An integrated procedure, combining finite element modeling and fatigue analysis
methods, is developed and applied to the fatigue optimization of a notched, induction
hardened, steel shaft subjected to combined bending and torsional loading. Finite
element analysis is used first to develop unit-load factors for generating stress-time
histories, and then, employing thermo-elastic techniques, to determine the residual
stresses resulting from induction hardening. These stress fields are combined using
elastic superposition, and incorporated in a fatigue analysis procedure to predict failure
location and lifetime. Through systematic variation of geometry, processing, and
loading parameters, performance surfaces are generated from which optimum case
depths for maximizing shaft fatigue performance are determined. General implications
of such procedures to the product development process are discussed.
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