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Haigh diagram I

a = FL m = 0 a = FLP
time
Surface roughness

m = FLP
Size of raw material

a Y FL FLP FLP
Solid Mechanics

Plastic deformations

a Y FL FLP

Loaded volume

Y UTS

Haigh diagram

Reduced Haigh diagram

FLP Y UTS
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Haigh diagram II
SFa = SFm = Kf = 1 + q( Kt 1) Kf Kt ( K t m , Kf a )
P

AA' AP OB' OA

m = const a = const
Kf a = const Kt m
C

SFam

OC' = OP
A

Y
Solid Mechanics

m UTS

Service stress
High Cycle Fatigue (HCF) part II

A B Safety factors
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Modern Fatigue Design

Background Evolution in structural design due to increased computational power CAD/CAE - software Need for new fatigue design methods that are valid for a general type of loading easy to implement in a computer code Several options, but no method with general validity HCF: equivalent stress is defined and compared to a fatigue limit (expressed in the equivalent stress) LCF : calculation of damage connected to the constitutive model of the material. Fatigue damage connected to the plastic deformation LEFM : effective stress intensity range
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Multiaxial high cycle fatigue initiation

Problem: The Haigh diagram is valid for Uniaxial loading One stress component Solution: Assume that, in the general case, fatigue behaviour is influenced by Applied shear stress amplitude Hydrostatic stress Based on these assumptions, derive a fatigue initiation criterion that defines a limiting stress magnitude for which fatigue cracks will develop) for a general type of loading. Assumes undamaged material (continuum mechanics)
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Hydrostatic stress
The hydrostatic stress is the mean value of normal stresses acting on the material point (positive in tension) A tensile (positive) hydrostatic stress opens up microscopic cracks ( Stage II crack growth)

1 h = x +y +z 3

The hydrostatic stress is a stress invariant

regardless of coordinate system

Solid Mechanics

11 12 13 ij = 21 22 23 31 32 33 1 1 h = ii = ( 11 + 22 + 33 ) 3 3

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Shear stress measures

The shear stress initiates slip bands which leads to microscopic cracks (stage I crack growth) Since a static shear stress have no influence on the fatigue damage, the shear stress amplitude is employed Two measures Tresca shear stress

Tresca vM

1 3 = 2

von Mises stress

1 = 2

(1 2 )2 + ( 2 3 )2 + ( 3 1 )2

We need to define the amplitudes of these

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Equivalent Stress Measures

a Y FL
FATIGUE
Service stress
Shear stress amplitude

Plastic zone FATIGUE

e3 c3

FLP
Plastic zone

Stresses during one load cycle

e3

NO FATIGUE

NO FATIGUE
e3

NO FATIGUE
Uniaxial Case One stress component

m UTS

FATIGUE

Plastic zone
Multiaxial Case Six stress components (general case) Hydrostatic stress and shear stress amplitude are taken to reflect the fatigue properties The stresses during a load cycles are defined by a closed curve
Anders Ekberg

Mid value and amplitude of this stress component are taken to reflect the fatigue properties The stresses during a load cycles are defined by a service stress
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Shear Stress Amplitude

General It has been found empirically that a superposed static shear stress does not have any influence on the fatigue initiation FL = FLP whereas FL FLP In order to eliminate the influence of a superposed shear stress, the shear stress amplitude is normally used in multiaxial HCF-criteria This amplitude is the difference between the current shear stress magnitude and the mid value of the shear stress for the current stress cycle For the general case, this amplitude is rather complicated to compute (see Fatigue a Survey , Appendix I)
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Shear stress Uniaxial case

Mohrs stress circle for loading in a uniaxial case

max
x

2 = 0 1 = max
time
45

max

max

2 = 0 1 = max

2 = 0

1 = max

45

45

Max normal and shear stress correspond to the same directions throughout the load cycle

P
time

max
time

max

mid
time
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The deviatoric stress tensor

