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Chapter (6) Endurance Limit Modifying Factors (Se): “duboS dail aril! i> daglio” The rotating-beam specimen used in the laboratory to determine endurance limits is prepared very carefully and tested under closely controlled conditions. Itis unrealistic to expect the endurance limit of a mechanical or structural member to match the values obtained in the laboratory. Some differences include: © Material: composition, basis of failure, variability * Manufacturing: method, heat treatment, fretting corrosion, surface condition, stress concentration © Environment: corrosion, temperature, stress state, relaxation times = Design: size, shape, life, stress state, speed, fretting, galling Marin’s equation is written as: Se = kakp keka ke ky S'e Where: Set endurance limit at the critical location of a machine part in the geometry and condition of use. S'e: rotary-beam test specimen endurance limit ka: surface condition modification factor. Kp t size modification factor. Ke: load modification factor. kg: temperature modification factor. ke: reliability factor. ky: miscellaneous-effects modification factor. Test specimen endurance limit (S'e) : “éqctal datas Janttiio den” 0.5Sur Sur < 200 kpsi (1400 MPa) SL=} 100 kpsi Sy > 200 kpsi 700 MPa Sy, > 1400 MPa Surface Factor (ka) : “aul Jato” k= asin Table 6-2 parametters for Marin Surface Modification Ground Machined or cold-drawn Hot-rolled ‘AS-forged Size Factor (k,) : Rotiting: For bending and torsion loads, the trend of the size factor data is given by: (d/0.3)-°')7 = 0.879d-° ~— O11 0.0252 aoe, = {0.0540 fom = Lo.osaxa + 0.1u(b — x) bending axial torsion Temperature Factor (k,): kg= a. 0.975 + 0,432(107%) Tp — 0.115(1075) 7,” + 0, 104(10-*) 7, — 0,595(107!) 7,4 ‘RT where 70 = T,; = 1000°F. S: a= i = 0.99 + 5.9(10-*) Te — 2.1(1076) Tp? R Or from Table 6-4 Effect of Operating Temperature on the Tensile Strength of Steel.* (St: tensile strength at operating temperature; Spr: tensile strength at room temperature; 0.099 # s* # 0.110) ees a eee ae 20 1.000 70 1.000 50 1.010 100 1.008 1.020, 200 1.020, 1.025 300 1.024 1.020, 400 1.018 1.000, 500 0.995 0.975 600 0.963 0.943 700 0.927 0.900, 800 0.872 0.843 900, 0.797 0.768 1000 0.698 0.672 1100 0.567 0.549 Reliability Factor (k.) : ke = 1 = 0.08 z, eee Ceiesiaea 50 1,000 90 0.897 95 0.868 99 0.814 99.9 0.753 99.99 0.702 99.999 0.659 99,9999 0.620 Miscellaneous-effects Factor (k,) : Given by Ky=1 The Stress-Life Method: Figure 6-9 Test-specimen geometry for theR. R. Moore rotating-beam machine. The bending moment is uniform, M = Fa, over the curved length and at the highest-stressed section at the mid-point of the beam: Figure 6-10 An S-N diagram plotted from the results of completely reversed axial fatigue tests. Material: UNS G41300 steel, normalized; Sy = 116 kpsis maximum Sy.=125 kpsi. (Data from NACA Tech, Note 3866, December 1966.): |< Low eyele — <1 High cycle ——____>» Finite life | infinite [life psi strength 5, 10° 10! 10 10° 10% 108108 107 108 Number of stress cycles, N Fatigue strength fraction (f): given by the equation: f = 1.06 — 2.8(1075)S,, + 6.9(10-°)S%, 70 < Sy, < 200 kpsi f= 1.06 — 4.1(10~‘)S,, + 1.5(1077)S, 500 < Sy < 1400 MPa OR from the plot: plot of f for 70 = S,, = 200 kpsi Sa < 70 kpsiz —g=0.9 Fatigue strength fraction, f, of Sur at 10° cycles for S.