national aeronautics and space administration€¦ · mises-hencky theory (also called the...

185
, v NASA CONTRACTOR REPORT - -- ._ STATI·STICAL -COKPLEX USE (NASA-CR-72835)·· E 4340 STEEL AND ITS t . DATA FOR SA TY D. Kececiog1u. e lIN DESIGN BY RELIABILI _ ) 15 Nov. 1970 , . Univ •• Tucson. CSCL 11F 'al (At:l- ZOna _------- \, --_. "-.. \187 P _---- ----,-- --- . i NASA N73-1255 1 Uncl as J / STATISTICAL COMPLEX FATIGUE DATA FOR SAE 4340 ·STEEL AND ITS USE IN DESIGN BY RELIABILITY , l' . I, i:: .' j: : i, I ,. ; I.' I i. I I i I' . " Tucson, Arizona by Dr. Dimitri Kececioglu and John L. Smith . jI(J, L Prepared under Grant No. 03-002-044 by The University of Arizona for NATIONAL AERONAUTICS AND SPACE ADMINISTRATION D. C. Reprod"uced by . \ NATIONAL TECHNICAL . _. __ ._ _ l,'!ASHINOTON, , i j I I I i i j. I j j i I I I I I !. j i J j ! :, I I . I Ii'bp. : 1 ... ;,t . https://ntrs.nasa.gov/search.jsp?R=19730003824 2020-04-30T11:04:47+00:00Z

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Page 1: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

,v

NASA CONTRACTORREPORT

--- ._ STATI·STICAL - COKPLEX USE(NASA-CR-72835)·· E 4340 STEEL AND ITS t

. ~FATIGUE DATA FOR SA TY D. Kececiog1u. elIN DESIGN BY RELIABILI _ ) 15 Nov. 1970, . Univ •• Tucson. CSCL 11F'al (At:l-ZOna _-------\, --_. "-..

\187 P _---- ----,----- .

i

l"t8~-NASA CR-~X*

N73-1255 1

Unclas

G3/1'!.-~88~~_--

J

/

STATISTICAL COMPLEX FATIGUE DATA FOR SAE 4340 ·STEEL ANDITS USE IN DESIGN BY RELIABILITY

,l' .I,i::.'j: :i, I,. ;

I.'Ii .IIiI' .

"

Tucson, Arizona

by Dr. Dimitri Kececioglu and John L. Smith. jI(J, L

Prepared under Grant No. 03-002-044 by The University ofArizona

for

NATIONAL AERONAUTICS AND SPACE ADMINISTRATIOND. C.

Reprod"uced by . ~!\ NATIONAL TECHNICAL. INF~~~~!.e~~~.;~~~~ICE_. __ ._ ~Sp.r.i~fi"-Id,,~22151 _

l,'!ASHINOTON,

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Page 2: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

I

1.\

//

/

STATISTICAL COMPLEX FATIGUE DATAFOR SAE 4340 STEEL "AND ITS USE

IN DESIGN BY RELIABILITY

by

Dr. Dimitri Kececioglu and Johti L. Smith

Prepared for

NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

.November 15,1910Contract NG~ 03-002-044

Project Management

byVincent R. Lalli

NASA-Lewis Research CenterCleveland, .Ohio

College of EngineeringTHE UNIVERSITY OF ARIZONA

Engineering Experiment Station. Tucson, Arizona

J

ii

11

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- iv

TABLE OF CONTENTS".......-.-Page

• • • •• • • •

I, I • • • •

'ix

vii

• •• • •

• • •

· .. .I I

• • •

• • •LIST OF ILLUSTRATIONS· •

LIST OF TABLES

INTRODUC'l'ION

• • • • • • • • • •

1

xi

· . -I •• •I • • I

• •• • •

I • • •• • •

• • • •• • •

I

ABSTRACT

CHAF-TEll

1.1 Background on Testing Program • • • • • • 1

1.2 Data Reduction. • • I • • • • • • • • • • 7

1.3 Goodness-of-Fit Tests • • • • • • • • • • 10.i .Lt, Generation of Statistical Fatigue

Diagrams From Test Data • .. • I • • • • • 10

1·5' 110dification of One Test Nachine. • • • • 11

II DATA REDUCTION • • I • • I I I • I • • I • • • 12

2.1 Determination of Stress Levels andStress Ratios • • • • • • • • I I " I • 12

Stress-to-Failure Data (StaircaseMethod) • • • >... . . . . . . . . .. . I • 19

• • •

Endurance Tests for R = ~ andR=1.0 •••••••••••

Endurance Tests for. R = 3.5

• I25

31

• I •

2.4

Cycles-to-Failure Data at SpecificStress Ratios and Levels •••••

Normal Distribution Fit to the Data • • •

35

36

2.4.1 Determination of Mean, StandardDeviation, Skewness, and Kurtosis. 36

Preceding page blank

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.i.-·:.; .. _

v

TABLE OF CONTENTS (continued)

Page

CHAPTER' "

-\'-.-,

II DATA HEDUCTION (continued)

2.5 Loe-Normal Distribution Fit to the Data •. 42

2.5.1 Determination of Mean, Standard'Deviation, Skewness, and Kurtosis.

2.6.1 Chi-Square Goodness~of-FltTest •• '

2.6.2 Kolmogorov-Smirnov Goodness~of­Fit Test • • • • • • • • • • • • ._

Goodness-of-Fit Tests • • • • • " • • • • " ,

J

43 '

43

44

45

47• •• •• •• • • •Discussion of Results2.7

2.8 Construction of Statistical FatigueDiagrams at Various Numbers of Cycles ofLife ...'. • • • • • • • • • • • • • • 53

./

III OVERALL CONCLUS I CI~S • • • • • • • • • • • • •

IV REcom'1ENDATI01'JS • • • • • ., . • • • • • • • •

APPENDIX AI Cm·iPUTER PRCGRAr'l TO CALCUUTESTRESS LEVELS AND RATIOS.'. • • • • • •

2.8.1 Use of Statistical FatigueDiagrams in Design • • • •

Modification of One Test Machine.

• • • •

• • • •

76

84

93

95

96

APPENDIX Bl COr:IPUTER PROGRAI1 TO CALCULATEPARAHE']1ER ESTH1ATES FOR TP.:E NORr·iALAND LOG-1'~02I'~AL DISTRIBUTIONS AEDCONDUCT GOODi(ESS-OF-FIT TESTS • • • • • 115

APPENDIX C, CAlJIBRATIOl: CONSTAETS OF EACHNACHINE FO?. 'I'm:: DIFFERENT NODES • • • •

/,

_.:_." ,;::, .

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.. \

. TABLE OF CONTENTS (continued)

vi

CIL\PTER..... ''''''-'''-''-

i. ....:... ~~I .

Page

APPEl'JDIX D:

APPEHDIX EI

cmiFUTER OUTPUTS LISTING STRESSLEVELS A!'!D RATIOS OF INDIVIDUALSPECH1ENS FOR THE VARIOUS STRESSLEVELS. • • • • • • • • • ~ .'. •

COHPUTER OUTPUTS LISTING STRESSLEVELS AND RATIOS OF ItIDIVIDUALSPECINENS FOR THE ENDURANCE TESTS

• • •

• • •

APPE~~IX FI FRINTOUT OF PROGRAM TO CALCULATETHE STRENGTH DIS'I'RIBUTIOE ESTD'IATESFOR liliAN AND STANDARD DEVIATION • • • •

LIST OF REFERENCES • • • • • • ' .. . ~ . . . .

./

• • •, ,

I

. r, I,

I!

I

i

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vii

LIST OF ILLUSTRATIONS

!\

page

FIGURE

1.1 Schematic Diagram of Test Machines Showingthe Loading Configuration • • ',' • • • • • • • 2

1.2 Stress Element on Surface of Test Specimen ••• 4

1.3

1.4

Test Specimen • • • • • • • • • • • •

S-N Diagram ShoHing Cycles-to-FailureDistributions for a Specific Non-ZeroStress Ratio •• '.' ••••• ~ •••

• • • •

• • • •

• '6

• 8

Illustration of a Visicorder Record Sh01'11ngthe Bending, Torque and Calibration Traces ••. 13

-2.2 Flot·, Chart of Calculations to Obtain NominalStresses in the Specimen Groove/From theStrain Gage Outputs ••••••• • • • • • • 17

2.3 Endurance StrenGth Data Obtained by theStaircase Method for Stress Ratio of ~ forSAE 43lj·0 Steel, NIL-S-5000B, Condition C4,Rockl-Tell C 35/40 • • • ~ • • ',' • -. '. • • • • 26

2.4 Endurance Strength Data Obtained by theStaircase Method for Stress Ratio of 1.0for SAE 4340 Steel, MIL-S-5000B, ConditionC4, Roc.lnlell C 35/4,0,. • • • • • • • • • • • Ii 27

<j-.

2.6

Endurance Strength Data Obtained by theStaircase Method for Stress Ratio of 3.5ror SAE 4340 Steel, MIL-S-5000B, ConditionC4, Roc~1ell C 35/40 • • • • • • • • • • •

Cycles-to-Failure Distributions andEndurance Strength Distribution for StressRatio of 00 • • • • • • ~ • • • • • • • 0 0

Cycles-to-Failure Distributions andEndurance Strength Distribution for StressRatio of 3.5 ••• o· 0 •••••••••• ' 0

• 0

o •

• •

32

.\,49

so

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\,

viii

LIST OF ILLUSTRATIONS (continued)

page

FIGURE

2.8 Cycles-to-Failure Distributions andEndurance Strength Distribution for StressRatio of 0.825 ••••••••.•••• ••••• 51

/

Cycles-to-Failure Distributions at StressRatio of 0.44 ••••• • ; ••••••• • • 52

2.10 Fatigue Diagram ShmTing the rlodifiedGoodman Line and the Soderberg Line. • • • • • 53

2.11 Histogram Obtained From Cycles-to-FailureDistributions •••• • • • • • • • • • • • '. ,

- 2.12

2.13

Plot of Estimated Strength Distributionsat Various Cycles of Life and EstimatedCycles-to-Failure Distributions at VariousStress Levels for Stress Ratio ,of 3.5 ••

S~N Diagram Sho1'Ting Random Data Points andCell Structure for Testing and ObtainingDistributions •••• • • • • • • • • • •

• •

· '. 59

2.14 S-N Dia.gram for Stress Ratio of 00 ShoNingthe Estimated Cycles-to-Failure Distributionsand Test Band ••••••••••• '. • • • • 62

2.15 Relationship Beh:een the Stress Ratio Lines. • 72

2.16 Statistical Fatigue Diagram for Infinite Life.' 75

2.17 Conventional Fatigue Diagram Sh01·:ing theModified Goodman Line. • • • • ·' . • • • • • • 77, "

. 2.18 Sta.tistical Fatigue Diagram. • • • • • • • • • 78

2.19 Enlargement of Stress and StrengthDistributions on H2 Axis of Figure 2.18. • • • 79

2.20 The Distribution of Z = S - s • • • • • • • • 80

2.21 Gear Coupling Used on Fatigue Te?ting Machine. 86

2.22 Modified Gear Coupling\ ,f)

• • • .'. • ~ • • • • • " -92

'-. '-r"

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-."

1x

.- ;: -- .. , .- . _.._~::. . ~

. LIST OF TABLES

. ~

':'" ... ' ,page

TABLE

'~~1:

2.2

! -.""\ ;. - ':.. -' ':..................: I"~ :.' •" ,__ ~~. _ ._~___ '" .-_"" _ t,

. '-,'" , '. ~... - ~ - - ..Table' Shovl1ng- the Average Stress Le'vels andRatios at Which Specimens Were Tested. • • • • 20·

Estimates of the Mean and Standard Deviationof the Endurance Strength for Stress Ratiosof co • :3. 5 and 1. 0 • • • • • • '. • • • • •.•• 24' .

2.3 List of Specimens and the Corresponding ~

Stresses and Pan Weights for Endurance Testsat Stress Ratio = co • • • • • • • • • • • • • 28

2.4 List of Specimens and the CorrespondingStresses and Pan Weights for Endurance Testsat Stress Ratio = 1.0 • • • • • • • • • • •• 29

2.5 List of Specimens and Corresponding ActualStresses and Intended stresses for EnduranceTests at Stress Ratio = 3.5 ••• .'. • • • • 33

Normal Distribution Parameter Estimatesand the Maximum D-Values • • • • • • • • • • • 37

2.7 Log-Normal Distribution Parameter Estimatesand the I"iaximum D-Values • • • • • • • • • • •. 38

2.8 Tables of Critical Values of D to Use in theKolmogorov-Smirnov Goodness-of-Fit Test. • • • 46

Estimated Normal Parameters for StrengthDistributions at Various Cycles-or-Life. • • • 57

2.10 Cycles-to-Failure and Stress Data for StressRatio of co at Stress Levels of 73,000 psi.a~d 81,000 psi ••••••• '.' ••••••• 63

2.11 Alternatlne Strength Distribution Parametersand the Corresponding Distribution ParametersAlong the Various Stress Ratio Lines ~or

Infinite Life • • • • • • • • • • • • • • • .~ 68

Page 9: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

-TABLE ~,

LIST OF TABLES (continued)

\ . page\'---

2.12 Data and Results From Static Tests onNotched Specimens* ••••••••• -••••• 69

2.13 Data and Results From Static Tests onUnnotched Specimens. • • -. • • • • • • ,'-. •• 70

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Page 10: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

xi

ABSTRACT

A brief description or the complex fatigue machines

used in the test program is presented. .The data generated

from these machines are given and discussed. T~10 methods

of obtaining strength distributions from the data are

also discussed. Then follows a discussion of the con_v

struction of statistical fatigue diagrams and their'use

in-designing by reliability. Finally, ·some of the pro-.

blems encountered in the test equipment and a corrective

. modification are presented.

/

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Page 11: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

'. !\

CFJiPTER I

INTRODUCTION',--

1.1 B~ckgXQund on Testipg Program

The purpose of the test program is to generate cycles­

to-failure data by testing rotating specimens subjected to

a bending moment and a constant torque. The test machines

were designed and built at the Univer~ity of Arizona~

The following is a brief discussion of the test

. machines. For a more complete discussion of the design and

development of the test machines see Ref. 1. Presently

there are three machines at the Univer~ity of Arizona.

The test specimen is subjected to a bending moment by

weights hung at the end of a lever arm. Fig. 1.1 shows a

schematic diagram of the machine illustrating the loading

geometry. The torque is applied by turning the torque

coupling, which rotates shaft A with respect to shaft B

and holds the relative position of the shafts. After the

specimen is tightened in the holding collets the adjusting

nut on the torque coupling can be turned while holding

shaft A from rotating. This will rotate shaft B with

respect to shaft A. It requires a full 360 degree turn of

the adjusting nut to rotate shaft B one degree with respect

to shaft~A. Once the play' in the gear boxes 1s taken up

1

·.,.

Page 12: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

.2

SHAFT 'A'

TORQUE COUPLING

SHAFT 'B'GEARBOX

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III

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-l --H---+-

SPECINENTOOLHOLDER

. . SPHERICAL ROLLE~R. . /BEARIHG

TORQUE GAGES J' .t-- BENDING GAGES 1_ 'W. '

-~It::!+

GEAR COUPLING TO PROVIDE FIVOTSOTOOLROLDS~~ CAN DEFLECT D01..;1'~HARDSLIGHTLY HHEN LOAD IS AYFLIED

SHAFT FORMOTOR -.

Fig. 1.1 Schematic Diagram of Test Machines Showingthe Loading Configuration

-, -'"!'.

-- -.- ~-_._-._. ";"j >

Page 13: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

then torque 1s exerted on the specimen.

'I'he roagni tudes of the shear stress and the normal

stress that the specimen experiences are related to the."

stresses ";hich the toolholder experiences. Two strain

gage bridse curcu1ts are mounted on the toolholder in the

position ShO\'111 in Fig. 1.1. Acting through an amplifier

the output of one bridge is a measure of the normal stress

and the output of the other bridge 1s a meo.sure of the

shear stress that the toolholder experiences. The out­

puts are in the form of a Visicorder@record. The strain

gage outputs and how they are used to determine the stresses

in the specimen will be further discussed in Sect. 2.1.

Since the machines are capable of subjecting a specl-

--men to combined stresses, tests can be'conducted for any

combination of alternating and mean stresses. The alter­

nating stress is in the form of a normai stress caused by

a constant bending moment on the rotating specimen. Any

element of volu~e located at the surface of the specimen

will experience an alternating tension and c~mpresslon of

equal magnitude. If torque is applied the element will also

experience a constant shear stress perpendicular to the

normal stress. Figure 1.2 show the stress element.

Early in the research program a study was made of the

various failure theories. On the basis of ~~ls study it

was concluded that the von Mises-Hencky theory most closely

predicts fatigue failures in steel (1. p. 41).

