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Module 2

The document discusses the design of machine elements focusing on fatigue strength and stress concentration factors. It explains the causes of stress concentration, methods for its reduction, and the differences between static and fatigue failure, including mathematical models and failure stages. Additionally, it covers the endurance limit, factors affecting fatigue life, and provides examples and problems related to stress concentration and fatigue strength.

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0% found this document useful (0 votes)
12 views121 pages

Module 2

The document discusses the design of machine elements focusing on fatigue strength and stress concentration factors. It explains the causes of stress concentration, methods for its reduction, and the differences between static and fatigue failure, including mathematical models and failure stages. Additionally, it covers the endurance limit, factors affecting fatigue life, and provides examples and problems related to stress concentration and fatigue strength.

Uploaded by

roashinee.m2023
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Design of Machine Element

Fatigue strength
Module 2: Stress concentration factor, theoretical stress concentration factor,
causes of stress centration, reduction of stress concentration
Tapan Kumar Mahanta, Ph.D.
SMEC Chennai Campus
Stress concentration factor:
▪ Class Objectice1: Why stress concentration factor?
▪ Class Objective2: How stress concentration factor?
▪ Class Objective3: When stress concentration factor?

Assumptions:
▪ Homogeneous
▪ Uniform stress distribution
▪ Isotropic
Comparison of stress of rectangular plate with hole and
without hole:

(b)

(a)

(c)

Fig.1: Stress distribution of rectangular plate with hole & without Fig. 2: Stress Concentration
hole
Effect of discontinuity geometry:

Fig. 3: The discontinuity geometry has a significant effect on the stress distribution around it.
Theoretical stress concentration factor (𝑘𝑡 ):
▪ Used to determine maximum stress in component with changes in geometry.
▪ Stress concentration is defined as the localization of high stresses due to the
irregularities present in the component and abrupt changes of the cross-
section.

𝜎max
𝑘𝑡 =
𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙
𝜏𝑚𝑎𝑥
𝑘𝑡𝑠 =
𝜏𝑛𝑜𝑚𝑖𝑛𝑎𝑙
Where to consider stress concentration factor (𝑘𝑡 ):

Machine Design Failure

Static Dynamic

Ductile Brittle Fatigue

𝜺𝒕 ≥ 𝟎. 𝟎𝟓 𝜺𝒕 < 𝟎. 𝟎𝟓
No 𝑘𝑡 Yes 𝒌𝒕 Yes 𝒌𝒕
Causes of stress concentration :
▪ Variation in Properties of Materials
▪ Load Application
▪ Abrupt Changes in Section
▪ Discontinuities in the Component
▪ Machining Scratches
Process for reduction of stress concentration :

▪ Additional Notches and Holes in Tension Member

Fig. 4: Reduction of Stress Concentration due to V-notch: (a) Original Notch (b) Multiple Notches
(c) Drilled Holes (d) Removal of Undesirable Material
Process for reduction of stress concentration (contd.) :

▪ Fillet Radius, Undercutting and Notch for Member in Bending

Fig. 5:Reduction of Stress Concentration due to Abrupt Change in Cross-section: (a) Original Component
(b) Fillet Radius (c) Undercutting (d) Addition of Notch
Process for reduction of stress concentration (contd.) :
▪ Drilling Additional Holes for Shaft

Fig. 6: Reduction of Stress Concentration in Shaft with Keyway: (a) Original Shaft (b) Drilled Holes
(c) Fillet Radius
Process for reduction of stress concentration (contd.) :
▪ Reduction of Stress Concentration in Threaded Members

Fig. 7: Reduction of Stress Concentration in Threaded Components: (a) Original Component


(b) Undercutting (c) Reduction in Shank Diameter
Chart for the stress concentration factor :

Fig. 8: Stress Concentration Factor Fig. 9: Stress Concentration Factor Fig. 10: Stress Concentration Factor
(Rectangular Plate with Transverse (Round Shaft with Shoulder Fillet in (Flat Plate with Shoulder Fillet in
Hole in Tension or Compression) Tension) Tension or Compression)
Chart for the stress concentration factor :

