Metal Fatigue in Engineering

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Edition: 2nd
Format: Hardcover
Pub. Date: 2000-11-03
Publisher(s): Wiley-Interscience
List Price: $182.34

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Summary

Classic, comprehensive, and up-to-date Metal Fatigue in Engineering Second Edition For twenty years, Metal Fatigue in Engineering has served as an important textbook and reference for students and practicing engineers concerned with the design, development, and failure analysis of components, structures, and vehicles subjected to repeated loading. Now this generously revised and expanded edition retains the best features of the original while bringing it up to date with the latest developments in the field. As with the First Edition, this book focuses on applied engineering design, with a view to producing products that are safe, reliable, and economical. It offers in-depth coverage of today's most common analytical methods of fatigue design and fatigue life predictions/estimations for metals. Contents are arranged logically, moving from simple to more complex fatigue loading and conditions. Throughout the book, there is a full range of helpful learning aids, including worked examples and hundreds of problems, references, and figures as well as chapter summaries and "design do's and don'ts" sections to help speed and reinforce understanding of the material. The Second Edition contains a vast amount of new information, including: * Enhanced coverage of micro/macro fatigue mechanisms, notch strain analysis, fatigue crack growth at notches, residual stresses, digital prototyping, and fatigue design of weldments * Nonproportional loading and critical plane approaches for multiaxial fatigue * A new chapter on statistical aspects of fatigue

Author Biography

RALPH I. STEPHENS is Professor of Mechanical Engineering at The University of Iowa in Iowa City. ALI FATEMI is Professor of Mechanical, Industrial, and Manufacturing Engineering at The University of Toledo in Ohio. ROBERT R. STEPHENS is Associate Professor of Mechanical Engineering at The University of Idaho in Moscow, Idaho. The late HENRY O. FUCHS was Professor, and then Professor Emeritus, at Stanford University in Palo Alto, California.

