Fundamentals of Metal Fatigue Analysis
I.D. # 94024 Duration 3 Days
There is a potential for metal fatigue in any situation where a component is subjected to cyclic loads. Fatigue failures of various types are a key concern in increasing the reliability of products. Problems involving fatigue have become more severe with the demand for lighter weight structures and components. The effective use of fatigue analysis and predictive tools is critical for reducing the development time of new products. Two methods of metal fatigue analysis will be covered. The first is the stress-life approach. This method is used for high cycle or very long life fatigue problems where loads have fairly constant amplitude. Applications of this method include engine components, gears and shafts. The second method is the strain life approach, which is used for cases involving low cycle fatigue where loads may have a variable amplitude. Applications of this method include suspension and chassis components. The strain-life approach is also more useful when dealing with non-ferrous alloys. Other key topics to be addressed include residual stress, shot peening, cycle counting methods and environmental effects. Extensive use of example problems and case studies will be used. The overall objective of the course is for participants to gain an understanding of the phenomenon of metal fatigue and most importantly learn what methods are available to predict and prevent failures.
Learning Objectives
By attending this seminar, you will be able to:
  • Differentiate various fatigue analysis methods
  • Identify factors which can adversely affect fatigue behavior
  • Apply processes which can be used to improve fatigue behavior
  • Describe methods for analyzing fatigue at notches
  • Indicate the steps necessary to determine the life of components subjected to variable amplitude loading
Who Should Attend
This course is intended for design, analysis or test engineers who deal with fatigue problems.
Prerequisites
The participant needs little if any exposure to metal fatigue analysis methods. The participant should have had the standard undergraduate courses in stress analysis and material science.
Seminar Content
DAY ONE
  • Overview of Metal Fatigue and Analysis Methods
  • The Stress-Life Approach
    • The S-N diagram and endurance limit
  • Modifying Factors
    • Size and shape
    • Surface finish and treatments
    • Types of loading
  • Mean Stress Effects
  • Residual Stress and Shot Peening
  • Example Problems
DAY TWO
  • The Strain-Life Method
    • Limitations on the stress-life method
    • Cyclic stress-strain behavior
    • The strain-life diagram and parameters
  • Mean Stress Effects
  • Variable Amplitude Loading
  • Damage Summing Methods
    • The Miner-Palmgren Rule
    • Non-linear methods
  • Example Problems
DAY THREE
  • Cycle Counting Methods
  • Analysis of Notches
    • Stress-life method
    • Strain-life method
  • Example Methods
  • Environmental Effects
Instructor(s): Jess J. Comer
Dr. Jess J. Comer has significant teaching experience in the areas of machine design, dynamics of machines, metal fatigue and failure analysis. He is co-author of the text "Fundamentals of Metal Fatigue Analysis" and is a registered Professional Engineer in South Dakota. Dr. Comer is a member of SAE, ASME and ASEE. He holds a B.S. and an M.S. in mechanical engineering from South Dakota School of Mines and a Ph.D. from the University of Illinois at Urbana-Champaign.
Testimonial
"Excellent Class! The way stress-life and strain-life fatigue are presented allows the student to walk away from the class prepared to do fatigue calculations."
Brian Budzynski
Engineer
Caterpillar, Inc.

"Very good coverage of material from authoritative instructor. Course notes will now become my primary reference for all future problems that I encounter on this topic."
Eugene F. Renzi
Senior Design Analysis Engineer
Metaldyne Corporation

"Excellent course for those involved in accelerated testing."
Glenn E. Steed, Jr.
Senior Product Engineer
Hendrickson International
Fees: $1725 SAE Members*: $1385 - $1555
* The appropriate SAE Member discount will be applied through the Registration process.  Discounts vary according to level of membership: Elite Member 20%; Premium Member 15%; Classic Member 10%
CEU 2