TOPIC

FEA FOR FATIGUE LIFE ASSESSMENT OF

VALVE COMPONENT SUBJECTED TO
INTERNAL PRESSURE LOADING.
(THROUGH SOFTWARE)

PRESENTED BY

Tallat Masood (17-MS-PT-AMD-01)

M Hassan Anwar Bhatti (17-MS-PT-ENE-018)
Theoretical or Form Stress Concentration
Factor
The theoretical or form stress concentration factor is defined as the
ratio of the maximum stress in a member (at a notch or a fillet) to the
nominal stress at the same section based upon net area.
Mathematically, theoretical or form stress concentration factor,

The value of Kt depends upon the material and geometry of the part.
Fatigue Stress Concentration Factor
• When a machine member is subjected to cyclic or fatigue loading, the
value of fatigue stress concentration factor shall be applied instead of
theoretical stress concentration factor.
• Mathematically, fatigue stress concentration factor,
Factors to be Considered while Designing
Machine Parts to Avoid Fatigue Failure
• The following factors should be considered while designing machine
parts to avoid fatigue failure:
1. The variation in the size of the component should be as gradual as
possible.
2. The holes, notches and other stress raisers should be avoided.
3. The proper stress de-concentrators such as fillets and notches should be
provided wherever necessary.
4. The parts should be protected from corrosive atmosphere.
5. A smooth finish of outer surface of the component increases the fatigue
life.
6. The material with high fatigue strength should be selected.
7. The residual compressive stresses over the parts surface increases its
fatigue strength.
Endurance limit and Fatigue failure
 When a material is subjected to repeated stresses, it fails at
stresses below the yield point stresses. Such type of failure of
a material is known as fatigue.
 The failure is caused by means of a progressive crack
formation which are usually fine and of microscopic size. The
failure may occur even without any prior indication.
 The fatigue of material is effected by the size of the
component, relative magnitude of static and fluctuating
loads and the number of load reversals.
 A standard mirror polished specimen, as shown in figure is rotated in a fatigue
testing machine while the specimen is loaded in bending.

 As the specimen rotates, the bending stress at the upper fibres varies from
maximum compressive to maximum tensile while the bending stress at the lower
fibres varies from maximum tensile to maximum compressive.
 In other words, the specimen is subjected to a completely reversed stress cycle. This
is represented by a time-stress diagram as shown in Fig. (a).
 Endurance or Fatigue limit (σe) is defined as maximum value of the
completely reversed bending stress which a polished standard specimen
can withstand without failure, for infinite number of cycles (usually 107
cycles).
 It may be noted that the term endurance limit is used for reversed
bending only while for other types of loading, the term endurance
strength may be used when referring the fatigue strength of the material.
 It may be defined as the safe maximum stress which can be applied to the
machine part working under actual conditions.
 We have seen that when a machine member is subjected to a completely
reversed stress, the maximum stress in tension is equal to the maximum
stress in compression as shown in Fig.(a). In actual practice, many
machine members undergo different range of stress than the completely
reversed stress.
 The stress verses time diagram for fluctuating stress having values σmin
and σmax is shown in Fig. (c). The variable stress, in general, may be
considered as a combination of steady (or mean or average) stress and a
completely reversed stress component σv.
 The following relations are derived from Fig. (c):

Alternating stress
max min
a = 2

Mean stress
max + min
m = 2
Factors affecting endurance limit
1) SIZE EFFECT:
 The strength of large members is lower than
that of small specimens.
 This may be due to two reasons.
 The larger member will have a larger
distribution of weak points than the smaller
one and on an average, fails at a lower stress.
 Larger members have larger surface Ares. This
is important because the imperfections that
cause fatigue failure are usually at the surface.
 Effect of size:
Increasing the size (especially section
thickness) results in larger surface
area and creation of stresses.
This factor leads to increase in the
probability of crack initiation.
This factor must be kept in mind while
designing large sized components.
2) SURFACE ROUGHNESS:
 almost all fatigue cracks nucleate at the surface of the
members.
 The conditions of the surface roughness and surface
oxidation or corrosion are very important.
 Experiments have shown that different surface finishes of
the same material will show different fatigue strength.
 Methods which Improve the surface finish and those which
introduce compressive stresses on the surface will improve
the fatigue strength.
 Smoothly polished specimens have higher fatigue strength.
 Surface treatments. Fatigue cracks initiate at free surface,
treatments can be significant
 Plating, thermal or mechanical means to induce residual
stress
3) EFFECT OF TEMPERATURE:

 Fatigue tests on metals carried out at below

room temperature shows that fatigue
strength increases with decreasing
temperature.