Table of Contents

Preface xv
Biographical Sketches xix
Introduction And Historical Overview
1(18)
Mechanical Failure Modes
1(2)
Importance of Fatigue Considerations in Design
3(2)
Historical Overview of Fatigue
5(4)
Summary
9(1)
Dos and Don'ts in Design
10(1)
Biographical Sketches
10(9)
References
16(1)
Problems
17(2)
Fatigue Design Methods
19(14)
Strategies in Fatigue Design
19(4)
The In-House Tool
21(1)
The New Model
22(1)
The New Product
22(1)
Design to Code
22(1)
Fatigue Design Criteria
23(2)
Infinite-Life Design
23(1)
Safe-Life Design
23(1)
Fail-Safe Design
24(1)
Damage-Tolerant Design
24(1)
Analysis and Testing
25(3)
Probabilistic Design and Reliability
28(1)
CAE and Digital Prototyping
28(1)
In-Service Inspection and Acquisition of Relevant Experience
29(1)
Summary
30(1)
Dos and Don'ts in Design
30(3)
References
31(1)
Problems
31(2)
Macro/Micro Aspects Of Fatigue Of Metals
33(26)
Fatigue Fracture Surfaces and Macroscopic Features
34(9)
Fatigue Mechanisms and Microscopic Features
43(12)
Summary
55(1)
Dos and Don'ts in Design
56(3)
References
56(1)
Problems
57(2)
Fatigue Tests And The Stress-Life (S-N) Approach
59(34)
Fatigue Loading, Test Machines, and Specimens
59(8)
Fatigue Loading
59(3)
Fatigue Test Machines
62(3)
Fatigue Test Specimens
65(2)
Stress-Life (S-N) Curves
67(7)
General S-N Behavior
67(3)
Fatigue Limit Under Fully Reversed Uniaxial Stressing
70(4)
Mean Stress Effects on S-N Behavior
74(5)
Factors Influencing S-N Behavior
79(4)
Microstructure
79(1)
Size Effects
80(1)
Surface Finish
80(2)
Frequency
82(1)
S-N Curve Representation and Approximations
83(3)
Example of Life Estimation Using the S-N Approach
86(2)
Summary
88(1)
Dos and Don'ts in Design
89(4)
References
89(1)
Problems
90(3)
Cyclic Deformation And The Strain-Life (ϵ-N) Approach
93(29)
Monotonic Tension Test and Stress-Strain Behavior
93(5)
Strain-Controlled Test Methods
98(1)
Cycle-Dependent Material Deformation and Cyclic Stress-Strain Behavior
98(7)
Strain-Based (ϵ-N) Approach to Life Estimation
105(6)
Determination of Strain-Life Fatigue Properties
111(2)
Mean Stress Effects
113(2)
Surface Finish and Other Factors Influencing Strain-Life Behavior
115(1)
Summary
116(1)
Dos and Don'ts in Design
117(5)
References
118(1)
Problems
119(3)
Fundamentals of Lefm And Applications to Fatigue Crack Growth
122(64)
LEFM Concepts
123(10)
Loading Modes
123(1)
Stress Intensity Factor, K
124(2)
K Expressions for Common Cracked Members
126(6)
Superposition for Combined Mode I Loading
132(1)
Crack Tip Plastic Zone
133(3)
Fracture Toughness-Kc, KIc
136(6)
Fatigue Crack Growth, da/dN-δK
142(13)
Sigmoidal da/dN-δK Curve
144(2)
Constant Amplitude Fatigue Crack Growth Test Methods
146(1)
da/dN-δK for R=0
147(4)
Crack Growth Life Integration Example with No Mean Stress Effects
151(4)
Mean Stress Effects
155(5)
Cyclic Plastic Zone Size
160(2)
Crack Closure
162(3)
Small Fatigue Cracks And Lefm Limitations
165(5)
Plasticity Extension of Lefm and Elastic-Plastic Fracture Mechanics
170(4)
Summary
174(1)
Dos and Don'ts in Design
175(1)
References
176(4)
Problems
180(6)
Notches and Their Effects
186(57)
Concentrations and Gradients of Stress and Strain
187(9)
S-N Aproach for Notched Members
196(13)
Notch Sensitivity and the Fatigue Notch Factor, Kf
196(3)
Effects of Stress Level on Notch Factor
199(1)
Mean Stress Effects and Haigh Diagrams
200(6)
Example of Life Estimation with the S-N Approach
206(3)
Notch Strain Analysis and the Strain-Life Approach
209(17)
Notch Stresses and Strains
210(2)
Neuber's Rule
212(3)
Strain Energy Density or Glinka's Rule
215(2)
Plane Stress versus Plane Strain
217(1)
Example of Life Estimation Using the Strain-Life Approach
218(8)
Applications of Fracture Mechanics to Crack Growth at Notches
226(5)
The Two-Stage Approach to Fatigue Life Estimation
231(3)
Summary
234(2)
Dos and Don'ts in Design
236(7)
References
237(2)
Problems
239(4)
Residual Stresses And Their Effects On Fatigue Resistance
243(27)
Examples
243(2)
Production of Residual Stresses and Fatigue Resistance
245(12)
Mechanical Methods
245(7)
Thermal Methods
252(2)
Plating
254(2)
Machining
256(1)
Relaxation of Residual Stresses
257(2)
Measurement of Residual Stresses
259(2)
Stress Intensity Factors for Residual Stresses
261(3)
Summary
264(1)
Dos and Don'ts in Design
265(5)
References
266(1)
Problems
267(3)
