ADDIS ABABA SCIENCE AND TECHNOLOGY UNIVERSITY
COLLEGE OF ENGINEERING
DEPARTMENT OF ELECTRO - MECHANICAL ENGINEERING
Design of Machine Elements I
Chapter-3
Design For Fatigue Loads
By: Nebyat Y.
Contents
3.1 Introduction
3.2 Stress Concentration Factors, Reduction
3.3 Fluctuating Stresses
3.4 Fatigue Failure
3.5 Endurance Strength and Notch Sensitivity
3.6 Design for Finite and Infinite Life
3.7 Soderberg, Goodman and Gerber Theories
3.8 Modified Goodman Diagram
3.9 Fatigue design under Combined Stresses
Introduction
Ship Break
Introduction
Fatigue loading is the changes observed in a material under the
influence of stress generated during cyclic loading.
This is generally represented by plotting a stress cycle curve (S-N
curve), where S represents stress and N represents the number of
cycles to failure.
There is progressive and localized structural damage when fatigue
loading occurs, and if the local stresses are high enough leads to the
initiation of a crack, the growth of the crack and finally fracture.
Fatigue Failure
Fatigue loading causes fatigue failure, which occurs in three stages:
•Crack initiation
•Slow, stable crack growth
•Rapid fracture
The majority of engineering failures are caused by fatigue.
The greatest concern in circuit boards, engines and many industrial
applications is thermal fatigue.
Thermal fatigue can arise from thermal stresses produced by cyclic
changes in temperature
A load cycle is defined as the duration from one peak in the studied
variable to the next peak.
In a general case, all cycles do not have the same amplitude.
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Types of fatigue loading
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2. Fluctuating stress:
2. Repeated stress cycles
3. Irregular or random stress cycle:
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The stresses which vary from one value of compressive to the same value of
tensile or vice versa, are known as completely reversed or cyclic stresses.
Notes: 1. The stresses which vary from a minimum value to a maximum value
of the same nature, (i.e. tensile or compressive) are called fluctuating stresses.
2. The stresses which vary from zero to a certain maximum value are called
repeated stresses.
3. The stresses which vary from a minimum value to a maximum value of the
opposite nature (i.e. from a certain minimum compressive to a certain maximum
tensile or from a minimum tensile to a maximum compressive) are called
alternating stresses.
It has been found experimentally that when a material is subjected to repeated
stresses, it fails at stresses below the yield point stresses. Such type of failure of
a material is known as fatigue.
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Composite materials
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Irregular or random stress cycle:
This type of fatigue loading where a member could be
subjected to irregular loads just as in the case of an
aircraft wing subjected to wind loads.
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Factors affecting fatigue Stress:
1) Effect of stress concentration
2) Size effect:
3) Surface Roughness:
4) Surface Residual Stress:
5) Effect of temperature:
6) Effect of metallurgical variables;
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It may be noted that the term endurance limit is used for reversed
bending only while for other types of loading, the term endurance
strength may be used when referring the fatigue strength of the material.
It may be defined as the safe maximum stress which can be applied to
the machine part working under actual conditions.
The stress verses time diagram for fluctuating stress having values
min and max is shown in Fig. (e).
The variable stress, in general, may be considered as a combination of
steady (or mean or average) stress and a completely reversed stress
component v. The following relations are derived from Fig. (e):
Stress Concentration Factors, Reduction
The theoretical or form stress concentration factor is defined as the
ratio of the maximum stress in a member (at a notch or a fillet) to the
nominal stress at the same section based upon net area.
Mathematically, theoretical or form stress concentration factor,
The value of Kt depends upon the material and geometry of the part.
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When using this rule for ductile materials with static loads, be careful to
assure yourself that the material is not susceptible to brittle fracture in
the environment of use.
The usual definition of geometric (theoretical) stress-concentration
factor for normal stress Kt and shear stress Kts is given by as
σmax = Ktσnom (a)
τmax = Ktsτnom
Notch Sensitivity
Fatigue Strength Diagram
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Fatigue design under Combined Stresses
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