Solutions Manual to Accompany Yel ee re nCe VC TUM Ee Limee lat Second Edition Ralph |. Stephens Ali Fatemi Robert R. Stephens Henry O. FuchsThis book is printed on acid-free paper. @ Copyright © 2001 by John Wiley & Sons, Ine. All rights reserved Published simultaneously in Canada, No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying. recording. scanning or otherwise, except as permitted under Sections 107 of 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 750-4744. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 605 Third Avenue, New Yark, NY 10158-0012, (212) 850-601 1, fax (212) 850-6008, E-Mail: PERMREQ @ WILEY.COM. This publication is designed to provide accurate and authoritative information in regard to the subject matter covered. It is sold with the understanding that the publisher is not engaged in rendering professional services. If professional advice or other expert assistance is required, the services of a competent professional person should be sought. This material may be reproduced for testing or instructional purposes by instructors using the text, Metal Fatigue in Engineering, Second Edition by Ralph L. Stephens, (ISBN: 0-471-5 1059-9), Library of Congress Cataloging-in-Publication Data: ISBN: 0-471-03194-1 Printed in the United States of America, 987654321‘CONTENTS, Chapter 1. Introduction and Historical Overview 2. — Fatigue Design Methods 3. Macro/Micro Aspects of Fatigue of Metals 4 Fatigue Tests and the Stress-Life (S-N) Ay 5. Cyclic Deformation and the Strain-Life (e-N) Approach 6. Fundamentals of LEFM and Applications to Fatigue Crack Growth 7. — Notches and Their Effects 8. Residual Stresses and Their Effects on Fatigue ‘istance 9. Fatigue From Variable Amplitude Loading 10, Multiaxial Stresses Il. Environmental Effects 12. Fatigue of Weldments 13. Statistical Aspects of Fatigue EE & Frere %Problem 1.1 —failure modes (a) Helical gear/shaft set Fatigue of the gear teeth at the root of the gear tecth. Failure by excess wear of the tecth face. Static ductile or brittle fracture of the gear teeth due to a high overload. Excess deformation of the gear teeth or the shaft causing greater noise, stress, and shorter life. Fatigue failure of the shaft due to combined bending and torsion of the shaft. Fretting fatigue between the gear and the shaft. Ifa pin holds the gear to the shaft, then the pin, gear, or shaft could fail in fatigue at this location. b) Ship propeller 1, Excess corrosion, 2. Cavitation fatigue of the blades. 3. Corrosion fatigue of the blades due to multiaxial loading and corrosion environment. 4. Excess deformation or fracture from hitting a foreign object. (c) Handlebar on 2: mountain bike 1. Excess deformation or fracture from an overload such as hitting a foreign object ‘or wiping out. 2. Fatigue failure at the gooseneck interface. Could be corrosion fatigue too, 3. Esthetic failure from corrosion. (d) Airplane landing gear 1. Excess deformation or fracture from a severe impact landing. 2. Fatigue of various parts duc to cyclic landing/taxi/takeoff. Could be corrosion fatigue too. 3, Wear or fretting at shaft /bearing/pin interfaces. (c) Automotive engine connecting rod 1. Fatigue failure at connections or geometrical changes. 2. Wear at the sleeve bearing region. (f)_Door key 1. Excess deformation or fracture due to overload during turning. 2. Fatigue failure due to repeated use. 3. Damage by excess deformation from external loads such as dropping the key. 4. Wear of the key due to repeated use. eyo - xsProblem 1.2- component examples and failure modes. (a) Simple and inexpensive 1. Barstool: leg buckling, fatigue, excess deformation from leaning back. 2. Car door handle: fatigue, excess deformation from overload. 