Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

3 MECHANICAL PROPERTIES OF MATERIALS

Review Questions
3.1 What is the dilemma between design and manufacturing in terms of mechanical properties?
Answer. To achieve design function and quality, the material must be strong; for ease of
manufacturing, the material should not be strong, in general.
3.2 What are the three types of static stresses to which materials are subjected?
Answer. tensile, compressive, and shear.
3.3 State Hooke's law.
Answer. Hooke's Law defines the stress-strain relationship for an elastic material: = E, where E =
a constant of proportionality called the modulus of elasticity.
3.4 What is the difference between engineering stress and true stress in a tensile test?
Answer. Engineering stress divides the load (force) on the test specimen by the original area;
whereas true stress divides the load by the instantaneous area which decreases as the specimen
stretches.
3.5 Define tensile strength of a material.
Answer. The tensile strength is the maximum load experienced during the tensile test divided by the
original area.
3.6 Define yield strength of a material.
Answer. The yield strength is the stress at which the material begins to plastically deform. It is
usually measured as the 0.2% offset value, which is the point where the stress-strain curve for the
material intersects a line that is parallel to the straight-line portion of the curve but offset from it by
0.2%.
3.7 Why cannot a direct conversion be made between the ductility measures of elongation and reduction
in area using the assumption of constant volume?
Answer. Because of necking that occurs in the test specimen.
3.8 What is work hardening?
Answer. Work hardening, also called strain hardening, is the increase in strength that occurs in metals
when they are strained.
3.9 Under what circumstances does the strength coefficient have the same value as the yield strength?
Answer. When the material is perfectly plastic and does not strain harden.
3.10 How does the change in cross-sectional area of a test specimen in a compression test differ from its
counterpart in a tensile test specimen?
Answer. In a compression test, the specimen cross-sectional area increases as the test progresses;
while in a tensile test, the cross-sectional area decreases.
3.11 What is the complicating factor that occurs in a compression test that might be considered analogous
to necking in a tensile test?
Answer. Barreling of the test specimen due to friction at the interfaces with the testing machine
platens.
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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

3.12 Tensile testing is not appropriate for hard brittle materials such as ceramics. What is the test
commonly used to determine the strength properties of such materials?
Answer. A three-point bending test is commonly used to test the strength of brittle materials. The test
provides a measure called the transverse rupture strength for these materials.
3.13 How is the shear modulus of elasticity G related to the tensile modulus of elasticity E, on average?
Answer. G = 0.4 E, on average.
3.14 How is shear strength S related to tensile strength TS, on average?
Answer. S = 0.7 TS, on average.
3.15 What is hardness, and how is it generally tested?
Answer. Hardness is defined as the resistance to indentation of a material. It is tested by pressing a
hard object (sphere, diamond point) into the test material and measuring the size (depth, area) of the
indentation.
3.16 Why are different hardness tests and scales required?
Answer. Different hardness tests and scales are required because different materials possess widely
differing hardnesses. A test whose measuring range is suited to very hard materials is not sensitive for
testing very soft materials.
3.17 Define the recrystallization temperature for a metal.
Answer. The recrystallization temperature is the temperature at which a metal recrystallizes (forms
new grains) rather than work hardens when deformed.
3.18 Define viscosity of a fluid.
Answer. Viscosity is the resistance to flow of a fluid material; the thicker the fluid, the greater the
viscosity.
3.19 What is the defining characteristic of a Newtonian fluid?
Answer. A Newtonian fluid is one for which viscosity is a constant property at a given temperature.
Most liquids (water, oils) are Newtonian fluids.
3.20 What is viscoelasticity, as a material property?
Answer. Viscoelasticity refers to the property most commonly exhibited by polymers that defines the
strain of the material as a function of stress and temperature over time. It is a combination of viscosity
and elasticity.

