Fatigue Failure

Theories: Fatigue
Criteria
Design 1
Mechanical Engineering Faculty
Engineering Division
Universidad Santo Toms
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Types of fatigue loading
Fluctuating

Fully Repeated
Reversed

max min max min

m a r max min
2 2
Alternating Range
Mean stress
stress of stress 2
Fatigue problems:
Completely Reversing Simple Loading:
1. S e Cload Csize Csurface Ctemp Creliab S e'

2. Determine fatigue stress-concentration factor.

3. Determine fatigue life constants a and b.

4. Determine fatigue strength Sf at N cycles, or, N

cycles to failure at a reversing stress rev

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Fatigue problems:
Fluctuating Simple Loading:
S
1. e Cload C size C surface Ctemp C reliab S '
e

2. Determine fatigue stress-concentration factor. (6-9)

3. Calculate m and a. Apply Kf to both stresses.
4. Apply a fatigue failure criterion. (11-13)
5. Check for localized yielding.
6. For finite-life fatigue strength, equivalent completely
reversed stress

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Fatigue problems:
Combination of Loading Modes:
S
1. e Cload C size C surface Ctemp C reliab S '
e

2. Apply a general fatigue failure criterion. (15-17)

3. Conservative check for localized yielding using von
Mises stresses.

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Effect of Mean Stress
S 'f

m 0
m 0
m 0

N 6
Notch Sensitivity (q)

from eFatigue website from Budinas-Nisbett, p.1010

K f 1 qK t 1
4P

n
; K n

d2
t

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Notch Sensitivity (q)
1
q a: Neuber Constant [in0.5]
a
1 r : Notch radius [in]
r

Axial and bending loads Torsion loads

a K f n
a
a K f s
n
a

m K fm n
m
m K fms mn

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Notch Sensitivity (q)
Reversed Bending or Axial loads Reversed Torsion Loads

From Budynas-Nisbett, pg. 287-288

Only for steels (english units):

a 0.245799 0.307794 10 2 Sut 0.150874 10 4 Sut2 0.266978 10 7 Sut3
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Mean Stress Concentration Factor
When plastic strain at a notch cannot be avoided:
K if K f max
n
Sy
f
y
S K n

K fm Sy
f a
if K f max
n

n
m
0 if K f max
n
min
n
2S y Conservatively
or
K fm 1
K if K fs max
n
S ys
fs
S ys K fs a
n

K fms if K fs max
n
S ys
n
m
0 if K fs max
n
min
n
2S ys

Avoid localized plastic strain at a notch: K fm K f

10
Fatigue Strength Surface

From Norton, pg. 358

11
Fatigue Criteria

a m Sy
2
a m
1
S e S ut
a m
1
S e S ut

2 2
a m
1
a m e ut
S S
1
Se Sy
Adapted from Budynas-Nisbett, pg. 297 12
Modified Goodman Diagram

FAILURE
ZONE
N<1

SAFETY
ZONE
N>1

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Modified Goodman Diagram

OF S a
L: Load point Nf
OL a
F: Failure point

Se Sut
Nf
Se m Sut a

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General analysis procedure
START

Determine N

No The material Yes

has infinite life?

S n Cload Csize Csurface Se Cload Csize Csurface

Ctemp Creliab S n' Ctemp Creliab Se'

S f aN b
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General analysis procedure
torsion? Yes

No
a K fs an
m K fsm mn

Yes
bending?

a K f an No
m K fm mn
Yes
axial?

a axial K f axial an axial

No
m axial K fm axial mn axial
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General analysis procedure
von Mises Stresses

12

2

2
a a
' a axial
3 a
0.85
'
m
m m axial 3
2 2
m
12

S f Sut
Nf END
S f m Sut a

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Resume
Types of fatigue loading:
Fluctuating
max min max min
Fully
reversed m ; a
2 2
Repeated

Mean Stress Effect: Sf if m< 0

Sf if m> 0

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Resume
1 K f 1
Notch Sensitivity: q a

Kt 1
1
r
Always try to avoid localized plastic strain at notches.
If you cant, use Kfm expressions or, conservatively,
set Kfm = 1.

Se nothed
Se
Kf

from eFatigue website

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Resume
Fatigue Criteria:
Gerber
Goodman
ASME-elliptic
Soderberg

Factor of safety (Modified Goodman):

Se Sut
Nf
Se m Sut a
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References
Norton, R.L. Machine Design: an integrated
approach. 3rd ed, 2006.
Budynas and Nisbett. Shigleys Mechanical
Engineering Design. 8th ed, 2006.
Urugal, A.C. Mechanical Design. 2004.
eFatigue Website.
https://www.efatigue.com/

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any questions?

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