel
S
e
=

0.5S
ut
100 ksi
700 MPa
S
ut
200 ksi (1400 MPa)

S
ut
> 200 ksi

S
ut
> 1400 MPa

Steel
0.4S
ut
S
e
=

S
ut
< 60 ksi (400 MPa)

S
ut
60 ksi

24 ksi
160 MPa
S
ut
< 400 MPa

Cast iron
Cast iron
Ken Youssefi
MAE dept., SJSU
15
Relationship Between Endurance Limit and
Ultimate Strength
Aluminum alloys
S
e
=

0.4S
ut
19 ksi
130 MPa
S
ut
< 48 ksi (330 MPa)

S
ut
48 ksi

S
ut
330 MPa

Aluminum
For N = 5x10
8
cycle
Copper alloys
S
e
=

0.4S
ut
14 ksi
100 MPa
S
ut
< 40 ksi (280 MPa)

S
ut
40 ksi

S
ut
280 MPa

Copper alloys
For N = 5x10
8
cycle
Ken Youssefi
MAE dept., SJSU
16
Correction Factors for Specimens Endurance Limit

= endurance limit of the specimen (infinite life > 10
6
)

S
e


For materials exhibiting a knee in the S-N curve at 10
6
cycles

= endurance limit of the actual component (infinite life > 10
6
) S
e

N
S S
e
10
6
10
3

= fatigue strength of the specimen (infinite life > 5x10
8
)

S
f



= fatigue strength of the actual component (infinite life > 5x10
8
)

S
f

For materials that do not exhibit a knee in the S-N curve, the infinite
life taken at 5x10
8
cycles
N
S
S
f
5x10
8
10
3
Ken Youssefi
MAE dept., SJSU
17
Correction Factors for Specimens Endurance Limit
S
e
= C
load
C
size
C
surf
C
temp
C
rel
(S
e
)


Load factor, C
load
(page 326, Nortons 3
rd
ed.)
Pure bending
C
load
= 1

Pure axial
C
load
= 0.7

Combined loading
C
load
= 1

Pure torsion
C
load
= 1 if von Mises stress is used, use
0.577 if von Mises stress is NOT used.

S
f
= C
load
C
size
C
surf
C
temp
C
rel
(S
f
)


or
Ken Youssefi
MAE dept., SJSU
18
Correction Factors for Specimens Endurance Limit
Size factor, C
size
(p. 327, Nortons 3
rd
ed.)
Larger parts fail at lower stresses than smaller parts. This is
mainly due to the higher probability of flaws being present in
larger components.
For rotating solid round cross section
d 0.3 in. (8 mm) C
size
= 1
0.3 in. < d 10 in. C
size
= .869(d)
-0.097
8 mm < d 250 mm C
size
= 1.189(d)
-0.097
If the component is larger than 10 in., use C
size
= .6
Ken Youssefi
MAE dept., SJSU
19
Correction Factors for Specimens Endurance Limit
For non rotating components, use the 95% area approach to calculate
the equivalent diameter. Then use this equivalent diameter in the
previous equations to calculate the size factor.
d
equiv
= (
A
95
0.0766
)
1/2

d
d
95
= .95d
A
95
= (/4)[d
2
(.95d)
2
] = .0766 d
2
d
equiv
= .37d

Solid or hollow non-rotating parts
d
equiv
= .808 (bh)
1/2
Rectangular parts
Ken Youssefi
MAE dept., SJSU
20
Correction Factors for Specimens Endurance Limit
I beams and C channels
Ken Youssefi
MAE dept., SJSU
21
Correction Factors for Specimens Endurance Limit
surface factor, C
surf
(p. 328-9, Nortons 3
rd
ed.)
The rotating beam test specimen has a polished surface. Most
components do not have a polished surface. Scratches and
imperfections on the surface act like a stress raisers and reduce
the fatigue life of a part. Use either the graph or the equation with
the table shown below.
C
surf
= A (S
ut
)
b
Ken Youssefi
MAE dept., SJSU
22
Correction Factors for Specimens Endurance Limit
Temperature factor, C
temp
(p.331, Nortons 3
rd
ed.)
High temperatures reduce the fatigue life of a component. For
accurate results, use an environmental chamber and obtain the
endurance limit experimentally at the desired temperature.
For operating temperature below 450
o
C (840
o
F) the
temperature factor should be taken as one.
C
temp
= 1 for T 450
o
C (840
o
F)
Ken Youssefi
MAE dept., SJSU
23
Correction Factors for Specimens Endurance Limit
Reliability factor, C
rel
(p. 331, Nortons 3
rd
ed.)
The reliability correction factor accounts for the scatter and
uncertainty of material properties (endurance limit).
Ken Youssefi
MAE dept., SJSU
24
Fatigue Stress Concentration Factor, K
f
Experimental data shows that the actual stress concentration factor is not as
high as indicated by the theoretical value, K
t
. The stress concentration factor
seems to be sensitive to the notch radius and the ultimate strength of the
material.