Fig. 11: Stress Concentration Factor Fig. 12: Stress Concentration Factor
(Round Shaft with Shoulder Fillet in Bending) (Round Shaft with Shoulder Fillet in Torsion)
Theoretical stress concentration factor of elliptical hole :
▪ Theoretical stress concentration factor
a
𝑘𝑡 = 1 + 2
b
where,
a = half width (or semi-major axis) of the ellipse perpendicular to the direction of
the load
b = half width (or semi-minor axis) of the ellipse in the direction of load

A very sharp crack is indicated and the stress at


b=0, 𝑘𝑡 =∞ the edge of the crack becomes very large

circular hole in a flat plate, which is subjected


a= b, 𝑘𝑡 =3 to tensile force, is 3

Fig. 13: Plate with elliptical hole


Problem1(stress concentration) :
Find the maximum stress induced in the following cases taking stress
concentration into account:
1. A rectangular plate 60 mm × 10 mm with a hole 12 diameter as shown in below
figure and subjected to a tensile load of 12 kN.
2. A stepped shaft as shown in Fig. and carrying a tensile load of 12 kN.
Problem2(stress concentration) :
A flat plate subjected to a tensile force of 5 kN is shown in Fig.14. The plate
material is grey cast iron FG 200 and the factor of safety is 2.5. Determine the
thickness of the plate.

Fig. 14: Plate with a hole


Problem3(stress concentration) :
A non-rotating shaft supporting a load of 2.5 kN is shown in Fig.15. The shaft is
made of brittle material, with an ultimate tensile strength of 300 N/mm2. The
factor of safety is 3. Determine the dimensions of the shaft.

Fig. 15: Non rotating shaft


Competitive exam questions(stress concentration) :

ANS: C
Fatigue strength:
▪ Class Objectice1: Difference between fatigue and static failure
▪ Class Objective2: Interpret the strength life (S-N) diagram, Endurance limit
▪ Class Objective3: Difference between finite and Infinite life

Assumptions:
▪ Homogeneous
▪ Uniform stress distribution
▪ Isotropic
Static vs Fatigue failure:

Static Fatigue

▪ Load not varies with time ▪ Load varies with time ( cyclic, alternative,
fluctuation, variable, repeated & dynamic)
▪ Constant load

▪ Static failure occurs because of deformation/ ▪ Fatigue failure happen suddenly & catastrophic
Yield

▪ Failure occurs at Yield strength ▪ Failure occurs below Yield strength

▪ Static failure theory well understood ▪ Complex and high variation


Different type of failure:
Machine Design Failure

Static Fatigue

𝜺𝒕 ≥ 𝟎. 𝟎𝟓 𝜺𝒕 < 𝟎. 𝟎𝟓

Ductile Brittle S-N method

Theory of failure applicable Theory of failure applicable Stress life method applicable
(𝑺𝒚𝒕 = 𝑺𝒚𝒄 ) (𝑺𝒚𝒕 ≠ 𝑺𝒚𝒄 )
Mathematical model of cyclic stress:
𝜎𝑚𝑎𝑥
𝜎𝑚𝑎𝑥

+ Repeated stress
+ Fully reversed stress
Stress
Stress

time +
-

𝜎𝑚𝑎𝑥 𝜎𝑚𝑖𝑛 =0
𝜎𝑚𝑖𝑛 time

𝝈𝒎𝒂𝒙 − 𝝈𝒎𝒊𝒏
𝝈𝒂𝒍𝒕𝒆𝒓𝒏𝒂𝒕𝒊𝒗𝒆 = 𝝈𝒔𝒕𝒓𝒆𝒔𝒔 𝒂𝒎𝒑𝒍𝒊𝒕𝒖𝒅𝒆 = 𝝈𝒂 =
𝟐
𝝈𝒎𝒂𝒙 + 𝝈𝒎𝒊𝒏
𝝈𝒎𝒆𝒂𝒏 = 𝝈𝒎𝒊𝒅𝒓𝒂𝒏𝒈𝒆 = 𝝈𝒎 =
+ 𝟐
Stress
Fluctuating stress

time
-

𝜎𝑚𝑖𝑛
Fatigue failure due to crack propagation:
▪ Stage I:Fatigue crack nucleation
▪ Stage II: Fatigue crack propagation
▪ Stage III: Fatigue unstable crack

