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UNIT-2: Chapter-5
Introduction
5.1 Design for Fluctuating Loads
5.2 Estimated Endurance Limit , Se
5.3 Endurance Limit for Axial loading
5.4 Endurance Strength of Machine Components
Example (5.1, 5.2)
5.5 Theoretical Fatigue Stress Concentration factor Kt
5.6 Notch Sensitivity Factor, q
5.7 Miscellaneous factors Ke
5.8 Methods of Reducing Stress Concentration
5.9 Failure points under fluctuating and pulsating stresses
5.10 Soderberg and Goodman lines (for axial and bending stresses)
5.11 Gerber Curve
5.12 Fluctuating Torsional Shear Stresses
5.13 Fatigue Design Under Fluctuating Combined Stresses
5.14 Combined Loading due to Rotating Shaft Subjected to
Constant Torque and Stationary Bending Load
Example (5.3, 5.4, 5.5, 5.6)
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UNIT-2: Chapter-5
Design for Fluctuating Loads
5.1 A large number of mechanical components are subjected to
loads that are not static but fluctuating or cyclic. Even a static
load causes cyclic stresses in a rotating shaft. As such we shall
discuss design of mechanical elements subjected to fluctuating
cyclic stresses.
Ultimate and yield strengths were used in the design under static
loads. In the case of fluctuating loads, in addition to ultimate and
yields strengths, we shall need the strength of materials under
fluctuating stresses. It is called fatigue strength of a material
which is much lower than ultimate or yield strength.
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Fig. 5.1
Fig. 5.2
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Fig. 5.3
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Stress-time relations
Fig. 5.4
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Fig. 5.5
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Fig. 5.6
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Fig. 5.7
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For Steels,
Se = 0.5 Sut Sut 1400 MPa
Se = 700 MPa Sut > 1400 MPa (5.5)
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Fig. 5.7
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UNIT-1: Chapter-5
Se = Ka Kb Kc Kd Ke Se (5.12)
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Fig. 5.8
The surface finish factors in the figure are based on large number of
experiments on wrought steels and are not applicable to other ductile
materials like aluminum.
Cast iron is generally not used for machine components under fluctuating
loads; but if needed ka may be used as 1 because even the mirror finished.
Cast-iron specimen will have graphite flakes and other discontinuities.
Ka = 1 for cast iron (5.13)
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d 7.5 1.00
7.5 <d 50 0.85
d > 50 0.75
For axial loading 1.00
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UNIT-2: Chapter-5
Reliability Factor Kc
The published fatigue strength data has a scatter, and the SN curve is plotted
through the mean of the scatter points. It means that the endurance limit has
a reliability of 50%, i.e., 50-percent components may fail earlier than the one
million stress cyber. The standard deviation of the data points for steels is
limited to 8% of the mean value. Using this value of standard deviation,
reliability factor Kc for a desired reliably is calculated below:
Table 5.2 Values of Reliability Factor
Reliability R (%) Kc
50 1.000
90 0.897
95 0.868
99 0.814
99.9 0.753
99.99 0.702
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UNIT-2: Chapter-5
Example 5.1
A 20-mm bar is made of 45C8 steel (Su = 630, Sy = 380 MPa) is subjected to a completely
reversed bending stress.