Problems
Answers to problems labeled (A) are listed in an Appendix at the back of the book.
Strength and Ductility in Tension
3.1 (A) (SI Units) A tensile test specimen has a gage length = 50 mm and its cross-sectional area = 100
mm2. The specimen yields at 48,000 N, and the corresponding gage length = 50.23 mm. This is the
0.2 percent yield point. The maximum load of 87,000 N is reached at a gage length = 64.2 mm.
Determine (a) yield strength, (b) modulus of elasticity, and (c) tensile strength. (d) If fracture occurs
at a gage length of 67.3 mm, determine the percent elongation. (e) If the specimen necked to an
area = 53 mm2, determine the percent reduction in area.
Solution: (a) Y = 48,000/100 = 480 MPa
(b) s = E e. Subtracting the 0.2% offset, e = (50.23 - 50.0)/50.0 - 0.002 = 0.0026
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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

E = s/e = 480/0.0026 = 184.6 x 103 MPa

(c) TS = 87,000/100 = 870 MPa
(d) EL = (67.3 - 50)/50 = 17.3/50 = 0.346 = 34.6%
(e) AR = (100 - 53)/200 = 0.47 = 47%
3.2 (USCS Units) A tensile test specimen has a gage length = 2.0 in and diameter = 0.798 in. Yielding
occurs at a load of 31,000 lb. The corresponding gage length = 2.0083 in, which is the 0.2 percent
yield point. The maximum load of 58,000 lb is reached at a gage length = 2.47 in. Determine (a) yield
strength, (b) modulus of elasticity, and (c) tensile strength. (d) If fracture occurs at a gage length of
2.62 in, determine the percent elongation. (e) If the specimen necked to an area = 0.36 in2, determine
the percent reduction in area.
Solution: (a) Area A = (0.798)2/4 = 0.50 in2. Yield strength Y = 31,000/0.50 = 62,000 lb/in2
(b) s = E e. Subtracting the 0.2% offset, e = (2.0083 - 2.0)/2.0 - 0.002 = 0.00215. This is the elastic
strain to be used in calculating modulus of elasticity.
E = s/e = 62,000/0.00215 = 28.84 x 106 lb/in2
(c) TS = 58,000/0.5 = 116,000 lb/in2
(d) EL = (2.62 - 2.0)/2.0 = 0.62/2.0 = 0.31 = 31%
(e) AR = (0.5 - 0.36)/0.5 = 0.28 = 28%
3.3 (SI Units) During a tensile test in which the starting gage length = 100.0 mm and the cross-sectional
area = 150 mm2. During testing, the following force and gage length data are collected: (1) 17,790 N
at 100.2 mm, (2) 23,040 N at 103.5 mm, (3) 27,370 N at 110.5 mm, (4) 28,910 N at 122.0 mm, (5)
27,400 N at 130.0 mm, and (6) 20,460 N at 135.1 mm. The final data point (6) occurred immediately
prior to failure. Yielding occurred at a load of 19,390 N (0.2% offset value), and the maximum load
(4) was 28,960 N. (a) Plot the engineering stress strain curve. Determine (b) yield strength, (c)
modulus of elasticity, (d) tensile strength, and (e) percent elongation.
Solution: (a) Student exercise.
(b) Yield strength = load at yielding divided by original area; thus, Y =19,390/150 = 129.3 MPa
(c) The first data point (1) occurred prior to yielding. Modulus of elasticity E = s/e
Engineering strain e = (100.2 - 100)/100 = 0.002; engineering stress = 17,790/150 = 118.6 MPa
E = 118.6/0.002 = 59,300 MPa
(d) Tensile strength = maximum load divided by original area: TS = 29,420/150 = 196.1 MPa
(e) Percent elongation EL = (135.10 100)/100 = 0.351 = 35.1%
Flow Curve
3.4 (A) (SI Units) In Problem 3.3, determine the strength coefficient and the strain-hardening exponent in
the flow curve equation.
Solution: Starting volume of test specimen V = LoAo = 100(150) = 15,000 mm3.
We must select two data points that occur after yielding but before necking. Necking occurs after
the maximum load is reached. The two points selected are (2) and (4): (2) F = 23,040 N and L =
103.5 mm; and (4) F = 28,910 N and L = 122.0 mm.
(2) A = V/L = 15,000/103.5 = 144.93 mm2
True stress = 23,040/144.93 = 159.0 MPa. True strain = ln(103.5/100) = 0.0344
(4) A = 15,000/122.0 = 122.95 mm2
True stress = 28,910/122.95 = 235.1 MPa. True strain = ln(122.0/100) = 0.1989
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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

