A.

Sign Convention and Section properties

!! ! !! !
!= ;! = circle
64 32
! !
!! ! !! !
!= ;! = thin tube ; ! = !"#
8 4
!
!!
!= rectangle
12

B. Stress
1. From Bending (M) and Axial (N) Loads
!" !
!=− +
! !
where σ is along the axis of the beam/shaft
For moments in two planes, the contribution in the “x” axial direction from bending is:
!" !!" !!" ! !
− =− − !" !"
! !!! !!!
2. From Torsional (T) and Shear (V) Loads
!" !"
!= +
! !"
4! 3!
!! = 0 at top and bottom; middle circle ; rectangle
3! 2!

3. From Internal pressure p on a cylinder of radius r and thickness t

!" !"
!!"#!$ = ; !!!!" =
2! !

C. Energy Methods
Deflection from a point load F (neglecting contribution from V). Use dummy load if no point load applied
at location of interest.
! ! !
! !" ! !" ! !"
!= !" + !" + !"
! !" !" ! !" !" ! !" !"

D. Failure: SF*(Stress in Part)=material limit

D1. Static Failure Criteria D2. Failure by buckling

1. Ductile material 1. Material limit for Buckling: Scr

a. Material limit: Sy or Sys (=Sy/2) !! !
Euler (long, slender): !!" = !! !
b. Stress in part: !
i. Max normal: max !! , !! !!! !! !
!! !!! !! !!! !! !!! Johnson (short, stubby): !!" = !! −
ii. Max shear: max , , !!! ! !
! ! ! !/!
!! !!! !
iii. Distortion energy: Cutoff Johnson Euler: =
!/! ! !" !!
!! = !!! + !!! − !! !! + 3!!"
!
!
Equivalent length Le depends on supports
!! = !!! + !!! − !! !! ! !
!= !
2. Brittle material:
a. Material limit: SUT, SUC !!
Design for !
Use σ1- σ2 plot for modified Mohr !"#
2. Stress in Part
! axial compression force
!= =
! cross sectional area

1
Basic definitions
* .
! = ln %&(& ) = ln % '(*) ; - =
' *
/0
At Necking: /1 = - (solve for !3456 ); For PLSH !3456 = 7
89:; 8 <>?@A
UTS (engineering)= <=
= <9:; <=
>?@A
Flow stress: Yf, or -B ; Average flow stress CDor -
DDDDB
Constant volume: G = GH ; !I + !K + !L = 0
Effective stress and strain -D, !̅
1 I
-D = ((-I − -K )K + (-I − -L )K + (-K − -L )K ) (K
√2
√2 I
!̅ = ((!I − !K )K + (!I − !L )K + (!K − !L )K ) (K
3
Plane Strain (1 is height direction)
√L K
-D = |-I |; !̅ = |!I |
K √L
Axisymmetric (1 is height direction)
-D = |-I |; !̅ = |!I |
∫0
W /1D X1D >
CD = DDD
-B = 1D
; For PLSH CD = DDD
-B = 3YI
1D
Z = ∫H -D [!̅; Ideal Work = (Z)(G)

Forging
Brick
`a
\]^_ = 2( -B %1 + (ℎ ) Cylinder
√3 2`m( )
\]^_ = -B %1 +
\ = 2( -B c (Kd ⁄e )(]gh) 3ℎ
√3 \ = -B c (Kd ⁄e )(ngh)
. = \]^_ 2ai
el
. = \]^_ om K
el
j = k .[ℎ
e j = k .[ℎ
e
Rolling
`p
.n = 2( pi- DDDB q1 + r2ℎ s
√3 ]^_
p = √tΔh
w = .p(2
^
x = wy; y = ; { = 2ot| (units for power: P=Nm/s)
z
Drawing
-/ }/4]~ = k -D [ !̅
-/ ']~ = -/ }/4]~ + -Bn}5}'3 + -n4/Ä3/]3
Max reduction/pass: -/ ']~ = -B at exit
Drawing Force: ./ = -/ ']~ (area)
 Summary of key equations for Fatigue

S-N coordinates (sm=0)

Sn=Sn’(CLCGCSCRCT) (see Table 8.1 for factors)

