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Course Material 14-02-2015 040302 4205
Course Material 14-02-2015 040302 4205
Course Material 14-02-2015 040302 4205
Stres
s
Time
Fig. 1.2: Fluctuating stress
Stres
s
=0
Time
= 0 Time
e e K sur
(1.2)
e e K d
(1.3)
Where, K d = modified design factor
We know that the modified design factor is reverse of fatigue stress concentration factor
So,
1
Kd
(1.4)
Kf
Where,
K f 1 q( Kt 1)
(1.5)
Where,
q = notch sensitivity.
1.7 Combined Influence of size, Surface Finish, notch sensitivity and stress concentration
on Endurance Limit
When a machine member is subjected to variable loads, the endurance limit of the material for
that member depends upon the many conditions like as the type of loading, finishing of surface
and size of specimen, so the endurance limit has been changed by .
So the endurance limit for reversed loading is,
e e K d K sf K sz
(1.6)
e 0.4 u
(1.11)
Cast iron,
e 0.35 u
(1.12)
(1.13)
And for non-ferrous metals and alloys, e 0.3 u
1.13 Factor of safety for fatigue loading
When a component is subjected to fatigue loading, the endurance limit is the criterion for failure.
Therefore, the factor of safety should be based on endurance limit. Mathematically,
Endurance limit stress
For steel,
e = 0.8 or 0.9 u
(1.15)
EXAMPLE
1.1 A component machined from a plate made of steel 40C8 (Ultimate strength= 630 N/mm2) is
shown in fig. it is subjected to a completely reversed axial force of 50kN. The expected
reliability is 90% and factor of safety is 2. The size factor is 0.85. Determine the plate thickness
of plate foe finite life, if the notch sensitivity factor is 0.8.
Solution:Given
P 50kN, u 630 N / mm2 , ( fs ) 2.0, R 90%, q 0.8, Ksz 0.85
Step-I Endurance limit stress for plate
e' (0.5) u 0.5 630 315N / mm2
Now from the Data Hand Book For machined surface
Ksf=0.76,
And for 90% reliability
Kr=0.897
For design factor from data hand book for
The
D 100
2
d 50
r 5
0.1
d 50
Kt= 2.27
K f 1 q( Kt 1)
=1+0.8(2.27-1) =2.016
1
1
Kd
0.496
Kf
2.016
e e K d K sf K sz K r
= 315 (0.496) (0.76) (0.85) (0.896)
= 90.54 N/mm2
Step II Permissible stress amplitude
For steel,
( e ) a (0.8) e (0.8) 90.54 72.43N / mm2
Now,
( )
72.43
a e a
36.22 N / mm 2
fs
2
Step-III Plate thickness
Since,
P
P
a
A (50)t
P
t
27.61mm
50( a )
2. COMBINED STEADY AND VARIABLE STRESS
The failure points from fatigue tests made with different steels and combinations of mean and
variable stresses are plotted in Fig., as functions of variable stress (v) and mean stress (m).
The relationship between variable stress (v) and mean stress (m) for axial and bending
loading for ductile materials are shown in Fig. The point e represents the fatigue strength
corresponding to the case of complete reversal ( m = 0) and the point u represents the static
ultimate strength corresponding to v = 0. A parabolic curve drawn between the endurance limit
(e) and ultimate tensile strength (u) was proposed by Gerber. Generally, the test data for ductile
material fall closer to Gerber parabola as but because of scatter in the test points, a straight line
relationship (i.e. Goodman line and Soderberg line) is usually preferred in designing machine
parts.
