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Razali Hassan
Razali Hassan
Razali Hassan
Razali Hassan
Stage 3: Final
catastrophic failure
Remaining area
(ligament) cannot
sustain loading
anymore.
Unstable (significant)
crack propagation and
rapid failure.
Fracture when the
remaining material
cannot support the
loads.
Razali Hassan
2.
3.
diagram.
limit, denoted as
Assuming a crack is
discovered early in stage II,
the crack growth can be
approximated by the Paris
equation as KI is the
variation in stress intensity
factor due to fluctuating
stresses.
The bar shown in Fig. 616 is subjected to a repeated moment 0 M 1200 lbf
.in. The bar is AISI 4430 steel with Sut = 185 kpsi, Sy = 170 kpsi, and KIc = 73
kpsiin. Material tests on various specimens of this material with identical heat
treatment indicate worst-case constants of C = 3.8(10-11)(in/cycle)/(kpsiin)m
and m = 3.0. As shown, a nick of size 0.004 in has been discovered on the
bottom of the bar. Estimate the number of cycles of life remaining.
m = 3.0.
1. Find the stress range , it is always computed by using the nominal (uncracked) area. Thus
I bh 2 0.25(0.5) 2
0.01042in 3
c
6
6
Therefore, before the crack initiates, the stress range is
M
1200
which is below the yield strength. As the crack grows, it will eventually become
long enough such that the bar will completely yield or undergo a brittle fracture.
For the ratio of Sy/Sut it is highly unlikely that the bar will reach complete yield.
For brittle fracture, designate the crack length as af . If = 1, then from Eq. (5
37) with KI = KIc, we approximate af as
1 K Ic
a f
max
1 73
0.1278in
115.2
af
h
0.1278
0.256
0.5
1
73
0.112in
1
.
07
(
115
.
2
)
0.112
1
da
1
da
Nf
(1.07(115.2) a )3
C ai ( a ) m 3.8(1011) 0.004
0.112
5.047(103 )
Nf
64.7(103 )cycles
a
0.004
Low-cycle fatigue considers the range from N=1 to about 1000 cycles.
In this region, the fatigue strength Sf is only slightly smaller than the tensile
strength Sut .
High-cycle fatigue domain extends from 10 to the endurance limit life (10
to 10 cycles).
Experience has shown that high-cycle fatigue data are rectified by a
logarithmic transform to both stress and cycles-to-failure.
(S 'f ) N 'F (2 N )b
then
'F
Sut
(2.103 )b
ut
log( 2 N e )
The endurance limit of the rotating-beam specimen might differ from the
actual application due to the following differences from laboratory tests.
Material : composition, basis of failure, variability
Manufacturing : method, heat treatment, fretting corrosion, surface
condition, stress concentration
Environment : corrosion, temperature, stress state, relaxation times.
Linear elastic fracture mechanics (LEFM) is the basic theory of fracture, that
deals with sharp cracks in elastic bodies. It is applicable to any materials as
long as the material is elastic except in a vanishingly small region at the
crack tip (assumption of small scale yielding), brittle or quasibrittle fracture,
stable or unstable crack growth
Elastic-plastic fracture mechanics is the theory of ductile fracture, usually
characterized by stable crack growth (ductile metals) the fracture process is
accompanied by formation of large plastic zone at the crack tip
propagation initiates.