FFT_2
Fatigue failure theories and Design against fluctuating load (Contd.)
Endurance Limit
Note that the fatigue strength S falls steadily and linearly (on log-log coordinates in
HCF region) as a function of number of cycles N until reaching a knee at about 106 to
107 cycles. This knee defines an endurance limit Se' for the material. Not all
materials exhibit this knee. “Many low-strength carbon and alloy steels, some
stainless steels, irons, molybdenum alloys, titanium alloys and some polymers” do.
The term endurance limit is used to represent the infinite-life strength only for the
above type of materials.
Fatigue Strength
The materials, such as “aluminum, magnesium, copper, nickel alloys, some stain-less
steels, and high-strength carbon and alloy steels” show S-N curves that continue to
fall with increasing N, though the slope may become smaller beyond about 107 cycles.
These materials do not have an endurance limit, thus their fatigue strength S f is
usually taken as the average failure stress at N = 5E8 cycles or some other value of N.
The materials which exhibits knee in S-N curve and are used for cycles < 106 cycles
of operation, fatigue strength also called endurance strength, S f can be defined at
any N.
Theoretical fatigue strength Sf or Corrected endurance limit Se
The theoretical fatigue strength S f or endurance limit Se of the different materials
can be estimated from the following empirical relationships. These are typically from
fully reversed bending tests.
Steels: S e 0.5S ut for Sut < 1400MPa
S e 700 MPa for Sut 1400MPa (2a)
Irons: S e 0.4S ut for Sut < 400MPa
S e 160 MPa for Sut 400MPa (2b)
Aluminiums: Sf @ 5E8 0.4 S ut for Sut < 330MPa
S f @ 5 E 8 130 MPa for Sut 330MPa (2c)
Copper Alloys: Sf @ 5E8 0.4 S ut for Sut < 280MPa
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FFT_2
S f @ 5 E 8 100 MPa for Sut 280MPa (2d)
where
Sut: Ultimate Tensile Strength
Corrected fatigue strength Sf or Corrected endurance limit Se
The fatigue strengths or endurance limits obtained from standard fatigue-test
specimens or from estimates based on static tests must be modified to account for
physical differences between the test specimen and the actual part being designed. A
set of strength-reduction factors should be incorporated. These factors are multiplied
by the theoretical estimate to obtain a corrected fatigue strength or endurance limit for
the particular application.
S e C load C size C surf C temp C reliab S e (3a)
S f C load C size C surf C temp C reliab S f (3b)
where
S e : corrected endurance limit for a material that exhibits a knee in its S-N curve.
S f : corrected fatigue strength at a particular number of cycles N for a material that
does not exhibit a knee.
C load , C size , C surf , C temp , C reliab : Strength reduction factors
Creating Estimated S-N Diagrams
The S-N diagram in HCF regime on log-log axis can be drawn in the bandwidth from
103 to 106 cycles and beyond by reasonably estimating fatigue strength, Sm at 103
cycles from the following equations (These equations are based on test data).
Sm = 0.9 Sut for bending (4a)
Sm = 0.75 Sut for Axial loading (4b)
If the material exhibits a knee, then the corrected S e from equation 3a is plotted at N
= 106 cycles and a straight line is drawn between Sm and S e . The curve is continued
horizontally beyond that point (See Fig.2a) shows this type of S-N diagrm If the
material does not exhibit a knee, then the corrected S f from equation 3b is plotted at
the number of cycles for which it was generated (shown at N = 5 x 108) and a straight
line is drawn between Sm and S f . This line may be extrapolated beyond that point,
but its accuracy is questionable, though probably conservative.
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FFT_2
Fig. 2: Estimated S-N Curves for (a) Materials with Knee, (b) Materials Without Knee
The equation of the line from Sm to Se or Sf can be written as
S aN b (5a)
Or
log S log a b log N (5b)
The constants a and b can be estimated by knowing the coordinates (Sm, N1) and (Se
or Sf, N2). Now the equations for constant b can be written as
1 S
b log m (6a)
3 Se
1 Sf
b@ 5 E 8 log (6b)
5.699 Se
Question
How many cycles of life of a 150 mm square hot rolled finished bar made of ductile
steel can be expected if the alternating stress is 100 MPa? Given that tested Sut is 600
MPa, the operating temperature is 500°C maximum, the loading is fully reversed
bending, and required reliability is 99.9%. [Answer: 3x105]