Page 14: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

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41

'tyxm

't xym

± Sxa

';:ym' ..-,.'tyxm

, ~

Fig. 1.2 Stress Element on Surface of Test Specimen

./

Shigley (2, P. 185) makes the point that the von

Mises-Hencky theory (also called the distortion-energy

theory) "las developed to predict yield under static loads.

However, because of the good agreement between fatigue

/

de. ta and the theory it was accepted as the failul-'e governing

___criterion for the research program. ~

nitudes of the alternating and mean stresses a stress

ratio 'ias defined in terms of the von Mlses stresses

(2, P. 188)~For an ordinary element subjected to bi-axial

stresses the von Hises stresses are given by:

i! .

; .

Page 15: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

5

[82 82 2 ]

1S = - 8 Sya + + 31: xya 2

a. xa xa ya

[S2 S + S2 + 31: 21

Sm = - 8 ] 2 \xm xm ym ym xym .,---.,

For the case of an alternating normal stress along the x

axis and a constant shear stress perpendicular to the x

axis, the above equations reduce to

S = Sxaa

S = JJt XYIDm

The stress ratio is defined as

/

where

= (3)

R = stress ratio /

S = alterne.ting normal stressa

S = mean normal stressm

t Xym= mean shear stress.''j

The specimens being used for the'test program are

made of 8AE 4J40 steel, condition C-4, heat treated to

35 - 40 Re The specimens were all manufactured from the

same heat. Fig. 1.3 ShO\'IS the specimen geometry.

The ultimate purpose of the test program is to develop

statistical fatigue diagrams which can be used to design a

specified reliability into a rotating shaft subjected to a

bending moment and a constant torque 'for a specified life.

I. , .

Page 16: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

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Page 17: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

, J

7

In order to secure data to construct the statistical

fatigue surfaces the following test plan'was proposed

(1, pp. 132-138):~

1. Tests are to be conducted at various alter~

nati~g stress levels, holding the stress

ratio constant, to determine the cycles-to-

failure distributions at the various levels.

Tests, of 18 specimens at each level, are to~

be conducted at 4 to 6 different stress

levels for each stress ratio. This data can

then be plotted on log~log paper with stress

level on the ordinate and cycles-to- failure

on the abscissa. The resulting diagram will

look like fig. 1.4. Such a diaeram can be

obtained for' each stress ratio except R = o.2. Once the cycles-to-failure diagrams are ob­

tained then the strength distributions for

specified lives would be obtained and these

distributions used in constructing the fatigue

diagrams to be used to design by reliability.

..

...

1.2 p~ta Reduction.J

The data as t~1cen from the testing machines is in the

form of a Visicorder record which contains two traces for

each specimen. One trace records the amplitude of the alter-

nating normal stress as seen by the strain gages on the

j

Page 18: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

\ ..

CYCLES-TO-FAILURE - LOG10 SCALE

['

Fig. 1.4 S-N Diagram Showing Cycles-to-Failur~Distributions for a Specific Non-ZeroStress Ratio.

. 8

. i

Page 19: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

,9

toolholderand the other trace records the magnitude/

of the constant shear stress. From these records the

nominal normal stress and average nominal shear stress ,can".

be obtained for all the specimens which were tested at a

given level. Theretermination of these stress levels

from the Visicorder records is discussed in Section 2.1.

The terms, "nominal normal stress" and ~nominal' shear

stress" refer to the stresses the specimen i'l'ould exper-

1ence at the outermost fiber of the cross section if it

did not contain a stress riser; ie, if the test section

were of a consta.nt diameter and that diameter were equal

to the diameter across the base of the groove in the

present specimen./

Section 2.2 discusses the methods employed in deter­

mining the endurance level at the various stress ratios.

Sections 2.3. 2.4 and 2.5 deal "11th the calculation

of the mean and standard deyiation, and the coefficients

of skewness and kurtosis of both the cycles-to-failure da.ta

and the natural logarithms of the cycles-to-feilure data.

T,-lo computer programs '\'Tere developed to aid in the'

reduction of the test data:'

1. A program to reduce the Visicorder records

to stresses and stress ratios.

"

Page 20: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

z..

10

A program to calculate the mean and· stande.rd

deviation of the cycles-to~failure data and

test how well the data fits the normal dis-"tr1bution. The program also makes these

/.

calculations for the log-normal distribution.

Th~ progra.ms are d1 scussed. in Appendices A and B.

Included in the -discussion is a complete description of the

input dEl..ta card formats for ee.ch deck a.nd a flow chart for

The firs£ program mentioned above-was developed by

this au.thor whereas the second was previously written but

was mod.1f.led to be used with the data of this research

program.

1.3 £L92Q~f~~9f-FitTests

Seotion 2.6.1 discusses the Chi-square goodness-of-

fit tent and its applicability to the test data. Section

2.6.2 discusses the Kolmogorov-Smirnov goodness-of-

fit te~t and its applicability.

1.4 Q~11.s1',?t!oYL2.f Stati,stica-1.. Fatig]..~~ Di8.l!rarnsr

From

~~.~t~.. Da ta

Whe generation of tbe stati~tical fatigue diagrams

requl~es that the strength distributions at various cycles.\

of lite be knOl'l·n. The test Pl~n that 1'laS proposed at the

beg1nntng of the research effort was set up.with the

objeotlve of obtaining test data from 'Nhich estimates could

;;

Page 21: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

11

be made of these strength distributions. Section 2.8

discusses the proposed method and its limitations. In the

same section a~other test plan and method is proposed' for

obtaining the re~uire~ distribution based onactu~l data.

Section 2.8.1, discusses how to use statisti~al fatigue

diagra.ms to design a shaft to a specified reliabi1ity. The

assumptions and 'limitations of the method are also dis-

cussed.

1.S ~ificati9n of One Test ~achine.:

-\011 th tl)e approval of Dr. Kec~ci9glu and I1r. Vincent R.

-Lalli of NASA-Lewis this author made a modification to

"

one of the three test machines in December, 1969. It is

believed that this modification '"Till eliminate some of the

problems encountered ,oJ! th the machines. None of the data

presented in this report was obtained from the modified

machine. Details of 'the modification are presented in

Section 2.9.

)'

\,

Page 22: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

.' > 'I

<-CHAPTER II'

,'\ DATA REDUCTION.'-....:..

2.1 peterm~na~ion of Stress Levels and Stress Ratios

As stated in the introduction, the raw data is in the

form of a Visicorder record' containing two traces.

Figure 2.1 is an illustration of what such a record looks

like ~ The traces are.a m'easure of the alternating normal

stress and constant ,,:shear stress as seen by the strain

gages which are mounted on the machine toolholdef. The

values of these traces ,0 in terms of divisions, can be

converted into values of nominal normal stress and nominal/

shear stress in the groove of the specimen. However, to

be able to make this conversion several constants must be

known which relate the output of the strain gages on the~. ..

toolholder to the nominal stresses in the groove of the

specimen. The calibrations required to obtain these con­

stants are qUite extensive and since the original cali­

brations were not conducted by this author only a brief

discussion will be undertaken here. For a complete dis­

cussion of the ca.libration 'procedure see Ref. 3.

There are five constants required to make the con~

version from divisions on the Visicorder record to nominal

12

Page 23: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

BENDING GAGE OUTFUT TORQUE G~GE'OUTPUT

TORQUECAIIEF~ATION

TRACE

ZERO. BENDING

TRACE

ZEROTORQUE

TRACE

,.-----ROTATING BY POi.·!ER--------,

-..t-rT~~ROTATING BY EAED / ~_!

BENDInGCALIBRATIONTRACZS

L •.' \ .

Fig. 2.1 Illustration ofa Visicorder Record Showingthe Bending, Torque and Calibration Traces

Page 24: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

"

=

1~

stresses in the test speci~en. They ares

constant to relate the output of the,strain gages on the specimen to the

, actual stress in the specimen.

'totK -bit - cr ot·

where

=

=

=

=

constant to relate the output of the

bending strain gages on the toolholderto the output of the strain gages on the

specimen.

constant to relate the actual shearstress in the specimen to the output of

th~ torque strain gages on the toolholder., .

constant to relate the output of thebending gages on the to61holder to the

./

output of the torque gages on the tool-holder ,-rhen the toolholder is subjected

to a changing torque while the bending,moment is held constant.

constant to relBtethe output of the torque

gages on the toolholder to the output ofthe bending gages on the toolholder.when

the toolholder is SUbjected to a changingbending moment While the torque 1s heldconstant.

=\

normel stress in the specimen as indicated by

the output of strain b~ees on the test speci~en.

Page 25: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

" .

CI = actual normal stress in the specimen.as

Clot = normal stress in the toolholder a.s indicatedby the strain gages on the toolholder.

~I

las = actual shea.r stress in the specimen.

~ot = shear stress as indicated by the straingages on the toolholder.

The last, two constants listed are interaction con-

stants. Due to misalignment, a bending gnge may record an

output"'t-Jhen the shaft is sUbject~d. to pure torsion. Like­

wise, a misaligned torque gage may react to a pure bending

on the shaft. These t~TO constants take this interaction

into account.

Whenever a strain gage on the toolholder ,is replaced

or when a change is made, to the michine that alters its

loading characteristics some of the calibration constants~,

may change. Therefore" "lhenever such changes are TIl:ad,e,

calibration tests must be performed to obtain corrected

values for the constants that are affected by the change.

Changes that affected the calibretion constants ....rere me.de

at three different times throughout the test program. In

order to kno;rwhat constants were in effect during given

time periods each time period was designated as a mode of

operation. The values or these constants are given in

Appendix C.

"

Page 26: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

16

Figure, 2.2 shows the sequence of calculations required

to convert the strain ga3e outputs, as recorded by the

Visicorder f to nomin~l stresses in the groove of the test'.

specimen. The meanings of the symbols used in Fig. 2.2

Which have not been defined earlier in this section are:

= number of Visicorder record divisions used

when adjusting the gain in the bendingchannel of the amplifier.

number of Visicorder record divisions usedwhen ad justing the gain in the torque che.nnelof the amplifier.

Reb ~- value in ohms of the calibrating resistanceused when adjusting the gain in the bendingchannel amplifier.

Rct = value in ohms of ca.librating resistance usedwhen adjusting the gain in the torque channel

~f of the amplifier.

=

=

amount of deflection, in Visicorder divisions.

caused by the toolholder bending stra.in gagebridge output when load is applied to the

specimen.

amount of deflection, in Visicorder divisions,caused by 'the toolho1der torque strain gage

bridge output when load is applied to specimen.

Page 27: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

Output bending stressin toolholder fromVisicorder divisions,

°ot· =

Output bendtng stress into61holder corrected fortorque ~nteraction ,

~ ,Cfot = a ot - Kt,ib t ot

Actual nominal bendingstress in specimen groove

17

Output shear stressin toolholder fromVisicorder divisions

Output shear stress intoolholder corrected forbending interaction

I

tot = tot - Kb/ t aot

/

Actual nominal shearstress in specimen groove

=/a ot

K Kgr-th bgr

/Stress Ratio

R = _(Ja~.fJtas

Fig. 2.2 Flow Chart of Calculations to Obtain NominalStresses in the Specinen G~oove From theStrain Gage Outputs.

Page 28: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

E = modulus of elasticity for steel

= 30 x 106 psi.

. \

.R b resistance of each bending gage '--='g= 190 ohms.

Rgt = resistance of each torque gage

= 120 ohms.

Gb = bending gage factor

= 3.23

J Gt = torque gage factor=. 2.05

NQ

, = number of active gages in each bridge

= 4<'

J th = polar moment of inertia of the toolholder

cross section where the gages are mounted.v

Cth = radius of the toolholder i'lhere the gages are

mounted.

= 1.000 inches.

= polar moment of inertia .of the specimencross section at the base of the groove.

= radius of the specimen at the base of thegroove.

= .• 249 inches.

In Fig. 2.2 the equation for a ot ' in the second

Page 29: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

19

• •CJ ot - ~t(b tot1,.+ Kt / b Kb/ t

=

box on 'the left. is an a.pproximation. ·The full equation

lSI

Upon examination of the values of Kt / b and Kb/ t in

Appendix C. it is seen that they are small B.nd th~ product

ls negligllble compared to 1. Thus. Eq.(4) reduces to

the one given in Fig. 2.2 •

A program for the CDC 6400 computer at The University

.of Arizona using FORTRAN IV was developed to determine

CJas 't "Las and R. as per Fig. 2.2, from the data. . The,

program, along with user instructions and flow chart, is

presented in Appendix A.

Table 2.1 lists the average stress levels and ratios

at which test data were collected. The computer outputs

listing the stresses in the individual specimens are given

in Appendix D.

2.2 St~ss-to:.lliilureData (Sj;.ft.irca§e !'!ethod)

The method used for testing specimens to determinec

the distribution of the endurance strength was the stnir­

case method (II-. p. 48 j 5) sometimes called the "up a.nd

down method". Briefly, the method consists of testing 8.

specimen subjected to a stress equal to the estimated

endurance strength. If the specimen fails, the next speci­

men is subjected fo a stress one increment Imler than the

failed specl~en. If the specimen does not fail by a

Page 30: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

'.

.~-

,J)

TAEL

E2

.1

TAEL

ESH

OWIN

GTH

EAV

ERAG

EST

RESS

'LEV

ELS,

AND

RATI

OS

ATW

HICH

SPEC

Ir1EN

SWERE~

TEST

ED

Av

erag

eA

vera

.ge

Sta

nd

ard

Num

ber

of

Av

erag

eS

tan

dar

dD

ev.

Str

ess

Nor

mal

Dev

.N

orm

alS

pec

imen

sS

hea

ro

fS

hea

rR

ati

oS

tress

*-p

s1Stress~~·::·

Test

ed

Stress~:·**

Stress*J,~

_,1

44

,00

01

50

01

20

°1

14

,00

09

00

18

°°

00

98

,00

02

70

01

80

08

1,0

00

90

0(

18

00

73

,00

01

80

01

80

0

15

1,0

00

38

50

,1

22

5,0

00

80

0

3·5

11

5,0

00

18

20

18

19

,50

07

00

83

,00

01

20

01

81

3,5

00

75

0--

--

74

,00

07

50

18

12

,50

06

00

"1

11

.00

01

25

01

27

3,5

00

20

50

92

,00

06

70

0'\

18

66

,50

03

40

00

.82

5,

76

,00

03

15

01

85

3.5

00

3L~50

65

,00

03

85

01

84

7,0

00

13

00

0.4

46

9,0

00

lL l-

OO1

89

0,0

00

'16

00

60

,00

07

00

18

78

,50

01

40

0"j'

*R

ound

edo

ffto

neare

st1

,00

0p

si.

**R

ound

edo

ffto

neare

st5

0p

si.

*~H~

Rou

nded

off

ton

eare

st5

00

psi.

( ,

(.'1

'".

t\) o

Page 31: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

21

predetermine~ time the test is termin~ted and the next spec-." J .~ .7:" .t-.~.: 0 ':.: ,:.~. _": :': ": .~~. .,.., . ~ ,"

imen is SU?j~~t~dto~a ~tress one increment higher. This'~"':',i .... : .,. _' :-. . I •

proced~re continues until the desired sample size is,','"....

obtain~.d.· It 'should be noted that only approxlmately~. ,,; ~'. ~'-,

"/ .... ,

50~~ of the --t'ested spe'cimens are used in the calculations".. r "

of mean anq stan~ard deviation. The calculations are based

on either the successes or failures, whichever has occurred"t-. .... ~ '.,. -~ .. -- ',.,. "~. ."' .•' ("':: :._..... ". - ,I. } p.... __ ._ •• _. _ >'," • _ • _,. '__ • ,_ '\.. ~

the least number, of times. The specimen just preceding

the first change of mode is considered as the beginning~1r}::::_ :~ C-:,;:".?: ~.~" ....._: ~~ ....-~ ..- .. :,.

of the test. ,A change~of mode is a success followed byC' ~

t.·-~~l ~:. : >. .L ~~ .... ::~.- ,I :. 'L •• I .... -'

a failure or a failure followed by a success.

The equations for calculating the estimates of the').:-

mean and standard deviation of the endurance strength are:1]::>: D.. ~~~-~.··:::. 'c . - ':'. :'"~'~.:: ::

given by (5, p. 114).

wher,a.

ro, = mean,.:.: ••~. ~'." • >.-' •.• -.-

fi,,;= s.tanQard devlation

./

(5)

.(6~

_.' _,·Y. =. tjle ).O\'lest .St!BSS level at \-lhich a success or"--, ..

. .. .-.- ... ~- . --. - .

fai~ure .(whichever the analysis is based on)

" ,C>ccurred.

""", ,d. == stre~s .increment... ..-.o:~-~- ..- •..•...•._.. -.-

"":-' .. "-.

Page 32: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

22

"-N ~ effective sample size; Ie. the number of speci-

"mens used in the calculations.

'--n

A = I: i n11=0

nB"= I:

1=0

n = number of success (or failures) ''lhich occurred at

the I th level.