(p. 340, Nortons 3
rd
ed.)
Steel
K
f
= 1 + (K
t
1)q
Notch sensitivity factor
Fatigue stress
concentration factor
Ken Youssefi
MAE dept., SJSU
25
Fatigue Stress
Concentration Factor,
q for Aluminum

(p. 341, Nortons 3
rd
ed.)
Ken Youssefi
MAE dept., SJSU
26
Design process Fully Reversed Loading for Infinite Life
Determine the maximum alternating applied stress (
a
) in terms of
the size and cross sectional profile
Select material S
y
, S
ut
Use the design equation to calculate the size
S
e
K
f

a
=
n
Choose a safety factor n

Determine all modifying factors and calculate the endurance
limit of the component S
e
Determine the fatigue stress concentration factor, K
f
Investigate different cross sections (profiles), optimize for size or weight

You may also assume a profile and size, calculate the alternating stress
and determine the safety factor. Iterate until you obtain the desired
safety factor

Ken Youssefi
MAE dept., SJSU
27
Design for Finite Life
S
n
= a (N)
b
equation of the fatigue line

N
S
S
e
10
6
10
3
A
B
N
S
S
f
5x10
8
10
3
A
B
Point A
S
n
= .9S
ut
N = 10
3
Point A
S
n
= .9S
ut
N = 10
3
Point B
S
n
= S
f
N = 5x10
8
Point B
S
n
= S
e
N = 10
6
Ken Youssefi
MAE dept., SJSU
28
Design for Finite Life
S
n
= a (N)
b
log S
n
= log a + b log N
Apply boundary conditions for point A and B to
find the two constants a and b
log .9S
ut
= log a + b log 10
3
log S
e
= log a + b log 10
6
a
=
(.9S
ut
)
2
S
e
b
=
.9S
ut

S
e
1
3
log
S
n
K
f

a
=
n
Design equation
Calculate S
n
and replace S
e
in the design equation
S
n
=
S
e
(
N
10
6
)

(
S
e
.9S
ut
)
log
Ken Youssefi
MAE dept., SJSU
29
The Effect of Mean Stress on Fatigue Life
Mean stress exist if the
loading is of a repeating or
fluctuating type.
Mean stress
Alternating
stress

a
S
e
S
y
Soderberg line
S
ut
Goodman line
Gerber curve
Mean stress is not zero
Ken Youssefi
MAE dept., SJSU
30
The Effect of Mean Stress on Fatigue Life
Modified Goodman Diagram
Mean stress
Alternating
stress

a
S
ut
Goodman line
S
y
S
y
S
e
Safe zone
C
Yield line
Ken Youssefi
MAE dept., SJSU
31
- S
yc
The Effect of Mean Stress on Fatigue Life
Modified Goodman Diagram
+
m

a
S
ut
Goodman line
S
y
Yield line
Safe zone
-
m
C
S
y
S
e
Safe zone
Ken Youssefi
MAE dept., SJSU
32
The Effect of Mean Stress on Fatigue Life
Modified Goodman Diagram
+
m

a
S
ut
Safe zone
-
m
C
S
y
Safe zone
S
e
- S
yc
Finite life
S
n
1 =
S
ut

m
+
Fatigue,
m
>0

Fatigue,
m
0

a
=


S
e
n
f

a
+
m
=


S
yc
n
y
Yield

a
+
m
=


S
y
n
y
Yield
n
f
S
e
1
=
S
ut

m
+
Infinite life
Ken Youssefi
MAE dept., SJSU
33
Applying Stress Concentration factor to Alternating
and Mean Components of Stress
Determine the fatigue stress concentration factor, K
f
, apply directly to
the alternating stress K
f

a

If K
f

max
<S
y
then there is no yielding at the notch, use K
fm
= K
f

and multiply the mean stress by K
fm
K
fm

m

If K
f

max
>S
y
then there is local yielding at the notch, material at the
notch is strain-hardened. The effect of stress concentration is reduced.
Calculate the stress concentration factor for the mean stress using
the following equation,
K
fm
=

S
y
K
f

a

m
n
f
S
e
1
=
S
ut
K
f

a
K
fm

m
+
Infinite life
Fatigue design equation
Ken Youssefi
MAE dept., SJSU
34
Combined Loading
All four components of stress exist,

xa
alternating component of normal stress

xm
mean component of normal stress

xya
alternating component of shear stress

xym
mean component of shear stress
Calculate the alternating and mean principal stresses,

