Strain-life approach

1. A cylindrical bar of structural steel with an initial diameter of 50 mm is loaded in

tension. The following deflection measurements are made over a 250 mm gauge length.

Load (MN) Deflection (mm) Comment

0 0 Start of test
0.33 0.20 Behaviour is elastic
0.37 0.25 Sudden drop in load
0.33 1.00 Load nearly constant
0.53 50.00 Maximum load (necking starts)
0.30 64.00 Fracture (Final diameter = 30 mm)

Determine
i) Modulus of elasticity, E ii) Upper yield point iii) Lower yield point
iv) 0.2 % offset yield strength, Sy v) Ultimate strength, Su
vi) Engineering and true strain at start of necking
vii) Strain hardening exponent, n
viii) % reduction in area, % RA
ix) True fracture ductility, εf
x) True fracture strength, σf
xi) Strength coefficient, K
[Bannantine, E 2.2]

2. The table below lists stress range and strain range values for several stabilized hysteresis
loops for a stainless steel. From these data determine the cyclic strength coefficient K’
and cyclic strain hardening exponent n’. The modulus of elasticity for the material is 200
GPa.

∆ε ∆σ (MPa) ∆ε ∆σ (MPa) ∆ε ∆σ (MPa)

0.0008 168 0.008 578 0.016 698
0.002 350 0.01 610 0.018 736
0.004 500 0.012 634 0.020 768
0.006 560 0.014 666

Sy (0.2 % offset) = 325 MPa, Su = 650 MPa, n = 0.19. Did it harden or soften?
[Bannantine E2.12]
3. A metal has the monotonic tension properties E = 193 GPa, S y (0.2 % offset) = 325 MPa,
Su = 650 MPa, σf = 1400 MPa, εf = 1.73, % RA = 80, n = 0.193 .
Under cyclic loading will the material harden or soften. Calculate strain reached on the
first half cycle for a stress amplitude of 200 MPa. Given that the material has the
following cyclic properties. K’ = 1660 MPa, n’ = 0.287. Determine the stable total strain
and plastic strain amplitude for a stress amplitude of 200 MPa. Repeat the calculations
above. But now determine the stress response for a strain amplitude (∆ε/2) of 0.01.
 [Bannantine E2.13]

4. Given below are the results of constant amplitude strain controlled tests on a high
strength aluminum (E = 72.5 GPa)

Total strain Stress Reversals Total strain Stress Reversals

amplitude amplitude to failure amplitude amplitude to failure
(∆ε/2) ∆σ/2 (MPa) (2Nf) (∆ε/2) ∆σ/2 (MPa) (2Nf)
0.0725 611 10 0.0123 470 620
0.0445 594 28 0.0082 445 2000
0.029 559 90 0.0056 394 8400
0.0182 525 284 0.0047 338 24800

Determine the strain life properties (σ f’ , εf’ , b, c) for this material. It has been observed
that some high strength aluminums cannot be represented well by the four parameter
strain-life equation. Plot the data above and discuss how well this material follows the
four parameter model. An engineering rule of thumb is that a strain amplitude of 1%
(∆ε/2 = 0.01) corresponds to a life of 1000 cycles (or 2000 reversals). Does this rule hold
for the materials discussed above? [Bannantine E2.29]

5. Given below are the results of constant amplitude strain-controlled tests. The material
has a modulus of elasticity, E of 200 GPa.

Total strain Stress amplitude Reversals to

amplitude (∆ε/2) ∆σ/2 (MPa) failure (2Nf)
0.00202 261 416714
0.0051 372 15894
0.0102 428 2671
0.0151 444 989
Determine
i) Cyclic stress-strain properties (K’, n’)
ii) Strain-life properties (σf’ , εf’ , b, c)
iii) Transition life (2Nt)
iv) Fatigue life at strain amplitude, ∆ε/2, of 0.0075
[Bannantine E2.24]

6. At the transition life, 2Nt, determine the stress and strain amplitude (∆σ/2, ∆ε/2) in
terms of the cyclic stress-strain properties (E, K’, n’) of a material. [Bannantine E2.20]

7. Listed below are the strain-life properties for a high and low strength steel.
 Steel σf’ (MPa) εf’ b c E (GPa)
Low strength 800 1 -0.1 -0.5 200
High strength 2700 0.1 -0.08 -0.7 200

i) Determine the transition life (2Nt) for the two steels.

