University of Gonder

Institute of Technology (IoT)

Department of Mechanical Engineering
Machine Elements-I MEng 3152
CHAPTER # 1

INTRODUCTION: Stress Concentrations and Failure

Causes /Types/ Prevention

By: Andebet T.
 2.1 Stress Concentration
➢ Whenever a machine component changes the
shape of its cross-section, the simple stress
distribution no longer holds good and the
neighborhood of the discontinuity is different.
This irregularity in the stress distribution caused
by abrupt changes of form is called stress
concentration.

➢ A stress concentration (stress raisers or stress

risers) is a location in an object where stress is
concentrated. An object is strongest when force is
evenly distributed over its area, so a reduction in
area, e.g., caused by a crack, results in a localized Internal force lines are
denser near the hole
increase in stress.
 Stress Concentration
➢ via a propagating crack, when a concentrated stress exceeds the
material's theoretical cohesive strength. The real fracture strength of a
material is always lower than the theoretical value because most
materials contain small cracks or contaminants (especially foreign
particles) that concentrate stress.

➢ It occurs for all kinds of stresses in the presence of fillets, notches,

holes, keyways, splines, surface roughness or scratches etc.
Theoretical or Form Stress Concentration
Factor
➢ The theoretical or form stress concentration factor is defined as the
ratio of the maximum stress in a member (at a notch or a fillet) to the
nominal stress at the same section based upon net area.

➢ Mathematically, theoretical or form stress concentration factor,

➢ The value of Kt depends upon the material and geometry of the part.
Fatigue Stress Concentration Factor
 When a machine member is subjected to cyclic or fatigue
loading, the value of fatigue stress concentration factor shall be
applied instead of theoretical stress concentration factor.

 Mathematically, fatigue stress concentration factor,

 Notch Sensitivity
➢ Notch Sensitivity: It may be defined as the degree to which the theoretical
effect of stress concentration is actually reached.

➢ Notch Sensitivity Factor “q”: Notch sensitivity factor is defined as the ratio
of increase in the actual stress to the increase in the nominal stress near the
discontinuity in the specimen.

 Where, Kf and Kt are the fatigue stress concentration factor and theoretical
stress concentration factor.

➢ The stress gradient depends mainly on the radius of the notch, hole or fillet
and on the grain size of the material.
➢ Since the extensive data for estimating the notch sensitivity
factor (q) is not available, therefore the curves, as shown in
figure may be used for determining the values of q for two
steels.
Methods to reduce stress concentration
 The presence of stress concentration can not be totally
eliminated but it may be reduced to some extent.

 A device or concept that is useful in assisting a design

engineer to visualize the presence of stress concentration
and how it may be mitigated is that of stress flow lines.

 The mitigation of stress concentration means that the stress

flow lines shall maintain their spacing as far as possible.
▪ In Fig. (a), we see that stress lines tend to bunch up and cut very close
to the sharp re-entrant corner. In order to improve the situation, fillets
may be provided, as shown in Fig. (b) and (c) to give more equally
spaced flow lines.
▪ It may be noted that it is not practicable to use large radius fillets as in
case of ball and roller bearing mountings. In such cases, notches may
be cut as shown in Fig. (d).
 Following figures show the several ways of reducing the stress concentration in
shafts and other cylindrical members with shoulders, holes and threads :

 The stress concentration effects of a press fit may be reduced by making more
gradual transition from the rigid to the more flexible shaft.
 Factors to be Considered while Designing Machine
Parts to Avoid Fatigue Failure
 The following factors should be considered while designing machine parts to avoid
fatigue failure:

 1. The variation in the size of the component should be as gradual as possible.

 2. The holes, notches and other stress raisers should be avoided.

 3. The proper stress de-concentrators such as fillets and notches should be provided
wherever necessary.

 4. The parts should be protected from corrosive atmosphere.

 5. A smooth finish of outer surface of the component increases the fatigue life.

 6. The material with high fatigue strength should be selected.

 7. The residual compressive stresses over the parts surface increases its fatigue
strength.
Endurance limit and Fatigue Failure
➢ It has been found experimentally that when a material is
subjected to repeated stresses, it fails at stresses below the yield
point stresses. Such type of failure of a material is known as
fatigue.

