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Lecture Notes On Machine Design
Lecture Notes On Machine Design
Lecture Notes On Machine Design
Reading
Homework
Chapter 6
HW 4 available, due 2-7
Tests
Fatigue Example 1
Fatigue
Variable stresses
Repeated stresses
Alternating stresses
Fluctuating stresses
Fatigue failure
Stress-life
Strain-life
Easiest to implement
Ample supporting data
Represents high-cycle applications adequately
Fatigue analysis
2 primary classifications of
fatigue
Alternating no DC component
Fluctuating non-zero DC
component
Smooth
Circular
Ideal conditions
S f (N )
Infinite life
Se
Implies N
S f (N )
Implies that the value of that strength (endurance limit) applies to a LAB SPECIMEN in
controlled conditions
Variables without a (Se, Sf)
Se
= 0.5 Sut
for
Sut < 200 ksi (1400 MPa)
= 100 ksi (700 MPa) for all other values of Sut
Iron
Se
S f (N )
a
Se
a
Se
= 0.4 Sut
for
Sut < 48 ksi (330 MPa)
= 19 ksi (130 MPa) for all other values of Sut
= 0.4 Sut
for
Sut < 35 ksi (250 MPa)
= 14 ksi (100 MPa) for all other values of Sut
Estimating Sf (N)
S 'f N aN b
1 0.9Sut
b - log
3 S e
1 0.9Sut
b - log
3 S e
5.7
Correction factors
These will account for differences between an ideal lab specimen and real life
Se = ka kb kc kd ke kf Se
ka surface factor
kb size factor
kc load factor
kd temperature factor
ke reliability factor
Kf miscellaneous-effects factor
Modification factors have been found empirically and are described in section 6-9 of
Shigley-Mischke-Budynas (see examples)
If calculating fatigue strength for finite life, (Sf), use equations on previous slide
Surface (ka)
Size (kb)
Accounts for effects of operating temperature (Not significant factor for T<250 C [482 F])
Reliability (ke)
Endurance limits differ with Sut based on fatigue loading (bending, axial, torsion)
Temperature (kd)
Loading (kc)
Accounts for scatter of data from actual test results (note ke=1 gives only a 50% reliability)
Miscellaneous-effects (kf)
Residual stresses
Corrosion
etc
Temperature Effect on Se
Reliability Factor, ke
Now what?
SC factor fatigue
= kfnom+ = kfo
t = kfstnom = kfsto
Fatigue SC factor
kf = [1 + q(kt 1)]
kfs = [1 + qshear(kts 1)]
q and qshear
Example
= 1.8
Infinite life
Design Equation:
= Se /
Example, cont.
= Se /
What do we need?
Considerations?
Se
nom
P
P
F
2083 F
A b - d h 60 - 12 10
Example, cont.
1 qkt - 1 nom
k f nom
r = 6 mm
Sut = 448 MPa = 65.0 ksi
q ~ 0.8
Example, cont.
Unloaded hole
d/b = 12/60 = 0.2
kt ~ 2.5
q = 0.8
kt = 2.5
nom = 2083 F
1 qkt - 1 nom
1 0.82.5 - 12083F
4583F
Example, cont.
Now, estimate Se
Steel:
Se = 0.5 Sut for Sut < 1400 MPa (eqn. 6-8)
700 MPa else
AISI 1020 As-rolled
Correction factors
These will account for differences between an ideal lab specimen and real life
Se = ka kb kc kd ke kf Se
ka surface factor
kb size factor
kc load factor
kd temperature factor
ke reliability factor
Kf miscellaneous-effects factor
Modification factors have been found empirically and are described in section 6-9 of
Shigley-Mischke-Budynas (see examples)
If calculating fatigue strength for finite life, (Sf), use equations on previous slide
Example, cont.
Modification factors
Surface:
ka = aSutb (Eq. 6-19)
ka = (4.45)(448)-0.265 = 0.88
Example, cont.
Size:
Axial loading
kb = 1 (Eq. 6-21)
Load:
kb
kc
Axial loading
kc = 0.85 (Eq. 6-26)
Example, cont.
Temperature:
Reliability:
kf = 1
Endurance limit:
Miscellaneous:
Design Equation:
Se 177MPa
1.8
4583F
177x106
F
21.4 kN
45831.8
Fluctuating
P
m
A
Mr
a
I
Alternating Stresses
Fluctuating stresses
Mean Stress
'm
2
Stress amplitude
'
a
max min
max - min
2
Together, m and a
characterize fluctuating
stress
Soderberg
Modified Goodman
Gerber
ASME-elliptic
Yielding
Points above the line: failure
Book uses Goodman primarily
Straight line, therefore easy algebra
Easily graphed, every time, for every problem
Reveals subtleties of insight into fatigue problems
Answers can be scaled from the diagrams as a check on the
algebra
a > Sf
Failure
Same as with alternating stresses
Or,
a
Sf
<1
m
Sut
Failure
Static Failure
Relationship is easily
seen by plotting:
Goodman Line
a
Sf
m
Sut
Sf
m
Sut
Case 1: m fixed
Sa
Case 2: a fixed
Sm
Case 3: a / m fixed
Sa
Sm
a
Sf
m
Sut
Example
Given:
Find:
Example, cont.
Find m and a
My
I
1
1
1
I bh3 w - d h 3 75 - 10183 3.16x10-8 m 4
12
12
12
h
ym ax 0.009 m
2
1
F L 1
M m m Fm L 9.36x103 0.3 702 Nm
4
2 2 4
1
F L 1
M m ax m ax Fm axL 10.67x103 0.3 800 Nm
4
2 2 4
M y
m m m ax 200 MPa
I
M y
m ax m ax m ax 228 MPa
I
a m ax - m 28 MPa
Example, cont.
m = 200 MPa
a = 28 MPa
nominal
Su = 1400Mpa
k f 1 qkt - 1
a a k f a
nom
m m k f m
nom
2.1428 60 MPa
2.14200 428 MPa
Example, cont.
Find strength
Eqn. 7-8: Se = .504Sut
Modification factors
Surface:
Size :
Load :
ka aSut
Equation (7 - 19) :
2.8 d eq 51 mm
Bending
a 271
b -0.995
ka 0.201
d eq 0.808hb
kb 1.24d eq
kb 0.86
kc 1 (Eq. 7 - 25)
1
2
- 0.107
Example, cont.
Design criteria
Goodman line:
a
Se
m
S ut
1/ n
121
121 1400
121 1400
1 60 428
121 1400
1.25
1400
Example, cont.
m = constant
Sa m
1
S e Sut
Sa
428
1
121 1400
Sa 84 MPa
S
84
a
1 .4
a 60
Less conservative!