Advanced Mechanics of Solids – Mod-IV
Topics discussed : Repeated stresses & Fatigue in metals.
Repeated stresses & Fatigue in metals
Introduction
Some machine parts are subjected to static loading. Since many of the machine parts (such as axles, shafts,
crankshafts, connecting rods, springs, pinion etc.) are subjected to variable or alternating loads (also
known as fluctuating or fatigue loads) . So there is a need to discuss about the variable or alternating
stresses.. For example in below figure the fiber on the surface of a rotating shaft subjected to a bending load,
undergoes both tension and compression for each revolution of the shaft.
Any fiber on the shaft is therefore subjected to fluctuating stresses. Machine elements subjected to
fluctuating stresses usually fail at stress levels much below their ultimate strength and in many cases below
the yield point of the material too. These failures occur due to very large number of stress cycle and are
known as fatigue failure. These failures usually begin with a small crack which may develop at the points
1|5 Prepared by SCH
Of discontinuity, an existing subsurface crack or surface faults. Once a crack is developed it propagates with
the increase in stress cycle finally leading to failure of the component by fracture.
There are mainly two characteristics of this kind of failures:
(a) Progressive development of crack.
(b) Sudden fracture without any warning since yielding is practically absent.
Fatigue failures are influenced by
(i) Nature and magnitude of the stress cycle.
(ii) Endurance limit.
(iii) Stress concentration.
(iv) Surface characteristics.
For machined steel endurance limit is approximately half the ultimate tensile stress.
Fatigue fracture is caused by the simultaneous action of cyclic stress, tensile stress and plastic strain.
If any one of these 3 is not present then fatigue failure cracking will not initiate and propagates.
When the material is subjected to cyclic stresses (fluctuating stresses) it will initiate micro cracks.
The tensile stress component causes crack propagation. So cracks grows with fluctuating load &
finally fails. It will be a sudden failure. That makes it very dangerous, without any warning.
Fatigue failure is completely unpredictable.
Fatigue failure is brittle in nature, even in ductile metals with less plastic deformation.
Mechanism of fatigue failure – 3 stages
1. Initiation of crack due to cyclic stresses.
2. Crack propagation until remaining uncracked part of a part becomes too weak to sustain the load
imposed. (due to tensile stress)
3. Final sudden failure of remaining c/s.
Stress cycle
A typical stress cycle is shown in below figure using standard specimen. The maximum, minimum, mean
and variable stresses are indicated. The mean and variable stresses are given by
2|5 Prepared by SCH
3|5 Prepared by SCH
Endurance limit
A typical plot of stress amplitude (S) against number of cycles to fail (N) is shown in above Fig.
Fatigue life : fatigue life of any material/structure is the no of stress cycles required to cause failure
(N). This number is the function of ( stress level, type of stress, material properties ).
4|5 Prepared by SCH
Fatigue strength formulations:
Fatigue strength experiments have been carried out over a wide range of stress variations in both tension and
compression below figure shows a schematic diagram of experimental plots of variable stress against mean
stress and Gerber, Goodman and Soderberg lines. But the following are important from the subject point
of view:
1. Goodman method 2. Soderberg method.
σu is the ultimate stress , σy is the yield stress & σe is the endurance limit.
Goodman analysis is based on ultimate stress and Soderberg analysis is based on yield
stress.
Straight line joining σu & σe is termed as Goodman line. Instead of a straight line if it is a
curve then it is termed as Gerber line.
Straight line joining σy & σe is termed as Goodman line.
Equation of these lines can be written using the slope of the lines.
From Goodman line/ soderberg line, the value of maximum fluctuating stress( endurance
limit ) can be applied on a material corresponding to the mean stress of fluctuating stress
can be find out. (For this draw a vertical line from mean stress parallel to y-axis, intercept a
point on the line and then draw a horizontal line and get the value of endurance limit.)
****************
5|5 Prepared by SCH