The lowest level is considered the zeroth level. the nextstthe 1 level, etc. In Eq. (5) above the (+) is used if

the calculations are based on successes and the (-) if

based on failures.

The above analysis requires that the variate being

tested is assumed to be normally distributed or can be

transformed to anorroal distribution (5, p. 111). Also,

the stress increment should be in the range of .5a to 2a,

where a is the standard deviation of the distribution.

Therefore, some prior knowledge of the variance is helpful

for good results.

The staircase method is very good for the determination

of the mean of the variate being tested. However, the

estimate of the variance can be poor if the sample size" -

1s not large. Mood and Dixon state that (S, p. 112),

uNeasures of ~reliablli!l. may \-lell be very misleading if the

sample size is ;tess thanfort21. or !ifJ.y. II It is not clear,

Page 33: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

23

i.J"}~I'1eVer,'~-l·lhether- they are referring to effective or actual

sample size, the effective sample size being approximately

50% of the act~aJ. sample size. Because of· research pro­

gram limitations the effective sample sizes of the endur­

anCe tests range from 16 .. to 18.

En~~r?nce tests ~ere conducted at R = ~, 3.5, 1.0 and

0.44. As sf~t~d-b~i~~e, the tests of specimens which do.' .~. -. - ... ._-~ - - . -",

not fail are terminated at a predetermined time. For1

stress ratio of ~ the tests were terminated after 90 hours----~-,;....:.._..__._.__._.._--- --~------ ._..._------

.-

W~lch--is-e~uivalent to more than 9.5 milliori cycles. In-------_._--_.~._-_."""-~._._-----.~ •.. _.'-'._-

conducting the endurance tests at stress ratio of 00, of the

eighteen specimens which failed, sixteen failed before 48• t ". .. 0-;', ,

hours of , running time. ,- - /-i" .• -. ~

<- ; -For stress ratio of 1.0 the tests were terminated at

'---- --_._-------_._-_._------_..-- ---

48 hours which is equivalent to over 5 million cycles.

Of the eighteen specimens which failed during the endurance

;:~ests at R.= 1.0 all.failed before 24 hours of running time.

~h~ endurance tests at R = 3.5 were terminated at 24 hours

which represents more than 2.5 million cycles •. .

.' The endurance .tests at R = 0.44 have not been com-c:.

pleted as of the date of this report. They are also being

terminated at 24 hours of running time.

The calculation of the means and standard deviations

from the staircase data will be discussed separately in the

next two sections. The results of those calculations are

Page 34: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

"given in Table 2.2

"\'

--' TABLE 2.2

ESTnL~TES OF THE HEAN AND STAl\TJ)ARD DEVIATIONOF THE E1IDURANCE STRENGTH FOR STRESS

RATIOS OF «), 3.5 AND 1.0

''--- '

Stress Ratio Nean* (psi) Sta.ndard Deviation**

co 57,000 3,800~,

3.5 55,000 3.700:,

1.0 57,000 3.300

(.0

Estima.tes a.re based on the calculations discussed in

Sections 2.2.1 and 2.2.2 •

* Rounded off to nearest 1,000 psi.

** Rounded .off to' nearest 100 psi •

./

, .

Page 35: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

L: 2.2.1 ~ndurance Test§ f£r R = ~ and R = 1.0

The tests were based on the amount of weight. '.

25

placed on the loading arm. An increment of one pound in--.-the pan was used to obtain the staircase. The calculations

for mean and standard deviation were also based on weight

and these values were then converted to psi.

Figures 2.3 and 2.lj. ShOi'1 the staircase plots

for the tests. They were taken from an earlier report

(6, pp •. 48-49). Tables 2.3 and 2.4 list the specimens

that 'Nere used in the endurance level calculations for

R = ~ and R = 1.0 respectively._I

To obtain a better estimate of the endurance

strength distribution the average of the stresses in all/

the specimens for a given pan weight was found and then the

increment between these averages for the different pan

weights was calculated. In order to obtain a uniform

Incrementan average was found for the increments.

For stress ratio of ~ the calculations are

based on successes. The average stress at each pan weight

and the number of specimens t'lhich succeeded at each level

ls:

Pan Height Stress Number ofpounds psi Successes

27 .b?~ 61,857 126 "'0 59,999 225 54,~JO 1024 51,915 223 .59,421 1

Page 36: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

;,

.~

osu

ccess

,if

spec

imen

surv

ived

101cycl~s

ofa

ilu

re,

ifsp

ecim

enb

rok

eb

efo

re1

07

'cy

cle

s

~

:.'

Num

ber

of

Sp

ecim

ens

o5

10

1520

I 2530

35("

Fig

.2

.3E

nd

ura

nce

Str

en

gth

Dat

aO

bta

ined

by

the

Sta

ircase

Met

hod

"fo

rS

tre3

sR

at:!

.oo

feo

f.or

SAE

4-34

0S

teel,

I1IL

-S-5

000l

.),

Co

nd

itio

nC

4,R

ock

wel

lC

35

/40

.

t\)

0-.

Page 37: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

Leg

end:

()su

ccess

,if

spec

imen

surv

ived

4:7

:1'0

6cy

cle

s

ofa

.ilu

re,

ifsp

ecim

enb

rok

eb

efo

reL~

x1

06

cycl

cn

:.>,

"

o5

10

152

025

3035

40N

umbe

ro

fS

peci

men

s

Fig

.2

.4E

nd

ura

nce

Str

eng

thD

ata

Ob

tain

edby

the

Sta

ircase

Met

hod

for

Str

ess

Rat

ioo

f1

.0fo

rSA

E4

34

0S

teel,

MIL

-S-5

0CO

B,

Co

nd

itio

nc4

,R

ock

wel

lC

35/4

0.(

N.

"'-J

Page 38: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

TABLE 2.)

LIST OF S:FECI~:.ENS AJlJl) THE CORRESPOlIDINGSTRESSES AND PAN HEIGHTS FOR

ENDURANCE TESTS AT STRESS RATIO = ~

Specimen Pan Nomina.l Norma.lNumber Height stress in Specimen

pounds psi.

87 25.0 60,51917, 25.0 37,476

--74 25.0 46,827 -202 J 25.0 51,125182 25.0 57,353124 25.0 60,lUl

216 26.0 '58,017/,

205 24.0 49;580199 25.0 54,036209 25.0 53,903177 24.0 54,249168 25.0 57,132190 26.0 61,981

-.207 ,27.0 61,857142 25.0 65,528208 23.0 . 59,422

\

----

28

Page 39: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

29

'F~:', i:C1-~/.-: tIST' OF 'SPECIMENS AND THE CORRESPONDING

"f:(;::: DC;:::· ~< ''"/. '··STRESSES AND PAN WEIGHTS FOR '-~'- ," '" ._. '\" .' .

. E~IDURANCE TESTS AT STRESS F.ATIO = 1.0·tt;",:;; .C':,::*: c-' 'r '":.:-.:' ~.• :: _ ~ •• ~. .' . .

~ ..' . r· ~._.. .- .' ..... -

$pec1men Pan Nominal Normal Stress StressNU!l1ber Height in Specimen Ratio,

: . .p<:)1Jnds psi •.. '.. -- .. -.

248 27.0 48,979 .721..~ ::- • -"!,,,.".

288 27.0 61.723 1.072. :':"-267 '" ::.:: 26.0 58,350 1.045.. ,.

..c··"·-300 - ~ : ':. ,27 .0·. 55,537 1.005.,

~ .'.' '" 0 ~'15.. " .?b,'O: . 59,810 1.169... -.- 409···· " ...... ". . .

25.0 57,067 1.066:. ::':;64 ","",' ... -,

2~·. 0":.. .. _. : •••• f 52,863 1.040.' , ~"'372 "r:'26 0 58.885 1.042- ..-_ .... -- , . . :: '- ...... 3~2.. : ... 28.0 61,561 1.031't' .,- '.,~ ~.. - ._- -~, . " .._, , ..

429 27.0 58.918 '1.019359 27.0 58,727 1.055417 : ,r 26 0 55,581 .996· . -- -' .- .336 . .. 26.0 54,156 .909,.. _.. ' i ..435 26.0 56.298 1.114401 25.0' 57,266 1.081400 '. 29.0 60,166 1.064

.. ·

386' · 28.0 : 58,619 1.063~:::~.

402 27.0 . 58,288 1.087

"'-:,!":",:::.-",,..• __ .J...,.....:..::

.., ~ .-, ~ -...'t,:,;_", •

• _ ...... "J

.,

Page 40: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

30

Note that the average stress for the one spcciwen at a

pan weight of 23 pounds is greater than the average stress

for both 25 and 24 pounds. To eliminate this inconsistency,'I

the one data point taken at 23 pounds ues elil:1ine. tGd from

the calculations. Then, taking the average of the incre-

ments betvTp.en the other four levels the value of 3, 31!}

psi. for the stress increment was obtained.

In order to get values for the number of spec­

imens '\'lhich succeeded at each level, 1t was assumed that

each specimen tested at a given pan weight was subjected to

a stress equal to the average stress calculated for that

Page 41: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

and

. 1:: ;.• ~

,-, ' .....

m = 57.317 psi.

s 1.620 (3.314) [15(27.2-(17),2 + 0.029J= .~.- -" (15)2

s = 3.818 psi.

Thus the estimates for the mean and standardr-"'C _: .·;deviation of the enclurance strength distribution for stress(: .--

;~~~atlo of 00 are 57.317 psi. and 3.818 psi. respectively.

Similarly. the estimates for the mean and,~r-.. '

'standard deviation. of the endurance strength distribution-! \, .. ~ -.. -----..- - .-',::for.istress ratio of"··-l~O., "Tere found to be 56.785 psi. and

The staircase method was used to conduct the..­

'..

) ,_ ....---'<;3.290 psi •• respe'ctively.

~':' ~'. ----;:Endura,n.9.? Level f..Q.r R_ = ~.5.

(tests at this ratio also. but instead of basing the tests-

:;.on ,pa.n '\'Teight they l'Tere based on stress in the specimen.

The.stress increment was chosen to be 3.000 psi. Figure 2.5,1

;ShOi'lS the staircase plot for these tests. Table 2 i 5 lists

:the specimens which were used in the calculation of the

{distribution parameters. Also listed are the stress as

,recorded by the strain ga.ges. the target stress and actual~ .

~tress ratio in.each spccimen6;.'"

~.

Table 2.5 iridicates that the stresses were not.,..- . '-

held as close as targeted when the tests were conducted.

The scatter may be due: to carelessness on t~e part of the'-.- .•~. .

operators and terii ma~hine operating inconsistencies.

Page 42: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

Leg

end

:.

6o

success

,if

spec

imen

surv

ived

2.5

x1

0cy

cle

s.

6.

Ofo

.1lu

re,

ifsp

ecim

enb

rok

eb

efo

re2

.5x

10

cy

cle

s

69 66.

'\/~6

JP

.I,

~

16

til

0ti

lC,

)

H ,~57 54 51

'-,'0

;.,

510

.15

2025

3035

40

(

.j I ;

Fig

.2.

5N

umbe

ro

fS

pec

imen

s

En

du

ran

ceS

tren

gth

Dat

aO

bta

ined

by

the

Sta

ircase

Met

hod

for

Str

ess

Rati

oo

f3

.5fo

rSA

E43

40S

teel,

MIL

-S-5

000B

,C

on

dit

ion

CL~,

Ro

ckw

ell

C3

5/4

0.

\.0

)l\

)

Page 43: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

",. .. -.-., ... .~-" .'

TABLE 2.5

LIST OF SPECIi>1ENS AIm CORRESPONDING ACTUAL STRESSES.~.;",:. "',,"::" :"~ ~-~ ", ~

AND INTENDED STRESSES FOR ENDURANCE~ TESTS AT STRESS RATIO = 3.5

-

Specimen. Actual Normal Intended Normal Actual

Number S:tress in Stress in StressSpecimen (psi) Specimen (psi) Ratio

477 5.5,917 60,000 3 •.5446.5 .5.5,82.5 . .57,000 4.26478 .58,291 60.000 - 3.64.506 .51,2.56 57,000 . 3.22528 .57.376 ~ 60,000 3.78444 .53,410 57,000 3.26466 54,236 .57,000 ;.60.524

/

47,071 . .51.000 3.03546 .50.292 54,000 3.93499 60,903 57.000 . .5.72532 .54.533 57,000 4.43483 50,828 54,000 3.10.529 51,381 54,000 3•.56587 52,067 54.000 3 . .50581 .54,320 57,000 3.67611 .56,U26 ·60,000 3.42,

.589 .54,118 57.000 3.4-7603 53,813 - 57.000 3.41

33

Page 44: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

These are dHrcu.s'sed·' in·:Section 2.9. Because of this the

.. average ~"actual:::stres-s ':at"each target level 1'1aS determined

'''''. '.tf· '11 --, .. :- ",-.",'- !; ": . ~ '"~C.,·, ,as 0 011s. ,. C",_, ~ -" , •. _, ,:' - .,

Average .·Ac.tu8.1..:.,~_·::.~"~,':,~'l'a~get 'Stress

Stres?.;:.~Jp~~~~:.." (psi)

Number of

.Successes

57,1'03'·': c'

·fE.s..~ t B23 " :'~.'

51,142.t,1'·47; 071 '

~~'::::'::'; '.60,000

,~-,...= ..57,000~. :"'- .. ' ~ .

.54,000

51,000

'4

941

......-.•.~. " .....

. ..:.-:/,-'-~" '-:

r'," •·•.The average stress increment bet'\<leeri these......... " ;... ,- .-- -- .' ~ '- - .". -.' ;.-' - ... -.

levels is3.37'Z"ps1.· Using Eqs: (5) and (6) l'There.;........ ..- _..' _. - .......- .-- "...- . ~ '., . ' .. - "..---'. ~-

. ,d")r'~' ; ,r,.".~...-' ~.y _=-1}7. 071 . psi.\..-..... ~-\. , .......:. ,," \..~.. "'-.. - - ... :,:.- .

,/

. -,Eo G"..:;i,.::.z,.,· +Co:. "';,.:= 1.f~ /~ ~.~ (; ', ... ::::> ...

·r~':.···,,,· .;.~ .. :~.' .. ,.... )-'" - •., ..-~,-~, -_ •.•',<. ". K'~ ~' "1 ni"=' 1(4) + 2(9) + )(4).

fE-.~:;'__:.':-: :.:: "::,:"::.:' ~~1.. c_=)4

l·}.:;·C.:).~'·<:.O-'}'c-~':·B'~'~ i 2 ni= 1 (4) + 4(9) + 9(l~)1=1

1],:',': :-..:: :::. -? :'.". , .- .- ." - - 76

.then . ., . '.. ., .' ,... , ,. .'- - ..... - . - .

::.~ =.47,071 + 3.377 ( ~'+~ )

= 55, 139 ps1 •

"

+ 0.029J

"l' 0,.-_ ~, ..... "'l>~.-."... ~_

:: - . '" -, ".-••~ .f

. .t.t,C: ,--.:6 . ,... E.:'~,· .~_

Page 45: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

35

Thus, the estimated mean and standard devi-

. ation of the endurance strength distribution for stress

ratio of 3.5 a:r;e 55,139 psi.• and 3,738 psi., respectively.

2.3 £y.~les~-to-~·.~J1t2I.e I?C!.~gj; S~Jflc S1;;1:'~£:LB2~tJ.2§'

~nd Leve1Ei

It was desired to determine how the cyc1es-to~

failure data at each stress level and ratio vIas dis-

tributed.

Based on a study made by Broome (7) in an enrlier

report on this research program it. was decided to fit the

. normal and log-normal distributions to the data and con-

duct goodness-of-fit tests.

The parameters for these two· distributions were

estimated using the unbiased 'estimates for mean and stan­

dard deviation. For the normal case the cycles-to-.

fallureis the variate and for. the log-normal case the

natural logarithms of the cycles-to-failure is the variate.

The moment coefficients of skewness and kurtosis were

also estimated from the data. For the normal distribution-the values of these two parameters are 0 and 3. respec-

tively.

The Kolmogorov-Smirnov goodness-of-fit test was used

as a. measure of hm'; 1'Jel1 the distributions fi t the data.

A computer program was used to make the calculations.

The program had been deve~oped previously but it was modifie~.

Page 46: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

by this author to include the Kolmogorov-Smirnov test.

The original program, which was written by Patel (8), used

only the Chi-square goodness-of-fit test. The pro8ra~~and

user instructions are included in Appendix B.

Table 2.6.lists the results obtained by estimating

the normal distribution parameters from the data and con-

ducting the Kolmogorov-Smirnov goodness-of-fit test.

Table 2.7 lists the results obtained by using the natural

logarithms of the cycles-to-failure data.

