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Materials 335

Mid-semester test 2005


Test 2 (Closed book, 40 minutes)
(This test accounts for 15% of the grade for the unit)

All intermediate calculations, assumptions, and related workings out should be provided in
order to gain full credit.
The propeller and shaft of an aircraft engine are shown schematically in the figure below. The
propeller has a mass, m, and generates a forward force, F, relative to the aircraft at a constant
rotational speed of N revolutions per minute. The shaft has a diameter, d, where it joins the
propeller and increases with a fillet of radius, r, to a diameter of D at a distance, L, from the
propeller centre of mass. The shaft transmits a power, P, to the propeller.

Question continued on following page

Student Name: _______________________________ Student No.: ________________ Total Pages: ____

D:\Data\Curtin\Lecture courses\Materials 335\2005\Mid-semester test\September 23rd\Mid-semester_test_2_solutions_003.doc

9/23/2005

(i)
Show that the effective mean stress, m, and alternating stress, a, at the fillet can be
given by the following:

a =

32mgL
K f (b )
d3

[4 marks]

2F
2F
480 P

m = 2 K f (a) + 2 K f (a) +
K f (t )
2 3
d
d
N d

[8 marks]
Where Kf(b), Kf(a), and Kf(t) are the fatigue stress intensity factors for bending, axial, and
torsional loading, respectively.
(ii)
Estimate the factor of safety for the following conditions: d = 50 mm, D = 100 mm, r
= 4 mm, L = 100 mm, F = 4000 N, m = 1000 kg, P = 50 kW, and N = 3000 rpm. Assume the
shaft to be made from commercially polished steel with an ultimate tensile strength, Su, of
1200 MPa.
[16 marks]

[Total marks: 28]

Notes:

In order to gain full credit you will need to clearly indicate (for example, by drawing
intersecting lines in the appropriate positions) how the fatigue data figures in the following
pages were utilised.
You are required to fill out the details on the front page of this question booklet and return
this question booklet with your answer booklet.

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Fatigue property sheet


All symbols have their usual meaning.

106 cycle strength:

Load type

Factor

Bending

Sn = CLCDCSSn
* A lower value may be used
to account for known or
suspected undetermined
bending due to load eccentricity.

Torsion

1.0
0.58
1.0 for D 10 mm
0.9 for 10 D 50 mm
From figure shown below

CL
CD
CS

Axial

0.9*
1.0

103 cycle strength:

Bending loads: 0.9 Su


Torsional loads: 0.9 Sus
Axial loads: 0.75 Su

Reduction of endurance strength due to surface finish steel parts (Adapted from R. C. Juvinall, p. 234 in
Engineering considerations of stress, strain and strength, McGraw-Hill, Inc., New York, 1967).

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Fatigue property sheet (continued)

Theoretical stress concentration factors for a shaft with a fillet: (a) bending, (b) axial, and (c) torsional loads (R.
E. Peterson, in Stress concentration design factors, John Wiley & Sons, Inc., 1953).
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Fatigue property sheet (continued)

Notch-sensitivity curves for use with theoretical factors, Kt (Adapted from R. E. Peterson, Notch sensitivity, in
Metal fatigue, G. Sines and J. L. Waisman, eds., McGraw-Hill Book Company, New York, 1959).

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Mid-semester test 2005 Test 2 (solutions)

The system contains the following stresses acting at the fillet:


(a)

Alternating bending stress, a(b), due to mg

(b)

Constant axial stress, m(a), due to F

(c)

Constant torsional stress, m, due to P

(a)

Alternating bending stress, a(b), due to mg. From the supplied figure:

a(b ) =

32 M
d3

[1 mark] #

M = mgL

[1 mark]

We need to take into account Kf for bending:

a(b ) =

32mgL
K f (b )
d3

[1 mark]

There is only one alternating stress:


32mgL
K f (b )
d3

a =

(b)

Constant axial stress, m(a), due to F. From the supplied figure:

m( a ) =

4P
d2

[1 mark]

(note different P from that given in figure)

[1 mark]#

P=F
We need to take into account Kf for axial:

m( a ) =

4F
K
d 2 f (a)

[1 mark]

Equivalent expression also accepted.


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(c)

Constant torsional stress, m, due to P. From the supplied figure:


16T
d3

[1 mark] #

60
T =
P
2 N

[1 mark]

m =

We need to take into account Kf for torsion:

m =

480 P
K
N 2 d 3 f (t )

[1 mark]

We can obtain the equivalent mean stress, m, by assuming failure due to the maximum
distortion energy theory as follows:
[1 mark]

m =

x + y
2

x y
2
+
+ xy
2

[1 mark]

2F
2F
480 P

m = 2 K f ( a) + 2 K f (a) +
K f (t )
2 3
d
d
N d

Equivalent expression also accepted.


