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MaterialsandManufacturing2(ENB331)
DrTuquaboTesfamichael
(Unit Coordinator)
(UnitCoordinator)
t.tesfamichael@qut.edu.au
Semester2,2011
1
Lectures
Thursdays810aminRoomD101
TextBooks:
W.D.Callister,MaterialsScienceandEngineering:An
Introduction, (2007,7th Edition)
S.KalpakjianandS.R.Schmid,ManufacturingEngineeringand
Technology(2006,5th Edition)
Outline:
Outline:
Failure:Fracture,Fatigue,Creep(wks1,2&8,TT)
MetalCuttingandMachiningEconomics(wks3&4,MR)
CuttingToolTechnology andOperations(wks5&6,WS)
AdvancedManufacturing(wk7,MR)
PolymersandCeramics(wks9&10,MR)
Composites(wk11,TT)
JoiningProcesses(wk12,WS)
Lecturers:
DrMaksymRybachuk:maksym.rybachuk@qut.edu.au
DrWijithaSenadeera:w3.senadeera@qut.edu.au
Project:
DrRabiulAlam:RabiulA@nojapower.com.au
MrJonathanJames:jm.james@qut.edu.au
Tutorials:
MrMarkBroadmeadow:mark.broadmeadow@qut.edu.au
Mr Mark Broadmeadow: mark broadmeadow@qut edu au
MissMaryamShirmohammadi:m.shirmohammadi@qut.edu.au
MrIsuruWlckramasinghe:m.wickramasinghe@qut.edu.au
LabPracticals:
MrPeterGillett:peter.gillett@live.com.au
MrAlexanderMalaver:alexander.malaverrojas@qut.edu.au
Technicalstaff:
MrGregPaterson:g.paterson@qut.edu.au
MrArminLiebhardt:armin.liebhardt@qut.edu.au
Tutorials
Tutorialswillstartinweek3.
Youwillhave8tutorialsduringthesemester.
Pleasehavealooktheweekbyweektimetablein
theunitinformation.
All
AllocationtotutorialisViaQUTVirtual:
i
i l i Vi QUT Vi
l
https://qutvirtual.qut.edu.au/
Practical
GroupProject
Twopracs(wks46forprac1,wks79forprac2)
AllocationViaPracallocationsystem:
http://www.bee.qut.edu.au/study/current/resources/o
nlinesys/
Pracreportstobesubmittedindividually:
Prac reports to be submitted individually :
4informationclasses(wks2,3,5&7)andallocation
toclassesisViaQUTVirtual.
1demonstrationprac(wk8)thatyouneedto
allocateViaPracallocationsystem.
YouMUSTalsoallocateyourselftoaparticulargroup
of not more than 5 members through the
ofnotmorethan5membersthroughthe
BlackboardwebsiteundertheUsersandGroups
menu.
Groupreporttobesubmittedthroughtwostages
(progressreportinwk6andfinalreportinwk12).
Pleasereadtheprojecthandoutfordetail
information.
Duedatesforprac1isinwk7andprac2inwk102.
Pleasefollowtheformatgivenintheprachandoutsfor
yourpracreports.
Important:youmustwearcoveredshoeandshould
followanysafetyfromthelabdemonstratorand/or
technicalstaff!
Assessment
FailureMechanisms
Twoprac15%
GroupProject35%
Finalexam(50%)
CRAwillbeusedforthethreeassessments.
W.D.Callister,Chapter8
AdditionalReferences
Hertzberg:DeformationandFractureMechanicsof
EngineeringMaterials
g
g
Broek:ElementaryEngineeringFractureMechanics
Barsom &RolfeFractureandfatigueControlin
Structures
Farahmand,FractureMechanicsofMetals,
Composites,Welds,andBoltedJoints Applicationof
LEFM,EPFM,andFMDMTheory
FailuresinEngineeringStructures
MostfailuresinEngineeringstructuresoccurreddueto
propagationofcracksfromdefects.
Thiscanbecancaused:
poordesign,poormaterialselection,imperfections,
processingandfabricationsofmaterials, assemblyandservice
conditions of components, etc.
conditionsofcomponents,etc.
Examplesofcatastrophicfailure:
LibertyShipsandT2Tanker(WorldwarII).
CometAircraft(mid1950s).
Molassestank(1919,1973).
Titanic(1912).
KingsBridgeinMelbourne(1962).
10
11
12
De Havilland Comet in
mid-1950
ClassificationofFailureMechanisms
1.Fracture:failureofmaterialsunderstatic
(constant)loading:
Brittlefracture:breakingofmaterialsfollowing
elasticdeformation(fracturedominantfailure).
