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5 Multiaxial Fatigue
5 Multiaxial Fatigue
d-socie@uiuc.edu
Tel: 217 333 7630
Fax: 217 333 5634
Multiaxial Fatigue © 2001-2011 Darrell Socie, University of Illinois at Urbana-Champaign, All Rights Reserved 1 of 125
Outline
Multiaxial Fatigue © 2001-2011 Darrell Socie, University of Illinois at Urbana-Champaign, All Rights Reserved 2 of 125
State of Stress
Stress components
Common states of stress
Shear stresses
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Stress Components
σz
Z
τzy
τzx
τyz
τxz
σy
τyx
τxy
σx
Y
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Stresses Acting on a Plane
Z
Z’ X’
σx’
τx’z’ Y’
τx’y’
φ
θ Y
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Principal Stresses
τ13
σ3 τ12
τ23
σ2
σ1
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Stress and Strain Distributions
100
% of applied stress
90
80
-20 -10 0 10 20
θ
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Tension
σ3 τ γ/2
σ ε
σx
σ1 ε1
σ1 σ2
σ2 = σ3 = 0 ε2 = ε3 = −νε1
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Torsion
σ2 τ γ/2
σ3 σ ε3 ε
τ xy
σ1 ε1
σ3
Y
σ2 ε2
X σ1
σ1 = τxy
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Biaxial Tension
σ3
τ γ /2
σ3 ε
σ
σ1 = σ x
σ1 = σ 2 ε1 = ε2
σ2 = σ y
2ν
ε3 = − ε
1− ν
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Shear Stresses
σ3 σ3
σ2 σ2
σ1 σ1
Maximum shear stress Octahedral shear stress
σ1 −σ3 τoct =
1
(σ1−σ3 )2 +(σ1−σ2 )2 +(σ2 −σ3 )2
τ13 = 3
2
3 3
Mises: σ= τoct τoct = τ13 = 0.94 τ13
2 2 2
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State of Stress Summary
Stresses acting on a plane
Principal stress
Maximum shear stress
Octahedral shear stress
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Fatigue Mechanisms
Crack nucleation
Fracture modes
Crack growth
State of stress effects
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Crack Nucleation
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Slip Bands
Extrusion
Undeformed
material
Intrusion
Loading Unloading
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Slip Bands
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Mode I, Mode II, and Mode III
Mode I Mode II Mode III
opening in-plane shear out-of-plane shear
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Stage I and Stage II
loading direction
free
surface
Stage I Stage II
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Case A and Case B
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Mode I Growth
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Mode II Growth
shear stress
slip bands
10 µm
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304 Stainless Steel - Torsion
1.0
Damage Fraction N/Nf
0.8
0.6
0.4
Tension
0.2 Shear
Nucleation
0
2 3 4 5 6 7
1 10 10 10 10 10 10 10
Fatigue Life, 2Nf
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304 Stainless Steel - Tension
1.0
Damage Fraction N/Nf
0.8 Tension
0.6 Nucleation
0.4
0.2
0
2 3 4 5 6 7
1 10 10 10 10 10 10 10
Fatigue Life, 2Nf
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Inconel 718 - Torsion
1.0
Tension
Damage Fraction N/Nf
0.8
0.6
Shear
0.4
0.2
Nucleation
0
2 3 4 5 6 7
1 10 10 10 10 10 10 10
Fatigue Life, 2Nf
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Inconel 718 - Tension
1.0
Tension
Damage Fraction N/Nf
0.8
0.6
0.4
Shear
0.2
Nucleation
0
2 3 4 5 6 7
1 10 10 10 10 10 10 10
Fatigue Life, 2Nf
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1045 Steel - Torsion
1.0
Tension
Damage Fraction N/Nf
0.8
f
0.6
0.4
0.2 Shear
Nucleation
0
2 3 4 5 6 7
1 10 10 10 10 10 10 10
Fatigue Life, 2Nf
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1045 Steel - Tension
1.0
Damage Fraction N/Nf
0.8
0.6 Tension
0.4
Shear
0.2 Nucleation
0
2 3 4 5 6 7
1 10 10 10 10 10 10 10
Fatigue Life, 2Nf
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Fatigue Mechanisms Summary
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Stress Based Models
Sines
Findley
Dang Van
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Bending Torsion Correlation
Octahedral stress
Principal stress
0.5
0
0 0.5 1.0 1.5 2.0
Shear stress in torsion
