FATIGUE PROPERTIES I

UNIAXIAL STRESS FATIGUE

Fatigue and Endurance
Machine parts and structural members are frequently subjected to
time varying loads and stresses. It is important to know the strength of
materials under such conditions. The materials are known to fail under
reversal of stress at much smaller stress amplitudes than their static
ultimate / fracture / strengths. The number of cycles applied in static test
is just one-quarter of a cycle. As the number of cycles increases, the
amplitude of reversed stress causing failure decreases. This is why
machine parts fail soon at low levels of stress amplitude, when working at
high speeds. This phenomenon of the decreased resistance of a material to
repeated stresses is called fatigue. The testing of a material by the
application of such stresses is known as fatigue test or endurance test.
Nature of Fatigue Failures
The nature of fatigue failure is different from that of static failure.
In general before the final fracture / failure, a sort of plastic flow or
stretching of crystals occurs. The final fractured surface has a fibrous
structure, resembling that of a static brittle fracture. Fatigue fracture
normally starts from a crack, where the stress is concentrated and
progresses till the part is completely separated. The final separation
occurs suddenly, when the crack has progressed to that extent that the
remaining area is just not enough to withstand the magnitude of the stress
and practically a static brittle fracture finally occurs. It is confirmed by
the small area of the final fracture resembling that of a static brittle
fracture. But the surface of the progressively cracked area normally
has a mirror finish, because of the repeated closing and opening and
rubbing / abrasion of the surface. (Read books to know of mechanical,
sonic, thermal, pitting/fretting, corrosive fatigues)
Types of Time-varying Stresses
Fourier series can express any wave shape as the sum of sinusoidal waves
of different amplitudes and frequencies. Therefore the simple fatigue tests
focus attention only on a sinusoidal load stress pattern. There are three
situations of loads:
(1) General (Fluctuating) (2) Completely Reversed (3) Repeated
In the stress wave there are minimum and maximum values: Smax,
Smin. Then in general
Mean stress, Sm = (Smax + Smin)/2
Stress-amplitude, Sa = (Smax - Smin)/2
1

Students may sketch each case to understand

1.

General (Fluctuating)
S = Sm + Sa sin 2t/T
Sm = (Smax + Smin)/2;
Sa = (Smax - Smin)/2
Smax = Sm + Sa;
Smin = Sm - Sa

2. Completely Reversed
S= Sa sin 2t/T
Sm = 0
Smin = - Smax
Sa = Smax
3. Repeated
S= Sa(1 + sin 2t/T)
Smin = 0 & Smax = + 2 Sa
Or
Smax = 0 & Smin = - 2 Sa
Cases 2 and 3 are only special cases of case 1.
COMPLETELY REVERSED STRESS
Fatigue Tests
The mostly used type of time-varying stress in fatigue tests is
completely reversed stress. The specimens may be subjected to different
type of reversed stresses.
1 Axial
2 Torsion
3 Bending
a) Rotating simply supported beam with two-point loads
b) Cantilever beam with reversing end load
c) Rotating Cantilever beam with end load
The mostly used test is reversed bending in a rotating beam
with four-point loads. (Refer Fig 4.17 in Printed Material)
2

The two ends of the beam-like specimen of circular cross section

tapering towards the middle are supported on swivel bearings. The gage
length of the specimen lies in the mid-portion of the specimen. At the
ends of the gage length two more bearings are provided, through which
two equal weights are hung. Now the gage length has pure bending state.
When the specimen is rotated from one end, the fibers in the specimen are
exposed to alternating tensile and compressive bending stress. The
number of cycles to fracture is recorded for one set of two equal weights
applied.
Thus, for each of the stress amplitudes, a separate specimen with
separate different set of two weights is used and the corresponding
number of cycles observed. Thus for each point in Sa-N plot, one
specimen needs to be tested to fracture.
The SaN relation is plotted and is called S-N curve. The
amplitude of stress Sa is called as endurance / fatigue strength for the
particular life, expressed as number of cycles, N and denoted as Se.
In specifying the endurance/fatigue strength, therefore, both the
stress and the corresponding number of cycles to failure must be stated.
It should be noted that there is another term endurance limit Sel,
which is different from endurance strength. Most ferrous alloys, say
steels have endurance limit, a stress amplitude below the magnitude of
which their life is infinite. This will not apply to all materials.
Design Criterion
In general, for a given life of N cycles, fatigue failure occurs when
the amplitude of completely reversed stress Sa = Se. For safety / no
failure at N cycles, then
Sa S = Se
If a factor of safety is required
Sa Sew = Se / FS

(1)
(1A)

