Required fatigue strength (RFS) – a simple concept for determining an equivalent stress range indicating the necessary minimum joint quality in contrast to the actual modified equivalent strength (MES) method

Abstract

Abstract This paper treats different fatigue (FAT)-scenarios for determining damage-equivalent stress ranges according to two methods for transforming a stress or load spectrum into a damage-equivalent constant amplitude loading, i.e., the Modified Equivalent Stress (MES) and the Required Fatigue Strength (RFS) concepts. The MES method is suggested by the IIW-recommendations for fatigue design and the RFS method is applied especially in the design of vehicle safety components. The resulting MES- and RFS-ranges are similar, but not equal. The MES-method delivers a damage-equivalent stress range that depends on the selected FAT-value, i.e., the position of the Woehler-curve is decisive. In contrast, the RFS-method results in a damage-equivalent fictitious Woehler-line that indicates the lowest necessary strength quality for a given stress spectrum. The allocation of the modified equivalent stress range to the appertaining bi-linear Woehler-curve does not result in the fatigue life caused by the spectrum. Only in the case of a linear Woehler-curve, the fatigue life is directly obtained. In the case of the RFS-application, the fatigue life is by definition equal to the spectrum length. For durability tests, the modified equivalent stress range (at $${L}_{S}$$ L S cycles) and the associated FAT-Woehler-curve should not be used. However, the Woehler-curve derived by the RFS-method allows experimental durability proofs for any amplitude-cycle combination along it. Furthermore, the required lowest necessary strength also enables the selection of the most cost-effective manufacturing technique and quality. The RFS-Woehler-curve also results in a FAT-value with a defined probability of failure depending on the required safety factor.