Fatigue Design

JFE Steel Corporation Lecture on October 2018
Fatigue Design Practice
October 2018
JFE Steel Corporation

Steel Research Laboratory
Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 1
Introduction of Lecturer
Jumpei Yasunaga (安永隼平)’s Profile
List
April 2007 –
B. Sc. Eng. Dept. of Architecture and Building Science, Tohoku Univ.
March 2011
April 2011 –
M. Eng. Dept. of Architecture and Building Science, Tohoku Univ.
March 2013
April 2013 – JFE Steel corp., Steel research laboratory,
Present Civil engineering research Dept.
April 2015 –
D. Eng. Dept. of Architecture and Building Science, Tohoku Univ.
March 2018
Major : Steel Structure

1. Plastic buckling
2. Fatigue analysis
3. Wind engineering
Maasvlakte Oil → “Wind induced buckling
Terminal, Rotterdam of cylindrical tanks”
Copyright © 2018 JFE Steel Corporation. All Rights Reserved. ※1： http://www.jfe-steel.co.jp/ 2
Today’s Program
1 Introduction of Fatigue and Etc.
2 Example of Fatigue Problem
3 Theory and Design of Fatigue
4 Exercise of Fatigue Problems
Steel Structure －Outline－
Akashi Bridge(Hyogo, Japan) Metropolitan Highway(Tokyo, Japan)
Noibai New International Airport

Merits (Hanoi, Vietnam)
1 Light Weight
2 High Strength
3 Reliable Material Sky Tree
4 Easy to Processing (Tokyo, Japan)
※http://www.600496.com/en/109.aspx?ID=644 ※https://ja.wikipedia.org/wiki
Steel Structures are Marvelous!

Steel Structure －How to make?－
Continuous Caster
Rolling
Iron ore
Torpedo Car
Coke Converter
Lime Blast Furnace
Steel Making ※1
Mill Sheet
Assembling Welding Robots NC Machine

Completion (Bridge)
Fabricating ※2
Steel Structures are Reliable !
※1：JFE Steel URL：http://www.jfe-steel.co.jp/museum/jfe_iron/making.html
Copyright © 2018 JFE Steel Corporation. All Rights Reserved. ※2：JFE Engineering URL:http://www.jfe-eng.co.jp/support/support_04.html 5
Steel Structure － Week Points －

3 Big Weak Points of Steel Structures
1 Fatigue
2 Corrosion
3 Buckling
Steel Structures Engineer should know!

Example of Fatigue Problem
(In case of Aluminum)
Do you know this airplane?
Entebbe Airport, Uganda in 1952

Doesn’t it look cool?
https://en.wikipedia.org/wiki/De_Havilland_Comet
Answer : Comet Airplane
At the lecture
BOAC Comet 1 G-ALYX (Yoke X-Ray) at London

Heathrow Airport in 1953 prior to a scheduled flight
Comet was the world's first passenger jet airliner

(designed and built in Britain)
http://en.wikipedia.org/wiki/De_Havilland_Comet
What happen?
At the lecture
3 catastrophic crashes happened in March 1953

https://www.youtube.com/watch?v=_BZnn5OYcBc
Documentary Video

https://www.youtube.com/watch?v=_BZnn5OYcBc
What does this accident instruct us ?
Comet’s body was Aluminum but may happen

the similar accident in steel structure・・・
There is a possibility of causing a Big Accident

by Fatigue Problem!
We should detect Weak Points!
Engineer should know

basic fatigue theory & Design
Let’s Study Fatigue Phenomenon!
(1) S-N Curve

What are the important factors of fatigue?
Stress Range
Joint type
Stress Concentration
Welding (Residual Stress)
At the lecture
Cyclic Number of Stress
Using term
Vibration
Fatigue Strength of Joint
Joint of Joint of
Stiffener Crossbeam
Gusset Plate Δσ
12 150
500
30
213 75 213
Joint of
Bracing Gusset
Sole Plate
Design Specimen Experiment
Fatigue Weak Points of Steel Bridge※ (Simplified)
Investigate by Experiment
※：www.st.nagasaki-u.ac.jp/ken/matsuda/lecture/.../4_evaluation-2.pdf
Experimental data plotting
800
700 Various
Stress
600 Range
Range of Stress（MPa）
500
400 Fatigue Experimental Data