1a
,
2a
= (
xa
/2) (
xa
/2)
2
+ (
xya
)
2

1m
,
2m
= (
xm
/2) (
xm
/2)
2
+ (
xym
)
2
Ken Youssefi
MAE dept., SJSU
35
Combined Loading
Calculate the alternating and mean von Mises stresses,

a
= (
1a
+
2a
-
1a

2a
)
1/2

2 2

m
= (
1m
+
2m
-
1m

2m
)
1/2

2 2
Fatigue design equation
n
f
S
e
1
=
S
ut

m
+ Infinite life
Ken Youssefi
MAE dept., SJSU
36
Design Example
R
1 R
2
10,000 lb.
6 6
12
D = 1.5d d
r (fillet radius) = .1d
A rotating shaft is carrying 10,000 lb force
as shown. The shaft is made of steel with
S
ut
= 120 ksi and S
y
= 90 ksi. The shaft
is rotating at 1150 rpm and has a
machine finish surface. Determine the
diameter, d, for 75 minutes life. Use
safety factor of 1.6 and 50% reliability.
Calculate the support forces, R
1
= 2500, R
2
= 7500 lb.
A
The critical location is at the fillet, M
A
= 2500 x 12 = 30,000 lb-in

a
=

Calculate the alternating stress,
Mc
I
=
32M
d
3
=
305577
d
3

m
= 0
Determine the stress concentration factor
r
d
= .1
D
d
= 1.5
K
t
= 1.7
Ken Youssefi
MAE dept., SJSU
37
Design Example
Assume d = 1.0 in
Using r = .1 and S
ut
= 120 ksi,
q (notch sensitivity) = .85
K
f
= 1 + (K
t
1)q = 1 + .85(1.7 1) = 1.6
Calculate the endurance limit
C
load
= 1 (pure bending)
C
rel
= 1 (50% rel.)
C
temp
= 1 (room temp)
C
surf
= A (S
ut
)
b
= 2.7(120)
-.265
= .759

0.3 in. < d 10 in. C
size
= .869(d)
-0.097
= .869(1)
-0.097
= .869

S
e
= C
load
C
size
C
surf
C
temp
C
rel
(S
e
) = (.759)(.869)(.5x120) = 39.57 ksi


Ken Youssefi
MAE dept., SJSU
38
Design Example
Design life, N = 1150 x 75 = 86250 cycles
S
n
=
S
e
(
N
10
6
)

(
S
e
.9S
ut
)
log
S
n
=
39.57

(
86250
10
6
)

(
39.57

.9x120

) log
= 56.5 ksi

a
=

305577
d
3
= 305.577 ksi
n =

S
n
K
f

a
=
56.5
1.6x305.577
= .116 < 1.6
So d = 1.0 in. is too small
Assume d = 2.5 in
All factors remain the same except the size factor and notch sensitivity.
Using r = .25 and S
ut
= 120 ksi,
q (notch sensitivity) = .9
K
f
= 1 + (K
t
1)q = 1 + .9(1.7 1) = 1.63
C
size
= .869(d)
-0.097
= .869(2.5)
-0.097
= .795

S
e
= 36.2 ksi


Ken Youssefi
MAE dept., SJSU
39
Design Example

a
=

305577
(2.5)
3
= 19.55 ksi
n =

S
n
K
f

a
=
53.35
1.63x19.55
= 1.67 1.6
d = 2.5 in.
Check yielding
n =

S
y
K
f

max
=
90
1.63x19.55
= 2.8 > 1.6 okay
S
e
= 36.2 ksi

S
n
=
36.20

(
86250
10
6
)

(
36.2

.9x120

) log
= 53.35 ksi
Ken Youssefi
MAE dept., SJSU
40
Design Example Observations
n =

S
n
K
f

a
=
56.5
1.6x305.577
= .116 < 1.6
So d = 1.0 in. is too small
Calculate an approximate diameter
n =

S
n
K
f

a
=
56.5
1.6x305.577/d
3

= 1.6 d = 2.4 in.
So, your next guess
should be between
2.25 to 2.5
M
max
(under the load) = 7500 x 6 = 45,000 lb-in
Check the location of maximum moment for possible failure
R
1 R
2
= 7500

6 6
12
D = 1.5d d
r (fillet radius) = .1d
A
M
A
(at the fillet) = 2500 x 12 = 30,000 lb-in
But, applying the fatigue stress conc. Factor of 1.63,
K
f
M
A
= 1.63x30,000 = 48,900 > 45,000

