CRN 32718 Universityof | sailor SCHOOL OF COMPUTING, SCIENCE AND ENGINEERING TRIMESTER TWO EXAMINATION PROGRAMME(S): BEng/MEng (Hons) AERONAUTICAL ENGINEERING BEng/MEng (Hons) AIRCRAFT ENGINEERING WITH PILOT STUDIES AIRCRAFT STRUCTURES E2 (P41) Friday 10 May 2019 10:00-13:00 Instructions to Candidates Exam Duration: THREE HOURS Full marks may be obtained for correct answers to Five full questions. Answer TWO questions from SECTION A and TWO questions from SECTION B. The FIFTH question may be answered from either SECTION A or SECTION B. ‘Answer ONLY a total of five questions (only the first five questions will be marked). Additional answers will be ignored. Cross out any answers that you don't want to be marked Selected Formulae and relevant data sheets are included at the back of this Exam Paper. Approved electronic calculators may be used. You are not allowed to remove this exam paper from the venueCRN 32718 SECTION A Five springs are arranged as shown in Figure 1 below. Nodes 1 and 3 are rigidly fixed. Loads of 100N and 200N are applied in the directions as shown at nodes 2 and 4 respectively. Find the following: (a) Displacements of nodes 2 and 4 (12 marks) () Forces at nodes 1 and 3 (2 marks) (©) Internal force in each spring, (6 marks) 10 Nimm 20 N/mm 1Q0N 5 Ninm 15 Nimm 200N + 7 2 3 4 10 Nimm Figure 1CRN 32718 ‘The pin-jointed framework shown in Figure 2, is made from members with a circular cross- sectional diameter of 40 mm and a material Young's Modulus of 200 GNim*. The framework is loaded with a vertical force of 20 KN at joint E. ‘The self-weight of each member can be ignored. (a) Demonstrate that the pin-jointed framework is statically determinate. (2 marks) (6) Calculate the loads in each member. (8 marks) (c) — Calculate the vertical and horizontal deflection of point E, and hence calculate the magnitude and direction of the loaded joint. (10 marks) 4m 3.5m eal Figure 2CRN 32718 The I-beam cross-section shown in Figure 3 is subjected to a bending moment of 250 KNm about the centroidal y axis and to a bending moment of 80 kNm about the centroidal z axis as illustrated on the diagram. Determine the position of the centroid, C, and calculate the values of the section second moments of area, Iyy, [zz and lyz using the tabular method with reference from the y'z’ axes shown at the bottom of the section. Hence, calculate the bending stress at point A and calculate the orientation of the neutral axis to the centroidal y axis. (20 marks) Figure 3CRN 32718 (@ Define structural instability and explain its classifications. (10 marks) (8) Calculate the critical load using Euler’s method for the pin-ended column shown in Figure 4. (10 marks)@ 7 CRN 32718 SECTION B ‘A non-destructive test procedure was carried out on a circular metal bar with a surface diameter of 180 mm. A 3.4 mm diameter, circular crack, was detected in the cross sectional plane, at the centre of the bar. The bar has is required to sustain an axial tensile load of 2.5 MN. Determine if the bar will fracture at this load and, if not, determine the factor of safety. Assume that the bar is thick, and use the fracture ‘equation with plastic zone size correction. Use the following information for the bar material; Yield stress = 450 MPa Fracture Toughness, Kic =30 MPa m!? Flow shape parameter for a circular crack = 2/n (8 marks) Determine the plain strain fracture toughness value, Kjc, for a metal alloy, that was subjected to a three point bend, fracture toughness test. Also, determine if the value of Kicis valid. Use the following information, related to specimen properties; Fracture Load, Pq 32.5 KN Yield stress 650 MPa Width, W 50 mm Breadth, B 25.23 mm. Fracture length, a = 22.85 mm (including fatigue pre crack) [aw 0.000 [0.007 [0.002 [0.003 [0004 [0.005 [o.006 [0.007 [0.008 [0.009 |__| __swress intonsty