FATIGUE
Mechanical Fatigue
Thermal Fatigue
Thermo-mechanical Fatigue
Corrosional Fatigue
Contact Fatigue
Fatigue Failure: Failure of materials under dynamic
loading.
Failure occurs under yield or tensile stress values.
Fatigue failure is brittle-like (relatively little plastic
deformation) - even in normally ductile materials. Thus
sudden and catastrophic!
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FATIGUE
What is the failure type ?
Fatigue failure is brittle-like (relatively small
plastic deformation) - even in normally ductile
materials. Thus sudden and catastrophic!
Applied stresses causing fatigue may be axial (pure
tension or tension-compression), flexural (bending) or
torsional (twisting).
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FATIGUE
Fatigue failure proceeds in three distinct
stages:
1. Crack initiation in the areas of stress
concentration (near stress raisers),
2. Incremental crack propagation,
3. Final catastrophic failure.
Fatigue Crack Initiation and Propogation
By brittle materials the crack initiation number is high
By ductile materials the crack initiation number is low
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Crack Initiation
Surface
During dynamic loading, slip bands
start to move.
Slip bands
Due to this movement, micro cracks
occur at the surface. Bands are moving
These micro cracks causes notch
effect and an increase in stress. Microcracks
Crack Initiation
These microcracks grow by
each loading and forms to
macrocracks.
By each loading fatigue
Crystal striations are formed and fatigue
Surface
Slip
crack moves forward.
bands
Slip
bands
Crystal
Surface
Slip
bands
Static loading
Dynamic loading
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Incremental crack propagation
• By fatigue, first slip bands move 450
to stress direction.
• After this movement (about 3-4 grain
size), the crack propagation direction
moves perpendicular to applied
stress.
Incremental crack propagation
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Bending Failure (Two Sides)
Sudden Fracture
Fatigue-2
Fatigue-1
Fatigue Fracture at a Crankshaft
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Rotating – Bending Fatigue Failure,
low sudden brittle area – low nominal stresses
Strong circumference notch effect
Crack nucleation
Brittle fracture
FATIGUE TEST
Fatigue = failure under cyclic stress.
compression on top
Explain!
specimen
be a r ing motor counter
be a r ing
flex coupling
tension on bottom Load
Stress varies with time.
-key parameters are S and Sm
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Application of Fatigue Testing
g
max
Tensile
g
ort=0
Time
Compression
min
max min σg = Stress amplitude, σm = Mean Stress
g
2 min
min Stress Ratio
m max max
2
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S-N Fatigue Diagram, (Wohler Diagram)
Wöhler analysed the effect of dynamic loading on fatigue life.
By his test amplitude stress value was zero (σg = 0).
He plot his values on a stress – cycle diagram
y: Fatigue
(Endurance) limit
Stress
cycle
Fatigue (Endurance) limit
• In BCC structure metals (Fe, ...it consists an fatigue limit.
• In FCC structure metals (Ni, Cu ...) it does not consist an fatifue limit.
Therefore fatigue strength is described as the stress value by 107 or 108
cycle.
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FATIGUE DESIGN PARAMETERS
S = stress amplitude
Fatigue limit, Sfat: case for
-no fatigue if S < Sfat unsafe Steel
Endurance Limit
Sfat
safe
• For steels Sfat = 35%-60% Adapted from Fig.
8.17(a), Callister 6e.
of YS 10 3 10 5 10 7 10 9
• Think about design N = Cycles to failure
criteria factor, N in
S = stress amplitude
chapter 6 case for
unsafe Al (typ.)
• Sometimes, the fatigue
limit is zero!
safe Adapted from Fig.
8.17(b), Callister 6e.
10 3 10 5 10 7 10 9
N = Cycles to failure
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Fatigue (Endurance) limit
y : Material property (fatigue strength)
g : Stress (amplitude)
g < y No Fatigue
g > y fatigue
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Fatigue (Endurance) limit
Low cycle fatigue: high loads, plastic and elastic
deformation (N < 104)
High cycle fatigue: low loads, elastic
deformation (N > 104)
Emphirical Drawing of a Wöhler (S-N) Diagram
Fatigue limit
σC = tensile strength
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Graph of endurance limit versus tensile strength
The Effect of Average Stress and
Application of Fatigue Testing
Examples of stress cycles. (a)
Equal stress in tension and
compression, (b) greater tensile
stress than compressive stress,
and (c) all of the stress is
tensile
What if average
stress is not zero
ort 0 (R 0)
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The Effect of Average Stress and
Application of Fatigue Testing
Increasing the mean
stress leads to a
decrease in fatigue
life
What if average stress is not zero
ort 0 (R 0)
• Sodergerg
• Goodmann
• Gerber
• Smith diagrams
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a Soderberg
fat
Unsafe
x
x
Safe
mean
0 y
ort≠0
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Factors Effecting Endurance Limit
Loading Conditions
-Average stress level
-Impact factor
Ambient Conditions • Corrosive environment
-Temperature • Increasing temperature
-Corrosive enviroment • Increasing surface roughness
Component Geomety
-Thickness
-Crosssection Shape
(Square, circle ...)
-Notch effect
• Increasing tensile strength
Tensile Strength • Surface hardening
• Increasing surface smootheness
FATIGUE + FRACTURE
MECHANICS
PARIS – ERDOĞAN EQ.
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Fatigue behavior of cracked component
Paris-Erdoğan Eq.
Crack growth rate versus
stress-intensity factor range
for a high-strength steel. For
this steel,
C = 1.62 x 10 –12
n = 3.2
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FATIGUE MECHANISM
• Crack grows incrementally
typ. 1 to 6
Paris-Erdoğan Eq.
increase in crack length per loading cycle
crack origin
• Failed rotating shaft
--crack grew even though
Kmax < Kc
--crack grows faster if
• D increases
• crack gets longer
• loading freq. increases.
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35
36
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Example, Design of a Rotating Shaft
• A solid shaft for a cement kiln produced from the
tool steel in Figure must be 96 in. long and must
survive continuous operation for one year with an
applied load of 12,500 lb.
• The shaft makes one revolution per minute during
operation.
• Design a shaft that will satisfy these requirements.
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The stress-number of cycles to failure (S-N) curves for a tool steel
and an aluminum alloy
N=525600 cycle 40 40
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Example SOLUTION
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