ME311 Machine Design

Lecture 6: Fluctuating Fatigue

and the Goodman Diagram;
Impact
W Dornfeld
17Oct2013

Fairfield University
School of Engineering

Fluctuating Fatigue
Last lecture we discussed
loading that alternately went
from tension to
compression with the
extremes equal and
opposite.
Now we look at the more
general case where there
could be a mean value.
This is called Fluctuating
Fatigue, and is
characterized by both a
mean and an alternating
component.

alt

range

mean

Time

mean =
alt =

max + min
2

max min
2

= Average or Steady Stress

= Stress Amplitude

Hamrock
Section 7.3

 mean =

max + min
2

alt =

80
40

40

-40
40

max min
2

mean

alt

Fluctuating or
Fully Reversing?

Effect of Mean Stress

This axis is the

fraction that alt
is of the
Endurance
Strength, Se

Circles
represent
failures

As the Mean stress

increases, the
material breaks at a
lower Alternating
stress amplitude.
This axis is the fraction that mean is of
the Ultimate Strength, Sut

Fluctuating Fatigue Diagrams

Several ways are available
to characterize the
Fluctuating Fatigue
behavior. Two common
ones are:
Goodman line and
Gerber line.
Both approximate the
material behavior. We will
use the Goodman line
because it is simpler and
conservative.
The Modified Goodman
Diagram is the red line and
is the Goodman line
truncated by the Yield line.

Modified Goodman
Diagram

Hamrock
Section 7.10

Drawing the Modified

Goodman Diagram
The diagram is based on
material properties Sut,
Sy, and Se.
As with the S-N curve, Se
should be derated to
reflect your part:
Se = kf ks kr kt km Se
(My Part)

(Test Specimen)

For torsional (shear)

loading, use
Ssy = 0.577 Sy,
Sus = 0.67 Sut, and
Se for Torsion

Drawing the Modified

Goodman Diagram

Then plot your alternating

and mean stress.
If your point is below the
Mod Goodman line, the part
should have unlimited life.

alt

mean

Note: This is very different from the complete Modified

Goodman Diagram that Hamrock details on P. 237 240.
We will not use that version it is pretty confusing.

Factors of Safety
Alt.
Only

The Factor of Safety

depends on how the
stresses behave. They
might:
1. Grow proportionately
2. Only grow in mean
3. Only grow in alternating
How they behave depends
on the actual hardware and
loading involved.

Proportional
alt

Mean Only

mean

If alt and mean Increase Proportionately

To make the
Goodman Line
w/F.O.S. go through
(M,A) :

1
A = Se ( M )
n Sut

Se
Load
Line
Se/n

A
mean
M

alt
A

1 M
=
S e n Sut

1 A M
=
+
n S e Sut
Equations of
the Goodman
Line:

alt =

alt =

Sut/n

Se
mean + S e = Se ( mean + 1)
Sut
Sut

For a Factor of Safety of n :

Sut

mean

or

alt = Se (1

1 mean
)
n
Sut

alt = Se (

mean
Sut

If alt and mean Increase Proportionately

alt

Lim

Equation to find alternating

stress when operating point
hits the FOS line or
Goodman line.

1
Se
=
n M Se
1 +

A Sut

Se

Set n = 1 to get this

level

Se/n

alt
A

Sut/n

me
an

Sut

If Only alt Increases

Equation of the
Goodman Line:

alt = Se (1

mean
Sut

a max = Se (1

M
Sut

Se

a max

alt

Equation to find alternating

stress when operating point
hits the Goodman line.

a max
n=
A

mean

Sut

Fatigue Exercise
Given a bar of steel
with these properties
Yield
UltimateTensile
Endurance

On a Goodman Diagram, predict

fatigue for these loadings:

40 ksi
65 ksi
30 ksi

Min

Max

0
-27

36
37

Mean

14

70

Alternating Stress (ksi)

60

50

40

30

20

10

0
0

10

20

30

40

Mean Stress (ksi)

