Design Stress and Fatigue

Design Stress & Fatigue
MET 210W
E. Evans
Parts Fail When?
Crack initiation site
This crack in the part is very small.

If the level of stress in the part is
SMALL, the crack will remain stable
and not expand. If the level of stress
in the part is HIGH enough, the
crack will get bigger (propagate)
and the part will eventually fail.
Design Factor
Analysis
Failure Strength
Factor of Safety
Applied Stress
Example :
Sy
Design
Failure Strength
Allowable Stress
Design Factor
Example :
ALLOW
Sy
N
Factors Effecting Design Factor
Application
Environment
Loads
Types of Stresses
Material
Confidence

Application
How many will be produced?
What manufacturing methods will

be used?
Environment
Loads
Types of Stresses
Material
Confidence
What are the consequences of

failure?
Danger to people
Cost
Size and weight important?
What is the life of the component?
Justify design expense?

Application
Environment
Loads
Types of Stresses
Material
Confidence
Temperature range.
Exposure to electrical voltage or
current.
Susceptible to corrosion
Is noise control important?
Is vibration control important?
Will the component be protected?
Guard
Housing

Application
Environment
Loads
Types of Stresses
Material
Confidence
Nature of the load considering all

modes of operation:
Startup, shutdown, normal
operation, any foreseeable
overloads
Load characteristic
Static, repeated & reversed,
fluctuating, shock or impact
Variations of loads over time.
Magnitudes
Maximum, minimum, mean

Application
Environment
Loads
Types of
Material
Confidence
What kind of stress?

Direct tension or compression
Direct shear
Bending
Stresses Torsional shear
Application
Uniaxial
Biaxial
Triaxial
Application
Environment
Loads
Types of Stresses
Material
Confidence
Material properties
Ultimate strength, yield strength,
endurance strength,
Ductility
Ductile:
Brittle:
%E 5%
%E < 5%
Ductile materials are preferred for

fatigue, shock or impact loads.
Application
Environment
Loads
Types of Stresses
Material
Confidence
Reliability of data for

Loads
Material properties
Stress calculations
How good is manufacturing
quality control
Will subsequent handling, use
and environmental conditions
affect the safety or life of the
component?
Design Factor
Adapted from R. B. Englund
Design Factor
Predictions of Failure
Static Loads
Brittle Materials:
Maximum Normal Stress
Modified Mohr
- Uniaxial
- Biaxial
Ductile Materials:
Yield Strength
Maximum Shear Strength
Distortion Energy
- Uniaxial
- Biaxial
- Biaxial or Triaxial
Predictions of Failure
Fluctuating Loads
Brittle Materials:
Not recommended
Ductile Materials:
Goodman
Gerber
Soderberg
Maximum Normal Stress

Uniaxial Static Loads on Brittle Material:
In tension:
Kt d = Sut / N
In compression:
Kt d = Suc / N
Modified Mohr
Biaxial Static Stress on Brittle Materials
45 Shear Diagonal
Sut
Suc
Sut
1
1, 2
Suc
Stress concentrations
applied to stresses before
making the circle
Often brittle materials have

much larger compressive
strength than tensile strength
Yield Strength Method

Uniaxial Static Stress on Ductile Materials
In tension:
d = Syt / N
In compression:
d = Syc / N
For most ductile materials, Syt = Syc
Maximum Shear Stress

Biaxial Static Stress on Ductile Materials
max d = Sys / N = 0.5(Sy )/ N

Ductile materials begin to yield when the maximum shear
stress in a load-carrying component exceeds that in a tensiletest specimen when yielding begins.
Somewhat conservative use Distortion
Energy for more precise failure estimate
Distortion Energy
Static
Biaxial or Triaxial Stress on Ductile Materials
Shear
Diagonal
Sy
Best predictor of failure for

ductile materials under static
loads or completely
reversed normal, shear or
combined stresses.
Sy
Sy
' 12 22 1 2
= von Mises stress
Sy
Distortion Energy
Failure:
> Sy
Design:
d = Sy/N
von Mises Stress

