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Examples
EG2101 / EG2401
March 2015
Dr Rob Thornton
Lecturer in Mechanics of Materials
www.le.ac.uk
Semester 1 example problems
2
Example L11a AA7074-T8
=
A 50mm wide sample plate of 7074-T8 aluminium
alloy contains a central through-crack of length
2a
W
For 7074-T8:
Kc = 22.2 MN m-3/2; y = 520MPa
1. Under an applied stress of 200 MPa, determine
2a if the plate will fail by fracture with a crack half-
length a of:
1 mm; 5 mm; 10 mm
2. Determine the critical crack size ac below which
the plate will not fracture under the applied
stress, using an appropriate value of Y
1 3. Determine the limiting crack size ay below which
2
the plate will fail by yielding (assume Y = 1)
= cos
3
Solution L11a AA7074-T8
1. Is Y significant? a = 10 mm; Y = ?
2. Setting K = ?; = ? MPa; Y = ?
ac = ? [ans = 3.73 mm]
3. Setting K = ?; = ? MPa; Y = 1
ay = ? [ans = 0.58 mm]
4
Example L11b High-strength steel
6
Example L11b - Graphs
7
Paris Law integration (1)
Paris Law describes the steady-state crack growth
typically seen under cyclic loading
d
Definition: =
d
We can therefore calculate fatigue life by rearranging
and integrating this relationship:
d
= 0
d = 0
8
Paris Law integration (2)
Carry out the Paris Law integration:
1
= 2 d (1)
0
9
Paris Law integration (3)
10
Paris Law integration (4)
11
Paris Law integration (5)
Got it now?
Great.
Trying not to refer to your previous 10 pages of
integrations, have a go at the following example
13
Example L13 Engine crankshaft (1)
14
Example L13 Engine crankshaft (2)
Kc = 45MN m-3/2
max = 225MPa (tensile), min = 60MPa (compressive)
a0 = 2.5mm
A = 1.5 x 10-12 m/(MN m-3/2)m per cycle, m = 2.5
15
Example L14a Variable cyclic loading (1)
N1 = 5.44 x 105
N2 = 5.35 x 103
N3 = 3.24 x 104
=1
16
Example L14a Variable cyclic loading (2)
0.4%C
steel
2000 series
Al-Cu
17
Example L14a Variable cyclic loading (3)
% %
i /MPa Ni Nfi
18
Example L14b Fatigue + Fracture
d ;
= ; = = 0
d
d
A 65.4 mm wide aircraft inspection panel is made
of 7074-T651 aluminium alloy. The material
W properties are:
Fracture toughness, Kc = 25.8 MN m-3/2
Yield stress, y = 505 MPa
Following inspection, an edge through-crack of
a length 6.4 mm is found. During flight, this plate is
subjected to a cyclic stress of 90 30 MPa.
1. Ignoring the effect of the mean stress, calculate
the number of cycles to failure (Nf) using Paris
Law and the material constants (in their
standard units):
Y a/W
A = 1.2 x 10-12 / m = 2.8 [ans = 4.33 x 106]
1.12 0.0
1.37 0.2
2. Briefly describe what effect would the mean
stress have on the fatigue life of the
2.11 0.4 component?
2.83 0.5 19
Example L14b Tips
Q1: Calculate fatigue life
The process to get to the fatigue life is
W much the same as Example L13
except that you must use linear
interpolation for the geometry factor
a (Y) using the values in the table
provided
In this example you can assume a
constant value of Y as the crack grows,
Y a/W but what effect would it have if you
1.12 0.0 accounted for its variation with crack
1.37 0.2
length (a)?
2.11 0.4
2.83 0.5 20
Example L14b Tips
+ Mean stress K
0 +
-
0
Q2: Effect of positive a
mean stress? m3 > m2 > m1
Refer back to your
lecture notes
Sketch some typical
curves for the different
mean stress values
indicated to the right
Nf
21
Exam reminder
22
Good luck!
www.le.ac.uk