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Dynamic Loading
MI-212
Introduction to Fatigue in Metals
Static conditions : loads are applied gradually, to give sufficient time
for the strain to fully develop.
Since these failures are due to stresses repeating for a large number of
times, they are called fatigue failures.
When machine parts fails statically, the usually develop a very large
deflection, thus visible warning can be observed in advance; a fatigue
failure gives no warning!
Fatigue Failure in Metals
A fatigue failure arises from three stages
of development:
Stage I : initiation of micro-cracks due to cyclic
plastic deformation (these cracks are not
usually visible to the naked eyes).
Stage II : propagation of micro-cracks to initiation
macro-cracks forming parallel plateau like
fracture surfaces separated by longitudinal
propagation
ridges (in the form of dark and light bands
referred to as beach marks).
fracture
Stage III : fracture when the remaining
material cannot support the loads.
Fracture Patterns of Fatigue
Failure
Fatigue Life Methods in Fatigue
Failure Analysis
Let N be the number of cycles to fatigue for a specified level of
loading
For 1≤ N ≤ 103, generally classified as low-cycle fatigue
Three major fatigue life methods used in design and analysis are
1. stress-life method : is based on stress only, least accurate especially
for low-cycle fatigue; however, it is the most traditional and easiest to
implement for a wide range of applications.
2. strain-life method : involves more detailed analysis, especially good
for low-cycle fatigue; however, idealizations in the methods make it
less practical when uncertainties are present.
3. linear-elastic fracture mechanics method : assumes a crack is
already present. Practical with computer codes in predicting in crack
growth with respect to stress intensity factor
Characterizing Fluctuating
Stresses
Fluctuating stresses often of
sinusoidal patters due to the
nature of some rotating
machinery.
𝜎𝑓′ 𝑖𝑠 𝑡ℎ𝑒 𝑓𝑎𝑡𝑖𝑔𝑢𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑓𝑜𝑟 𝑚𝑜𝑠𝑡 𝑚𝑒𝑡𝑎𝑙𝑠, 𝑡𝑟𝑢𝑒 𝑓𝑟𝑎𝑐𝑡𝑢𝑟𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
b= fatigue strength coefficient or Basquin’s exponent (≈ -0.05 to -0.12)
2𝑁𝑓 𝑖𝑠 𝑡ℎ𝑒 𝑛𝑢𝑚𝑒𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑣𝑒𝑟𝑠𝑎𝑙𝑠 𝑡𝑜 𝑓𝑎𝑖𝑙𝑢𝑟𝑒.
Fatigue Life
The Strain-Life Method
Stress life approach is applicable to elastic limit or high cycle loading.
Situation involving high stress, high temperature or stress
concentration, where significant plasticity is involved.
∆𝜖𝑝
Loading is characterised by the plastic strain amplitude 2
.
𝜖𝑝
Plot between log vs. log 2𝑁𝑓 𝑦𝑖𝑒𝑙𝑑𝑠 𝑎 𝑙𝑖𝑛𝑒𝑎𝑟 𝑏𝑒ℎ𝑎𝑣𝑖𝑜𝑢𝑟, which can be
2
∆𝜀𝑝
𝑖𝑠 𝑡ℎ𝑒 𝑝𝑙𝑎𝑠𝑡𝑖𝑐 𝑠𝑡𝑟𝑎𝑖𝑛 𝑎𝑚𝑝𝑙𝑖𝑡𝑢𝑑𝑒
2
𝜀𝑓′ fatigue ductility coefficient ≈ 𝜀𝑓
C is fatigue ductility exponent (-0.5 to -0.7 for many metals.
Stress/ Strain Life Method
∆𝜀𝑝
Coffin Manson expression is used to express 2
If the stresses are low enough that the strain are elastic, the lifetime is
likely to be long.
Transition State:
The transition life (2Nt) is found by setting the plastic strain amplitude
control performance.
performance.
Here, 2Nfi are number of cycles to failure at σai, d is the partial damage.
𝑛𝑖
=1
𝑁𝑓𝑖
𝑖
a
Sy Yield line
Gerber curve
Se
Alternating
stress Goodman line
Sy Sut m
Soderberg line
Mean stress
The Effect of Mean Stress on Fatigue Life
Modified Goodman Diagram
a
Sy Yield line
Se
Alternating
stress Goodman line
C
Safe zone
Sy Sut m
Mean stress
The Effect of Mean Stress on Fatigue
Life Modified Goodman Diagram
a
Sy Yield line
Se
Goodman line
C
Safe zone Safe zone
- m - Syc Sy Sut + m
Fatigue Failure Criteria for
Fluctuating Stresses
Updated Equations
Linear-Elastic Fracture Mechanics
Method
Fatigue cracking consists
three stages
material constants
number of cycles
Endurance Limit for Steels
For steels, the endurance limit
relates directly to the minimum
tensile strength as observed in
experimental measurements.
where
– = surface condition modification factor
– = size modification factor
– = load modification factor
– = temperature modification factor
– = reliability factor
– = miscellaneous-effects modification factor
– = rotary-beam test specimen endurance limit
Surface and Loading Factors
Surface Factor : the surface modification factor depends on the quality
of the finish of the actual part surface and on the tensile strength of the
part material. It can be calculated as