CONFIDENTIAL 8 UNIVERSITI TUN HUSSEIN ONN MALAYSIA FINAL EXAMINATION SEMESTER I SESI 2013/2014 COURSE NAME FATIGUE AND FRACTURE MECHANICS COURSE CODE BDC 40403/ BDC 4053 PROGRAMME BACHELOR OF MECHANICAL ENGINEERING WITH HONOURS EXAMINATION DATE DECEMBER 2013/ JANUARY 2014 DURATION 3 HOURS INSTRUCTION ANSWER ALL QUESTIONS IN THIS QUESTION PAPER CONTAINS SEVEN (7) PAGES. UTHM Universiti Tun Hussein Onn Malaysia PART A, AND CHOOSE TWO (2) OUT OF FOUR (4) QUESTIONS IN PART B. CONFIDENTIALBDC 40403/ BDC 4033 PART A: ANSWER ALL QUESTIONS a Q (@) ‘A stressed element in a reciprocating link experiences a maximum stress of 180 MPa and a minimum of -20 MPa. Calculate other fatigue loading parameters: (Mean stress Stress amplitude Stress range Load ratio (12 marks) (b) The alloy Ti-6Al-4V (TABLE Ql) is used to make a cylindrical pressure vessel having closed ends with an inner diameter of 250 mm and wall thickness of 2.5 mm. Evaluate the pressure applied to cause fatigue failure in 10° cycles. (13 marks) A section of a component is shown in FIGURE Q2 (a). The component is made of steel with Sy = 550 MPa and a fully corrected endurance limit of S. = 180 MPa. The applied axial load varies from 2,000 to 10,000N, FIGURE Q2 (b) demonstrates the notch- sensitivity curve for steel whereas FIGURE Q2 (0), (4) and (¢) illustrate the geometric stress-concentration factor for fillet, hole and groove, respectively. ‘The failure of component is likely to occur at the weakest location, By assuming Kw = | and the modified Goodman diagram, (a) _ Evaluate the highest safety factor obtained at the component, (18 marks) (b) Select the location that likely to fail first. Support the argument with appropriate answer. (7 marks)BDC 40403/ BDC 4083 PART B : ANSWER TWO (2) QUESTIONS ONLY Q@ Q4 A rotating-bending fatigue test set-up is illustrated in FIGURE Q3. The test specimen is made of wrought AI7075-T6 alloy with S; 496 MPa, Sur = 565 MPa and S;= 163 MPa based on 108 cycles to failure. The smoothed specimen has a mid-span diameter of 7.5 mm, A dead weight of w = 40 kg is applied during the test. (a) Calculate the resulting stress amplitude and load ratio for the fatigue load cycles. (10 marks) (b) Assuming that the strength-life (S-N) curve for the material can be represented by Basquin equation: SN;= 4 (Np B, evaluate the fatigue life of the specimen. (15 marks) A component has been machined from a 38 mm diameter round steel bar. The steel has a normal endurance limit of 345 MPa and a tensile strength of 690 MPa. It is subjected to fluctuating tensile load that varies from 0 to 70 KN. At one point on the component, there is a feature with a stress concentration factor of 1.85. The other factors are: © ki —surface finish factor = 0.797 ka— size factor = 1 k3— load factor = 0.923 ka— temperature factor = 1 k3 —reliability factor -0.897 coco (a) Calculate the corrected endurance strength, S’. (10 marks) (b) Evaluate the safety factor of the component. (15 marks)es 6 BDC 40403/ BDC 4083 AA structural steel component contains a single internal ‘through’ crack of 15 mm in length caused by a faulty welding procedure. The component failed under an applied tensile stress of 550 MPa. Given the geometric factor is 1.3. (a) Determine the fracture toughness of the steel. (12. marks) (b) Evaluate the size of the internal through crack would need to be for the same ‘component to fail under a stress of 250 MPa. (13 marks) A steel plate with a central through-thickness flaw of length 16 mm is subjected to a stress of 350 MPa niormal to the crack plane. If the yield strength, Sy of the material is 1400 MPa, (a) Calculate the plastic-zone size, ty (12 marks) (b) Evaluate the effective stres intensity level at the crack tip, Ker (13 marks) - END OF QUESTIONS -BDC 40403/ BDC 4083 FINAL EXAMINATION SEMESTER / SESSION: SEMESTER 1 /2013/14 PROGRAMME BDD OURSE NAME: FATIGUE ANDFRACTURE COURSE CODE BDC 40403/ MECHANICS BDC 4083 TABLE QI a, =o s(2N,)' = AN? Yield Ultimate True oe f Material | Strength | Strength | Fracture (@Note: A and B are constant) | Pa) | of, (MPa) : | Fo(mPay | Ou (MPB) | ors (MPS) | oc MPay 4 b=B | cozata-av | 310 485 630 900 839 0.101 | teearav [1180 1225 1730 2030 1889 0.103 FIGURE Q2 (a) [Noth Sensiity Factor for Steels Sia_bpsi (MPa) mms e_ ass ao asaya asso 7 10 os 07 os rang. oe curve fran Sy that 20 ps igher than tt the materia seleted ° tin —2 0002 008005 OG OID OID O18 O16 ON 020 oh rads, FIGURE Q2 (b) 5BDC 40403/ BDC 4083 FINAL EXAMINATION SEMESTER /SESSION : SEMESTER 1 /2013/L4 PROGRAMME BDD SOURSENAME FATIGUE AND FRACTURE COURSE CODE. BDC 40403 MECHANICS. SP id=20 150 130. 1.207 o 005 al 01S 0aDS SD rid FIGURE Q2 (c) W Ora eA e ? a 4 an i { ‘ | att a eat 22 + — + | | I i a 10 0% 0% a0 05 a6 O70 aw FIGURE Q? (d)BDC 40403/ BDC 4083 FINAL EXAMINATION }EMESTER / SESSION: SEMESTER 1 /2013/14 PROGRAMME, BDD (OURSENAME ——: FATIGUE AND FRACTURE COURSE CODE. BDC 40403 MECHANICS: aor 0.05 a0 as a 02s 030 rd FIGURE Q2 (e) Flexible Coupling FIGURE Q3