The stress tensor

xx ij = yz zx xx ij = yz zx

xy xz yy yz zy zz

Split into volumetric and a deviatoric part

xy xz xy xz 1 0 0 xx h yy yz = h 0 1 0 + yz yy h yz zy zz zy zz h 0 0 1 zx

= h I + d
The volumetric part contains the hydrostatic stress The deviatoric part reflects influence of shear stresses
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Mid value of the deviatoric stress tensor

ij = aij + cij f (t ) aij and cij are constants f (t ) is a common time dependent function
Fixed principal directions Every component of corresponds to a fixed direction throughout the loading
d d d d xx (t ) xy (t ) xz (t ) 1 (t ) 0 0 d d d d d ij (t ) = yx (t ) yy (t ) yz (t ) = 0 2 (t ) 0 d d ( t ) d ( t ) d ( t ) 0 0 3 ( t ) zy zz zx d a11 0 d = 0 a22 0 0 d 0 0 c11 d 0 + 0 c22 d 0 a33 0

In-phase

f (t ) d c33 0 0
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Movie 1 Click me!

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Mid value of the deviatoric stress tensor III

Limitations In-phase loading
stress time

In in-phase loading , the stresscomponents have their max- and min-magnitudes at the same instant in time In out-of-phase loading, maxand min magnitudes occur at different instants of time for different stress components

stress time

The case of out-of-phase loading is much more difficult to analyse, for instance due to difficulties in Defining a stress cycle Defining a mid value of the shear stress
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Mid value of the deviatoric stress tensor IV

Limitations Fixed principal directions Rotating principal directions
d 1 d " ij ,p " = 0 0

0 d 1 0

0 0 d 3

corresponds to a rotating coordinate system Instead we have to look at the full deviatoric stress tensor and find its mid value
d ij ,m

( xx h ) ( xy ) ( xz ) d = m = ( yz ) ( yy h ) ( yz ) ( zy ) ( zz h ) ( zx ) m
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Mid value of the deviatoric stress tensor V

Finding the mid value in a general case Click me!

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Amplitude of the deviatoric stress tensor

The mid value of the deviatoric stress tensor is found as
d ij ,m d 1 0 0 m d = d = 0 0 m 1m (proportional loading) d 0 0 3m

(m denotes mid-value of component during stress cycle) or as

d ij ,m

( xx h ) ( xy ) ( xz ) d = m = ( yz ) ( yy h ) ( yz ) (general) ( zy ) ( zz h ) ( zx ) m

the amplitude of the deviatoric stress tensor is defined as

d d d d d d ij ( t = ( t (or ( t = ( t ) ) ) ) ,a ij ij ,m a m)
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Amplitude of the deviatoric stress tensor II

For in-phase loading with fixed principal directions (proportional loading), we can express the amplitude of the Tresca and von Mises stress using the amplitude of the deviatoric stress tensor
d d (t ) 3,a (t ) 1,a d d d Tresca,a (t ) = where ( 1,a (t ) = 1 (t ) 1,m etc ) 2 2 2 2 1 vM,a (t ) = ( t ) ( t ) + ( t ) ( t ) + ( t ) ( t ) ( ( ( 1,a 2,a ) 2,a 3,a ) 3,a 1,a ) 2 d (it can be shown that using a or a gives the same results) The max values are given as

Tresca,a vM,a =
Solid Mechanics

d d d d 3,a 1,a 1,min d = = 1,max where ( 1,a ) 2 2

1 2

(1,a 2,a ) + ( 2,a 3,a ) + ( 3,a 1,a )

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Equivalent stress criteria

Sines criterion

EQS

1 = 2 1 = 2

d 1 ,a

d 2 2,a

) +(
2

d 2 ,a

d 2 3,a

) +(
2

d 3 ,a

d 2 1,a

+ cS h,mid > eS

Crossland criterion

EQC

(1,a 2,a ) + ( 2,a 3,a ) + ( 3,a 1,a )

1,a 3,a = + cDV h,max > eDV 2

+ cC h,max > eC

Dang van criterion

EQDV

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Concluding remarks
Fatigue analysis Calculate the state of stress Apply the equivalent stress criterion, fatigue if

eq > e
In the case of no fatigue, calculate safety coefficient as

SF =
Pros

EQ
Cons
Corrosion correction etc. Lack of empirical knowledge Separates between fatigue / no fatigue

Suitable for computer analysis General state of stress Identify critical parts of component Have a physical basis
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Lunc
Solid Mechanics

h
Anders Ekberg

High Cycle Fatigue (HCF) part II