Estimate the following:
(a) Endurance Limit of 45C8 steel
(b) Endurance strength of polished 20-mm bar
(c) Endurance Strength of machined 45C8 steel bar of 20-mm dia with 99% reliability
(d) Fatigue strength of machined 45C8 steel 20-mm dia bar with 99% reliability for a life of
80,000 cycles
Solution
Given 20-mm bar of 45C8, Su = 630 MPa and Sy = 380 MPa
Loaded by completely reversed bending stress
Assumptions
- Actual fatigue data not known for the material
- Endurance limit to be estimated
- S-N curve to be constructed
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Analysis
Estimated endurance limit Se = 0.5 Sut from Equation 5.5 for steels
Size factor Kb = 0.85 (Table 5.1)
(a) Se = 315 MPa for polished 7.5 mm bar
(b) Se = Ka Kb Kc Kd Ke Se for Polished 20-mm bar:
Se = (1) (0.85) (1) (1) (1) (315) = 267.8 MPa
(c) Se for machined, 99% rel., 20-mm
Ka = Surface finish factor = 0.77
Kc = 0.814 (99% Rel)
Se = (0.77) (0.85) (0.814) (1) (1) (315) = 167.8 MPa
(d) Fatigue strength for 80,000 cycles: for the given bar, Se = 167.8 MPa (Point B)
log10 (Se) = log10 (167.8) = 2.225, Point B is (6, 2.225)
Fatigue st. at. 103 cycles, A
log10 (0.9 x 630) = 2.754, Point A is (3, 2.754)
log10 80,000 = 4.903
2.754 2.225
tan = = 0.1763, AC = (CD) (tan ) = (4.903 3) (0.1767) = 0.3355
3
log DE = 2.7540 0.3355 = 2.4185, DE = 262 MPa
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Fatigue strength of machined 45C8 bar of 20-mm dia for 80,000 cycles at 99% reliability is 262
Mpa.
Comment: If the design of bar is critical, an experiment should be conducted, because the
calculated fatigue strength is an estimate only.
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Example 5.2
A 20-mm bar is made of 45C8 steel (Su = 630, Sy = 380 MPa) is subjected to a
completely reversed tensile stress.
Estimate the following:
(a) Endurance Limit of 45C8 steel in tension
(b) Endurance strength of polished 20-mm bar
(c) Endurance Strength of machined 45C8 steel bar of 20-mm dia with 99%
reliability
(d) Fatigue strength of machined 45C8 steel 20-mm dia bar with 99% reliability
for a life of 80,000 cycles
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Kt = (5.14)
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Fig. 5.10
Fig. 5.9
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Fig. 5.11
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Fig. 5.14
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Fig. 5.15
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Fig. 5.16
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Fig. 5.17
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Fig. 5.18
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Fig. 5.19
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Fig. 5.20
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Fig. 5.21
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Modified Goodman line: Also shows the yield line for a ductile material.
It is drawn joining the Syt points on both axes. It is also called the limit of first
cycle stress, because if a part yields, it has failed and there would be no
safety in fatigue. Modified Goodman diagram is defined by two straight lines-
Goodman line from Se to the point of intersection with the yield line, there
after it follows the yield line
Fig. 5.22
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2
Gerber failure curve: ( ) + =1 (5.25)
2
Gerber design curve: ( ) + =1 (5.26)
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1
2 = [( )2 + ( )2 + ( )2 + 6 (xy2 + yz2 + zx2)] (a)
2
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1
2 = 2 [(1 2 )2 + (2 3 )2 + (2 3 )2 ] (b)
Goodman diagrams maybe used with equation (5.31) and (5.32) for design
purpose.
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(5.35)
= [ xa2 + 3a2 ].5
Soderberg or Goodman diagrams may now be used for design of
shafts in such cases.
Fig. 5.25
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Example 5.3
A 25-mm shaft is made of 30C8, Su = 500 MPa steel and is subjected to reversed
bending. There is a step in the shaft and the theoretical stress concentration at
the step is 2.1. The notch sensitivity factor is 0.84. Determine the endurance limit
of the shaft for a 50 percent reliability if the shaft is forged.