1/2 Bending fatigue limit
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Test Results
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Cyclic Tension with Static Tension
1.5
Fatigue strength
Axial stress
1.0
0.5
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Cyclic Torsion with Static Torsion
1.5
Shear Stress Amplitude
Shear Fatigue Strength
1.0
0.5
0
0.5 1.0 1.5
Maximum Shear Stress
Shear Yield Strength
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Cyclic Tension with Static Torsion
1.5
Bending Fatigue Strength
Bending Stress
1.0
0.5
1.5
Shear fatigue strength
Torsion shear stress
1.0
0.5
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Conclusions
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Sines
∆τoct
+ α(3σh ) = β
2
1
( ∆σ x −∆σ y )2 + ( ∆σ x −∆σ z )2 + ( ∆σ y −∆σ z )2 +6( ∆τ2xy + ∆τ2xz + ∆τ2yz ) +
6
α (σmean
x + σ mean
y + σ mean
z )=β
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Findley
∆τ
+ kσ n = f
2 max
tension torsion
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Bending Torsion Correlation
Octahedral stress
Principal stress
0.5
0
0 0.5 1.0 1.5 2.0
Shear stress in torsion
1/2 Bending fatigue limit
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Dang Van
τ( t ) + aσ h ( t ) = b
Σij(M,t) Eij(M,t)
σij(m,t)
εij(m,t)
m
V(M)
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Dang Van ( continued )
τ τ
τ(t) + aσh(t) = b
Failure
predicted
σh σh
Loading path
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Stress Based Models Summary
∆τoct
Sines: + α(3σh ) = β
2
∆τ
Findley: + kσ n = f
2 max
Dang Van: τ( t ) + aσ h ( t ) = b
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Strain Based Models
Plastic Work
Brown and Miller
Fatemi and Socie
Smith Watson and Topper
Liu
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Octahedral Shear Strain
0.1
Plastic octahedral
shear strain range
Torsion
0.01
Tension
0.001
10 10 2 10 3 10 4 10 5
Cycles to failure
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Plastic Work
1
102 103 104
Fatigue Life, Nf
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Brown and Miller
2 x103
Fatigue Life, Cycles ∆γ = 0.03
103
5 x102
2 x102
102
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Case A and B
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Brown and Miller ( continued )
ax i al
Uni
Equ
ibia
x ial
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Brown and Miller ( continued )
1
∆γ = ( ∆γ αmax + S∆ε αn ) α
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Fatemi and Socie
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Loading Histories
γ/ 3
ε
C F G
H I J
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Crack Length Observations
2.5
F-495 H-491
G-304
1.5
0.5
0
0 2000 4000 6000 8000 10000 12000 14000
Cycles
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Fatemi and Socie
∆γ σn,max τ'f
1+ k = (2Nf )bo + γ 'f (2Nf )co
2 σ y G
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Smith Watson Topper
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SWT
'2
∆ε1 σ
σn = (2Nf )2b + σ'f ε 'f (2Nf )b+c
f
2 E
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Liu
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Cyclic Torsion
Cyclic Torsion
Shear Damage Tensile Damage
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Cyclic Torsion with Static Tension
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Cyclic Torsion with Compression
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Cyclic Torsion with Tension
and Compression
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Test Results
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Conclusions
All critical plane models correctly predict
these results
Hydrostatic stress models can not predict
these results
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Loading History
0.003
Shear strain
-0.003
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Model Comparison
Summary of calculated fatigue lives
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Strain Based Models Summary
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Separate Tensile and Shear Models
