WORCESTER POLYTECHNIC INSTITUTE

MECHANICAL ENGINEERING DEPARTMENT

DESIGN OF MACHINE ELEMENTS

ME-3320, A’2018

Lecture 14
September 2018

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 Fatigue failure
Theoretical or uncorrected fatigue data
 Wohler strength-life or S-N diagram
 Theoretical or uncorrected fatigue strength: S f '
 Theoretical or uncorrected endurance limit: Se '

Uncorrected S-N diagram

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 Estimating fatigue failure criteria
Based on experimental observations (bending, torsion, axial fatigue testing).
If data are not available… research, estimate, or… perform experiments...

Some materials with a “knee”

 Se'  0.5 Sut
For steels: 
Se'  100 ksi (700 MPa)
 Se'  0.4 Sut
For irons: 
Se'  24 ksi (160 MPa)
for Sut  200 ksi (1400 MPa)
for Sut  200 ksi (1400 MPa)
for Sut  60 ksi (400 MPa)
for Sut  60 ksi (400 MPa)

Some materials without a “knee”

 S f '@ N 5108  0.4 Sut for Sut  48 ksi (330 MPa)
For aluminums: 
S f '@ N 5108  19 ksi (130 MPa) for Sut  48 ksi (330 MPa)

For copper  S f '@ N 5108  0.4 Sut for Sut  40 ksi (280 MPa)
alloys: 
S f '@ N 5108  14 ksi (100 MPa) for Sut  40 ksi (280 MPa)

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 Fatigue failure
Correcting theoretical fatigue data
 Materials with a “knee.” Correcting function:
Se  Cload  Csize  Csurface  Ctemperature  Creliabilit y  Se'

at 1 x 10 6 cycles

 Materials without a “knee.” Correcting function:

S f  Cload  Csize  Csurface  Ctemperature  Creliabilit y  S f '

at 5 x 10 8 cycles
 Correction factors:
Cload , Csize , Csurface , Ctemperature , Creliabilit y
 Other factors may need to be added… depending on
the type (& service) of components being designed...

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 Fatigue failure
Correcting theoretical fatigue data
 Loading effects (correction):

1.0 Bending / Torsion

Cload 
0.7 Axial Loading, e.g., tension/compression

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 Fatigue failure
Correcting theoretical fatigue data
 Size effects (correction; cylindrical parts):

 1.0 d  0.3 in (8mm) 


0.869d 0.097 0.3 in  d  10 in 

C size   0.097   cylindrical parts
1.189d 8.0 mm  d  250 mm 

 Larger sizes use 0.6 


 Size effects (correction; non-cylindrical parts):


 A95 
d  d equiv; d equiv    non - cylindrical parts

 0.0766 
 (See page 363 of Norton’s)

portionof the cross - sectionalarea of a 

 
A95  nonroundpart thatis stressedbetween 
95% and 100%of its max. stress 
 

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 Fatigue failure
Correcting theoretical fatigue data
 Surface effects (correction): Csurface  See Figure6 - 26

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 Fatigue failure
Correcting theoretical fatigue data
 Surface effects (correction; Shigley and Mischke):

Csurf   A Sut b if C surf  1 then Csurf  1

(Use this model in the required units, as indicated in Table 6-3)

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 Fatigue failure
Correcting theoretical fatigue data
 Temperature effects (correction):

 1.0 T  450 C (840 F ) 


1  0.0058(T  450) 450 C  T  550 C  
Ctemp  
1  0.0032(T  840) 840  F  T  1020  F 

 


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 Fatigue failure
Correcting theoretical fatigue data
 Reliability effects (correction): Creliab  See Table 6 - 4

Standard deviation

Within materials Manufacturing

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 Fatigue failure
Correcting theoretical fatigue data
 Once fatigue strength/endurance limit has been corrected…
construct estimated (corrected) S-N diagram

Corrected S-N diagram

Corrected
Sf

Se Materials with a “knee”

Materials without a “knee”

Corrected

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 Fatigue failure
Creation of estimated S-N diagrams
 Fatigue strength at 103 cycles: S m

0.90Sut Bending 
Sm     at N  10 cycles
3
0.75Sut Axial Loading

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 Fatigue failure
Creation of estimated S-N diagrams
 Curve fitting of model (HCF-high cycle fatigue): S ( N )  a N b

Use corrected valuesfor S f or Se

at 5 x 10 8 cycles

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 Fatigue failure
 Review Example 6-1: Ferrous materials (with a “knee”)

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 Fatigue failure
 Review Example 6-2: Nonferrous materials (without a “knee”)

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Fatigue Stress Concentration Factors (FSCF)

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 Fatigue failure theories:
Surface defects & stress concentrations
 Fatigue failures always begin at a crack
• Cracks may be present in raw material used for fabrication
(crystallographic defects; inclusions; etc.)
• Cracks may be introduced during fabrication
• Cracks develop over time due to cyclic loading (& corrosion)
• Cracks develop around stress concentrations
Shaft failed in fatigue.
Crack initiated at keyway
Shaft with keyway
Failure due to
“rotating bending”

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 Fatigue failure
Notches and stress concentrations
 Notches introduce stress-concentrations. See
lectures 07-08 and 13
Shaft with keyway

 Correcting for stress-concentrations.

Stress concentration factors in fatigue: K f , K fs

 Use of stress concentration factors in fatigue:

  K f  nominal
  K fs  nominal
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 Fatigue failure
Notches and stress concentrations
 Stress concentration factors in fatigue:

K f  1  q( Kt  1)

 Theoretical (static) stress-concentration factor: K t

1
 Notch sensitivity factor: q 
a
1
r
a = Neuber’s constant

 Neuber’s constant (depends on the value of the

ultimate tensile strength of the material used).
See, for example, Tables 6-6, 6-7, and 6-8

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Fatigue failure: Neuber’s constant
Notches and stress concentrations

May need to do curve fitting in order to

determine Neuber’s constant functions:
y  Neuber' s constant  a
y  f (x)
x  Sut

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Fatigue failure: Neuber’s constant
Notches and stress concentrations

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Fatigue failure: Neuber’s constant
Notches and stress concentrations

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 Fatigue failure
 Review Example 6-3: determining fatigue stress-concentration factors

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 Fatigue failure
 Review Example 6-3: determining fatigue stress-concentration factors

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“Representative example: stress concentrations
 Class discussions

L = 1.50

b = 1.25

a = 0.35

F D2 = 0.50
r = 0.05
r = 0.125
(about x-axis)
T
T
FTh P = FTh x

(rear
D1 = 0.35
bearing)
D3 = 0.25
(front bearing) Dimensions are in meters
me

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Representative example: stress concentrations
 Class discussions

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Representative example: stress concentrations
 Class discussions

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Representative example: stress concentrations
 Class discussions

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 Reading assignment

 Chapters 6 of textbook: Sections 6.0 to 6.5

 Review notes and text: ES2001, ES2501, ES2502

Homework assignment
 Author’s:
 Solve: 6-5(a,f,k)

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