Fitting an S-N curve

Since separate specimens are used to get each point in an S-N
curve, there is wide scatter in any experimental S-N curve data. The
scattered data is suitably fitted in to an S-N curve. Since the number of
cycles to fracture is very high, in the order of 10 6 or more, N-coordinate
is usually log N. The graph will be S log N curve. Sometimes the plot is
log S log N curve.
A very common form of S-N curve for fatigue failure is fitted as

NSn = q (constant)
(2)
n
[Here q has dimension of (Stress) , since N has no dimension]
For convenience, many a time, the stress is normalized arbitrarily with a
constant stress S0 and expressed as
N(S/S0)n = Q (constant)
[Here Q has no dimension: dimensionless]

(2A)

This type of curve fit has some limitations. At least there are two
limitations, one at low cycle and the other at very high cycle.
1) At low cycle fatigue range, that is, near zero cycle, N 0, S
tends to infinity in (2). But we know it is static case and S must be either
the yield strength SY or the ultimate strength Su as per the choice of
failure criterion made.
2) For most ferrous group of metals, the S-N curve becomes
asymptotic to a horizontal line with increasing N. The stress amplitude,
Se, corresponding to this asymptote is called the endurance / fatigue
limit, Sel. This means any stress amplitude below this value, theoretically,
can be applied for infinite number of cycles without fatigue failure.
Most of the conservative designs are made based on this limiting stress
amplitude Sel, which is the lowest.
When N tends to infinity, S tends to zero in (2), instead of limiting
to endurance limit Sel.
Therefore, some modifications have been proposed in (2) to
overcome these two limitations, as below.
(N + No) (Sa - Sel)n = B

(3)

Here in (3) if the static design criterion is, say SY at N = 0,

No = B/( SY - Sel )n
(3A)
When Sa = Sel in (3), N tends to infinity, confirming the endurance
limit.
However for most purposes, where it is neither very low cycle nor
very high cycle fatigue, the expression (2) or (2A) is used conveniently
and satisfactorily.
It must be kept in mind that N represents the number of cycles
to fracture at stress amplitude of S in completely reversed cycle
fatigue.

CUMULATIVE DAMAGE MINERS RULE

Machine and structural members are not always subjected to the
same steady stress amplitude, but some times to higher stress for some
number of cycles and other times to lower stress for another number of
cycles. When such situation arises, how can the fatigue strength be
assessed and how can one find the life spent and remaining?
One of the propositions to account for having run the parts for
partial life with different stress amplitudes and for calculating the
remaining life is the Miners Cumulative Damage Rule.
According to this simple linear rule, a part has expended its full
life if the stress amplitude is Si and it is run for Ni cycles under
completely reversed cycle so that it satisfies (2) or (2A),
NiSin = q

(4)

Ni (Si /S0)n = Q

(4A)

That is, its full life is Ni cycles at Si and it has been run to its full life of
Ni itself and this condition is therefore expressed as
Li = Ni/Ni = 1

(5)

At Si, if it is not run to its full life of N i cycles, but was run only for a
lower number of cycles ni < Ni, the proportion of life expended is only
Li = ni/Ni < 1 (at Si)

(6)

If it happens that the material is subjected to many such different stress

amplitudes Si for the corresponding number of cycles ni, then the total
amount of life expended is
L = Li = ni/Ni 1

(7)

Expression (7) is the Miners rule for cumulative damage.

Example 1: The fatigue property of the material of certain part was fitted
for N(in number of cycles) and S (in MPa) to be
N (S/600)6 = 30 x 103
a) If the part was subjected to the following sets of stress and number
of cycles, find the life expended so far.
5

Given Data
n = 5 x 104
105
5 x 105 Cycles of Run
S = 450
400
300
MPa
b) If it is required to run the part further at S = 400 MPa, find the
possible number of cycles for which it could be run further.
c) In stead, if the part has to be run further for104 cycles, what stress
amplitude can be applied?
Solution:
Calculated from N(S/600)6 = 30 x 103
S = 450
400
300
MPa
5
5
5
N = 1.686 x 10 3.41 x 10 19.2 x 10 Full-Life Cycles
Using Miners rule (7)
a) L = 5 x 104 / 1.686 x 105 + 105 / 3.41 x 105 + 5 x 105 / 19.2 x105
= 1/ 3.372 +1/ 3.41 + 1/ 3.84 = 0.85023
Remaining life LR = 1 0.85023 = 0.14977
b) For S= 400 MPa,
LR = 0.14977 = n / N = n / 3.41 x 105
n = 0.14977 x 3.41 x 105 = 0.5105 x105 cycles
c) For 104 cycles, the unknown is S at n = 104 cycles. Now
LR = 0.14977 = (n / N)
N = n / LR = 104 /0.1477 = 6.68 x 104 cycles
Then
(S / 600)6 = 30 x 103 / 6.68 x 104
S = 0.8751 x 600 MPa = 525 MPa
EFFECT OF OVER-STRESSING AND UNDER-STRESSING
A part may be over-stressed for some time before a steady state is
maintained. It is known that an earlier over-stressing reduces the fatigue
strength in the subsequent lower steady stress. Similarly an earlier understressing increases the fatigue strength. It has been also noticed that a
minimum number of cycles of over-stressing is needed to cause damage.
This is really complicated in nature and any attempt to take in to account
effect of the order in which, the over- or under-stressing is applied is
only suggestive and a designer should consider every case individually
and separately.