-7-

[1 mark]

(ii)

Estimate the factor of safety for the following conditions: d = 50 mm, D = 100 mm, r =
4 mm, L = 100 mm, F = 4000 N, m = 1000 kg, P = 50 kW, and N = 3000 rpm. Assume
the shaft to be made from commercially polished steel with an ultimate tensile strength,
Su, of 1200 MPa.
First of all we need to calculate the respective Kf values.

Theoretical stress concentration factors for a shaft with a fillet: (a) bending, (b) axial, and (c) torsional
loads (R. E. Peterson, in Stress concentration design factors, John Wiley & Sons, Inc., 1953).
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r/d = 4/50 = 0.08


D/d = 100/50 = 2.0
From the previous figure:
Kt(b) 1.82
Kt(a) 2.14

[1 marks]

Kt(t) 1.53
We also need to calculate the Peterson notch sensitivity factor, q:

Notch-sensitivity curves for use with theoretical factors, Kt (Adapted from R. E. Peterson, Notch
sensitivity, in Metal fatigue, G. Sines and J. L. Waisman, eds., McGraw-Hill Book Company, New
York, 1959).

r = 4 mm
Su = 1200 MPa

q(b) 0.93
q(a) 0.93

[1 marks]

q(t) 0.95

-9-

We also need to know the surface finish:

Reduction of endurance strength due to surface finish steel parts (Adapted from R. C. Juvinall, p. 234
in Engineering considerations of stress, strain and strength, McGraw-Hill, Inc., New York, 1967).

CS 0.88

[ mark]

We need to make use of the following equation:


K f = 1 + ( K t 1) qC S

[1 mark]

Kf(b) 1 + (1.82 1)(0.93)(0.88)


1.67(1)

Kf(a) 1 + (2.14 1)(0.93)(0.88)


1.93(3)

[1 marks]

Kf(t) 1 + (1.53 1)(0.95)(0.88)


1.44(3)

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a =

a =

32mgL
K f (b )
d3

32 x1000 x9.81x100 x10 3

( 50 x103 )

1.671

a = 133.6 MPa

[ mark]

m =

2F
2F
480 P

K f ( a) + 2 K f (a) +
K f (t )
2
2 3
d
d
N d

480 x5 x104
2 x 4000 1.933 +

1.933
1.443
m =
+
2
3 2
3 2
3 3

( 50 x10 )
( 50 x10 )
3000 x x ( 50 x10 )

2 x 4000

m = 1.969 x106 +

(1.969 x10 ) + ( 9.357 x10 )


6 2

6 2

m = 11.53 MPa

[ mark]

Construct a Goodman line:

Factor

CL
CD
CS

Load type
Bending

Torsion

Axial

1.0
0.58
0.9*
1.0 for D 10 mm
1.0
0.9 for 10 D 50 mm
From figure shown below
[1 mark] #

CL = 1
CD = 0.9

[1 mark] *

Sn = CLCDCSSn
Assume Sn = 0.5 Su

[ mark]

The loading type is always assumed to be fully reversed bending (i.e., CL = 1) when constructing the Goodman
line.
*
The specimen is assumed to be stress-free (i.e., Kf = 1) when constructing the Goodman line.
- 11 -

Sn = CLCDCS(0.5 x Su)
Sn = (1)(0.9)(0.88)(0.5 x 1200)

Sn = 475.2 MPa

a
Sn (475.2 MPa)

133.6 MPa

O 11.53 MPa

Su (1200 MPa)

m
[2 marks] #

We can obtain the following equations:

a = 475.2

a = 475.2 0.396 m
a =

475.2
m
1200

(i)

[1 mark]

(ii)

[1 mark]

133.6
m
11.53

a = 11.59 m

Solving these equations gives:


m = 39.66 MPa

[1 mark]
39.66
11.53

Factor of safety =

Factor of safety = 3.44

[1 mark]

Marks of each for: (i) m on x-axis, (ii) a on y-axis, (iii) labelling of Su or 1200 MPa on x-axis, (iv) labelling
of Sn or 475.2 MPa (or similar), (v) drawing of line between Sn and Su.
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Materials 337
Mid-Semester Test 2008

(a)

(b)

(c)

The fatigue surface finish factor, Cs, is not included in the equation for the one thousand
(103) cycle data point. Briefly explain the reason behind this omission?
(1 Mark)
Name three (3) characteristics or properties that are required in order to determine the
Peterson notch sensitivity factor, q ?
(2 Marks)
A square steel plate of width, w, and thickness, t, contains a circular hole of radius, r, at its
centre (w >> r > t). The plate is subjected to axial and shear stresses as shown in Figure 1
overleaf.
(i)

When analysing the possible failure of this component it is stated that the presence of
the hole will have negligible influence on the stress state for any region at a distance,
X, from the hole centre where X > Nr and N is typically 5. What engineering
principle may be invoked to justify this decision?
(1 Mark)

(ii)

Sketch a Mohrs circle to represent the stress state of the plate at a position far away
from the hole, i.e., unaffected by the presence of the hole. (Note: A hand drawn
Mohrs circle is satisfactory)
(4 Marks)

(iii)