2. It- Formal Dtstribution F~.t to the Data·.

The probability density function for the normal

distribution is given by

/

1 ( 2S;-~ }2f(x) - 1 e

- 2 '0 _ C<) < x <00=o.j2n' c

(7)

..

l'lhere ' A = mean

o = standard deviation

If)J... and 0 are not 1(n0i'1n from prior knowledge they

must be estimated from the data as discussed in the next,I. ~-

section.

2.4.1peter~1nationof Hean, Standard DeviRtL2DJ~

~ke\'mess and KU'l"tos1,s

By definition the moment generating function,

denoted by met), is the expected value of e tx which is

denoted by E [etXJ. For .the normal distribution

Page 47: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

;,

f\

,.

..'

TABL

E2

.6

.NOR

MAL

DIS

TR

IBU

TIO

NPARA~!ETER

ESTI

MA

TES

AND

THE

MAX

DV

ALU

ES

Str

ess

Ave

rage

Sam

ple

Nor

mal

Dis

t.P

aram

eter

sM

ax.

Alt

ern

s.ti

ng

0<3

O<l~,

Frat:-i~

Str

ess

Siz

eS

tan

dar

dD

Lev

el(p

si)

Mea

nS

kew

-D

evia

tio

nn

ess

Kurtosl~

Val

ue*

14

4,0

00

12

2,7

73

.53

2-1

.31~4

3.5

61

..1

75

11

4,0

00

:"'-1

89

,02

9<1

,02

4-.

24

71

.99

5.0

99

00

·98

,00

0-

18'

22

,17

1:3

,815

-.0

42

1.8

55

'.082

81

,00

01

87

7,9

77

12

,54

9.8

73

3.0

60

.181

.j.

73

,00

01

81

61

,98

43

4,2

86

-.6

16

2.2

01

.17

4~~--

15

1,0

00

-12

1,4

51

:27

5-.

22

21

.72

5'~113

-3•.5

11

5,0

00

186

,20

31

,01

0-.

797

3.3

97

.111

83

,00

01

83

9,6

08

12

,99

01

.87

67

.24

1.2

39

74

,00

018

74

,21

21

9,5

31

.14

72

.05

7.1

32

11

1,0

00

126

,55

41

,00

5.8

93

2.1.

;93

.29

60.

82.5

92

,00

018

20

,46

75

,59

5.2

39

-2.2

57

.11

97

6,0

00

186

1,0

28

11

,13

2.

-.L~28

\2.1

82

.10

96

5,0

00

181

27

,57

72

1,2

27

.171

'1.9

~~2

.11}

1,6

9,0

00

185

3,5

73

15

,J~'

701

.66

74

.83

3r

O-'

0.44

\~??r---

60

,00

01

81

42

,55

041

,5t$

5.3

93

3.0

57

•_I.H

3

,,....

