FATIGUE ANALYSIS OF OUTPUT SHAFT SUBJECTED TO PURE TORSION

1. INTRODUCTION
A shaft has a circular cross section & it is a rotating component used in almost all the
machine. It is used to transfer the energy from the one part to another part. A shaft
usually not a uniform cross section because it is mounted by the bearing, fly wheels,
clutches & other machine elements are mounted on the shaft. In the present shaft of
heat treated material is mounted by spur gear with pressure angle of 200 & supported
by the two bearing (Roller bearing)

Stress Analysis

Stress in the Shaft In actual practice there are three kinds of stress are induced in it.
a) Shear stress by the transmission of the torque.
b) Bending stress by the force acting upon machine element, and weight of shaft itself.
c) Stress from both combined torsional and bending loads.

2. SHAFT MATERIAL COMPOSITION

Material is used in the shaft is 18CrNiM06

Table 1 Chemical composition of 18CrNiM06

Composition Percentage
Carbon 0.15-0.21
Silicon 0.17-.35
Nickel 1.40-1.70
Manganese 0.25-0.35
Phosphorus 0.035
Sulphur 0.015
Chromium 1.50-1.80
 Tensile yield strength Sy =1790Mpa
 Ultimate tensile strength Su =2100Mpa
 Young’s modulus of material E = 207Gpa
 Passion’s ratio = 0.3
 Density =7800 Kg.m3
2.1. Fatigue stress concentration
When there is an existence of the existence of irregularities or discontinuities,
such as holes, grooves, or notches, in a part increases the theoretical stresses
significantly in the immediate vicinity of the discontinuity defined a stress
concentration factor Kt or Kts

DEPT. OF MECHANICAL ENGINEERING, UVCE,

BANGALORE
1
 FATIGUE ANALYSIS OF OUTPUT SHAFT SUBJECTED TO PURE TORSION

Effective maximum stress is fatigue is

𝜎 max= Kf 𝜎nom 𝜏max=Kfs 𝜏 nom (1)
Where Kf is a reduced value of Kt and is the nominal stress 𝜎0.
The factor Kf is commonly referred as fatigue stress-concentration factor and
hence the subscript f.
The resulting factor is defined by the equation

Maximum stress in notched specimen

Kf = (2)
Stress concentration notch free specimen

Kf =1+ q(Kt −1) or Kfs=1+qshear (Kts−1) (3)

Where q = Notch sensitivity factor

1
q = √a
(4)
1+
√r

Where √𝑎= Neuber constant

r = Fillet radius
Neuber constant is given by the equation
a. Bending: √a =0.246−3.08 (10−3) Sut+1.51(10−5) (Sut)^2−2.67(10−8) (Sut )^3....(5)
b. Torsion: √a =0.190−2.51 (10−3) Sut +1.35(10−5) (Sut) ^2−2.67 (10−8) (Sut) ^3....(6)
Applying Sut = 304.57 Ksi (1Ksi = 6.895 Mpa)
For the torsion = -0.045

1
q = √0.0765
= 0.9486
1+
√1.414
Where Kt = Stress concentration torsion

Graph stress concentration factor for torsion

DEPT. OF MECHANICAL ENGINEERING, UVCE,

BANGALORE
2
 FATIGUE ANALYSIS OF OUTPUT SHAFT SUBJECTED TO PURE TORSION

Where r = Fillet radius

d = Diameter of smaller shaft
D = Diameter of larger shaft
𝑟/𝑑 = 2/85 =.0235 𝐷𝑑 =100/85=1.1764
From the graph & question (3) Kt =1.85
Kfs =1+.9486(1.85-1)
=1.80631

2.2. Generation of SN Curve

Fatigue strength (Endurance limit ‘𝑆’) of the shaft material was calculated as
Sn = 0.5* UTS = 0.5* 2100 = 1050 N/mm2.
Considering the corrections factors for endurance limit we find the new
endurance
Load factor Temperature Surface factor Reliability factor Gradient factor
(CL) (CT) (CS) (CR) (CG)

0.58 1 0.5 0.897 0.9

𝑆᾽= 0.5 * Sut * 𝐶𝐿 ∗ 𝐶𝑇 ∗ 𝐶S * 𝐶𝑅 * 𝐶𝐺 ................ (7)

= 0.5 * 2100 * 0.58 * 1 * 0.5 * .897 * 0.9
= 245.822 Mpa

2.3. Meshing of shaft

Basic idea of FEM is to perform calculations at limited number of points called
nodes and interpolate the results for entire domain using interpolation functions.
Any continuous object has infinite degrees of freedom and such problems
cannot be solved using this method. So this method reduces the degrees of
freedom from infinite to finite by making assumptions and by
discretization/meshing in other terms creating nodes and elements.
Hexadominant mesh is used, relevance center is fine & elements size is 3mm
created the nodes 1141216 and elements 315798

DEPT. OF MECHANICAL ENGINEERING, UVCE,

BANGALORE
3
 FATIGUE ANALYSIS OF OUTPUT SHAFT SUBJECTED TO PURE TORSION

2.4. Loads acting on shaft

Figure 2 Load acting on the shaft

Stepped shaft is subjected to a torque of value 47960 Nm to the location of “B”

& fixed location of the spur gear “A”.

