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Final rupture occurs over a limited area C, characterizing a very small load required to cause it
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Crack initiation locations and propagation directions under various kinds of loading conditions
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FATIGUE FAILURE OF A PIN HAVING GREASE HOLES WITH ASYMMETRY RESULTING IN STRESS CONCENTRATION
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Fatigue failure of a steam engine connecting rod due to PURE TENSION load.
No surface crack. Crack may initiate anywhere that is the weakest or unknown source of weakness.
The crack propagated radially outward until some time after which the sudden rupture occurred.
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In this rod, the crack initiated due to forging flake slightly below the centre line.
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Fatigue life methods Fatigue strength and endurance limit Endurance limit modifying factors Stress concentration and notch sensitivity Fluctuating stresses Combination of loading modes Variable, fluctuating stresses, cumulative fatigue damage
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Fatigue Life Methods: Objective is to predict the failure in number of cycles N to failure for a specific type of loading
Low cycle fatigue (LCF) : 1 N 103 ; High cycle fatigue (HCF) : N > 103
Stress life methods Based on stress levels only Least accurate of the three, particularly for LCF It is the most traditional because easiest to implement for a wide range of applications Has ample supporting data Represents high cycle fatigue adequately Strain life methods Involves more detailed analysis of plastic deformation at localized regions Good for LCF Some uncertainties may exist in results because several idealizations get compounded Hence normally not used in regular practice but only for completeness and special occasions Linear elastic fracture mechanics methods (LEFM) Assumes that crack is already present and detected The crack location is them employed to predict crack growth and sudden rupture with respect to the stress nature and intensity Most practical when applied to large structures in conjunction with computer codes and periodic inspection
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Stress Life Method: Determination of the strength of materials under action of fatigue loads
R. R. Moore high-speed rotating beam machine. Pure bending by means of weights and no transverse shear. The specimen shown is very carefully machined and polished with a final polishing in the axial direction to void circumferential scratches. Number of revolutions of the specimen required for failure are recorded. Next, the test is repeated for a lower load, and so on. The results are plotted in the S-N diagram, which is either semi-log or log-log.
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M b = Fx F ( x a )
M b = Fx Fx + Fa = Fa
SFD
Mb BMD
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The S-N Diagram for steel (UNS G41300), normalized, Sut=812 MPa.
Endurance Limit, It is the stress at which the component can sustain infinite number of cycles
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For non-ferrous metals and alloys, as can be seen here, the S-N diagram never becomes horizontal and hence they do not have endurance limit. Hence, a stress at a specific number of cycles, normally at 5*108 cycles, must be used as fatigue strength
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Endurance limit:
for for
S e' = Endurance limit obtained in reverse bending S e = Endurance limit in the actual loading conditions
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S e = k a kb k c k d k e S
k a = aS
b ut
' e
Size factor, kb
kb = size modifying factor For rotating circular CS bars in bending and torsion only : (d / 7.62 )0.107 = 1.24d 0.107 if 2.79 d 51 mm kb = if 51 d 254 mm 0.859 0.000837d For axial loading no size effect, kb = 1.
What about bars that are : 1) Non - rotating circular, rectangular, I - section, channel section etc.?
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[ d 4
2 e
A0.95 = 0.01046d 2 K (2), for non - rotating circular CS bars Equation (1) and (2) d e = 0.37 d
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[ d 4
2 e
A0.95 = 0.05hb K (2), for non - rotating rectangular CS bars Equating (1) and (2) d e = 0.808 hb
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[ d 4
2 e
[ d 4
2 e
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Stress concentration
The single most influential factor leading to high possibility of crack initiation Stress concentration can be due to Function of geometry (sudden change in size/diameter; holes in the structure etc. and surface texture (surface presence of disintegrations etc.)
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finish,
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What is Kt?
Kt=Theoretical stress concentration factor
Maximum stress Kt = Nominal stress
P Nominal stress = (w d )t max = K t nom K t = Determined through experiments or numerical simulation such as FEM
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w d
What is Kt?:
Kt =
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K f = 1 + q(K t 1) q = notch sensitivity value (0~1) K t = Theoretical stress concentration factor (or geometric factor, from tables)
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How to estimate Kf
Kf = 1+q(Kt -1). When q=0, the material has no sensitivity to notches, and hence Kf=1. When q=1, or when notch radius is large for which q is almost equal to 1, the material has full notch sensitivity, and hence Kf = Kt.. Remember, Kt Kf and hence more conservative design results. In most practical cases the notch sensitivity is partial rendering 0<q<1. Hence use Kf = 1+q(Kt -1). For all grades of cast iron, use q=0.20. Use the different graphs as given to obtain q for bending/axial and torsional loading.
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How to estimate Kf
Contd.
Whenever the graphs do not give values of q for certain combinations of data, use either Neuber equation or Heywood equation.
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How to estimate Kf
Contd.
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How to estimate Kf
Contd.
Use Heywood equation when the notch is NOT circular/cylindrical but is a tranverse hole or shoulder or groove.
Kt Kf = 2(K t 1) a 1+ Kt r where a values are given in the Table 7 - 8 in Shigley's book. r = hole size/shoulder size/groove size
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How to apply Kf
If there is no notch, there is also no notch sensitivity, q=0, and Kf=1. Hence m= m0 and a= a0. In other words no stress concentration needs to be applied. When there is notch, 0<q<1, Kf>1, and:
If localized plastic strain at the notch is to be avoided, then apply Kf to both mean and range stresses. m= Kf m0 and a= Kf a0. If localized plastic strain is not a concern or can not be avoided by incorporating Kf, then apply Kf only to the range stress. m= m0 and a= Kf a0.
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max + min
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Reversed (completely reversed) mean stress is zero; equal reversals on both sides Repeated minimum stress is zero; mean stress equal to the range stress Fluctuating maximum, minimum and mean stress are all non-zero and arbitrary Alternating minimum stress is zero; mean stress is always compressive and is equal in magnitude to range stress
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Fluctuating loading
The mean load is not zero The actual loading may not readily be given by a mathematical function but needs to be approximated More critical and realistic than completely reversed loading
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Fig. 7.27
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n a n m + = 1 K Gerber line S e S ut n a n m = 1 K ASME Elliptic line + S S e yt a m 1 + = K Langer line (only for checking S yt S yt n for static yielding)
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min R= max
a A= m
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Different types of cyclic loads may be applied in combination, for example, bending, axial and torsional on machine componens When the loads and in-phase, the maximum values of loads occurs at the same time and so are the minimum values. Hence in such cases, we can estimate the maximum and minimum von-Mises stress values and then estimate the mean and range von-Mises stresses. Then fatigue criterion may be applied. Use kc =1 and Kf for each stress component separately by multiplying with Kf in combined loading situation.
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ni N =c i where ni is the number of cycles applied at stress level i N i is the number of cycle to failure at stress level i
0.7 < c < 2.2
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