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Plastic Stress Concentration Factors PDF
Plastic Stress Concentration Factors PDF
AND
THEIR EFFECTS
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 1
CHAPTER OUTLINE
Background
Stress/Strain Concentrations
S-N Approach for Notched Members
Strain-Life Approach for Notched Members
Applications of LEFM to FCG at Notches
The Two-Stage Approach
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 2
BACKGROUND
Notches cannot be avoided in many structures and
machines and notch effects have been a key problem in
the study of fatigue.
Examples:
Thread roots and the transition between the head and the shank
Rivet holes in sheets
Welds on plates
Keyways on shafts
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 3
BACKGROUND
To understand the effects of notches one must
consider five parameters:
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 4
STRESS AND STRAIN
CONCENTRATIONS AND GRADIENTS
As long as / = constant = E
Where:
or = the maximum stress or strain at the notch
S or e = the nominal stress or strain
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 5
STRESS AND STRAIN
CONCENTRATIONS AND GRADIENTS
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 7
STRESS AND STRAIN
CONCENTRATIONS AND GRADIENTS
Values of y/S and x/S are plotted
versus x/r.
Photoelasticity Technique:
A specimen with identical geometry to the actual notched part
is made of a certain transparent material.
Changes in optical properties of the transparent material
under load, measured by a polariscope, indicate stress
distributions and magnitudes.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 12
STRESS AND STRAIN CONCENTRATIONS
AND GRADIENTS
Thermoelasticity Technique:
Stress distribution is obtained by monitoring small
temperature changes of the specimen or component
subjected to cyclic loading.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 13
STRESS AND STRAIN
CONCENTRATIONS AND GRADIENTS
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 14
Stepped shaft in
tension, bending, and torsion
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 15
plate with opposite U-shaped notches
in tension and bending
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 16
STRESS AND STRAIN
CONCENTRATIONS AND GRADIENTS
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 17
STRESS AND STRAIN
CONCENTRATIONS AND GRADIENTS
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 18
STRESS AND STRAIN
CONCENTRATIONS AND GRADIENTS
b b
Kt 1 2 1 2
a r
where b is the axis transverse to the
tension force and r is the radius of
curvature at the endpoint of b.
2a r
With an ellipse 30 mm long and 10 mm
wide the stress concentration is: 2b
Kt = 7 if placed crosswise
Kt = 1.67 if placed lengthwise
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 27
S-N APPROACH FOR NOTCHED MEMBERS
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 29
S-N APPROACH FOR NOTCHED MEMBERS
(Notch Sensitivity and Fatigue Notch Factor, Kf )
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 30
S-N APPROACH FOR NOTCHED MEMBERS
(Notch Sensitivity and Fatigue Notch Factor, Kf )
Stress gradient:
The notch stress controlling the fatigue life is not the maximum
stress on the surface of the notch root, but an average stress
acting over a finite volume of the material at the notch root.
This average stress is lower than the maximum surface stress,
calculated from Kt
When small cracks nucleate at the notch root, they grow into
regions of lower stress due to the stress gradient.
K f
1
q
Kt 1
Kf = 1 + q (Kt - 1)
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 33
S-N APPROACH FOR NOTCHED MEMBERS
(Notch Sensitivity and Fatigue Notch Factor, Kf )
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 34
Values of √ for steel alloys
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 35
S-N APPROACH FOR NOTCHED MEMBERS
(Notch Sensitivity and Fatigue Notch Factor, Kf )
a 0 . 0254
2070 with Su in Mpa and a in mm
or Su
1 .8
300
a 0 . 001 with Su in ksi and a in inches
Su
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 37
S-N APPROACH FOR NOTCHED MEMBERS
(Effects of Stress Level on Notch Factor)
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 38
S-N APPROACH FOR NOTCHED MEMBERS
(Effects of Stress Level on Notch Factor)
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 39
EXAMPLE
For an 80 mm wide
sheet of 1020 hot-
rolled steel with a 10
80 mm
mm central hole,
construct the S-N
curve.