Substituting these values into the flow curve equation, we have

(2) 159.0 = K(0.0344)n and (4) 235.1 = K(0.1989)n
235.1/159.0 = (0.1989/0.0344)n
1.479 = (5.782)n
ln(1.479) = n ln(5.782) 0.3914 = 1.7547 n n = 0.223
Substituting this value with the data back into the flow curve equation, we obtain the value of the
strength coefficient K:
K = 159.0/(0.0344).223 = 337.1 MPa
K = 235.1/(0.1989).223 = 337.2 MPa
The flow curve equation is = 337.15 0.223
3.5 (SI Units) In a tensile test on a steel specimen, true strain = 0.11 at a stress of 245 MPa. When true
stress = 340 MPa, true strain = 0.31. Determine the strength coefficient and the strain-hardening
exponent in the flow curve equation.
Solution: Two equations: (1) 245 = K(0.11)n and (2) 340 = K(0.31)n
340/245 = (0.31/0.11)n 1.3878 = (2.8182)n
n ln(2.8182) = ln(1.3333) 1.0361 n = 0.3277 n = 0.316
Substituting this value with the data back into the flow curve equation, we obtain the value of the
strength coefficient K:
(1) K = 245/(0.11).316 = 492.1 MPa
Check: (2) K = 340/(0.31).316 = 492.3 MPa
The flow curve equation is: = 492.2 0.316
3.6 (USCS Units) During a tensile test, a metal has a true strain = 0.08 at a true stress = 37,000 lb/in2.
Later, at a true stress = 55,000 lb/in2, true strain = 0.24. Determine the strength coefficient and strain-
hardening exponent in the flow curve equation.
Solution: (1) 37,000 = K(0.08)n and (2) 55,000 = K(0.24)n
55,000/37,000 = (0.24/0.08)n 1.4865 = (3.0)n
n ln(3.0) = ln(1.4865)
1.0986 n = 0.3964 n = 0.3608
Substituting this value with the data back into the flow curve equation, we obtain the value of the
strength coefficient K:
(1) K = 37,000/(0.08)0.3608 = 92,038 lb/in2
Check: (2) K = 55,000/(0.24)0.3608 = 92,041 lb/in2
Averaging the calculated values of K, the flow curve equation is: = 92,040 0.3608
3.7 (SI Units) A tensile test specimen begins to neck at a true strain = 0.22 and true stress = 257 MPa.
Without knowing any more about the test, determine the strength coefficient and the strain-hardening
exponent in the flow curve equation?
Solution: If we assume that n = when necking starts, then n = 0.22.
Using this value in the flow curve equation, we have K = 257/(0.22).22 = 358.6 MPa
The flow curve equation is: = 358.6 0.22
3.8 (SI Units) A tensile test provides the following flow curve parameters: strain-hardening exponent =
0.25 and strength coefficient = 500 MPa. Determine (a) flow stress at a true strain = 1.0 and (b) true
strain at a flow stress = 500 MPa.
Solution: (a) Yf = 500(1.0).25 = 500 MPa
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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