Which steel would allow
ii) The largest completely reversed strain for a life of 200 reversals?
iii) The largest completely reversed stress for a life of 200 reversals?
iv) The largest completely reversed strain for a life of 2 x 10 6 of reversals?
v) The largest completely reversed stress for a life of 2 x 10 6 reversals?
[Bannantine E2.18]
8. The following relationships can be used to estimate the fatigue ductility coefficient, ε f’,
and fatigue ductility exponent, c, for steels

εf’ ≈ εf = ln [1/(1-RA)]

where RA is the reduction in area. For ductile steels (where ε f ≈ 1), c≈-0.6, and for
strong steels (where εf ≈ 0.5), c≈-0.5. How well do these approximations work for the
following steels?

% RA εf εf’ c % RA εf εf’ c
73 1.3 0.15 -0.43 11 0.12 0.18 -0.56
65 1.04 1.00 -0.66 49 0.68 0.68 -0.65
25 0.29 0.27 -0.53 43 0.56 0.66 -0.69
59 0.89 0.45 -0.68 72 1.27 0.85 -0.61
42 0.54 0.40 -0.73 55 0.79 0.89 -0.69
20 0.22 0.20 -0.77 35 0.43 0.09 -0.61
27 0.31 0.07 -0.76

[Bannantine E2.26]

9. The following stress-strain and strain-life properties are given for a steel
E = 30 x 103 ksi, K’ = 137 ksi, n’ = 0.22, σf’ = 120 ksi, εf’ = 0.95, b = -0.11, c=-0.64

i) Draw on log-log coordinates the elastic strain-life, plastic strain-life and total
strain-life curves.
ii) Determine the transition life (2Nt) both graphically and analytically.
iii) Draw the hysteresis loops corresponding to strain amplitude (∆ε/2) values of
0.05, 0.00125 and 0.0007. Determine the fatigue life in reversals at these three
strain levels.
iv) Determine the elastic, plstic and total strain amplitude for a life (2N f) of 500
reversals.
 v) Determine the elastic, plstic and total strain amplitude for a life (2Nf) of 2 x 10 6
reversals.
vi) Determine the cyclic stress amplitude corresponding to fatigue lives of 500 and 2
x 106 reversals.
vii) A component made from this material is required to have a life of no less than
104 reversals. The loading on the component causes a total strain amplitude of
0.008. Determine if the component will meet the life requirements.
[Bannantine E2.17]
10. Determine the lives to failure for a nickel alloy under the following load histories.

Histor Description Strain amplitude (∆ε/2) Mean strain (ε0)

y
A Fully reversed (R=-1) 0.005 0
B Fully reversed (R=-1) 0.010 0
C Zero to maximum (R=0) 0.005 0.005
D Zero to maximum (R=0) 0.010 0.010

Use the Marrow, Manson-Halford and Smith-Watson-Topper relationships for these

predictions. Compare the predictions made using the three methods. The stress-starin
and strain-life properties for the alloy are
E = 208.5 GPa, K’ = 1530 MPa, n’ = 0.073, σf’ = 1640 MPa , εf’ = 2.67, b = -0.06, c = -0.82

Listed below are actual test results for the four histories. Two tests were run for each
history. Compare the predictions to these values. Discuss the effect of mean strain on
fatigue life at high and low strain amplitudes.

Test result: Lives in reversals, 2Nf

History
Trail 1 Trial 2
4
A 2.8 x 10 2.6 x 104
4
B 2.4 x 10 2.6 x 103
C 1.6 x 104 1.4 x 104
D 1.8 x 103 1.9 x103

[Bannantine E2.35]

Problems on notch effect

1. A notched component has a theoretical stress concentration factor K t of 3. The

component is loaded to cause a nominal stress, S, of 200 MPa. Determine the resulting
notch root stress, σ, and strain, ε. The component is then unloaded to a nominal stress
of zero. Determine the residual stress at the notch root. What is the fatigue life of the
component if it is subjected to a cyclic nominal stress of 0 to 200 MPa (R=0)? Use a
 Neuber analysis and Marrow mean stress-strain life relationship. The strain life
properties for this material are E = 100 GPa, σf’ = 1000 MPa, εf’ = 1.0, b = -0.08, c = -0.60.
[Bannantine E4.21]

2. A Neuber analysis may be performed using either net section or gross section
properties. In some cases (primarily in cases with gross section yield) there will be a
difference between life predictions determined using the two different section
properties. Determine the fatigue life Nf , in cycles for a notched component undergoing
the fully reversed loading levels listed below. Use a Neuber analysis and compare the
prediction made using net and gross properties. The geometric and material properties
are
Kt (net section) = 2.16, Kt (gross section) = 4.33
E = 30 x 103 ksi , K’ = 154 ksi, n’ = 0.123
σf’ = 169 ksi, εf’ = 1.142, b = -0.081, c = -0.67

Case Net section stress amplitude (ksi) Gross section stress amplitude (ksi)
A 60.2 30.1
B 37.8 18.9

[Bannantine E4.26]