Fatigue limit prediction of notched components using short crack growth theory and an asymptotic interpolation method

Mechanical components have stress risers, such as notchs, corners, welding toes and holes. These geometries cause stress concentrations in the component and reduce the fatigue strength and life of the structure. Fatigue crack usually initiates at and propagates from these locations. Traditional fatigue analysis of notched specimens is done using an empirical formula and a fitted fatigue notch factor, which is experimentally expensive and lacks physical meaning. A general methodology for fatigue limit prediction of notched specimens is proposed in this paper. First, an asymptotic interpolation method is proposed to estimate the stress intensity factor (SIF) for cracks at the notch root. Both edge notched and center notched components with finite dimension correction are included into the proposed method. The small crack correction is included in the proposed asymptotic solution using El Haddad’s fictitious crack length. Fatigue limit of the notched specimen is estimated using the proposed stress intensity factor solution when the realistic crack length is approaching zero. A wide range of experimental data are collected and used to validate the proposed methodology. The relationship between the proposed methodology and the traditionally used fatigue notch factor approach is discussed.