-\ i

~4-

~~~

.62.~

'C::P

::P....:

;,\:

:;:;

t:r

~.

-Jr--

.~.

~1axlmum

D-V

alue

From

K-S

Test

~

t.( ,

w ....,

Page 48: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

TABL

E2

.7

LOG-

NORM

ALD

ISTR

IBU

TIO

NPA

RAM

ETER

ESTI~~TES

AND

MAX

D-V

ALU

ES

Str

ess

Av

erag

eSa

r.1pl

eL

og-N

orm

alD

ist.

Par

amet

ers

~H

e.x.

Alt

ern

ati

ng

Q0

(3~

0<4.

-~ "'l.......

.I...-

-....~

_~atio

Str

ess

Sta

nd

ard

1;:-

DS

ize

Mea

nSl(e·~l-

f-'•

<•

'~.'/;'"

;_

.

Lev

el(p

si)

{u

rto

sis

,.'D

evia

tio

nn

ess

Val

ue*

lL~4,

000

12

7.9

06

54

7.2

2791

4-1

.58

6,4

.25

8.2

07

11

4,0

00

189.

1019

61.1

1613

0-.

Ll'0

72

.12

3-

.09

20

09

8,0

00

18

9.9

92

12

3.1

7638

2-.

26

51

oL~5-

.094

-./

'

81

,00

01

81

1.2

52

66

7.1

53

95

4·5

75

-2

.69

7.•

159

73

,00

01

81

1.9

70

99

7.2

31 -1

-941

-.9

06

2.7

07

'-,.

19

8

15

1,0

00

12

,7

.26

26

76

.19

77

89

-.4

35

2.0

06

-.1

28

3.5

11

5,0

00

18

8.7

20

89

4.1

5724

7.L

I·03

-2

.86

9-

.08

6U

3,00

01

81

0.5

45

16

0.2

06

66

4.6

86

-4

.40

7-

.18

47

4,0

00

18

11

.18

03

38

.27

42

19

:....3

422

.50

1-

.08

4'

11

1,0

00

12

8.777701~

.ll~5966

,.7

}-I-

2-2

.29

5.2

80

0·.8

259

2,0

00

189

.89

01

29

.280

831

-.1

71

-1

.91

6.1

20

76

,00

01

81

1.Ob19L~0

.1°S

06

2-.

'70

32

.'4

57

-.1

11/.

65

,00

018

11

.7L~3320

.167

235

-.0

30

-1

.76

9.lL~7

0.4

46

9,0

00

18

10

.85

67

36

.2).}

t)421

1.2

10

-:3

.899

-.2

14

60

,00

01

81

1.8

25

35

1.3

05

28

2-.

45

73

.18

2.1

18

*M

aXim

umD

-Val

ueFr

omK

-ST

est

\~

..~

.J)

( I

\j.\

'

'v)

,

co

..~....

,..'.

Page 49: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

" .

1

o.J2'iT'

rCOtxJ e '

..00

dx

·39

Carrying out the integration yields

met)

which is the moment generating function for the normal

distribution.

The procedure for obtaining the rth,~oment

1s to take the r th derivative of the moment generating.

function l'lith respect to t and evaluate it at t = O.

By definition the r th sample moment is given

by nE r

1=1 xi .

n •

Taking the first derivative of the moment

generating function with respect to t and evaluating at

t = 0 yields

Then equating the first distribution' moment and the

first sample moment yields the estimate for the meannE

A i=l Xi (8)/1.= -n-

It can be sh01'711 that this is an unbiased estimator.

Taking the second derivative of the moment

generating function l'lith respect to t and evaluating at

Page 50: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

·... :.

40

t = 0 yields

2 2m2 = 0 +/"\

Equating the second moment yields

nt 2

= 1=1 x tn

but

nt x;: 2

= [i:=l ...1Jn·

'.':'.

thus

n[ t x J2

i=l i-- n 2 - =

/' .,

. 't1here

nt

xi- i=lx = =n sample mean.

It can be shown that this is a biased estimator f6r 02

For unbiasedness, the expected value of the parameter

estimator must equal the parameter (9, p. 72) thus in this

case for unbiasednessnt (x _i)2

E [ i=L-i_ J =n .2 .o •

"

p-1nE [

Going through the computations yields

nt ( -)2

i=l xi-x _ =n J

Page 51: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

,41, '.

Therefore the estimator

nI:' - 2

a 2 :: 1=..1 ~: t-X)

" n, \,','~

1s a biased estimate for cr 2 .' However, the unbiased

estimator for 02 is

nI: ( -)2

i=l xi-x--n-l-

The moment coefficients of skewness and kurtosis are

g1ven by

and 0(4 =

respectively, where

nI: -)2

= 1=1 (xi:.:_n

nL ( -)3

= 1=1 xi~=':­n

-'

and nI: -)4i=~i-:'_

n (See Ref. 10, p.48).

Evaluating the third and fourth derivatives of

the moment generating function at t = ° and su;bstituting

into the equations for 0(3 and ..DC L~ '..;111 lead to values of

eX) = ° and 0(4 = 3 for the normal distribution •.

The estimates of the ~ean, standard deviation

Page 52: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

/'

...42

and the moment coefficients of skewness and kurtosis have

been calculated for each group of 'cycles-to-failure data.

The estimates of the moment coefficients of skewness and~,-

kurtosis were calculated in order to give a further indi­

cation of hOi'r \'lell the. data fits the normal dictrlbutlon.

However, it is important to note that even though 0(3

of a symmetrical distribution is zero, obtaining avalv.e

of zero for the estimat~ of 0<3 from the data does not

necessarily mean that the distribution is symmetrical.

Mood and Graybill make this point (9, p. 109) and state

that, "knOi'rledge of the third moment gives almost no clue

as to the shape of the distribution." Therefore, the

moment coefficient of skewness is'not a good measure of

whether or not a distribution is symmetrical.

The moment coefficient of kurtosis is a

measure of the peakedness of the distribution.

Lo~-Nor~al Distribution Fit to the Data~ - - - -

A variate is distributed log-normal if the logarithm

of the variate is distributed normal. That is, by letting

y = l08eX then

1f(y) :::: - eo~2TI'

\-There the unbiased estimates of}{ and a are

nE

Yi~ - .i~lA= Y :::: n

Page 53: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

.'; .....

.~.. , .. :;: _..-.

Deter~ination of Mean, Standard De~iation,

§kewness and Kurtosi!

The determination of these parameters for the

log-normal distribution is the same as for the normal

distribution as covered in Section ,2.4.1 except the log

of the variate is used in the calculations.

'2.6 Goodness-of-Fit Tests---~..-...:;:;..;;;...;;.~

In o~der to determine how well the normal and log-

normal distributions fit the dat~ two goodness-of-fit

tests were proposed. They are the Chi-square and Kolmo30rov-/

Smirnov goodness-of-fit tests. However, both tests were

not used in determining whether or not to reject a

particular distribution. In all cases the Chi-square

goodness-of-fi t test "!as not valid because of the small

sample sizes. Further reasons for it not being valid are

given in the next section.

Since the COMputer program is w~itten using both

tests it should be pointed out that when analyzing data

where the Chi-square test is valid, if both tests are used

to determine rejection, the level of significance changes.

In other words, if the critical values for ~ejection are

based on a significance level of 0<.. for both tests and the

criteria for rejection of the null hypothesis is if either

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..44

one 6r the other or both tests rejects the distribution

then the level of slgniflcance in rejecting is not ~.

It is not clear what the ,confidence level would be sinc~

the extent to which the two tests are correlated is not

known. Therefore, only one test should be used in deter­

mining goodness-of-fit. For the data in this report only

the Kolmogorov~Smirnov test was used.

2.6.1 Phi-S~~~e Goodnes§:of-Fit Test

The Chi-square goodness~of-fit test can be .

used only '\'lith grouped data, that is, data divided intoI-~'

cells. The total Chi-square value is the sum of the Chi-

square values of each cell. This can be written as

kL

i=l

. where

'E = the expected frequency of the i th celli

°i = the observed frequency of the i th cell

lk = total number of cells

Vk _1 = total Chi-square value

·2'~k-1 can be shown to be distributed Xk _1

hence the name Chi-square test, where k-1 1s the number

of degrees of freedom. HO'lleVer, 1f the parameters of'

the hypothesized distribution must be estimated from the

data the degrees of freedom must'be decreased by the number

of parameters estima.ted. In the case '\'There the f1 t of the

Page 55: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because
Page 56: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

46

where

Dn = Kolmogornov statistic'-,

"Fn(x}

Xl= S f(x) dx

"_ co

f,(x) = probability density function of the

hypothesized distribution

xl = any specific value of the variate X

=xN (11 )

X": = number of observations less than or

equal to xl

N "- sample size/'

If Dn 1s greater than some critical value (Dc)

the hypothesized distribution is rejected at some level of

significance (~). The probability statement is P(D > D ) =n c .oC ." Table 2.8 lists the critical values for sample sizes

of 12 and 18 at various levels of significance.

TABLE 2.8

TABLES OF CRITICAL VALUES OF D TO USE IN THEKOLNOGOROV-SiHRNOV GOODl'JESS-OF-FIT TEST

Sample Level of Significance (ex:)

Size 0.10 0.05 0.01

12 0.338 0.375 0.450

18 0.278 0.309 0.371

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. .

In using the Kolmogorov-Smirnov test the\ ~

D-value is found at ea.ch data point. If at any point the

calculated D-value is greater than the critical va.lue .at~l

>the desired significance level, the hypothesis is rejected.

If not, the hypothesis is not rejected.

:·2.7 Qi.s.cussion of Resu.l~s

In 8 of the 15 stress levels tested the D-value-

.. (Kolmogol'OY Statistic) was less for the log-norme.~dis-

tribution than for the normal distribution. The moment

coefficient of kurtosis was closer to 3.0 for the log­

norma.l distribution in 9 of the i5cases. The moment

coefficient of skewness was closer to zero for the log­

.. 'normal distribution in 7 of the 15 cases. HOI'leve=c, asJ •

was mentioned in Section 2.4.1, obtaining a value close

to zero for the moment coefficient of skel'mess does not

necessarily mean that the distribution is sJ~metrlcal or

normal.

Based on the Kolmogorov-Smirnovt~st, in no case can

either the normal or the log-normal distribution be re­

jected with 90% confidence. For stress ratio of 0.44

at stress level 69,000 psi. the normal distribution can ~•

be rejected with 85% confidence •

From the above results i~ appears that the log­

normal distribution is favored.

The cycles-to-failure data for stress ratios of ~

/

Page 58: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

48

and 0.825 were previously analyzed and reported by Broome

- (7). He also concluded that the log-normal distribution

was favored. Ee also points out that from a phenomeno~

'.logical viewpoint the log-normal distributior. 18 justified.

Figures 2.6 through 2.9 show plots on log scales at

the average stress levels of the cycles-to-failure dis­

tributions for stress ratios of ~, 3.5 , 0.825 and 0.44 •

The distributions shown are log-normal. The mean line

'shown on each figure was obtained by fitting a straight

line, by the method of least squares, to the estimates of

the means of the distributions on each figure. The 3

standard deviation limits for each distribution are also

shm·m. To obtain a' smooth envelope the dashed lines ":ere/

drawn in by sight.

Specimens were tested at only two stress levels for

the stress ratio of 0.44. They were 69,000 psi. and

60.000 ps~. An attempt was made to test at a level of

75,000 psi •• but at a stress ratio of 0.44 this requires a

shear stress of 98,500 psi. The specimen began yielding

and finally broke as the torque Was. applied. Thus, for

stress ratio of 0~44 the cycles-to-failure tests were

restricted to two stress levels. The endurance tests for

stress ratio of 0.44 have not yet been completed but it

appears as thou8h the mean endurance limit ~s about

51.000 psi.

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Page 63: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

2.8 :ponstruction ,of StQ...t.~Gtical Fe.ti.n:u.e Diap;rams at

Various Numbers of Cycles of Life-- • _ _... .... '~_ . r.

-The ultimate objective of the research program is"

to construct statistical fatigue diagram~ from which

shafts can be designed for a specified cycle life and

reliability.

One kind of conventional fatigue diagram is one

using the modified Goodman line as shm'1n in Fig. 2.10 •

Sendura11ce

NODIFIED·· GOOD!tIAN LINE

SODERBERG LINE

NEAN srrRESS

Fig. 2.10 Fatigue Diagram Showing the ModifiedGoodman Line e.net the Soderberg Line.

The diagram is a plot of alternating stress on the

ordinate versus mean stress on the abscissa. The modified

Goodman line is a line connectil15 the endurance strength

and ultimate tensile strength. Another line, which

. ;,

! .

Page 64: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

\---

'_•.~ .. :' ., '

-, .

,connects the endurance strength and yield strength, is

called the Soderberg line. Both the modified Goodman line

and Soderberg line are conservative (2, p. 178).

The modified Goodman line is used to deslgn for an

infinite life. Other lines can be constructed connecting

the ultimate strength to some alternating stress corre-

sponding to a specified life. This line would be used to

design for that finite life. However, these types of lines

are deterministic and do not account for variability in the

strength of a material. If the 'strength distributions can

be determined for various stress ratios and cycles of life

then fatigue diagrams can be defined in terms of a mean line

and standard deviation about the -line.

The method of determining the streneth distributions

which has been proposed for this research program has been

discussed'in earlier reports (1, pp. 134-135; 11, pp. 24-26).

Briefly, once the mean line and 3a envelopes (a = standard

deviation) have been established on the S-N diagrams as

discussed in Section 2.7 then distribution parameters can

.be interpolated at evenly spaced stress levels. Suppose,

the strength distribution is desired at N cyc1es~ A hist-

ogram can be constructed along the N cycle line such that

the mj.dpointsof each histogram cell is one' of the inter­

polated stress levels, as shm'm in Fig. 2.11-. The ordin­

ate of each cell is the area, to the left of N1 ' under the

Page 65: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

55

distribution curve corresponding to that cell. For

exampl~, denoting the bottom distribution function on

Fig. 2.11 as f{NIS1 ) then the ordinate of the bottom hist-'\

ogram cell is

N1F (N1S1) = S. f (N Is1) dN.

_ co(12)

Likei'i'ise, the ordinate of the next cell '\'fill be

N1. F(NI3

2) = ) f (N IS2 j ,dN. (13)

_ co

In general the ordinate of the i th 'cell/ l'1ill be

"

.'

N1F(NIS i ) = '~ f(Nls i ) dN

_ co,/

(14)

and the total histogram will look like that shown in

Fig. 2~11. This total histogram, a~ a first approx-

1mation, is taken to be cumulative strength histogram of

specimens failing by N1 cycles. The probability density

histogram can be obtained fro~ this cl~u1ative histogram.

Denoting the strength random variable 8.long the N1 axis as

S then the value of the i th cell of the probability density

histogram ,is f(S1) = F(NIS i ) - F(NIS i _1 ). After the

probability density histogram is found the~ the normal di~-

tribution parameters can be estimated using statistical

method.s.

Page 66: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

.:\

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)

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Page 67: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

A computer program i'las developed by R. E. Smith (11)

using this method of estimating the strength distribution

parameters. A printout of the program is given in Appendix

F.The estimates of the strength distribution parameters

at cycles of 10,000, 50,000 and 100,000 for a stress ratio

of 3.5 are listed in Table 2.9. These distributions are

plotted on Fig. 2.12 • Note that the ± 30 limits are

inside the ± 30 envelope for the cycles-to-failure dis­

tributions; hence, for this case the method appears to ,

yield unconservative estimates of the strength distri-

but10n parameters. The reason for this \'1ill be inves-

tigated.

TABLE ~2.9

ESTIHATED NORf':1AL PARAHETERS FOR STRENGTH

DIS'l'RIBUTIOnS AT VARIOUS CYCLES-OF-LIFE

Cycles - Parameter Estimatesof Normal Distribution

ofLife N Nean Standard Dev.

(psi) (psi)

10,000 106,639 3,256

50,000 79,021 3,253100,000 70,972 2,313

\

"

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· 1

59

Another approach might be to base the strength dis-

tribution estimates on actual data so that some measure of

accuracy ca.n be obtained through the use" of an appro-\

priete goodness-of-fit test. The approximate distributions

of strength at a specified number of cycles is wanted,

then the distribution of the stresses to which the spec-I

1mens failing at N cycles rire subjected might be obtained

as follows. N 1s a random variable and the probability

"of even one specimen failing at exactly N cycles is zero.

Therefore~ the stren~th distribut~on at a discrete N isL.::,

unattainable, but a distribution of specimens failing

within a band of N is possible to obtain.

/

CONVENTIONALS-N LII\TE

Fig. 2.13 S-N Diagram Showins Random Data Pointsand Cell Structure for Testing and Ob­taining Distributions.

Page 70: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

60

Suppose the strength distribution is desired at

N1

cycles. From eXisting data an 'estimate of the con­

vention~IS-N curve can be obtained and a range of stress~ . .

correspondinsto 103 cycles and the endurance limit can

be obtained; Sand S on Fig. 2.13. Then specimens',0 e

could be tested at random levels '\'1i thin this range. The

stress range ,could be divided into cells, as shown in

Flg. 2.13 and specimens tested at random levels within

each cell. This would insure a more even distribution of

data points.

Once the random data is obtained then the parameter

estimates can be calculated and goodness-of-fit tests

conducted. A cell with N1 as its midpoint can be con­

structed as sh01·;n in Fig. 2.13. For a conservative

estimate the cell may be constructed so that N1 is the

lower boundary. The estimate of the mean strength at N1

cycles '\·;auld be the average of the stresses at which the

specimens were tested that failed within the N1 cell (the

darkened data points on Fig. 2.13). The width of the cell

would depend on ho'w good an estimate i-laS desired. Using

these data points the estimates of any distribution para~

meters could be obtained and goodness~of-fit tests con-

ducted to determine which distributions to reject. As an

example, Fig. 2.14 is the S-N diagram for stress ratio of ~

sh011ing the estimated distributions of the cycles-to-failure

data. Suppose it is desired to find the strength distribution., .'

Page 71: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

1

1

, .

61

for 70,000 cycles. If a cell of width 30,000 cycles is

constructed on the conservative side of 70,000 cycles it

passes through two distributions. The actual data pO~Dts

which fall within the cell can be obtained fro~ Table 2.10

which lists the cycles to fe.ilure data at these tl'iO stress

levels for stress ratio of ~. For stress level 73,000

psi. one point falls in the cell and for stress level

81.000 psi. 13 points fall in the cell for a 'total of 14

points. Calculating the mean and standard deviation of

the 'strength for these points yields

Then. using the Kolmogorov-Smirnov goodness-of-fit test./

it can be determined whether or hot the normal distribution

1s a good estimate for the strength distribution at 70,000

cycles.

The D statistic, as given by Eq. (10). is

where

and

e

2~2

dz

Page 72: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

0\

N

T

11

SAE

43

40

STE

EL

CO

ND

.C

-43

5-4

0R

•c

~--+-

+---4-