(
)
Ductilefracture:duetoelongationbeyondpointof
necking(yieldingdominantfailure).
Poor Design
Fracture
YieldingDominantFailure:
Formationofmicrovoidsandcavitiesatgrainboundariesor
interfacesbetweenmaterialandsmallimpurities.
Coalescenceofvoidsandcavitiestoformellipticalcrack.
Indoingthis,extensiveplasticdeformationaroundcracktip
untilcriticalcracklength.
Rapidpropagationofcrackbysheardeformationat~45o to
tensileaxis.
2.Fatigue: timedependentfailuredueto
repeatedstress/strain(cyclic),here<<y.
3.Creep: timedependentstrain(deformation)
understaticloadathightemperature.
YieldingDominantFailure
YieldingDominantFailure
CUPandCONEfracture.
DefectsinYieldingDominantFailurearemicroscopic:
Dislocations.
Interstitials.
grainboundaries.
Precipitates.
Fibrouscentralregionconsistingofmultiple
"dimples"(leftoverfrommicrovoids).
Shearlip(tearing)ofmaterialatouterregion.
FractureDominantFailure
FractureDominantFailures
Crackpropagatesrapidlyandperpendiculartotensile
axis.
Littleplasticdeformationaroundcracktip.
Veryflatfracturesurface(cleavage).
FlawsinFractureDominantFailurearemacroscopic:
Weldflaws.
porosity(holes).
Inclusions.
fatigueandstresscorrosioncracks.
fracture initiation
20
20
FractureMechanics
FractureMechanics
Concernedwithbehaviourofmaterialscontaining
flawsandtheconditionsinwhichtheypropagate.
Fracturemechanicsdeterminerelationshipbetween
materialproperties,defect(flaw)sizeandloads.
Usedasadesigntoolforengineerstoprevent
structuralfailuresifcrackexists.
Whatwewishtoknowisthemaximumstressthata
materialcanwithstandifitcontainsdefects(flaws)
ofcertainsizeandgeometry.
Uncracked sample
Cracked sample
Plastic collapse
(FMDM)
Elastic plastic
fracture mechanics
(EPFM)
Linear elastic
fracture mechanics
(LEFM)
Ductility
Defect size
HistoricaldevelopmentofFracture
Mechanics
StressConcentration
x2/a2 +y2/b2=1
Inglis carriedoutastressanalysis
aheadofanellipticalnotchinan
infiniteplate:
m
2a
1
b
Inglis foundthatstressis
concentratedduetonotchand
themaximumstress,m (fracture
strength)dependsuponthe
radiusofthenotchtip,.
Twoapproaches:
GriffithCrackTheorydevelopedbyA.A.Griffithin1920
basedon Energybalanceapproachofbrittlematerials
(LEFM).
StressAnalysisofcracksapproachbasedonelastictheory
concept
concept.
Ultimatelythesetwoapproachescanbeproved
equivalent.
WewillconsidertheElasticStressanalysisapproach
today.
EnergybalanceapproachwillbeusedinyourFracture
prac.
23
Radius of curvature:
b 2
a
2a
2b
Stressconcentrationfactor,Kt
24
Example
GeometricalEffectofCracks
Estimatethetheoreticalfracturestrengthofabrittlematerial
ifitisknownthatfractureoccursbythepropagationofan
ellipticallyshapedsurfacenotchoflength0.5mmandhaving
atipradiusofcurvatureof5X103mm,whenastressof
1035MPaisapplied.
m 2
Geometricalchangesof
section,defects,flaws,holes,
etcconcentratestress
differently.
e.g.maximumstress,m, ata
circularhole(sayabolthole)
inaplateis3timesthe
nominalstress,Whereas
anellipticalflawconcentrate
higherstresses.
1/ 2
0 .5mm
207 GPa
3 mm
5 x10
m 2 1035 MPa
Whatisthestressconcentrationfactor?
GeometricalEffectofCracks
26
GeometricalEffectofCracks
FromInglisequation,astheellipticalnotchturns
intoacrack, goesto0andm tendstoinfinity!
Thissuggeststhatthestressatthetipofallcracks
is infinite!
isinfinite!
Ifstressatcracktipisinfinite,whydontallcracks
causefractureatverylowstresses?
Reason:materialatthecracktipyields(plastically
deform)andsotheassumptionofelasticityby
Inglis doesnothold.
Cracksizeconvention:
2aifthereare2tips(e.g.internalflaw)
aifonly1tip(e.g.edgeorsurfacecrack)
28
StressDistributionaroundcracktip
Crackmodesofloading
InModeI,stressisappliedatinfinitedistancealonethey
axisandlocalizedtensileandshearstressesareinduced
aroundcracktipsaloneyandxaxes.
