Scribd
Upload
22 views

Assignment 2

The document contains 5 problems related to mechanical failure analysis of materials with cracks. Problem 1 involves calculating critical stress intensity factors and safe bending loads for cracked beams. Problem 2 calculates fracture toughness and fatigue life of a cracked plate under tension and bending. Problem 3 estimates fatigue life of a pressurized cylinder with an elliptical crack. Problem 4 analyzes speed limits and fatigue life of a cracked turbine disk. Problem 5 determines maximum crack sizes and fatigue lives of compound cylinders with cracks.

Uploaded by

154 ahmed ehab
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
22 views

Assignment 2

The document contains 5 problems related to mechanical failure analysis of materials with cracks. Problem 1 involves calculating critical stress intensity factors and safe bending loads for cracked beams. Problem 2 calculates fracture toughness and fatigue life of a cracked plate under tension and bending. Problem 3 estimates fatigue life of a pressurized cylinder with an elliptical crack. Problem 4 analyzes speed limits and fatigue life of a cracked turbine disk. Problem 5 determines maximum crack sizes and fatigue lives of compound cylinders with cracks.

Uploaded by

154 ahmed ehab
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 3

Cairo University MDPN 464

Faculty of Engineering Analysis of Mechanical Failures


Senior -2 MDE Program Assignment 2

Problem 1
A bar of brittle material of cross-section 20 × 20 mm and length 200 mm is loaded in pure
bending by a moment M = 45 N. m.

a. If a bar contains a crack of 8 mm deep is fractured during loading; what is the critical
intensity factor for such material.
b. If a bar of the same material and dimensions is subjected to pure bending and axial
pull P has a crack of 3 mm deep; what is the safe bending load that may be applied
to avoid fracture, knowing that P/ M = 5?.

Problem 2

a- A plate of 100 mm width, 5 mm thickness is failed under applied tensile force of 100
kN. Investigation of fracture surface indicates brittle fracture due to an edge crack of
length 8 mm. Estimate the fracture toughness of this material.

b- Regular maintenance inspection to machine components indicates an edge crack of


5 mm in a plate made of the above material and having the same dimensions. The
plate is subjected to tensile stress of 30 kN and to fluctuating bending moment of ±1
kN.m. Estimate the number of loading cycles this plate can withstand before
fracture.
(Crack growth rate of the material da/dN = 2.5 × 10 -12 (k) 3.5 (m/cycle & MPa).
The average correction configuration factor for the plate under tension is 1.12 and under
bending is 1.25 ).
Problem 3

A long closed cylinder of diameter 1000 mm and 20 mm thickness; is


made of a steel (KIC = 37 MPa m1/2).

If the cylinder has an initial elliptical circumferential crack of 8 mm and


is subjected to a pressure varying between 7.5 MPa and -1 MPa, then
estimate the number of loading cycles this cylinder can withstand
before fracture.

(Crack growth parameters: m = 3.5 and C = 2.5 × 10-12 (m/cycle &


MPa) ). Take an average value of f (a/W) = 1.3.

Problem 4

a) A thin annular turbine disc of outer diameter 500 mm and inner diameter of 200 mm, is
attached to 50 blades which cause an outward stress of 140 2 MPa during rotation
(where  is the angular velocity.
i. Calculate the speed at yielding for the disc using factor of safety 2.
ii. Calculate the speed at fracture, If inspection of the failed disc showed a
radial crack length of 40 mm.
iii. Estimate the number of on/off cycles of loading at which the the disc
fractured for an assumed radial crack length of 5 mm.
The disc material is steel with 400 MPa yield stress and Fracture Toughness of 80 MPa m1/2.

Problem 5

A group of compound cylinders, each composed of two cylinders of the same material by shrink
fit of radial interference  = 0.1414 mm with the dimensions shown in the figure 5(a).

Upon inspection, the compound cylinders are separated in two sets, the first set showed radial
crack–like defects at the inner circumference of the outer cylinder as shown in Fig. 5(a), while
the second set showed radial crack-like defects of 1.5 mm at the outer circumference of the
outer cylinder as shown in Fig.5(b).

a. For the first set, determine the longest crack which may be allowed so that the fracture
does not occur during shrinkage.
b. For the second set, determine the safe life if they are subjected to an internal pulsating
pressure of 200 MPa.
Take the following properties; E= 200GPa, KIC =20 MPa m1/2

m = 2, C = 2.2  10 -10 (m/cycle & MPa) in Paris law


Note : Due to shrinkage a contact pressure pc is generated. Upon loading by the internal
pressure pi, the compound cylinder is considered as a thick cylinder with  = ro / ri. Then
the total stresses are obtained by superposition.

Fig. 5(a) Crack in the 1st set Fig. 5(b) Crack in the 2nd set

You might also like