factor cooficiot (Compan paso |ejo Jes |ais [oie [921 [923 loz6 |o.20 (0.460 |9.37 [9.40 [9.43 [9.46 [949 [952 [954 [9.57 (0.470 |9.66 _|9.69 [9.72 9.78 [981 [984 9.87 (0.480 [9.96 [9.99 —]40.03 10.08 | 10.12 _]10.18_]10.18 [0.490 [10.28 110.37 |10.34 10.41 [10.44 110.48 [10.54 0.500 _|10.61 {10.65 [10.68 | 10.75 [10.78 [10.82 [10.85 Part of the Stress intensity factor coefficients for three point bend specimen © (8 marks) An engineering component is required to safely withstand a mean stress of 31 Mpa, at a stress amplitude of 39 MPa. Two possible alloys are considered for the manufacture of the component, Use the Soderberg equation to determine the suitability (if any) of these alloys. Apply a factor of safety of two to the stress amplitude and mean stress. The table below includes the material properties for the three alloys. Alloy Yield Stress (MPa) Endurance Limit (MPa) A 250 120 B 310 90 (4 marks)@ CRN 32718 (@ — Acomponent is made ofa metal alloy and is subjected to three different creep combinations, as shown in the table below. A diagram of the Larson Miller Parameter, LMP, for the alloy is presented in Figure 5. () Will the component survive the creep loading combinations? (0 marks) (i) If the component survives the above creep conditions, how many more hours can it survive at a stress of 300 MPa and a temperature of 460°C? (2 marks) Combination 1 Combination2 Combination 3 Stress (MPa) ase 130 90 Temperature (°C) 630 570 520 Required Time (hours) 2000 30000 150000 Creep combinations for the Titanium alloy ‘Stress (MPa) Figures Larson Miller Parameter for the Titanium Alloy (not to scale) The Larson Miller Parameter, LMP, for the nickel based alloy may be expressed by the following empirical relationship; LMP =T (20 + logiot;)10? where; T= Temperature (K) t= Rupture Time (hours) Use 0°C= 273K ‘Age hardening was carried out on two aluminium-copper alloy samples. The first sample reached the maximum hardness after 7 hours at an aging temperature of 210 °C, while it took 18 hours for the second sample at an aging temperature of 110 °C. Determine the aging time for an identical aluminium-copper alloy, which is required to reach maximum hardness for an aging temperature of 160 °C. Use 0 °C = 273 K. (8 Marks)CRN 32718 (@ — ()__ Determine the Basquin’s law equation for an aluminium alloy, subjected to sinusoidal fatiguie cycles (about a zero mean stress). See data below. (ii) For a component made from the same material, determine the stress range at 10'? Cycles (about a zero mean stress). Use the following fatigue data, (about a zero mean stress), for the above alloy, Stress Range (MPa) Number of cycles to failure 230 10 320 108 (10 marks) (Note: for the Basquin’s equation, present the values of the constants, a, and logC1, to five decimal places) (6) () — Anengineering component is made from a metal alloy with a plane strain facture toughness, Ki = 48 MPa m!”. The component is required to operate at a repeated fatigue stress, with a maximum tensile value of 300 MPa. During a routine inspection, an edge crack, of length, 2.2 mm, was discovered on the surface of the component. Determine the remaining fatigue life of the component. ‘The Paris law constants for the component are; A = 1.97x10" and m = 3 (for Ao in MPa, AK in MPam’™” and crack length, a, in m.). Use y=1.1 (8 Marks) (ii) The next inspection is scheduled after 1460 days for the above component. Determine whether the component should be replaced now or retained in service, if it is required to sustain a stress (with a maximum tensile value of 300 MPa) that fluctuates at a rate of 5 cycles per hour and operates at 24 hours per day. 5 (2 Marks)CRN 32718 (2) A composite laminate system is made of a resin reinforced with 30 % (by volume) long continuous length fibres. () Determine the Young’s Moduli in the longitudinal