Wellen und Achsen im Bereich der Antriebstechnik erfahren in den überwiegenden Anwendungen zyklische Beanspruchungen. Folglich ist für die Festigkeitsberechnung im Nennspannungskonzept eine möglichst exakte Kenntnis der Bauteilwöhlerlinie von zentraler Bedeutung. Halbzeug-Größe, Spannungsformzahl und die statischen Maximallasten beeinflussen neben weiteren Faktoren die Charakteristik der Wöhlerlinie bzw. die Dauerfestigkeit. Im Zusammenhang mit der Weiterentwicklung der Norm DIN 743 gilt diesen Größen der Fokus. Die vorliegende Arbeit betrachtet die Abschätzung der Zug-Druck-Wechselfestigkeit basierend auf dem technologischen Größeneinflussfaktor sowie der Makrohärte und deren Übertragbarkeit auf große Bauteildimensionen. In dem Zusammenhang wird der technologische Größeneinflussfaktor für Durchmesser bis 700 mm anhand einer numerisch-analytischen Simulation ermittelt und zudem mit Härtemessungen validiert. Ferner wird auf Grundlage von Treppenstufenversuchen die Abschätzung der Zug-Druck-Wechselfestigkeit aus der Härte für große Halbzeugdimensionen betrachtet. Neben dem technologischen Größeneinflussfaktor abhängig von der Härtbarkeit liegen als Ergebnisse Zusammenhänge zur Abschätzung der Zug-Druck-Wechselfestigkeit aus der Härte für große Halbzeuge vor. Darüber hinaus wird mit experimentellen Untersuchungen die Wöhlerlinie im Zeitfestigkeitsbereich analysiert. Basierend darauf werden der Wöhlerexponent sowie die Knick-Schwingspielzahl zur Dauerdauerfestigkeit in Abhängigkeit von der Formzahl abgeleitet. Abschließend widmet sich die Arbeit den Auswirkungen von statischen Maximallasten auf die Dauerfestigkeit. Dazu werden die lokalen elastisch-plastischen Beanspruchungen infolge von Maximallasten mit dem Örtlichen Konzept erfasst und in Treppenstufenversuchen die Dauerfestigkeit mit zusätzlicher Maximallast betrachtet. Ausgehend davon wird ein Konzept zur Abschätzung der lokalen Beanspruchungen sowie der lokalen Dauerfestigkeit bei Berücksichtigung des Einflusses der Maximallasten vorgestellt. / Shafts and axles of drive systems are stressed by cyclic loads in most applications. Therefore, an accurate calculation of the S-N-curve is fundamental for the system’s strength assessment based on nominal stresses. Component size, the stress concentration factor, and static loads influence the behavior of the S-N-curve and the fatigue strength, among others. In the context of a further development of the standard DIN 743, the scope is these values. This thesis focuses on the estimation of the fatigue strength for tension/compression based on the technological size factor as well as the macro hardness and their transferability to larger component sizes. In this context the technological size factor is determined by a numeric-analytical simulation for diameters up to 700 mm and is also validated with hardness measurements. Furthermore, the estimation of the fatigue strength for larger component sizes based on the hardness is supported by fatigue tests. In addition to the technological size factor depending on the hardenability, the results are obtained by an estimation approach for large components between the fatigue strength for tension/compression and the hardness. In the next step, the S-N-curve is analyzed with experimental investigations for the finite life area. Based on this, the slope of the S-N-curve (“Woehler slope”) and the knee point for the endurance limit depending on the stress concentration factor are determined. Finally, the thesis deals with the impact of static loads on fatigue strength. For this purpose, the local elastic-plastic stress-strain behavior due to static loads is calculated with the strain life assessment (local concept) and the fatigue strength influenced by static loads is analyzed as well. Based on this, an approach for the estimation of local stress-strain behavior and for the fatigue strength considering the static loads are proposed.

[pt] O presente trabalho se baseia na teoria dos defeitos equivalentes, também conhecida como teoria de Murakami, que permite a predição da vida-fadiga de materiais estruturais adotando o parâmetro (raiz quadrada de area), responsável por uma equivalência quantitativa entre heterogeneidades microestruturais (inclusões metalúrgicas) existentes na região de análise do material e descontinuidades mecânicas (furos) usinados nos corpos de prova. Neste contexto, a tese propõe novas equações, a partir da teoria de Murakami, para prever falhas por fadiga em carregamentos ultralongos (fadiga de altíssimo ciclo, VHCF) do aço DIN42CrMo4, de larga aplicação na fabricação de eixos virabrequins para unidades geradoras de usinas termoelétricas. Corpos de prova do aço DIN42CrMo4 foram usinados com furos de diâmetros variando entre 0,18 mm e 0,70 mm e ensaiados num regime de fadiga de altíssimo ciclo, variando o valor da amplitude de tensão do ensaio, para assim determinar em quais condições o material falha e obter a curva experimental S-N do aço DIN42CrMo4 na presença de diferentes tamanhos de defeitos (furos). Os resultados experimentais permitiram o desenvolvimento de equações em função do parâmetro e curvas de Wohler do material, em conformidade com diferentes descontinuidades mecânicas nos corpos de prova e resistências à fadiga do material. Consequentemente, se estabeleceu uma metodologia que permite uma correlação entre inclusões metalúrgicas, tensão aplicada e vida superlonga em fadiga de eixos virabrequins em serviço em usinas termoelétricas. / [en] The present work is based on the theory of equivalent defects, also known as Murakami s theory, which allows the prediction of the fatigue life of structural materials by adopting the parameter (square root of area), responsible for a quantitative equivalence between microstructural heterogeneities (metallurgical inclusions) existing in the region analysis of the material and mechanical discontinuities (holes) machined in the specimens. In this context, the thesis proposes new equations, based on Murakami s theory, to predict fatigue failures in ultralong loads (very high cycle fatigue, VHCF) of DIN42CrMo4 steel, widely used in the manufacture of crankshafts for generating units of thermoelectric power plants. DIN42CrMo4 steel specimens were machined with holes with diameters varying between 018 mm and 0.70 mm and tested in a very high cycle fatigue regime, varying the value of the test stress amplitude, to determine under what conditions the material failure and obtain the experimental S-N curve of DIN42CrMo4 steel in the presence of different sizes of defects (holes). The experimental results allowed the development of equations as a function of the parameter and Wohler curves of the material, in accordance with different mechanical discontinuities in the test specimens and resistance to fatigue of the material. Consequently, a methodology was established that allows a correlation between metallurgical inclusions, applied stress and super-long fatigue life of crankshafts in service in thermoelectric power plants.