➢ The failure is caused by means of a progressive crack formation

which are usually fine and of microscopic size. The failure may
occur even without any prior indication.

➢ The fatigue of material is effected by the size of the component,

relative magnitude of static and fluctuating loads and the number
of load reversals.
➢ A standard mirror polished specimen, as shown in figure is rotated in a fatigue
testing machine while the specimen is loaded in bending.

➢ As the specimen rotates, the bending stress at the upper fibres varies from maximum
compressive to maximum tensile while the bending stress at the lower fibres varies
from maximum tensile to maximum compressive.
➢ In other words, the specimen
is subjected to a completely
reversed stress cycle.
This is represented by a time-stress
diagram as shown in Fig. (a).
➢ Endurance or Fatigue limit (σe) is defined as maximum value of the
completely reversed bending stress which a polished standard specimen
can withstand without failure, for infinite number of cycles (usually 107
cycles).
➢ It may be noted that the term endurance limit is used for reversed bending
only while for other types of loading, the term endurance strength may
be used when referring the fatigue strength of the material.
➢ It may be defined as the safe maximum stress which can be applied to the
machine part working under actual conditions.
➢ We have seen that when a machine member is subjected to a completely
reversed stress, the maximum stress in tension is equal to the maximum
stress in compression as shown in Fig.(a). In actual practice, many
machine members undergo different range of stress than the completely
reversed stress.
➢ The stress verses time diagram for fluctuating stress having values σmin
and σmax is shown in Fig. (c). The variable stress, in general, may be
considered as a combination of steady (or mean or average) stress and a
completely reversed stress component σv.
➢ The following relations are derived from Fig. (c):

Alternating stress
max min
a = 2

Mean stress
max + min
m = 2
 Problem # 1
▪ A rectangular plate of 80 mm wide and 12 mm thick with a
transverse hole of 16 mm diameter is subjected to a tensile
load of 20KN as shown in figure. Taking stress
concentration into account, calculate stress induced.
 Problem # 2
 A stepped shaft of diameters 60mm and 30mm with a fillet radius of
6mm is subjected to a tensile load of 20 KN as shown in figure.
Taking stress concentration into account, calculate the maximum
stress induced.
 Problem # 3
 Find the value of the maximum stress on the fillet in fig. if the
stress concentration factor is equal to 1.75 D/d=1.5. what is the Fs
if the part is made of cast iron; σut=200 Mpa? Fs=2.74
Stress Concentration Factor
 Factors affecting endurance limit
 1) SIZE EFFECT:
➢ The strength of large members is lower than that of
small specimens.
➢ This may be due to two reasons.
▪ The larger member will have a larger distribution of
weak points than the smaller one and on an average,
fails at a lower stress.
▪ Larger members have larger surface Ares. This is
important because the imperfections that cause fatigue
failure are usually at the surface.
❖ Effect of size:

Increasing the size (especially section thickness) results in

larger surface area and creation of stresses.

This factor leads to increase in the probability of crack

initiation.

This factor must be kept in mind while designing large

sized components.
 2) SURFACE ROUGHNESS:

➢ almost all fatigue cracks nucleate at the surface of the members.

➢ The conditions of the surface roughness and surface oxidation or

corrosion are very important.

➢ Experiments have shown that different surface finishes of the same

material will show different fatigue strength.

➢ Methods which Improve the surface finish and those which introduce
compressive stresses on the surface will improve the fatigue strength.

➢ Smoothly polished specimens have higher fatigue strength.

➢ Surface treatments. Fatigue cracks initiate at free surface, treatments

can be significant

➢ Plating, thermal or mechanical means to induce residual stress

 3) Effect of Temperature:

➢ Fatigue tests on metals carried out at below room

temperature shows that fatigue strength increases
with decreasing temperature.