Fatigue From Variable Amplitude Loading
270(48)
Spectrum Loads and Cumulative Damage
270(4)
Damage Quantification and the Concepts of Damage Fraction and Accumulation
274(1)
Cumulative Damage Theories
274(3)
Palmgren-Miner Liner Damage Rule
274(3)
Nonlinear Damage Theories
277(1)
Load Interaction and Sequence Effects
277(4)
Cycle Counting Methods
281(10)
Rainflow Method
282(4)
Other Cycle Counting Methods
286(5)
Life Estimation Using the Stress-Life Approach
291(4)
Life Estimation Using the Strain-Life Approach
295(4)
Crack Growth and Life Estimation Models
299(9)
Simulating Service Histories in the Laboratory and Digital Prototyping
308(3)
Laboratory Test Methods
308(2)
Digital Prototyping
310(1)
Summary
311(1)
Dos and Don'ts in Design
312(6)
References
313(2)
Problems
315(3)
Multiaxial Stresses
318(26)
States of Stress and Strain and Proportional versus Nonproportional Loading
319(1)
Yielding and Plasticity in Multiaxial Fatigue
320(3)
Stress-Based Criteria
323(5)
Equivalent Stress Approaches
323(2)
Sines Method
325(1)
Examples Using the Stress-Life Approach
326(2)
Strain-Based, Energy-Based, and Critical Plane Approaches
328(9)
Strain-Based and Energy-Based Approaches
328(1)
Critical Plane Approaches and the Fatemi-Socie Model
329(4)
Example of Nonproportional Loading
333(4)
Fracture Mechanics Models for Fatigue Crack Growth
337(1)
Notch Effects and Variable Amplitude Loading
338(1)
Summary
339(1)
Dos and Don'ts in Design
340(4)
References
341(1)
Problems
342(2)
Environmental Effects
344(57)
Corrosion Fatigue
345(11)
Stress Corrosion Cracking/Environment-Assisted Cracking
345(2)
Stress-Life (S-N) Behavior
347(3)
Strain-Life (ϵ-N) Behavior
350(1)
Fatigue Crack Growth (da/dN-δK) Behavior
351(2)
Protection Against Corrosion Fatigue
353(2)
Corrosion Fatigue Life Estimation
355(1)
Summary
355(1)
Dos and Don'ts in Design
356(1)
Fretting Fatigue
356(8)
Mechanisms of Fretting Fatigue
359(2)
Influence of Variables
361(2)
Summary
363(1)
Dos and Don'ts in Design
363(1)
Low-Temperature Fatigue
364(9)
Monotonic Behavior at Low Temperature
364(1)
Stress-life (S-N) Behavior
365(1)
Strain-life (ϵ-N) Behavior
366(2)
Fatigue Crack Growth (da/dN-δK) Behavior
368(2)
Variable Amplitude Behavior and Fatigue Life Estimation
370(2)
Summary
372(1)
Dos and Don'ts in Design
372(1)
High-Temperature Fatigue
373(18)
Creep Deformation
374(1)
Stress-Strain Behavior Under Cyclic Loading and Hold Times
375(1)
Stress-life (S-N) Creep Behavior
376(5)
Strain-life (ϵ-N) Behavior
381(5)
Fatigue Crack Growth (da/dN-δK) Behavior
386(5)
Summary
391(1)
Dos and Don'ts in Design
391(1)
Neutron Irradiation
391(10)
References
394(5)
Problems
399(2)
Fatigue Of Weldments
401(27)
Weldment Nomenclature and Discontinuities
402(4)
Constant Amplitude Fatigue Behavior of Weldments
406(6)
Stress-Life (S-N) Behavior
406(2)
Strain-Life (ϵ-N) Behavior
408(1)
Crack Growth (da/dN-δK) Behavior
409(3)
Spot Welds
412(1)
Improving Weldment Fatigue Resistance
412(2)
Weldment fatigue Life Estimation
414(9)
General Weldment Fatigue Life Models
414(2)
Weldment Fatigue Design Codes and Standards
416(7)
Summary
423(1)
Dos and Don'ts in Design
424(4)
References
424(2)
Problems
426(2)
Statistical Aspects of Fatigue
428(19)
Definitions and Quantification of Data Scatter
429(1)
Probability Distributions
429(7)
Normal and Log-Normal Distributions
430(3)
Weibull Distributions
433(2)
Estimating Low Probabilities of Failure
435(1)
Tolerance Limits
436(2)
Regression Analysis of Fatigue Data
438(2)
Reliability Analysis
440(1)
Example Problem Using the Weibull Distribution
441(2)
Summary
443(1)
Dos and Don'ts in Design
443(4)
References
444(1)
Problems
444(3)
APPENDIX MATERIAL PROPERTIES 447(10)
Table A.1 Monotonic Tensile Properties and Fully Reversed, Bending Unnotched Fatigue Limits, Sf, of Selected Engineering Alloys
448(2)
Table A.2 Monotonic, Cyclic, and Strain-Life Properties of Selected Engineering Alloys
450(2)
Table A.3 Plane Strain Fracture Toughness, KIc, for Selected Engineering Alloys (Plate Stock, L-T Direction Unless Otherwise Specified)
452(2)
Table A.4 Fatigue Crack Growth Threshold, sδKth, for Selected Engineering Alloys
454(1)
Table A.5 Corrosion Fatigue Behavior in Water or Salt Water for Life ≤107 Cycles for Selected Engineering Alloys
455(2)
Author Index 457(8)
Subject Index 465

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