50

60

70

Alt

32

ksi
ksi
ksi

Fatigue Exercise
Min
Yield
UltimateTensile
Endurance

40 ksi
65 ksi
30 ksi

Max
0
-27
-18

Mean
36
37
46

Alt

18
5
14

18 ksi
32 ksi
32 ksi

45

40

Alternating Stress (ksi)

35

30

25

20

15

10

0
0

10

15

20

25

30

35

40

Mean Stress (ksi)

45

50

55

60

65

70

Fatigue Diagram for Finite Life

From EngRasp ETBX

Another Type of Fatigue Diagram

Note Finite Life curves

alt = 50 ksi
mean = 70 ksi

Stress Ratios for This Diagram

Stress ratio R =
alt = 50 ksi
mean = 70 ksi

min
max

alt
Amplitude ratio A =
mean

More Cantilever Beam

Details
12 Gauge (0.1094 thick)
0.75 in. wide
4 in. long
High Strength Steel, with
Sut = 245 ksi
Machined finish
Room Temperature

Ignore Stress
Concentration

Se = kf ks kr Se = (0.63)(1)(0.87)(100) = 54.8 ksi

CASE 2: Tip is flexed between 0.075 in and 0.225 in. What is life
for 95% survival?
By proportioning, the force now fluctuates between 8.631 lb and 3 x
8.631 = 25.893 lb.
Stresses go from +23.1 ksi to +69.3 ksi.
0.225
Tip
Deflection 0.150
(in)
0.075
0

alt

69.3
46.2

mean

23.1
0

Stress
(ksi)

Cantilever Beam, contd.

0.225
Tip
Deflection 0.150
(in)
0.075

69.3

alt

46.2
mean

Alternating Stress (ksi)

23.1
0

mean =
alt =

Stress
(ksi)

max + min
2

max min
2

69.3 + 23.1
= 46.2 ksi
2
69.3 23.1
=
= 23.1ksi
2
=

60

Se
40

A
20

Sut
0
0

20

40

M 60

80

100

120

140

160

Mean Stress (ksi)

180

200

220

240

260

 mean = 46.2 ksi

alt = 23.1ksi

Alternating Stress (ksi)

Cantilever Beam FOS

60

Se
40

A
20

Sut
0
0

20

40

M 60

80

100

120

140

160

180

200

220

240

Mean Stress (ksi)

What is the Factor of Safety?

A. If both alternating and mean stresses increase proportionately:
1 A M 23.1 46.2
=
+
=
+
= 0.422 + 0.189 = 0.611
n S e S ut 54.8 245

n=

1
= 1.64
0.611

B. If only alternating stress increases:

a max = S e (1

M
Sut

) = 54.8(1

a max 44.4
n=
=
= 1.92
A
23.1

46.2
) = 54.8(1 0.189) = 44.4 ksi
245

260

Impact
Static displacement of Weight on
Spring of stiffness, k

st =

W
k

Impact factor is

P
2h
I m = max = max = 1 + 1 +
static W
st

h
W

Effect is dependent on Spring

Stiffness. A soft spring means
large static deflection, which
means smaller Impact factor.

Impact significantly increases forces!

Impact
For this situation, what is:
1. The static deflection
2. The Impact factor
3. The max deflection
4. The max force

10Lb

10
10Lb
100
Lb/in

Impact
For the case of a weight sliding
horizontally with a velocity, V,
and hitting the spring

max

WV 2
=
gk

where g is the gravitational

constant, 386 in/s2 or 9.8 m/s2.
Recognizing that W/k = st

max =

stV
g

Impact
For this setup, what velocity
gives the same max force as the
falling weight just did?

100Lb/in
V
10Lb

10Lb

Impact
Read Hamrocks Example 7.10 of a diver landing on a diving board.
Note that the spring here is a beam, whose stiffness is calculated as
Force/Deflection.
Also note that he deflects the end of the board 4 inches, and sees a
max force of 2844 Lb!