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Multiaxial Fatigue

Professor Darrell F. Socie


Department of Mechanical Science and Engineering
University of Illinois at Urbana-Champaign

© 2001-2011 Darrell Socie, All Rights Reserved


Contact Information
Darrell Socie
Mechanical Science and Engineering
1206 West Green
Urbana, Illinois 61801
USA

d-socie@uiuc.edu
Tel: 217 333 7630
Fax: 217 333 5634

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Outline

 State of Stress ( Chapter 1 )


 Fatigue Mechanisms ( Chapter 3 )
 Stress Based Models ( Chapter 5 )
 Strain Based Models ( Chapter 6 )
 Fracture Mechanics Models ( Chapter 7 )
 Nonproportional Loading ( Chapter 8 )
 Notches ( Chapter 9 )

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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

Six stresses and six strains

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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

σ3 - σ2( σX + σY + σZ ) + σ(σXσY + σYσZσXσZ -τ2XY - τ2YZ -τ2XZ )


- (σXσYσZ + 2τXYτYZτXZ - σXτ2YZ - σYτ2ZX - σZτ2XY ) = 0

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Stress and Strain Distributions

100
% of applied stress

90

80
-20 -10 0 10 20
θ

Stresses are nearly the same over a 10° range of angles

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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

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

Growth along the surface Growth into the surface

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Mode I Growth

crack growth direction


5 µm

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Mode II Growth

shear stress
slip bands

10 µm

crack growth direction

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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

 Fatigue cracks nucleate in shear


 Fatigue cracks grow in either shear or tension
depending on material and state of stress

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Stress Based Models

 Sines
 Findley
 Dang Van

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Bending Torsion Correlation

1.0 Shear stress


1/2 Bending fatigue limit
Shear stress in bending

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

 Cyclic tension with static tension


 Cyclic torsion with static torsion
 Cyclic tension with static torsion
 Cyclic torsion with static tension

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Cyclic Tension with Static Tension

1.5
Fatigue strength
Axial stress

1.0

0.5

-1.5 -1.0 -0.5 0 0.5 1.0 1.5


Mean stress
Yield strength

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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

0 1.0 2.0 3.0


Static Torsion Stress
Torsion Yield Strength
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Cyclic Torsion with Static Tension

1.5
Shear fatigue strength
Torsion shear stress

1.0

0.5

-1.5 -1.0 -0.5 0 0.5 1.0 1.5


Axial mean stress
Yield strength

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Conclusions

 Tension mean stress affects both tension


and torsion
 Torsion mean stress does not affect tension
or torsion

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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

1.0 Shear stress


1/2 Bending fatigue limit
Shear stress in bending

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

Plastic Work per Cycle, MJ/m3 100 T Torsion


T
A Axial

0
90
A T 180
T 135
A
T 45
10 30
A T
T
A A
T
A

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

0.0 0.005 0.01


Normal Strain Amplitude, ∆ε n

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Case A and B

Growth along the surface Growth into the surface

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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

∆γ max σ 'f − 2σ n ,mean


+ S ∆ε n = A ( 2 N f ) b + B ε 'f ( 2 N f ) c
2 E

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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

J-603 I-471 C-399


2
Crack Length, mm

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

Virtual strain energy for both mode I and mode II cracking

∆WI = (∆σn ∆εn)max + (∆τ ∆γ)


'2
b+c 4σ
∆WI = 4σ ε (2Nf ) ' '
f f + (2Nf )2b
f
E
∆WII = (∆σn ∆εn ) + (∆τ ∆γ)max
'2
bo + co 4τ
∆WII = 4τ γ (2Nf ) '
f
'
f + (2Nf )2bo
f
G

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Cyclic Torsion

Cyclic Shear Strain Cyclic Tensile Strain

Cyclic Torsion
Shear Damage Tensile Damage

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Cyclic Torsion with Static Tension

Cyclic Shear Strain Cyclic Tensile Strain

Cyclic Torsion Shear Damage Tensile Damage


Static Tension

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Cyclic Torsion with Compression

Cyclic Shear Strain Cyclic Tensile Strain

Cyclic Torsion Shear Damage Tensile Damage


Static Compression

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Cyclic Torsion with Tension
and Compression

Cyclic Shear Strain Cyclic Tensile Strain

Cyclic Torsion Shear Damage Tensile Damage


Static Compression
Hoop Tension

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Test Results

Load Case ∆γ/2 σhoop MPa σaxial MPa Nf


Torsion 0.0054 0 0 45,200
with tension 0.0054 0 450 10,300
with compression 0.0054 0 -500 50,000
with tension and 0.0054 450 -500 11,200
compression

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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

Axial strain 0.006

-0.003

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Model Comparison
Summary of calculated fatigue lives