Stress amplitude

No. of cycles to Failure

 Higher the temperature,
lower the fatigue strength.

Stress amplitude

No. of cycles to Failure

4) Effect of metallurgical variables;
 Fatigue strength generally increases with increase
in UTS
 Fatigue strength of quenched & tempered steels
(tempered martensitic structure) have better
fatigue strength
 Finer grain size show better fatigue strength than
coarser grain size.
 Non-metallic inclusions either at surface or sub-
surface reduces' the fatigue strength
 S-N Diagram
 Fatigue strength of material is determined by R.R. Moore
rotating beam machine. The surface is polished in the axial
direction. A constant bending load is applied.

Typical testing apparatus, pure bending

Motor

Load

Rotating beam machine – applies fully reverse bending stress

 A record is kept of the number of cycles required to produce failure at a given stress,
and the results are plotted in stress-cycle curve as shown in figure.
 A little consideration will show that if the stress is kept below a certain value the
material will not fail whatever may be the number of cycles.
 This stress, as represented by dotted line, is known as endurance or fatigue limit
(σe).
 It is defined as maximum value of the completely reversed bending stress which a
polished standard specimen can withstand without failure, for infinite number of
cycles (usually 107 cycles).
 Relationship Between Endurance Limit and
Ultimate Strength
Steel
Steel
0.5Sut Sut ≤ 200 ksi (1400 MPa)
Se′ = 100 ksi Sut > 200 ksi
700 MPa Sut > 1400 MPa

Cast iron Cast iron

0.4Sut Sut < 60 ksi (400 MPa)

Se′ = 24 ksi Sut ≥ 60 ksi
160 MPa Sut < 400 MPa
 Relationship Between Endurance Limit and
Ultimate Strength
Aluminum
Aluminum alloys
0.4Sut Sut < 48 ksi (330 MPa)
Se′ = 19 ksi Sut ≥ 48 ksi
130 MPa Sut ≥ 330 MPa
For N = 5x108 cycle

Copper alloys
Copper alloys
0.4Sut Sut < 40 ksi (280 MPa)
Se′ = 14 ksi Sut ≥ 40 ksi
100 MPa Sut ≥ 280 MPa
For N = 5x108 cycle
Goodman Method for Combination of
Stresses:
A straight line connecting the endurance limit (σe) and the ultimate strength (σu), as
shown by line AB in figure given below follows the suggestion of Goodman.
A Goodman line is used when the design is based on ultimate strength and may be
used for ductile or brittle materials.
Now from similar triangles COD and PQD,
Soderberg Method for Combination
of Stresses
 A straight line connecting the endurance limit (σe) and
the yield strength (σy), as shown by the line AB in
following figure, follows the suggestion of Soderberg
line.
 This line is used when the design is based on yield
strength. the line AB connecting σe and σy, as shown in
following figure, is called Soderberg's failure stress
line.
If a suitable factor of safety (F.S.) is applied to the endurance
limit and yield strength, a safe stress line CD may be drawn
parallel to the line AB.
Modified Goodman Diagram:
 In the design of components subjected to fluctuating
stresses, the Goodman diagram is slightly modified to
account for the yielding failure of the components,
especially, at higher values of the mean stresses.
 The diagram known as modified Goodman diagram and
is most widely used in the design of the components
subjected to fluctuating stresses.
Modified Goodman Diagram for fluctuating axial and
bending stresses

Fatigue, m ≤ 0 Fatigue, m > 0

a a m 1
+ = Infinite life
Se Sut nf
Se a m
a = n + = 1 Finite life
f Sn Sut
Yield Se
Sy Yield
a + m = n Sy
y
C
a + m = n
y
Safe zone Safe zone

- m - Syc Sy Sut + m
Combined Loading
All four components of stress exist,

xa alternating component of normal stress

xm mean component of normal stress

xya alternating component of shear stress

xym mean component of shear stress

Calculate the alternating and mean principal stresses,

1a, 2a = (xa /2) ± (xa /2)2 + (xya)2

1m, 2m = (xm /2) ± (xm /2)2 + (xym)2

Combined Loading
Calculate the alternating and mean von Mises stresses,

a′ = (1a2+ 2a -2 1a2a)1/2

m′ = (1m2 + 2m2 - 1m2m)1/2

Fatigue design equation

′a ′m 1
+ = Infinite life
Se Sut nf
THANK YOU