Fig.1: Fatigue failure of a bolt Fig.2: Fatigue failure initiated at the end of the keyway
Fatigue failure Initiates:
▪ At discontinuities
▪ Changes in cross-sectional area, keys, holes (stress concentration)
▪ Rolling/sliding contact
▪ Scratches, tool marks, assembly/fabrication factor
▪ Material composition and processing : voids & inclusion
▪ Type of mechanical (axial, bending, torsion or combination) and thermo
mechanical fluctuation)
Rotating beam specimen ( 4 point bending test):

F F Fully reversed stress

M 𝜎𝑚𝑎𝑥

+
Stress

-
F F
𝜎𝑚𝑎𝑥
𝜎𝑚𝑖𝑛
Fig.3: Rotating beam specimen

Fig. 4: Shear and Fatigue Failure of Wire: (a) Shearing of Wire (b) Bending of Wire (c) Unbending of Wire
S-N curve:

F F F F

Fig. 4: Specimen for Fatigue Test

Fig.6: S-N diagram

Fig. 5: Rotating beam fatigue experiment set up


Endurance limit and fatigue life:

➢ The fatigue or endurance limit of a material is defined as the maximum


amplitude of completely reversed stress that the standard specimen can
sustain for an unlimited number of cycles without fatigue failure.

➢ The fatigue life is defined as the number of stress cycles that the standard
specimen can complete during the test before the appearance of the first
fatigue crack.
Endurance limit-Approximation method:

𝑆𝑒 = 𝑘𝑎 𝑘𝑏 𝑘𝑐 𝑘𝑑 𝑆𝑒′

Where, 𝑆𝑒′ = endurance limit stress of a rotating beam specimen subjected to


reversed bending stress (𝑁Τ𝑚𝑚2)
𝑠𝑒 = endurance limit stress of a particular mechanical component
subjected to reversed bending stress (𝑁Τ𝑚𝑚2)
𝑘𝑎 = surface finish factor
𝑘𝑏 = size factor
𝑘𝐶 = reliability factor
𝑘𝑑 = modifying factor to account for stress concentration.
Approximation relation between 𝑆𝑒′ 𝐚𝐧𝐝 𝑆𝑢𝒕 :

𝑆𝑒′ = 0 ⋅ 5𝑆𝑢𝑡 ( for steel)


𝑆𝑒′ = 0 ⋅ 4𝑆𝑢𝑡 ( for cast iron and cast steel)
𝑆𝑒′ = 0 ⋅ 4𝑆𝑢𝑡 ( for wrought aluminium alloy)
𝑆𝑒′ = 0 ⋅ 3𝑆𝑢𝑡 ( For cast aluminium alloys)
Surface finish factor (𝑘𝑎 ):
Shigley and Mischke have suggested an exponential equation
for the surface finish factor.

𝑏
𝑘𝑎 = 𝑎 𝑠𝑢𝑡 If 𝑘𝑎 > 1, set 𝑘𝑎 =1

The value of coefficients a and b are given below

Table 1: Values of coefficients a and b

Surface finish 𝒂 𝒃
Ground 1.58 -0.085
Machined or cold drown 4.51 -0.265
Hot-rolled 57.7 -0.718

Fig. 7: Surface Finish Factor Forged 272 -0.995


Size factor (𝑘𝑏 ):

Table 2: Values of size factor


Shigley and Mischke have suggested an exponential equation for
the size factor. For bendingand torsion, the equation is in the
Diameter (d) 𝒌𝒃 following form
mm
𝑑 ≤7⋅5 1.0 For 𝟐 ⋅ 𝟕𝟗𝒎𝒎 ≤ 𝒅 < 𝟓𝟏𝒎𝒎
𝑘𝑏 = 1 ⋅ 24𝑑 −0⋅107
7 ⋅ 5 < 𝑑 ≤ 50 0.85
For 𝟓𝟏𝒎𝒎 < 𝒅 ≤ 𝟐𝟓𝟒𝒎𝒎
𝑑 > 50 0.75 𝑘𝑏 = 0 ⋅ 859 − 0.000873𝑑

For axial loading, 𝑘𝑏 = 1


Reliability factor and modifying factor (𝑘𝑐 and 𝑘𝑑 ) :

