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On the base of engineering mechanics, this chapter will develop more specific
understanding in failure theories and material strength for machinery design. The
failure usually reflect one of the most important perspectives ([pE5spektiv]) in
assessing the safety of mechanical system and components.
σ
σ=constant
o t
Varying (fluctuating) stress: A varying stress varies its magnitude and directions all
the time. Static or varying load both can cause varying stress.
Fig.3.1 Stress-time relationships for some typical stress
(a) Static stress;(b) and (c) Non-symmetrical (or nonsinusoidal) fluctuating stresses;
(d) Sinusoidal fluctuating stress; (e) Repeated alternating (pulsant) stress; (f)
Completely reversed (symmetrical) stress
Stress
Working stress: Using the formula in mechanics of materials calculate the stress on
section plane of element
Calculated stress: Followed the theory of strength, calculate the stress that is equal
to simple tension
Ultimate stress: Some utmost of mechanical characters of material
Strength utmost: off set limit, limit of fatigue,
Allowable stress: Calculate the allowable maximum of stress
Safety factor :
σ lim
S=
[σ ]
τ lim
τ max ≤ [τ ] or τ max ≤
[ Sτ ]
The safety factor condition:
σ lim
Sσ = ≥ [ Sσ ]
σ
τ
Sτ = lim ≥ [ Sτ ]
τ
3.3.1 The Strength Calculation of Machine Elements Under the Static Stresses
σ lim
σ ca ≤ = [σ ]
S
Where σ ca ——calculated stress
3.3.2 The Strength Calculation of Machine Elements Under the Static Stresses
Explanation: machinery design mainly discuss the high cycle fatigue. Sometimes it
is necessary to do the strength check of static stress for the element which have
prodigious peak value but little action.
Since point D: Curve goes to be horizontal, it means as the N augments no longer
declines, it is called infinite life. N ≈ 106 : 25 ×107
Because of the value of N D is large, when doing the fatigue experiment we always
ordain a cycle index N O (cycle radix). We use N O and its fatigue limit σ r
σmax
σB AB
C
σrN
σr D
N
N=1/4 103 104
N N0≈107
interval CD: the relationship between N and fatigue limit σ rN :
N0
σ rN = σ r m
N
m
σ
N = r N0
σ rN
Among the equation above, the value of is definited by material testing.
As the testing result shown in interval CD, after relevant numbers of varying
stresses the check bar will happen endurance failure. But since the point D, if the
maximum stress less than the stress of the point D, In that way no matter how many
times of the circles, the material will never be destroyed.
High circle fatigue:
CD-----fatigue for finite life
After D----fatigue for infinite life
N0
σ rN = σ r m
N
N0
Kn = m life factor
N
Eg: In the strength calculation of gear and worm, use the following equation to
calculate the allowable stress.
σr
[σ ] = Kn
S
3. Constant Life Fatigue Curve (Material Fatigue Curve Ⅱ)
Material fatigue curve can also be shown by using the relationship among limit
stress amplitudes in the given N, it is called constant life fatigue curve.
Line OC correspond the static stress r=1, σ a = 0 ,choose the coordinate values of
eg:
σ −1
Kσ =
σ − 1e
σ-1e——symmetric cycle bending fatigue limit of element
σ-1 ——symmetric cycle bending fatigue limit of material
Amending the stress limit of material diagram A’G’:
The coordinate value changed:
A’(0,σ-1)→A(0, )or(0, σ −1 )
σ0 σ0 σ0 σ0
D’( , )→D( , )
2 2 2 2Kσ
The equation of AD:
σ −1 = K σσ ae '+ψσσ me '
3.3.2.3 The Strength Calculation of Machine Elements Under the Static Stresses
The characteristic of static stress: σ max , σ min holds the value on minimum life section
Or τ max ,τ min holds the value on minimum life section. Pure static varying stress: one of
the normal or tangential stress Doubleaction static varying stress: both normal and
tangential stress.
The design method: theoretical design
Use for calculation: safety factor checking
σ lim
Sca = ≥S
σ
Machine element’s fatigue value of pure static varying stress when calculating the
endurance bending strength of machine element, first calculate the maximum
(minimum) stress on minimum life section, second calculate the, and then definite the
operating point M on the limit stress curve of element . Which point is the value of the
limit stress depends on the varying discipline of the element working stress.
1.In the case of r=C (a constant),the cycle performance of the varying stress remains
the same .It is the stress condition of the majority of the rotating shaft.
