MANE-4030 Elements of Mechanical Design Exam #2, 4/1/2010 Prof. A. Maniatty 1.

Consider the steel beam fixed at one end and simply supported at the other, as shown below. Assuming that P = 1800 N, L = 3 m, a = 1.2 m, and I = 4 105 m4 , use Castiglianos method to find the redundant reaction at the simple (roller) support. (23 points)

MANE-4030 Elements of Mechanical Design Exam #2, 4/1/2010 Prof. A. Maniatty 2. A structural support member in a power plant (operates at about 20C) is made of 6061-T651 aluminum plate that is 25 mm thick, 150 mm wide, and 2 m long. The component is loaded in bending as shown with the resulting bending moment diagram provided for your convenience. During a routine inspection, a through-the-thickness edge crack of 7.5 mm length emanating from the lower edge is observed as sketched in the figure. If a safety factor of 1.5 guarding against fracture and yield is required, should the component be taken out of service? (22 points) 30 kN 1.0 m 0.5 m

30 kN 0.5 m 0.15 m

30 kN

through-thethickness crack

30 kN

M (N-m) 15,000

0.5 m

1.5 m

2m

MANE-4030 Elements of Mechanical Design Exam #2, 4/1/2010 Prof. A. Maniatty 3. A static force of 185 lb is applied at D near the end of the 15-in lever shown in the figure.

(a) If the bar is made of AISI 4620 (CD) steel, is it predicted to fail (assume critical location is A)? What is the safety factor guarding against failure? (10 points)

MANE-4030 Elements of Mechanical Design Exam #2, 4/1/2010 Prof. A. Maniatty (b) The bar shown below is made of ASTM class 50 gray cast iron and has dimensions d = 50 mm and D = 56 mm. If it is subjected to a static torque of 2000 N-m and a static axial load of 225 kN, is it predicted to fail? What is the safety factor? (16 points)

MANE-4030 Elements of Mechanical Design Exam #2, 4/1/2010 Prof. A. Maniatty 4. Short answer. (a) It has been suggested that AISI 1060 hot-rolled steel be used for a power plant application in which the cylindrical member is subjected to an axial load that cycles from 280 kN tension to 400 kN compression, repeatedly at a rate of 300 cycles per minute. The part is to have a fineground finish. A very long life is desired with a reliability of 99%. (i) Estimate the fatigue strength. (ii) Assuming stress concentration effects are negligible, the Goodman theory is a valid for this material and a safety factor of 1.2 guarding against fatigue failure, what diameter is required for the cylindrical member? (10 points)

(b) The stress state at a point is x = 10 MPa, y = 4 MPa, z = 5 MPa, xy = 3 MPa, xz = 0, yz = 6 MPa . What is the equivalent uniaxial stress associated with this stress state? (4 points)

MANE-4030 Elements of Mechanical Design Exam #2, 4/1/2010 Prof. A. Maniatty (c) A sheet-steel ( E = 30 10 6 psi, G = 11.5 10 6 psi) cantilevered bracket of rectangular cross section 0.125 inch by 4.0 inches is fixed at one end with the 4.0 inch dimension vertical. The bracket, which is 14 inches long, must support a vertical load, P, at the free end. Estimate the buckling load for this member? (6 points)

(d) It is recommended for a highly local, static loading in a brittle material that the full theoretical stress concentration factor be applied; however, for the same conditions in a ductile material, no stress concentration factor (i.e. Kt = 1) is usually needed. Explain why? (4 points)

MANE-4030 Elements of Mechanical Design Exam #2, 4/1/2010 Prof. A. Maniatty (e) A solid cylindrical bar of 2024-T4 aluminum alloy, whose fatigue behavior is represented in Fig. 5-31, is to be subjected to a duty cycle that consists of the following spectrum of completely reversed axial tensile stresses: 40 ksi for 1200 cycles, 25 ksi for 37,000 cycles, and 33 ksi for 4300 cycles. How many duty cycles are expected before fatigue failure? (5 points)