HOME  |  NEWS  |  BLOGS  |  MESSAGES  |  FEATURES  |  VIDEOS  |  WEBINARS  |  INDUSTRIES  |  FOCUS ON FUNDAMENTALS
  |  REGISTER  |  LOGIN  |  HELP
Blogs
Guest Blogs

Understanding Overload Failures

NO RATINGS
View Comments: Newest First|Oldest First|Threaded View
<<  <  Page 2/2
Shelly
User Rank
Iron
Vibration big cause of fatigue/crack propagation
Shelly   3/26/2012 10:21:54 AM
NO RATINGS
As mentioned earlier, repeated stresses/cycles on an assembly are a major contributor to fatigue and crack propagation.  The biggest contributor to repeated cycles is vibration.  Sometimes it's difficult to observe, but even high frequency vibration (though very small displacements) can be a fatigue factor due to their high cycle rate.

Vibration can be an issue when attaching a component to a moving machine (frequency depends on the machine dynamics), when designed to handle siesmic vibrations near fault lines (relatively low frequency <10Hz), or just designing to handle transportation to the end user (between 2-500Hz).  The frequency and amplitudes vary, but the main goal is to design components with resonant frequencies well above what the sample will see while in use or transport, and when designing machinery, to avoid stacking resonant frequencies so the components aren't exciting each other's resonant frequencies while in use.

Dave Palmer
User Rank
Platinum
Re: Migrating stress cracks versus quick breaks
Dave Palmer   3/26/2012 7:07:21 AM
NO RATINGS
@Mydesign: You're right that loads redistribute to a certain extent as a result of localized yielding, so that a linear FEA which predicts a stress greater than the yield strength in a small region doesn't necessarily indicate failure of the component. This is why designing to "get the red out" of a FEA model, without any insight into the physical situation, can result in overdesign. On the other hand, stresses below the yield strength can lead to fatigue failure if they are repeatedly applied. To get a handle on fatigue, it's important to know how the loads on a part vary over time. This is what I will discuss in the next installment.

Mydesign
User Rank
Platinum
Re: Migrating stress cracks versus quick breaks
Mydesign   3/26/2012 6:05:08 AM
NO RATINGS
1 saves
Dave, I think the weight is eventually distributed across the area, and then it can bear more weight than concentrate to particular points. I think in most of the industrial wing, the stress tests are doing for a mass areas rather than stress test in cubic/cm sqd.

Dave Palmer
User Rank
Platinum
Re: Migrating stress cracks versus quick breaks
Dave Palmer   3/23/2012 7:30:08 PM
NO RATINGS
@Chuck: Other engineers should feel free to weigh in on this, but in my experience, it's most common to design to the yield strength, with an appropriate factor of safety. Doing this should protect you against overload failures, provided that (as I pointed out in the article) the loads are what you think they are, and the yield strength is what you think it is.

Charles Murray
User Rank
Blogger
Re: Migrating stress cracks versus quick breaks
Charles Murray   3/23/2012 6:37:37 PM
NO RATINGS
Dave: In the kinds of parts that are mentioned here, such as the brake cam, are the parts typically designed in accordance with the yield strength of the material, or is there some "allowable stress" design method that's set forth that is not dependent on yield? If yield is not used as criteria, does it make any difference in terms of failure rates?

Dave Palmer
User Rank
Platinum
Re: Migrating stress cracks versus quick breaks
Dave Palmer   3/23/2012 10:07:35 AM
NO RATINGS
@Alex: Usually, a crack which grows over time is due to fatigue, which I'll cover in my next installment. (In plastic parts, cracks which grow over time could also be due to environmental stress cracking, which I've written about before. In metals, there is a phenomenon called stress corrosion cracking, which is analagous to environmental stress cracking; I might write about this later).

Based on what I've seen in my career, fatigue failures are actually far more common than overload failures.  However, overload failures are the easiest to understand, which is why I wanted to cover them first.

The mechanics of fatigue are a little more complicated.  As I'll discuss, a common mistake is to treat "fatigue strength" as though it's a property like yield strength or ultimate tensile strength.  It's not.  But the big picture is the same: you need to understand the forces that act on the part, and the properties of the material from which it is made -- as well as all of the variables which might cause either one to vary from its normal value.

Alexander Wolfe
User Rank
Blogger
Migrating stress cracks versus quick breaks
Alexander Wolfe   3/23/2012 9:08:17 AM
NO RATINGS
Could you do an explanation in a future post of the differences between a part (say, a bracket on a car) failing due to a migrating stress fracture versus a total, quick failure where it just breaks in two? Is that the same stress dynamic in play with different outcomes, or are they different processes entirely?

<<  <  Page 2/2
Partner Zone
More Blogs from Guest Blogs
Load dump occurs when a discharged battery is disconnected while the alternator is generating current and other loads remain on the alternator circuit. If left alone, the electrical spikes and transients will be transmitted along the power line, leading to malfunctions in individual electronics/sensors or permanent damage to the vehicle’s electronic system. Bottom line: An uncontrolled load dump threatens the overall safety and reliability of the vehicle.
While risk management sounds like one activity, in order to be conducted effectively, it must be broken down into three sub-components: risk assessment, risk monitoring, and response planning.
While many larger companies are still reluctant to rely on wireless networks to transmit important information in industrial settings, there is an increasing acceptance rate of the newer, more robust wireless options that are now available.
To those who have not stepped into additive manufacturing, get involved as soon as possible. This is for the benefit of your company. When the new innovations come out, you want to be ready to take advantage of them immediately, and that takes knowledge.
Design engineers will feel like kids in a candy store with the Cypress Semiconductor BLE Pioneer Kit. The development kit for low-power sensor-based systems is full of wireless wonder and exploration.
Design News Webinar Series
2/25/2015 11:00 a.m. California / 2:00 p.m. New York
12/11/2014 8:00 a.m. California / 11:00 a.m. New York
12/10/2014 8:00 a.m. California / 11:00 a.m. New York
3/31/2015 11:00 a.m. California / 2:00 p.m. New York
Quick Poll
The Continuing Education Center offers engineers an entirely new way to get the education they need to formulate next-generation solutions.
Mar 30 - Apr3, Getting Hands-On with Cypress’ PSoC
SEMESTERS: 1  |  2  |  3  |  4  |  5  |  67


Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies. You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived. So if you can't attend live, attend at your convenience.
Learn More   |   Login   |   Archived Classes
Twitter Feed
Design News Twitter Feed
Like Us on Facebook

Sponsored Content

Technology Marketplace

Copyright © 2015 UBM Canon, A UBM company, All rights reserved. Privacy Policy | Terms of Service