σ a σ max − σ min 1 − r
= = =C'
σ m σ max + σ min 1 + r
The limit stress of the point M
σ −1 (σ m + σ a ) σ −1σ max
σ max
'
= σ ae' + σ me
'
= =
Kσ σ a + ψ σ σ m Kσ σ a + ψ σ σ m
The calculation of safety factor and stress condition:
σ lim σ max
'
σ −1
Sca = = = ≥S
σ σ max Kσ σ a + ψ σ σ m
Static stress condition:
σ lim σ σs
Sca = = s = ≥S
σ σ max σ a + σ m
2. In the case of σ m = C , the mean stress of the varying stress remains the same.
It is the stress condition of the vibrating loaded spring.
The limit stress of point M:
ψσ σ + ( Kσ −ψ σ )σ m
σ max
'
= σ −1e + σ m (1 − ) = −1
Kσ Kσ
The calculation of safety factor and stress condition:
σ lim σ max
'
σ + ( Kσ −ψ σ )σ m
Sca = = = −1 ≥S
σ σ max Kσ (σ a + σ m )
Static stress condition:
σ lim σ σs
Sca = = s = ≥S
σ σ max σ a + σ m
3.In the case of σ min = C theminimum stress of the varying stress remains the same.
It is the stress condition of the bolt joining under the axial varying load.
σ min = σ m − σ a = C
The limit stress of point M:
2σ −1 + ( Kσ −ψ σ )σ min
σ max
'
= σ me
'
+ σ ae' =
Kσ + ψ σ
The calculation of safety factor and stress condition:
σ lim σ max
'
2σ + ( Kσ −ψ σ )σ min
Sca = = = −1 ≥S
σ σ max ( Kσ +ψ σ )(σ a + σ min )
illustration:when the law of how the stress varies is dubious,we always choose the
calculation method of r=C.
σ −1
Sca =
Kσ σ a + ψ σ σ m
If every circle of stresses make the equicohesive destruct on the material, the
material damage ratio of stress σ 1 is 1/ N1 in every circle, so in n1 circles the material
damage ratio of σ 1 is n1 / N1 and in n2 circles the material damage ratio of σ 2 is
n2 / N 2 .
If the stress is lower than σ −1∞ , we can believe that the stress is not damaging.
When the damage ratio is up to 100%,the material happens to endurance failure. So
we obtain:
m
z
ni n n n σ
∑ = 1 + 2 + 3 + ...... = 1 where:N i = N 0 −1
i =1 N i N 1 N 2 N3 σi
As the experiment shown:
1)When the sequence of stress operation is increased and then decreased, we obtain:
z
ni
∑N
i =1
<1
i
2) When the sequence of stress operation is decreased and then increased, we obtain:
z
ni
∑N
i =1
>1
i
z
ni
In general case: ∑N
i =1
= 0.7 ~ 2.2
i
∑nσ
i =1
i i
m
< N 0σ −m1
σ −1
Sca = ≥S
σ ca
The fatigue value of doubleaction static varying stress
The element which is under the alternate stress of bending and torsion is belong to
this kind of fatigue value.
Eg: when the shaft is under the action of bending and torsion, the calculation value
of safety factor and strength condition is :
S σ Sτ
Sca = ≥S
Sσ2 + Sτ2
Among this:
Sσ ——only under the normal stress σ , the calculation value of safety factor
σ −1
Sσ =
K σσ a +ψσσ m
Sτ ——only under the shearing stress τ , the calculation value of safety factor
τ −1
Sτ =
K ττ a +ψττ m
3.3.3 the Measure for Increasing the Fatigue Value of Machine Element
In the design phase the design measure should be taken to increasing the fatigue
value of machine element :
①. Lower the stress concentration as much as possible;
②. Choose the material of high fatigue value;
③.Choose the heat treatment method and reinforced technics to increasing the
fatigue value of machine element;
④. Increase the surface texture of machine element;
⑤.Decrease or eliminate the original crack size of the element surface.
For the case of constant ratio r, When the working points are on fatigue safety
zone:
k N σ −1
Sσ a = ≥ [ Sσ a ]
(kσ ) D σ a +ψ σ σ m
Example3.1 The fatigue limit of symmetric σ -1 = 275Mpa, off set limit σ s = 355MPa,
the critical number of cycles is N 0 = 107 ,index of life is m=9.Estimate: when the number
of cycles Nis 105 ,5 × 106 , or 108 , the life factor K N andfatigue limit σ -1N .
Example 3.4 The material of shaft is 40Cr, thermal refining, its mechanical character is
ψ 0 = 0.2, σ −1 = 355MPa,τ −1 = 205MPa,ψ τ = 0.1. The diameter of the its minimum
life section is d=40mm, the bending momentM=300Ngm, the torque T=800Ngm, fatigue
limit influential factors Kσ = 2.5, Kτ = 1.5.