Modifying Factor to Account for Stress Concentration


Table 3: Reliability factor
1
𝑘𝑑 =
Reliability R(%) 𝒌𝒄 𝑘𝑓
50 1
➢ The endurance limit ( 𝑆𝑠𝑒 ) of a component subjected to
90 0.897
fluctuating torsional shear stresses is obtained from the
95 0.868 endurance limit in reversed bending (𝑆𝑒 )
99 0.814
𝑠𝑠𝑒 = 0.5𝑠𝑒 (torsional shear stress)
99.9 0.753
99.99 0.702 𝑠𝑒 𝑎 = 0.8𝑠𝑒 ( axial stress)
99.999 0.659
Reversed stresses- Design for Infinite life & Finite life:

Infinite life Finite life


➢ Endurance limit become the criterion of failure. ➢ Endurance limit become the criterion of failure.

𝑆 𝑠s𝑒
➢ Factor of safety (n) = 𝜎𝑒 or
a 𝜏a

𝑠𝑒 𝑠𝑠𝑒
𝜎𝑎 = 𝑛
or 𝜏𝑛 = 𝑛

Fig.7: Infinite life region Fig.8: Finite life region


Problem 1:
A forged steel bar, 50mm in diameter, is subjected to reverse bending stress of
250 𝑁Τ𝑚𝑚2 . The bar is made of steel 40C8 ( Sut= 600 𝑁Τ𝑚𝑚2 ). Calculate the
endurance strength of the bar for a reliability of 90%

Surface finish 𝒂 𝒃
Ground 1.58 -0.085
Machined or cold 4.51 -0.265 Reliability 𝒌𝒄
drown R(%)
Hot-rolled 57.7 -0.718 50 1
Forged 272 -0.995 90 0.897
95 0.868
Diameter (d) 𝒌𝒃
99 0.814
mm
99.9 0.753
𝑑 ≤7⋅5 1.0
99.99 0.702
7 ⋅ 5 < 𝑑 ≤ 50 0.85
99.999 0.659
𝑑 > 50 0.75
Problem 2:
A rotating bar made of steel 45C8 (Sut = 630 𝑁Τ𝑚𝑚2 ) is subjected to a
completely reversed bending stress. The corrected endurance limit of the bar is
315 𝑁Τ𝑚𝑚2 . Calculate the fatigue strength of the bar for a life of 90,000 cycles
Problem 3:
A forged steel bar, 50 mm in diameter, is subjected to a reversed bending
stress of 250 𝑁Τ𝑚𝑚2 . The bar is made of steel 40C8 (Sut =600 𝑁Τ𝑚𝑚2 ), The
corrected endurance limit of the bar is 100.64 𝑁Τ𝑚𝑚2 . Calculate the life of the
bar.
Fatigue strength:
▪ Class Objectice1: Stress concentration factor in fatigue
▪ Class Objective2: Impact of notch sensitivity on material on fatigue
▪ Class Objective3: Goodman and Soderberg equation due to application of
fluctuating stresses on material

Assumptions:

▪ Homogeneous
▪ Uniform stress distribution
▪ Isotropic
Fatigue stress concentration factor ( 𝑘𝑓 ):
𝐸𝑛𝑑𝑢𝑟𝑎𝑛𝑐𝑒 𝑙𝑖𝑚𝑖𝑡 𝑜𝑓 𝑛𝑜𝑡𝑐ℎ 𝑓𝑟𝑒𝑒 𝑠𝑝𝑒𝑐𝑖𝑚𝑒𝑛
𝑘𝑓 =
𝐸𝑛𝑑𝑢𝑟𝑎𝑛𝑐𝑒 𝑙𝑖𝑚𝑖𝑡 𝑜𝑓 𝑛𝑜𝑡𝑐ℎ 𝑠𝑝𝑒𝑐𝑖𝑚𝑒𝑛

𝑘𝑓 = 1 + 𝑞 𝑘𝑡 − 1

Where 𝑘𝑡 = theoretical stress concentration factor


𝑘𝑓 = fatigue stress concentration factor
𝑞= notch sensitivity factor

Incre𝑎𝑠𝑒 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑣𝑒𝑟 𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑘𝑓 −𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙


𝑞= =
𝐼𝑛𝑐𝑟𝑒𝑎𝑠𝑒 𝑜𝑓 𝑡ℎ𝑒𝑟𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑣𝑒𝑟 𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑘𝑡 −𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙
𝑘𝑓 −1
=
𝑘𝑡 −1
Fatigue stress concentration factor ( 𝑘𝑓 ) Contd.:
𝑘𝑓 = 1 + 𝑞 𝑘𝑡 − 1