One such method due to Joseph Marin [Ref 1] / Corten & Dolan
[Ref 2] is explained here. Another method by Manson can be seen in
literature [Ref 3]
The reference stress-amplitude is S1 the first applied stress in the
use of Marins method. Any run above this reference stress is construed to
be overstressing, causing more damage and reducing endurance life. Like
wise any run below this reference stress, strengthens the material and
prolongs the fatigue life.
According to this rule, if ni cycles are run at stress amplitude Si,
then the actual life expended is not ni but ni (Si / S1)d ,where d 0. Then
the equivalence of expression (7) becomes
L = Li = (ni/Ni) (Si / S1)d 1

(8)

If d = 0, (8) reduces to Miners rule (7),( since anything raised to zero is

ONE)
References
1 Marin, J, Significance of Material Properties in Design for
Fatigue Loading, Machine Design, Jan-March, 1957
2 Corten, and Dolan, Cumulative Fatigue Damage, Proc. Inst.
Mech Eng,65, London, 1956, p235
3 Shigley, Joseph E (Original in British units) / N. Siva Prasad &
others of IIT Madras (in SI units) , Mechanical Engineering Design, Tata
MGraw Hill, 2003,
Example 2: The fatigue property of the material of certain part was fitted
for N(in number of cycles) and S (in MPa) to be
N (S/600)6 = 30 x 103
a) If the over- and under-stressing exponent d = 2 and if the part
was subjected to the set of stress amplitudes and the corresponding cycles
in the following order, find the life expended so far.
Given Data
Cycles Run n = 105
Stress amp S = 400

5 x 104
450

5 x 105
300

MPa

b) If it is required to run the part at S = 450 MPa, find the possible

number of cycles for which it could be run further.
c) In stead, if the part has to be run for104 cycles, what stress
amplitude can be applied further?.
Solution:
N calculated from N (S/600)6 = 30 x 103

S = 400
450
300
MPa
5
5
5
N = 3.41 x 10
1.686 x 10 19.2 x 10 Full-Life Cycles
5
Cycles Run n = 10
5 x 104
5 x 105
Using over/under-stressing effect expression (8) with reference stress
amplitude S1 = 400 MPa,
a) L = (105 / 3.41 x 105)(400/400)2
+ ( 5 x 104 / 1.686 x 105)(450/400)2
+ (5 x 105 / 19.2 x 105)(300/400)2
= 1/ 3.41 + 1.265625/ 3.372 + 0.5625/ 3.84 = 0.8150
Remaining life LR = 1 0.8150 = 0.1850
b) For S = 450 MPa,
LR = 0.1850 = (n / 1.686 x 105) (450/400)2
= (n / 1.686 x 105) (1.265625)
n = 0.1850 x 1.686x 105 /1.265625 = 2.4645 x104 cycles
c) For 104 cycles,
LR = 0.1850 = (n / N) (S/400)2
(A)
4
Now n = 10 cycles; S is unknown and N is also not known as long as S is
unknown. But N can be found in terms of S from S-N relation (2A).
N (S/600)6 = 30 x 103
Then
1/N = (S/600)6 /30 x 103
Therefore, substituting in (A)
LR = 0.1850 =104 [(S/600)6 /30 x 103] (S/400)2
= 104 (S)8/(4002 x 6006 x 30 x 103)
S = 504 MPa

EFFECT OF MEAN STRESS ON FATIGUE STRENGTH

So far only completely reversed stress was considered. In practice
there are situations, where a static mean stress exists; over and above it,
an alternating stress is superposed. A simple example is the spokes of a
bicycle wheel. Initially the spokes are tensioned. When the spokes are in
vertical position, added compression stress reduces the tensile stress and
in its horizontal position added tensile stress increases the tensile stress.
This alternates in every rotation.
This problem is viewed at its two extreme situations.