Model Equation Life


Epsilon 6.5 14,060
Garud 6.7 5,210
Ellyin 6.17 4,450
Brown-Miller 6.22 3,980
SWT 6.24 9,930
Liu I 6.41 4,280
Liu II 6.42 5,420
Chu 6.37 3,040
Gamma 26,775
Fatemi-Socie 6.23 10,350
Glinka 6.39 33,220

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Strain Based Models Summary

 Two separate models are needed, one for


tensile growth and one for shear growth
 Cyclic plasticity governs stress and strain
ranges
 Mean stress effects are a result of crack
closure on the critical plane

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Separate Tensile and Shear Models

σ3 σ
σ1

σ2
σ1 = τxy

Inconel 1045 steel stainless steel

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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

Transverse Longitudinal Spiral

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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

200 300 400 500


Shear Stress Amplitude, MPa

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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∆γ1+ 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

Crack growth rate, mm/cycle


∆K = 10.0
10-5 ∆K = 8.2

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

 Multiaxial loading has little effect in Mode I


 Crack closure makes Mode II and Mode III
calculations difficult

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Nonproportional Loading

 In and Out-of-phase loading


 Nonproportional cyclic hardening
 Variable amplitude

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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

out-of-phase γxy/2 γxy/2


diamond

εx εx

square γxy/2 cross γxy/2

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

γxy/2 γxy/2 γxy/2


out-of-phase diamond square cross γxy/2

εx εx εx εx

in-phase

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Nonproportional Hardening

εx εx = εosin(ωt)
t

γxy γxy = (1+ν)εosin(ωt)


t
In-phase

εx εx = εocos(ωt)
t

γxy γxy = (1+ν)εosin(ωt)


t
Out-of-phase

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In-Phase

600 300

Axial Shear

-0.003 0.003 -0.006 0.006

-600 -300

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90° Out-of-Phase

600 300
Axial Shear

-0.003 0.003-0.006 0.006

-600 -300

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Critical Plane

Proportional 600 Out-of-phase 600


Nf = 38,500 Nf = 3,500
Nf = 310,000 Nf = 40,000

-0.004 0.004-0.004 0.004

-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

150 150 150

0 0 0
Shear Stress ( MPa )

-150 -150 -150

-300 -300 -300


-600 -300 0 300 600 -600 -300 0 300 600 -600 -300 0 300 600
300 300 300
Case 4 Case 5 Case 6

150 150 150

0 0 0

-150 -150 -150

-300 -300 -300


-600 -300 0 300 600 -600 -300 0 300 600 -600 -300 0 300 600

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Stress-Strain Response (continued)
300 300 300
Case 7 Case 9 Case 10

150 150 150

0 0 0
Shear Stress ( MPa )

-150 -150 -150

-300 -300 -300


-600 -300 0 300 600 -600 -300 0 300 600 -600 -300 0 300 600
300 300 300
Case 11 Case 12 Case 13

150 150 150

0 0 0

-150 -150 -150

-300 -300 -300


-600 -300 0 300 600 -600 -300 0 300 600 -600 -300 0 300 600

Axial Stress ( MPa )

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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

Case A Case B Case C Case D


σx σx σx σx

σy σy σy σy

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Shear Stresses

Case A Case B Case C Case D

τxy τxy τxy τxy

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Simple Variable Amplitude History

150
0.006

εx σx

-0.003 0.003 -300 300

-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

-0.003 0.003 -0.003 0.003


ε30 ε60

-300 -300

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Stress-Strain on 120° and 150° Planes

120º plane 300 150º plane 300

-0.003 0.003 -0.003 0.003


ε120 ε150

-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

Load or strain history

Cyclic plasticity model

Stress and strain tensor

Search for critical plane

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Nonproportional Loading Summary

 Nonproportional cyclic hardening increases


stress levels
 Critical plane models are used to assess
fatigue damage

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Notches

 Stress and strain concentrations


 Nonproportional loading and stressing
 Fatigue notch factors
 Cracks at 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

Stress concentration factor depends on type of loading


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Shear Stresses during Torsion

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

 Uniaxial loading that produces multiaxial


stresses at notches
 Multiaxial loading that produces uniaxial
stresses at notches
 Multiaxial loading that produces multiaxial
stresses at notches

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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

Out-of-phase shear loading is needed to produce


nonproportional stressing
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Plate and Shell Structures

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

 Uniaxial loading can produce multiaxial


stresses at notches
 Multiaxial loading can produce uniaxial
stresses at notches
 Multiaxial stresses are not very important in
thin plate and shell structures
 Multiaxial stresses are not very important in
crack growth

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Final Summary

 Fatigue is a planar process involving the


growth of cracks on many size scales
 Critical plane models provide reasonable
estimates of fatigue damage

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Multiaxial Fatigue

University of Illinois at Urbana-Champaign

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