temperatures, and it preserves high toughness
even at low temperatures (Ref 44, 68, 69).
Impact tests provide useful quantitative com-
parative data with relatively simple test speci-
mens and equipment. However, these tests do
not provide property data for design purposes for
material sections containing cracks or defects.
Data of this type are obtained from fracture
mechanics, in which theoretical and/or experi-
mental ways determine the fracture of structural
materials containing pre-existing cracks and
defects.
The number of cycles to failure (N) obtained
by the S-N curve under load or a stress-control
condition is related to the total life of the part up
to failure. Fatigue cycles throughout the life of
the machine part consist of crack initiation and
its propagation. Crack propagation refers to
stable crack growth up to the crack instability.
The S-N curve approach does not separate the
crack initiation phase from propagation. Indus-
trial experts assume that the crack has already
initiated in the machine part, and only the total
number of cycles associated with the propaga-
tion are of interest. Existing or initiated cracks
assumed in the machine part are the result of
dynamic load cycles induced during manu-
facturing, prior to its use. The size of the pre-
existing crack can be assumed based on the
capability of suitable inspection. The expert may
assume an initial surface crack after testing and
makes a decision about the application of the
part.
Using the available initial defects in the
material, the total life of the part can be assessed
by an appropriate fracture mechanics method.
Basic factors affecting the shape of the S-N
curve are:
Materials selection and heat treating or cold
working conditions
Various types of loading on the specimen,
such as tension, compression, torsion, or a
combination
Loading conditions described by medium
stress, amplitude stress, and frequency
Influences on the environment carried by
temperature, corrosion, and other factors
Some major factors that affect the strength of
a metal include:
Stress concentration: Fatigue strength is
greatly reduced by the presence of stress
raisers, such as notches, holes, keyways, or
sharp changes in cross sections.
Surface roughness: In general, the smoother
the surface finish on the metal sample, the
higher the fatigue strength.
Surface condition: Since most fatigue fail-
ures originate at the metal surface, any major
change in the surface condition will affect
the fatigue strength of the metal.
Environment: If a corrosive environment is
present during the cyclic stress of a metal,
the chemical attack greatly accelerates the
rate at which fatigue cracks propagate.
During machining processes, various defects
occur on the surface, such as small scratches and
grooves, and are introduced into the workpiece
surface. Typical failures are moving machine
parts, such as shafts, connecting rods, and gears.
It is estimated that failures of machine parts in
machines contribute approximately 80% of
fatigue failures. These surface detects can limit
the fatigue life. Improving the surface finish by
polishing will increase fatigue life significantly.
One of the most effective methods of in-
creasing fatigue life is the existence of residual
compressive stresses in a thin surface layer.
Thus, applied surface tensile stress will be par-
tially reduced in magnitude by the residual
compressive stress. The net effect is the prob-
ability of crack formation and a consequent re-
duction in fatigue failure.
According to the AISI standard, the heat
treatable structural steel 4140 contains between
0.38 and 0.45% C, 0.90 and 1.2% Cr, and 0.15
and 0.30% Mo. It has very high hardenability,
contributing to high strength values in products
with high mass. Molybdenum yields a desirable
fine microstructure after hot working as well as
heat treatment, contributing to a good strength-
to-toughness ratio. Due to its fine-grained
microstructure, it also reaches a relatively high
toughness in the heat treated condition.
The strength of the steel as well as its sur-
face hardness and wear resistance may be in-
creased by heat treatment and thermochemical
treatment.
Mechanical properties of steel having a dia-
meter of up to 40 mm and between 40 to
100 mm are given in Table 4.
Tensile strength of the steel varies between
880 and 1080 N/mm
2
, and a minimum tough-
ness value, r
3
, equals approximately 41 J. The
steel is very sensitive to notch and transition
on machine parts subjected to fatigue loading.
Fatigue strength of the material is lowest under
torsional load, s
T
, and varies for the diameters
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