1 First extreme is the condition of failure due to only static stress,

without alternating stress. Failure then would occur either at yield stress
or at ultimate stress, as the choice of a designer.
Let us choose yield stress SY. Then Sm SY
2 Next extreme is the condition of failure due to only completely
reversed stress, without static mean stress. Failure occurs at endurance
strength Se at a given number of cycles N (or endurance limit Sel, as the
choice may be).
Then Sa Se
Sketch
If the mean stress Sm on x-axis and the completely reversed stress
amplitude Sa on the y-axis are plotted, the two extremes provide one
intercept point on x-axis (SY,0) and another intercept point on y-axis
(0, Se).
What will be the relation in between these two extreme points,
when there is a combination of the two, is the question.
There are four propositions generally known (Sketches). Two are
linear, the third is parabolic and the fourth is elliptical relation.
Soderberg (Linear):

(Sa/Se) + (Sm/SY) = 1

(9)

Modified Goodman (Linear):

(Sa/Se) + (Sm/Su) = 1

(10)

Gerber (Parabolic) :

(Sa/Se) + (Sm/Su)2 = 1

(11)

Elliptical*

(Sa/Se) 2 + (Sm/Su)2 = 1

(12)

*The Elliptic relation can be shown to represent energy. Here

sometimes SY is used in place of Su.
Soderberg or Modified Goodman relations are the mostly used.
The Soderberg relation (9) can be rewritten as
Sa + (Se/SY) Sm = Se
For no failure / just failure
Sa + (Se/SY) Sm Se

(9A)
(9B)

This (9B) is rewritten as

.
Sa + p Sm Se

(9C)

where p = (Se/SY)
Further (9C) can be expressed in the same form as (1), as
(Sa)eq Se
(9D)*
where (Sa)eq = Sa + p Sm
*(9D) is used later also in combined stress status.
Comparing (1) and (9D) and using (2) and (2A), with the new higher
(Sa)eq, it is clear that the life N will be smaller. This is due to the effect of
added mean stress.
It should be noted that the effect is assumed to be the same, for
compressive (-) or tensile (+) mean stress, even though, in practice,
compressive mean stress improves the fatigue life. (See Figs 4.15 &
4.16 in printed notes)
Langer condition
While all these refer to a mean and a reversed stress combination at
high cycle fatigue, a check at low cycle, especially at very first cycle for
static failure is essential. When the magnitude of Smax = (Sm + Sa)
exceeds the static failure strength, ether SY or Su (to be specified), static
failure would occur. Langer suggested a simple and obvious relation,
taking yield as static failure criterion.
Smax / SY 1
(13)
Or since Smax = Sm + Sa,
(Sa/ SY) + (Sm/SY) 1
(13A)
(Sa + Sm) SY
(13B)
The condition (13A) is a straight line passing backward at 45 degrees
from SY (at Sm axis).
Note: The condition (13 or 13A or 13B) is automatically satisfied for
Soderberg relation as long as Se < SY (which is the case in actual
materials). For the other 3 relations, a check is necessary for the factor of
safety during the first cycle [Ref 3]. Ask for sketch in class!
For Modified Goodman (Linear) case, there is a point beyond that, (10)
will not be applicable; only (13 B) will apply. This point is the point of
intersection of these two. Solving, we get the coordinates as:
Sm = Su (SY Se)/(Su Se) & Sa = Se (Su - SY)/(Su Se).
It will be clearer in a sketch.

10

Thus the full range of MGM relation is not applicable and the toe at the
higher side of Sm is shortened. (Draw sketch & explain)
EXAMPLES
Example 1: A bolt of 3000 mm2 in cross section is made of a material
with a fatigue strength for complete stress reversal Se = 240 MPa for a
given number of cycles, a tensile yield of SY = 360 MPa and a tensile
ultimate strength of Su = 400 MPa. The bolt is subjected to a static mean
load of 18 x 104 N. What completely reversed fatigue load would cause
failure at same number of cycles? Use: a) Soderberg , b) Modified
Goodman, c) Gerber and d) Elliptic relation and check for first cycle
failure.
Solution:
Soderberg relation
Sa/Se + Sm/SY =1
Sm = P/A =18 x 104 / 3000 = 60 MPa
Sm/ SY = 60/360 = 1/6
Sa = (1 1/6) Se = 5/6 x 240 = 200 MPa
Pa = Sa x A = 200 x 3000 = 60 x 104 N
Check for Langer condition: Sa + Sm = 200 + 60 = 260 < 360 = SY
Safe.
Modified Goodman relation
Sa/Se + Sm/Su =1
Sm/ Su = 60/400 = 3/20
Sa = (1 3/20) Se = 17/20 x 240 = 204 MPa
Pa = Sa x A = 204 x 3000 = 61.2 x 104 N
Check for Langer condition: Sa + Sm = 204 + 61.2 = 265.2 < 360 = SY
Safe.
Gerber relation:
Using SY:
Sa/Se +(Sm/SY)2 =1
Sa = (1 1/36) Se = 35/36 x 240 = 233.33 MPa
Pa = 233.33 x 3000 = 70 x 104 N
Check for Langer condition: Sa + Sm = 233 + 60 = 293 < 360 = SY
Safe.
Using SU:
Sa/Se +(Sm/SU)2 =1
Sa = (1 9/400) Se = 391/400 x 240 = 234.6 MPa
Pa = 234.6x 3000 = 70.38 x 104 N
Check for Langer condition: Sa + Sm = 234.6 + 60 = 294.6 < 360 = SY
11

