FT 14
M S Ramaiah University of Applied Sciences
Faculty of Engineering and Technology, Bangalore-58
Mechanical and Manufacturing Engineering Department
Course: [Link] in Advanced Machinery Design
7th Module: AMD504- Vibration, Fatigue and Fracture
Lab Exercises
Design for Infinite Life
Problem 1:
A plate made of steel 20C8 (UTS= 440MPa) is hot rolled and normalized
condition is shown in figure 1. It is subjected to a completely reversed axial
load of 30kilo Newton. The notch sensitivity factor q can be taken as 0.8 and
the expected reliability is 90%. The size factor is 0.85. The FOS is 2. Determine
the dimensions of the plate.
Fig: 1
Problem 2:
A rod of a linkage mechanism made of steel (UTS=500MPa) is subjected to a
completely reversed axial load of 100kilo Newton. The rod is machined on a
lathe and the expected reliability is 95%. There is no stress concentration.
Determine the diameter of the rod using a FOS of 2 for an infinite life condition
Problem 3:
A component machined from a plate made of steel 45C8 (UTS=630MPa) is
shown in fig.3. It is subjected to a completely reversed axial force of 50kilo
FT 14
Newton. The expected reliability is 80% and FOS=2. The size factor=0.85.
Determine the plate thickness for infinite life of the notch sensitivity is 0.8.
Fig. 2
Design for Finite Life
Problem 3:
A rotating bar made of steel 45C8 (UTS= 630MPa) is subjected to a completely
reversed bending stress. The corrected endurance limit of the bar is 315MPa.
Calculate the fatigue strength of the bar for a life of 90000cycles
Problem 4:
A forged steel bar 50mm diameter is subjected to a reversed bending strength
of 250MPa. The bar is made of steel 40C8 (UTS=600MPa). Calculate the life of
the bar for a reliability of 90%
Problem 5:
Fig. 3
A rotating shaft, subjected to a non –rotating force of 5kilo Newton and simply
supported between two bearings A and E is shown in fig.3. The shaft is
machined from plain carbon steel 30 C8 (UTS=500MPa) and the expected
FT 14
reliability is 90%. The equivalent notch radius at the fillet section can be taken
as 3mm. what is the life of the shaft.
Problem 6:
The section of a steel shaft is shown in Fig.4. The shaft is machined by a
turning process. The section XX is subjected to a constant amplitude bending
moment of 500kilo Newton-m. The shaft material has a UTS of 500MPa, Yield
strength=350MPa and endurance limit in bending for a 7.5mm diameter
specimen of 210MPa. The notch sensitivity factor can be taken as 0.8. The
theoretical stress concentration factor may be interpolated from following
values. The rt stands for fillet radius and ‘d’ is the shaft diameter. The reliability
is 90%. Determine the life of the shaft
Fig 4
Problem 7:
A cantilever beam made of cold drawn steel 20C8 (UTS=540MPa) is subjected
to a completely reversed load of 1000N as shown in Fig.5. The notch sensitivity
factor q at the fillet can be taken as 0.85 and the expected reliability is 90%.
Determine the diameter‘d’ of the beam for a life of 10000cycles.
FT 14
Fig.5
Cumulative Damage in Fatigue
Problem 8:
The work cycle of mechanical component subjected to completely reversed
bending consists of the following three elements
(i) +/- 350MPa for 85% of time
(ii) +/- 400MPa for 12% of time
(iii) +/- 500MPa for 3% of time
The material for the component is 50C4 (UTS=660MPa) and the corrected
endurance limit of the component is 280MPa. Determine the life of the
component.
Stress-Life Approach
Problem 9:
Fig.6
FT 14
A cantilever beam made of cold drawn steel 40C8 (UTS=600MPa and YS=380MPa)
is shown in Fig.6. The force P acting at the free end varies from -50N to +150N.
The expected reliability is 90% and the factor of safety is 2. The notch sensitivity
factor at the fillet is 0.9. Determine the diameter ‘d’ of the beam at the fillet cross
section.