3. Hammer; fatigue of the handle, wood handle rotting, chipping of the hammer metal head from pounding, wood handle chipped away from poor striking. (b) Complex and expensive 1. Automotive transmission: gear or shaft fatigue or wear failures, excess deformation or fracture from improper shifting causing damage from fatigue or hitting external objects. 2. Indy 500 race tire: excess wear, fatigue of the case, foreign object damage. 3. Giant coal mining bucket: corrosion fatigue of connections, excess deformation, wear of edges. Problem 1.3- failure mode examples (a) Brittle fracture- §.S. Schenectady T-2 tanker liberty ship fractured while in dock, (b) Ductile fracture- continuous rotation of a paper clip until fracture. (c) Excess deformation- crushing a beer or soda can. (a) Creep mpture- old locomotive steam engine boiler/pressure vessel. (c) Wear- automobile wheel bearing. (0) Stress corrosion eracking- Point Pleasant bridge in West Virginia, 1967. (g) Esthetic failure- corrosion of a steel chrome plated auto bumper or tire wheel. (h) Fatigue- automobile engine crank shaft from years of cyclic loading. Problem 1.4 — bicycle failure modes 1. Excess deformation or fracture of the handle bar, frame, or wheels during an impact accident. 2, Wear of the chain, chain sprocket, shifting mechanism, wheel bearings, and seat, 3. Fatigue failures of all welded connections, pedal shaft and bolted connections, shock absorber connections, 4. Esthetic failure due to paint chipping and subsequent corrosion. 5. Fretting fatigue at the handle bar/goose neck connection. 4-2Problem I.5- three synergistic failure modes 1. Corrosion and fatigue interaction. 2. High temperature creepy fatigue interact 3. Low temperature embrittlement and corrosion and fatigue Problem 1.6- four actual failures involved with. Depends upon the student experience and therefore no general answer. Problem 1.7- one page paper on cost of failure in the USA. Depends on the student, but could inelude the following ideas: Increase cost of failures due to more mechanical systems in use, more technical sophistication needed, high legal payments/costs in products liability litigation, more drug/alcohol use, inflation, higher effeciency desired, lower safety factors, others. ‘Decrease in cost of failures due to better emphasis on safety and products liability, better standards/eodes, OSHA, CPSC, FAA, NTSB ete., improved digital prototyping, ‘improved testing capabilities, improved instructions/wamings, federal government recalls and regulations, higher quality materials/manufacturing/inspection, others. Problem 1.8- write paper on one of the references Depends upon student and reference chosen and therefore no general answer . 1-5Problem 2.1- automobile safety critical parts, (a) Ea independent acting brakes at four wheels, leak before burst radiator, multiple wheel nuts, some body frames with multiple path loading, exhaust system, multiple spark plugs/fuel injectors, dual headlights, shock absorbers. (b) Safe-life: wheel bearings, axles/spindles both front and rear, steering system, some frames without multiple path loading, tires, wheels, and others. It would be difficult to make most safe-life parts fail-safe, since redundancy, multiple load paths, crack stoppers or inspection would have to be added. The cost could be pronibited in most cases. It may not be needed in many situations, but in some it is jesirable. Problem 2.2- damage-tolerant design in automotive field Because the added cost