Safe.
Elliptical relation:
Using SY:
(Sa/Se) 2 +(Sm/SY)2 =1
(Sa/Se) 2 =1- (Sm/SY)2 = 1 1/36 = 35/36
Sa = 35/36 x Se = 0.986 Se = 0.986 x 240 = 236.64 MPa
Pa = 71 N
Check for Langer condition: Sa + Sm = 236.64 + 60 = 296.64 < 360 = SY.
Safe.
Using SU:
(Sa/Se) 2 +(Sm/SU)2 =1
(Sa/Se) 2 =1- (Sm/SU)2 = 1 9/400 = 391/400
Sa = 391/400x Se = 0.988686 Se
= 0.988686 x 240 = 237.28 MPa
Pa = 71.185 N
Check for Langer condition: Sa + Sm = 237.28 + 60 = 297.28 < 360 = SY.
Safe.

Example 2: A steel cantilever horizontal beam 750 mm long, 100 mm

wide and 200 mm deep is subjected to an end down ward fluctuating
load, varying from a minimum value of Pmin = 180000 N to a
maximum value Pmax. The material has a fatigue strength = 210
MPa at a given number of cycles and a yield strength = 240 MPa.
Determine Pmax that will cause fatigue failure, according to
Soderberg relation at the same number of cycles.
Solution:
Smin = Pmin x L x c/ I =180000 x 750 x 100 x12 /(100 x 2003)
= 202.5 MPa
Sa = (Smax Smin)/2 and Sm = (Smax + Smin)/2
Soderberg relation is
(Sa)/Se + (Sm)/SY =1
Therefore
(Smax Smin)/2Se + (Smax + Smin)/2SY =1

12

(Smax Smin) + (Smax + Smin)(Se/SY)= 2Se

Let p = Se/SY Therefore,
(Smax Smin) + (Smax + Smin)p = 2Se
Smax (1+p) Smin(1 p) = 2Se
Smax = 2Se/(1+p) Smin(1 p)/ (1+p)
Now p = Se/SY = 210/240 = 7/8 = 0.875 Therefore,
Smax = 2 x 210/1.875 202.5 x 0.125/1.875 =210.5 MPa
Smin: Pmin = Smax: Pmax
Pmax = (210.5 /202.5) 1800000 = 1871111 N
Check for Langer condition: Smax = 210.5 < 240 = SY. Safe.
Example 3: A member of circular cross section of 50 mm diameter is
subjected to an axial static tensile load Pm = 80,000 N, through the
center. A completely reversed axial load Pa is applied at a distant 10 mm
from the centroid of the cross section. The fatigue strength of the
material Se for completely reversed stress at N = 106 cycles is 210 MPa,
the static tensile yield strength is 240 MPa and the ultimate strength is
270 MPa. What could be the minimum value of Pa, that would cause
fatigue failure at N = 106 cycles, for Soderberg, Modified Goodman,
Gerber and Elliptic relations?
Solution:
The eccentric load would be equivalent to a force and a moment at the
center.
(Note, there is a drastic mistake in Marins example, pp 195/196, in not
considering the force)
The uniformly distributed Sa1 = Pa/A = Pa x 4/ 502 = 0.00051Pa MPa .
The bending moment due to eccentric load
M = Pa x e
The bending stress at extreme fiber
Sa2 = (Pa x e) x c/I = Pa x 10 x 25 x 64/(504)
= 0.000815Pa MPa
Sa = Sa1 + Sa2 = (0.000510+0.000815) =0.001325Pa MPa (at the
extreme fiber)
Pa = Sa/0.001325 N
Sm = Pm/A = Pm x 4/ (502)
= 0.00051 Pm = 0.00051 x 80000 = 40.8 MPa
Sm/ SY = 40.8/240 = 0.17;
Sm/Su = 40.8/270 =0.151111