(b) = (500/500)1/.25 = (1.0)4.0 = 1.00

3.9 (A) (USCS Units) The flow curve for a certain metal has a strain-hardening exponent = 0.20 and its
strength coefficient = 26,000 lb/in2. Determine (a) flow stress at a true strain = 0.15 and (b) true strain
at a flow stress = 20,000 lb/in2. (c) What is the likely metal in this problem?
Solution: (a) Yf = 26,000(0.15).20 = 17,791 lb/in2
(b) = (20,000/26,000)1/.20 = (0.7692)5.0 = 0.269
(c) The flow curve parameters indicate that the metal is probably annealed pure aluminum,
according to Table 3.4.
3.10 (USCS Units) A metal is plastically deformed in a tensile test. The starting specimen had a gage
length = 2.0 in and an area = 0.50 in2. At one point during the test, the gage length = 2.3 in, and the
corresponding engineering stress = 25,000 lb/in2. At another point prior to necking, the gage length =
3.0 in, and the corresponding engineering stress = 28,000 lb/in2. Determine the strength coefficient
and the strain-hardening exponent for this metal.
Solution: Starting volume V = LoAo = 2.0(0.5) = 1.0 in3
(1) Area at gage length = 2.3 in: A = V/L = 1.0/2.3 = 0.4348 in2
Given engineering stress = 25,000 lb/in2, force F = 25,000(0.5) = 12,500 lb
True stress = 12,500/0.4348 = 28,749 lb/in2 and true strain = ln(2.3/2.0) = 0.1398
(2) Area at gage length = 3.0 in: A = 1.0/3.0 = 0.3333 in2
Given engineering stress = 28,000 lb/in2, force F = 28,000(0.5) = 14,000 lb
True stress = 14,000/0.3333 = 42,000 lb/in2 and true strain = ln(3.0/2.0) = 0.4055
These two data points can be used to determine the parameters of the flow curve equation.
(1) 28,749 = K(0.1398)n and (2) 42,000 = K(0.4055)n
42,000/28,749 = (0.4055/0.1398)n
1.4609 = (2.9006)n
ln(1.4609) = n ln(2.9006)
0.3791 = 1.0649 n n = 0.356
(1) K = 28,749/(0.1398).356 = 57,915 lb/in2
Check: (2) K = 42,000/(0.4055).356 = 57,915 lb/in2
The flow curve equation is: = 57,915 0.356
3.11 (SI Units) A tensile test specimen has a starting gage length = 75.0 mm. It is elongated during the test
to a length = 110.0 mm before necking occurs. Determine (a) the engineering strain and (b) the true
strain. (c) Compute and sum the engineering strains as the specimen elongates from: (1) 75.0 to 80.0
mm, (2) 80.0 to 85.0 mm, (3) 85.0 to 90.0 mm, (4) 90.0 to 95.0 mm, (5) 95.0 to 100.0 mm, (6) 100.0
to 105.0 mm, and (7) 105.0 to 110.0 mm. (d) Is the result closer to the answer to part (a) or part (b)?
Does this help to show what is meant by the term true strain?
Solution: (a) Engineering strain e = (110 - 75)/75 = 35/75 = 0.4667
(b) True strain = ln(110/75) = ln(1.4667) = 0.383
(c) (1) L = 75 to 80 mm: e = (80 - 75)/75 = 5/75 = 0.0667
(2) L = 80 to 85 mm: e = (85 - 80)/80 = 5/80 = 0.0625
(3) L = 85 to 90 mm: e = (90 - 85)/85 = 5/85 = 0.0588
(4) L = 90 to 95 mm: e = (95 - 90)/90 = 5/90 = 0.0556
(5) L = 95 to 100 mm: e = (100 - 95)/95 = 5/95 = 0.0526
(6) L = 100 to 105 mm: e = (105 - 100)/100 = 5/100 = 0.0500
(7) L = 105 to 110 mm: e = (110 - 105)/105 = 5/105 = 0.0476
_____________________________________________

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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

