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Prototype
Ref: High temperature fatigue of engine components Virtual design validation of exhaust manifold, fe-safe
UGM 2010, FESI 2009
Fatigue of Materials
The stresses that cause failure are far below those needed to
cause fracture on single application of load
Fatigue is the cause for more than 90% of all in service failures
in structural materials
Mean stress
= ( + )/2
Stress ratio
= /
STRESS STRAIN
Fatigue CYCLING
Initial Straining
Time-independent stress-strain
material behaviour
Initial straining follows the
ordinary monotonic stress-
strain curve
If we now reverse the
direction of straining, starting
at A, the path followed is AB
Not the same as OA
Reversing again at B to the
original strain amplitude,
material follow path BA
Constant Amplitude Cycling
for Stable Materials
L F
K
G
J
H
I
Fatigue APPROACHES
Analysis of Fatigue - Approaches
Stress or Strain
is a stress level below which
material does not fail and can be
cycled indefinitely
Such endurance limit does not
exist for non-ferrous metals
For non-ferrous metals, fatigue
strength is generally defined as
the stress that will cause fracture Number of cycles to failure (N)
at the end of a specified number Fatigue / Endurance Limit
of cycles (usually 107) S applied stress
N number of cycles to failure
Categories of Fatigue
Stress or Strain Life?
Stress or Strain Life?
Stress life method is the least accurate approach especially for low
cycle applications
= +
= = 2
2
Where
plastic strain amplitude Ductility coefficient
2
True stress amplitude Ductility exponent
Strain Life Method
Manson-Coffin equation
describes fatigue in low cycle
fatigue regime
Strain Life Method
= +
= + = 2 + 2
2 2 2
This is due to constraint placed on the material near the root by the
surrounding mass of the material
Trends for Engineering Metals
Constant strain
amplitude cycling
High strength materials are desirable for High Cycle Fatigue. Have
low value of and low ductility
High ductility materials are desirable for Low Cycle Fatigue. Have low
values of and low strength
Effect of Mean Stress
& Stress Ratio
Variation of and R
Mean stress
= ( + )/2
Stress ratio
= /
Effect of Mean Stress and Stress Ratio
Ref: Mean stress effect on component life, Dana Corp, Fe-Safe User Group Meeting, 2005
Effect of Mean Stress and Stress Ratio
Most experimental data lies between the Goodman and Gerber values. The
Goodman relationship is more conservative and is safer for design purposes
Goodman Relation
Other Factors Affecting Fatigue Life
Ref: Effect of overload on fatigue life, Hundai Kai Motors R&D Centre, Fe-Safe user group meeting 2011
Simulating Forming Processes in
an Oil Pan
Ref: Fatigue assessment of an oil pan incorporating manufacturing effects, The J. Engg. Integrity Society, 2002