Stress amplitude

No. of cycles to Failure

Stress amplitude

No. of cycles to Failure

 4) Effect of metallurgical variables;
➢ Fatigue strength generally increases with increase in UTS

➢ Fatigue strength of quenched & tempered steels (tempered

martensitic structure) have better fatigue strength

➢ Finer grain size show better fatigue strength than coarser

grain size.

➢ Non-metallic inclusions either at surface or sub-surface

reduces' the fatigue strength
 S-N Diagram
➢ Fatigue strength of material is determined by R.R. Moore rotating
beam machine. The surface is polished in the axial direction. A
constant bending load is applied.

Typical testing apparatus, pure bending

Motor

Load

Rotating beam machine – applies fully reverse bending stress

➢ A record is kept of the number of cycles required to produce failure at a
given stress, and the results are plotted in stress-cycle curve as shown in
figure.
➢ A little consideration will show that if the stress is kept below a certain value
the material will not fail whatever may be the number of cycles.
➢ This stress, as represented by dotted line, is known as endurance or fatigue
limit (σe).
➢ It is defined as maximum
value of the completely
reversed bending stress
which a polished
standard specimen
can withstand without
failure, for infinite
number of cycles
(usually 107 cycles).
 Relationship Between Endurance Limit and Ultimate Strength

Steel
Steel
0.5Sut Sut ≤ 200 ksi (1400 MPa)
Se′ = 100 ksi Sut > 200 ksi
700 MPa Sut > 1400 MPa

Cast iron Cast iron

0.4Sut Sut < 60 ksi (400 MPa)

Se′ = 24 ksi Sut ≥ 60 ksi
160 MPa Sut < 400 MPa
 Relationship Between Endurance Limit
and Ultimate Strength
Aluminum
Aluminum alloys
0.4Sut Sut < 48 ksi (330 MPa)
Se′ = 19 ksi Sut ≥ 48 ksi
130 MPa Sut ≥ 330 MPa
For N = 5x108 cycle

Copper alloys
Copper alloys
0.4Sut Sut < 40 ksi (280 MPa)
Se′ = 14 ksi Sut ≥ 40 ksi
100 MPa Sut ≥ 280 MPa
For N = 5x108 cycle
Correction Factors for Specimen’s Endurance Limit
 Se = kakbkckdkekfSe’
 Where Se = endurance limit of component

 Se’ = endurance limit experimental

 ka = surface finish factor (machined parts have different finish)

 kb = size factor (larger parts greater probability of finding defects)

 kc = reliability / statistical scatter factor (accounts for random variation)

 kd = loading factor (differences in loading types)

 ke = operating T factor (accounts for diff. in working T &

room T)

 kf = stress concentration factor

 Correction Factors for Specimen’s Endurance Limit
• surface factor, ka
The rotating beam test specimen has a polished surface. Most
components do not have a polished surface. Scratches and
imperfections on the surface act like a stress raisers and reduce the
fatigue life of a part. Use either the graph or the equation with the
table shown below.
ka= A (Sut)b
Correction Factors for Specimen’s Endurance Limit

• Size factor, kb
Larger parts fail at lower stresses than smaller parts. This is mainly
due to the higher probability of flaws being present in larger
components.

For solid round cross section

d ≤ 0.3 in. (8 mm) kb = 1

0.3 in. < d ≤ 10 in. kb = .869(d)-0.097
8 mm < d ≤ 250 mm kb = 1.189(d)-0.097

If the component is larger than 10 in., use kb = .6

Correction Factors for Specimen’s Endurance Limit

• Reliability factor, kc

The reliability correction factor accounts for the scatter and

uncertainty of material properties (endurance limit).
Correction Factors for Specimen’s Endurance Limit

