Design of Machine Elements I

ME 3240
Lecture 2
Hctor M. Rodrguez, PhD, PE
(Edited by Dr. A. Cecchini, SP16)
Mechanical Engineering Department
Polytechnic University of Puerto Rico

Ch. 6: Failures from Variable Loading

Fatigue Analysis

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Endurance Limit Modifying Factors

S'e is the endurance limit for a carefully prepared and tested specimen
Se is the endurance limit of an actual mechanical or structural parts
Marin factors - are used to adjust the endurance limit:
=

Marin factors are used when testing of actual parts is not practical
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Surface Factor ka
The surface of the rotating-beam specimen is highly polished.
The surface modification factor depends on the quality of he finish of the
actual part surface and on the tensile strength of the part material.
Data of endurance limit versus ultimate strength for common finishes of
machine parts, can be represented by:

Surface finish has an impact on crack initiation

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Size Factor kb
The rotating-beam specimen has a mid-point diameter of 0.3 in.
Larger parts have greater surface area at high stress levels.
Size factor is obtained from experimental data.
The results for bending and torsion may be expressed as:

0.3 0.107 = 0.879 0.107

0.91 0.157
7.62 0.107 = 1.24 0.107
1.51 0.157

0.11 2
2 10
2.79 51
51 254

For axial load, there is no size effect, so kb = 1

Eq. above applies only for round, rotating diameter

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Size Factor kb
Equivalent diameter de (for not rotating parts or noncircular cross
section).
Equate the volume of material stressed at and above 95% of the

maximum stress to the same volume in the rotating-beam specimen.

For a rotating round section, the 95% stress area is the area of a ring:
0.95 =

2
0.95
4

= 0.0766 2

Equate 95% stress area for other conditions to previous equation and

solve for d as the equivalent round rotating diameter.

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Size Factor kb
For non-rotating solid or hollow rounds:
0.95 = 0.01046 2

Equating to A0.95 for a rotating round section and solving for equivalent
diameter:
= 0.370
Similarly, for a rectangular section hxb, A0.95 = 0.05 hb, and the
equivalent diameter is:
= 0.808

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1/2

Loading Factor kc
When fatigue test are carried out with rotating bending, axial, and
torsional loading, the endurance limit differ.
For single load types:
1.00
= 0.85
0.59

Combination of Loading Modes (Sec. 614) for more than one load type.

Accounts for different types of fatigue loading

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Temperature Factor kd
The tensile strength for steels increases slightly as the temperature rises
(above room temp.) and then decreases in the 400-700F range

Accounts for effect of operating temperature

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Temperature Factor kd
It is probably that the endurance limit is related to the tensile strength at
elevated temperatures in the same manner as at room temperature.
A fourth-order polynomial curve fit the data in previous table as:
= 0.975 + 0.432 103 0.115 105 2
+0.104 108 3 0.595 1012 4

Where 70 TF 1000F.

Accounts for effect of operating temperature

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Temperature Factor kd
If the rotating-beam endurance limit (Se) is known at room temperature,
the use :

From table or equation.

If the rotating-beam endurance limit is not given, then compute it using:
=

0.5
100

200
> 200

And the temperature-corrected tensile strength obtained form table or

equation. Them use kd = 1.

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Reliability Factor ke
The reliability factor accounts for the scatter of data such as shown in
figure:

Reliability factor adjusts to other reliabilities

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Reliability Factor ke
Most endurance strength data are reported as mean values.
The reliability modification factor accounts for standard deviations (equal
to 8 percent):
= 1 0.08

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Miscellaneous-Effects Factor kf
The factor kf is intended to account for the reduction in endurance limit
due to all other effects:
Residual stresses

Directional characteristics from cold working

Case hardening
Corrosion
Surface conditioning, e.g. electrolytic plating and metal spraying
Cyclic Frequency
Frettage Corrosion

Use when limited data is available, may require research or testing

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Stress Concentration and Notch Sensitivity

The existence of irregularities or discontinuities (e.g. holes, grooves,
notches, etc.), in a part increases the nominal stresses significantly.
This increment in stresses is accounted by using a stress concentration
factor (Kt or Kts):
= 0

= 0

Where 0 is the nominal stress.

Stress concentration includes notch effects

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Stress Concentration and Notch Sensitivity

Stress concentration factor Kt (Bending)

Stress concentration includes notch effects

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Stress Concentration and Notch Sensitivity

For fatigue, some materials are not fully sensitive to the presence of
notches and hence, a reduced value of Kt can be used.
For these materials, the effective maximum stress in fatigue is:

= 0

= 0

Where Kf (fatigue stress-concentration factor) is a reduced value of Kt.

The resulting factor is defined by the equation:

=

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Stress Concentration and Notch Sensitivity

Define q as notch sensitivity, ranging from 0 (not sensitive) to 1 (fully
sensitive):
1
1
=
=
1
1
For q = 0 Kf = 1
For q = 1 Kf = Kt
In analysis or design, find Kt from the geometry of the part, then specify the
material (find q), and solve for Kf using equation:

= 1 + 1

= 1 + 1

Notch sensitivity q for specific materials are obtained experimentally

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Notch Sensitivity: Graphical Approach

Notch sensitivity for reversed bending or axial loading:

1+

2
3
= 0.246 3.08 103 + 1.51 105
2.67 108
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Sut in ksi

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Notch Sensitivity: Graphical Approach

Notch sensitivity for reversed torsion:

1
1+

2
3
= 0.19 2.51 103 + 1.35 105
2.67 108
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Sut in ksi

20

Application of Kf
Some designers (and previous editions of textbook) sometimes applied
1/Kf as a Marin factor to reduce Se.
For infinite life, either method is equivalent.

For finite life, increasing stress is more conservative. Decreasing Se

applies more to high cycle than low cycle

Use Kf as a multiplier to increase the nominal stress

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Stress Concentration and Notch Sensitivity

Example: The rotating shaft is simply supported at A and D, and loaded by a nonrotating force F = 6.8 kN. Estimate the fatigue life of the part. (Sut = 690
MPa, Sy = 580 MPa).

Dimensions in mm, all fillets 3-mm radius. Material is machined from AISI 1050 cold-drawn steel.
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Stress Concentration and Notch Sensitivity

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