.-aL

\:.~

45H

AD

.

.50

0D

IA.

-r

~'~11lJ

III:I

III

,"'1I

II,

IIII

rt-+(h1ajJ~s-to-faiiur~

IDffi

1f' f'.

-.",-

W,

_Jb

'nl,J

IdJ,

t:::A

"K

.lI4

(":f

dtr4Il

"..t::

gj h

D,st

r,1

;;:1tff1

':..5

.1

-~~t

i'--:

'-..~

I~'l

hh

hh

.-c~

Ah

r~.

..kl

I}80

•.;.

.>8

0I,

:--.-~

~s-

=I

17

-e'

c:j

l-I

"-.

eI

1/

O':l

C"

I"'-

11Pc

H•

""

I'-

IJ'~

~~70.

j1'....

....."".

l'--

-L~

-.L

--l-

-'

l-[,.L.\7

['I

70.c

<:.

.........

~I.'

IVII

.I

t·'I-

-~

-~.(

.-.

60

~'d

60

-"r

....

...

'll'll

T;V

c·'"

IT'I'.

.L.ti

jCy

(le~-

tb

-rl

.11

'[:re

Ban

e--

',,-

_~

_'t50

~5

0.

II

II

11i'-

11l-f-r::L~-

gI

III

I·cu

_.""

,,,,,

"",,,,

,'"

't40

~).

.,

.I.

II

.I..i..

..1.,,

,,,"

..Il',,,...

"..

..:w

.'"LJ-

IJ.I"I

~l'I"

•Ci

40

Ti"

",,,,.I'l!l!

llll'''II'·'''''')IIi'

I~,II~'!I"II

'llI

"!!"

"I!!

l!!!"u

w<'

w:'jl

J,'

I1/,

I,1

.lI"

"..

",..l,H

lt!¥.T

,!',""",I.~"

,,",-

.,""""

'~•••

'j",t.

'I"+

"\''''1

1.ttt-+

1'I

'I

'"

.".$

.."'

·III

l·I.

I..·.+~1

."1

'1

10

32

·3L

I-5

68

10

42

3.4

56

81

05

2,3

L~5

68

10

62

345~'8

10

7

Cy

cle

s-to

-Feil

ure

Fig

.2

.14

S-N

Dia

gram

for

Str

ess

Rati

oo

f~

Sho

win

gth

eE

stim

ated

Cy

cle

s-to

-Fail

ure

Dis

trib

uti

on

san

dT

est

Ban

d•

18

0;,

16

0

14

0.

• -e ~1

20

·~

.. t/) ~

10

0~ .;..>

U)

90

.

...

•"

.'-

'-'.

-..

e~

..--

,

Page 73: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

TABLE 2.10

CYCLES-TO-FAILURE AND STRESS DATA FORSTRESS RATIO OF ~ AT STRESS LEVELS

~OF 73,000 PSI. A1ID 81.000 PSI.,'--

63

Average Stress Averoge StressLevel of 73,000 psi. Level of 81,000 psi.Actual Cycles-to- Actual Cycles-to-

Stress-psi. Failure Stress-psi. Failure73,796 125,950 81,820 64,99773,886 103,413 81.282 67,75970.969 . 145,783 81,321 83,812*72,029 195.824 80,421 78. 852':-~

71.973 93,303* '82.641 60,00274,3 l}2 178.192 81,027 6l },85773.404 196.894 80.667 71,968*72,572 183,306 79,201 86,349o

;l-

74,931 177,508 81,832 82,2lj·8*72,374 203,019 80,032 74,690*72,925 155.178 /80,871 75,662*74,,819 205,041 ' 83,112 71. 166'~75,982 172,661 82,001 71,556*'73,647 124,13'7 81.224 '73,089'K72,961 127,794 81,423 96,004*74,629 172,572 81,363 107,41568,029 172,275 81.363 98, 468~}72.164' 182.860 81,784 74,698~;'

-

* Indicates Specimens Whose Cycles-to-Failure Fall-

Within the Range of 70,000 to 100,000 Cycles.

Page 74: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

b~~_. S is the value of the stress of the data point being

examined and

S (x)n .•

§'"== N

._~here1 .:: •

S == the number of points "Thich have a. stress less

than 01' equal to s.

and":'_. :.. ~ ~

·N == total nu..111ber of points.

For example, using'the last data p~int uri4er the

.~l,OOO psi. stress level column in Table 2.10;

S = 81, 78l.j· psi.

N == 14

Since 81,78l.j· psi. is the sec:ond highest stress va.lue

of the data points there are 13 points less than or equa.l to

it, so

The value of z is

81. ,78h-80 t 51.6 4zl = -Z,b32"- - == o. 82

- From standard normal tables this vo.lue of zl corresponds to

Fn(X) = 0.620

Therefore-

. D = 0.309

From a table of critical D-vo.lues (\.;hich can be found in

most statistics books which discuss the Kolmogorov~Smirnov

Page 75: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

_~_"" - P(D> 0.292) = 0.15

test) it 1s seen that for a sample size of 14

ITpus, since th/~ D obtained here is greater than 0.292---

this normal distribution can be rejected with 85% 06n­

fidence that the distribution does not fit the data, 'but

oan not be rejected with 90% confidence.

Past studies by others indicate that for a given '?cycle life the fatigue strength distribution is normal

(12, p. 351).TV,J.<) ,;w'.'.4

One reason the normal 'distribution can be ~.

rejected here with 85% confidence may be that the sample

used to estimate the mean and standard deviation is not.

random and therefore the estimates may be biased. Definite

stress levels were aimed for and although there is some./

scatter about those levels, the sample cannot be considered

a random one. The properties of the estimators for the mean.-

and standard deviation are knOl'into be good if the sample

1s random. .If the sample is not random the estimates may

be biased or insufficient. It is for this reason, if this

method is used, that the data can give ~ittle more than

. gross approximations of the strength distribution parameters.

The present data might be useful if more tests were con-

ducted randomly throughout the stress range to give an

even distribution of points.

It must be pointed out that a very larg~ number of

specimens may.have to be tested to obtain enough specimens,

,:..

Page 76: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

66

so tha t preferably more than 35 fail \"1i thin the narrO\-T

cycle life range desired for sufficient accuracy, par­

:~1cularly for strength distributions at lower cycles of. life •

.. The staircase. method should also be tried for finite

life to see how the results from the three methods compare.'

Once the random data is obtained and the strength

distribution parameters have been calculated at the

- desired cycles of life, construction of the fatigue dia­

"_.grams, is ~e.latively simple.

AssQ~ing the stress ratio is held constant for the data

points on each S-N diagram then the alternating strength

distribution can be transformed to the mean strength

distribution through the constant R. When either dis-

tribution and the stress ratio, R, is known then the. other

distribution is completely defined, so only the alter­

nating strength distributions will be \-lorked 1'1i th.

The means and variances are related by

S = R Sandn m C1 S 2 = R2C1 S .2,

. a m

1'1here

§ =a

S =m

Os =a

mean of the alternati~g strength distribution'1~

mean of the mean strength distribution

-standard deviation of the alternatingstrength di~tribution

. I

Page 77: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

\."..standard deviation of the.mean strength

dis tr i bu t i 0:1

As an example, a fatigue diagram using the endurance,'- -

~,

strength distributions calculated in Se~tions 2.2.1 and

2.2.2 will be constructed. The endurance strength dis-

tribution parameters are listed in Table 2.11 •

The distribution for stress ratio of 0 is the

ultimate strength distribution for unnotched specimens as

obtained from tensile tests. The details and results of

these tests were reported in an earlier report (6) and

therefore will not be discussed here. The results are

presented in Tables 2.12 and 2.13 " Twenty specimens

• were tested. Ten were identical to those used in the

fa tigue tests (Fig. 1.3) and ten ,-tere unnotched specimens.

The unnotched specimens eXhibited a yield point, which was

recorded, and the notched specimens did not have a notice-

able yield point.

The reasons for using the ultimate strength· dis­

tribution obtained from the unnotched specimens rather than

that for the notched specimens is as .follm'ls. The mean or

constant stress that the specimens are subjected to in the

test program is a shear stress. However, a mean normal

,stress is desired for the mean stress axis of the fatigue

diagram. If the specimens would have. been tested to fracture

in static torsion the shear stress distribution ~rould have

been converted to normal stress b;>r the relationship Sm= .J)' t .

Page 78: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

~

TABL

E2

.11

ALT

ERN

ATI

NG

STRE

NG

THD

ISTR

IBU

TIO

NPA

RAM

ETER

SA~~

THE

CORRESPO~roING

DIS

TRIB

UTI

ON

PARA

MET

ERS

ALON

GTH

EV

ARI

OU

SST

RES

SRA

TIO

LI1~S

FOR

INFI

NIT

EL

IFE

,,'

Str

ess

En

du

ran

ceS

tren

gth

Co

rres

po

nd

ing

Dis

t..

Rati

oD

istr

ibu

tio

nP

ara

mete

rs'

Par

amet

ers

Alo

ng

RA

Xis

!ole

anp

si*

..~S

tan

dar

dD

ev.

!'1ea

np

si**

Sta

nd

ard

Dev

.R

Sp

si*

**

Sps

lol'<

**a

CiS

r'

CiS

ar

00

57

,00

03

,80

05

7,0

00

3,8

00

3.5

55

,00

03

,70

05

7,0

00

3,8

00

."1

.05

7,0

00

3,3

00

81

,00

01.

!-,7

00,

~'"0

17

8,0

00

2,5

00

17

8,0

00

2,5

00

*T

hes

ev

alu

es

are

the

dis

trib

uti

on

par

amet

ers

of

the

ult

imate

stre

ng

tho

fu

nn

otc

hed

spec

imen

so

bta

ined

fro

mte

nsil

ete

sts

.,

,**

Rou

nded

off

ton

eare

st1

,00

0p

si.

***

Rou

nded

off

ton

eare

st1

00

psi

.,(

"l.f.

.,",:'

0'\

Q:)

Page 79: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

? .

TABLE 2.12

DATA AND RESULTS FROH STATIC TESTSON NOTCHED SP3CH1EIJS*

(stress Ratio = 0)

'\......

TrueTest Ultimate Breaking Ulti83.te Bree.king

Load Load Stl:'ength StrenGthNo. 1. OOO.lbs. 1,000 Ibs. psi. *~. psi. .:<*

1 49.3 47.0 253,500 305.0002 49.6 . 47.0 255,000 305.0003 49.4 46.3 254,000 299,5004 50.3 47.4 259,000 299,5005 48.8 46.0 251,000 306,5006 49.2 46.0 253,000 302,5007 49.6 46.8 255,000 304,5008 49.8 47.1 256,000 305.5009 50.5 47.7 260,000 309,500

10 lj·9.9 47.5 256,500 302,000

Hee.n 255,500 30!~" 000

Sta.ndard 2,500 3,000Devia.tion

* Average specimen diameter at the base of thenotch 1s 0.4975 inches.

** All strengths rounded to nearest 500 psi.

Page 80: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

TABL

E2

.13

,.

DATA

AND

RESU

LTS

FROM

STA

TIC

TEST

SON

UNNO

TCHE

DSP

ECIM

ENS

(Str

ess

Rati

o=

0)

Test

Yie

ldU

ltim

ate

Bre

akin

gD

iam

eter

Are

aY

ield

~ltimate

i{e~\ing

No.

Loa

dL

oad

Loa

dA

vera

geAve~.

Str

en

eth

fStr

eng

thS

tren

gth

1000

lb10

00Ib

1000

lbIn

.In

'Os

i-l~

psi·:~

"psi

~.

131

8.5

32•.5

24

.30.

4753

p.1

77

41

77

,50

01

83

,00

02G

L t-,0

002

30

.63

1.5

23

.50.

4764

0.17

841

71

,50

017

6,.5

0025

1 .t ,,0

00

33

0.6

31

.62

3.3

o.475'~

0.17

751

72

,50

01

78

,00

024

9,00

04

20

.83

1.0

22

.80.

4755

0.17

76,

16

8,0

00

174

,50

025

1,50

0

52

9.9

'3

1.1

22

.90.

4758

0.:1

.778

16

8,0

00

17

5,0

00

254,

50Q

63

0.1

31

.32

3.2

0.47

220.

1752

17

2,0

00

17

8,5

00

256

,500

.'7

30

.43

2·5

'25

.00.

4787

0.18

001

69

,00

01

81

,00

025

6,0

008

30

.23

1.4

24

.20.

4757

0.17

771

70

,00

01

78

,00

025

3,00

0'.

9-

30

.63

1.6

23

.60.

l.l-7

63kJ

.178

21

72

,00

017

7,.5

0025

9,00

0.

24

.20.

4755

0.17

661

76

,50

010

30

.33

1.2

17

1,0

00

250,

500

11ea

n1

71

,00

01

78

,00

025

5,00

0

Sta

.nd

ard

.3

,00

02

,50

04

,50

0D

evia

:tio

n

*A

llS

tren

gth

sR

ound

edto

the

Nea

rest

500

psi

.

""o

Page 81: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

. }

It is generally accepted that the static strength

of ductile steel is not affected by a stress concentration.

ThercfoTe, theoretically, the same shear strength distri-~ .

bution should be obtained whether the specimens are notched

or not.

However, the mean normal strength distribution was

obtained directly from the tensile tests. In the case of

tensile tests a notch does have an affect on the strength.

The notched specimen has a higher ultimate strength due

to a radial stress being introduc~d into the specimen

at the root of the groove (6,. p."19). A grooved specimen

subjected to a static torque load would not experience

this radial stress. Therefore, the strength distribution

used at stress ratio of 0 is the ultimate strength dis-

tribution for the unnotched specimens.

In order to construct the fatigue diagram the dis­

tributions along the various stress ratio lines must be

calculated. The reqtiired relationships can be derived

from Fig. 2.15. They are: .

.. .

. but

gTan e = _a = R = stress ratio

Sm

S~=Si~

. "

Page 82: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

·.

./

Sa

'

.S.....---

a

Sm

..'

/.~

R-

AX

IS

\.

S.

m

-'

Fig

.2

.15

Rel

ati

on

ship

Bet

wee

nth

eS

tres

sR

ati

oL

ines

J~

.,.::...~

:'ji

-"~'

(

"l\)

Page 83: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

- -

Sin 0 Tan e R- 1 ' - 1[l+(Tan e )2J2 [l+R 2J 2 \

'--"\

thus

- 1~ (l+R 2) 2

S -a (16)- .R R

,

Using the same derivation the expressions for the

standard deviation along the R axis are

'18

aSaS

a== SinO-

R

'and

1Os (1+R 2 ) 2 /

Os_ 9.

== HR(18)

SR,3.5

Referring to Fig. 2.16 the distribution along the

alternating stress axis (R = (0) can be plotted directly.- 0

For this axis 0 = 90 and Eq. (15) yields S = S 00H, 00" a,

and Eq. (17) ytelds aS 00 == aS 00 .~_ H' a'

For the distribution along the stress ratio line

3.5 Eqs. (16) and (18) give

2 1= ~..0(l+R )"2

H

1.52~=- 3.5 57,201 psi.

Page 84: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

for the mean and

=

\'--

for the standard deviation.

The same procedure would be used along any other stress

ratio axis except the appropriate values of S and a· ~.a sa

would be u~ed. The results of the calculations for the

parameters for endurance are listed in Table 2.11 and the ~.

resulting fatigue diagram is Fig. 2.16. The endurance

tests for R= 0.44 have not yet been co~pleted but from the/

tests that have been run it appears as though the endurance

level will be in the range of 49,000 to 53,000 psi. and the

scatter will be wide. The actual distribution will probably

be very close to \-That the distribution sho1'm on Fig. 2.16,

in dashed lines, looks like.

It p~obably will not be possible to conduct tests at

ratios nuch 1m'Ter than 0.4-4, especially at high stress

levels. The stress ratio is R = S / S and the 1mver limita" m

on S is the endurance 1ev~1. The upper limit on Sis the. a myield strength 'l'1hichis 171,000 psi. Thus the lOi-rer limit

on stress ratio, assuming the endurance does not fall much

below 51,000 psi. 1s

Page 85: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

=:0

Ult

imat

eS

tren

gth

Dis

t.u

nn

otc

hed

speci~en

iR

:=1

.0

20

Yie

ldS

tren

gthD1stribution~'

~'"'\

.u

nn

otc

hed

sp

ecim

.en

."'-

._~'Jj\l

,\

,\f~\

"\

l""

.".

J,I

I..

,\I

¥~

IY

II

r!

II

I,

II

I!

II!

'r-;

-';!

-~~i

~:-'

\~~

'1I)

40

6080

100

120

14

0:6

0le

Oo

NEAN

STH

ESS

-kp

si•.

{ \

Fig

.2

.16

Sta

tisti

cal

Fati

gu

eD

iagr

amF

or

Infi

nit

eL

ife.

'""vc.;-

.

Page 86: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

·.' '19

This may not be a very good assumption since the

fatigue diagram shows that it does falloff rapidly at'\

101'1 stress ratios. At these 10\'T ratios yielding "lill be

the predominant failure mode. Unless the capability exists

to monitor the torque on the specimen continuously. it will

not be knO"Nl1 ,'rhether or not the initial torque load w'as

constant.throughout the test.~.

2.8.1 Qse of ~~~t;stiQal Fatigue ~la~rams in De~

The conventional use of fatigue diagrams is

to determine what combinations of mean and alternating

stress are safe for a given number of cycles of operation.

For example. in Fig. 2.17 the stress combination of Sa/.1.

and S would be considered safe for a design life ofm1.105 cycles but not for infinite life. The combination of

Sand S is not safe for 105 cycles of life. The8 1 m2 s

question arises, "Hith "That confidence can one say that a

combination is safe?" To anm'rer this question the dis­

tributions of the alternating and mean stresses to which

the component in question is.subjected and the distri­

bution of the. limiting fatigue boundary must be considered.

A method of obtaining t~e distribution of the fatigue

boundary at various cycles of life has been previously

discussed.

Page 87: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

MODIFIED GOODNAN LINE

-sy

MEAN STHESS

Fig. 2.17 Conventional Fatigue Diagram Sho~1ing theModified Goodman Line

/

If the distributions of the alternating and

mean stresses to which a shaft is subjected are known or

can be estimated then they can be plotted on the fatigue

diagram as shown in Fig. 2.18. If the shaft stress

distributions are normal and the stress ratio can be

assumed to be constant then the distribution along the

stress ratio axis (R2 axis in Fig. 2.18) can be obtained

from the relationships

77·

.. and

"lhere

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78

R = 00 , .:

(I)0(1)ZWH~E-rE-t~(I)p::

§(S~las)

a

R = 0

MEAN STRESS.', « .- ~

-

Fig. 2.18 Statistical Fatigue Diagram-

- of the stress distribu.tion a.long~-. ." sR = mean

.;t. 4''-

2__l.v -- the R2 axis..

r-

a = standard deviation of ·the stress. sR'

2 distribution along the R2

axis.

- of the alternating stress of thes = meanashaft.

a = standa.rd deviation of the alternatingsa

stress of the shaft.

Figure 2.19 shm'1s the stress a.nd streneth

distributions along the R2 axis. Once the parameters of

the distributions are knmm the probability of failure can

be calculated. Defining the random variable Z as

Z ::; S - s

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79

"Fig. 2.19 Enlargement of Stress and Strength Distri­butions on R2 Axis of Fig. 2.18 •

where

s = the random variable, strength~

s = the random variable, stress.

then the mean and standard deviation of Z can be shmm to

be normally distributed "Nith parameters (13, p. 113)

z = s - s

(20)

Failure occurs i':hen s> S or "'Then S - s < o.In Fig. 2.20 the shaded area represents the probability of

,failure. Stated in mathematical terms

o

P(Z < 0) ~ S... _ 00

1 e, dz

Page 90: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

feZ= s - s

z

80

Fig. 2.20 The Distribution of Z = S - s.

,.,Putting into the standard normal from by letting

then

S - sJo 2 + 0 2"1

S S

./

(21)

P(X< Xl) = e

For a knovm xl the value of P(X < Xl)' '\'lhich is the .prob­

ability of failure, can be obtained from standard normal

distribution area tables. The reli?-bility Re is defined as

Re = 1 - P(failure) = 1 - P(X < Xl)

,

which.can be expressed as

dx (22)

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81

Thus the' reliability of the shaft can be determined.

In most cases the designer must start with a''--­

level of reliability and determine the shaft diameter such

that for the imposed loads the specifiedre1ic.bility

\'1i11 bernet. The procedure in this case is to 1-lorlc back-)

wards through the preceding derivation. The alternating

stress in the shaft can be expressed in terms of the dia-

meter by

. (23)

\'1here

M = the bending moment on the section in

question.

- ./

D = diameter of the shaft.

4 S'

I 1TD moment of inertia of the shaft= M = cross

section.

The standard deviation of the stress can be

expressed in terms of the mean and the standard deviation

of the diameter of the shaft. Using the approximate

partial derivative method (13. p. 90) for the standard

deviation of the alternating stress yields

(24)

Theexpression.obtained using the approximate

partial derivative method may not be valid in certain cases.

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82

For example, in the case of a product Z = XY the standard

~deviation 6f Z is given by (13, p. 123) .

. whereas the expression given by the partial derivative

method is

0z ~ . J(X 0 )2 + (y ox)2' . (26)Y.

When the term (oXOy)2 is small compared to

other terms on the right side of.Eq. (25) then the approx-

imation \1ill yield good answers. If the values of ~X