10 mm
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 40
EXAMPLE
80 mm
Define the smooth line from 448 MPa at 1
cycle to 241 MPa at 106 cycles.
Kt 1 2 .7 1
K f
1 1 2 .4
0 . 24
1 1
r 5
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 41
EXAMPLE
The S-N line for the sheet with the hole then goes from 448 MPa at 1
cycle to 241/2.4 = 100 MPa at 106 cycles.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 42
S-N APPROACH FOR NOTCHED MEMBERS
(Effects of Stress Level on Notch Factor)
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 43
S-N APPROACH FOR NOTCHED MEMBERS
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 44
S-N APPROACH FOR NOTCHED MEMBERS
(Mean Stress Effects and Haigh Diagram)
Figure 7.9 shows the fatigue strengths of
smooth and notched specimens of 7075-
T6 AL alloy at 104 and at 107 cycles
plotted versus the mean stress.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 46
S-N APPROACH FOR NOTCHED MEMBERS
(Mean Stress Effects and Haigh Diagram)
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 47
S-N APPROACH FOR NOTCHED MEMBERS
(Mean Stress Effects and Haigh Diagram)
Tensile mean stress can increase the fatigue notch factor Kf above
the stress concentration factor Kt and can be fatal in fatigue loading.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 49
S-N APPROACH FOR NOTCHED MEMBERS
(Mean Stress Effects and Haigh Diagram)
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 50
S-N APPROACH FOR NOTCHED MEMBERS
(Mean Stress Effects and Haigh Diagram)
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 51
S-N APPROACH FOR NOTCHED MEMBERS
(Mean Stress Effects and Haigh Diagram)
Sa Sm
1
Sf /K f
Su
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 52
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 53
S-N APPROACH FOR NOTCHED MEMBERS
(Mean Stress Effects and Haigh Diagram)
Kt = 3
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 56
EXAMPLE OF S-N APPROACH FOR A
NOTCHED MEMBER WITH MEAN STRESS
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 57
STRAIN-LIFE APPROACH
FOR
NOTCHED MEMBERS
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 58
STRAIN-LIFE APPROACH
Notch Stresses and Strains
Notch Strain Analytical Methods
Linear rule
Neuber’s rule
Strain energy density or Glinka’s rule
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 59
STRAIN-LIFE APPROACH
A common application of the strain-life approach is in
fatigue analysis of notched members, because:
the deformation of the material at the notch root is often inelastic.
notch stresses and strains are explicitly considered in the strain-life
approach, whereas the S-N approach is only in terms of nominal
stresses.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 61
Notch Stresses and Strains
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 63
Notch Stresses and Strains
e p
E K
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 64
Notch Stresses and Strains
Analytical models
Require the value of elastic stress concentration factor, Kt (for
complex geometries linear FEA can be used to obtain Kt ).
Include the linear rule, Neuber's rule, and strain energy
density or Glinka's rule.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 65
LINEAR RULE
The linear rule is expressed as:
K Kt or = Kt e
e
The notch strain, , can be computed directly and, if desired, the notch
stress, , can then be obtained from the stress-strain curve (or
Ramberg-Osgood Equation).
For cyclic loading, notch and nominal stresses and strains are replaced
by their respective ranges.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 68
Neuber’s Rule
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 69
Neuber’s Rule
2
K f
S
E
2 1/ n 2
K S
Analogous to monotonic loading:
f
2
E 2K E
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 70
Neuber’s Rule
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 71
Neuber’s Rule
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 72
Strain Energy Density or Glinka’s Rule
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 73
Strain Energy Density or Glinka’s Rule
Wp d
0
2E n 1 K
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 74
Strain Energy Density or Glinka’s Rule
2 1/ n 2
2 KtS
E n 1 K E
2 1/ n 2
4 Kt S
E n 1 2K E
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 76
Plane Stress versus Plane Strain
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 77
Plane Stress versus Plane Strain
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 78
EXAMPLE OF LIFE ESTIMATION
OF A NOTCHED MEMBER
WITH -N APPROACH
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 79
Example of Life Estimation with -N Approach
We want to find:
(a) notch stress and strain from a 53.4 kN
(12 kip) monotonic load,
(b) notch stress and strain after
unloading from the monotonic load in
part (a) to zero,
(c) notch stress and strain amplitudes
from constant amplitude alternating
loads between 4.45 kN (1 kip) and
44.5 kN (10 kip), and
(d) the expected fatigue life to the
formation of cracks on the order of 1
mm from the loading in part (c).