Sum of incremental engineering strain values = 0.3938

(d) The resulting sum in (c) is close to the true strain value in (b). The summation process is an
approximation of the integration over the range from 75 to 110 mm in (b). As the interval size is
reduced, the summation becomes closer to the integration value.
3.12 A tensile specimen is elongated to twice its original length. Determine the engineering strain and true
strain for this test. If the metal had been strained in compression, determine the final compressed
length of the specimen such that (a) the engineering strain is equal to the same value as in tension (it
will be negative value because of compression), and (b) the true strain would be equal to the same
value as in tension (again, it will be negative value because of compression). Note that the answer to
part (a) is an impossible result. True strain is therefore a better measure of strain during plastic
deformation.
Solution: Engineering strain e = (2.0 - 1.0)/1.0 = 1.0
True strain = ln(2.0/1.0) = ln(2.0) = 0.693
(a) To be compressed to the same engineering strain (e = -1.0) the final height of the compression
specimen would have to be zero, which is impossible.
(b) To be compressed to the same true strain value (e = -0.693) the final height of the compression
specimen can be determined as follows:
= -.693 = ln(Lf/Lo)
Lf/Lo = exp.(-0.693) = 0.500 Therefore, Lf = 0.5 Lo
3.13 (SI Units) Given that the flow curve strain-hardening exponent = 0.30 and strength coefficient = 500
MPa, determine the tensile strength for the metal. Note that tensile strength is an engineering stress.
Solution: Tensile strength occurs at maximum value of load, and necking begins immediately
thereafter. At necking, = n, and true stress = 500(0.30)0.30 = 348.4 MPa.
Given that n = 0.30 and = n, then = 0.30 at this value of true stress.
From Eq. (3.7), = 0.30 = ln(Lf/Lo), then Lf/Lo = exp(0.30) = 1.3499
Tensile strength TS is an engineering stress defined by Eq. (3.2): e = (Lf-Lo)/Lo = Lf/Lo-1
Thus, e = 1.3499 1 = 0.3499
From Eq. (3.9), = s(1 + e). Rearranging, s = /(1+e) = 348.4/(1+0.3499) = 258.1 MPa
Therefore, TS = 258.1 MPa
3.14 (SI Units) A copper wire of diameter 0.80 mm fails at an engineering stress = 248.2 MPa. Its ductility
is measured as 75% reduction of area. Determine the true stress and true strain at failure.
Solution: Area reduction AR = (Ao - Af)/Ao = 0.75
Ao - Af = 0.75 Ao
Ao - 0.75Ao = 0.25 Ao = Af
If engineering stress = 248.2 MPa, then true stress = 248.2/0.25 = 992.8 MPa
True strain = ln(Lf/Lo) = ln(Ao/Af) = ln(4) = 1.386. However, it should be noted that these values
are associated with the necked portion of the test specimen.
3.15 (A) (USCS Units) A low-carbon steel tensile specimen with starting gage length = 2.0 in and
cross-sectional area = 0.5 in2 reaches a maximum load of 20,000 lb. Its elongation at this point is
25%. Determine (a) tensile strength, (b) engineering strain, (c) true stress, and (d) true strain at this
maximum load.
Solution: (a) Tensile strength TS = maximum load divided by original area:
TS = Fmax/Ao = 20,000/0.5 = 40,000 lb/in2

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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