= S$’. = 0.58 ur at 106 cycle: f 09 0.88. os 078 0.76, 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Sue KPSi Fatigue Strength: Osa eH (8) a= 5. b log S. S,;= aN? If a completely reversed stress Srev is given by: Sf = Orey The number of cycles to failure can be expressed as the result of completely reversed stress: Orev ‘Ve a Stress Concentration factor (K,): fatigue stress-concentration factor ( Ky): Omax = Kpoo or Tmax = KyTo maximum stress in notched specimen stress in notch-free specimen Notch sensitivity (q): Kr-1 ia! Kat Me ST When we find the value of q, we can calculate the value of Kyfrom the equation: Kp= 1+ q(K,— 1) r Ky = 1 + Qshear(Kis — 1) q ifq=0,5>5 Kyl, ifq=135 ky=K, Kj dl teat Ragnelle oss iy Sa gl a ye a ass obte S yp I) lang Kya)! led hte Bl Ging 48 JS Nil Ge 2 Go gh Ula Ge Kyl ek hes ot Ky Ssh qin ony iat Notch radius r, mm 25 —— Sweels Alum. alloy 0.02 0.04 0.06 (0.08010 0.121016 Notch radius r, in Kp= 1+ q(K,— 1) or Kg = 1 + Gstear(Kis — 1) ifq@=0>> ky=1, if q=1>5 k,=K, ii bed any I SSF Sa Sa aly SSD J St A SL gad TS een ge BSE KF pl 4 a8 as Sues Cle Sypull La Males IK, ot alls cbt: Ga 9! Gaya ab JS Lisle Ll des load : deat aus citi tay VG aes ube: Le (Neuber constant: Va) vast le ty Cia Hla as JS (Ail Load....., Bending Load.....,Tortion Load) SSSI, 5 i pate ants cule ie Vd Bending or axial load: Va = 0.246 — 3.08(10°*)Sy + 1.51(10*)Si, — 2.6710 *) Sir Torsion load: Va = 0.190 — 2.51(10™)S,, + 1.35(10-)S2, — al = 1 net q= 1. wa K= eae "Th Var pac La Uy all ly 4S Ll peal Ts ak pnt eye SS KY) el sola Ts (Suet! 0.20 cll se call 0 Ge Chis « Vp Acai (cast irons)» ji) 81 Sa Gall Analun G) agsall la jo geal g = 0,20 Rall plains goog « Lilaall ilall Gy SG SI atts gle cast irons).) » 5! Characterizing Fluctuating Stresses: Fax + Frnin 2 Fin = = minimum stress @, = midrange component = maximum stress o, = range of stress = amplitude component a, = static or steady stress O max + O min stress ratio Onin R= O max the amplitude ratio Oa A=— om The nominal mean stress method (set sa 5 Kf sao and sm 5 smo) gives roughly comparable results to the residual stress method, but both are approximations There is the method of Dowling21 for ductile materials, which, for materials with a pronounced yield point and approximated by an elastic—perfectly plastic behavior model, quantitatively expresses the steady stress component stress- concentration factor Kfm as K;|Omax,o| < Sy Kj|Omax.o| > Sy K5|Cmax,o — Fmino| > 2S, For the purposes of this book, for ductile materials in fatigue, + Avoid localized plasticstrain at a notch, Set sa 5 Kf sao and sm 5 Kf smo. + When plastic strain at a notch cannot beavoided, use Eqs. (6-39); or conservatively, set sa 5 Kf sao and use Kfin 5 1, that is, sm 5 smo Fatigue Failure Criteria for Fluctuating Stress: The very clever diagram of Fig. 6-26 is unique in that it displays four of the stress components as well as the two stress ratios. A curve representing the endurance limit for values of R beginning at R 5 21 and ending with R 5 | begins at Se on the sa axis and ends at Sut on the sm axis. Constant-life curves for N=105 and N =104 cycles Figure 6-24 Modified Goodman diagram showing all the strengths and the limiting values of all the stress components for a particular midrange stress Midrange stress Figure 6-25 Plot of fatigue failures for midrange stresses in both tensile and compressive regions. Normalizing the data by using the ratio of steady strength component to tensile strength SmySut, steady strength component to compressive strength SmySucand strength amplitude component to endurance limit SayS9 ¢ enables a plot of experimental results for a variety of steels. [Data source: Thomas J. Dolan, “Stress Range,” Sec. 6.2 in O. J. Horger (ed.), ASME Handbook — Metals Engineering Design, McGraw-Hill, New York, 1953.] 