of redundancy, multiple load paths, crack stoppers and non- destructive inspection, and much less catastrophic in nature. There is much less NDI capability in the auto industry due to cost. Less control on maintenance/inspection. Problem 2.3 — fatigue design considerations for stretch versions. (a) commercial jet 1, ‘New load magnitudes and history within the inserted section and outside the inserted section will alter fatigue resistance of frame, skin, and mechanical systems. . New connections are needed that often are prime fatigue failures. . New hydraulics and fittings may be needed that could be fatigue failures. Landing gear systems, wings, fuselage will have different stresses and alteration of fatigue resistance. . Different inspection may be needed. . Different engines may be needed. Many others awn naw (b)limousine 1. sameas | to 3 above. Problem 2.4 —toading modes (a) Hip replacement prosthesis: axial, shear, combined bending/torsion. (b) Jet engine turbine blade: centrifugal force, flow pressure, vibration and hence axial, shear, combined bending/torsion, pressure. (©) Chair rear leg: axial, bending, torsion, shear. (d) Motorcycle front axle: combined bending/torsion, shear. {e) Alaska pipeline: intemal pressure, bending, shear, axial 2-1Caray Force al oaal axl wo larnding mewn, lara reine Problem 2.5- load spectra for prob.2.4, and how to determine. (2) Hip prosthesis denei wa lie t __ ©) et engine urine bade bad forint if \t . (©) Chair rear leg (4) Motorcycle front axle ol (©) Alaska pipeline AT Service load spectra would be obtained through various load, torque, displacement transducers or accelerometers placed on prototypes, previous models, of through computational dynamies programs such as DADS or ADAMS. The specific techniques would differ for each component. For example, the hip prosthesis spectrum could be obtained from special “walking” platforms that measure forces through scales or other transducers, Strain gages could be attached to turbine blades and the chair leg and. calibrated to forees. Rotary transducers could be used on the motorcycle axle while strain gages and pressure gages could be used on the pipeline. a-2Problem 4.1 Sy = Smet Sum _ yon -c00 + Swen = FOOMI, Zz = z 5 t = —100Mhe fe Sinai = ~ 600 PPG, See SmanSmin 2 yan tte) — 2 = soo Mt BS = Sng Sun = 7O-bee = soot Mla acom , met GEE AEB = HG 400 ceeldey @ ane it exter : q — = & 1 eqeledece * ee , = Ihe days 3. Wereyles = [eda ob cycler = Iibodys = 3.9y5 wWiler'e tert was Lo ayiot ayde \ r des =Qa7(o.= 4.3 yeert (b) 20 He ‘ (30 ealsec\CRC dre c/4m) 0.34 bys = FB hots fotcycles fetes 2.9 dys [8 egeles teks 34 © ise He 10% egcles (Fe cual teen eh) = a0Tldys = LGY heat fo legeles = bWMdys = L5G beat 1a® cpl) = Ziggy Comchovin: Fa tyy derby com ha 0 Geynemitls Bmcsel oF Hee oud essttat coma tor} frgrrad. @ zoete g lo ——>7 a (eo 1.34 howe (ee 1103) (60 «e/a Gente) SS = [a That wt noe Le? + 13g bowed & sdsPrololam 4.3 ae bicycle pedal she ft ~ (350 min [p10 y11) (1000 eyelet mike) = asune ~ sypet cyber ———==—, Anu velve Sprig (reeee mid(sea0 rom)( om fA) so mi/uy = peek 2% loleyiles pane lath} sw eh Go yens)( 360 der gow )( 4 ue dy) = Pw 2 Lotept oN euelet Gubmslile brike ped ( S458 tries Jtg)( 6 begs] weet) S8 werkslyae)( perry) = Vs aesd\ie LL 0 the Regd Tha shmt anrwas are peasant. OF coupat Much Scefler will otsp Lv Abdel: parte end hi lencsp eters,Prilolem 4.4 P — ie (—9)» . . 