300
For a certain joint
200
100 Run Out (No crack)

0
0.00E+00 2.00E+07 4.00E+07 6.00E+07 8.00E+07 1.00E+08 1.20E+08
Ｎ（Number）
Too sensitive to stress! → Change the axis

Logarithm Axis
(log)
10000
1000
100
10
1
(log)
1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08 1.0E+09
Ｎ（Number）
Seem to be Relevant・・・
Plots with S-N curve
(log)
10000
1000
100 This joint’s S-N Curve!
10
(log)
1
1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08 1.0E+09
Ｎ（Number）
We could decide S-N Curve for joint !

Summary of S-N Curve Text：Fig. 2-1
(log) In case of steel m≒3

10000
m
S-N Curve（50%）  3 N  C
1000 1
Experimental Data
100
Fatigue Limit
S-N Curve（95%）
10
1
(log)
1.0E+02 1.0E+04 1.0E+06 1.0E+08 1.0E+10
Ｎ（Number）
S-N Curve Represent Joint fatigue Strength

(2) Cumulative Damage
Evaluate Fatigue Damage

×1.2 mil.
×1.2 mil.
150 MPa
100MPa
Which specimen is damage more ?
Very easy to estimate

How to evaluate fatigue ?
×1.2 mil.
×1.0 mil.
×4.0 mil.
×4.0 mil.
150 MPa
100 70 60MPa
?
Which specimen is damage more ?
Need to Get Rule to Estimate Composite Problem

Cumulative Damage Text：Fig. 2-2
(log)
n1
Δσ1 n2
Δσ2
n3
Δσ3
(log)
N1 N2 N3
Ｎ（Number）
Damage Index Limit State
Miner’s Rule ni ni
D D 1
Ni Ni
Damage can be calculated by Miner’s Rule

×1.2 mil.
×1.0 mil.
JSSC：C Rank Curve ×4.0 mil.
×4.0 mil.
2.0×106：58MPa 150 MPa ＞ 100
Constant=2.0×106×583 70 60MPa
1000
 3N  C
1503×N=2.0×106×583 D1=1.2/1.2≒1.0 ＞ D2=1.0/3.9+4.0/11+4.0/18
⇒ N=1.2×106
1.2 mil.
≒ 0.8 n
150MPa D i
Stress range Δσ (MPa)
1.2 mil.
1.0 mil.
Ni
100MPa 3.9 mil.
100 11 mil.
70MPa 4.0 mil.
18 mil.
60MPa 4.0 mil.
10
1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08 1.0E+09
N (cycles)

×1.2 mil.
×1.0 mil.
×4.0 mil.
×4.0 mil.
150 MPa
100 70 60MPa
Left Stress Experience is Damage More !
So We can do Fatigue Design by S-N curve!

(3) Crack Growth Theory
Why is crack growing?

σ
σy
Stress intensity factor
KI
y 
σY 2 r
Crack r
Plastic Area
Crack Tip
Crack tip’s Stress Concentration

Crack Propagation Theory Text：Fig. 2-3
Crack Tip
a
Δσ Δσ
Crack a
Crack Tip
K   　
aF
Range of Stress Coefficient for correction
intensity facto of Shape etc.
Crack Propagation Theory Text：Fig. 2-4
× Fracture
Limitation of Crack Initiation
Log ∆
da/dN
high
Propagation
Velocity
low
Ⅰ Ⅱ Ⅲ
ΔKth Log ΔK Stress

Concentration
da
 C K 
m
Paris’ Law
dN
Let’s Study Fatigue Design!
Concept of Fatigue Design
S-N Curve
Joint Rank/Category

