Example 1

For the following R=-1 AISI 1090 steel test data, plot two S-N curves, one using log-
linear coordinates and the other using log-log coordinates. a) Use linear regression to
estimate the best fit curves for the two coordinate systems. Show these lines on the
same graphs with the data b) Estimate the fatigue limit for the material, c) estimate the
fatigue strength at 5x105 cycles to failure, d) estimate the expected fatigue life at 200
MPa, e) Sketch upper and lower bounds for the data and comment on the observed
scatter.

Stress amplitude (MPa) Nf

130 1x107 (no failure)
130 1750000
130 1600000
130 1930000
130 1x107 (no failure)
150 1860000
150 1100000
150 601300
150 485000
170 190567
170 465000
170 153140
170 311250
185 144430
185 152060
185 176960
185 116430
220 46240
220 52020
220 62500
220 95000
220 65300
245 30100
245 38500
245 26300
245 29600

 
Solution

The equations of the least square method for fitting of the straight line y A  B
are,

n6xiyi  6xi6yi 6yi 6xi

B
2 A B , where
n6x 2 i  (6xi) n n
n is number of data points and xi , y are values of data. Least square method with respect
to log y is exploited as follows:

The power function y=AxB is by taking logarithms transformed to log y = log A+Blog x and
the previously given equations for A and B are used. Hence, in the diagram with log-log
scales, y=AxB becomes a straight line. In this case, n = 24 because the two non-failed data
points should be excluded from the analysis. We compute the needed values and sums to
obtain the constants A and B. It MUST be noted that in linear regression, the dependent
variable y is Log(cycles to failure)

log-log y=AxB Nf=A(Va)B A=19.94

coordinates Log(Nf)=A+BLog(Va) A=10A= 5.5x1019
B=-6.48
log linear y=A+Bx Log(Nf)=A+BVa A = 8.11
coordinates B = -0.0152

2 run-out data points are

excluded from linear regression

Y=19.94 -6.48X

Y = 8.11 - 0.0152X 2 run-out data points are

excluded from linear regression
These values are transformed to represent the traditional plotting method with Log(Nf) on
the horizontal axis

log-log Va =C(Nf)D C = - A/B = 3.08

coordinates Log (Va)=C+DLog(Nf) C =10C= 1202
D =1/B = -0.154
log linear Va = C+DLog(Nf) C = -A/B = 536
coordinates D =1/B = -66.0

Va

Nf
Linear-log plot with regression lines for Va =1202(Nf)-0.154 (green line) and Va = 536+(-
66.0)Log(Nf)(violet line)
 '()
220

200

180

Va
160

140

120

&f
Log-log plot with regression lines for Va =1202(Nf)-0.154 (green line) and Va = 536+(-
66.0)Log(Nf)(violet line)

b) Estimate the fatigue limit for the material

The exact fatigue limit cannot analytically be defined; it is, however, Va 130 MPa,
because two of five specimens did not fail with this stress.

c) estimate the fatigue strength at 5x105 cycles to failure,

Using Va =1202(Nf)-0.154 the strength is Va = 159 MPa

Using Va =536+(-66.0)Log(Nf) the strength is Va = 160 MPa

The figures show that these curves nearly intersect at 500 000 cycles

d     d     

Using (Va/1202) (1/-0.154) =Nf the life is Nf = 114000 cycles

Using Log-1((536-Va ) /66.0) = Nf the life is Nf = 123000 cycles

 e   ! "d #$ ! %#"d #!  data and comment on the observed scatter.
Scatter was found especially at longer fatigue lives. A standard deviation for all data could
be estimated.
Example 2
E

Example 2

An unnotched member fabricated from AISI 4142 steel (see table) is subjected to the
load history shown below. Use the Gerber mean stress correction equation and a)
perform a rainflow count of the load history, b) estimate the number of cycles to failure
and c) estimate the number of (blocks) repetitions to failure.
Rainflow counting yield 3 large amplitude cycles and 200 small amplitude cycles

Use the Gerber equation:

2
Va Vm
1  ,
V ar V u

V 2 V 2
Va 1  m V 1  m AN b
V u ar V u f

From table for 4142 steel:

A 1
 MPa b 0.0

u 1757 MPa

For m = 600 MPa.

600 2
1  1837 N f  0.0762 , which gives Nf =
1757
600

For m = 880 MPa.