Fig. 2.1: Gerber line, Goodman line and Soderberg line for fatigue
UNIT- I/ FATIGUE CONSIDERATIONS IN DESIGN
1
m F .S v
F .S u
e
(2.1)
PQ QD OD OQ
OQ
1
CO OD
OD
OD
v
m
1
e / F .S
u / F .S
UNIT- I/ FATIGUE CONSIDERATIONS IN DESIGN
1
m
m
1
e
F .S u / F .S
F .S u
1
m v
F .S u e
(2.4)
Considering the load factor, surface finish factor and size factor, the equation may be written as,
v K f
1
m
(2.5)
F .S u e K sr K sz
Considering the theoretical stress concentration factor (Kt), then the equation may be written as,
v K f
Kt
1
m
(2.6)
F .S
u
e K sr K sz
2.3 Soderberg method for combination of stresses
A straight line connecting the endurance limit (e) and the yield strength (y), as shown by the
line AB in Fig., is known as Soderberg's failure stress line. This line is used when the design is
based on yield strength. 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. Let us consider a
design point P on the line CD. Now from similar triangles COD and PQD,
OD
CO
OD
OD
e / F .S
y / F .S
m
1
F .S y / F .S
1
e
m
F .S y
m v
F .S y e
UNIT- I/ FATIGUE CONSIDERATIONS IN DESIGN
(2.7)
1
(2.8)
m
F .S y e K sr K sz
EXAMPLE
1.2 A cantilever beam made of cold drawn carbon steel of circular cross-section as shown in Fig.
is subjected to a load which varies from F to 3 F. Determine the maximum load that this
member can withstand for an indefinite life using a factor of safety as 2. Assume the following
values: = 550 MPa, = 470 MPa, = 275 MPa, Ksz = 0.85; Ksur = 0.89 Fatigue stress
concentration factor, Kf =1.378.
150
20
-F
13
125
3F
Solution:Given
= 550 MPa, = 470 MPa, = 275 MPa, Ksz = 0.85; Ksur = 0.89
Fatigue stress concentration factor, Kf =1.378
We know that the maximum bending moment at point A,
M max Wmax 125 3F 125 375FN mm
And that the minimum bending moment at point A,
M min Wmin 125 F 125 125FN mm
Mean or Average bending moment,
M M min 375 (125F )
M m max
125FN mm
2
2
M M min 375 (125F )
M a max
250 FN mm
2
2
Section modulus,
Z
d3
(13) 3 215.7mm3
32
32
Mean and variable bending stresses,
M
125F
m m
0.58FN / mm 2
Z
215.7
M
250 F
v m
1.16 FN / mm 2
Z
215.7
Now the fatigue stress concentration factor,
K f 1 q( K t 1) 1.378
We know that according to Goodmans formula,
UNIT- I/ FATIGUE CONSIDERATIONS IN DESIGN
v K f
1
m
F .S u e K sr K sz
1 0.58F
1.16 F 1.378
2
550
275 0.89 0.85
0.00873F
F 57.3N
And we know that according to Soderbergs formula,
v K f
1
m
F .S y e K sr K sz
1 0.58F
1.16 F 1.378
2
470
275 0.89 0.85
0.00891F
F 56 N
2.4 Design of machine members subjected to combined, steady and alternating stresses
When a machine part is subjected to both variable normal stress and a variable shear stress; then
it is designed by using the following two theories of combined stresses :
1. Maximum shear stress theory, and 2. Maximum normal stress theory.
According to Soderberg's formula,
v K f
1
m
(2.9)
F .S y e K sr K sz
Multiplying throughout by y, we get
y
F .S
y v K f
e K sr K sz
(2.10)
The term on the right hand side of the above expression is known as equivalent normal stress
due to reversed bending.
Equivalent normal stress due to reversed bending,
y v K f
(2.11)
neb m
eb K sr K sz
Similarly, equivalent normal stress due to reversed axial loading,
y v K f
nea m
ea K sr K sz
(2.12)
v K f
1
m
F .S y e K sr K sz
(2.13)
y
F .S
y v K f
e K sr K sz
(2.14)
The term on the right hand side of the above expression is known as equivalent shear stress.
UNIT- I/ FATIGUE CONSIDERATIONS IN DESIGN
(2.15)
The maximum shear stress theory is used in designing machine parts of ductile materials.
According to this theory, maximum equivalent shear stress,
1
(2.16)
es (max)
( ne ) 2 4( es ) 2
2
The maximum normal stress theory is used in designing machine parts of brittle materials.
