For AISI 3140 steel ([Link]
ID=AISI_3140&prop=all&Page_Title=AISI%203140 this link gives the properties of AISA 3140 steel )
The only thing which is going to decide that whether the failure would occur first at the fillet and not at
the hole is the stress concentration factor.
Kt = A(r/D) b
D/d = 2, which gives
A= .90879
b= -.28598
Kt = 1.9
Now for the hole we will consider following tables
In the case of hole
Now for Kt = stress concentration factor (Pg 997 Appendix D Machine Design by Robert Norton )
First we have d/D = .5
Kta = 3.9702- 9.292(d/D)+27.159(d/D) 2 + 30.231(d/D)3 – 393.19(d/D)4 + 650.39(d/D)5 +15.451(d/D)6 =
5.8846
Ktb = 3.92150 – 24.435(d/D) + 234.06(d/D) 2 – 1200.5(d/D)3 + 3059.5(d/D)4 – 3042.4(d/D)5 = -3.604
Kt = Kta+Ktb = 2.22
So the stress concentration factor is higher in the case of hole so we will consider it for the failure
calculation
Sut = 689.5 MPa
For steel bar under torsion
Se’ = .29 Sut ≈ 200 MPa
For 50% reliability, reliability factor
Kr = 1
For ground surface finish, surface finish factor
Ks = 1.58x(689.5)-.085 (slide 238 MEL [Link])
Temperature factor = Ktemp = 1
Size factor = Ksize = 1.24(20)-.107 (slide 241 MEL [Link])
Se = Ks*Kr* Ktemp *KsizeSe’/Kt = 74.45 MPa
Yield stress = Syt = .75 Sut
= .75 * 689.5 = 517.125 MPa
Now stress σ= 16T/πd3
Table 1
S. No. Tmax Tmin Tm Ta σm σa Sti
1 180 0 90 90 57.32484076 57.32484076 -------
2 500 150 325 175 207.0063694 111.4649682 185.8686
3 300 -25 137.5 162.5 87.57961783 103.5031847 124.6064
4 200 -200 0 200 0 127.388535 127.3885
We can see that case 1 lies in region of safety (and hence imparts infinite life) but case 2,3 don’t lie in
region of safety and case 4 is a case of reversed loading . So we will extrapolate the goodman graph and
find St which we will find through similar triangles. We will use St in SN line equation to find the life cycle
due to individual stresses. We will use the following formula
Sti = OQ = AO*MD/AM 2.791, 1.873
The results are given in table 1
For the SN curve we will solve the following two equations
log(.9Sut) = k1*log103 + k2
log(Se) = k1*log106 + k2
here Sut and Se are in Mpa
Solving the 2 equations for k1 and k2 we get
k1 = -.306
k2 = 3.709
so now we will solve the following equation for cases 2,3 and 4
log(Sti) = -.306logNi + 3.709
this gives following table 2
Ni no of cycles in 10 seconds period αi
(ni)
infinite 5 0.22727
3
50723.48 8 0.36363
6
173780.08 3 0.13636
4
186208.71 6 0.27272
4 7
SUM 22
αi = ni/sum
now we will use miner’s formula
Σ αi/Ni = 1/N
Where N = total life
Solving we get N = 106209.41 cycles
Q2.
a) Generally a preload value is determined experimentally but a 90% preload is generally safe for
all dynamic loading applications
For M12 SAE grade 5.8 bolt
At = 84.27 mm2
Sp = proof strength = 380
So Fi = .9SpAt = .9*380xE6*84.27xE-6 = 28.82 kN
This preload can be achieved by torquing the bolt with a torque wrench
b) Force applied on the cap = PA = P*π*d2/4 = .071P
Now there are 10 bolts so
10*preload = .071P
So P = 10*28820/.071 = 4059154.92 Pa = 4.06MPa
c) Bolt properties for SA grade 5.8 bolt are international standards and hence can be found out in
every book
Sut = 520 MPa
Yield strength = Sy = 420 Mpa
For axial loading Se’ = .45Sut =234
For the below values of different factors this link has been referred
[Link]
%20design1/pdf/Module-3_lesson-[Link]
Size factor C1 = .85
Load factor C2 = .85
Surface finish factor C3 = .76 (for machined surfaces)
Temperature factor C4 = 1
Reliability factor C5 = .897 (90% reliability)
Kf = 2.2 (from slide 103 MEL 311 part 2)
Se = C1C2C3C4C5Se’/kf = 52.38 Mpa
Now we will use modified goodman line and factor of safety 1 we have (refer to slides 104 and
105 of MEL 311 part 2 )
σm σa
+ =1 --------------1
Sut Se
σm σa
+ =1 ------------------2
Sy Sy
Solving equations 1 and 2 we have
σm= 408.798
σa = 11.2
tanθ = σa/ σm = .027
here F = load on the bolt assembly
Fbmax = Fi + Fmax Kb/(kb + kp) = Fi + Fmax [Kb/(kb + .25kb)] = Fi + .8Fmax
Fi = preload
Kb = bolt stiffness
Kp = part stifness
Fbmin = Fi + Fmin Kb/(kb + kp) = Fi
σa = (Fbmax –Fbmin)/(2*A) = .4Fmax/A
σm = Fi+.4Fmax/A
where A = 84.27 mm2
now
σm/520xE6 + σa/52.38xE6 ≤ 1
solving we get
Fmax ≤ 3432.694 N
Now tan θ = σa/ σm = .045 which is greater than .027 hence this line will be applicable
Similarly solving
σm/420xE6 + σa/420xE6 ≤ 1
solving we get
Fmax ≤ 8216.75 N
From the two values of Fmax we chose the smaller one
Now there are 10 bolts so this Fmax will be multiplied with 10
PA = .071P = 10*3432.694
P = .483 Mpa
d) Maximum stress in a thin walled vessel (whether cylindrical or spherical)is= pr/2t
Where r = radius
t = thickness
p = pressure
assuming the vessel to be of steel and taking the UTS of this steel to be same as that AISI 3140
properties of this steel on this link
[Link]
ID=AISI_3140&prop=all&Page_Title=AISI%203140
we have
UTS = 689.5 Mpa
and yield strength = 422 MPa
so 422xE6 = pr/2t
t = (483000 * .15)/(2*422xE6) = .00009 m = .09 mm
this is the minimum thickness the wall of the vessel must have
References :
Robert L. Norton --Machine Design: An integrated Approach Second Edition
MEL [Link]
MEL 311 part [Link]
[Link]
VRc1oC&pg=PA176&lpg=PA176&dq=life+of+a+component+in+fluctuating+stresses&source=bl&
ots=by9GIcFn3Z&sig=1ggvzVgIcw-
B1s5p5kFs92L6Pmg&hl=en&ei=KPVvTJqbJY7qvQPrqvlB&sa=X&oi=book_result&ct=result&resnu
m=2&ved=0CBoQ6AEwAQ#v=onepage&q=life%20of%20a%20component%20in%20fluctuating
%20stresses&f=false pg 178