0 08 -06 04 -02 0 02 04 06 Compression 5,5, Tension S,/5,, Midrange ratio Figure 6—26 Master fatigue diagram created for AISI 4340 steel having and Sut 5 158 and Sy 5 147 kpsi. The stress components at A are smin 5 20, smax 5 120, sm 570, and sa 5 50, all in kpsi. (Source: H. J. Grover, Fatigue of Aircraft Structures, U.S. Government Printing Office, Washington, D.C., 1966, pp. 317, 322. See also J. A. Collins, Failure of Materials in Mechanical Design, Wiley, New York, 1981, p. 216.) ‘Load line, slope r= SJ, Modi Goodman ine ASME-eliptic tine Midrange srs Figure 6-27 Fatigue diagram showing various criteria of failure. For each criterion, points on or “above” the respective line indicate failure. Some point A on the Goodman line, for example, gives the strength Sm as the limiting value of sm corresponding to the strength Sa, which, paired with sm, is the limiting value of sa, When the midrange stress is compression, failure occurs whenever sa 5 Se or whenever smax 5 Syc, as indicated by the left-hand side of Fig. 6-25. Neither a fatigue diagram nor any other failure criteria need be developed. © It is a straight line and the algebra is linear and easy. © Itis easily graphed, every time for every problem. * It reveals subtleties of insight into fatigue problems. * Answers can be scaled from the diagrams as a check Considering the modified Goodman line as a criterion, point A represents a limiting point with an alternating strength Sa and midrange strength Sm. The slope of the load line shown is defined as r 5 SaySm. The criterion equation for the Soderberg line is The criterion equation for the Soderberg line is Sa, Sm we 4 My] Se Sy Similarly, we find the modified Goodman relation to be: Sa + Se Sut The Gerber failure criterion is written as: 2 $4 (SY Se \Sut he ASME-elliptic is written as SEN (Sm\e (3) +(S) = S s Sa + Sn = S, the design factor or factor of safety: On 1 CO Soderberg — + - Se S, fn Ta | Fm _ 1 mod-Goodman — + — = — _ 7. Gerb nGa (“22 1 erber —— = Se Sut nO >~ 2 NO», 2 ASME-elliptic ("2:) + ("Z2) =1 S. 5, The design equation for the Langer first-cycle-yielding is: Langer static yield o, + 0, = The failure criteria are used in conjunction with a load line oe Failure criterion: A — Om \~ Failure criterion: + ) = fe (Sut Sa fe, nS. \? Design equation: y= >( 7") (s)[-1+ yl + (So On 20 Om Failure criterion: =1 Design equation: Failure criterion: Design equation: ny = [( = Failure criterion: Desi tion: = (2+%)" >0 sian equation: n= (5+ On = Table 6-6 Amplitude and Steady Coordinates of Strength and Important Intersections in First Quadrant for Modified Goodman and Langer Failure Criteria Intersecting Equations Sr . Load tne r= 5* Table 6-7 Amplitude and Steady Coordinates of Strength and Important Intersections in First Quadrant for Gerber and Langer Failure Criteria faennen Table 6—8 Amplitude and Steady Coordinates of Strength and Important Intersections in First Quadrant for ASMEE lliptic and Langer Failure Criteria Intersecting Equations Intersection C Load line r = S./Sq F, = X,VF, + ¥,F, is oo1s 09 0021 oi 0.028 02 0.082 024 0.086 026, 0070 027 0.084 028 oi9 030 our 034 028 038 a2 042 056 os Use D018 H/C <0014

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