Regulation of Design for steel structure
(1) JSSC
Japanese Society of Steel Construction
(2)AASHTO
American Association of State Highway and
Transportation Officials
(3)Eurocodes
European standards
Text：Fig. 3-1
Design S-N curve JSSC (Japan) Table3-2
10000 Strong
Rank Limit stress (MPa)
Δσf (MPa) Constant Varying

A 3 at N0=2×106 Δσce (MPa) Δσve (MPa)
1000 CB
1
ED A 190 190 88
GF
H B 155 155 72
I C 125 115 53
100
Week D 100 84 39
E 80 62 29
F 65 46 21
10 Constant G 50 32 15
Varying
H 40 23 11
I 32 16 7
1
1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08 1.0E+09
N (cycles)
JSSC : 9 ranks of S-N curves are provided

Rank of Joint (JSSC)
D-E
E
Partial Welding
D-E
Full
Penetration
F-G Welding
E-F
H
Edited by JSSC： Fatigue Design Recommendations for Steel Structures and its Commentary
– attached design example－，Gihodo-Syuppan，2012
Simple Joint Type

Text：Fig. 3-2
Design S-N curve AASHTO (USA) Table3-2
100
Strong
Categ Constant Threshold

A
ory A times3108 (ΔF)TH (ksi)
B (ksi)
B' A
C&C A 250 24
Stress range Δσ (KSI)
' D B
E
B 120 16
B'&C'
10 C B’ 61 12
Week E'
D
C 44 10
C’ 44 12
E
D 22 7
E' E 11 4.5
E’ 3.9 2.6
1
1.0E+05 1.0E+06 1.0E+07 1.0E+08
N (cycles)
AASHTO : 8 ranks of S-N curves are provided

Category (Rank) of Joint (AASHTO)
AASHTO： LRFD BRIDGE DESIGN SPECIFICATION, Seventh Edition, 2014
More Practical Joint Type

What are different between JSSC and AASHTO?

JSSC AASHTO
Rank Limit stress (MPa) Rank Limit stress (MPa)
Δσf (MPa) Constant Varying Δσf (MPa) Constant Varying

at N0=2×106 Δσce (MPa) Δσve (MPa) at N0=2×106 Δσce (MPa) Δσve (MPa)
A 190 190 88 A 160 165 -
B 155 155 72 B 125 110 -
C 125 115 53 B’ 100 83 -
D 100 84 39 C 90 69 -
E 80 62 29 C’ 90 83 -
F 65 46 21 D 71 48 -
G 50 32 15 E 56 31 -
H 40 23 11 E’ 40 18 -
I 32 16 7
Unit & Joint Type are different !

But, They are Similar.
Let’s Exercise!
Exercise 1
Table. 3-3
JSSC ：Rank E
AASHTO：Category C Parameters Value
Δσ 180 N/mm2
(≒26.1 ksi)
n 2
p 1
ADTT 4
Fig. 3-5
Perform fatigue design for the joint shown in Fig. 3-5 by both the JSSC and
ASSHTO methods. As shown in Table 3-3 acting ntraf times （Eq. （3-5））, the
load condition is stress of Δσ = 180 N/mm2 ( ≒ 26.1 ksi) acting ntraf times
ntraf  (365)(75)n( ADTT ) SL Eq. （3-5）
Tips! : You need two step to design.
At first check the limit stress, second check the calculate ntraf
1 N/mm2 = 0.145038 ksi
Design S-N curve JSSC & AASHTO
10000
3
JSSC Δσf (MPa)
at
Constant Varying
E
N0=2×106 Δσce (MPa) Δσve (MPa)
1000 1
A 190 190 88
B 155 155 72
100
C 125 115 53
D 100 84 39
10 E 80 62 29
F 65 46 21
G 50 32 15
1
1.0E+02 1.0E+04 1.0E+06 1.0E+08 H 40 23 11
N (cycles) I 32 16 7
100 Categ Constant Threshold

