03MCHQD – MACHINE DESIGN – 2015-2016

TECHNICAL REPORT 2 –FATIGUE

PROBLEM 1 - Wöhler curve

1) Plot the Wöhler (m = 0) curve (log-log coordinates) taking into account the following features:
- the curve equation is n x N=C in the finite life range (high cycle fatigue life);
- the endurance limit is D-1 = 250 MPa (N  106);
- the tensile strength is Rm = 600 MPa.
2) Calculate the values of the constant C and of the exponent n of the Wohler curve.
3) Two samples with circular section (diameter d = 7mm) are loaded by alternate (tension –
compression) loads Pa1 = 10 kN e Pa2 = 15 kN. Estimate the fatigue life of the two samples by
using the Wöhler curve plotted above.

PROBLEM 2 - Component fatigue strength – surface effect, size effect (FKM method)
A shaft with diameter d = 30 mm is made of steel 42CrMo4. The surface roughness is Ra = 1.6 m.
The shaft is subjected to mean and alternating bending moment Mfm = 600 Nm, Mfa = 200 Nm.
- Plot the Haigh diagram (Goodman line simplification).
- Use the FKM method to calculate the “effective” applied stresses (see slides 40-45 Fatigue-Chapter
3)
- Verify the shaft capability to have an infinite life: according to the standard FKM plot the admissible
area and verify if applied stress falls inside that area.

PROBLEM 3 -Component fatigue strength – notch effect, composite stresses (FKM method)
A shaft has a shoulder with diameter variation from d=36 mm to D=40 mm and fillet radius r=2 mm.
The surface is ground (Ra = 3.2 m). The shaft is subjected to alternating torsion Mta=500 Nm and
alternating bending moment Mfa=350 Nm. The material is steel 34CrMo4.
For Kt diagrams see slides 65-69 Fatigue-Chapter 3.
As the previous problem verify the shaft capability to have an infinite life

HOMEWORK: PROBLEM 4 - Haigh, Goodman-Smith and Moore diagrams

From experimental tests on steel samples the following material properties are obtained:
Rm = 1180 MPa, Rp0.2 = 880 MPa, D-1 = 480 MPa.
1) Construct on the same graph the simplified Haigh diagram (Goodman line) and the simplified
Haigh diagram according to FKM (see slides 54-55 Fatigue-Chapter 2)
2) starting from the simplified Haigh diagram (Goodman line) construct the Smith- Goodman diagram
and Moore diagram (see slides 61-62 Fatigue-Chapter 2)

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PROBLEM 5- Fatigue life prediction: linear damage-Miner’s rule (m = 0)
Data in the table below show a case of six blocks of alternate stresses ai in a sample with m = 0
MPa applied for a number of cycles ni. Using the linear damage rule determine the fatigue life of the
sample (see slide 6 Fatigue-Chapter 4). Consider that the material is steel with D-1 = 250 MPa
(N  106) and tensile strength Rm = 600 MPa. The equation of the estimated Wöhler curve with
m = 0 is:
 ak  N  C where k = 8.97 and C= = 3.23241027.

ai (MPa) 400 350 325 200 150 100

ni 1.0 e3 1.0 e3 1.7 e4 2.0 e5 2.5 e5 2.5 e5

GUIDELINES FOR SOLUTION

- Calculate the utilization fraction αi for each level of stress

- Calculate the number of cycles to failure N for each level of stress with a >D-1 using the
equation of the estimated Wöhler curve
- Calculate the sample life by means of the “Linear Damage or Miner's Rule” see fatigue slides
chapter 4, slide 6.
- Apply as alternative method the equivalent stress calculation as in fatigue slides chapter 4,
slide 12.

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PROBLEM 6- Fatigue life prediction: cycle counting
The figure below represents the stress fluctuation of a part during what is believed to be a typical
mission of 20 seconds. Estimate the life (in hours) of the part.
Data: Rm = 900 MPa, Rp0.2 = 750 MPa, from the master diagram at m = 0 D-1 = 400 MPa for N=106
and a = 640 MPa for N=104.

700
600
500
MPa 400
300
200
100
0

GUIDELINES FOR SOLUTION

- Calculate the parameters of the Wohler curve from the materials data, assume the exponent
k =const for each value of m
- Use the “bathtub” method to extract constant cycles from the mission (time history) in figure
in order to obtain a table where ni is the “total occurrence number” αi is the utilization
ni
fraction  i  (see fatigue slides chapter 4, slides 17-22),
 ni
i
ID max (MPa) min (MPa) m (MPa) a (MPa) ni 

- For each point ( mi ,  ai ) Calculate the equal life points  ai at m = 0, see fatigue slides
chapter 4, slide 29.
- Calculate the  a,eq (slide 12 chapter 4)
- Calculate the total life in cycles
- Calculate the number of missions in the total life
- Calculate the total life in hours considering that one mission lasts 20s

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