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Piyush Shakya presents a document on time-varying load failures. The document discusses the history and examples of fatigue failure, which occurs due to repetitive or fluctuating loads and results in failure at stress levels lower than static failure. It also examines factors that influence fatigue life such as surface finish, stress concentration, reliability, and derating. Examples are provided to illustrate how to calculate fatigue life and endurance limits based on these factors.

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Prabhath Jyøthülâ PJ
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590 views31 pages

Lecture7,8 PDF

Piyush Shakya presents a document on time-varying load failures. The document discusses the history and examples of fatigue failure, which occurs due to repetitive or fluctuating loads and results in failure at stress levels lower than static failure. It also examines factors that influence fatigue life such as surface finish, stress concentration, reliability, and derating. Examples are provided to illustrate how to calculate fatigue life and endurance limits based on these factors.

Uploaded by

Prabhath Jyøthülâ PJ
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
You are on page 1/ 31

Time-varying Load Failures

Piyush Shakya

405, Machine Design Section


Department of Mechanical Engineering
IIT Madras
email: pshakya@iitm.ac.in

August 9, 2019

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 1 / 31


Contents

1 Fatigue Failure: Introduction

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 2 / 31


History

• Source: www.trainweb.org/tgvpages/images/maintain/bogie.jpg

• Source: Meral Bayraktar, Necati Tahrali and Rahmi Guclu, “Re-


liability and fatigue life evaluation of railway axles”, Journal of
Mechanical Science and Technology 24 (3) (2010) 671 679.
Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 3 / 31
Loss of Life to Fatigue Failure

• Aloha Airlines, Boeing 737, Hawaii, USA, 28th April 1988.


Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 4 / 31
Fatigue Failure Examples

• Source: Machine Design An Integrated Approach, R. L. Norton.


Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 5 / 31
Fatigue Failure Examples

• Source: Shigley’s Mechanical Engineering Design, R G Budynas, J


K Nisbett.
Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 6 / 31
Fatigue Failure Examples

• Source: Shigley’s Mechanical Engineering Design, R G Budynas, J


K Nisbett.
Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 7 / 31
Fatigue Failure Examples

• Source: Shigley’s Mechanical Engineering Design, R G Budynas, J


K Nisbett.

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 8 / 31


August Wohler Experiments

• Source: S. S. Manson and G. R. Halford, Fatigue and Durability of


Structured Materials, ASM International, March 2006, pp. 45-46.

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 9 / 31


Fatigue Failure

• Failure fatigue occurs under repetitive or fluctuating loading con-


ditions.

• Fatigue failure occurs at stress levels much lower that the stresses
that cause static failures.

• The life (often referred to as the number of cycles to failure) becomes


a critical parameter in design.

• The cracks initiating the fatigue failure usually begins at a stress


raiser (stress concentration)

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 10 / 31


Fatigue Failure (Assumptions)

• Loads alternate between a clear maximum and minimum (OR) are


totally random.

• The alternating frequency does not matter.

• The presence of corrosion is not considered. Typically, the effect of


corrosion will enhance under loads.

• Sinusoidal loading has been assumed for convenience. It has been


observed that the actual pattern of the load does not matter as long
as σm and σa remain constant.

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 11 / 31


Rotating Beam Machine

• Source: Design of Machine Elements, V B Bhandari.

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 12 / 31


Rotating Beam Machine

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 13 / 31


Rotating Beam Machine Sample Preparation

• The sample is carefully machined and polished. The final polishing


is done in the axial direction to avoid the circumferential scratches.
• Notice the fixed dimensions.
• 250 mm radius curve to avoid any stress concentration.
• No effect of temperature.
• No consideration of the variability between sample to sample (for
reliability).

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 14 / 31


Strength Life Diagram (Ferrous Material)

• Source: Design of Machine Elements, V B Bhandari.


Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 15 / 31
Strength Life Diagram (Aluminium Alloys)

• Source: Shigley’s Mechanical Engineering Design, R G Budynas, J


K Nisbett.

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 16 / 31


Endurance Limit and Tensile Strength Correlation

• Source: Shigley’s Mechanical Engineering Design, R G Budynas, J


K Nisbett.
Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 17 / 31
Surface Finish Factor (Ka ) for Steel

• Source: Design of Machine Elements, V B Bhandari.


Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 18 / 31
Z Statistic for Reliability Factor

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 19 / 31


Reliability Factor (Kc )

• Source: Shigley’s Mechanical Engineering Design, R G Budynas, J


K Nisbett.

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 20 / 31


Derating Factor for Stress Concentration
In the sample taken by R. R. Moore, it was carefully examined to avoid
any discontinuity and a radius of 250 mm was provide to avoid any
stress concentration. However, in the real life the machines may have:
• Cracks/blow holes
• Weld cavity
• Air holes
• Foreign inclusions
• abrupt change in the cross section
• Discontinuities (oil grooves, keyways, spline, screw threads)
Theoretical stress concentration factor
highest values o f actual stress near discontinuity
Kt = Nominal stress obtained by elementary equations f or minimum cross−section

Photoelastic experiments

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 21 / 31


Derating Factor for Stress Concentration
• When the stress in the vicinity of the discontinuity reaches the yield
point, there is plastic deformation, resulting in a redistribution of
stresses.
• Therefore, it is common practice to ignore the theoretical stress con-
centration factor for components that are made of ductile materials
and subjected to static load
• The effect of stress concentration is more severe in case of brittle
materials, due to their inability to plastic deform
• Therefore, stress concentration factors are used for components
made of brittle materials subjected to both static load as well as
fluctuating load.
Endurance limit o f notch f ree specimen
• Fatigue stress concentration factor K f = Endurance limit o f notched specimen
Increase o f actual stress over nominal stress
• Notch Sensitivity q = Increase o f theoretical stress over nominal stress

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 22 / 31


Stress Cocentration Factor (Kt )

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 23 / 31


Stress Cocentration Factor (Kt )

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 24 / 31


Stress Cocentration Factor (Kt )

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 25 / 31


Notch Sensitivity Factor (q)

• Source: Design of Machine Elements, V B Bhandari.

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 26 / 31


S-N Diagram for Steel (High Cycle Fatigue)

• Source: Design of Machine Elements, V B Bhandari.


Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 27 / 31
Example 1

• A 25 mm diameter shaft is made of forged steel 30C8 (Sut = 600


N/mm2 ). There is a step in the shaft and the theoritical stress
concentration factor at the step is 2.1. The notch sensitivity factor
is 0.84. Determine the endurance limit of the shaft if it is subjected
to reversed bending moment?

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 28 / 31


Example 2

• A cantilever beam made of steel Fe 540 (Sut = 540 N/mm2 and S yt


= 320 N/mm2 ) and subjected to a completely reversed load (P) of
5 kN is shown below. The beam is machined and the reliability is
50%. The factor of safety is 2 and the notch sensitivity factor is 0.9.
Calculate the diameter d of the beam for infinite life.

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 29 / 31


Example 3

• A forged steel bar, 50 mm in diameter, is subjected to a reversed


bending stress of 250 N/mm2 . The bar is made of steel 40C8 (Sut =
600 N/mm2 ). Calculate the life of the bar for a reliability of 90%.

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 30 / 31


Thank You

Piyush Shakya ME3201 (Design of Machine Elements) August 9, 2019 31 / 31

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