1 Xaeckeon Se my/r = (%) 2m (rsne) 1 © const) = de/ys Be fuser pe = Wt = Br BAW) SS tuhich «4 Sinuside}Problem 45 Adv] disedy.: The nectmpulre coarduule ty she condyse. the dal. Feo much ond does nt privide © cheer preture «F Pht SW hehwiir. The los- lo; pht dxbouls tte doba ond ols much Leber plerprets din of the dik. 2b giver mere eccunk shits 66 Se, Sng end No, Tien Phe log-log pal Se @ aos teatro Hea, sue] 230 mPe ——_ see = Seyele: Lo acouse % 1:2 veTexeles Scetler was most pikictle at Seuzer Ini). Tha chive velus were cstimbed by eye a3 reesenchte velun. wot enoush dite eresled A Justity mare corset metudahere,2 oy N 1g we 27 60 MPe aoa Se, By il, 1’ Se , 40 sl 2 See Se Su 3a qo 7 3 = 27H MPa, Fa + Se A, ~ (2008 8lnr)(.003-) ~ O.8z2y0ts = F22KN Prablen 4:10 Sez Sue * Swe Ces} 2 Smt 4 or ~ a Zz Sen = Sut t Suv 2 Swe - 35 dad Grads ~ * Sefse + Sm/s. 2 | = Smet? 4 Smwe5s 2 (220) 2(s") oS > 290 MAL Moy) eS Salsg + Suda = \ = Sma tT 5, i. 2 (22) 3 (cco) Srenp = 304 MPa ph ee Ditkreaee reds SY eos wv 52, Aik Rereer oO 29 thi dibipenee & Sault end Play 01 ay werd gia peesen ble peluer end cen be owned diber chatty eekly Wont, 4-3Prololon 4.1 Frew Tolle RL Sut F82 MP, 352 ByS mL 34] = [BEM Asot @ soy = (8) Sey ig, bebe oe ‘Qs pet @-s(ee)= (Cents be [03 4 E2Y APZ) Wi ge-ar - Sun fsue 2 Sma # 0-3 Smt 5 Seat fet Sendo 2 Sno Ce3e) . g.6dme OY AES = Sus Sentient Sees tlezted oy Say “Seu Use wed Gordnen Cov mem Shast Ax Sifs Sats Se s Se + Le ObSmy ot Sme 2 | Se Su tot et Smeg = S97 MPw Sms = G. 2S) Fn3z MP a Sa~ 60s)? ¢5Mhe . Aye Sus tlie)» Co mN nny 2151 & Sy 2 Bs oe ©) pepeed (4) Se oS ener. Ao 5 8 S& esac vee 2 Sue = ACM) = s oops See, As Su < 953 ia Sy B= teste)! we TM by Se feglsve) Sf yp¢ foe 2! ° fos (lee) 0.0737 Conn fase © wd santfygs 3.049 . Tap Tae TRE Sud] 2 482(109) Snob he be Sass 222 (267) = — S3YHE See -eCast) > (ee mh woe 1d = peTmPa.Palen 4-2 (OD Fechys aktechim Te mw Sme welds Sy Sie cad revfive Lek S¢ wile Su Fev omntt pilibed zpeeuias wot stag effect felw, Le + or hot Ler Ks = 03S Fran Fig Wer for aca Longed Maes 4 * (C2 \e Lor) x 12.3 ks1 We >. \ Af Se (Ws R20 2. See Sm uw et wet +t a Sue See ev Sx 5 Seg Sm. Sta See Se Se 12-3 . 160 1 bo Spe esi = Sm = ILE (108 exeles)} SS e . By iG) Sus tro ksi swe» A( Ae) # At Se Saf sevtvaei ge L fos 2b 23) BF Se é “wo t ale 5 Oust . Si Sue 327 wi Ot SE o tee Sug = 170 (10%) 2 ay rey ote 14d or fed safe + M/s 2 Fee BE ed Sue Spt IEE ay geo a (aster) chk prety — Syug = Sut Sua 2 Sy (ES 41082 In 2 IS Le yell in 27SPralolem 4.03 by remeniy ote Frugal we lime ar machin’ surface, Se *(E “Cr. VY(o.25) = 22 ksi sie Sel Fove Fro Fis LIS w zea 3 s \™~ WAN, ss. Ae nae t & Sey Se Sa lel se. = Se = 21 sy Sew * tee TP Set Se = O“cyde$) fe = ReSe (oreveed) B > 25 Se pe sexzen HF A(Ne) ArSe = Dles(ze)- be Y w Bee ate) cline ne = 70.097 Pa (at) on 48.9 ks0 408 . Swe = . q Sn a Be teydel see Se Sm ~ SF Ses, eases! (ute) Check yeettin — Soe ~ Smt Sao 2440 Fs SH A ISL Se Le Se By remaniy He a8 Frsed ser fine wits unchin'y, 5¢ wes mnester eee te 160% 03 cil Sag eel Su For Bod Sor WE eles PP D4 eyelet 5g 5a $ Sua pacreeed shin 6S 2. The werner me af ercotent. Bisset cert. at ange tired.Preblem 5: C= 2% cr Ger ve subls n € = Biitre)= Zi 4 ess 3.0148 Te SCire)= Spr+4e2)z or Di Ahevences between Engrneeriy aol ten Fhe sees ant Shar are, br OME 2 NG aot HA pre 2 fSatbers = hee S| ates =2% These smelt differences Can offen be Kegleedel Ly enginarty dessa purperers |S El e100 =bb) E= os. 257 65750 MPa or 68.95 GPa e 00040 7 Sys 293 MPe (see ge curve) Sy = B24 MPS (sen S-e curve) BAe pref (ey) €” THR Dm: an) Blt Dae) le Hsd/4. 