Fatigue I

fatigue
L. Vergani
Fatigue of Materials
From latin fatigare.
Components of machines, vehicles and structures are frequently subjected to repeated loads (cyclic loads) and the resulting cyclic stresses can lead to microscopic damage. This damage can accumulate until it develops into a crack that leads the failure of the component, even at stresses well below the ultimate strength of materials. This process of accumulating damage is the FATIGUE.
Mechanical failure due to:

55% 10% 15% 20% 10% high cycle fatigue (HCF) low cycle fatigue (LCF) fatigue (RCF, CF, creep-fatigue,) static loading other kind of failure
L. Vergani - approccio SS-N
Fatigue of materials
Mechanical failures due to fatigue have been studied for more than 150 years. One early study was in 1828 by Albert in Germany. Fatigue was studied in the mid-1800s by several researchers in response to failures of components as railway axles, shaft, gears.. The fatigue failures are frequent also at present
Fatigue damage MECHANISMS
The damage is characterized by three steps:
Nucleation of the crack (from the surfaces or internal from existing defects) Propagation (short crack, long crack) Final failure
Nucleation of a micro-crack
The nucleation of a micro-crack is due to the plastic strain and the persistent slip band (PSB).
Nucleation of a micro-crack
In the most strained zones the material fails and microcracks nucleate. In the first stage these micro-cracks propagate in the direction of the maximum tangential stress (Stage I). They can be inter-granular or transgranular.
Da Suresh - Fatigue of Materials

Propagation of a micro-crack
During the Stage I the propagation of the micro-cracks is influenced by the microstructure of the material. When the dimensions of the micro-crack are increasing the friction between the crack faces is increasing too. The propagation of the cracks continues in a plane perpendicular to the applied load (Stage II), until the sudden failure.
Da Suresh - Fatigue of Materials
Propagation of a micro-crack
The fatigue propagation zone is fairly flat and marked by the beach marks. When the crack has reached a sufficient size a final failure occurs.
The final failure can be ductile (involving large deformation) or brittle (involving little deformation) depending on the material.
Description of a cyclic loading
Variable loading
off-shore structure
airplane
Da Broek - The Practical Use of Fracture Mechanics

Description of a cyclic loading
10
With the aim to evaluate the effect of the fatigue the cyclic loading could be schematized as: Alternating stress
a =
max min max + min

2 2
Mean stress
med =
R=
Amplitude ratio
min max
Fatigue design
uni-axial loading
11
A. HCF (fatigue strength, Haigh diagram, Whler curves). B. LCF (CoffinManson curves) C. Elasto-plastic fracture mechanics (EPFM) D. Linear-elastic farcture mechanics (LEFM).
High stress amplutude
Low stress amplutude
No cracks
Large cracks
Fatigue design
Amplitude of the loading cycles Complexity applied loadings Geometry and dimensions B Acceptability of the damage Environment Experience
Uniaxial Stress No cracks Low stress amplitude High stress amplitude Multiaxial Stress
12
Large cracks
A D
Fatigue characterization of materials Whler curves (S-N curves)

R=costant (very often =-1)
13
UTS
The diagram of curves S-N is a log-log diagram
S-N curves
14
UTS
We can enter in these curves by considering the life or by considering the stress amplitude
FA
Fatigue test machines
15
da Davoli, Vergani, Beretta, Guagliano, Baragetti Costruzione di macchine 1 McGraw-Hill
Rotating bending test machine scheme

Macchine di prova
16
Rotating bending test machines

Fatigue test machines Axial loading test machine
17
da Davoli, Vergani, Beretta, Guagliano, Baragetti Costruzione di macchine 1 McGraw-Hill

Fatigue characterization of materials
18
The tests to evaluate the fatigue strength of materials are carried out by using standard specimens (norma ISO 1143)
d = 10 mm Ra= 0.3m Kt = 1
FAf/Rm= 0.4 - 0.6 FAa/Rm= 0.3 - 0.45 FAt/Rm= 0.23 - 0.33