13

Soderberg:
Sa = Se (1-Sm/ SY) = 210 x (1 0.17) = 174.3 MPa
Pa = 174.3/0.001325 = 131320 N
Check for Langer condition: Sa + Sm = 174.3 + 40.8 = 215.1 < 240 = SY.
Safe
Modified Goodman
Sa = Se (1-Sm/ Su) = 210 x (1 0.151111) = 178.3 MPa
Pa = 178.3/0.001325 = 134541 N
Check for Langer condition: Sa + Sm = 178.3 + 40.8 = 219.1 < 240 = SY.
Safe
Gerber:
Using SU:
Sa = Se [1-(Sm/ SU)2]= 210 x [1 (0.1511)2] = 205.2 MPa
Pa = 205.2/0.001325 = 155164 N
Check for Langer condition: Sa + Sm = 205.2 +40.8 = 246 > 240 = SY.
Not safe.
Therefore the maximum Sa could be only (240 40.8) =199.2 MPa..
Pa = 150340 N
[Using SY:
Sa = Se [1-(Sm/ SY)2]= 210 x [1 (0.17)2] = 204 MPa
Pa = 204/0.001325 = 153910 N
Check for Langer condition: Sa + Sm = 204 +40.8 = 244.8 > 240 = SY.
Not safe.
Therefore the maximum Sa could be only (240 40.8) =199.2 MPa..
Pa = 150340 N]
Elliptic:
Using SU:
Sa =Se [1-(Sm/ SU)2]= 210 x [1 (0.1511)2] =207.5886 MPa
Pa = 207.5886/0.001325 = 156671 N
Check for Langer condition: Sa + Sm = 207.59 +40.8 = 248.39> 240 = SY
Not safe
Therefore the maximum Sa could be only (240 40.8) =199.2 MPa..
Pa = 150340 N

14

[Using SY:
Sa =Se [1-(Sm/ SY)2]= 210 x [1 (0.17)2] =207 MPa
Pa = 207/0.001325 = 156184 N
Check for Langer condition: Sa + Sm = 207 +40.8 = 247.8 > 240 = SY
Not safe
Therefore the maximum Sa could be only (240 40.8) =199.2 MPa..
Pa = 150340 N]

Example 4: (Important):
The fatigue property of the material of certain part was fitted for N(in
number of cycles) and S (in MPa) to be
N (S/600)6 = 30 x 103
The over- and under-stressing exponent d = 2. The yield strength
of the material is 600 MPa. There is a mean stress Sm = 100 MPa. The
part was subjected to a set of stress amplitudes and the corresponding
cycles in the following order.
n = 104
104
105 Cycles Run
Sa = 400
450
300
MPa
a) Find the life expended so far.
b) If it is required to run the part at Sa = 450 MPa, find the possible
number of cycles for which it could be run further.
c) In stead, if the part has to be run for104 cycles, what stress
amplitude Sa can be applied further?.
Solution:
Calculate first the values of Se equivalents for the 3 loadings.
Recall Soderberg relation
(Sa/Se) + (Sm/SY) =1
From this
Se = Sa /(1 - Sm/SY)
= Sa/(1 - 100/600) =6/5 Sa = 1.2 Sa
For this Se, calculate the corresponding N from N(Se/600)6 = 30 x 103
and tabulate.
n = 104
104
105 Cycles Run
Sa = 400
450
300
MPa
Se = 480
540
420
Mpa
5
5
5
N= 1.1444 x 10
0.5645 x 10
2.55 x 10 Full-Life Cycles

15

Using over/under-stressing effect expression (8) with reference to stress

amplitude S1 = 480 MPa,
a) Ls = (104 /1.1444 x 105)(480/480)2
+ (104 / 0.5645 x 105)(540/480)2
+ ( 105 / 2.55 x 105)(420/480)2
= (1/ 11.444) + (1.265625/ 5.645) +( 0.5625/2.55)
= 0.532173
Remaining life LR = 1 0.5321730 = 0.467827
b) For Sa = 450 MPa, Se = 1.2 Sa = 540 and N = 0.5645 x 105.
Over-stressing factor = (540/480)2 = 1.265625.
LR = 0.4678 = (n / 0.5645 x 105) (540/480)2
= (n / 0.5645 x 105) (1.265625)
n = 0.4678 x 0.5645 x 105 /1.265625 = 2.0865 x104 cycles
c) For 104 cycles,
LR = 0.4678 = (n / N) (Se/480)2
Now n = 104 cycles; Se is unknown and N is also not known as long as S
is unknown. But N can be found in terms of Se from S-N relation.
N (Se/600)6 = 30 x 103.
Then
1/N = (Se/600)6 /30 x 103
Therefore
LR = 0.4678 =104 (Se/480)2 (Se/600)6 /30 x 103
= 104 (Se)8/(4802 x 6006 x 30 x 103)
= (Se)8/322.48626x 1020
Se8 = 0.4678 x 322.48626 x 1020 = 1508591 x 1016
Se = 592 Mpa
Sa = Se/1.2 = 493 Mpa
Check for Langer: Smax = Sa + Sm = 493+100 = 593 < Sy = 600 MPa
Just safe!
ADDITIONAL IMPORTANT EXAMPLES in FATIGUE -I
Example 5 (important)
The material has an S-N relation for completely reversed fatigue life
N(S/600)10 = 105

(A)

