1.

0 INTRODUCTION

Fatigue, a complex phenomenon with only partial understanding, poses challenges in analytical
design approaches due to the involvement of "random" factors in material behaviour. Therefore, material
testing becomes crucial in the realm of engineering to prevent failures caused by fatigue. When conducting
fatigue analysis, two methods can be employed: stress-life calculation and strain-life calculation. For low
cycle fatigue, typically defined as failure occurring in fewer than 1000 cycles, the strain-life method proves
to be more accurate compared to the stress-life method. In fact, the strain-life method stands as the superior
approach in comprehending the underlying nature of fatigue failure. By incorporating these methodologies
and recognizing the significance of material testing, risks can be mitigated associated with fatigue and
enhance the reliability of structures and components.

Material Strength Properties used in this report is Isotropic Type. The material of the shaft is made of
Mild Steel. The mass density of the material is 7.85E-9 t/mm 3. Young Modulus of 2.2E+5 MPa, Poisson’s
Ratio of 0.275, Ultimate Tensile Strength of 345 MPa, and Yield Limit of 207 MPa. A Multi-Axial Fatigue
analysis is performed on a model consisting of total of 77357 Nodes and 47326 Elements. Two bearings of
structural type constraints are applied on both end of the shaft. Another structural type of constraint with Z
symmetry is applied on the cross-section surface of the shaft. A reversing load with magnitude of 3400 N in
the negative direction of Y-Axis is applied on a point that’s located around between point B and C.

2.0 ANALYSIS SETUP

Cross-Section Surface

Point A Point B Point C Point D

Bearing Constraint Load = 3400 N Bearing Constraint

Figure 1: Model setup of this analysis

Y-

X-Axis
Name of Author : Achmad Ferry Firdiansyah Technical Report 01: Fatigue Analysis on a
Rotating Shaft (Durability 101)
Author Matrix ID : TL21035
Report Version : Final Version
Name of Lecturer : Dr. Ahmad Syahrizan Bin Sulaiman
Date of Completion : 10 June 2023

1
3.0 MANUAL CALCULATION
For an actual mechanical component, Se is reduced to S’e which is less than 0.5 Sut.

𝑆𝑓 = 𝑎𝑁𝑏
3 6
Where N is cycles to failure and the constants a and b are defined by the points 103, (Sf )10 and 10 , Se with
3
(Sf )10 = f Sut. Substituting these two points gives
(𝑓 𝑆𝑢𝑡)2 1 (𝑓 𝑆𝑢𝑡)
𝑎= 𝑏 = − 𝑙𝑜𝑔
𝑆𝑒 3 𝑆𝑒
If a completely reversed stress σrev is given, setting Sf = σrev, the number of cycles-to-failure can be
expressed as

1/𝑏
𝑁 = (σ𝑟𝑒𝑣)
𝑎
In typical S-N diagram, it is only applicable for completely reversed loading. A Marin equation is written as,

𝑆𝑒 = 𝑘𝑎𝑘𝑏𝑘𝑐𝑘𝑑𝑘𝑒𝑘𝑓𝑆′𝑒

where  Se is the endurance limit for a specific part

 S’e is the endurance limit for a test specimen.

 ka is a surface factor that accounts for the finish (ground, machined, forged, and so on.)

 kb is a size factor that accounts for the size of the part.

 kc is a loading factor that accounts for different types of loading (bending, axial, torsion)

 kd is a temperature factor.

 ke is a reliability factor to account for scatter in the test results from one specimen to another.

 kf is a miscellaneous factor to account for everything else (residual stress, directional

characteristics, corrosion, electrolytic plating, and so on).
The midrange stress is calculated as follows:
𝑆𝑚𝑎𝑥 + 𝑆𝑚𝑖𝑛
𝑆𝑚 =
2
The alternating stress is calculated as follows:
𝑆𝑚𝑎𝑥 − 𝑆𝑚𝑖𝑛
𝑆𝑎 = | |
2
If the value entered for S is the ultimate tensile strength or yield strength, then this procedure is equivalent to
the modified Goodman relation or the Soderberg line:
𝑆𝑎 𝑆𝑚
+ =1
𝑆𝑒 𝑆 Technical Report 01: Fatigue Analysis on a

The total damage from stress amplitudes are: Rotating Shaft (Durability 101)
𝑛1 𝑛2 𝑛3 Report Version : Final Version
𝐷𝑎𝑚𝑎𝑔𝑒 = + +
𝑁1 𝑁2 𝑁3
Date of Completion : 10 June 2023

2
At 1000 cycles, the transition from low cycle to high cycle is assumed and Su, where,

𝑆𝑢 = 𝑓 × 𝑆𝑢𝑡 = 0.844 × 690 = 582 𝑀𝑃𝑎

The shift from high cycle to infinite life is anticipated to occur at 1E6 cycles and Se. The adjusted
endurance limit Se is derived using the correction factors ka through kf, where kc and kf are considered to be
1.

