5.4.1. Formulation of Fatigue

Fatigue analysis is usually performed to assess the safe life of such a part using the stress/strain-life (SN/EN) methods. The following series of steps is generally performed.

  • Complex loading is reduced to a series of simple cyclic loadings using a technique such as rainflow analysis.

  • A histogram of cyclic stress is created from the rainflow analysis to form a fatigue damage spectrum.

  • For each stress level, the degree of cumulative damage is calculated from the S-N curve.

  • The effect of the individual contributions is combined using an algorithm such as Miner's rule.

Stress-life (SN) method and strain-life (EN) method are both available in the Motion postprocessor fatigue analysis and fatigue life can be evaluated in three ways as a material property type.

5.4.1.1. Fatigue Life Evaluation

The SN curve can be developed from the SN material property using the following steps.

Figure 5.10: Parameters for SN Curve

StepInput ParametersCalculated Output
1Parameters for SN Curve

Parameters for SN Curve

Where SRI1 is the intersection of b1 line and the stress axis.

2Parameters for SN Curve

Parameters for SN Curve

If Parameters for SN CurveParameters for SN Curve

then, Parameters for SN Curve = Parameters for SN Curve

3Parameters for SN CurveParameters for SN CurveParameters for SN Curve
4 Parameters for SN Curve , Parameters for SN Curve , Parameters for SN Curve Parameters for SN Curve

Figure 5.11: SN Curve

SN Curve

The SN curve can be developed from the EN material property using the following steps.

Figure 5.12: SN Curve from EN Material Property

SN Curve from EN Material Property

Figure 5.13: Parameters for SN Curve from EN Material Property

StepInput ParametersCalculated Output
1Parameters for SN Curve from EN Material Property

Parameters for SN Curve from EN Material Property

Parameters for SN Curve from EN Material Property

Parameters for SN Curve from EN Material Property

2Parameters for SN Curve from EN Material PropertyParameters for SN Curve from EN Material Property
3Parameters for SN Curve from EN Material Property

Parameters for SN Curve from EN Material Property = Parameters for SN Curve from EN Material Property

Parameters for SN Curve from EN Material PropertyParameters for SN Curve from EN Material Property

Parameters for SN Curve from EN Material Property = Parameters for SN Curve from EN Material Property

4Parameters for SN Curve from EN Material Property Parameters for SN Curve from EN Material Property = Parameters for SN Curve from EN Material Property
5 Parameters for SN Curve from EN Material Property , Parameters for SN Curve from EN Material Property , Parameters for SN Curve from EN Material PropertyParameters for SN Curve from EN Material Property

The EN curve can be developed from EN material property as following steps.

Figure 5.14: EN Curve

EN Curve

Figure 5.15: Parameters for EN Curve from EN Material Property

StepInput ParametersOutput
1 Parameters for EN Curve from EN Material PropertyElastic Y intercept value = Parameters for EN Curve from EN Material Property

Slope = Parameters for EN Curve from EN Material Property

2 Parameters for EN Curve from EN Material PropertyPlastic Y intercept value = Parameters for EN Curve from EN Material Property

Slope = Parameters for EN Curve from EN Material Property

3 

Parameters for EN Curve from EN Material Property

E-N Curve is divided into elastic Parameters for EN Curve from EN Material Propertyand plastic () term.


5.4.1.2. Concept of Repeated Load

A real fatigue test is carried out with constant minimum and maximum stresses and this is known as a constant amplitude stress test. Stress range (𝚫σ) is the gap between max stress (σmax) and min stress (σmin). The median of these is known as the mean stress (σm). The mean stress of figure (a) is 0, (b)~(c) have mean stress. Stress amplitude (σa) is half of stress range.

Figure 5.16: Concept of repeated load

Concept of repeated load
Concept of repeated load
Concept of repeated load
(a)Perfect-alternating current(b) Internal mean stress(c)Internal repeated stress

Formulas for these are as follows.

These formulas can be expressed by max stress and min stress as follows.

5.4.1.3. Mean Stress Effect

A general SN curve shows the life-cycle according to stress amplitude under zero mean stress conditions. Experimental relationships can be developed, taking into account the influence of mean stress. These relationships link the fatigue limit of alternation stress with one of yield strength, tension strength and breaking stress of alternation stress. If the analysis type is SN, select either Neglect, Modified Goodman, Gerber Locus, Soderberg or DE Elliptic. If analysis type is EN, select either Neglect, Morrow, or S-W-T.

In SN analysis, the following formulae represent mean stress influence.

Modified Goodman
Gerber Locus
Soderberg
DE elliptic
Endurance strength
Ultimate strength
Yield strength

Figure 5.17: Diagram for various criteria of failure

Diagram for various criteria of failure

In EN analysis, the following formulae represent mean stress influence.

Morrow
S-W-T

The S-W-T formula is undefined when is a negative value.

5.4.1.4. Plastic Correction

The strain-life method is suitable for fatigue tests of low cycles that exhibit a large degree of plastic strain. The relationship between stress and plastic strain is non-linear. However, generally for a fatigue test, you should use a linear relationship. In fatigue life using the strain-life method, the formula for the total strain-stress relationship includes elastic strain and plastic strain.

Figure 5.18: From elastic to plastic

From elastic to plastic

  1. Neuber's law is the theory that the area created by the stress-elastic strain in Hooke's law and the area created by the total stress-strain in Ramberg-Osgood's law are same.

    → @

    , are stress and strain in Hooke's law. When adapting the formula for Ramberg-Osgood's law at @, as below.

    Ramberg-Osgood' formula →

    Figure 5.19: Neuber's Law

    Neuber's Law

  2. ESED (equivalent strain energy density) is the theory that strain energy by Hooke's law and total strain energy by Ramberg-Osgood's law is same.

This formula is adapted from Ramberg-Osgood's formula.

Figure 5.20: ESED Method

ESED Method

5.4.1.5. Stress/Strain Combination

The combination of stress/strain can be defined as follows.

Figure 5.21: Stress/Strain Combination

Type Definition
VonMises

From Principal stress (Stress/Strain Combination)

Stress/Strain Combination

Stress/Strain Combination

Stress/Strain Combination

Stress/Strain Combination

Signed VonMisesStress/Strain Combination
Max PrincipalStress/Strain Combination
Min PrincipalStress/Strain Combination
Max ABS PrincipalStress/Strain Combination
Max ShearStress/Strain Combination
Signed Max ShearStress/Strain Combination
Averaged PrincipalStress/Strain Combination