(b) Elongation is usually defined after fracture has occurred, but in this case we are given its value
while the test is still in progress; elongation = (L - Lo)/Lo = 0.25. The definition of engineering
strain is the same: e = (L - Lo)/Lo, according to Eq. (3.2). Thus, e = 0.25.
(c) True stress is defined as the load divided by the instantaneous area. Assuming no necking, we
know that AL = AoLo, or A = AoLo/L
Given the value of elongation, then L - Lo = 0.25 Lo
Therefore, L = 1.25 Lo or Lo/L = 0.80
A = 0.80Ao = 0.80(0.50) = 0.40 in2
True stress = 20,000/0.40 = 50,000 lb/in2
(d) True strain = ln(1.25) = 0.223
3.16 Derive an expression for true strain as a function of D and Do for a tensile test specimen of round
cross section, where D = the instantaneous diameter of the specimen and Do is its original diameter.
Solution: Starting with the definition of true strain as = ln(L/Lo) and assuming constant volume of
a cylindrical test specimen, we have V = AoLo = AL
Therefore, L/Lo = Ao/A
A = D2 and Ao = Do2
Ao/A = Do2 /D2 = (Do/D)2
= ln(Do/D)2 = 2 ln(Do/D)
3.17 Prove Eq. (3.8): Show that true strain = ln(1 + e), where e = engineering strain.
Solution: Starting definitions: (1) = ln(L/Lo) and (2) e = (L - Lo)/Lo
Consider definition (2): e = L/Lo - Lo/Lo = L/Lo - 1
Rearranging, 1 + e = L/Lo
Substituting this into definition (1), = ln(1 + e)
3.18 Prove Eq. (3.9): Show that true stress = s(1 + e), where s = engineering stress and e = engineering
strain.
Solution: Starting definitions: (1) = F/A, where A = instantaneous area, and (2) s = F/Ao, where
Ao = original area. We also note the definition of engineering strain: (3) e = (L - Lo)/Lo= L/Lo -1.
Assuming constant volume of a cylindrical test specimen, V = AoLo = AL, or L/Lo = Ao/A
Substituting this ratio in (3), e = Ao/A 1. Rearranging, Ao/A = 1 + e.
The load F in (1) and (2) is the same. Rearranging (1) and (2), F = A = sAo
Thus, = s(Ao/A) or = s(1 + e)
Compression
3.19 (SI Units) The flow curve for austenitic stainless steel has the following parameters: strength
coefficient = 1200 MPa and strain-hardening exponent = 0.40. A cylindrical specimen of starting
cross-sectional area = 1000 mm2 and height = 75 mm is compressed to a height of 60 mm. Determine
the force required to achieve this compression, assuming that the cross section increases uniformly.
Solution: For h = 60 mm, = ln(75/60) = ln(1.25) = 0.223
Yf = 1200(0.223).40 = 658.6 MPa
Starting volume V = 75(1000) = 75,000 mm3
At h = 60 mm, A = V/L = 75,000/60 = 1250 mm2
F = YfA = 658.6 (1250) = 823,250 N
3.20 (A) (SI Units) The following flow curve parameters were obtained for a metal alloy in a tensile test:
strength coefficient = 550 MPa and strain-hardening exponent = 0.25. The same metal is now tested
in a compression test in which the starting height of the specimen = 50 mm and its diameter = 30 mm.

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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

Assuming that the cross section increases uniformly, determine the load required to compress the
specimen to a height of (a) 45 mm and (b) 35 mm.
Solution: The starting volume of test specimen V = hDo2/4 = 50(30)2/4 = 35343 mm3
(a) At h = 45 mm, = ln(50/45) = ln(1.1111) = 0.1054
Yf = 550(0.1054).25 = 313.4 MPa
A = V/L = 35343/45 = 785.4 mm2
F = YfA =313.4(785.4) = 246,144 N
(b) At h = 35 mm, = ln(50/35) = ln(1.4286) = 0.3567
Yf = 550(0.3567).25 = 425.0 MPa
A = V/L = 35343/35 = 1009.8 mm2
F = YfA = 425.0(1009.8) = 429,165 N
3.21 (USCS Units) In a compression test, a steel test specimen (modulus of elasticity = 30 x 106 lb/in2) has
a starting height = 2.0 in and diameter = 1.5 in. The metal yields (0.2% offset) at a load = 140,000 lb.
At a load of 260,000 lb, the height has been reduced to 1.6 in. Determine (a) yield strength and (b)
flow curve parameters (strength coefficient and strain-hardening exponent). Assume that the
cross-sectional area increases uniformly during the test.
Solution: (a) Starting volume of test specimen V = hD2/4 = 2(1.5)2/4 = 3.534 in3.
Ao = Do/4 = (1.5)2/4 = 1.767 in2
Y = 140,000/1.767 = 79,224 lb/in2
(b) Elastic strain at Y = 79,224 lb/in2 is e = Y/E = 79,224/30,000,000 = 0.00264
Strain including offset = 0.00264 + 0.002 = 0.00464
Height h at strain = 0.00464 is h = 2.0(1 - 0.00464) = 1.9907 in.
Area A = 3.534/1.9907 = 1.775 in2.
True strain = 140,000/1.775 = 78,862 lb/in2.
At F = 260,000 lb, A = 3.534/1.6 = 2.209 in2.
True stress = 260,000/2.209 = 117,714 lb/in2.
True strain = ln(2.0/1.6) = 0.223
Given the two points: (1) = 78,862 lb/in2 at = 0.00464, and (2) = 117,714 lb/in2 at = 0.223.
117,714/78,862 = (0.223/0.00464)n
1.493 = (48.06)n
ln(1.493) = n ln(48.06)
0.4006 = 3.872 n n = 0.103
0.103
K = 117,714/(0.223) = 137,389 lb/in2.
The flow curve equation is: = 137,389 .103
Bending and Shear
3.22 (USCS Units) A ceramic specimen is tested in a bending test. Its width = 0.50 in and thickness = 0.25
in. The length of the specimen between supports = 3.0 in. Determine the transverse rupture strength if
failure occurs at a load = 1250 lb.
Solution: TRS = 1.5FL/bt2 = 1.5(1250)(3.0)/(0.5 x 0.252) = 180,000 lb/in2
3.23 (A) (SI Units) A bending test is used on an experimental cemented carbide material. Based on
previous testing of the material, its transverse rupture strength = 1000 MPa, what is the anticipated
load at which the specimen is likely to fail, given that its width = 15 mm, thickness = 7.5 mm, and
length = 50 mm?
Solution: F = (TRS)(bt2)/1.5L = 1000(15 x 7.52)/(1.5 x 50) = 11,250 N
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Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