Alternate Form
' 2x 2y x y 3 2xy
For uniaxial stress when y = 0,
Triaxial Distortion Energy
'
2
' 3
2
x
2
xy
(1 > 2 > 3)
( 2 1 ) 2 ( 3 1 ) 2 ( 3 2 ) 2
Fluctuating Stress
Varying stress with a nonzero mean.
alternating = a
Stress
max
max min
mean
2
max min
a
2
Stress Ratio,
mean
min
min
R
max
Time
-1 R 1
Fluctuating Stress Example

Bending of Rocker Arm
Valve Open
Valve Spring Force
Valve Closed
Tension in Valve Stem

Valve Closed
RBE
2/1/91
Valve Spring Force
Valve
Open
Adapted from R. B. Englund
Fatigue Testing
Bending tests
Spinning bending elements most common
Constant stress cantilever beams
Top View
Front View
Fixed Support
Applied Deformation
Fully Reversed, R =
-1
Test Data
Stress, (ksi)
Fatigue Testing
Number of Cycles to Failure, N

Data from R. B. Englund, 2/5/93
Endurance Strength
The stress level that a material can survive
for a given number of load cycles.
For infinite number of cycles, the stress
level is called the endurance limit.
Estimate for Wrought Steel:
Endurance Strength = 0.50(Su)
Most nonferrous metals (aluminum) do not
have an endurance limit.
Typical S-N Curve
Estimated Sn of Various Materials
Actual Endurance Strength

Sn = Sn(Cm)(Cst)(CR)(CS)
Sn
= actual endurance strength (ESTIMATE)
Sn
= endurance strength from Fig. 5-8
Cm
= material factor (pg. 174)
Cst
= stress type:
1.0 for bending

0.8 for axial tension
0.577 for shear
CR
= reliability factor
CS
= size factor
Actual Sn Example
Find the endurance strength for the valve stem.
It is made of AISI 4340 OQT 900F.
From Fig. A4-5.
Su = 190 ksi
From Fig. 5-8.
Sn = 62 ksi
(machined)
62 ksi
Actual Sn Example Continued

Sn = Sn(Cm)(Cst)(CR)(CS)
= 62 ksi(1.0)(.8)(.81)(.94) = 37.8 ksi
Sn,Table 5-8
Wrought Steel
Axial Tension
Actual Sn
Estimate
Reliability, Table 5-1

Size Factor, Fig. 5-9
99% Probability
Sn is at or above the
Guessing: diameter .5
calculated value
Goodman Diagram
a
Sy
Yield Line
Sn
NO FATIGUE
FAILURE REGION
-Sy
FATIGUE
FAILURE REGION
Goodman Line
a m
1
Sn S u
Sy
Su
Goodman Diagram
Safe Stress Line
K t a
Sn
m 1
Su N
Sy
Yield Line
Sn
FATIGUE
FAILURE REGION
Goodman Line
a m
1
Sn S u
Sn/N
SAFE ZONE
-Sy
Su/N
Sy
Su
Safe Stress Line
Example: Problem 5-53.

Find a suitable titanium alloy. N = 3
1.5 mm Radius
30 mm
DIA
42 mm DIA
F varies from 20 to 30.3 kN

FORCE
MAX = 30.3
30.3 20
5.15 kN
2
30.3 20
mean
25.15 kN
2
alt
MIN = 20
TIME
Example: Problem 5-53 continued.

Find the mean stress:
25,150 N
m
35.6MPa
(30 mm )2
4
Find the alternating stress:

a
5,150 N
(30 mm )2
4
7.3MPa
Stress concentration from App. A15-1:

D 42 mm
1.4;
d 30 mm
r 1.5 mm
.05
d 30 mm
Kt 2.3
Example: Problem 5-53 continued.