and 0y differ from each other by 3 or 4 orders of mag-/

nltude then the term is no longer. negligible. Then exact

expressions for the standard deviations must beJ.used.

They can be found in Chapter 3 of ne~. 13.

The standard deviation of the shaft diameter

is a function of the tolerance on the diameter. Assuming

the distribution of the shaft diameter is normal then

99.73% of the shaft diameters will fall within + 3 0D •, ~t

Denoting the' shaft diameter as D - , where in most cases

the tolerance2t is known, then 3an ~ t.

The mean and standard deviation of the moment

can be determined from the loading distribution. The

only unknOl",rn in equations. 21, 23, and 24 is D the diameter

of the shaft and it can be solved for.

Page 93: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

This, then, is a method of designing a

rotating shaft, subjected.to a bending moment and a torque,,

. for a specified number of cycles of life i'1ith a predeter-.

mined reliability.

HOi'1eVer it is important to recall the limi ta.-

tions and assumptions.

i . . ·The amount of data used in estimating the

distribution parameters can have a sub-

stantial effect on the shape of the dis-

tribution. The most pronounced effect is

1n the tails. Since the calculation of

reliability is based on the overlap of the

tails of tl'TO distributions it j.s neces-

ary to have good estimates of the distri­

butions in order to obtain accurate values

of reliability.

2. The tests were conducted on specimens of

given geometry; hardness, and material at

room temperature. The fatigue surfaces

generated from these tests are valid only

for this type of specimen, environment and

loading. The loading was a bending moment

and a torque causing an alternating normal

stress acting parallel to the centerline of

the shaft and a constant shear stress acting

perpendicular to the centerline.

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84

3. It was assumed that along any given stress

ratio axis the strength distribution is

normal. '\.:..-" . "._,

4. It "Tas also assumed that the ratio of the

alternating and mean stresses, to 'Nhich the

shaft being designed is subjected, is con-

stant. . ,

..

Obviously, it '\'Tould be an almost impossible task~.

typeto generate statistical fatigue surfaces to cover every

of material and donfigUration. Ho\,rever, it is feasible that

enough tests could be conducted to allow empirical equations

to be developed relating different stress concentration

'factors and conventional physical properties for the more/ J

common steels. This '\tould make ft possible to design from

a diagram which was not generated for that particular con-

figuration and material.

2.9 Mpdification of. One Test Macpip2IJ.

This section will discuss pome of the problems

encountered in working with the test machines and the

measures taken to overcome some of the problems. Two of

the most troublesome areas are the instrumentation and the

gear couplings. The gear couplings are the means by which

the toolholder arms are allmled to s\'ring dm'm'(?ard slightly

when the bending load is applied. Referring to Fig. 1.1

it is seen that the bending load configuration also applies

a shear load to the couplings. However,the couplings

Page 95: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

were not designed to withstand radial shear loading,

their purpose being to transmit torsionalJloads only.

The couplings consist of three major parts. Two of the",

parts are pressed onto the shafts that are being coupled

and have an external gear. The-third part is an internal

gear sleeve "rhich slides over with the other t"t'lO ps.rts

with the gears meshing as shoi'm in Fig. 2.21 •

A radial shear load causes the sleeve to cock allowing

the centerline of one shaft to fall belrn~ the centerline-

of the other. This misalignment. along with the angular

deflection downward caused by the bending load, causes

varying degrees of vibration in the toolholders and speci-

men. vlhen the, gear couplings are nei'l the mis8,lignment is

small and there is very little vibration, but as the teeth,

in the couplings wear the misalignment and vibration

become greater.

Note, also, that there is no definite pivot point in

the couplings, thus the length of the moment arm betw'een

the loading bearing and the pivot point can change while

the machine is running causing a change in stress applied

to the specimen. H01'1eVer, from observing tests in progress

it appears as though the magnitude of the alternating stress

remains quite constant for runs of up to about two hours.

This investigator has never monitored a run,lonser- than about

two hours. The reason for this 1s that it is necessary

Page 96: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

.,

:...::

-'-'

TOO

LHO

LDE

RS

P'.A

FT

SNA

PRI

NG

I!liII

II;:

1Ii

'!l!

'1_

__

.1p\p

[til-

__,...)1

lill

li-~

I.

[IiI

,I>

I,f•

,/>

'fI

f>

/.,),

1I

"n

.rIJ 77-;?7~7j/j~'7-~'~---

//

/.

\:".

-'

o

.G

E!i..'

qB

OX

SF'

.AFT

Fig

.2

.21

Gea

rC

ou

pli

ng

Use

don

Fat

igu

eT

est

ing

Mac

hine

.(

co.'

0\

Page 97: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

to have the contact points off the slip rings when the"." ....

specimen breaks. Just prior to the specimen breaking, it"' ~

and the toolholder arms vibrate quite a bit. If the

points are dOi'ln on the sliprings1'Then this happens they

can become damaged or broken. Usually the endurance tests

are monitored for about 20 minutes.

Another problem is that there is a difference in the

number of divisiO!ls, as recorded by the Visicorder, bet''ieen

the static and d;~lnamic outputs. In other words, after the

~pecimen is loaded, the machine is. rotated by hand and the-

Visicorder trace is observed. Then the loads are adjusted'

until the desired output is attained. However, when thes

machino" is rotated under pOHer tht1 output is a different

amount, sometimes as much'asfour divisions. This can

represent as high as 8,000 psi. depending upon the gain

setting of the amplifier. The change can be easily cor-

rected for the bending stress simply by changing the

weight'on the loading arm. This can be done while the

machine is running. To make. the correction for torque

load the machine must be shut dO"m and the torque coupling

adjusted. HO'·rever, the amount of change behleen static

and dynamic outputs is not constant. After adjusting the

torque to allOiq for the change, "1hen the machine is

restarted the change may be a different amount so the

machine must again be "shut dO".vn and read just-ed.

Page 98: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

' ..:....

86

There is another complication entering the problem.

After about 30 seconds of running time the torque trace\

begins to drift quite a bit. The amount of drift depends

upon '-ihich machine is being used and the torque load

applied to the specimen. The highe~ the torque load the

less the drift. Tests were made to determine if the torque

load was changing or if the drift was due to amplifier

drift. Several factors led to the conclusion that the

drift is caused by drift in the amplifier; one being the

fact tha. t the torque output drifts up"lard in t\'10 machines.

It is hard to believe that if the torque were changing,

it would become greater. The tests seemed ~o indicate

that the zero datum point was drifting. However, it

drifted only when the machine was running. The drift,

when the machine was not running would amount to one

division, at the most, in about 2 hours whereas the drift

amounted to as high as 3 divisions in 2 minutes ~lith the

machine runnine;. One result of the drift is. tha t if, ''Then

adjusting the torque load, the proper number of divisions

1s not obtained in one or tHo tries the torque \'Till start

to drift and no accurate measure of the amount of torque on

the specimen can be obtained •.. When this happens the loads

must be removedfro!ll the specimen, one holding collet

must be loosened and the amplifier recalibrated.· This is

very time consuming, especiallyif.this procedure must

A

Page 99: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

89

be gone through bro or three time s.

The drift problem could proba.bly be eliminn.'ted by

obtainin5 sol~d state amplification equipment. The pre-"\

sent equipment has been in use since the start of the

research program and is not solid state. OV~~lning solid

state equipment is plaru1ed for the ncar future.

It is not qUite clear what is causing the difference

betNeen the static and dynamic outputs. For the bending

stress it seems feasible that such a difference may be

caused by the difference in the rate of elastic deformation

of the toolholder. ~hen the machine is rotated by hand the

rate of deformation is S10H but under pONer th8 machine

rotates at about 1,750 rpm and the deformation of an element

on the surface of the toolholder may lag behind the applied,

load. Using this line of reasoning it would seem that as

the peak load is reached, if the correspondlngdeformation

1s lagging, then as the load begins to decrease the deform-

stion will continue to increase only to that point where

the deformation corresponds to the decreasing load. In

other "rords, the toolholder never reaches the a,llount of

deformation corresponding to the peak load. This renson-

1ng would mean that the divisions of Visicorder output

should be greater for the static case than for the dynamic

case. HOT::cver, the opposl te is true. In all cnses, Hhere a

difference in the,bending output 'has been experienced, the

Page 100: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

90

bendlnggagc output has been greater with the machine

runnir.s tmder pO\>Ter than ''lhen turned by hanel.

The above,reasoning cannot explain the differen~e in

outputs in the torque gage bridge either, because the

torque load is not alternating but is constant.

'The torque gage bridge output for the stntic case hr.ts

been greater than for the dynamic case in most tests.

This can be easily explained. Torque 1s exerted on the

specimen through the torque coupling on the backshaft.

(Fig. 1.1). The torque" is transmitted from the backshaft.

to the toolholder shafts through the gear boxes. When

torque 1s applied through the torque coupling the rate at

which it is applied is very slow. When torque is applied

the play in the gearboxes 1s taken up along with any other

play ~"n the system. Then '\':hen the machine is started the

1nitial impact causes more play to be taken up and the

torque decreases. At very high torque levels all the play

1~ taken up in the initial application of the torque.

The initial starting impact causes very little decrease in

torque gase bridge output, but the lower the torque level

the greater is the amount of decrease. For the lower levels

it 1s more difficult to take the decrease into account bv" .

setting the torque higher because at any given torque level

the amount of decrease fro~ specimen to specimen is not the

same. Several trials enable one to determine the change

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91

and set the divisions accordingly.

Late in November, 1969 one machine was partially

. dismantled for~the purposc·of modifying the gear couplings.

The modification consisted of placing a spherical bearing

inside of each of the two couplings. The bearings do

several things to eliminate some of the problems. They

absorb the radial shear load and create a definite point

about which the toolholder arms can pivot. The bearings

have not been in use long enough to determine 'Nhether or

not the rate of gear tooth wear will decrease in the

couplings, but it is believed that it will. Since there

ls nO"1 a definite pivot point, even if there :ts excessive

tooth l'lear the outer l.'ing '\'Till not be able to misalign and

cause vibration. In Fig. 2.22 note that the inner dia­e.,

meter of the spherical bearing has a sliding fit \'li th the

shaft through it. This is true of both bearings. This

eliminates the possibility of subjecting the specimen to an

axial load when tightening the specimen in the collets.

Since the spherical bearings have been installed, about

34 endurance tests at a,stress ratio of 0.44 have been run

on the modified machine. No vibrational problems have been. ,

encountered and it appears as though the difference between

the static and'dynamic outputs is minimal.

Page 102: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

;,

,,:,;,

:.',

..,.

TOOL

HOLD

ERSH

AFT

BEA

RIN

GRETAI~mR

RIN

G

BEA

HIN

GSE

AI'T

K'-

-;r-

--

--t~.

I/«

«C

dt

/II J

I!r

I.I~-

\I

\l._

!L_

_

SPH

ERIC

AL

BEA

RIN

G

GEAR

BOX

SHA

FT

Fig

.2

.22

Mo

dif

ied

Gea

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ou

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ng

.(

'0.

N

Page 103: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

'..

CHAPTER III

OVERALL CONCLUSIONS

1. Estimates. for the normal distribution parameters

were obtained for the endurance level at stress ratios of

~; 3.5 and 1.0. The tests at stress ratio of 0.44 are

in progress.

2. Estimates for the normal and log-norma~ distri­

bution parameters ~Tere obtained from the cycles-to-failure

de,ta. By comparing the D-values and the coefficients of

skel'mess and kurtosis it "Tas concluded that the data tends

tOHards the log-normal distribution•. It l'laS also conoluded

that in order to make a'more conclusive decision a larger

sample size at each stress level would be reqUired.

3. .The method previously proposed to obtain strength

distribution parameter estimates yields optimistic'values

and should be studied further.

4. If random data is obtained by ~he method proposed

in this report estimates which might have favorable

properties may be obtained.

5. Fatigue surface Has generated using the endur­

ance data which is among the first few attempts to obtain

such design data. Efforts to generate such data based on

larger samples, with solid state instrmnentation, and with

9~

Page 104: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

greater operator care, should be continued.

6. On th~ basis of the 34 specimens tested on the

"machine 11i th the modified couplings it is concluded that

the spheric~l bearings improved the running ch~r~cter-

lstics of the machine. It 1s hoped that the long range

performance would also be satisfactory.t"''-

. .-.. ~ ..'" ~

/

5

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CHAPTER IV~. ,

RECOH!>iEUDATIONS

,J.

1. Ne'\'l' 'solid-state instrumentation should be pur-

chased. ' The ne\'1 instrumentation should be drift free a.nd

should have the capabili t~T of constantly monitoring the

strain gage outputs.

2. The gear couplings should be modified on the

remaining~1o machines.

3., The endurance tests for stress ratios of ~ and

1~O should be checked.

4. Before the next phase of the test program is,/

embarked upon the machines should be recalibrated to see

if the calibration constants are the same.

, S. Larger sample sizes should be used in future

tests,preferably 30 or more at each stress level tos' ,

obtain the much needed cycles-to-fa1lure design data.

6. The feasibility ofincol"pora.ting random stress

levels to produce de.ta from \'1hich better strength distri­

bution parameters might be estimated should be investi-

gated~

".::

. ~'" .

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APPENDIX As

COMPUTER PROGRAM TO CALCULATESTRESS LEVELS AND RATIOS

The purpose of this program is to convert the visi-

corder records into normal stresses, shenr stresses and

stress ratios. The program also calculates the means and ',.'

standard deviations of the stresses and ratio of each group, ,

of data. It also calculates the,cyc1es-to-fai1ure from

times to failure data, but the program will also accept

cyc1es-to- failure data. The pro~ram distinguishes be­

tween the two through the use of a code number. The code/

also tells the program whether or not a group of data are

endurance test data. This discrimination is necessary

because of the calculation of mean and standard deviation

of the stresses. The program will not calculate the endur-f ' "

ance level distribution parameters. The discrimination

code is fed in as dal"E:l. alid is as follm'ls:

0 if the failure data is in times to failure

1 if the data is an endurance test2 if the failure data is in cycles-to-failure.

The input format for the code will be discussed shortly.

The program will accept as many sets of data as

desired and the groups may be mixed; ie, endurance test,

group with cycles-to-failure data and group with times

96

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97

to failure data. 'A group is all the data for one stress

level. A group of data consists of the follm'iing. The

first card contains in this order, the number of speci-~,-

~,

mens in the level, the mode of the run and the code. TheJ'

mode is dependent upon the date the run was r::::::(~e. For a'

further discussion on mode see Section 2.1.

The fields,on the data card are as follows:

spac,es 1 to 5 number of specimensspaces 6 to 10 modespaces 11 to 15 - code

The number of specimens. mode and code are fixed point

numbe'rs and have no dec1mals but the numbers must be

placed to the right 1n each field.

The next sequence of cards reads in the cycles-to~

fa~lure or times tofa1lure 1n hours. minutes and seconds.

If the data 1s1n times to failure there are ten groups on

a card,. so the number of cards required ,'rill depend upon~

how many specimens are in the level. The format across

.. '

the card is:

spaces 1 and 2 blankspaces :3 and 4 - hoursspaces 5 and 6 - minutesspaces 7 and 8 - secondsspaces 9 and 10 blank

-and the sequence continues 1n this manner. If the failure

data is in cycles-to-failure the format 1s 8 fields of 10

spaces each and the decimals apperir in the last space of

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"

'each fiel&, ie, spaces 10; 20, 30, etc. If the group of

,data is for an endurance test there is no failure data

and thet:e cards are left out. The program \'1il1 auto": "­

maticsl11 handle it if the proper code number is put on

the firr;t card.

Follo'Yd.ng the cycles-to-failure cards are' the cards

bontnin1ne the information for each specimen in the stress

level. The information must be placed on each card as

follO\H.l ,

.! .

pan weight./

Bp~COB 1 to 5 test numbersp~CCG 6 to 10 - specimen numberspaces 11 to 15 - machine numberspacos 16 to 20 with a

deo1mal in space 20

. ,•. t.

spaoes 21 to 30 with a

decimal in space 28 bending calibration resistance

spacos 31 to 40 with adQo1mal in space 3~ number of bending calibration

divisions

apnoea 41 to 50 with a

decimal in space 48 number of divisions 6f bending

spnoea 51 to 60 with adocimal 1n space 58 torque calibration resista.nce

opnocs 61 to 70 with a(l(lolmal, in space 68 number of torque calibration

divisions

sl\.l\ces 71 to 80 '\'1i th a

daolmal in space 78 nurnberof divisions of torque

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99

.~'he test number, specimen number and machine number

are fixed point numbers and mus~be placed to the right