3.24 (SI Units) A torsion test specimen has a radius = 25 mm, wall thickness = 3 mm, and gage length =
50 mm. In testing, a torque of 900 N-m results in an angular deflection = 0.3. Determine (a) the
shear stress, (b) shear strain, and (c) shear modulus, assuming the specimen had not yet yielded. (d) If
failure of the specimen occurs at a torque = 1200 N-m and a corresponding angular deflection = 10,
what is the shear strength of the metal?
Solution: (a) = T/(2R2t) = (900 x 1000)/(2(25)2(3)) = 76.39 MPa
(b) = R/L, = 0.3(2/360) = 0.005236 radians
= 25(0.005236)/50 = 0.002618
(c) = G, G = / = 76.39/0.002618 = 29,179 MPa
(d) S = (1200(103))/(2(25)2(3)) = 101.86 MPa.
3.25 (USCS Units) A torque of 6000 ft-lb is applied in a torsion test on a thin-walled tubular specimen
whose radius = 1.5 in, wall thickness = 0.125 in, and gage length = 2.0 in. This causes an angular
deflection = 1. Determine (a) shear stress, (b) shear strain, and (c) shear modulus, assuming the
specimen had not yet yielded. (d) If the specimen fails at a torque = 8000 ft-lb and an angular
deflection = 20, calculate the shear strength of the metal.
Solution: (a) Shear stress = T/(2R2t) = (6000 x 12)/(2(1.5)2(0.125)) = 40,744 lb/in2
(b) Converting 1 to radians, = 1(2/360) = 0.01745 rad.
Shear strain = R/L = 1.5(0.01745)/2.0 = 0.01309
(c) Shear modulus G = / = 40,744/0.01309 = 3.11 x 106 lb/in2.
(d) Cross-sectional area of tube A = 2Rt = 2(1.5)(0.125) = 1.1781 in2
Shear strength S = T/A = (8000 x 12)/1.1781 = 81,487 lb/in2
Hardness
3.26 (A) (SI/USCS Units) In a Brinell hardness test, a 1500-kg load is pressed into a specimen using a 10-
mm-diameter hardened steel ball. The resulting indentation has a diameter = 3.2 mm. (a) Determine
the Brinell hardness number for the metal. (b) If the specimen is steel, estimate the tensile strength of
the steel.
Solution: (a) HB = 2(1500)/(10(10 - (102 - 3.22).5) = 3000/(10 x 0.5258) = 182 BHN
(b) The estimating formula is: TS = 500(HB).
For a tested hardness of HB = 182, TS = 500(182) = 91,000 lb/in2
3.27 One of the inspectors in the quality control department has frequently used the Brinell and Rockwell
hardness tests, for which equipment is available in the company. He claims that the Rockwell
hardness test is based on the same principle as the Brinell test, which is that hardness is measured as
the applied load divided by the area of the impression made by an indentor. Is he correct? If not, how
is the Rockwell test different?
Solution: No, the inspectors claim is not correct. Not all hardness tests are based on the applied
load divided by area. The Rockwell hardness test measures the depth of indentation of a cone or
small-diameter ball resulting from an applied load.
3.28 (USCS Units) A batch of annealed steel has just been received from the vendor. It is supposed to have
a tensile strength in the range 60,000 - 70,000 lb/in2. A Brinell hardness test in the receiving
department yields a value of HB = 118. (a) Does the steel meet the specification on tensile strength?
(b) Estimate the yield strength of the material.