16

The material has been subjected to a mean stress of 100 MPa and to a
fatigue loading scheme in the following order:
S1 = 400 MPa for n1 = 2 x 105 cycles
S2 = 300 MPa for n2 = 106 cycles
The over/under stressing the exponent d = 3. Determine using Soderberg
relation and a yield stress of 600 MPa
a) the remaining life
b) the number of cycles n3 that can be run further at S3 = 350 MPa
c) the amplitude S4 that can be applied for n4 = 18 x 105 cycles, in
the remaining life as found in (a)
Solution
Sa/Se + Sm/SY = 1
(B)
a) For Sa = S1 and S2, find the corresponding values of Se.
Se1 = Sa1/ (1 - Sm/SY) = 400/(1- 100/600)) = 400x6/5 = 480 MPa
Se2 = Sa2/ (1 - Sm/SY) = 300/(1- 100/600)) = 300x6/5 = 360 MPa
Find the corresponding values of Ni for Se1 and Se2
N1 = 105/(480/600)10
N2 = 105/(360/600)10

= 9.31 x 105
= 165.38 x 105

Ls = n1/N1 (Se1/Se1)3 + n2/N2 (Se2/Se1)3

= (2 x 105/9.31 x 105 ) (480/480)3 + (106/165.38 x 105) (360/480)3
= 0.2148 + 0.0605x 0.42188 = 0.2403
LR = 1 0.2403 = 0.7597
b) Se3 = Sa3/ (1 - Sm/SY) = 350/(1- 100/600) = 350x6/5 = 420 MPa
N3 = 105/(Se3/600)10 = 105/(420/600)10= 35.4 x 105
LR = 0.7597 = n3/N3(Se3/Se1)3 = n3/N3(420/480)3 = 1.4927 n3/35.4 x 105
n3 = 0.7597 x 35.4 x 105 x0.66992 = 18 x 105 cycles
c) n4 is given as 18 x 105 cycles
LR = 0.7597 = n4/N4(Se4/Se1)3
N4(Se4/480)3 = 18 x 105 /0.7597 = 23.6935 x 105
Eliminating N4 using (A)

17

23.6935 x 105 =105 x (Se4/480)3 / (Se4/600)10

= 105 x (Se4)-7 x (600)10 /(480)3
23.69 x 105 x (Se4)7 = 105 x(600)10 /(480)3
(Se4)7 = (600)10 /(480)3 /23.69 = 1014 (6)10 /(4.8)3 /23.69
= 1014 (6)7 ( 6/4.8)3 /23.69
(Se4) = 420 MPa
Using (B)
(Sa) = 420 x5/6 = 350 MPa
Note: Since questions (b) and (c) have Sa and n interchanged,
coincidently, the results reflect that. It is also incidentally a verification of
the method used.
Example 6 (More important model)
A material has an S-N relation for completely reversed fatigue life
N(S/600)10 = 105
The material has been subjected to the following loading scheme already:
S1 = 300 MPa for n1 = 2 x 107 cycles
S2 = 400 MPa for n2 = 106 cycles
Determine for a severity index exponent d = 0.5,
a) the remaining life
b)the number of cycles n3 that can be run further at S3 = 350 MPa
c) the number of cycles n4 that can be run further at the completely
reversed Sa
= S4 = 350 MPa along with a steady mean stress Sm =
100 MPa, if the yield strength SY is 600 MPa and the Soderberg
relation is applied.
d) the value of Sm, if it is to be run along with a completely reversed
Sa = S5 =
350 MPa for n5 = 18 x105 cycles.
Solution
a) N1 = 105/ (300/600)10 = 10.24x107
N2 = 105/ (400/600)10 = 57.665x105
Ls = n1/N1 (S1/S1)0.5 + n2/N2 (S2/S1)0.5
= (2 x 107 / 10.24x107) (S1/S1)0.5 + (106 /57.665x105 ) (400/300)0.5
= 0.1953125 + 0.2002429 = 0.39555538
18

LR = 1 Ls = 0.60444462
b) S3 = 350 MPa ; N3 = (600/350)10 x 105 = 219.2 x 105
LR = 0.60444462 = (n3/219.2 x 105)(350/300) 0.5
n3 = 0.60444462 x (219.2 x 105)/ (350/300) 0.5
= 122.666 x 105 cycles
c) Given Sm = 100 MPa and Sa = 350 MPa. n4 = ?
Se4 = Sa4 /(1 Sm/SY) = 350/ (1 100/600) = 350 x 6 /5 = 420 MPa
N4 = = (600/420)10 x 105 = 35.4 x 105
n4 = 0.60444462 x (35.4 x 105)/ (420/300) 0.5
= 18.084 x 105 cycles
d) Given Sa5 = 350 MPa and n5 = 18 x 105 cycles. Sm = ?
LR = 0.60444462 = ( n5/N5)(Se5/Se1)0.5
Let Se5 be unknown for an unknown Sm.
They are related by Soderberg relation
Sa/Se + Sm/SY =1
(1 Sm/SY) = Sa/Se
(1 Sm/600) = 350/ Se5
Sm = (1 - 350/ Se5) 600