880 2
1  1837 N f  0.0762 , which gives Nf =
1757
320

 max   min  max   min

Stress amplitude: a Mean stress: m 
 

The stress history Rainflow Table:

j Nj     ! a N fj N j / N fj

1 3 0 1200 600 600 4,68E+05 6,41E-06

2 200 520 1200 860 340 1,13E+08 1,77E-06

203 8,18E-06
The Palmgren-Miner rule:

j j

N N
Nj Nj
" Bf 1, where B f is the number of repetitions.
k 1 fj k 1 fj

1
j Nj
Bf | #$$%%% repetitions = 24 800 000 cycles
k 1 N
fj
Example 2b

An aircraft component is fabricated from Ti-6Al-4V solution treated and aged titanium
alloy (see table with Problem 3). At the critical point in the component, the stress history is
determined to be

Develop a rainflow table of for the history shown. Estimate the number of repetitions of the
given history necessary to cause fatigue failure.

The Palmgren-Miner rule:

j j

N N
Nj Nj
1 Bf 1, where B f is the number of repetitions.
k 1 fj k 1 fj

 max   min
Stress amplitude: a
2

Equivalent completely reversed stress for the cases where mean levels are involved:

V ar V maxV a V f 2 N f b

, V ar V maxV a is known as SWT-equation (Smith, Watson & Topper).

1 V max V a b

Nf
2 V 'f

For Ti-6Al-4V, b = -0.104 and  f = 2030 MPa.

The stress history:

Rainflow Table:

j Nj  m  m  N j N  / N 

1 400 200 800 300 4,32E+05 9,26E-04

2 8000 -400 200 300 3,39E+08 2,36E-05

3 1 -400 1000 700 2,51E+03 3,98E-04

1,35E-03

1
j


Nj
Bf | 7 repetitions.
N fj
k 1
Example 3

A stepped shaft has a diameter D = 50mm, d = 30mm and r = 3mm. determine and
compare Kt for a) axial loading and b) bending and c) torsion. Estimate the fatigue
notch factor, Kf for R=-1 axial loading if the shaft is made of the following steels: 1)
normalized 1038 (HB 163), 2) quenched and tempered 1038 (HB 195), 3) hot rolled
4340 (HB 243)
and 4) quenched and tempered 4340 (HB 409).
 r 3 D 50
0.1 1.6
d 30 d 30

The elastic stress concentration factor Kt for axial loading is defined from Figure:

K t | 1.9

 Kt for bending loading is defined from Figure:

K t | 1.7
 Kt for torsion loading is defined from Figure:

K t | 1.4

A value of fatigue notch factor k f could be obtained according to Peterson for R = -1 loading from

1.8
kt  1
kf 1 , where a 0.0254 2070 (for steels).
a Su
1
r

1.8
2070
The value of a can be obtained for 1038 (HB 163), Su = 582 MPa, 0.0254 0.2 .
582

1.90  1
We obtain k f 1 1.
0.249
1
3
 1.8
2070
For 1038 (HB 195), Su = 649 MPa, 0.0254 0. .
649

1.90  1
We obtain k f 1 1.
0.205
1
3

1.8
2070
For 4340 (HB 243) Su = 827 MPa, 0.0254 0. .
827

1.90  1
We obtain k f 1 1.
0.132
1
3

1.8
2070
For 4340 (HB 409), Su = 1468 MPa, 0.0254 0.0 .
1468

1.90  1
We obtain k f 1 1.
0.047
1
3

The following summary and comparison of the values of Kt shows that axial is the most critical
loading type. Kt for bending loading is only slightly less critical. However for torsion, Kt is only
about 74 % compared to bending load.

Kt 1,90 1,75 1,40

Kt % 100 92 73,7

axial loading bending torsion

Kf a

1038 (HB 163), Su = 582 MPa 1,83

1038 (HB 195), Su = 649 MPa 1,84

4340 (HB 243), Su = 827 MPa 1,86

4340 (HB 409), Su = 1468 MPa 1,89

 Example 4
Example 4Exa

The smooth specimen is subjected to cyclic loading. The required fatigue life is
100 000 cycles to failure. Compute the allowable stress amplitude for mean stress 0, 200,
400 and 800 MPa. Use the Goodman mean stress correction equation. Use this data to
construct a constant life diagram for Nf = 1X105. (see the sample constant life diagram
below taken from the lecture slides)
The Goodmans equation generally gives reasonable results:

a m
1 ,
 ar Vu

Vm Vm
Va 1  V ar 1  A
N f b
Vu Vu

From table for 4142 steel:

A 1  MPa b 0.0

u 1757 MPa

For m = 100 MPa.

V  0.0762
Va 1  m 1837 100000  , at Nf = 100 000 cycles, we get
1757

a
MPa Nf cycles

801,19 1

Therefore:

0.0648
Va 801.19N f 

For m = 0 MPa.

