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Fatigue Failure
Fatigue Failure
Brittle Material
Ultimate strength
Factor of safety = Allowable stress
Ductile Material
Yield strength
Factor of safety =
Allowable stress
In developing a machine,
• It is impossible to avoid changes in cross-section, holes, notches, shoulders
etc.
• Discontinuity in a member affects the stress distribution
• The discontinuity acts as a stress raiser
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Stress concentration factor (Flat bar)
2𝑏
𝜎3 = 𝜎1 1+
𝑎
𝜎3
𝑘𝑡 =
𝜎nominal
𝜎max
𝑘𝑡 =
𝜎nominal
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Dynamic loading
Rotating shaft
Static loading
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Dynamic loading Setup
• Mirror finished specimen
• Dimension < 7.5 mm
• 50 % reliable S-N diagram
• By changing the loads/
weights the failure cycles can
be obtained
• The stress amplitude at which the specimen fails at infinite load cycle is called
endurance limit.
• Experimentally N > 106
For steel:
3
𝑆𝑓10 = 0. 9 𝑆𝑢𝑡
6
𝑆𝑒10 = 0. 5 𝑆𝑢𝑡 If Sut ≤ 1400 Mpa
6
𝑆𝑒10 = 700 If Sut > 1400 Mpa
6
10 = 𝑘 𝑘 𝑘 𝑘 𝑘 10 6
𝑆𝑒𝑚 𝑎 𝑏 𝑐 𝑑 misc𝑆𝑒
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Surface finish factor
• Test specimen is polished to mirror finish
• Free from surface scratches and imperfections.
• The actual component may not even require
such a surface finish.
• Poor surface finish results in
• Scratches and geometric irregularities
on the surface
• Higher stress at the surface
• Result in stress concentration.
• The endurance limit is reduced
• Surface finish factor are same for axial, torsoinal
ad bending.
Test specimen
Reliability factor
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Fatigue stress concentration factor
Static stress concentration factor Fatigue stress concentration factor
Yield/Fracture strength
Factor of safety =
Maximum stress
𝜎max
𝑘𝑡 =
𝜎nominal
• Only depends upon the geometry of the
machine component. • Material dependent parameter.
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Factors influencing endurance limit
6
10 = 𝑘 𝑘 𝑘 𝑘 𝑘 10 6
𝑆𝑒𝑚 𝑎 𝑏 𝑐 𝑑 misc𝑆𝑒
For steel:
3
𝑆𝑓10 = 0. 9 𝑆𝑢𝑡
6
𝑆𝑒10 = 0. 5 𝑆𝑢𝑡 If Sut ≤ 1400 Mpa
6
𝑆𝑒10 = 700 If Sut > 1400 Mpa
Design methodology
(Q: Find the dimensions or material properties of machine component for infinite life)
3 6
Step 1: Find 𝑆𝑓10 (High cycle threshold value, 103 cycles) and 𝑆𝑒10 (Infinite cycle
threshold value, endurance limit of the material, 106 cycles) from 𝑆𝑢𝑡.
Step 2: Find 𝑘𝑎 𝑘𝑏 𝑘𝑐 𝑘𝑑 (reduction factors) from the charts and tables.
Step 3: Find the machine component endurance limit 𝑆𝑒𝑚 106 = 𝑘 𝑘 𝑘 𝑘 𝑆106 .
𝑎 𝑏 𝑐 𝑑 𝑒
Step 4: Find the maximum stress generated in the machine component 𝑆𝑚𝑎𝑥(function of
dimensions and material properties)
106 ≥ 𝑆
Step 5: 𝑆𝑒𝑚 𝑚𝑎𝑥 X Factor of safety (solve this relation and obtain the required
parameters)
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Thank you !!!
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