and transverse directions, and the plane shear modulus, Giz. (4 Marks) (ii) The laminate is subjected to a tensile stress of 28 MPa, at an angle of + 22°, to the fibre direction. Determine the Transformation Matrix, T, and the stresses acting on the principal materials axes (parallel and perpendicular to the direction of fibres) of the laminate. (5 Marks) (iii) Determine the Compliance Matix, 8, and the strains acting on the principal ‘materials axes of the laminate. (5 Marks) Use the following information; ‘Young’s Modulus of the fibres 10 GPa ‘Young's Modulus of the matrix 9 GPa Shear Modulus of the fibres 7 GPa Shear Modulus of the matrix = 1.80 GPa Poisson’s ratio v12 = 0.28 (®) Describe and discuss, using sketches, the Vacuum Bagging process that is used for the manufacture of composite systems. (6 Marks)CRN 32718 FORMULAE AND DATA SHEET (Section A) I= bd/12 Tithe), 192) = A Elle) *BO 72) AFF Area of Circle: 4 aCRN 32718 Linear, homogeneous second order differential equation standard solution: y =Csindx + Deosdx uCRN 32718 FORMULAE SHEET (SECTION B) FRACTURE Plane Strain Fracture Toughness; Ky¢ = owyi1a Leak-Before-Break Condition : Ki — oy Fracture Toughness with crack tip correction; Plain strain condition (thick sections), Ke=Yoyna+n) = Yo. {a '} or; Three Point Bend; Kyg = ae. and For Validity; B = 2.5(Kie/oy)? FATIGUE Basquin Equation; Ao Ni =C Miner's Rule; SDNINe= Ni/Na + No/Ne +Na/Ns + _ 1% da 1° agtig® Smart Nr=Number of cycles to failure, between ao and ac a= Crack length a = Initial crack length a (oF aes) = Final, critical, length Ac = Stress range (can be taken as the maximum fatigue stress in tension) A and m are material constants \y = Flow shape parameter Paris law; Soderberg Relation; 6, = Stress amplitude Om Mean stress Id stress By or Fatigue limit (or Endurance limit or Fatigue strength, when applicable) FOS = Factor of Safety CREEP Robinson's Rule; Et. Rate = 1/t= Ae | where, t, is in hours and, T, in Kelvin. 2CRN 32718 LONG CONTINUOUS COMPOSITE LAMINATES Vet Ve=1 Ec=E1.=EmVm+ EVs COMPOSITE LAMINATES (Strains) ‘The strain law for an orthotropic material under plane stress conditions, referred to the material axis (1 and 2), has the following form; 4 o 4 |=[S]o, ya] lt ‘Where, [S], is termed the Compliance matrix, written in the form; [l=|Sa Sa Sz Sy Sn Sy, Where; Su=1V/E1 S2=1/E2 S3=WG2 Sau=-we = Se= vy Ei En And, $13 = S23 = S31 = S32 = 0, for an orthotropic material under plane stress conditions. Also; w= vai ae 1] ‘Where; Gn = In-plane shear modulus ‘Young’s Modulus in the | direction ‘Young’s Modulus in the 2 direction v2 = Poisson’s ratio with stress in the 1 direction and contraction in the 2 direction. oisson’s ratio with stress in the 2 direction and contraction in the 1 direction, 13CRN 32718 COMPOSITE LAMINATES (Stresses) The stress law for an orthotropic material under plane stress conditions, referred to the material axis (1 and 2), has the following form; feleel a Where, [Q, is termed the Stiffness matrix (which is the inverse of [S]). In general, the stiffness matrix is written in the form; Oy Oe Oe [al-}2, On Ox Oy On On Q3= Gir And, Qis = Qes = Qui = Qo = O, for an orthotropic material under plane stress conditions. compo: /AMINATES (Arbitrary Orientation) If the principal materials axis, or material axis (1 and 2) of the lamina do not coincide with the reference axis, or laminate axis (x and y), at some arbitrary orientation with angle, 0, then use the following relations to transform the stresses and strains; a o o, oO ,|-f]o, 2, |=[e1|@, ta, Ty, Ty, Ta. a & & a & |=[T] 2, and e, |=[T'| & Yn Toy. to Yn, ‘Where, [T] is the transformation matrix and [TJ! is the inverse of [T], written in the form; eos 2s eof Hts and Ine] °c ~208 th=|2 ct te : es es (c?=s*) es es (c?—s*)) Where, c=cos® and s=sin0CRN 32718 END OF EXAMINATION PAPER