AbuDhabiUniversity

CollegeofEngineering&ComputerScience

DepartmentofMechanicalEngineering

Assignment2(DueDate:MonMay04,2015)

[1] A plumber wishes to unscrew an old cast iron pipe

using a 15" wrench. The pipe is 24" long, 1.75" i.d., 2.0"
o.d. and is secured at its lower end in an old rusted fitting.
Application of oil and the uttering of certain (technical)
words have not been successful in freeing the rust.
Determine the maximum force that can be applied to the
end of the wrench without breaking the pipe.
For the cast iron, Sut = 15ksi, Suc = 45ksi. Assume that local
stress irregularities at the lower end of the pipe (due to screw
threads, etc.) locally double the stresses expected in that area,
i.e. there is a stress concentration factor of 2.
How could the plumber change his procedure to get a better
chance of unscrewing the pipe without breaking it? Justify your
answer.

MEC430MachineDesign

FailureAnalysis

15 in

F
24 in

Pipe outer diameter = 2.0 in

Pipe inner diameter = 1.75 in
Pipe material: Cast iron having:
Sut = 15 ksi, Suc = 45 ksi
Stress concentration factor at
bottom of pipe = 2.0

[2] A thin walled closed-ended pressure cylinder with mean diameter D equal to 30 in. and a
thickness t equal to 1.0 in. is subjected to an internal pressure of 1000 psi. The material yield
strength for the cylinder is Sy is 30 kpsi. What is the factor of safety using Tresca and von-Mises
criteria? What is the axial load that should be put on the cylinder in order to make the two factors of
safety from Tresca and von-Mises to be the same? What is the new factor of safety?
SOLUTION:

[3] A thin-walled pressure vessel with cylindrical body and spherical ends is subjected to an internal
pressure, . The following data is given:
Spherical end mean diameter
Cylindrical wall thickness
Material yield strength
Material ultimate strength
Poissons ratio
Ignoring the transition (discontinuity) stresses between
the cylinder walls and the spherical ends, use von-Mises and Tresca criteria to:
a) Find which part of the vessel will yield first (i.e., the cylindrical or the spherical part).
b) Find the value of at yield for both cases.

[4] A steel bar has ultimate strength, Sut = 700 MPa, yield strength, Sy = 500 MPa, and a fully corrected
endurance limit Se = 200 MPa. For each of the following cases find the factors of safety which guard against
static and fatigue failures (use Soderberg, Goodman and Gerber criteria):
a)
b)
c)

Pure shear with a mean value m = 140 MPa, and an alternating value a = 70 MPa
Mean shear stress xym = 140 MPa, and an alternating normal stress xxa = 80 MPa
Mean normal stress xxm = 140 MPa, alternating normal stress xxa = 80 MPa, mean shear stress xym
= 70 MPa, and alternating shear stress xya = 80 MPa

Solution:
Sut = 700 MPa, Sy = 500 MPa, Se = 200 MPa
m = 140 MPa, a = 70 MPa
max = m + a
= 140 + 70 + 210 MPa
The yield strength in shear is Ssy = 0.577 Sy = 0.577 (500) = 288 MPa
Therefore
The static factor of safety = Ssy / max = 288/210 = 1.37
a)

The endurance limit in shear Sse = 0.577Se = 0.577(200) = 115 MPa

The fatigue factor of safety = Sse / a = 115/70 = 1.64

c)

xm = 140 MPa, xym = 70 MPa,

xxa = 80 MPa,

xya = 80 MPa

The principal mean stress values are

pm

xxm yym
2

yym
2
xxm
xym
2

140
140
2

70
2
2

1m 168.99 MPa

2 m 0.0
3m 28.99 MPa
Then the equivalent mean von-Mises stress is
1
( 1m 2 m ) 2 ( 2 m 3m ) 2 ( 3m 1m ) 2
em
2
185.195 MPa
the static factor of safety
S
700
F .S ut
3.76
em 185.195
Similarly for xxa = 80 MPa, xya = 80 MPa

The principal alternating stress values are

pa

xxa yya
2

yya
2
xxa
xya
2

80
80
2

80
2
2

1a 129.44 MPa

2 a 0.0
3a 49.44 MPa
Then the equivalent alternating von-Mises stress is
1
ea
( 1a 2 a ) 2 ( 2 a 3a ) 2 ( 3a 1a ) 2
2
159.99 MPa
Now, we can use em and ea to find the required factor of safety.

[5] The cold drawn steel plate sown in the figure is subjected to a constant tension load of 1000 lb and a fluctuating
bending moment between 800 and 1200 lb-in. Estimate the factor of safety guarding against yielding and fatigue failure
by using the maximum shear theory and the Goodman line.
What is the minimum KIC for the material that would allow a crack of size a = 0.05 emanating at the center of the
notch on both sides.
The following data is available:
Goodmans line equation:
a

2
N
m 1

Se / Fs Su / Fs

Stress intensity factor may be calculated from the following

equation:

K I 1.1 aT ,

aT a 0.1

Sut = 85 ksi (85,000 psi) Syt = 55 ksi

Se = 0.5 Sut (without modification)
Static Stress concentration factor for bending and tension at
the notch = 2.5
Fatigue Stress concentration factor at the notch = 2.75
Combined reduction factor for endurance limit = 0.65

0.5

0.1R

[6] Find the diameter of the hole (2r) and total width
D of the plate in figure if the part is to be safe for
continuous operation. The load varies between 160
kN to 89 kN. Use a safety factor ns=1.5, ultimate
strength, Su = 560 MPa, yield strength, Sy=356 MPa,
endurance limit, Se=220 MPa, notch sensitivity factor,
q =0.9. The plate is 25 mm thick. Use the Goodman
equations.

25 mm

2r
D

25 mm

Stress

[7] The crank shown in figure has a diameter d = 15 mm and

is made of 2024-T4 Aluminum alloy having Sut = 430 MPa, Syt
= 330 MPa and Se = 160 MPa (corrected value) for 108
cycles. The load P varies between 0 and 500 N and will be
applied for 108 cycles. Assume Gerber relation is valid.
i) Is the design governed by yield or fatigue failure?
ii) Determine the factor of safety for yield using the maximum shear criterion. (18 Points)

ma
a=m
m

min=0

Time
P

max 2

min
2

22 2
2

133.59

fs ,
104.17

11 133.59 f S MPa,

11 33 S yt

gives

where f s : factor of safety

22 104.17 f S MPa,
f S 2.47

33 0