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 80
Example of Life Estimation with -N Approach
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 81
Example of Life Estimation with -N Approach
PART (a): Find notch stress & strain from a 53.4 kN monotonic load
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 82
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 83
Example of Life Estimation with -N Approach
2 1 / 0 . 06 2
2 3 x 600
or: 207000 0 . 06 1 1172 207000
15 . 65 resulting in = 872 MPa
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 84
Example of Life Estimation with -N Approach
KtS 3 x 600
K te 0 . 0087
E 207000
1 / 0 . 06
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 85
Example of Life Estimation with -N Approach
PART (b): Find notch stress and strain after unloading from the
monotonic load in part (a) to zero
For unloading, we can assume Masing behavior with a factor of two
expansion of the monotonic stress-strain curve.
Unloading is from S1 = Smax = 600 MPa to S2 = 0, or S = 600 MPa.
From Neuber's rule we obtain:
2 2
K f
S 3 x 600
15 . 65
E 207000 resulting in: = 1566 MPa,
1/ n 1 / 0 . 06 and = 0.0100.
2 2
E 2K 207000 2344
Residual stress, min, and strain, min, after unloading are calculated as
(and shown in Fig. 7.23) :
min = max - = 903 -1566 = -663 MPa, and
min = max - = 0.0173 - 0.0100 = 0.0073.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 86
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 87
Example of Life Estimation with -N Approach
2 1 / 0 . 06 2
4 3 x 600
15 . 65
Or 207000 0 . 06 1 2 x1172 207000
0 . 0087 2
207000 2344
or = 1515 MPa
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 89
Example of Life Estimation with -N Approach
Part (c): Find notch stress and strain amplitudes from constant
amplitude alternating loads between 4.45 kN and 44.5
kN.
The nominal behavior for cyclic loading is also elastic since Smax, |Smin|,
and Sa are smaller than S′y = 600 MPa.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 90
Example of Life Estimation with -N Approach
We first need to calculate notch root stress and strain at the maximum
load.
1/ n 1 / 0 . 14
max max max max
max
E K 207000 1434
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 91
Example of Life Estimation with -N Approach
2 2
E 2K 207000 2868
Substituting this value into the cyclic stress-strain equation results in:
1/ n 1 / 0 . 14
max max 712 712
max
0 . 0102
E K 207000 1434
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 93
Example of Life Estimation with -N
Approach
For unloading: 2 1/ n 2
4 Kt S
E n 1 2K E
2 1 / 0 . 14 2
or 4 3 x 450
8 .8
207000 0 . 14 1 2 x1434 207000
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 94
Example of Life Estimation with -N Approach
Then
Kt S 3 x 450
Kt e 0 . 0065
E 207000
1 / 0 . 14
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 96
Results Are Summarized as Follows
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 97
It can be seen from this table that the most conservative fatigue life
is obtained from Neuber's rule and the least conservative life from the
linear rule, result from strain energy density rule falling in between.
From Fig. 7.16, for a nominal stress amplitude of Sa = 225 MPa, the
predicted life using Basquin’s equation for the notched part is about
11000 cycles based on the Haigh diagram approach for long life, and
about 28000 cycles based on the modified Goodman equation.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 99
CRACK GROWTH AT NOTCHES
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 100
CRACK GROWTH AT NOTCHES
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 101
CRACK GROWTH AT NOTCHES
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 102
CRACK GROWTH AT NOTCHES
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 104
CRACK GROWTH AT NOTCHES
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 105
CRACK GROWTH AT NOTCHES
To quantify the influence of the stress-
strain field of a notch on crack growth,
consider a very wide plate with a
circular hole containing a pair of small
through-thickness cracks as shown.