Solutions
Assumptions
As actual fatigue data is not known, Se of the material to be estimated
Se = 0.5, Sut = 0.5 (500) = 250 MPa
Analysis
Se = Ka Kb Kc Kd Ke Se
Ka = surface finish factor
Kb = size factor
Kc = reliability factor
Kd = 1 / stress conc. factor = 1 /Kf
Ke = Misc. factors
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Example 5.4
A circular rod made of ductile material has endurance strength of 280 N/mm2 and ultimate
strength of 350 N/mm2. The member is subjected to a variable axial load varying from + 70
kN (tensile) to 300 kN (Compressive). Take fatigue stress concentration factor as 1.8 and
factor of safety as 2.0. Find a suitable diameter of the rod. (UPTU/2005-06)
Solutions
Given: Rod of ductile material Se = 280 MPa, Sut = 350 MPa, Axial Load varying + 70 kN to
300 ka, fs = 2.0, Kf = 1.8
Assumption:
- Equation for Goodman line will be used because Se and Sut are given
- Ka = Surface finish factor = 0.85 assumed
for Su = 350, machines
To find dia d.
Analysis:
1
+ =
Se = 280 MPa, Kf = 1.8, fs = 2.0
Su = 350 MPa
Se = Ka Kb Kc Kd Ke Se
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1 185
= = /2
2
1
+ =
115 185
= 2000 + = 3456 2
350 132.2
d = 66.3 mm
Comment: Ductile material as such Sue was assumed to be equal to Sut.
Dia d = 68 mm is suggested.
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Example 5.5
A bar of steel has an ultimate tensile strength of 700 MPa, a yield point stress
of 400 MPa and fully corrected endurance limit (Se) of 220 MPa. The bar is
subjected to a mean bending stress of 60 MPa and a stress amplitude of 80
MPa. Superimposed on it is a mean torsional stress and torsional stress
amplitude of 70 and 35 MPa respectively. Find the factor of safety.
Solutions
Given Data:
Sut = 700 MPa
Syt = 400 MPa
(Se)rod = 220 MPa Torsional stress
= 60
= 80
= 70
= 35
Bending stress
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Assumptions:
The stress cycles have the same frequency and are in phase.
The design is fatigue under fluctuating combined two dimensional stress
system.
Using Distortion energy theory.
Analysis:
2
1
= ( )2 + ( )2 + ( )2 6( + + )
2
, = 0, = = , , = 0
1
2 = 2 2 + 6 2
2
= 2 + 3 2
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1 1
2 2 2
= [ + 3 ] ; = [2 +3 2 2
]
1 135.2 100
= + = +
() 700 220
fs = 1.54
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Example 5.6
A rotating shaft of 38-mm is made of forged 40C8 steel (Sut = 550 MPa, Syt = 400
MPa). The shaft is stepped down to 32-mm, diameter and is subjected to a
bending moment (maximum 150 N-m, minimum 50 N-m) at the step. Determine
factor of safety for 99% reliability and machined surface finish. Fillet radius at the
step = 2 mm.
Solutions
Given: Material
40C8
Sut = 550 MPa
Syt = 400 MPa
Mmax = 150 N.m
MMin = 50 N.m
Assumptions: the frequency of variation of moment is equal to the speed of shaft
Analysis:
150 + 50
= = 100 1000 .
2
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150 50
= = 50 1000 .
2
3
D/d = 38 /32 = 1.19 = = 3217 3
32
r/d = 2 /32 = 0.0625
q = 0.75 (Fig. 5.13)
Kt = 1.9 (Fig. 510)
Kf = 1 + q (Kt 1) = 1.675
Surface finish factor Ka = 0.78 (Fig. 5.8, Sut = 550, machined
Size factor Kb = 0.85(Table 5.1)
Reliability factor Kc = 0.814 (Table 5.2)
Modifying factor Kd = 1/Kf = 1/1.675 = 0.597
Misc. factor Ke = 1
Se = Ka Kb Kc Kd Se
= (0.78) (0.85) (0.814) (0.597) (550/2)
= 88.6 N/mm2
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100 103
= = = 31.08 /2
3217
50 103
= = = 15.54
3217
Using Soderberg
1 31.08 15.54
= +
400 88.6
fs = 3.95
Comment:
Se has been estimated as Sut /2. However, a factor of safety of the order of 4
is quite acceptable.
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