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Lecture - 06 Fatigue I

This document provides an introduction to fatigue in metals, including key concepts like the S-N diagram and endurance limit. It discusses how fatigue is tested and modeled, and factors that influence fatigue life estimation such as load conditions, surface finish, temperature, and reliability. Case studies of metal fatigue failures in aircraft are presented to illustrate real-world applications.

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8 views

Lecture - 06 Fatigue I

This document provides an introduction to fatigue in metals, including key concepts like the S-N diagram and endurance limit. It discusses how fatigue is tested and modeled, and factors that influence fatigue life estimation such as load conditions, surface finish, temperature, and reliability. Case studies of metal fatigue failures in aircraft are presented to illustrate real-world applications.

Uploaded by

wkho0007
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Lecture: Fatigue I

MEC3416 Machine Design

Dr Jing Fu (Clayton)
Dr Jen Nee Lim (Malaysia)
Introduction to Fatigue in Metals
• Loading produces stresses that are variable, repeated, alternating,
or fluctuating
• Maximum stresses well below yield strength (assumed to be safe)
• Failure occurs after many stress cycles
• Failure is by sudden ultimate fracture
• No visible warning in advance of failure

2
Case in history

Hawaii, Aloha Flight 243, a Boeing 737, an upper part


of the plane's cabin area rips off in mid-flight. Metal
fatigue was the cause of the failure.

3
How to identify
• “Beach Marks”. Very smooth region
because surfaces have been rubbing
against each other.
• Rough surface, final catastrophic
failure.

4
Stages of Fatigue Failure
• Stage I – Initiation of micro-crack due
to cyclic plastic deformation
• Stage II – Progresses to macro-crack
that repeatedly opens and closes,
creating bands called beach marks
• Stage III – Crack has propagated far
enough that remaining material is
insufficient to carry the load, and fails
by simple ultimate failure

5
Modelling fatigue – How to test
• Test specimens are subjected to repeated stress while counting
cycles to failure - most common test machine is R. R. Moore high-
speed rotating-beam machine
• Subjects specimen to pure bending with no transverse shear
• As specimen rotates, stress fluctuates between equal magnitudes of
tension and compression, known as completely reversed stress
cycling
• Specimen is carefully machined and polished

6
Fatigue testing
• txt

A commercial fatigue test machine Boeing 787 dreamliner in fatigue test, Feb 2010

7
Understanding the fatigue data
• Plotting Life N (number of cycles until fatigue failure) vs stress level
• This is a statistical process. Not all samples have the same initial
flaws.
• A linear model can be observed in the Log-Log plot.

8
Endurance limit Se
• If the load never exceeds a certain limit, it never fails: Endurance
Limit
• Occurs usually between 106-107 cycles. If it survived till here, it will
not fail.

9
Relationship of endurance limit and hardness
• A conservative estimation of endurance limit is 250 HB

10
S-N Diagram for Nonferrous Metals
• Nonferrous metals often do not have an endurance limit.
• Fatigue strength Sf is reported at a specific number of cycles
• References e.g. Mark’s Handbook. Perform testing

11
General cases beyond standard fatigue testing
• Testing (standard) machine based on bending only
• Axial loading has lower fatigue strength, usually 10% lower,
multiplying basic endurance limit Sn’ by 90%
• Torsional loading typically causes endurance limit Sn’ by 58%
• Torsional shear strength can be estimated by Sus=0.8Su

12
Estimation the fatigue
life of a general case
• Factors that affect endurance
limit. See Table 8.1

13
Factors (cont’d)

14
CL Load Factor
• Bending and Axial, negligible difference to the ideal case. CL=1.0
• Just as or less likely for load to concentrate on a flaw.
• Torsion, CL=0.58. Material weaker in shear.

15
CG Gradient Factor
• Axial Load – Uniformly distributed load across a cross-section. More
likely to stress random flaws in the material.
• Bending and Torsion, high load only at the outer surfaces. Less likely
to stress random flaws in the material.
• Larger cross-sections, larger probability for flaws.
• >50mm, need to find out (i.e. look up data if available or do
experiments)

16
CS Surface Factor
• More imperfections in surface, more
likely for flaw and therefore shorter
fatigue life or lower endurance limit.

17
CT Temperature Factor
• Materials weaker at higher temperatures. (> 840 F/450 C)

18
CR Reliability Factor
• S’n is a statistical mean.
• Assume Gaussian distribution for the sample with an 8%
standard deviation (typical for most materials).
• If you want to be 99.9% sure that it does not fail, need to be 3 x
the standard deviation below therefore 0.753.
• If less reliability is tolerable, can choose a higher value of CR

19
Summary
• Introduction of is fatigue and its characteristics.
• S-N diagram and endurance limit.
• Look up Sn’ (idealized), then find out all the factors that reduce it (Table
8.1).The actual fatigue life Sn= Sn’CLCGCSCTCR

• References:
o Juvinall RC, Marshek KM. Fundamentals of machine component design. Hoboken, NJ:
John Wiley & Sons; 2019
o Budynas RG, Nisbett JK, Shigley JE. Shigley's mechanical engineering design. Boston:
McGraw-Hill; 2008.

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