L. Vergani approccio SS-N
POLITECNICO DI MILANO
19
If multiple fatigue tests are run at one stress level, there is always considerable statistical scatter in the fatigue life. If the statistical scatter in cycles failure is considered a distribution as in figure is obtained.
If the logarithm of Nf is considered as the variable a symmetrical distribution is obtained: standard Gaussian (normal) (equivalent to lognormal distribution of Nf) statistical use is resonable.
20
Statistical analysis of fatigue data permits the average fatigue curves t.o be established along with additional S-N curves for various probabilities of failure
21
The experimental data are treated by the statistical approach: STAIR CASE. This approach allows to determine the fatigue strength characterized by the 50% of probability of failure. A large number of specimens to be experimentally tested is required. The number of specimens has to be odd in order to have a different number of failure and survivors. Before starting the tests the maximum number of loading cycles and the value of are chosen.

5 broken specimens (3 2 and 2 3) 6 run out specimens (2 2, 3 1 and 1 )
22
Less frequent event
FA
3 2 + 2 3 = 5 2
failure
S-N Curves
23
N=K
m a
UTS m FA 103
107 Log 3 10 m= Log FA UTS
107
The S-N curves can be schematized

From the specimen to the component
24
Surface finish effect Dimension effect Notch effect
With the aim to consider these effects the follwing parameters are defined:
25
Surface finish effect: the coefficient b3 is defined equal to the ratio between the fatigue strength obtained by specimens with different surface finish and the fatigue strength obtained by standard specimens (roughness Ra=0.3 m)
b3 pattern versus ultimate strength of materials

(1- lucidato; 2-rettificato fine; 3-rettificato; 4,5tornito)
26
27
Dimensional effect: the coefficient b2 is defined equal to the ratio between the fatigue strength obtained by specimens with generic dimensions and the fatiguestrength obtained by standard specimens (d=10mm).
b2 pattern versus the dimensions
28
Notch effect: the fatigue notch coefficient Kf is defined equal to the ratio between the fatigue strength obtained by standard specimens and the fatigue strength obtained by notched specimens Kf depend on Kt by the notch sensivity q.
q=
K f 1 Kt 1
Bending and axial fatigue
Torsion fatigue
Notch sensitivity
Peterson rule:
29
q=
1 a 1+ r
Neuber rule:
q= 1+
a=0.0634 (tempered and quenched steel) a=0.254 (annealed steel) a=0.634 (aluminium alloys)
0.8 0.6 0.4 0.2
800
1200
1600 Rm [MPa]
From specimen to the component Kf=1+q(Kt-1) KtA=2,5

A
r
30
B
Mf1 Mf2
KtB=5
rA> rB
At the same max :
M fA = 2 M fB =
KtB M fB KtA
From experimental tests: KfA=2,1 e KfB=3,6 If the notch radius is larger (KtA=2,5) the value of Kf decreases of 16%, on the contrary if the notch radius is lower (KtB=5), the value decreases of 28%.
KfB> KfA
The gradient effect is secondary

The fatigue limit of the component becames:
31
' FA( a , f ) =
FA( a , f )b2b3
Kf
The S-N curve of the component a
FA FA
Mean stress effect
32
Haigh diagram:
FA
Rm
Mean stress effect:
33
Semplified diagram:
The yielding limit is considered
sn
FA
Rc
sn
sn
Rm
Mean stress effect:
34
Compression mean stress effect
35
The surface tretament are applied to improve the fatigue behavior of mechanical component Thermo-chemical treatment (carburizing and nitriding) Mechanical treatment (shot peening, cold rolling)
Compressione mean stress effect
36
Without residual stresses:

a
FAf P' lim P' A R c res P 0 med P lim med R m
OPlim 1 = OP
With residual stresses:
AP' lim 2 = AP'
Haigh diagram: torsion
37
Finite life estimation
38
If the service required life is lower than the life corresponding to the fatigue limit (N=106107):
A semplified Whler diagram is constructed (F) value is determined
max Rm
F FAf
F> FAf
FAf 1 2 3 4 5 6 Log N 7
=105
39
Mf D d
Mf M
M f = M o sin t The shaft is loaded by a varaible bending moment N=105 b2 b3 FAf = FAf b2 b3 Kf and matreial characteristics K ff are known
Finite life
Whler diagram
max Rm
40
F FAf
Log N
example
41
F0
L2
F0 L1 d
Steel: 39NiCrMo3 (Rm=900MPa, Rsn=700MPa). L1=40mm L2=60mm d=15mm B=5mm F= F0(1+sint) f>107 Failure?
F0=10.000N
Example stress:
42
60
50
med=-50MPa a=60MPa
b2, b3, Kf, FA
Example
a
43
Rs FAf P lim P 60 med Rs -50 Rs Rm
Haigh diagram
' FA
b2b3 = FA Kf
a>0
m<0
OPlim OP
example
44
example
45
FAf
rot
P lim med
46
Example
Lomologazione del manubrio illustrato in figura richiede che esso superi senza rompersi una prova di fatica dalla durata di 5x105 cicli con una carico applicato F1, alternato intorno al valor nullo, di 1 kN. Si stimi se, assegnati il materiale e le dimensioni geometriche, il manubrio superer la prova. Dati
Mat.: 39NiCrMo3 (Rm=900 MPa, Rp0.2=650 MPa) L=400 mm a= 200 mm Sez. A-A (circolare cava) De= 25 mm Di=20 mm Kt=1.7
L F1
a
F1 F1
A-A
F1

Fatigue I

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fatigue

Mechanical failure due to:

L. Vergani - approccio SS-N

Fatigue damage MECHANISMS

The damage is characterized by three steps:

L. Vergani - approccio SS-N

L. Vergani - approccio SS-N

Da Suresh - Fatigue of Materials

L. Vergani - approccio SS-N

Da Suresh - Fatigue of Materials

Description of a cyclic loading

Da Broek - The Practical Use of Fracture Mechanics

Description of a cyclic loading

max min max + min

L. Vergani - approccio SS-N

High stress amplutude

Low stress amplutude

L. Vergani - approccio SS-N

L. Vergani - approccio SS-N

Fatigue characterization of materials Whler curves (S-N curves)

The diagram of curves S-N is a log-log diagram

L. Vergani - approccio SS-N

L. Vergani - approccio SS-N

Fatigue test machines

da Davoli, Vergani, Beretta, Guagliano, Baragetti Costruzione di macchine 1 McGraw-Hill

Rotating bending test machine scheme

Rotating bending test machines

Fatigue test machines Axial loading test machine

da Davoli, Vergani, Beretta, Guagliano, Baragetti Costruzione di macchine 1 McGraw-Hill

Fatigue characterization of materials

FAf/Rm= 0.4 - 0.6 FAa/Rm= 0.3 - 0.45 FAt/Rm= 0.23 - 0.33

Fatigue characterization of materials

L. Vergani approccio SS-N

Fatigue characterization of materials

L. Vergani approccio SS-N

Fatigue characterization of materials

Less frequent event

107 Log 3 10 m= Log FA UTS

The S-N curves can be schematized

L. Vergani - approccio SS-N

From the specimen to the component

Surface finish effect Dimension effect Notch effect

L. Vergani approccio SS-N

From the specimen to the component

b3 pattern versus ultimate strength of materials

L. Vergani approccio SS-N

L. Vergani approccio SS-N

From the specimen to the component

b2 pattern versus the dimensions

L. Vergani approccio SS-N

From the specimen to the component

Bending and axial fatigue

L. Vergani approccio SS-N

0.8 0.6 0.4 0.2

L. Vergani approccio SS-N

From specimen to the component Kf=1+q(Kt-1) KtA=2,5

At the same max :

The gradient effect is secondary

L. Vergani approccio SS-N

From the specimen to the component

The S-N curve of the component a

L. Vergani approccio SS-N