Ken Youssefi
MAE dept., SJSU
41
Example
A section of a component is shown.
The material is steel with S
ut
= 620 MPa
and a fully corrected endurance limit of
S
e
= 180 MPa. The applied axial load
varies from 2,000 to 10,000 N. Use
modified Goodman diagram and find
the safety factor at the fillet A, groove B
and hole C. Which location is likely to
fail first? Use K
fm
= 1
P
a
= (P
max
P
min
) / 2 = 4000 N
P
m
= (P
max
+ P
min
) / 2 = 6000 N
Fillet
r
d
= .16
D
d
= 1.4
4
25
=
35
25
=
K
t
= 1.76
Ken Youssefi
MAE dept., SJSU
42
Example
K
f
= 1 + (K
t
1)q = 1 + .85(1.76 1) = 1.65
Calculate the alternating and the
mean stresses,

a
=

P
a
A
=
4000
25x5

= 52.8 MPa K
f
1.65

m
=

P
m
A
=
6000
25x5

= 48 MPa
n
S
e
1
=
S
ut

m
+
Infinite life
Fatigue design equation
n = 2.7
n

180
1
=
620

52.8 48
+

Using r = 4 and S
ut
= 620 MPa,
q (notch sensitivity) = .85
Ken Youssefi
MAE dept., SJSU
43
Example
Hole
d
w
= .143
5
35
=
K
t
= 2.6
Using r = 2.5 and S
ut
= 620 MPa,
q (notch sensitivity) = .82
K
f
= 1 + (K
t
1)q = 1 + .82(2.6 1) = 2.3
Calculate the alternating and the
mean stresses,

a
=

P
a
A
=
4000
(35-5)5

= 61.33 MPa K
f
2.3

m
=

P
m
A
=
6000
30x5

= 40 MPa
n = 2.5
n

180
1
=
620

61.33 40
+

Ken Youssefi
MAE dept., SJSU
44
Example
Groove
r
d
= .103
D
d
= 1.2
3
29
=
35
29
=
K
t
= 2.33
Using r = 3 and S
ut
= 620 MPa,
q (notch sensitivity) = .83
K
f
= 1 + (K
t
1)q = 1 + .83(2.33 1) = 2.1
(35-6)5

Calculate the alternating and the
mean stresses,

a
=

P
a
A
=
4000
= 58.0 MPa K
f
2.1

m
=

P
m
A
=
6000
29x5

= 41.4 MPa
n = 2.57
n

180
1
=
620

58.0 41.4
+

The part is likely to fail at the hole, has the lowest safety factor
Ken Youssefi
MAE dept., SJSU
45
Example
F
a
= (F
max
F
min
) / 2 = 7.5 lb. F
m
= (F
max
+ F
min
) / 2 = 22.5 lb.
The figure shows a formed round wire cantilever
spring subjected to a varying force F. The wire is
made of steel with S
ut
= 150 ksi. The mounting
detail is such that the stress concentration could
be neglected. A visual inspection of the spring
indicates that the surface finish corresponds
closely to a hot-rolled finish. For a reliability of
99%, what number of load applications is likely to
cause failure.
M
a
= 7.5 x 16 = 120 in - lb M
m
= 22.5 x 16 = 360 in - lb

a
=

Mc
I
=
32M
a
d
3
=
32(120)
(.375)
3
= 23178.6 psi

m
=

Mc
I
=
32M
m
d
3
=
32(360)
(.375)
3
= 69536 psi
Ken Youssefi
MAE dept., SJSU
46
Example
C
load
= 1 (pure bending)
C
temp
= 1 (room temp)
Calculate the endurance limit
C
rel
= .814 (99% reliability)
C
surf
= A (S
ut
)
b
= 14.4(150)
-.718
= .394
A
95
= .010462 d
2
(non-rotating round section)

d
equiv
= A
95
/ .0766 = .37d = .37 x.375 = .14

d
equiv
= .14 < .3 C
size
= 1.0

S
e
= C
load
C
size
C
surf
C
temp
C
rel
(S
e
) = (.394)(.814)(.5x150) = 24.077 ksi

n
S
e
1
=
S
ut

m
+

n

24077

1
=
150000

23178.6

69536

+

n = .7 < 1

Finite life
S
n
1 =
S
ut

m
+
Find S
n
, strength for finite number of cycle
S
n
1 =
150000

23178.6

69536

+
S
n
= 43207 psi

Ken Youssefi
MAE dept., SJSU
47
Example
S
n
=
S
e
(
N
10
6
)

(
S
e
.9S
ut
)
log
43207 =
24077

(
N
10
6
)

(
24.077

.9x150

) log

N = 96,000 cycles