1/26/2011

Project1testingsetup
ComponentFailure

24370 Spring2011
ProfessorSteveCollins

Announcements
HW2assigned,duenextWednesday
Homeworks guideprojects

Project1Questions?
Whereweareinthecourse
Tools:sketching,SolidWorks
Analyses:stress,failure(today)
Nextup:Design!
Firstloop:geometry,mass,andfactorofsafety

FailureinMechanicalEngineering
Whatisfailure?
Compromisation ordegradationofanykind
Commonly:breakingorpermanentlybending
Also:bendingtoomuch,wear,dynamicfailure
Also: bending too much wear dynamic failure

Today:customcomponentfailure
Common&mosteasilyestimatedmodes
Later:catalogcomponentfailure

ButfirstFailure!

FailedMechanicalParts

AvoidingFailure
Realitycanbeatrickyplacetooperate
Failureisverydifficulttoestimateaccurately
Models:simple,generalizable,butmissdetails
Empiricaldata:accurate,butcasespecific
Empirical data: accurate but case specific
Prototyping:bestdata,butexpensive

WhatdoesaMechanicalDesignEngineerdo?
Usemodelsorempiricaldatafirst
UseappropriateFactorsofSafety
Prototypeandtest

1/26/2011

CommonFailureModes
Staticloading

Failureduetostaticloading
Relatedtodevelopmentofexcessivestress

Primarilyrelatedtostress
Ultimatestressexceeded breakage
Yieldstressexceeded
Yield stress exceeded plasticdeformation
plastic deformation
Impermissibledeflection

Exceedingyieldstressisoftenunacceptable
Whichmaximumstresstouse?
Manymodels,dependingonmaterial&risks
Many models depending on material & risks
Typically,vonMises equivalent(distortionenergy)
=(((1 2)2 +(2 3)2 +(3 1)2 ))
Ssy =0.58Sy
Purenormalstressequivalents

Buckling breakage

Cyclicloading:fatigue
Similarstressanalysis,verydifferentbehaviour
Fatiguelife(#cycles)exceeded breakage

Failureduetostaticloading

ModelsofFailureduetoStaticLoading

Relatedtodevelopmentofexcessivestress
Exceedingyieldstressisoftenunacceptable
Whichmaximumstresstouse?
Manymodels,dependingonmaterial&risks
Many models depending on material & risks
Typically,vonMises equivalent(distortionenergy)

Stressconcentrations?
InDuctilematerials,usuallynot
Stressdistributing,strainhardening

InBrittlematerials,definitelyyes
(later:alsofatigue)
Andstressconcentratorsareeverywhere!

Ductilevs BrittleFailure
Ductilematerialsstrainalot,thenfail
Brittlematerialsjustfail
Typically,f 0.05
Often,only
Of
l u reported
d

FractureMechanics

Failureusuallyoccursalongcracks
Cracksareeverywhere!
Brittlematerialsparticularlysusceptible
Researchoncrackpropagationongoing

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StaticFailureAnalysisSummary
Useempiricaldatatodetermineyieldstrength
Orultimatestrengthforbrittlematerials

Determinemaximumstressindesign
Simplemodels(lastweek)
Si l
d l (l
k)
Stressconcentrationsforconservativeorbrittlecases

SpecialCase:ContactStress
Stronganalyticalmodelsfor
sometypes,e.g.cylindrical:
IvetypicallyusedFEA
SolidWorks
S lidW k example
l
Pininhole

FEAanalysis(lastweek)

Comparetoobtainfactorofsafety
Design:setm Sy FOS1
Obtainingthisrelationshipthatsthefunpart!

SolidWorks contactexample

Deflection
Possiblefailuremode:excessivedisplacement
Compressionortension: =FLA1 E1
Load,length,area,andmaterialstiffness

Torsion: =TLJ11 G11

Rotationalequivalents

Bending:dependsuponloading
Manyapproaches:seeShigley,others
Cantilever:e =FL3 E1 I1

Stiffness:rearrangeterms

Buckling

SolidWorks BucklingExample

Specialdeflection
Long,thinelements
incompression
Unstable
Smalldeformations
increaseleverage

Simplemodel
Fcr =C2 EI L2

FEA:SolidWorks

1/26/2011

FailureduetoFatigue
Everyoneknows:pushhardandthingsbreak
Butlotsoflittlepushesbreakingsomething?
Crazy,buttrue.Thisisfatigue

Fatigueoccursbelow(apparent)yieldstresses
(
)
Samestresses,differenteffects

Afteranumberofcycles,thepartfails
Predictingfatiguefailure:

StagesofFatigueFailure
Stages:
A Crackinitiation
Atconcentrator
Oratcrack
Or at crack

B Propogation
Oftenhidden

C Finalfailure
Oftenbrittle

Difficulttomodel,butempiricaldatauseful
Insightintomechanismshelpfultoo

Patternstellastory

FatigueLifeandStrength
Needtoaccountfor#cyclesaswellasload
Peaksustainablestress,S
Numberofcycles,N

DiagramsofSvs.N
Di
fS
N
Materialspecific
Detailedfatiguedata
Idealizedconditions

Scalarfatiguestrength
PeakstressSthatmaybefullyreversedNtimes

FatigueLife:SteelSNDiagram

EnduranceLimitforSteels

1/26/2011

AluminumSNDiagram

InterpretingSNDiagrams
Steelhasinfinitefatigueliferegion
Fatiguestrengthcorrespondstoinfinitelife

Aluminum(andmostothermaterials)donot
FatiguestrengthtypicallymeansN=10
F i
h
i ll
N 108

SNdiagramsusefulforsublimitperformance
Often,wejustwant(N=108)
Careful:thisdataisforspecificconditions

FatigueLifeAnalysis
Stresslifemethod
Simplest,mostdata,N103,butleastaccurate

Othermethods:strainlife(lowN),fracture(crack)

Obtainmaterial
Obtain materialspecific
specificfatiguestrength
fatigue strength
Generally,useempiricaldata
Steelendurancelimit:Se 0.5Sut

Applystrengthreducingfactors
Duetosurface,size,load,temp,freq,etc.

Comparetopeakstressincomponent
Usefatiguestressconcentrationfactors

FinalCaveats
Failureisstochastic
Inmanyways
e.g.actualyieldstress

Indesign:
I d i
Modelinguseful
Emprical datauseful
Prototypingcrucial
Iterationisreality

FatigueAnalysisExample
Material:Alum7075T6,Sf =23ksi,Su =83ksi
Fatiguestrengthmodificationfactors:
Loading:bending kc =1
Surface:ground
Surface: ground
ka =a Sub ,a =1.34,b =0.085 ka =0.92

Size:diameterD=1
Kb =0.879D0.107 kb =0.88

Partstress
Peakbendingstressm =9ksi (noconcentrators)

Synthesis:Sf =ka kb kc Sf =18ksi

FOSf =2

SuggestedReading
Shigley Chapters4,5&6
Basicsfortheuninitiated
Detailsfortheexpert
Includesformulaefromlecture
Includes formulae from lecture
AccompanimenttoHW3(nextweek)