NO

 SMART  PHONE  USAGE  or  ACCESS  TO  ONE  

 

 
 
• You  are  not  allowed  to  use  a  smart  phone.  
• You  should  not  scan  or  photograph  your  test  pages  with  any  
imaging  devices.  
After  you  are  done,  LEAVE  your  test  on  your  
Desk.  You  may  take  the  formula  sheets  with  you.  
 
Formula  Sheets    
 
 Some  useful  formulae  from  mech  mat  
M T bh 3 πd 4 πd 4
S= y; τ = r; I = ;I= ;J= ;
I J 12 64 32
Cyclic  Loading  Parameters  
S S − Smin S + Smin  
R = min ; Sa = max ; Sm = max
€ Smax 2 2  

Loosely  used  estimates  (use  only  if  the  actual  data  is  not  available)  
€  
S f = 0.5Su for Su ≤ 1400 MPa (200 ksi)
Sf = 700 MPa (100 ksi) for Su ≥ 1400 MPa (200 ksi)
   
Su ≈ 3.45HB for MPa units
Su ≈ 0.5HB for ksi units
 
! Sa Sm
#Goodman for Infinite life (fatigue limit): + =1
#
€ Mean  stress  effects   " S f Su

S S
# Goodman for Finite life (fatigue Strength): a + m = 1
#$ SNf Su
 
 
Sa Sm
Criterion for uniaxial yielding + = 1  
S"y Sy
 
Size  effect  (for  components  larger  than  10  mm  or  0.4  inch):  0.7  to  0.8  (use  0.75)  
 
€ Loading  (type)  effect:  
• Fully  reversed  axial:  Varies  0.75  to  0.9  (use  0.8)  
• Fully  reversed  shear:  0.57  
 
B
Basquin’s  Equation: SNf = A( N f )
 
A  and  B  are  constants,  which  determined  from  Su  and  Sf  

€
 Effects  of  Surface  Finish  on  the  Fatigue  Limit  of  Steels  
 

 
 
 
 
 
 
 Fatigue
Limit
as
a
function
of
UTS
for
Peened
and

Unpeened
Specimens
 9/13/11


Residual Stress by Mechanical Processes: Shot-

Effect of Residual Stress on Fatigue Limit Effect
plating
on
fatigue

peening & Cold (Surface) Rolling

Shot‐peening
is
a
cold
working
process
used
to
produce
a

compressive
residual
stress
layer
and
modify
mechanical

on
 properties
of
metals.
It
entails
impacting
a
surface
with
shot

(round
metallic,
glass
or
ceramic
particles)
with
force
sufficient

to
create
plastic
deformation.



Residual Stress distribution at the shot-peened surface

or

a.  Shaft not peened
d,
 b.  Shaft peened

 c.  Scratched plate not peened
).
 d.  Scratched plate peened

 
bar
 Thermal
Processes

Fatigue
limit
of
Several
Shallow
quenched
notched

steels



Compr. Residual Stress (by shot-peening) Vs UTS

Residual Stress by Mech Processes

Cold (Surface) Rolling
– Fatigue Limit of Cut threads vs rolled threads


Residual Stress by Mech Processes


(Beneficial)
Effects
of
Shot‐peening
on
Carburized
Gears
[13]



CH3COOH
–
Acetic
Acid


Residual Stress by Mechanical Processes:

Cold (Surface) Rolling of a Fillet
Residual Stress by Mech Processes: Autofrettaging

Autofrettage
is
a
metal
fabrication
technique
in
which
a
  
pressure
vessel
is
subjected
to
enormous
pressure,

  causing
internal
portions
of
the
part
to
yield
and
 Carburizing
is
a
heat
treatment
process
in
which
iron

resulting
in
internal
compressive
residual
stresses.


• 
Goal:
To
increase
the
durability
of
the
final
product.
 or
steel
is
heated
in
the
presence
of
another

• 
Examples:


 material
(gaseous,
liquid,
solid
or
plasma
source
of

• 
high‐pressure
pump
cylinders

• 
battleship
and
tank
cannon
barrels
 carbon)
which
liberates
carbon
as
it
decomposes.

• 
fuel
injection
systems
for
diesel
engines
 The
outer
surface
or
case
will
have
higher
carbon


content
than
the
original
material.
When
the
iron
or

steel
is
cooled
rapidly
by
quenching,
the
higher

carbon
content
on
the
outer
surface
becomes
hard,

2

while
the
core
remains
soft
and
tough.
It
produces

case
hardness
depths
of
up
to
0.25
inches
(6.4
mm).
 1