σ3 σ
σ1
σ2
σ1 = τxy
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Cyclic Plasticity
∆ε
∆γ
∆εp
∆γp
∆ε∆σ
∆γ∆τ
∆εp∆σ
∆γp∆τ
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Mean Stresses
σ 'f − σ mean
∆ε eq = ( 2 N f ) b + ε 'f ( 2 N f ) c
E
∆γ max σ'f −2σn
+ S∆εn = (1.3 + 0.7S) (2Nf )b + (1.5 + 0.5S) ε 'f (2Nf )c
2 E
∆γ σn,max τ'f
1+ k = (2Nf )bo + γ 'f (2Nf )co
2 σ y G
'2
∆ε1 σ
σn = (2Nf )2b + σ'f ε 'f (2Nf )b+c
f
2 E
2
∆WI =[(∆σn ∆εn )max + (∆τ∆γ)]
1−R
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Fracture Mechanics Models
Mode I growth
Torsion
Mode II growth
Mode III growth
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Mode I, Mode II, and Mode III
Mode I Mode II Mode III
opening in-plane shear out-of-plane shear
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Mode I and Mode II Surface Cracks
σ
Mode II
σ σ
Mode I
σ
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Biaxial Mode I Growth
10-3 ∆σ = 193 MPa 10-3 ∆σ = 386 MPa
λ = -1 λ = -1
λ=0 λ=0
λ=1 λ=1
da/dN mm/cycle
da/dN mm/cycle
10-4 10-4
10-5 10-5
10-6 10-6
10 20 50 100 200 10 20 50 100 200
∆K, MPa m ∆K, MPa m
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Surface Cracks in Torsion
Mode II
Mode III
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Failure Modes in Torsion
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Fracture Mechanism Map
60
No Cracks
1500 50
Spiral
Yield Strength, MPa
Hardness Rc
Cracks
Longi- 40
tudinal
Transverse
1000 Cracks
30
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Mode I and Mode III Growth
10-3
da/dN, mm/cycle
10-4 ∆KI
10-5 ∆KIII
10-6
5 10 20 50 100
∆KI , ∆KIII MPa m
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Mode I and Mode II Growth
7075 T6 Aluminum
10-2 Mode I R = 0
Mode II R = -1
10-3
da/dN, mm/cycle
10-4
10-5
10-6
SNCM Steel
10-7 Mode I R = -1
Mode II R = -1
1 10 100
∆KI , ∆KII MPa m
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Fracture Mechanics Models
=C(∆K eq )
da m
dN
[
∆K eq = ∆K +8∆K + 8∆K4
I
4
II
4
III (1 − ν ) ]
0.25
[
∆K eq = ∆K +∆K +(1+ν)∆K
2
I ] 2
II
2 0 .5
III
∆K eq =[∆K +∆K ∆K + ∆K ]
2
I I II
2 0 .5
II
0 .5
E 2
∆K eq (ε)=(FII ∆γ ) +(FIE∆ε)
2
πa
2(1 + ν )
σn,max
∆K eq (ε )=FG∆γ1+ k πa
σ
ys
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Fracture Surfaces
Bending Torsion
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Mode III Growth
∆K = 14.9
10-4 ∆K = 12.0
∆K = 11.0
10-6
10-7
10-8
10-9
0.2 0.4 0.6 0.8 1.0
Crack length, mm
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Fracture Mechanics Models Summary
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Nonproportional Loading
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In and Out-of-Phase Loading
γ
1+ ν
εx εx = εosin(ωt)
t
εx ε
γxy γxy γxy = (1+ν)εosin(ωt)
t
∆γ
In-phase
εy γ
εx εx = εocos(ωt)
t 1+ ν
ε
γxy γxy = (1+ν)εosin(ωt)
t
Out-of-phase ∆γ
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In-Phase and Out-of-Phase
γ xy
2 τ xy
2
∆γxy
2 εx
∆2τxy σx
ε θ
1
∆ε x
∆σ x
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Loading Histories
εx εx
εx εx
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Loading Histories
in-phase
out-of-phase
diamond
square
cross
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Findley Model Results
∆τ/2 MPa σ MPa ∆τ/2 + 0.3 σ N/N
n,max n,max ip
in-phase 353 250 428 1.0
90° out-of-phase 250 500 400 2.0
diamond 250 500 400 2.0
square 353 603 534 0.11
cross - tension cycle 250 250 325 16
cross - torsion cycle 250 0 250 216
εx εx εx εx
in-phase
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Nonproportional Hardening
εx εx = εosin(ωt)
t
εx εx = εocos(ωt)
t
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In-Phase
600 300
Axial Shear
-600 -300
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90° Out-of-Phase
600 300
Axial Shear
-600 -300
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Critical Plane
-600 -600
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Loading Histories
0 1 2 3 4
5 6 7 8 9
10
11 12 13
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Stress-Strain Response
300 300 300