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9
Solutions for Fundamentals of Modern Manufacturing, 5e (published by Wiley) MPGroover 2012

Solution: (a) TS = 500(HB) = 500(118) = 59,000 lb/in2. This lies outside the specified range of
60,000 to 70,000 lb/in2. However, from a legal standpoint, it is unlikely that the batch can be
rejected on the basis of its measured Brinell hardness number without using an actual tensile test to
measure TS. The formula for converting from Brinell hardness number to tensile strength is only an
approximating equation.
(b) Based on Table 3.2 in the text, the ratio of Y to TS for low carbon steel = 25,000/45,000 =
0.555. Using this ratio, we can estimate the yield strength to be Y = 0.555(59,000) = 32,700 lb/in2.
Viscosity of Fluids
3.29 (A) (SI Units) Two flat plates are separated by a gap of 4 mm and move relative to each other at a
velocity of 5 m/s. The space between them is occupied by a fluid of unknown viscosity. The motion
of the plates is resisted by a shear stress of 10 Pa due to the viscosity of the fluid. Assuming that the
velocity gradient of the fluid is constant, determine the coefficient of viscosity of the fluid.
Solution: Shear rate = (5 m/s x 1000 mm/m)/(4 mm) = 1250 s-1
= (10N/m2)/(1250 s-1) = 0.008 N-s/m2 = 0.008 Pa-s
3.30 (USCS Units) Two parallel surfaces move relative to each other at a velocity of 25 in/sec and are
separated by a gap of 0.5 in. The gap is filled by a fluid of unknown viscosity. The relative motion is
resisted by a shear stress of 0.3 lb/in2 due to the viscosity of the fluid. If the velocity gradient in the
space between the surfaces is constant, determine the viscosity of the fluid.
Solution: Shear rate = (25 in/sec)/(0.5 in) = 50 sec-1
= (0.3 lb/in2)/(50 sec-1) = 0.0006 lb-sec/in2
3.31 (SI Units) A 125.0-mm-diameter shaft rotates inside a stationary bushing whose inside diameter =
125.6 mm and length = 50.0 mm. In the clearance between the shaft and the bushing is a lubricating
oil whose viscosity = 0.14 Pa-s. The shaft rotates at a velocity of 400 rev/min; this speed and the
action of the oil are sufficient to keep the shaft centered inside the bushing. Determine the magnitude
of the torque due to viscosity that acts to resist the rotation of the shaft.
Solution: Bushing internal bearing area A = (125.6)2 x 50/4 = 19729.6 mm2 = 19729.2(10-6) m2
d = (125.6 - 125)/2 = 0.3 mm
v = (125 mm/rev)(400 rev/min)(1 min/60 sec) = 2618.0 mm/s
Shear rate = 2618/0.3 = 8726.6 s-1
= (0.14)(8726.6) = 1221.7 Pa = 1221.7 N/mm2
Force on surface between shaft and bushing = (1221.7 N/mm 2)(19729.2(10-6)) = 24.1 N
Torque T = 24.1 N x 125/2 mm = 1506.4 N-mm = 1.506 N-m

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10