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%
high cycle fatigue (HCF)
10%
low cycle fatigue (LCF)
15%
fatigue (RCF, CF, creep-fatigue,)
20%
static loading
10%
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

10
Description of a cyclic loading
With the aim to evaluate the effect of the fatigue the cyclic
loading could be schematized as:
Alternating stress
Mean stress
Amplitude ratio
a =
max min
med =
R=
min
max
max + min
2
11
Fatigue design
uni-axial loading
A. HCF (fatigue
strength, Haigh
diagram, Whler
curves).
High stress
amplutude
B. LCF (CoffinManson curves)

C. Elasto-plastic
fracture mechanics
(EPFM)
Low stress
amplutude
No cracks
D. Linear-elastic
farcture mechanics
(LEFM).
Large cracks
Fatigue design
12
9Amplitude of the loading cycles

9Complexity applied loadings
9Geometry and dimensions

B
9Acceptability of the
High stress
amplitude
damage
Multiaxial Stress
9Environment
9Experience
Uniaxial Stress
No cracks
Low stress
amplitude
Large cracks
Fatigue characterization of materials
13
Whler curves (S-N curves)

R=costant (very often =-1)
UTS
The diagram of curves

S-N is a log-log diagram
14
S-N curves
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
Rotating bending test machines

16
17
Fatigue test machines

Axial loading test machine
da Davoli, Vergani, Beretta, Guagliano,

Baragetti Costruzione di macchine 1
McGraw-Hill
18
The tests to evaluate

the fatigue strength
of materials are
carried out by using
standard specimens
(norma ISO 1143)
d = 10 mm
FAf/Rm= 0.4 - 0.6
Ra= 0.3m
FAa/Rm= 0.3 - 0.45
Kt = 1
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 )
Less frequent event
FA
3 2 + 2 3
=
5
2
failure
22
23
S-N Curves
107
Log 3
10
m=
Log FA
UTS
N=K
m
a
UTS
m
FA
103
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
29
q=
Peterson rule:
Neuber rule:
a
1+
r
q=
1+
a=0.0634 (tempered and quenched

steel)
0.8
a=0.254 (annealed steel)
0.6
a=0.634 (aluminium alloys)
0.4
0.2
800
1200
1600 Rm [MPa]
30
From specimen to the component

Kf=1+q(Kt-1)
KtA=2,5
KtB=5
Mf1
Mf2
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
31
The fatigue limit of the component becames:
' FA( a , f ) =
FA( a , f )b2b3
Kf
The S-N curve of the component

a
FA
FA
32
Mean stress effect
Haigh diagram:
FA
Rm
33
Mean stress effect:
Semplified diagram:
The yielding limit

is considered
sn
Rc
FA
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)
36
Compressione mean stress effect
Without residual stresses:

a
OPlim
1 =
OP
FAf
P'
lim
P'
A
R
res
With residual stresses:

P
lim
med
med
AP' lim
2 =
AP'
Haigh diagram: torsion
37
38
Finite life estimation
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
=105
Log N
7
39
Mf
Mf
D
d
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
40
Whler diagram
max
Rm
F
FAf
Log N
41
example
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
42
stress:
60
50
med=-50MPa
a=60MPa
b2, b3, Kf, FA
Example
43
a
Haigh diagram
Rs
FAf
P
lim
P
60
med
Rs
a>0
Rs
-50
m<0
OPlim
OP
Rm
'
FA
b2b3
= FA
Kf
44
example
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
L
F1
Sez. A-A (circolare cava)

De= 25 mm
F1
A-A
F1
Di=20 mm
Kt=1.7
F1

Fatigue I

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fatigue

From latin fatigare.

Mechanical failure due to:

high cycle fatigue (HCF)

low cycle fatigue (LCF)

fatigue (RCF, CF, creep-fatigue,)

other kind of failure

L. Vergani - approccio SS-N

Fatigue damage MECHANISMS

The damage is characterized

Nucleation of the crack (from

L. Vergani - approccio SS-N

The nucleation of a micro-crack is due to the plastic

L. Vergani - approccio SS-N

Da Suresh - Fatigue of Materials

During the Stage I the propagation of the micro-cracks is

L. Vergani - approccio SS-N

Da Suresh - Fatigue of Materials

The fatigue propagation

The final failure can be

Description of a cyclic loading

Da Broek - The Practical Use of Fracture Mechanics

Description of a cyclic loading

L. Vergani - approccio SS-N

B. LCF (CoffinManson curves)

L. Vergani - approccio SS-N

9Amplitude of the loading cycles

9Geometry and dimensions

L. Vergani - approccio SS-N

Fatigue characterization of materials

Whler curves (S-N curves)

The diagram of curves

L. Vergani - approccio SS-N

We can enter in these

L. Vergani - approccio SS-N

Fatigue test machines

da Davoli, Vergani, Beretta, Guagliano, Baragetti

Rotating bending test machine scheme

Rotating bending test machines

Fatigue test machines

da Davoli, Vergani, Beretta, Guagliano,

Fatigue characterization of materials

The tests to evaluate

FAf/Rm= 0.4 - 0.6

FAa/Rm= 0.3 - 0.45

FAt/Rm= 0.23 - 0.33

Fatigue characterization of materials

If the logarithm of Nf is considered as the variable a symmetrical

L. Vergani approccio SS-N

Fatigue characterization of materials

The experimental data are treated by the statistical approach:

L. Vergani approccio SS-N

Fatigue characterization of materials

Less frequent event

The S-N curves can be schematized

L. Vergani - approccio SS-N

From the specimen to the component

Surface finish effect

L. Vergani approccio SS-N

From the specimen to the component

Surface finish effect: the coefficient b3 is defined equal to the

L. Vergani approccio SS-N

L. Vergani approccio SS-N