0.0648
Va 9382 N f 

a MPa Nf cycles
 896,8 1

Therefore:

0.0648
Va 896.8N f 

For  = -100 MPa.

Va 
938  100 2 N f 0.0648

a
MPa Nf cycles

992,41 1

Therefore:

0.0648
Va 992.41N f 
 A stepped shaft with a diameter D = 30 mm, d = 24 mm and r = 1.3 mm. The required
fatigue life is 1 000 000 cycle and is loaded in bending. a) Determine Kt and Kf , b)
Compute the allowable stress amplitude for mean stress 0, 200, 400 and 800 MPa and c)
use this data to construct a constant life diagram for Nf = 1X106.

Kt for bending loading is defined from Figure:

D/d = 30/24 = 1.25, r/d = 1.3/24 0.054167.

Kt | 1.9

A value of fatigue notch factor k f could be obtained according to Peterson for R = -1 loading from
 1.8
kt  1
kf 1 , where a 0.0254 2070 (for steels).
a Su
1
r

1 .8
2070
The value of a can be obtained, 0.0254 0.0
 .
1757

1.98  1
We obtain k f 1 1. 
0.0341
1
2

Using the value of k f , the nominal stress amplitude corresponding to the fatigue limit is:
 ar
S ar 
k
Example 5
For RQC-100 steel and using the Morrow mean stress correction, obtain equations relating
stress amplitude(Va)vs. cycles to failure (Nf) in the cases where the mean stress(Vm)is a)
100 MPa tension, b) zero and c) 100 MPa compression. Plot the curves on the same graph
using log-log coordinates.

The Morrows equation generally gives reasonable results for ductile steels:

a m
1  ,
 ar V'f

V ar V 'f 2 N f b

Va V 'f  V m 2 N f b

From table for RQC-100:

$ 'f !"# MPa b 0.%&()

For *m = 100 MPa.

Va 
+938  100 , 2 N f 0.0648 , by substituting Nf = 1 cycle, we get

a
MPa Nf cycles

801,19 1

Therefore:

0.0648
Va 801.19-N f .

For 1/ = 0 MPa.

0.0648
Va 93822 N f 3

a MPa Nf cycles

896,8 1

Therefore:

0.0648
Va 896.84N f 5

For 1/ = -100 MPa.

Va 
6938  100 7 2 N f 0.0648
a
MPa Nf cycles

992,41 1

Therefore:

0.0648
Va 992.41:N f ;

Sm = S @ ? ><==

S @ ? <==
Example 6

Sometestdatapointsforthestressstraincurveof2024T351aluminiumduringaxialstressare
given:

V,MPa H
317 0.00474
341 0.00607
366 0.00950
390 0.01910
414 0.03290
439 0.05230
TheelasticmodulusforthematerialisgivenasE=73100MPa.

a) determinetheplasticstrain,Hp,foreachpointandplotVvsHponalogloggraphand
determinetheconstantsHandnfortheRambergOsgoodmaterialmodel(seeslide13
page6fromlectureslideset5)
b) PlottheresultingH=f(V)lineandtestdata(usealinearlineargraph).Determinerthe0.2%
offsetyieldstrength.


Foreachpoint,Histhetotalstrain,He=V/EandHp=HHe

V,MPa H He Hp

317 0.00474 0,004337 0,000403
341 0.00607 0,004665 0,001405
366 0.00950 0,005007 0,004493
390 0.01910 0,005335 0,013765
414 0.03290 0,005663 0,027237
439 0.05230 0,006005 0,046295


TheresultingloglogplotisshownandthevaluesHandnfortheequation



arefoundbylinearregression.H=528MPa,n=0.066
 1000

H=528MPa
stress(MPa)

1/n

1
0,0001 0,001 0,01 0,1 1
pstrain

totalstrainisfromtheRambergOsgoodcurve



Theresultingcurvewiththedatapointsisshown

500

450 0 offsetyield

400

350

300
stress(MPa)

250

200

150

100

50
0 offset

0 0,01 0,02 0,03 0,04 0,05 0,06

s


The0.2%offsetyieldstrengthoccurswhenHp=0.2%=0.002.ThisisV=350.3MPa
Example 7
Anelastic,linearhardeningmaterialhaselasticmodulusE=200GPa,yieldstrengthV0=fy=500
MPaandavalueofG=0.1(seeslide11page5fromlectureslideset5).Assumethatthematerial
behavesaccordingtotheelasticlinearhardeningspringslidermodel(seelectureslideset4).
Estimate(sketch)thematerialbehaviorfor:

a) completelyreversedcyclicstrainingatHa=0.006
b) strainingfrom H=0toH=0.012followedbydecreasingstraintoH=0.005andthenincreasing
straintoH=0.015.