Case 1 Case 2 Case 3
0 0 0
Shear Stress ( MPa )
0 0 0
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Stress-Strain Response (continued)
300 300 300
Case 7 Case 9 Case 10
0 0 0
Shear Stress ( MPa )
0 0 0
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Maximum Stress
All tests have the same strain ranges
2000
Equivalent Stress, MPa
1000
200 2
10 103 104
Fatigue Life, Nf
Nonproportional hardening results in lower fatigue lives
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Nonproportional Example
σy σy σy σy
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Shear Stresses
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Simple Variable Amplitude History
150
0.006
εx σx
-0.006 -150
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Stress-Strain on 0° Plane
300 150
τxy
-0.003 εx 0.003 -0.005 γxy 0.005
-300 -150
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Stress-Strain on 30° and 60° Planes
300 300
30º plane 60º plane
-300 -300
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Stress-Strain on 120° and 150° Planes
-300 -300
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Shear Strain History on Critical Plane
0.005
Shear strain, γ
time
-0.005
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Fatigue Calculations
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Nonproportional Loading Summary
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Notches
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Notched Shaft Loading
MT
MX
MY
σθ
τθz
σz
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Stress Concentration Factors
6
Stress Concentration Factor
Bending
5
d D
4
ρ
Torsion
3
D/d
2.20
2 1.20
1.04
1
0
0.025 0.050 0.075 0.100 0.125
Notch Root Radius, ρ/d
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Hole in a Plate
λσ
σθ
a τrθ
σ σ σr σr
θ
τrθ
r
σθ
λσ
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Stresses at the Hole
4
3
λ=1
2
1 λ=0
σθ
0
σ
30 60 90 120 150 180
-1
Angle
-2
λ = -1
-3
-4
1.5
1.0
τrθ
σ
0.5
0
1 2 3 4 5
r
a
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Torsion Experiments
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Multiaxial Loading
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Thickness Effects
Longitudinal Tensile Strain
0 0.004 0.008 0.012
Transverse Compression Strain
Thickness
0.001 50 mm
x
0.002 30 mm
y
0.003 15 mm z
100
0.004
0.005 7 mm
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Applied Bending Moments
MX
MX
1 2 3 4
MY
MY
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Bending Moments on the Shaft
A
MY
MX
C
D B
C
A’ A
B’ D’
C’
D
Location
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Bending Moments
∆M A B C D
2.82 1 1
2.00 3 2
1.41 2 1
1.00 2
0.71 2
∆M = 5 ∑ ∆M 5
A B C D
∆M 2.49 2.85 2.31 2.84
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Torsion Loading
MX
σT σ1
t1 t3
MT σz σ1 = σz
σT
MX
σT σ1 = σT
t2 t4
MT σz
σT σ1 σT
t1 t2 t3 t4
Kt = 3 Kt = 4
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Fatigue Notch Factors
6
5 D
d D d = 2.2
Stress concentration factor
4
ρ
3
Kf Bending
2 Kt Bending
Kt Torsion
1 Kf Torsion
0
0.025 0.050 0.075 ρ 0.100 0.125
Notch root radius, d
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Fatigue Notch Factors ( continued )
bending
Peterson’s Equation
torsion
2.5
KT − 1
conservative Kf = 1 +
a
Calculated Kf
2.0 1+
r
1.5
non-conservative
1.0
1.0 1.5 2.0 2.5
Experimental Kf
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Fracture Surfaces in Torsion
Circumferencial Notch
Shoulder Fillet
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Stress Intensity Factors
1.50
λ = −1
1.25
λ=0
1.00
σ
F 0.75 λ=1
R
0.50
λσ λσ
a
0.25
σ
0.00
1.00 1.50 2.00 2.50 3.00
a
R
= C (∆K eq )
da
K I = F ∆σ πa
m
dN
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Crack Growth From a Hole
λ = -1 λ = 0 λ= 1
100
80
Crack Length, mm
60
40
20
0
0 2 x 10 6 4 x 10 6 6 x 10 6 8 x 10 6
Cycles
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Notches Summary
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Final Summary
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Multiaxial Fatigue