2) A fir 4/433} = Sed yey MPa (4,193) (0.236) 4st ec (At A) -h (Be y's £(2)% a8! o e\h% y on *_ pe (6-3) (4, 1, ths b= AF proos De Pee as = Ce 5 CG) Cheers severe l poche spp kimatel equelly Speced Between Yretblig Gad netrmete tenn Shere on th tee Shere Shank Curie (Gerry bethen £ -& 10 Pemde ) at plot Epe €-Tfe vermr an a Wy. ley plet-The best At hae Gives a4) MPG and N= 2,067 + See gragh.oor on 1 Ey, eneProblem oy Values of n for He meaterels Mpted tn Tehle Aw vengey between Gost od aed while Velueo of in” rege betwees og o4g af 6334 L Reahas of h/n’ Vary Berne a3. ad Naa, trdtestys @ feton of G fend cerretehen between wtnd Varioter, Taiseferr a ne deer wad eyed.Nem 50S. Cyehe Seftery or hardenig can Camre a sight hrand cheye in defermeAter cerpense of th medeuht ar compared With menotenrt | hy Wgnerty elie setter er harden Can pein Cd iA SASK Kicead Unde rast £ creer heh of Share / strait in eye loadin.Preblen Sb The curver of AEp vr. 2N for eck of th meters wn FLY, $6 Ok Sheen im bath vectarsnier aad Semembs Plots: po mates 6 for whch Cyehi plaste steam ralvey with Cycles 1h A excl? hardening meteatl whereas A mater O wiih hereared eyehe plas shaw 1 a eyelet So tdeny melee Os Tarr Biyuerr Lew padeeade that mort clazseo ie cyte’ oh fermedin of the meter © occur early mm hte 0.011 0.008 your 0.005 0.003 0.001 1 10 100 1000 10000 oon 0.009. 0.005 0.003 0.001Preblem 5.4 Frem EP. SY Od Tru Az, . gor antl ¢ oss Max-Ten? 9.01 Ba Cay) + 286 (nt ) rerulliy Me = Pha Sycler lye ~ 9070 ~26 Rye-10e a8 Cn) + 266 (2m,) reevitty in Nps YER Syeley Fy, 5. th aventes ™% B face eeles ata Shans arphlar ef eel. Te resutds fer he Man Ten ad Rye-l0o Stele are withs a feeder of abert 2 fem thi estimates 5-1cz 1 3 ~ eet B8 = Blew) HAE Cn) . =ay¥il Ace, Ef (np )s 307 Gauge) «0103 veal a= BE Cong) My 209 Ge) 1 Po TEOHET c/c\ BH _ f 204 x rolece zn ( =) -( Tavs ) = 5SbF4 or Myatt, bs cylio 5 0104 = 143 (ssa) + ase (sr6ay) @~ Zereoe = Q00/6| + %00 6} = c00322 SaiPredlen sly ne Er, 6N + OB = kG Mery Sst Oe a” . eT. ie la = O, Cane) . 7 EF SG! Age. S On, yS FFem EP S18 | wen (deel vie a ‘ Piles Ce ) Ce) Sub rhs 2Np fom Ef, (a) inte ep Sis! Og= ae Ae, as Ne - ‘ Ce te) j (e ore (Aen) (4) Cempariy ex. (4) en En SM rele ie y 1, Se gd onl (6) Me alo - 43Predlen Ste @ ep, ¢,- SB az ~ Eigoee €a. Oa,Mp 4 EPA zie 9.02 iso Qaljto Yoo el oer aoin) joo aol sss O.00F4 Z200 0.466 yge 0.0030 F200 a.a03s 217 dol} $2000 00d 330 9.00057 [12 e000 Ti abhor Cp ond b) pleh Oh VS 2 Me i H [EEE saa wee ET 1.6600 E01 1.6002 1609 1.004 1.6408 1108 E007 1.6408 Foversais to FatTe chtan &% ser |. te Bot 18000 1.Es0t 1.Es02 1.6402 E08 LEVOS 1.6408 1.6407 1.808 Reversals to Failure, 2Nt b) Teodtarn band 47 pet Ua vs, de psa a K*= 1463 MPa oy, MPa 1 ee E08 sea 16402 te! s-1s7Preslem So 13 Plets of Of” vs, Gy an Eve. €, de ret thee Areng corrector bedneen Ter adap oF Bedivcen. €,7 ad ps 2000 1500 |_| ____} ____] . “6 1000 | — oot | a 0 pee ° soo 1000 1600 * 12 1 08 “3 06 f-— 04 4 02 * oO 0 02 04 06 08 1 12 14 16 18 & s-13Prete SAL peso Equation Slay 1 o.3ar 0.04 aise 456 = s Ge acx(S) Cane) +20 (&) CS) Cot) tusitg date fem Teale AD. oEY coef oss, 883 0b MenaTent Ge ests GHEY Cy) eo (re) CH) Gop) aR. 404 a5: - ’ : ‘ a Rec-120' E, 20613 3S) (ale) Tackles) (234) ty) Fe there plerhé IN = 2000 2Ng = 260.000 elarhi — plasht tebe? fash: Plsh, Tetel Han-Ten EFS Gomre 6.006/5 aood¥L 0,016 0.0083) aanlts™ Ch S.xh eaomn does. ORS — wale © ages 0.0014] Roe —100 Efsiry 900352 0.000343 aooja 2002S" © Quoo/t Poazt} EF. 52) a035) 0.00431 9.00834 9.0023. Ga003? Yeo2s4 Cemparig, total Stra tnpiituses om Ef, $.14 bith these predoctet Fem EF, Sul we Cay sen @ Fes Fomehly Clete OBreamert for both steele aA Hey INC af 10S cycles «Fer ped cqeder thee iy gerd ep cmt for th Lut tte drffermes th gree 20% der Rwe~ 109. 5-14 Heaton sherds