• Load factor, kd

Pure bending kd = 1
Pure axial kd = 0.7
Pure torsion kd = 1 if von Mises stress is used, use 0.577 if
von Mises stress is NOT used.
Combined loading kd = 1
❖ Operating temperature factor
➢ Accounts for the difference between the test
temperature and operating temperature of the
component
➢ For carbon and alloy steels, fatigue strength not
affected by operating temperature – 45 to 4500C
ke = 1
➢ At higher operating temperature
➢ ke = 1 – 5800( T – 450 ) for T between 450 and
550oC, or
➢ ke = 1 – 3200( T – 840 ) for T between 840 and
1020oF
Fatigue Stress Concentration Factor, Kf
Experimental data shows that the actual stress concentration factor is not as
high as indicated by the theoretical value, Kt. The stress concentration factor
seems to be sensitive to the notch radius and the ultimate strength of the
material.
Notch sensitivity
Kf = 1 + (Kt – 1)q factor
Fatigue Stress
Concentration Factor, Kf
for Aluminum
Design process – Fully Reversed Loading for Infinite Life
• Determine the maximum alternating applied stress, a, in terms of
the size and cross sectional profile
• Select material → Sy, Sut
• Choose a safety factor → n

• Determine all modifying factors and calculate the endurance

limit of the component → Se

• Determine the fatigue stress concentration factor, Kf

• Use the design equation to calculate the size

Se
Kf a =
n
• Investigate different cross sections (profiles), optimize for size or weight

• You may also assume a profile and size, calculate the alternating stress
and determine the safety factor. Iterate until you obtain the desired
safety factor
Design for Finite Life

Sn = a (N)b equation of the fatigue line

A A

S B S B
Se Sf

103 106 N 103 5x108 N

Sn = .9Sut Sn = .9Sut
Point A Point A
N = 10 3
N = 103

Sn = Se Sn = Sf
Point B Point B
N = 10 6 N = 5x108
Design for Finite Life
Sn = a (N)b log Sn = log a + b log N

Apply conditions for point A and B to find the two

constants “a” and “b”
2
(.9Sut)
3
a=
log .9Sut = log a + b log 10 Se
log Se = log a + b log 106 1 .9Sut
b= log
3 Se

Se
⅓ log ( .9S )
N ut
Sn = Se ( 106 )

Calculate Sn and replace Se in the design equation

Sn
Kf a = Design equation
n
 Fluctuating stresses
➢ The failure points from fatigue tests made with different steels and
combinations of mean and variable stresses are plotted in figure as
functions of stress amplitude(σa) and mean stress (σm).

➢ The most significant observation is that, in general, the failure point

is little related to the mean stress when it is compressive but is very
much a function of the mean stress when it is tensile.

➢ In practice, this means that fatigue failures are rare when the mean
stress is compressive (or negative). Therefore, the greater emphasis
must be given to the combination of a variable stress and a steady (or
mean) tensile stress.
 a
Sy Yield line

Gerber curve
Se
Alternating
stress Goodman line

Sy Sut m
Soderberg line
Mean stress
 Goodman Method for Combination
of Stresses:
 A straight line connecting the endurance limit (σe) and the ultimate
strength (σu), as shown by line AB in figure given below follows
the suggestion of Goodman.

 A Goodman line is used

when the design is based

on ultimate strength

and may be used for

ductile or brittle

materials.
Now from similar triangles COD and PQD,
Soderberg Method for
Combination of Stresses
➢ A straight line connecting the endurance limit (σe) and the
yield strength (σy), as shown by the line AB in following
figure, follows the suggestion of Soderberg line.

➢ This line is used when the design is based on yield

strength. the line AB connecting σe and σy, as shown in
following figure, is called Soderberg's failure stress line.
If a suitable factor of safety (F.S.) is applied to the endurance limit
and yield strength, a safe stress line CD may be drawn parallel to the
line AB.
 Modified Goodman Diagram:
➢ In the design of components subjected to fluctuating
stresses, the Goodman diagram is slightly modified to
account for the yielding failure of the components,
especially, at higher values of the mean stresses.