in each field. There is one card for each test specimen'---

1"\

and the cards must be placed in the same order as the

failure data is placed.· on the cards precedinc ~~:~dse c~rds.

For data at stress' ratio of 00 there 1'lill be no torqu.e

stress data. In this case these fields can be left blank.

The computer reads blanks on data cards as zeTOs •

. This makes up one group of data at a given stress

level and ratio. As many groups.may be run as desired by

simply placing the groups one behind the other.

FolloHing is a listing of important variables in the

program and Fig. A - 1 is a flow/chart of the program.

Figure A - 2 is a program listing. The outputs from this

program are given in Appendixes D and E.

\

\

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. .List of Definitions for Program to Find

Stress Levels and Ratios (PROGRAM STRESS)I.

100

= 0 if failure data is in times to failure.- ·1 if data is from an endurance level.

. J

= 2 if failure data is in cycles-to-failure.

times to failure in hours, minutes and seconds.

NCARDS

!10DE

NCODE

XHOURS(I)XMIN(I) ­SECS(I)

TOTCY(I)

NOTEST

NOSPEC

=

=

=

n~~ber of specimens tested at given level.. ."

number of mode depending on date·of test.

cycles-to-failure.

test number.

speciman number,'

MACHNO = machine number. /

PANWT

RCALB

ENCALB

ENVISB

BCALT

ENCALT

= amount of ''leight on loading arm.

= calibration resistance used in bending channel.

= number of visicorder divislons used ''lhencalibrating bending channel.

= number of divisions during actual test.

= calibrationresistarice used in torque channel.

= number of visicorder divisions used whencalibrating torque channel.

ENVIST =ENA =RGAGEB =RGAGET =GB =

-..

n~'llber of divisions during actual test.

number of active arms in strain gage bridge.

resistance of:bending strain gages.

resistance of torque strain gages.

bending gage factor.

.. ...

Page 111: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

= torque gage factor.GT

CBGR

CGRTH

CT

CTB

CBT

RPl1

=

=

=

=

calibration constantKBGR •

c,~libratiol1 constant KGR•.THcalibration constant KT •

cali~rationconstant KT/ Bcalibration constant KB/T •

revolutions per minute of machine.

101

SOUTH = output normal stress corrected for interaction.

TAUTH = output shear stress corrected for interaction.

STRGR(I) = normal stress in specimen groove.

TAUGH(I) = shear stress in specimen groove.

SOUTHP = output stress not corrected for interaction.

TAUTHP = output 'stress not corrected for interaction •

. \

G

Page 112: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

102

Program to Calculate Stress Levels and Rat10s

"~r.·'\IN PROGHA?'l (STRESS)

READ NCARDS. MODE. NCODE ~--~--~ 9

," YES

PRINT HEADINGSENDURANCL!: TESTSAND r~ODE

NO

PRINT HEADINGSNON ENDURANCEAND i'10DE

spnIATOD ==TID ==

SPJC ==

THJC ==

COi'JST

F1g. A - 1

== .49752001.3125

12tl~2f~~PDIA~

lh2-1.J.15l)(TOD4 _TID1.J.L

(1 ) (TaD)

THJC== SP·JC

".. :,. ...'. " .

Page 113: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

"

103

.'

READ NOTEST, NOSPEC, MACHNO, ~ f:\PANY1T, RCALB, E}·~CALB, EilrvrsB,·2 ~

RCALT, EtJCALT, E!\TVrST

E = 30000000.ENA = 4.RGAGEB = 190.RGAGET = 120.GB = 3.23GT = 2.05.

/;/./y------------'-------

Logical if statements to choose correctcalibration constants for HACHNO and i';ODE

' ..'-,. .!~.~..

NO YES

SOUTH (ENVISB] (R) (RGAGEB)= -r1E--:t-'ic-'-"i~LB1TEl~AT( GB11RcALB J

STRGR(l)

TAUGR(I)

Fig. A - 1 (continued)

SOU1~H .= rCGRTHT~CBGH)

== 0.0

..

Page 114: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

104

s

.. ' ~

PRINT }!O~~ST, l!CSPSC I ;TACENO,PAl\Jl'IT, TCY, RCALE, E~rC~'\LB,

EINI SB, RCALT, E~JCALrr, En'll ST ,STRGR(I), TADGE(I) ,:;i""

NO

CYBH = (XHOURS (I» (60) (RPM)CYMIN = (XMIN(I»(RPM)

CYSEC = .lSEP§tb·~) (~'pNl

TCY = CYHR+CYMIN+CYSEC

/

TOTCY(I)

PRINT No'rEST, NOSPEC, r'!AC!'Il'~O,

PAWNT, Tey, RCALB, ENCALB,ENVISB, RCALT, ENCALT, E~~IST,

STRGR(I), TAUGR(I)

6

Fig. A - 1 (continued)

Page 115: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

105

.' -!-ENVISB 2..l~ (RGAGEe.LSOUTHP = (ENCA~BrrEN~(GBrnT~~LB)

'l'AUTHP . (ENV1sTt(1tJ~'yt\GET) )= TENCALT I(El..JA GT rRCALT-

SOUTH = SOUTHP-(CTB)(TAUTHP)

THUTH ='TAUTHP-(CBT)(SOUTH)

SOUTHSTRGH( I) == TCGR'l'H reCBGR'}

TAUGR(I) = (CT)(TAUTH)(CONST).:"

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. ( /

,.:1'

YES

YES

PRDJT NOTEST, NOSPEC, .J1ACHNO, PA~J1!!T, RCALB,ENCALB, EIJVISB, RCALT,ENCAVf, ElJVIST, STRGR ( I ),TAUGR(I), R(I)

Fig. A-l (continued)

TOTCY(I)

YES

4

NO

Page 116: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

5

° '.

CYHR = (XHOURS(I»(60.)(RPM)CYMIN = (XMIN(I»(RPM)

CYSEC = lSECS{g~~iRPl~)

TCY = CYHR+CYMIN+CYSEC

PRINT NOTEST, NOSPEC, MACHNO, ,PA~dT, TCY, RCALB, ENCALB,ENVISB, RCALT, ENCALT. ENVIST,STRGR(I), TAUGR(I), R(I)

6

Fig. A - 1 (continued)

0'---_

106

.,:~° ,.

Page 117: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

YES9 kT----< NO

107

Calcul ['~ -ce mean 8.nd ~-=-- --=-}l':.::'0,---<-standard deviationof norms.l stressSUBROU'I'INE MEAN

PRINrr XI'I~:AN, DEV

9

NO'

Calculate mean andstandard deviationof shear stressSUBROUTINE ME1\3

PRINT XMEAN, DEV

r r--~-:---L_----:--l

CRlculate mean andstandard deviation'01' stress ra.tioSUBROUTINE HEAN

PRIN~~ XHEAH, DEV

Fig. A-l (continued)

Page 118: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

Program to Find I'lea.n a.nd Standard Devla tion

SUBROUTINE BEAN

108

SIG~rA

TOP2= O.

= o.

SIGMA = SIGMA+X(I)TOP2 = TOP2+(X(I)-MEAN)2

YES

I...--~XMEANSIGHA

= DATA

DEV = TOP2DNrA--l.O

FEINT XHEAN, DEV

"

Fig. A-l (continued)

Page 119: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

APPE1~IX A (continued)

1,' ,

. /I

Fig. A-2 Computer Printout ofPROGRAt-l (STHESS)

109

--_.._----_.._- •. -

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Page 125: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

APPENDIXB "'----

1-

Progra~r: to Calcu'late the Parameters of the !'Jormal

and Log-Normal Distributions and Conducts

Goodness-or-Fit Tests

This program calculates the mean and standard devi-

ation of the cycles-to~failure data for both the normal and

log~·normf:\l distributions and calculates the moment<'

coefficients of skewness and kurtosis. It also performs

the Chi-square and Kolmorgorov-Smirnov goodness-of~flt

tests. The input consists ofa/

1. a card containing the number of data points at

. that stress level, the accuracy of the data, the

stress level and the stress ratio.

2. a card or series of cards containing the cycles­to-failure data listet in descending order.

3. a card or series of cards containing the cumu­lative frequency of the cycles-to-failure'up tothat point. These must be listed in the sameorder as the cycles-to-failure data.

The input format for the first card iSI

spaces 1 to 3 - number of data points in fixed pointformat.

spaces 4 to 8 with a

decimal in space 7 ~ number of data points in floatingpoint format

115

Page 126: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

116

/

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spaces 9 to 17 with adecimal in space 13

spaces 18 to 27 with a

decimal in space 26

accuracy of the cycles-to­failure data. ~-

stress level at which the datawas taken.

spaces 28 to 35 with a~

decimal in. space 30 stress ratio at i'1hich the data.

was taken.

The cards containing the cycles-to-failure data have

eight fields of ten spaces each with the decimal at the

right of each field. In other ~ords the first data point,0

1s in spaces 1-10 1'11 th the decira.~l in space lOs the second

data point in spaces 11-20 with the decimal in space 20, et6.

The· format of the cards containing the cumulative

frequency ~ata is 26 fields of three spaces each with the

decimal to the right of each field. The first value is 1n

spaces 1-3 with the decimal 1n space 3, the secon~ value

1s 1n spaces4~6 with the decimal in space 6, etc.·

The program 1s set u.p t.o accommodate as many sets

of data as desires.

Follow~ng is a list of important v&D.d)les used in the

program. Figure B-1 is a flm.; diagram of the program and

Fig. B-2 is a printout of the program. Figure B-3 is

an example of the output for one set of data. The output

shoin1 is for data tested at a stress level 114,,000 psl. and

stress ratio of (.0.

Page 127: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

117

List of Definitions for Pro~ram to Fit Normaland Log-Normal Distributions to Cycles­

to-Failure ·Data (PROGRAM CYTOFR)

l>1ai11 Progr?m:

l'IDATA -- DATA = number of observations.

STRLV = stress level in psi.

AKURCY = accuracy to "lhich cycles-to-failure data.are knm'ln.

RATIO

X(I)

= stress ratio

= cycles-to-failure data

CUNFRQ(I) = cumulative frequency of each XCI), ie,number of X's less than or equal to XCI) •

./

PCAREA(I) = CUHFRQ(I)/NDATA

. Subroutine to calculate the mee,n and standa.rd deviatton of

the cycles-to-failure data (SUBROUTI~ffi MEAN)

SIGf1A = sum of the X(I)' s

XMEAIil = average of the X(I) 's

n{X{I)-Xr1EAN)2TOP2 = L

i=l

DEV = standard deviation of the X(I)' s

Function subroutine to find the. area under the normal

curve (FUNCTION PROB(X».

Page 128: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

Subroutine for Chi-square goodness-of-fit test (SUB­

ROUTI1\'15 CRISQA). \"--'-

118

largest value of cycles-to-failure.

smallest value of cycles-to-failure.

cell upper bound.

number of observations in 3th cell~

expected value of 3 th cell.'.~

K =XHAX :::

XMIN =

CSV =CEV -CLB :::

CUB :::

FREQ(3) :::

REQAREA ( J ) ==

CHISQR :::

U(I) :::

number cells.

cell starting value.

cell end value.

cell lower boundi

total Chi-square value.

Chi-square value of I th ·cel1.

.)

Subroutine for l~olmogorov-Smirnov test· (SUBROUTINE DTEST).

ABUNCN

::: abscissa value on standard normal curve fora given XCI).

::: area under standard normal curve fro!l1 ­to Z (I) •

DSTAT(I) = absolute difference between the data cumu­lative frequency Bnd the hypothesized cumu­lative frequency.

XMEAN ::: average of the X(I)'s.

DEV ::: . standard deviation of the X(I)'s

PHOB('r) ::: area under the standard normal curve from

-T to +1'.

Page 129: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

119

...-- - :.-

Subroutine to calculate the tllOment coefficients of Ske\'1-

ness and klITtosis (SUBROUTINE ALPHA). ~_

.- .J .... -

ALPHA)

ALPHA4 =

moment coefficient of skewness.

moment coefficient of· skewness.

VAH

TOP)

SKEH

STDEV

Top4

TKURT

. n ... -.. 2 .= L (X(I)-X)

"-1=1 . -

= third moment of the data.

::: biased estimator for standa.rd deviation.

n L~:::. L (XCI )-X)

1:::1,/

<"

= fourth moment of the data.

Page 130: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

Probr:t"'nm to Calculate Parameter Estimates for theNormal ancl Log-Normal Distributions and ConductGoodness-of-Fit Tests

}~IN PROGRAM (CYTOFR)

READJJDATA, DATA, AKURCY, STRLEV, RATIO

NO

READ Cur·1FHQ (I) , s

'--

120

PCAREA(I)

YES

:: £1!.2EFi9J1l....NDA'l'A ~'-------r

NO ~">--:;.;..."-----::>'j I :: 12:!-1

~ PRINT STRLV, RATIO, X(I)'s

Calculate mean and standard deviation of X(I)'sSUBROU1'IHE HEA!'T

Fig. B-1

Do Chi-square goodness-of-fit testSUJ3HOUTnm CHISQA .I-----

Cb

Page 131: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

121

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Do Kolmogorov-Smirnov Goodness-of-Fit TestSUBROUTINE DTEST

!Ca.lculate Homent Coefficients· of

SkevTness and KurtosisSUBhOUTIiE ALPHA

,

\t

. LOG X(I)NX (I) = [( .2"6- -I- LOGe (20) ) (10000. )J + .5

/

X(I) == NX(I)

XCI) - JJIl. - 10000 •._t-~__-=-.:....:....:....:...=---- -,- ..-J

YES T

">-~':I<:--_-~~ I = 1+1

PRINT STRLEV,·RATIO, X(I)'s

Calculate mean and standard deviation of X(I)'sSUBROUTD7E r·1EAH

Fig. B-1 (continued)

Page 132: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

· .

Do Chi-square

goodness-of-fit testSUBROUTIlJE CRISQA'

Do Kolmogorov-Smirnovgoodness-of-fit test

SUBROUTINE DTEST

Calculate moment coefficientsof skewness and kurtosis

/

SUBROUTINE ALPIL\

Fig. B-1 (continued)

\ ....-

122 .

Page 133: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

Subroutine to Find Hean a.nd Sts.ndard Deviation

SUBj10UT'INE NEAN

0~l'J:.@

.I~SIGHA = O.

'.!'OP2 == o. .

ty~-= 1[2; __[

r----~-'L_----:-~-......SIGHA - SIGI·IA+X (I)

TOP2 == TOF2+(X(I)-MEA~)2

123

YES NO:>-----{.. I -- 1-:-1

'l'OP2DEV:= DA'l'A--=T:Q

I~P-R-I-NT Xl-JEAN I !2EV7

Fig. B-1 (corttinued)

Page 134: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

124

Subroutine to Find Arei Under-Standard Normal Curve

FUNCTION PROB(X)

\..-

(

<0

XSQ ::: X2

FROB::: 1.0PTERH:= 1.0FACTOR::: 1.0ODDINT ::: 3.0

6

/' ...

> 0

1RECXSQ ::: ~- X2

FROB::: 1.0-(.79788453) EXP[_X 2/2 ,-' -(--x--)(l.0-nECXSQ(1.~RECXSQ

(3.-RECXSQ(15.-RECXSQ(10S»»)]

Fig. B-1 (COi1til1ued)

Page 135: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

125

·.1._

\

'--

PTERM _ _ PTERM~~L- U)'FAC'fOR

P'J'ERJvlTERM:: OD5fwf

PROB == PROB+TERt1

>0

J

..

FROB ::: {. 797G81l55)(X) (PROB)

-..

Fig.· B-1 (conti~ued}

/'

\

FACTOR == FACTOR+l.0ODDIHT = ODDINT+2.0

6

Page 136: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

'. 126

Subroutine to Conduct Chl-SquB.!'e Goodness-of~Fit Test

SUBROUTnm CHISQA

.. '\...-

CHISQH :: 0.0

K = 1.5 + (3.322) LOG 10 (DATA)

REALK = KXNAX ::: X(1)XJ1D\' == X (1)

YES

NO

NO

XHIN =: XlI

.YES

. I ::: 1+1

1

Fig. B-1 (continued)

Page 137: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

. 127

RANGE··= XHAX-XIUN

DIVIDE = j~~D~CY .

KJ.1 - [RAf1GE+AKURCY + ( 5)AKUnCV] (T'!T"IDF)\. - .HEALK •. .b .-. - - v -

RIel = KH

RKlH = DIvIDE

PRINT xr'1AX, XIHN, vI, l....-- 113' 11

\.......-

I = 1+1

NO

A == IB = (. 5) AKURCY

CSV(I) = XMIN+(A-l.0)(W)CEV(I) :;: CSV(I)+H-AKURCYCLB(I) - CSV(I)-BCUB(I) = CEV(I)+B

YES

CUB(I) = CEV(I)+BCEV(K) ::: XHAXCUB(K) = C~V(K)+E

. Fig. B-1 (continued)

Page 138: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

IJ '= ·3+11·....,...·---!>Il '---__-.--__.....J

. (

FREQ(J) = FREQ(J)+1.0

128

NQ

~../.' Fig •. B-1 (contim.wd)

Page 139: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

. 129

·.i..- .

T = Z(1)

AREA(I) ~ Eli~~~Tl

\ ---

NO YFS

REQAREA(l) = .5-ABEA(1)l·lAHU ::: K··l

0-;: I = 1+1 !------------v;

.S

REQAREA(I)IAHEA (I) - AREA (r·n I

.j Fig. B-1 (continued)

..-

D

REQAREA(I) =AREA{I) + AREA(M)

Page 140: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

T .~R-E-'Q-.P-iR-E-A--= .5-AREA(K-l) I

''---

130.,.. ,~.

"

EXFl1EQ(n) :: DATA~<-REQAREAOn

. EXFREQ(~2-FB~QJH}2U(~1) =: ~- EXF"'REQ (;:fr~ ..1-

CHISQR :: CHISQR+U(Io1)

PRINT I, CLB(l), CUB(l),EXFREQ(I), FREQ(I), D(I)

NO

\

Fig. B-1 (continued')

Page 141: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

=_.~.Subroutine to Conduot Kol~ogorov-Sm1rnov:v~. . : . GoodnessO"of-Fi t Test

. SUBROUTINE ·DTESTi

4 Z ( I ) ~j I L-XHEAnl---~ = DEV--

\-.~

131

T .- -2 (I ) 1--"'_00-__<-:;°_<

_. Ds'rAT (I)

ARUNCN == 1--P~B<Tl

DSTAT = ARUHC"'7PCABEA(I)

.>-.....;>.--=O_--.:{2 == Z (I) I=0

= • 5-PCARSA ]

/

ARUNCP =PRO~LTl + .5~-------1

DSTAT(I) =ARUNCF-PCAREA(I)

NO YRS

I == 1+1

4

PRINT DSTAT(I)'s

Fig. B-1" (continued)

Page 142: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

Subroutine to Find the l'ioment Coefficients ofSkewness and Kurtosis

SUDI.{OUTI1JE· ALPHA

TOP) = 0TOp4 = 0VAH :::: 0

VAH :::: VAR+(X(I)-XEEAN)2TOP) = TOP)+(X(I)~XMEAN»)rropl.j· := TOP4-:-(X(I)-Xi'1EAN)4

,..... -

132

~

YES

STDEV =: YAJLDA'l'A

SKEHALPHA) - ------ (srrDEV)3

. TOP!f·TKURT :::: DA'r1

ALPHA4:: TKURT(~ri'D'~V'> [j:

I--.._-!~>A, PRINT ALPHA] I ALFHA4

Fig. B-1 (continued)

Page 143: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

I .I'i

APPENDIX B (continued.)

..

/

Figo' B-2 Computer Printout ofPHOGHAH (CYTOFR)'

\

\ .

133

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APPENDIX C

CALIBRATION COlTSTAH'1'S OF EACH NACHINE

}i'OR r'BE DIFFERENT f'JODES

Mode 11 26 July, 1966 to 10 August, 1967

l10de 2: 11 August, 1967 to 1 June1 1969

Machine Kb~r K Kt Kt / b Kb/ tgr-th

1 1.0123 0.0208 0.8752 -0.0459 0.0290

2 1.0123 0.0188 0.8201 0.0344 0.0422.'

:

3 1.09L:-6 0.02U. 0.9330 0.0 -0.0:tLI-9:

Mode 3: 2 June, 1969 to 1 February, 1970

Nachine K N' Kgr-th Kt Kt / b Kb/ tbor

1 1.0123 0.0208 0.8752 -0.0459 0.0290

2 1.0123 0.0188 0.8201 0.0344 0.0422

:3 1.0946 0.0211 0.7721 0.0 -0.0127

Page 156: NATIONAL AERONAUTICS AND SPACE ADMINISTRATION€¦ · Mises-Hencky theory (also called the distortion-energy theory) "las developed to predict yield under static loads. However, because

· :.'. ..;". ~ :.

APPENDIXC (continued)

CALIBRATION CONSTANTS OF EACH I'-1ACHINE

FOR THE DIFFERENT MODES

110de 4: 2 February, 1970 to next change

146

MachinE K Kgr-th Kt Kt / b Kb/ t··be;r

1 1.0123 0.0208 0.8752 -0.01.:·59 -0.0290/

2 1.0123 0.0188 0.8201 0.0344· 0.042·2I

0.7721 -0.0123 1.01.23 0.0197 0.0 --

.'

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APPENDIX D

COI1PUTEH OUTPUTS LISTING STRESS

LEVELS AND RATIOS OF nmIVIDUA.L

SPECIMENS FOR Tlffi VARIOUS STRESS LEv~LS

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LIST OF REFERENCES

Kececicglu, Dr. Dimitri, McKinley, J. N., and Saroni,Mauric~ J. "A Probabilistic Method of DesigningSp~clfied Reliabilities Into Mechanical Componentsl':i th Time Dependent Stress and Strength Dish'ibutions."Report to NASA on Grant NGR 03-002-044·, Janu.8.ry 25, 19G7.331 pp.

Shigle~T, J. E. r.echaniqa~ Engineerinl2: Delli:.D' 1st edtNeN York: McGraw-Hill Book Company, Inc., 1963, 631 pp.

Kececioglu, Dr. Dimitri, and McCom1ell, J~ffrey B."Ca) i O}'H tion of Combined Bending-Torsion FatigueR~liab1lity Research Machines and Reliability Data

. Redu'c t1 on. " Report to NASA on Grant NGR 03-002-04·!~·,

July 31, 1969. 151 pp.

A Guide r6r Fati~ue Testin~ and the Statisticalxr;o.lxiL~_2f·Fatig.ll8 Da'ta. 2nd' ed. As rn1 Special Te-chnicalI)ublic~::.tion No. 91-A,1963. 83 PP. ;

Dixon, H. J., and Hood, A. r·l."A ~lethod for Obtainingand Analyzing Sensitivitv Data." Jou~np' or th~ ~~~~·c~n

g!lti~tical Assoc,iatioD, v Vol. J}3, 1948. -'.~ pp:--i·09--12·g-:--~-..:::..:..

Kececioglu, Dr. Dimitri, Saroni, M. J., Broome, H. Wilsonand HcConnell, Jeffery. "Design and Development of and.

. Results Fro~ Combined Bending-Torsion.Fatigue ReliabilityRese::trch l':achincs." Report to NASA on Grant NGR 03-002··044, July 15, 1969. 57 pp.

Ke(jec~.o[SlD., Dr •. Dimttri ,. 8.nd Broome t H •.\-1 ilson •.·'P:cob::::b.i~~st~~-Gr3.phical.. Hnd Phenoraenolcgical_ ..~nalys isof Combined. Bending-Torsion Fatigue Reliability Data."Report to NASA on Grant NGR 03-002-044, July 30, 1969.79 pp.

a, Fatel, Anilkumar V. "A Statistical Study of FatigueStrength of AISI h3 l l-0 Steel Under Combined Stresses."Masters Report. Tucson: The University of Arizona, 1969.;

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175

10. Hahn, G. J. and Shapiro. S. S. Statistical Models------_.__.._--.,........tD.-1~~n.stu~er~D.B.. NeN York: John i-I iley & Sons, 19b7.355 pp. ,

'--

11. Sm!th, Bicihard E. "Time Dependent Reliability ofCo:npOn(~!lts Subjected to Simple Fatigue." MastersThosis. Tucson: The University of Arizona, 1965150 pp.

12. - Ju"{inall,R •. c. Stres~ Strain and Stre~gth. Nel'l York:1'lcG:::-8.H-Hill Bool~ Comp;-ny, 196"7:---5"80pp:----

13. !1~1u6e11 f !!:.Ncu YOl'\{:

B. PrQ..babilistic A12..DJ:'08.ches to DesLe;.u.John Hiley & Sons. 19i58:" ,32,3 pp.