DEPT. OF MECHANICAL ENGINEERING, UVCE,

BANGALORE
4
 FATIGUE ANALYSIS OF OUTPUT SHAFT SUBJECTED TO PURE TORSION

3. RESULT AND DISCUSSION

3.1. Shaft Shear stresses

The maximum shear stress is shown in which appears in the cross-section of the
shaft 𝜏𝑚𝑎𝑥 , with the fatigue stress concentration kfs = 1.8
𝜏𝑚𝑎𝑥 = 397.73 * 1.8
= 715.914 Mpa

3.2. Equivalent alternating stress or Equivalent von-mises stress

Equivalent von-mises stress or alternating stress 𝜎𝑣 =√3∗𝜏𝑚𝑎𝑥2

DEPT. OF MECHANICAL ENGINEERING, UVCE,

BANGALORE
5
 FATIGUE ANALYSIS OF OUTPUT SHAFT SUBJECTED TO PURE TORSION

𝜎𝑣 =√3∗𝜏𝑚𝑎𝑥2
= √3∗715.9142
= 1239.99 Mpa

In a Stress Life fatigue analysis, one always needs to be query an SN curve to

relate the fatigue life to the stress state. Thus of the “equivalent alternating
stress” is the stress used to query the fatigue SN curve after accounting for
fatigue loading type, mean stress effects, multiaxial effects and any other factors
in the fatigue analysis. Thus in a fatigue analysis, the equivalent alternating
stress can be thought of as the fast calculated quantity before determining the
fatigue life. The maximum value of the equivalent stress is 1244.6 Mpa, which
takes place in the cross-section of the shaft where the Roller -bearing was
located.

3.3. Number of cycles

Figure 5 Showing the fatigue life

This represents the number of cycles until the part will fail due to fatigue

2500

2000

1500 4408,

1000

500

0
1 10 100 1000 10000 100000 1000000
Graph of theoretical calculation

DEPT. OF MECHANICAL ENGINEERING, UVCE,

BANGALORE
6
 FATIGUE ANALYSIS OF OUTPUT SHAFT SUBJECTED TO PURE TORSION

3.4. Factor of safety of fatigue life

Figure 6 Factor of safety

Endurance stress
Factor of safety of fatigue life =
equivalent alternating stress
Endurance stress = 245.82 Mpa
FOS = 245.82/1240
= 0.19824

3.5. Fatigue damage

Figure 7 Fatigue damage

Fatigue Damage is a contour plot of the fatigue damage at a given design life. Fatigue
damage is defined as the design life divided by the available life
Design life
Fatigue Damage =
Available life
= 106 /4408
= 226.86

DEPT. OF MECHANICAL ENGINEERING, UVCE,

BANGALORE
7
 FATIGUE ANALYSIS OF OUTPUT SHAFT SUBJECTED TO PURE TORSION

Table 2 Result of Comparison

Parameters Analytical results FEM results
a. Shear stress in Mpa 715.91 718.58
b. Equivalent alternating in Mpa 1239.99 1244.6
c. Fatigue life cycles 4408 4330
d. Factor of safety .1984 .1975
e. Fatigue damage 226.82 232.52

4. CONCLUSIONS
Failure analysis of the shaft is investigated in detail. Force acting on the bearing
due to the torque is determined .Endurance limit & fatigue factor of safety is
calculated. Fatigue life of the shaft is estimated & fatigue damage is calculated.
Forces and stresses are calculated by using an analytical approach and ANSYS
software. Both methods show that the stresses and fatigue life are nearly same
and in the admissible range.
1. From the static analysis it was observed that maximum stress is located at the
change in the cross-section area of the shaft it is found 1313 Mpa.
2. Fatigue life is found to be 4330 cycles.
3. Factor of safety is .1975<1 which means the design is not safety.
4. Fatigue damage at the given life is 232.52
5. Stress concentration is more where there is a change in the cross-section of
the shaft.

REFERENCES
[1] Failure Analysis and Fatigue Life Estimation of a Shaft of a Rotary Draw Bending Machine
B. Engel, Sara Salman Hassan Al-Maeeni Vol:11, No:11, 2017
[2] M. G. Deepan Marudachalam, K. Kanthavel, and R. Krishnaraj, “Optimization of shaft
design under fatigue loading using Goodman method,” International Journal of Scientific
& Engineering Research, Vol. 2, Issue. 8, ISSN 2229-5518, 2011.
[3] S. Gujaran, and S. Gholap, “Fatigue analysis of drive shaft,” International Journal of
Research in Aeronautical and Mechanical Engineering, Vol. 2, Issue. 10, P. 22-28, 2014.
B. Prediction of Fatigue Life of Crank Shaft using S-N Approach Mahesh L. Raotole
Prof. D B Sadaphale , Prof. J. R.Chaudhari (ISSN 2250-2459, ISO 9001:2008 )
[4] “Finite Element Structural and Fatigue Analysis of Single Cylinder Engine Crank Shaft”
Bhumesh J. Bagde Laukik P. Raut ISSN: 2278-0181 Vol. 2 Issue 7, July – 2013
[5] “Mechanical Engineering Design” Shigley-Ninth Edition
[6] “Fundamentals of Machine Component Design” ROBERT C. JUVINALL Professor of
Mechanical Engineer

DEPT. OF MECHANICAL ENGINEERING, UVCE,

BANGALORE
8