▪ When the material has no sensitivity to notches (q=0) and 𝒌𝒇 =1


▪ When the material is fully sensitive to notches (q=1) and𝒌𝒇 = 𝒌𝒕

Fig. 1: Notch Sensitivity Charts (for Reversed Bending and Fig. 2: Notch Sensitivity Charts (for Reversed
Reversed Axial Stresses) Torsional Shear Stresses)
Problem 4:
A plate made of steel 20C8 (Sut = 440 N/mm2) in hot rolled and normalised
condition is shown in below Fig. It is subjected to a completely reversed axial
load of 30 kN. The notch sensitivity factor q can be taken as 0.8 and the
expected reliability is 90%. The size factor is 0.85. The factor of safety is 2.
Determine the plate thickness for infinite life.
Problem 4:

Reliability 𝒌𝒄
R(%)
50 1
90 0.897
95 0.868
99 0.814
99.9 0.753
99.99 0.702
99.999 0.659
Problem 4:
Problem 5:
A component machined from a plate made of steel 45C8 (Sut = 630 N/mm2) is
shown in below Figure. It is subjected to a completely reversed axial force of 50
kN. The expected reliability is 90% and the factor of safety is 2. The size factor
is 0.85. Determine the plate thickness t for infinite life, if the notch sensitivity
factor is 0.8
Problem 5:
Problem 5:
Problem 6:
A rotating shaft, subjected to a nonrotating force of 5 kN and simply supported
between two bearings A and E is shown in below figure. The shaft is machined from
plain carbon steel 30C8 (Sut = 500 N/mm2) and the expected reliability is 90%. The
equivalent notch radius at the fillet section can be taken as 3 mm. What is the life of
the shaft?
▪ Taking the moment of the forces about bearings A and E, the reactions at A and E
are 2143 and 2857 N respectively
✓ The possibility of a failure will be at the three sections B,
C and D.
✓ The failure will probably occur at the section B rather
than at C or D.
✓ At the section C, although the bending moment is
maximum, the diameter is more and there is no stress
concentration.
✓ At the section D, the diameter is more and the bending
moment is less compared with that of section B.
✓ Therefore, it is concluded that failure will occur at the
section B.
Rotating beam specimen ( 4 point bending test):
F F

Fig.3: Rotating beam specimen


F F
𝜎𝑚𝑎𝑥
𝜎𝑚𝑎𝑥

Fully reversed stress


+ Fluctuating stress Stress Stress
Stress +

= +
time -
-
𝜎𝑚𝑎𝑥
𝜎𝑚𝑖𝑛
𝜎𝑚𝑖𝑛

𝝈𝒎 𝝈𝒂
Fluctuating stress= mean stress + stress amplitude:

𝝈𝒎𝒂𝒙=𝟒𝟎
40
𝝈𝒂
10 𝝈𝒂 =30
𝝈𝒎 𝝈𝒎 =10
𝝈𝒂 = + 10

𝝈𝒂 =30
𝝈𝒎𝒊𝒏=−𝟐𝟎
-20

𝝈𝒎 𝝈𝒂

𝝈𝒎𝒂𝒙 +𝝈𝒎𝒊𝒏 40−20


𝝈𝒎 = = = 𝟏𝟎
𝟐 2

𝝈𝒎𝒂𝒙 −𝝈𝒎𝒊𝒏 40− −20


𝝈𝒂 = = = 𝟑𝟎
𝟐 2
Goodman and Soderberg equation:
𝑺𝒆 C
𝑺𝒚𝒕
P
)
Stress amplitude (

𝑺𝒆
O Q D
𝑺𝒚𝒕

Similar triangle COD and PQD


𝑃𝑄 𝑄𝐷 OD − OQ
= =
𝐶𝑂 𝑂𝐷 OD
𝑺𝒚𝒕 𝑺𝒖𝒕 𝑃𝑄 OQ
Mean stress ( ) =1−
𝐶𝑂 𝑂𝐷
Fig.4: Goodman and Soderberg line 𝜎𝑎 𝜎𝑚
+ =1 Soderberg equation
𝑆𝑒 𝑠𝑦𝑡
When factor of safety (n) considered
𝜎𝑎 𝜎𝑚
Soderberg equation Goodman equation + =1 Goodman equation
𝑆𝑒 𝑠𝑢𝑡
𝜎𝑎 𝜎𝑚 1 𝜎𝑎 𝜎𝑚 1
+ = + =
𝑆𝑒 𝑠𝑦𝑡 𝑛 𝑆𝑒 𝑠𝑢𝑡 𝑛
Stress amplitude ( )

