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L. Vergani
Fatigue of Materials
10%
15%
20%
static loading
10%
Fatigue of materials
Mechanical failures due to fatigue have been studied for more than
150 years. One early study was in 1828 by Albert in Germany.
Fatigue was studied in the mid-1800s by several researchers in
response to failures of components as railway axles, shaft, gears..
The fatigue failures are frequent also at present
Nucleation of a micro-crack
Nucleation of a micro-crack
In the most strained zones the material fails and microcracks nucleate. In the first stage these micro-cracks
propagate in the direction of the maximum tangential
stress (Stage I). They can be inter-granular or transgranular.
Propagation of a micro-crack
Propagation of a micro-crack
Variable loading
off-shore structure
airplane
10
With the aim to evaluate the effect of the fatigue the cyclic
loading could be schematized as:
Alternating stress
Mean stress
Amplitude ratio
a =
max min
med =
R=
min
max
max + min
2
11
Fatigue design
uni-axial loading
A. HCF (fatigue
strength, Haigh
diagram, Whler
curves).
High stress
amplutude
Low stress
amplutude
No cracks
D. Linear-elastic
farcture mechanics
(LEFM).
Large cracks
Fatigue design
12
High stress
amplitude
damage
Multiaxial Stress
9Environment
9Experience
Uniaxial Stress
No cracks
Low stress
amplitude
Large cracks
13
UTS
14
S-N curves
UTS
FA
15
Macchine di prova
16
17
18
d = 10 mm
Ra= 0.3m
Kt = 1
POLITECNICO DI MILANO
19
If multiple fatigue tests are run at one stress level, there is always
considerable statistical scatter in the fatigue life. If the statistical scatter in
cycles failure is considered a distribution as in figure is obtained.
20
Statistical analysis of fatigue data permits the average fatigue curves t.o
be established along with additional S-N curves for various probabilities
of failure
21
FA
3 2 + 2 3
=
5
2
failure
L. Vergani approccio SS-N
22
23
S-N Curves
107
Log 3
10
m=
Log FA
UTS
N=K
m
a
UTS
m
FA
103
107
24
With the aim to consider these effects the follwing parameters are
defined:
POLITECNICO DI MILANO
25
b3 pattern versus
ultimate strength
of materials
(1- lucidato; 2-rettificato
fine; 3-rettificato; 4,5tornito)
POLITECNICO DI MILANO
26
27
b2 pattern versus
the dimensions
POLITECNICO DI MILANO
28
Notch effect: the fatigue notch coefficient Kf is defined equal to the ratio
between the fatigue strength obtained by standard specimens and the
fatigue strength obtained by notched specimens
Kf depend on Kt by the notch sensivity q.
q=
K f 1
Kt 1
Bending and
axial fatigue
Torsion
fatigue
POLITECNICO DI MILANO
Notch sensitivity
29
q=
Peterson rule:
Neuber rule:
a
1+
r
q=
1+
0.8
0.6
0.4
0.2
800
1200
1600 Rm [MPa]
30
KtB=5
Mf1
Mf2
rA> rB
M fA = 2 M fB =
KtB
M fB
KtA
KfB> KfA
31
' FA( a , f ) =
FA( a , f )b2b3
Kf
FA
FA
POLITECNICO DI MILANO
32
Haigh diagram:
FA
Rm
POLITECNICO DI MILANO
33
Semplified diagram:
sn
Rc
FA
sn
sn
POLITECNICO DI MILANO
Rm
34
35
36
OPlim
1 =
OP
FAf
P'
lim
P'
A
R
res
med
AP' lim
2 =
AP'
37
38
If the service required life is lower than the life corresponding to the fatigue
limit (N=106107):
A semplified Whler
diagram is constructed
(F) value is determined
max
Rm
F
FAf
F> FAf
FAf
1
=105
Log N
7
POLITECNICO DI MILANO
39
Mf
Mf
D
d
M
M f = M o sin t
The shaft is loaded by a varaible bending moment
N=105
b2 b3
FAf
= FAf
b2 b3 Kf and matreial characteristics
K ff
are known
Finite life
40
Whler diagram
max
Rm
F
FAf
Log N
41
example
F0
L2
F0
L1
d
F0=10.000N
Example
42
stress:
60
50
med=-50MPa
a=60MPa
b2, b3, Kf, FA
Example
43
a
Haigh diagram
Rs
FAf
P
lim
P
60
med
Rs
a>0
Rs
-50
m<0
OPlim
OP
Rm
'
FA
b2b3
= FA
Kf
44
example
example
45
FAf
rot
P
lim
med
46
Example
Lomologazione del manubrio illustrato in figura richiede
che esso superi senza rompersi una prova di fatica dalla
durata di 5x105 cicli con una carico applicato F1, alternato
intorno al valor nullo, di 1 kN.
Si stimi se, assegnati il materiale e le dimensioni
geometriche, il manubrio superer la prova.
Dati
Mat.: 39NiCrMo3 (Rm=900 MPa, Rp0.2=650 MPa)
L=400 mm
a= 200 mm
L
F1
F1
A-A
F1
Di=20 mm
Kt=1.7
L. Vergani approccio SS-N
F1
POLITECNICO DI MILANO