K small 1 . 12 ( K t S ) l
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 106
CRACK GROWTH AT NOTCHES
K long S a
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 107
CRACK GROWTH AT NOTCHES
Figure 7.26b shows variation of K as a
function of the crack length, l,
normalized by the radius of the hole, c.
´ c
l 2
1 . 12 K t 1
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 108
CRACK GROWTH AT NOTCHES
Many attempts have been made to account for the anomalous fatigue
crack growth from notches. While these models have proven useful,
they have not provided a complete correlation between notch fatigue
crack growth data and LEFM long crack growth data.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 110
THE TWO STAGE APPROACH
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 111
THE TWO STAGE APPROACH
In some situations,
stage 2 may be negligible in comparison to stage 1 (i.e. rotating
bending of a small notched shaft)
on the other hand, cracks may be present. Stage 1 then becomes
negligible in comparison to stage 2.
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 112
EXAMPLE OF THE TWO STAGE APPROACH
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 113
EXAMPLE OF THE TWO STAGE APPROACH
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 114
EXAMPLE OF THE TWO STAGE APPROACH
The fracture toughness, Kc, for RQC-100 for this thickness, along with
the Paris equation for R 0 are:
da
Kc ≈165 MPa√m and
12 3 . 25
2 . 80 x10 ( K)
dN
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 115
EXAMPLE OF THE TWO STAGE APPROACH
The strain-life prediction model is for crack nucleation lengths on the
order of 1 mm.
The LEFM model must then assume an initial crack length comparable
with this length, thus let the initial crack length be 1 mm.
We should check to see if this crack size emanating from the keyhole
notch is greater than the transitional crack length l΄.
Although the expression in Eq. 7.33 for transitional crack length is for a
crack emanating from both sides of a hole in a very wide plate, it can
be used as a first approximation for the transitional crack length in this
example problem (A more precise solution would take into account the
geometry factor)
´ c 9 .5 / 2
l 2 2
0 . 46 mm 0 . 5 mm
1 . 12 K t 1 1 . 12 ( 3 ) 1
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 116
EXAMPLE OF THE TWO STAGE APPROACH
2 3
( 0 . 247 ) P a a a
K 54 . 98 417 . 28 939 . 76 739 . 31
w w w w
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 117
EXAMPLE OF THE TWO STAGE APPROACH
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 118
EXAMPLE OF THE TWO STAGE APPROACH
Calculation of the plane stress initial plastic zone radius 2ry using
Kmax = 77 MPa m and Sy = 883 MPa gives 2ry = 2.4 mm, or ry =
1.2 mm:
2
1 K max
2 ry
Sy
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 119
EXAMPLE OF THE TWO STAGE APPROACH
The fatigue crack growth life, Nf, which we define here as Ng can be
found by integrating the Paris equation:
da n n
A( K ) A ( K max K min )
dN
or N f ac
da
Ng N f
dN n
0 ai
A ( K max K min )
ac
1 da
12 3 . 25 3 . 25
2 . 8 x10 0 . 247 ( Pmax Pmin ) 2 3
ai a a a
54 . 98 417 . 28 939 . 76 739 . 31
w w w
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 120
EXAMPLE OF THE TWO STAGE APPROACH
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 123
SUMMARY AND DOS AND DON'TS IN DESIGN
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 125
SUMMARY AND DOS AND DON'TS IN DESIGN
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 126
SUMMARY AND DOS AND DON'TS IN DESIGN
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 127
SUMMARY AND DOS AND DON'TS IN DESIGN
Neuber's rule has been the most widely used model. It assumes the
geometrical mean of the stress and strain concentration factors to be
equal to the theoretical stress concentration factor (√K K = Kt).
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 128
SUMMARY AND DOS AND DON'TS IN DESIGN
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 129
SUMMARY AND DOS AND DON'TS IN DESIGN
Ali Fatemi - University of Toledo All Rights Reserved Chapter 7 – Notches and Their Effects 132