It is a requirement that the maximum strain at the edge of the hole should be
estimated using a strain gauge. Use the Mohrs circle to estimate at what angle, , the
strain gauge should be placed.
(4 Marks)

(iv)

Using approximate values for the mechanical properties of the plate, estimate the
value of the maximum strain measured by the strain gauge. Assume that the strain
gauge is small and located exactly at the edge of the hole.
(5 Marks)

(v)

Use the maximum distortion strain energy theory (von Mises theory) to estimate the
factor of safety assuming an ultimate tensile strength, u, of 1500 MPa.
(3 Marks)
(Total 20 Marks)

400 MPa

50 MPa

150 MPa

Figure 1: Schematic diagram of a square steel plate containing a hole


together with a strain gauge (shown in red) attached at the hole edge

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Mid-Semester Test 2008 (Solutions)

(a)

The fatigue surface finish factor, Cs, is not included in the equation for the one thousand
(103) cycle data point. Briefly explain the reason behind this omission?
The stress required to produce failure after 103 cycles is sufficiently high (on the order of
0.9u) that the surface is being damaged to such an extent (e.g., plastic deformation if the
stress is above y) that the initial state of the surface becomes unimportant.
(1 Mark)

(b)

Name three (3) characteristics or properties that are required in order to determine the
Peterson notch sensitivity factor, q ?
If we consider the information required to determine q from the standard figure then any 3
from: (i) notch radius, (ii) material type (steel or aluminium), (iii) loading type, and (iv)
ultimate tensile strength, u.
(2 Marks)

(c)

A square steel plate of width, w, and thickness, t, contains a circular hole of radius, r, at its
centre (w >> r > t). The plate is subjected to axial and shear stresses as shown in Figure 1
overleaf.
(i)

When analysing the possible failure of this component it is stated that the presence of
the hole will have negligible influence on the stress state for any region at a distance,
X, from the hole centre where X > Nr and N is typically 5. What engineering
principle may be invoked to justify this decision?
Saint-Venants Principle
(1 Mark)

(ii)

Sketch a Mohrs circle to represent the stress state of the plate at a position far away
from the hole, i.e., unaffected by the presence of the hole. (Note: A hand drawn
Mohrs circle is satisfactory)
-ve
(400, -50)
-ve

(275, 0)

+ve

x1 (MPa)

(150, 50)
+ve
x1y1 (MPa)
(4 Marks)
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(iii)

It is a requirement that the maximum strain at the edge of the hole should be
estimated using a strain gauge. Use the Mohrs circle to estimate at what angle, ,
the strain gauge should be placed.
Strictly speaking, the correct answer is that no angle will give the maximum
strain for the strain gauge configuration shown (as the strain gauge is
measuring the radial strain, r, whereas we have generally relied upon
measuring the tangential strain, (as >>r for most stress concentrations
around a hole)).
(4 Marks)
or
Alternatively, it would be sensible to put the strain gauge at the angle of maximum
principal stress, 1.
(2 Marks)
-ve
(400, -50)
2
-ve

(275, 0)

+ve

x1 (MPa)

2
1

(150, 50)
+ve
x1y1 (MPa)
From the Mohrs circle we can estimate that 2 158.2o

(1 Mark)

79.1

(1 Mark)
(iv)

Using approximate values for the mechanical properties of the plate, estimate the
value of the maximum strain measured by the strain gauge. Assume that the strain
gauge is small and located exactly at the edge of the hole.
The stress state is biaxial so we need to use the following equation (from Lecture 2):

x =

1
( x y )
E
( Mark)

For steel a typical value for E would be 200 GPa (10%) and would be 0.250.3.
( Mark)

-4-

In this case:
x = 1

y = 2

and

(1 Mark)
From the Mohrs circle we can estimate 1 and 2 as follows:
1 409.6 MPa
2 140.4 MPa
( Mark)
For a square plate containing a hole with w >> r then (from Lecture 4):
Kt 3
(1 Mark)
Therefore the respective stresses at the edge of the hole would be:

1 409.6 x 3

1 1229 MPa

2 140.4 x 3

2 421.1 MPa
( Mark)

Therefore, the estimated strain will be given by:

x =

1
(1229 0.3x 421.1) 106
200 x109

x = 5.51 x 10-3
(1 Mark)

Note that inclusion of 1 only results in x = 6.15 x 10-3


(v)

Use the maximum distortion strain energy theory (von Mises theory) to estimate the
factor of safety assuming an ultimate tensile strength, u, of 1500 MPa.
We need to use the following equation:

equiv = 12 + 22 1 2
(1 Mark)
Substituting in the appropriate values:

equiv = 12292 + 421.12 1229 x 421.1

equiv = 1082 MPa


-5-

(1 Mark)
Thus, our specimen contains the same amount of distortion strain energy as for a
uniaxial tensile specimen at 1082 MPa.
The factor of safety can thus be calculated from:
Factor of safety =

u
1500
=
= 1.387
equiv 1082
(1 Mark)

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