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Fig. Torsional Shear Stress

Torsional shear stress in circular bars can be calculated using equations that relate shear stress to applied torque. Fatigue failure can occur in machine elements subjected to fluctuating stresses, even below the yield point, due to a large number of stress cycles. The fatigue strength of a material depends on factors like stress range, surface finish, and stress concentrations from notches or fillets. Stress concentration factors are used to account for localized high stresses in fatigue life calculations.

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84 views51 pages

Fig. Torsional Shear Stress

Torsional shear stress in circular bars can be calculated using equations that relate shear stress to applied torque. Fatigue failure can occur in machine elements subjected to fluctuating stresses, even below the yield point, due to a large number of stress cycles. The fatigue strength of a material depends on factors like stress range, surface finish, and stress concentrations from notches or fillets. Stress concentration factors are used to account for localized high stresses in fatigue life calculations.

Uploaded by

krish
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Torsional shear stress

Fig. Torsional shear stress


(1)

From equation (1)

(2)
(3)

(4)

where

The relation (1) may be written as

Equations (2) – (5)


From equation (1)

(5)

Equations (2) (3) and (5) are based upon the following assumptions
Fig. Rectangular bar under torsion

Rectangular bar- sockets for drilling, boring or tightening


(6)

(7)
Stresses developed in a rotating shaft subjected to a bending load
 Conditions often arise in machines and mechanisms when stresses
fluctuate between a upper and a lower limit. For example in Fig.

Fig. Stresses developed in a rotating shaft subjected to a bending load.

 The fiber on the surface of a rotating shaft subjected to a bending load,


undergoes both tension and compression for each revolution of the shaft
 Any fiber on the shaft is therefore subjected to fluctuating stresses.
 Machine elements subjected to fluctuating stresses usually fail at stress
levels much below their ultimate strength and in many cases below the
yield point of the material too.
***Ultimate strength - the maximum tensile stress that a material can withstand before rupture
*** yield point - stress beyond which a material deforms by a relatively large amount for a small increase in the stretching force.
 These failures occur due to very large number of stress cycle and are
known as fatigue failure.
 These failures usually begin with a small crack which may develop at the
points of discontinuity, an existing subsurface crack or surface faults.
 Once a crack is developed it propagates with the increase in stress cycle
finally leading to failure of the component by fracture

Fatigue is a phenomenon where structures fail when subjected to a cyclic load.


There are mainly two characteristics of this kind of failures:
(a) Progressive development of crack.

(b) Sudden fracture without any warning since yielding is practically absent.

Fatigue failures are influenced by


(i) Nature and magnitude of the stress cycle.

(ii) Endurance limit.

(iii) Stress concentration.

(iv) Surface characteristics.

These factors are therefore interdependent.

For example, by grinding and polishing, case hardening or coating a surface,

the endurance limit may be improved.

** Endurance limit - s the stress level below which an infinite number of loading cycles can be applied to a material without causing fatigue failure. 
Stress cycle
A typical stress cycle is shown in Fig. where the maximum, minimum, mean and
variable stresses are indicated.
The mean and variable stresses are given by

Fig. A typical stress cycle showing maximum, mean and variable stresses
Endurance limit

Fig. shows the rotating beam arrangement along


with the specimen.

Fig . A typical rotating beam arrangement


The loading is such that there is a constant bending moment over the specimen
length and the bending stress is greatest at the center where the section is
smallest.
The arrangement gives pure bending and avoids transverse shear since bending
moment is constant over the length

Large number of tests with varying bending loads are carried out to find the number of
cycles to fail
A typical plot of reversed stress (S) against
number of cycles to fail (N) is shown in Fig.
 The zone below 103 cycles is considered as low cycle
fatigue,
 zone between 103 and 106 cycles is high cycle fatigue with
finite life
 Beyond 106 cycles, the zone is considered to be high cycle
fatigue with infinite life.
 The above test is for reversed bending. Tests for reversed axial,
torsional or combined stresses are also carried out.
 For aerospace applications and non-metals axial fatigue testing is
preferred.
 For non-ferrous metals there is no knee in the curve as shown in
Fig. indicating that there is no specified transition from finite to
infinite life.

Fig. A schematic plot of reversed stress (S) against number of cycles to fail (N) for non-metals,
showing the absence of a knee in the plot.
• The endurance limits are obtained from standard rotating
beam experiments carried out under certain specific
conditions.

• They need be corrected using a number of factors. In general


the modified endurance limit σe’ is given by
C1 is the size factor and the values may roughly be taken as

For large size C1 = 0.6.


Then data applies mainly to cylindrical steel parts. Some authors consider ‘d’ to
represent the section depths for non-circular parts in bending.
 C3 is the surface factor and since the rotating beam specimen is given a
mirror polish the factor is used to suit the condition of a machine part.
 Since machining process rolling and forging contribute to the surface quality
the plots of C3 versus tensile strength or Brinnel hardness number for
different production process, in Fig, is useful in selecting the value of C3.
Fig. Variation of surface factor with tensile strength and Brinnel hardness
for steels with different surface conditions
Stress concentration
 Stress concentration is defined as the localization of high stresses due to irregularities or abrupt

changes in the cross section.

 However, it is important to realize that stress concentration affects the fatigue strength of

machine parts severely and therefore it is extremely important that this effect be considered in

designing machine parts subjected to fatigue loading.

 This is done by using fatigue stress concentration factor defined as


Theoretical stress concentration factor Kt
The theoretical stress concentration factor is defined as the ratio of maximum stress in
a member (at notch or fillet) to the nominal stress at the same section based upon net
area.

Kt = Maximum stress / nominal stress


The value of the Kt depends upon the material and geometry of the part

*** Nominal stress : Stress calculated on the basis of the net cross section of a
specimen without taking into account the effect of geometric discontinuities 
Notch sensitivity factor q
Notch sensitivity factor q is given by the ratio of increase in actual stress over
nominal stress with increase in theoretical stress over nominal stress. These
increase in stresses are due to stress concentration

The value of q is different for different materials and this normally lies
between 0 to 0.7.

The index is small for ductile materials and it increases as the ductility
decreases.

Notch sensitivities of some common materials are given in table


1. A rectangular stepped steel bar is shown in Fig. The bar is loaded in bending.
Determine the fatigue stress-concentration factor if ultimate stress of the materials is
689 MPa.

From the geometry r/d = 0.125 and D/d = 1.25.


Fig. Variation of notch sensitivity with notch radius for steel and aluminium alloy with different ultimate tensile
strengths
• From the stress concentration chart
• Stress- concentration factor Kt ≈ 1.7
• From figure-
• Notch sensitivity index, q ≈ 0.88
• The fatigue stress concentration factor K is now given by
f

• Kf = 1+q (Kt -1) =1.616

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