Sn data not available for titanium so we will guess!
Assume Sn = Su/4 for extra safety factor.
TRY T2-65A, Su = 448 MPa, Sy = 379 MPa

K t a
Sn
m
1
Su
N
(Eqn 5-20)
2.3(7.3 MPa)
35.6 MPa 1
.297
.8(.86)( 448 MPa / 4) 448 MPa N
Size
1
N
3.36
Reliability 50%
Tension
.297
3.36 is good, need further information on Sn for titanium.
Example:
Find a suitable steel for N = 3 & 90% reliable.
3 mm Radius
50 mm DIA
30 mm
DIA
T varies from 848 N-m to 1272 N-m

TORQUE
MAX = 1272 N-m
1272 848
212 N m
2
1272 848
mean
1060 N m
2
alt
MIN = 848 N-m
TIME
T = 1060 212 N-m
Example: continued.
Stress concentration from App. A15-1:
D 50 mm
1.667;
d 30 mm
r
3 mm
.1 Kt 1.38
d 30 mm
Find the mean shear stress:

)
Tm 1060 N m(1000 mm
m
m
200MPa
Zp
(30 mm )3
16
Find the alternating shear stress:

Ta 212000 N mm
a
40MPa
3
Zp
5301 mm
Example: continued.
So, = 200 40 MPa. Guess a material.
TRY: AISI 1040 OQT 400F
Su = 779 MPa, Sy = 600 MPa, %E = 19%
Verify that max Sys:
Ductile
max = 200 + 40 = 240 MPa Sys 600/2 = 300MPa
Find the ultimate shear stress:

Sus = .75Su = .75(779 MPa) = 584 MPa
Example: continued.
Assume machined surface, Sn 295 MPa
Find actual endurance strength:
(Fig. 5-8)
Ssn
= Sn(Cm)(Cst)(CR)(CS)
= 295 MPa(1.0)(.577)(.9)(.86) = 132 MPa
Sn
Wrought steel
Shear Stress
Size 30 mm
90% Reliability
Example: continued.
Goodman:
K t a
Ssn
m
1
S su N
(Eqn. 5-28)
1.38( 40 MPa) 200 MPa 1
.7606
132 MPa
584 MPa N
1
N
1.31
.7606
No Good!!! We wanted N 3
Need a material with Su about 3 times bigger than this
guess or/and a better surface finish on the part.
Example: continued.
Guess another material.
TRY: AISI 1340 OQT 700F
Su = 1520 MPa, Sy = 1360 MPa, %E = 10%
Ductile
Find the ultimate shear stress:

Sus = .75Su = .75(779 MPa) = 584 MPa
Find actual endurance strength:

Ssn = Sn(Cm)(Cst)(CR)(CS)
= 610 MPa(1.0)(.577)(.9)(.86) = 272 MPa
Sn
shear
wrought
size
reliable
Example: continued.
Goodman:
K t a
Ssn
m
1
S su N
(Eqn. 5-28)
1.38( 40 MPa) 200 MPa

1
.378
272 MPa
1140 MPa N
1
N
2.64
.378
No Good!!! We wanted N 3
Decision Point:
Accept 2.64 as close enough to 3.0?
Go to polished surface?
Change dimensions? Material? (Cant do much better in
steel since Sn does not improve much for Su > 1500 MPa
Example: Combined Stress Fatigue
RBE
2/11/97
Example: Combined Stress Fatigue Contd

PIPE: TS4 x .237 WALL
MATERIAL: ASTM A242
Equivalent
Reversed,
Repeated
DEAD WEIGHT:
SIGN + ARM + POST = 1000#
(Compression)
45
Bending
RBE
2/11/97
Repeated one direction

Stress Analysis:
Dead Weight:
P
1000 #
315.5 psi
2
A 3.17 in
(Static)
Vertical from Wind:

P
200 #

63.09 psi
2
A 3.17 in
(Cyclic)
Bending:
M 500 # (60 in)

9345.8 psi
3
Z
3.21 in
(Static)

Stress Analysis:
Torsion:
T
200 # (100 in)
3115 .3 psi
3
ZP
2(3.21 in )
Stress Elements:
STATIC:
315.5 psi
(Cyclic)
(Viewed from +y)