𝑆𝑒 = 𝑘𝑎𝑘𝑏𝑘𝑐𝑘𝑑𝑘𝑒𝑘𝑓𝑆′𝑒 = 0.798 × 0.858 × 345 = 236 𝑀𝑃𝑎

The greatest stress will occur at B, where the moment MB is 695.5 Nm, based on a moment diagram, shaft
diameters, and stress concentrations at each fillet. The section modulus is defined as
𝐼 𝜋𝑑3 𝜋323
= = = 3.217 × 103 𝑚𝑚3 = 3.217 × 10−6 𝑚3
𝐶 32 32
And for stress is
𝑀𝐵 695.5 𝑁𝑚
σ𝐵 = 𝐾𝑓 = 1.55 = 335 𝑀𝑃𝑎
𝐼/𝐶 3.217 × 10−6 𝑚3
Because the stress totally reverses, the maximum and lowest stress are Smax = 335 MPa (tension) and Smin
= -335 MPa (compression), resulting in Sm=0 and Sa=335 MPa for the mean and alternating stress.
The zero-mean alternating stress is Sa0=Sa=335 MPa since the mean stress is 0.
The slope of the S-N curve is
𝑙𝑜𝑔(𝑆𝑢) − 𝑙𝑜𝑔(𝑆𝑒) 𝑙𝑜𝑔(582) − 𝑙𝑜𝑔(236)
𝐵= = = 0.1308
𝑙𝑜𝑔(𝑁𝑒) − 𝑙𝑜𝑔(𝑁0) 𝑙𝑜𝑔(1𝐸 + 6) − 𝑙𝑜𝑔(1𝐸 + 3)
Interpolating the S-N curve at the zero-mean alternating stress gives:
1 1
𝑆𝑢 582 0.1308
𝐵
𝑁 = 𝑁0 ( ) = 1000 ( ) = 68200 𝑐𝑦𝑐𝑙𝑒𝑠
𝑆𝑎0 335

4.0 ANALYSIS RESULTS FROM AUTODESK INVENTOR NASTRAN

Technical Report 01: Fatigue Analysis on a

Rotating Shaft (Durability 101)
Report Version : Final Version
Figure 2: S-N Graph for the model.
Date of Completion : 10 June 2023

3
 Critical Point =
61940 Cycles

Non-Critical Point
= 1E+10 Cycles

Figure 3: Figure depicts the cycles on the Critical Point

and Non-critical point on the model.
5.0 RESULTS
Metho Maximum Cycles
d
FEA 6194
0
Manual Calculation 6820
0

6.0 CONCLUSION
Fatigue is a critical phenomenon that affects the performance and durability of rotating shafts. The
stress experienced by a shaft at any given point is not constant but varies as the shaft rotates. This cyclic
loading introduces fatigue, which can have detrimental effects on the shaft's integrity over time. Even a
seemingly flawless component, when subjected to repeated loads of sufficient magnitude, will eventually
develop a fatigue crack. This crack typically initiates in highly stressed regions, often near the surface of the
shaft, and continues to propagate until it culminates in a final fracture.
To evaluate the fatigue life of a rotating shaft, engineers employ constant amplitude loading. This
approach involves subjecting the shaft to a consistent magnitude of cyclic loading throughout its operational
life. By conducting careful calculations and analysis, the maximum number of cycles that the shaft can
withstand before fracturing can be predicted. This prediction serves as an important measure of the shaft's
fatigue life and informs maintenance schedules and replacement strategies.
In conclusion, the stress variation caused by the rotation of a shaft introduces fatigue, which can lead
to the development of cracks and eventual fracture. By utilizing constant amplitude loading and conducting
manual calculations, the fatigue life of a rotating shaft can be predicted, indicating the number of cycles it
can withstand before failure. This information is vital for maintaining the operational integrity of rotating
shafts
and ensuring the overall reliability and safety of machinery and equipment.
Technical Report 01: Fatigue Analysis on a
Rotating Shaft (Durability 101)

4
 Report Version : Final Version

Date of Completion : 10 June 2023