FLUCTUATING STRESSES

Fatigue load
 The loads, which vary in magnitude and/or
direction with respect to time, are known as
fatigue, fluctuating or alternating loads.
 It has been observed that, when the
mechanical component is subjected to
fluctuating loads, it fails at a stress
considerably below the ultimate strength
and quite frequently even below the yield
strength. Such failure is Fatigue failure.
 B
Instantaneuos
Fast Fracture!

A
Crack
nucleation
and Growth
Fluctuating stresses
 When the mechanical component is
subjected to the fatigue or fluctuating
load, the stress induced is known as
fluctuating stress.
 Repeated & Reversed Stress
 an element subjected to a repeated and
alternating tensile and compressive stresses.

Continuous total load reversal over time

Definitions:
  max   min
a   = Alternating stress
2 2

 max   min
m  = Mean stress
2

 min
R = R value:

 max R = 0, repeated and one direction, i.e. stress

cycles from 0 to max value.
R =-1, Fully reversed (R-R Moore)
1.Repeated and Reversed Stress

 min
R  1
 max
The average or mean stress is zero.
 Fluctuating Stress
 When an element experiences alternating
stress, but the mean stress is NOT zero.

Load varies between P and Q over time

2.Fluctuating Stress Example
• Bending of Rocker Arm
Valve Spring Force
Valve Open

Valve Closed

• Tension in Valve Stem

Valve Closed
Valve Spring Force

Valve
Open
Tensile Stress w/ Tensile Mean

max  min
a 
2

max  min
m 
2
Partially Reversed w/ Tensile Mean

max  min
a 
2

max  min
m 
2

max is tensile and min is compressive

Partially Reversed w/ Compressive Mean

max  min
a 
2

max  min
m 
2

max is tensile and min is compressive

Compressive Stress w/ Compressive Mean

max  min
a 
2
max  min
m 
2

max and min are both compressive

Repeated – One Direction Stress
 Fatigue Failure, S-N Curve

Test specimen geometry for R.R. Moore

rotating beam machine. The surface is polished
in the axial direction. A constant bending load is
applied.

Typical testing apparatus, pure bending

Motor

Load

Rotating beam machine – applies fully reverse bending stress

Fatigue Failure, S-N Curve
N < 103 N > 103

Finite life Infinite life

S′e

Se′ = endurance limit of the specimen

 Design for Finite Life

Sn = a (N)b equation of the fatigue line

A A

S B S B
Sf
Se
10 3
106 N 103 5x108 N

Sn = .9Sut Sn = .9Sut
Point A Point A
N = 10 3 N = 103
Sn = Se Sn = Sf
Point B Point B
6
N = 10 N = 5x108
Sn = a (N)b log Sn = log a + b log N

2
(.9Sut)
a=
log .9Sut = log a + b log 10 3
Se
log Se = log a + b log 106 1 .9Sut
b= log
3 Se

Se
⅓ log ( .9S )
N
Sn = Se ( 106 )
ut

Calculate Sn and replace Se in the design equation

Sn
Kf a = Design equation
n
Design of components subjected to fluctuating
stresses for infinite life

a
Sy Yield line

Gerber curve
Se
Alternating
stress Goodman line

Sy Sut m
Soderberg line
Mean stress
 The Effect of Mean Stress on Fatigue
Life Modified Goodman Diagram
a
Sy Yield line

Se
Alternating
stress Goodman line
C
Safe zone

Sy Sut m
Mean stress
 a
Sy Yield line

Se

Goodman line
C
Safe zone Safe zone

- m - Syc Sy Sut +m

 Fatigue, m ≤ 0 Fatigue, m > 0
a a m 1
+ = Infinite life
Se Sut nf
Se a m
a = n + = 1 Finite life
f Sn Sut
Yield Se
Sy Yield
a + m = n Sy
y
C
a + m = n
y
Safe zone Safe zone

- m - Syc Sy Sut +m

 Combined loading
All four components of stress exist,
xa alternating component of normal stress
xm mean component of normal stress

xya alternating component of shear stress

xym mean component of shear stress

Calculate the alternating and mean principal stresses,

1a, 2a = (xa /2) ± (xa /2)2 + (xya)2

1m, 2m = (xm /2) ± (xm /2)2 + (xym)2

 Calculate the alternating and mean von Mises stresses,

2 2
a′ = (1a + 2a - 1a2a)1/2
2 2

m′ = (1m + 2m - 1m2m)1/2

Fatigue design equation

′a ′m 1
+ = Infinite life
Se Sut nf
THANK YOU