CYCLIC:
9345.8 psi
z
x
z
x
63.09 psi Repeated

One Direction
= 3115.3 psi
Fully Reversed

Mean Stress:
Static
Repeated / 2
8998.8 psi
(CW)
TIME
Stress
9345.8
-315.5
-31.5
Alternating Stress:
m
MIN = -63.09 psi
max
max
(CW)
(0,-3115.3)
1
(-31.5,-3115.3)
max
8998.8 psi
4499.4 psi
2
max 3115 .34 psi

Determine Strength:
Try for N = 3 some uncertainty
Size Factor? OD = 4.50 in, Wall thickness = .237 in
ID = 4.50 2(.237) = 4.026 in
Max. stress at OD. The stress declines to 95% at
95% of the OD = .95(4.50) = 4.275 in. Therefore,
amount of steel at or above 95% stress is the same
as in 4.50 solid.
ASTM A242: Su = 70 ksi, Sy = 50 ksi, %E = 21%
t
3/4
Ductile

We must use Ssu and Ssn since this is a combined
stress situation. (Case I1, page 197)
Sus = .75Su = .75(70 ksi) = 52.5 ksi
Ssn = Sn(Cm)(Cst)(CR)(CS)
= 23 ksi(1.0)(.577)(.9)(.745) = 8.9 ksi
Hot Rolled
Surface
Wrought steel
Combined or Shear Stress
Size 4.50 dia

90% Reliability

Safe Line for Goodman Diagram:
a = Ssn / N = 8.9 ksi / 3 = 2.97 ksi
m = Ssu / N = 52.5 ksi / 3 = 17.5 ksi
Alternating Stress, a
K t a
Ssn
10
Ssn
N=1F
Not Fai
ai l
Ssn/N
N=3
Safe
5
mean = 4499.4
1
2.29
.426
Su
Ktalt
m
1
S su N
1.0(3115 .3 psi) 4499.4 psi 1
.426
8900 psi
52500 psi N
5
3115.3
10
15
Mean Stress, m
Su/N
20

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Design Stress & Fatigue

Parts Fail When?

Crack initiation site

This crack in the part is very small.

Factors Effecting Design Factor

Factors Effecting Design Factor

How many will be produced?

What manufacturing methods will

What are the consequences of

Factors Effecting Design Factor

Factors Effecting Design Factor

Nature of the load considering all

Factors Effecting Design Factor

What kind of stress?

Factors Effecting Design Factor

Ductile materials are preferred for

Factors Effecting Design Factor

Reliability of data for

Adapted from R. B. Englund

Maximum Normal Stress

Often brittle materials have

Yield Strength Method

Maximum Shear Stress

max d = Sys / N = 0.5(Sy )/ N

Biaxial or Triaxial Stress on Ductile Materials

Best predictor of failure for

von Mises Stress

Triaxial Distortion Energy

Fluctuating Stress Example

Valve Spring Force

Tension in Valve Stem

Valve Spring Force

Number of Cycles to Failure, N

Typical S-N Curve

Estimated Sn of Various Materials

Actual Endurance Strength

= actual endurance strength (ESTIMATE)

= endurance strength from Fig. 5-8

= material factor (pg. 174)

1.0 for bending

Actual Sn Example Continued

Reliability, Table 5-1

Safe Stress Line

Example: Problem 5-53.

F varies from 20 to 30.3 kN

Example: Problem 5-53 continued.

Find the alternating stress:

Stress concentration from App. A15-1:

Example: Problem 5-53 continued.

TRY T2-65A, Su = 448 MPa, Sy = 379 MPa

T varies from 848 N-m to 1272 N-m

MAX = 1272 N-m

T = 1060 212 N-m

Find the mean shear stress:

Find the alternating shear stress:

Verify that max Sys:

max = 200 + 40 = 240 MPa Sys 600/2 = 300MPa

Find the ultimate shear stress:

1.38( 40 MPa) 200 MPa 1