Fatigue Analysis

Endurance Strength
Fatigue failure occurs when a machine element is subjected to fluctuating load. The
inherent strength of the material weaken at every cycle until eventually the structure is
overcome by the applied cyclic load.

To determine the strength of material under fatigue loading, specimens are subjected to
repeated loading of specified magnitude and counted to destruction. The most widely
used is the R. R. Moore machine fatigue test.

Above: Moores' Fatigue Test machine

Endurance Limit

Se' = 0.5Sut if Sut 1400MPa (See Eqn 6-8 pg 274)

NB: Endurance limits found only in steel and titanium

Endurance Limit Modifying Factors Pg 278

b
Surface factor, ka = a Sut

0.265
Eg: If surface is machined: ka = 4.51Sut

0.107
Size factor for round kb = 1.24d if 2.79 d 51mm
and rotating shaft,
0.157
kb = 1.51d if 51 < d 254mm

Load factor, kc = 1 ==> bending load

kc = 1 0.85 (for bending and axial load combined)

Temperature factor, kd , Reliability factor, ke , Misc factor, kf = 1

Endurance Limits, Se = ka kb kc kd ke kf Se'

Repeated and Reversed

max - maximum stress acting on the specimen

min - minimum stress acting on the specimen

max - maximum shear stress acting on the specimen

min - minimum shear stress acting on the specimen

Kf - stress concentration factor

max + min
mean stress acting on the specimen m = Kf
2
max min
alternating stress acting on the specimen a = Kf
2
 STRESS CONCENTRATION
Kt theoritical stress concentration factor Pg 105 See Table A-15 to A-16

Kf 1
q= notch sensitivities. (concentration factor are less severe for some materials).
Kt 1
See Fig 6-20, 6-21 and eqn. 6-32 & 6-33. For Cast Iron: q = 0.2

( )
Kf = 1 + q Kt 1 actual stress concentration factor (reduced value of Kt due to
different material type ie different notch sensitivities)

t = Kf n SC stress (at Stress Concentration region)

Sample Problem 1

Given : P = 15kN
2
Cross section area : An = ( 25mm) ( 25mm) = 625 mm
P 6
Normal stress (without notch) , n = = 24 10 Pa
An

Stress concentration occurs at notch : See pg 1003 Fig A-13-3 :

r 2.5mm w 30mm
= = 0.1 = = 1.2 Kt = 2.38
d 25mm d 25mm

Sut = 400MPa rf = 2mm q = 0.73

(
Kf = 1 + q Kt 1 = 2.007)
2
Cross section area at notch region : At = ( 25mm) ( 25mm 5mm) = 500 mm
P
Actual stress at notch : t = Kf = 60.27 MPa
At
 Fatigue Failure Criterion

a m 1
Langer's eqn (for early cycle yielding) : + = [6-48]
Sy Sy

a m 1
Modified Goodman equation: + = [6-45]
Se Sut

2
a m
Gerber equation: + =1 [6-46]
Se S
ut
a m 1
Soderberg equation: + = [6-44]
Se Sy

If = 1.0 then the stress ( m , a) lies on the Langer line or the other fatigue curves.
Any points lower than the curves are safe i.e. > 1.0.

To ensure the materials do not yield at the first cycle loading, the Langer's equation must
be applied against both stresses m , a . If the material is considered safe by Langer,
further analysis must done using any of the Fatigue equations as can be explained by the
figure below. The Soderberg lines is an exception to the above because it does need to
be accompanied by Langer's test.
Fatigue Strength @ Finite Life Pg 276

b
Method 1: To find the finite life, we need the equation Sf = a Nx

Total numer. of cycles, Nx < 1000000

If Sut < 490MPa then f = 0.9

If 490 Sut 1400MPa get f from Fig 6-18 pg 277

(f Sut)2 1 f Sut
a= b = log
Se 3 S e
1
b
a
if m = 0 then Nx =
a

If m 0 then do the following steps:

a m
Apply modified Goodman equation: + =1 to get Sf
Sf Sut
1
b
b Sf
Use the equation derived from Sf = a Nx that is, Nx =
a
Stress Concentration Factor at Finite Life

( ) ( )
K3 = 1 Kf 1 0.18 0.43 10 Sut + 0.45 10
2 (
5 )
Sut
2

1 Kf
2
K3 log
3 K3
KN = Nx
Kf

From the figure above, when the mean stress is compressive, failure occurs when a = Se
In a complete setup, the figure below shows the safe area for Goodman Fatigue life.