(A)
(B)
(C)

Go to
LR = 0.60444462 = (18 x 105/N5)(Se5/300)0.5
N5 = 18.084 x 105 x (Se5/300)0.5/0.60444462 = 30 x 105 x (Se5) 0.5/(300)0.5
Recall
N5(Se5/600)10 = 105
Substituting for N5
[30 x 105 x (Se5) 0.5/(300)0.5] (Se5/600)10 =105
Simplifying
(Se5)10.5 = 60010 3000.5/30
Se5 = 60010/10.5 3000.5/10.5/301/10.5 = 442.4442 x 1.312 /1.3825 = 419.88
420 MPa
Now from (C) & substituting for Se5
Sm = (1 - Sa/Se)SY = 600 x (1 350/420) = 100 MPa
(It tallies with (c))

19

PROBLEMS in UNIAXIAL FATIGUE

Completely reversed stress:
1. A connecting rod of square cross section 25mm by 25 mm is
subjected to a completely reversed bending moment M and
completely reversed axial load of 44,000 N. The fatigue strength of
the material at N = 105 cycles is 330 MPa. Assume that the
maximum stresses occur at the same instant of time. Determine the
bending moment M that will produce fracture of the rod at 105
cycles.
2. A circular rod of diameter of 50 mm is subjected to a completely
reversed longitudinal load P at a distance of 10 mm from the center
of the cross section. The uniaxial fatigue strength of the material
for complete stress reversal at N = 106 cycles is 420 MPa.
Determine P required to cause failure in N = 106 cycles.
3. A steel cantilever beam with across section 25 mm wide and 75
mm deep is 1200 mm is subjected to a completely reversed load of
amplitude P. The fatigue strength of the material at N = 104 cycles.
What is the value of P that will cause failure in N = 104 cycles.
Over/under stressing Effect:
4. An SAE-40 heat-treated steel is to be used for a member, which is
subjected to varying stress amplitudes. The S-N curve for this
material is approximately represented by
S6.4N = 7006.4 x 31000
For a overstressing exponent d = 6.0, determine the remaining life
of this member in terms of the number of cycles ni for a stress 650 MPa,
if the member has been subjected earlier to the following spectrum:
Stress MPa / Number of cycles:800/10000, 700/20000, 600/30000 and
500/50000
5. In Problem 4, if ni is given as 10000, find the stress that can be
applied in this remaining life.
Effect of Mean Stress:

20

6. A steel rod 40 mm in diameter is subjected to a fluctuating axial

load varying from a maximum value of Pmax to a minimum value
Pmin = 88,000 N. The steel used has a tensile yield strength of 700
MPa, an ultimate strength of 800 MPa, and a fatigue strength Se
for completely reversed stress at N = 106 cycles of 400 MPa.
Determine the value of Pmax for fracture at N = 106 cycles, using
the following relations: a) Soderberg, b) Modified Goodman, c)
Gerber and d) Elliptic.
7. A cantilever beam of 3000 mm long with a section modulus Z = I/c
= 656500 mm3 is subjected to an end fluctuating load varying from
zero to P. For the material used SY =630 MPa, Su = 840 MPa and
Se = 420 MPa for N = 105 cycles. Determine the failure load P at N
= 105 cycles based on the Soderberg, Modified Goodman, Gerber
and Elliptical relations.
8. A connecting rod of circular cross section with a diameter of 50
mm is subjected to an eccentric longitudinal load at a distance 10
mm from the center of the cross section. The load varies from P/2
to P. The material used has strength properties of SY = 300 MPa, Su
= 400 MPa and Se = 240 MPa (at N = 105 cycles). Determine P
based on all the 4 relations.
Effect of both Mean Stress and Over/under stressing together:
9. The fatigue property of the material of certain part was fitted for
N(in number
of cycles) and S (in MPa) to be
N (S/600)6 = 30 x 103
The over- and under-stressing exponent d = 3. The yield strength
of the material is 600 MPa. There is a mean stress Sm = 100 MPa. The
part was further subjected to a set of stress amplitudes and the
corresponding cycles in the following order.
n = 104
Sa = 400

104
350

105
300

Cycles Run
MPa

Using Soderberg relation

a) Find the life expended so far..
b) If it is required to run the part at Sa = 300 MPa, find the possible
number of cycles for which it could be run further.
c) In stead, if the part has to be run for104 cycles, what stress amplitude
Sa can be applied further?.

21

10. Solve the problem in Example 1, with a mean load, P = 54 x 104 N.

Check for Langer condition.
( Ans: S & M.G: OK; G: just OK; E: does not)
Workout seriously the problems to score any marks. Dont put aside
for tomorrow, that never comes.

22