Problem 10:
A transmission shaft if cold drawn steel 27Mn2 (UTS=500MPa and YS=300MPa) is
subjected to a fluctuating torque which varies from -100N-m to +400N-m. The
FOS is 2 and the expected reliability is 90%. Neglecting the effect of stress
concentration, determine the diameter of the shaft. Assume a distortion energy
theory of failure.
Problem 11:
A spherical pressure vessel, with a 500mm diameter inner diameter, is welded
from steel plates. The welded joints are sufficiently strong and do not weaken the
vessel. The plates are made from cold drawn steel 20C8 (UTS=440MPa and
YS=242MPa). The vessel is subjected to internal pressure, which varies from zero
to 6MPa. The expected reliability is 50% and the FOS is 3.5. The size factor is 0.85.
The vessel is expected to withstand infinite number of stress cycles. Calculate the
thickness of the plates.
Finite-Life Problems (Fluctuating Load)
Problem 12:
A cantilever spring made of 10mm diameter wire is shown Fig. 7. The wire is made
diameter wire of stainless steel 4Cr18Ni10 (UTS=860MPa, YS=690MPa). The force
P acting at the free end varies from 75N to 150N. The surface finish of the wire is
equivalent to the machined surface. There is no stress concentration and the
expected reliability is 50%. Calculate the number of stress cycles likely to cause
fatigue failure.
FT 14
Fig.7
Problem 13:
A polished steel bar is subjected to axial tensile force that varies from 0 to Pmax.
It has a groove 2mm deep and having a radius of 3mm. The theoretical stress
concentration factor and notch sensitivity factor at the groove are 1.8 and 0.95
respectively. The outer diameter of the bar is 30mm. The ultimate tensile strength
of the bar is 1250MPa. The endurance limit in reversed bending is 600MPa. Find
the maximum force that the bar can carry for 105 cycles with 90% reliability.
Problem 14:
A machine component is subjected to fluctuating stress that varies from 40 to
100MPa. The corrected endurance limit stress for the machine component is
270MPa. The ultimate tensile strength and yield strength of the material are 600
and 450MPa respectively. Find the factor of safety using
(i) Gerber theory
(ii) Soderberg line
(iii) Goodman line.
Also, find the FOS against static failure
Problem 15:
Fig.8
FT 14
A cantilever beam made of cold drawn steel 40C8 (UTS=600MPa, YS=380MPa) is
shown in fig.8. The force P acting at the free end varies from -50N to 150N. The
expected reliability is 90% and the factor of safety is 2. The notch sensitivity factor
at the fillet is 0.9. Determine the diameter d of the beam at the fillet c/s using
Gerber curve as failure criterion
Fatigue Design under Combined Stresses
Problem 16:
A machine component is subjected to 2-D stresses. The tensile stress in the X-
direction varies from 40 to 100MPa while the tensile stress in the Y-direction
varies from 10MPa to 80MPa. The frequency of variation of theses stresses are
equal. The corrected endurance limit of the component is 270MPa. The UTS of
the material of the component is 660MPa. Determine the FOS used by designer
Problem 17:
A transmission shaft carries a pulley midway between the two bearings. The
bending moment at the pulley varies from 200N-m to 600N-m, as the torsional
moment in the shaft varies from 70N-m to 200N-m. The frequencies of variation
of bending and torsional moments are equal to the shaft speed. The shaft is made
of steel FeE 400(UTS=540MPa and YS=400MPa). The corrected endurance limit of
the shaft is 200MPa. Determine the diameter of the shaft using a FOS=2.
Life Estimation using S-N approach
Problem 18:
An un notched circular rod with a diameter of 10mm is subjected to constant
amplitude bending at room temperature with Sm= 200MPa. The material is
340MPa and Sy’= 1000MPa. If the rod is commercially polished, estimate the
values of Sa, Smax, Smin, and R for a medial fatigue life of 50,000 cycles and no
yielding
FT 14
Problem 19:
Fatigue testing can take appreciable amount of time. Calculate the number of
hours, days or weeks it would take to apply 106, 107, or 108 cycles for test
frequencies of 1Hz