➢ The diagram known as modified Goodman diagram and is

most widely used in the design of the components
subjected to fluctuating stresses.
 Modified Goodman Diagram for fluctuating
axial and bending stresses
Fatigue, m ≤ 0 Fatigue, m > 0
a a m 1
+ = Infinite life
Se Sut nf
Se a m
a = n + = 1 Finite life
f Sn Sut
Yield Se
Sy Yield
a + m = n Sy
y
C
a + m = n
y
Safe zone Safe zone

- m - Syc Sy Sut + m
Combined Loading
All four components of stress exist,

xa alternating component of normal stress

xm mean component of normal stress

xya alternating component of shear stress

xym mean component of shear stress

Calculate the alternating and mean principal stresses,

1a, 2a = (xa /2) ± (xa /2)2 + (xya)2

1m, 2m = (xm /2) ± (xm /2)2 + (xym)2

Combined Loading

Calculate the alternating and mean von Mises stresses,

a′ = (1a2+ 2a -2 1a2a)1/2

m′ = (1m2 + 2m2 - 1m2m)1/2

Fatigue design equation

′a ′m 1
+ = Infinite life
Se Sut nf
 Design Example 10,000 lb.
12˝ 6˝ 6˝
A rotating shaft is carrying 10,000 lb force as
shown. The shaft is made of steel with Sut = d D = 1.5d
120 ksi and Sy = 90 ksi. The shaft is A
rotating at 1150 rpm and has a machine R1 R2
r (fillet radius) = .1d
finish surface. Determine the diameter,
d, for 75 minutes life. Use safety factor
of 1.6 and 50% reliability.
Calculate the support forces, R1 = 2500, R2 = 7500 lb.

The critical location is at the fillet, MA = 2500 x 12 = 30,000 lb-in

32M 305577
Calculate the alternating stress, a = Mc
= = m = 0
I πd 3
d 3

Determine the stress concentration factor

r
= .1
d
Kt = 1.7
D
= 1.5
d
 Design Example
Assume d = 1.0 in

Using r = .1 and Sut = 120 ksi,

q (notch sensitivity) = .85
Kf = 1 + (Kt – 1)q = 1 + .85(1.7 – 1) = 1.6

Calculate the endurance limit

Cload = 1 (pure bending)

Crel = 1 (50% rel.)
Ctemp= 1 (room temp)
-.265
Csurf = A (Sut)b = 2.7(120) = .759

0.3 in. < d ≤ 10 in. Csize = .869(d)-0.097 = .869(1)-0.097 = .869

Se = Cload Csize Csurf Ctemp Crel (S′e) = (.759)(.869)(.5x120) = 39.57 ksi
Design Example
Design life, N = 1150 x 75 = 86250 cycles
Se 39.57
N ⅓
log ( .9S )
ut 86250 ⅓ log ( .9x120 )
Sn = Se 6 ( ) Sn = 39.57 ( 6
) = 56.5 ksi
10 10

305577 Sn 56.5
a = = 305.577 ksi n=
Kfa
=
1.6x305.577
= .116 < 1.6
d3
So d = 1.0 in. is too small

Assume d = 2.5 in
All factors remain the same except the size factor and notch sensitivity.

Using r = .25 and Sut = 120 ksi,

Kf = 1 + (Kt – 1)q = 1 + .9(1.7 – 1) = 1.63
q (notch sensitivity) = .9

Csize = .869(d)-0.097 = .869(2.5)-0.097 = .795 → Se = 36.2 ksi

Design Example

Se = 36.2 ksi → Sn = 53.35 ksi

305577
a = 3
= 19.55 ksi
(2.5)
Sn 53.35
n= = = 1.67 ≈ 1.6
Kfa 1.63x19.55

d = 2.5 in.

Check yielding

Sy 90
n= = = 2.8 > 1.6 okay
Kfmax 1.63x19.55
THANK YOU