Usingthespringslidermaterialmodelforelasticlinearhardeningmaterialandtheparameters
given,theresultingstressstrainresponseduringmonotonicloadingwouldbeasshown.



Forcompletelyreversedcyclicloading,thestressstrainresponseisasshown.Notethatoncethe
straincycleisreversed,thematerialyieldonlywhenthechangeinstrainattainstwicetheinitial
yieldstrength.Seethefigure.Forcompletelyreversedyieldingthecycleisalwaysperfectly
symmetric.

 
b)ThestraincycleforstrainingfromH=0toH=0.012followedbydecreasingstraintoH=0.005and
thenincreasingstraintoH=0.015isshown


Example 8

Anotchedcomponenthaskt=3.Thecomponentisloadeduntilnominalstress,S=200MPa.The
componentisthenunloadedtoanominalstressofS=0.Strainlifepropertiesofthematerialare:
E=100GPa,Vf=1000MPa,Hf=1.0,b=0.08andc=0.60.

a) determinethelocalstressandlocalstrainatthenotchatS=200MPa.
b) determinetheresiduallocalstressandlocalstrainatthenotchatS=0MPa
c) usetheNeuberanalysisandMorrowmeanstresscorrectiontoestimatethefatiguelifeof
thecomponent.


Findthefollowingequationsfromthelecturenotesfortheweek6andsolvethemissingconstants
forthecyclicstressstraincurve:
' f
H'  1000MPa
H ' f b / c  
H'
10.08 / 0.60 
1000MPa

b 0.08 2
n' n'
c  0.60 1 

Neubers rule and the cyclic stressstrain curve are used to estimate both the maximums and
amplitudes of the local notch stress and strain. For the initial monotonic response, assumed to
followthecyclicstressstraincurve,wehave:
1 1
V max V nc V max V max 2 / 15
H max f V max
 max 
E Hc 100000MPa 1000MPa 
Eliminationof  betweenequationsgivesanequationinvolvingstressthatcanbesolvedbytrial
anderrororothernumericalprocedure.However,e.g.acalculatorwithanumericalsolvercanbe
suggestedtobeusedtosolve  .
1
V nc
(k t S max ) 2 V 2  V E
H c ,Substituting  intooriginalequationgives  .
1
V 2 / 15
3 200MPa  2
V 2  V 100000 MPa
  463.54166 ...M 
1000 MPa    max
 max | 463.5M

then


0 0
3 3
D D


0 0
3 3
D D
1 1

Q
I


P
D(
[

P+
D
[
V V 463 5 2
V  c 463 5
7 77 10 3 
P
D
[

P
D
[
15
H  
c 100000 1000

Forcyclicloading,itisconvenienttoworkinthetermsofamplitudesusingthecyclicNeuber`srule
andthesamestressstraincurve,butevaluatethesefor:
    3
D
P
D
[

P
L
Q

'  200 
Theneededequationsare:
1 1
 
Q


'V 'V c 'V 'V 2
(

0
3
D

0
3
D
'H  2  2
2 c 100000 2 1000

and
.
6

0 0
3 3
D D

 2 3 0 200 2
W

'
(

'V'H .
100000

Solvingthesegives:
 3 ,
3
D

'  590  'H 6 11 10 

Theminimumvaluesforcyclicloadingcanbeobtained:

0
3
D

3
D

   
P
L
Q

P
D
[

' 464  590 126



7 77 103  6 11 103 | 1 66 10 

P
L
Q

P
D
[

H H  'H
! !
3
D

3
D

Hence,thesolutionfor1(a)is " ,andfor1(b) " $ #126

P
D
[

P
L
Q

| 464 .


Theestimatedstressstrainresponseisshowninthefollowingfigure.Thiswasplottedbyequating
'& 2 f ('% / 2) forthebothbranchesofthehysteresisloop.
Morrow'smeanstresscorrectionestimateisknownas:

'H + ' f + m
,a (2 N f *b  H ' f (2 N f *c
2 E 
wehave:
0 3
3 D
D
1

-1000  168.





2  0 08  1 02  0 60
0

3 06 10 3
100000
1


I

| 4 4 10 5 cycles/

 
Exmpale 9

UsingthematerialpropertiesgiveninTableA.2,Constructthemonotonicandcyclicstresssrain
curvesforRQC100hotrolledsteelforstrainbetween0and2%.Doesthismaterialcyclically
hardenorsoften?

fromtable








m

cyclic
V / Va

H / a

Overthisrangeofstrain,themonotoniccurveisabovethecycliccurve,thereforethematerial
softens.