Threemodesofcracktipopeninghavebeenidentified:
y
x
y
(Opening mode)
((sliding
g mode))
(tearing mode)
2a
y
r
x
xy
Mostfracturesinactualengineeringsituationsoccur
underconditionsofModeIloading.
30
LinearElasticFractureMechanics(LEFM)
K I
cos
2 r
sin
K I
cos
sin
1 sin
2
2
2 r
xy
K I
sin
2 r
1 sin
2
cos
sin
Stressintensity
Stressdistributionaroundanycrackinstructureis
similaranddependsonlyontheparametersrand
Relatesthestressfieldmagnitude (Localstresses)and
distribution aheadofacracktip.
Stressanalysisiscomplicated,butsolutionsformodeI
crackingare:
Thesearelocalized
cracktiptensile
andshearstresses
3
2
ij
r ,
K I.
1
. f ij
2 r
Thedifferencebetweenvariouscracksliesinthe
magnitudeofthestressfieldparameter,K
it d f th t
fi ld
t K calledthe
ll d th
stressintensityfactor.
KI isstressintensityfactorinModeIandhasaunitofMPa m
Kdescribestheintensityofthestressfieldaheadofa
sharpcrackinanystructuralmember:
plates,beams,airplanewings,pressurevessels,etc.
32
Stressintensity
Stressintensity
Thestressofprimaryinterestandinmostpractical
applicationsisy.
Fory tobeamaximum,
KI
2r
Forathroughthicknesscrack(central
crack)infiniteplateoflength 2a,the
stressintensityfactorcanberelated
totheappliedexternalstressas:
K I y 2r
2a
KI
y
r
x
xy
Stressintensity
Stress
intensity
factor
2r
a
2r
Constant of proportionality
Comparethiswithstress
concentrationfactorbyInglis.
K t
a
2r
For infinite plate
y C
a
2r
Comparison leads to :
K I a
Notesonstressintensity
DeviationsfromGeometry
Solutiondeterminedabovewasonlyfora
centrecrackedplateloadeduniaxiallyandin
planestress.
g
Solutioncanbeextendedtoothergeometries
withsomemodifications.
Solutionassumesthatalmostallofthe
materialbehaveselastically (smallscale
yieldingonly).
Deviationsfromthegeometrydescribedcan
beincorporatedinthestressanalysis.
Usualtoincorporatethemasafactor,Yinthe
stress intensity equation:
stressintensityequation:
KI Y a
35
36
KI valuesforthree
crackgeometries
Example effectofspecimenwidth
2a
Assumetheplatehasafinite
width,W.
KI dependsuponWandthisis
f
factoredintotheequation.
d
h
a
K I f a
W
Stress,
Anumberofsolutionshavebeen
proposedforf(a/W)
38
Example:Cracksgrowingfromaroundhole
a
K I f
a , where
a
a
a
f
1 0 . 256
1 . 152
W
W
W
KI
1
2a
1
W
a
12 . 200
whena/rapproacheszero,f(a/r)
h
/
h
f( / )
becomes3.
whena/r approachesinfinite,
f(a/r)becomes1andthusKI
approachesthatofathrough
thicknesscrackinaninfiniteplate.
2.5
KI
f(a/W)
Series1
a
ta n
Series2
Series3
Series4
a
1.5
KI
a
sec
a/W
Manysolutions,buttheyallcomeout
tomoreorlessthesame.
39
FractureToughness(KIC)
Thestressintensityfactor(KI)dependsonboththe
magnitudeofappliedstressandcracklength.
WhenKI reachesacriticalvaluefractureoccurs!
Thiscriticalstressintensityfactorisdefinedasfracture
toughness, KIC.
toughness,K
IC
KIC isameasureofamaterialsresistancetoBRITTLE
fracturewhenacrackispresent.
K IC Y a
Material
Selection
Design
Stress
Designwithfracturemechanics
Example:AircraftWing
The7075T651highstrengthaluminumalloyis
generallyusedforaircraftwings.Thematerialhasa
fracturetoughnessof26.DuringNDT(non
MPa m
destructivetesting),thelargestflawsizemonitoredon
the wing of an aircraft was an edge crack of 9 mm in
thewingofanaircraftwasanedgecrackof9mmin
length.Whatisthemaximumallowableload(pressure)
sothatanycatastrophicfailurecanbeavoided?
c
K IC
Y amax
26 MPa m
1.12 0.009m
138MPa
Allowableloadshouldbelessthan138MPa.
42