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Thin walled structures are among the main parts for several industrial machines. They usually expose variant stresses; therefore fatigue is their major failure mechanism. However experimental observations of the cross section of failed parts indicate that their fatigue fracture differs from what generally expected as high-cycle fatigue behavior. The mathematical estimations demonstrate that stress concentration due to surface roughness plays greater role compare to other surface metallurgical factors which may be predominant factor in the case of fatigue crack generation for thick walled structures. Generating several experimental data, an attempt is made in this study, to investigate fatigue failure of these particular parts. In addition the practical equation available in machine component design books is modified to implement the effect of manufacturing parameters properly. Application of developed equation makes it possible for designers to communicate with manufactures in a better way by proposing expected surface quality. The manufacturers are supposed to choose suitable fabricating parameters (particularly machining parameters) to achieve required quality. In addition this criterion may be inspected easily by quality control managers even via visual inspection.

Keywords: Surface roughness, Fatigue endurance, Thin walled structure, Machined part

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