Mean stress (
)
Goodman, Soderberg and Gerber equation:

Soderberg equation

Goodman equation

Gerber equation
Problem 1:
A hot rolled steel rod under goes axial cyclic loading and nominal stresses
𝑁 𝑁
𝝈𝒎𝒊𝒏 =14 to 𝝈 𝒎𝒂𝒙 =70 have been calculated, The rod has a hole in the
𝑚𝑚2 𝑚𝑚2
centre of the rod with 𝑘𝑡 =1.7 and 𝑞= 0.9. The yield strength of the rod is given
𝑁 𝑁
by 𝑆𝑦 = 310 2 and Ultimate strength of the rod is 𝑆𝑢𝑡 = 565 2 . Endurance
𝑚𝑚 𝑚𝑚
𝑁
limit is 𝑆𝑒 = 138 . Using Goodman criteria, determine the FOS
𝑚𝑚2

𝝈𝒎𝒂𝒙 = 70

𝝈𝒎𝒊𝒏=𝟏𝟒

0
Fig.5:Steel rod specimen
Problem 2:
A hot rolled steel rod under goes axial cyclic loading and nominal stresses
𝑁 𝑁
𝝈𝒎𝒊𝒏 = -69 to 𝝈𝒎𝒂𝒙 = 103 have been calculated, The rod has a hole in
𝑚𝑚2 𝑚𝑚2
the centre of the rod with 𝑘𝑡 =1.7 and 𝑞= 0.9. The yield strength of the rod is
𝑁 𝑁
given by 𝑆𝑦 = 310 2 and Ultimate strength of the rod is 𝑆𝑢𝑡 = 565 2.
𝑚𝑚 𝑚𝑚
𝑁
Endurance limit is 𝑆𝑒 = 138 . Using Goodman criteria, determine the FOS
𝑚𝑚2

𝝈𝒎𝒂𝒙 = 103

𝝈𝒎𝒊𝒏=−𝟔𝟗

Fig.6:Steel rod specimen


Problem 3:
Problem 3:
Problem 3:
Problem 3:
Problem 4:
Problem 4:
Problem 4:
Problem 4:
Problem 4:
Problem 4:
Problem 5:
Problem 5:
Problem 5:
Problem 5:
Problem 5:
Problem 6:
Problem 6:
Problem 6:
Problem 6:
Problem 6:
Modified Goodman and Soderberg equation ( Combined
effect of variable normal and shear stresses):
Soderberg equation
Modified Goodman and Soderberg equation ( Combined
effect of variable normal and shear stresses):
Problem 7:
Problem 7:
Problem 7:
Problem 7:
Problem 7:
Problem 7:
Problem 7:
Problem 7:
Problem 8:
Problem 8:
Problem 8:
Problem 8:
Problem 8:
Problem 8:
Problem 8:
Problem 8:
Problem 8:
Problem 8:
Problem 8:
Problem 8:
Modified Goodman diagram:

Fig.5: Modified Goodman Diagram for Axial and Bending Stresses


Modified Goodman diagram:

Fig.5: Modified Goodman Diagram for torsional shear Stresses


Cumulative damage in fatigue:
= Fatigue life in no. of cycle at a
stress amplitude of
= Actual no. of cycles the
component is loaded at a stress
amplitude of

Where , = % of total life


for n1

Miner’s Equation
Problem 9:
The work cycle of a mechanical component subjected to completely reversed
bending stresses consists of the following three elements:
(i) ± 350 N/ mm2 for 85% of time
(ii) ± 400 N/ mm2 for 12% of time
(iii) ± 500 N/ mm2 for 3% of time
The material for the component is 50C4 (Sut = 660 N/ mm2 ) and the corrected
endurance limit of the component is 280 N/ mm2. Determine the life of the
Component.

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