ory A times 108 (ΔF)TH (ksi)
AASHTO A
(ksi)3
250 24
C
B 120 16
10 B’ 61 12
C 44 10
C’ 44 12
D 22 7
E 11 4.5
1 E’ 3.9 2.6
1.0E+05 1.0E+06 1.0E+07 1.0E+08
N (cycles) All Rights Reserved.
Copyright © 2018 JFE Steel Corporation. 41
Exercise 2
Table. 3-4
Paramet Load 1 Load 2 Load 3
ers
Δσ 150 N/mm2 40 N/mm2 90 N/mm2
(=21.8 ksi) (=5.8 ksi) (=13.1 ksi)
n 2 2 2
JSSC ：Rank E p 1 1 1
AASHTO：Category C ADTT 4 5 10
Fig. 3-5
As in Example 1, perform fatigue design for the joints shown in Fig. 3-5 by
the JSSC and ASSHTO methods. The load conditions are the three types of
loads shown in Table 3-4 acting ntraf times （Eq. （3-5））. Calculate the
cumulative fatigue damage according to the Miner rule.
ntraf  (365)(75)n( ADTT ) SL Eq. （3-5）

Design S-N curve JSSC & AASHTO
10000
3
JSSC Δσf (MPa)
at
Constant Varying
E
N0=2×106 Δσce (MPa) Δσve (MPa)
1000 1
A 190 190 88
B 155 155 72
100 C 125 115 53

D 100 84 39
10 E 80 62 29
F 65 46 21
G 50 32 15
1
1.0E+02 1.0E+04 1.0E+06 1.0E+08
H 40 23 11
N (cycles) I 32 16 7
100 Categ Constant Threshold

ory A times 108 (ΔF)TH (ksi)
AASHTO A
(ksi)3
250 24
C
B 120 16
10 B’ 61 12
C 44 10
C’ 44 12
D 22 7
E 11 4.5
1 E’ 3.9 2.6
1.0E+05 1.0E+06 1.0E+07 1.0E+08
N (cycles) All Rights Reserved.
Copyright © 2018 JFE Steel Corporation. 43
Thank you!

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JFE Steel Corporation Lecture on October 2018

Fatigue Design Practice

JFE Steel Corporation

Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 1

Major : Steel Structure

1 Introduction of Fatigue and Etc.

2 Example of Fatigue Problem

3 Theory and Design of Fatigue

4 Exercise of Fatigue Problems

Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 3

Steel Structure －Outline－

Akashi Bridge(Hyogo, Japan) Metropolitan Highway(Tokyo, Japan)

Noibai New International Airport

Steel Structures are Marvelous!

Assembling Welding Robots NC Machine

Steel Structure － Week Points －

Steel Structures Engineer should know!

Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 7

Do you know this airplane?

Entebbe Airport, Uganda in 1952

BOAC Comet 1 G-ALYX (Yoke X-Ray) at London

Comet was the world's first passenger jet airliner

3 catastrophic crashes happened in March 1953

Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 11

What does this accident instruct us ?

Comet’s body was Aluminum but may happen

There is a possibility of causing a Big Accident

We should detect Weak Points!

Engineer should know

Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 13

(1) S-N Curve

Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 14

Cyclic Number of Stress

Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 15

Fatigue Strength of Joint

400 Fatigue Experimental Data

100 Run Out (No crack)

Too sensitive to stress! → Change the axis

100 This joint’s S-N Curve!

We could decide S-N Curve for joint !

Summary of S-N Curve Text：Fig. 2-1

(log) In case of steel m≒3

S-N Curve Represent Joint fatigue Strength

Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 21

Evaluate Fatigue Damage

Which specimen is damage more ?

Very easy to estimate

Need to Get Rule to Estimate Composite Problem

Cumulative Damage Text：Fig. 2-2

Damage can be calculated by Miner’s Rule

How to evaluate fatigue ?

Left Stress Experience is Damage More !

So We can do Fatigue Design by S-N curve!

Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 27

Why is crack growing?

Crack tip’s Stress Concentration

Crack Propagation Theory Text：Fig. 2-4

ΔKth Log ΔK Stress

Copyright © 2018 JFE Steel Corporation. All Rights Reserved. 31