Material S1000 Sn’ (bending) “n”
Name: (bending) Cycles
lculation Process October 11, 2017
Steel 0.9 Su 0.5 Su (max=100 ksi) 106
Cast Iron 0.9 Su 0.4 Su (max=24 ksi) 106
h Calculation, General Titanium Biaxial State of Stress, Ductile
0.9 Su Material
0.45-0.65 Su 106
Aluminum 0.9 Su 0.4 Su (max = 19 ksi) 5x108
of the following at the worst stressed point (or
Magnesium 0.9every
Su candidate 0.35worstSu stressed 108
erall worst stressed point is unclear): Copper 0.9 Su 0.25-0.5 Su (max= 14 ksi) 108
Nickel Alloys 0.9 Su 0.35-0.5 Su 108
ME 3221 Shaded: - Fall 2017 no endurance limit (noτknee) Name:
σbend,mean σaxial,mean torque,mean
Fatigue Strength 1 ksi = 6.895 Calculation
MPa Process October 11, 2017
σ σ s
bend,alt S-N (axial,alt
Interpolating m=0)
τ torque,alt
FatigueFatigue
Fatigue Strength Calculation, General Biaxial State of Stress, Ductile Material
Wednesday, October 7, 2020 1:05 PM
Wednesday, October 7, 2020 1:05 PM
1 . If σ
For salt/smean=Constant
mean and
1. alternating
Compute eachstress
of thecomponent by its
following at the appropriate
worst Kf(or
stressed point everyaxial stresses
candidate worst stressed
mplify them by K
point if the = 1.4.
A overall worst stressed point is unclear):
σbend,mean point
of stress at every potential worst-stressed σaxial,mean
into itsτtorque,mean
mean and alternating
σbend,alt σaxial,alt τtorque,alt

2. Multiply each mean and alternating stress component by its appropriate Kf 1 . If σaxial stresses
exist, further amplify them by KA = 1.4.
σym
3. Split the(if any)
state σya (if
of stress at every potential worst-stressed any)into its mean and alternating
point
components:
Modified Goodman (sm ≠ 0)
τxym τxya
σym (if any) alternating σya (if any)
mean
stresses stresses
σxm τxym σxa τxya

mean alternating
stresses stresses
σxm σxa

ormulas will apply to most cases:

Kf,bend σbend,mean + K for
TheEquations
Kf,axial
following Aformulas
σaxial,mean
combining
will stresses
apply
τ axial
in xym
to most
= Kf,torque
direction
cases:
τtorque,mean
Class note examples Page 1
x (y is the hoop direction)
Kf,bend σbend,alt + KA Kf,axial σaxial,alt τxya = Kf,torque τtorque,alt
σxm = Kf,bend σbend,mean + KA Kf,axial σaxial,mean τxym = Kf,torque τtorque,mean
σ xa = Class
valent, or “von Mises”,Kf,bendstresses
note
σ Page 1 for+ the
examples bend,alt
KA Kmean
f,axial σand τxya =elements
alternating
axial,alt Kf,torque τtorque,alt
using
energy theory: KAequivalent,
4. Compute =1.4; Kf=1+q(K -1) (q Mises”,
or t“von and Kt from plots)
stresses for the mean and alternating elements using
the distortion
! energy theory: Note, the mean stress could be either positive or
σem = ± − +2
σxm negative. The nature of the loads and their relation
σxm σym + ! 2
σym 2
3τxym
σem = ± σxm − σxm σym +toσym the +
2 stresses
2
3τxym must be considered to determine the
2
! correct sign.
2 − σ σ + σ!
σea = σxa 2 2
σea = yaσ+
xa ya 2 3τxya sym,
2 sya2 are usually zero, unless there is an
xa − σxa σya + σya + 3τxya
internal pressure load.
rnating stress
Note:isThe
always takenstress
alternating as a ispositive number.
always taken However,
as a positive the mean
number. However,stress
the mean stress
positive ormay be eitherThe
negative. positive or negative.
nature The nature
of the loads of the relation
and their loads and to
their
therelation to the stresses
stresses
must be examined to
ned to determine the correct sign.determine the correct sign. 2
5. Compute the endurance limit, Sn , corresponding to loading in pure bending.
ndurance limit, Sn , corresponding to loading in pure bending.
6. Apply the fatigue diagram equations using σ and σ .
 ME 3221: Fall 2018
Material Removal: Important Equation Summary

1) Geometry

t0 sin f r cos a
r= = tan f =
t c cos(f - a ) 1 - r sin a
g = cot f + tan(f - a ) b = tan -1 µ
2) Forces
i) Tool-chip interface:
F = R sin b
N = R cos b
F
µ = = tan b
N

ii) Workpiece plane iii) Shear plane

Ft = R sin( b - a ) Fs = R cos(f + b - a )
Fc = R cos( b - a ) FN = R sin(f + b - a )
iv) R 2 = F 2 + N 2 = Ft 2 + Fc 2 = Fs 2 + FN 2
v) k = shear yield strength = Y/2
F wt0
ts = k = s As =
As sin(φ )
3) Speeds

V: tool speed; Vc=chip speed

V Vs V Vc t
= = C =r= 0
cos(f - a ) cos a sin f V tc
­ ­ ­
Workpiece Shear plane Tool-chip interface

4) Power/ Energy
Power
Specific energy, ut = MRR = wt0V (Ideal orthogonal cutting)
MRR
Ut from Table 8.3

Ptotal = Pfriction + Pshear Ptotal = Fc.V

Pfriction = FVc Pshear = FsVs