According to this theory, maximum equivalent normal stress,
1
1
ne(max) ne
( ne ) 2 4( es ) 2
(2.17)
2
2
2.5 Design for finite life
When the component is to be designed for finite life the S-N curve can be used
This curve is valid for steels.
es (max)
410 MN/m2 = 410 106 N/m2 ; u = 0.5 u = 275 106 N/m2 ; F.S. = 2 ; Ksz = 0.85 ; Ksur =
0.62
Let d= required shaft diameter
We know that mean and Variable Torque,
T T
330 (110)
Tm max min
110 N m
2
2
T T
330 (110)
Ta max min
220 N m
2
2
Now the mean and variable shear stress
16Tm 16 110 560
m
3 N / m2
3
3
d
d
d
16Tv 16 220 1120
v 3
3 N / m2
3
d
d
d
Since the endurance limit in shear is e is (0.55) e and strength in shear y is (0.55) y
Therefore
e (0.55) e 0.55 275 10 6 151.25 10 6 N / m 2
110 N m
2
2
M M min 440 (220)
M a max
330 N m
2
2
Z
d 3 0.0982d 3 m 3
32
Now mean and variable stress
M
110
1120
m m
3 N / m2
3
Z
0.0982d
d
M
330
3360
m m
3 N / m2
3
Z
0.0982d
d
Since there is no reversed axial loading, therefore the equivalent normal stress due to reversed
bending load,
y v K f
neb m
eb K sr K sz
Mm
1120
3360 410 10 6 1
d3
d 3 275 10 6 0.62 0.85
10626
N / m2
d3
Now we know that the maximum equivalent shear stress,
1
es (max)
( ne ) 2 4( es ) 2
2
2
2 d3 d3
d 39.5mm
2
P P
k 'b k ' c
So
(2.24)
k 'b
Pb Pi P
k 'b k 'c
Pb Pi CP
(2.25)
k 'b
C
k 'b k 'c
(2.26)
Where
(2.30)
2
2 A A A
P CP
m i
(2.31)
A
A
And
1
1 P CP Pi
(2.32)
a max min i
2
2 A A A
CP
(2.33)
a
2A
So
P
m i a
(2.34)
A
Now from this procedure the size of bolt can be obtained.
EXAMPLE
1.4 The assembly of two circular plates with 3d and d as outer and inner diameters are clamped
together by means of bolt, is subjected to a variable loads P varying from 0 to 10kN. The bolt is
made of plain carbon steel 45C8 ( =630N/mm2, =380N/mm2, E=207kN/mm2). The two
circular plates are made of aluminium (E =71kN/mm2). The fatigue stress concentration factor is
2.2 and the expected reliability is 90%. The initial pre-load in the bolt is 5kN. Determine the size
of bolt, if the factor of safety is 2.
Solution:Pi 5kN, P 0to10kN, ( fs ) 2
For bolt
=630N/mm2, =380N/mm2, E=207kN/mm2
For plate
E =71kN/mm2
Step-I Endurance limit stress for bolt
e' (0.5) u 0.5 630 315N / mm2
Now from the Data Hand Book For machined surface
Ksf=1.0,
And for 90% reliability
Kr=0.897
UNIT- I/ FATIGUE CONSIDERATIONS IN DESIGN
1
1
0.4545
Kf
2.2
e e K d K sf K r
= 315 (0.4545) (1.0) (0.897)
=128.42N/mm2
Kd
E
207000
k b' d 2 d 2
(3251.55d 2 ) N / mm
4
l
4
50
E
k c' (2d ) 2 (d ) 2 (3345.52d 2 ) N / mm
4
4
l
Step-II mean and variable loads on bolt
k 'b
C
k 'b k 'c
So,
max
And
3251.55d 2
0.4929
3251.55d 2 3345.52d 2
min
v
1
m
F .S y e K sr K sz K r
2
y
e K sr K sz K r
1 7464.5 / A
2464.5 / A
2
380
315 (0.897) (0.4545)(1.0)
1 19.64 19.18
2
A
A
A 76.63mm 2