A generalized procedure was developed to predict fatigue failure in the design of induction hardened pins. Finite element analysis was used to determine the elastic and inelastic strain response at subsurface locations. The finite element mesh was arranged in a layered fashion in which each layer had a unique cyclic stress-strain curve. The procedure incorporated the effects of residual stresses due to induction hardening and used the strain-life approach to determine fatigue life and damage. The areas of predicted failure agreed with those observed in the field.

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