MAAE 4102 Strength and Fracture

MAAE 4102 - Strength and Fracture

Problem Analysis
Stress Life
1.

A method used to present mean stress fatigue data is to generate a family of curves on an
S-N plot, with each curve representing a different stress ratio, R. Generate the curves for
R values of -1, 0 and 0.5 for a steel with an ultimate strength of 100 ksi. For this
example, use the Gerber relationship to generate these curves. Use Eqn. 1 to estimate the
fully reversed (R = -1) fatigue behaviour between 103 and 106 cycles.
S = 1.62 SU N 0.085

(1)

2.

Another method used to present mean stress fatigue data is to generate a family of curves
on an S-N plot, with each curve representing a different mean stress value, m. Generate
the curves for mean stress values of 0, 20 and 40 ksi for a steel with an ultimate strength
of 100 ksi. For this example, use the Goodman relationship to generate these curves.
Again use eqn. (1) to estimate the fully reversed (mean = 0) fatigue behaviour.

3.

Given a material with an ultimate strength of 70 ksi, an endurance limit of 33 ksi, and a
true fracture strength of 115 ksi, determine the allowable zero to maximum (R = 0) stress
which can be applied for 103, 104, 105 and 106 cycles. Make predictions using the
Goodman, Gerber and Morrow relationships.

4.

A component undergoes a cyclic stress with a maximum value of 75 ksi and a minimum
value of -5 ksi. Determine the mean stress, stress range, stress amplitude, stress ratio and
amplitude ratio. If the component is made from a steel with an ultimate strength of 100
ksi, estimate its life using the Goodman relationship.

5.

A switching device consists of a rectangular cross-section metal cantilever 200 mm in

length and 30 mm in width. The required operating displacement at the free end is 2.7
mm and the service life is to be 100 00 cycles. To allow for scatter in life performance a
factor of 5 is employed on endurance. Using the fatigue curves given in Fig. 1 determine
the required thickness of the cantilever if made in (a) mild steel, (b) aluminum alloy.
Esteel = 208 GN/m2, E Aluminum = 79 GN/m2.

6.

A pressure vessel support bracket is to be designed so that it can withstand a tensile

loading cycle of 0-500 MN/m2 once every day for 25 years. Which of the following
steels would have the greater tolerance to intrinsic defects in this application: (i) a
maraging steel (KIC = 82 MN m -(3/2), C = 0.15 x 10-11, m = 4.1), or (ii) a mediumstrength steel (KIC = 50 MN m-(3/2), C = 0.24 x 10-11, m = 3.3)? For the loading situation a
geometry factor of 1.12 may be assumed.

Problem Set
Page 1 of 8

MAAE 4102 Strength and Fracture

x - Aluminium Alloy 24S-T3 reversed axial stress

- Mild steel reversed axial stress
Fig 1
7.

A series of crack growth tests on a moulding grade of polymethyl methacrylate gave the
following results:
da/dN (m/cycle)
K(MN m-3/2)

2.25 x 10-7
0.42

4 x 10-7
0.53

6.2 x 10-7
0.63

17 x 10-7 29 x 10-7
0.94
1.17

If the material has a critical stress intensity factor of 1.8 MN m-3/2 and it is known that the
moulding process produces defects 40 m long, estimate the maximum repeated tensile
stress which could be applied to this material for at least 106 cycles without causing
fatigue failure.

8.

A series of tensile fatigue tests on stainless steel strips containing a central through hole
gave the following values for the fatigue endurance of the steel. If the steel strips were
100 mm wide, comment on the notch sensitivity of the steel. Stress concentration values
are given in Fig 2.
Hole diameter (mm)
Fatigue endurance (MN/m2)

No hole
600

Problem Set
Page 2 of 8

5
250

10
270

20
320

25
370

MAAE 4012 Strength and Fracture

Figure 2.

9.

The fatigue endurances from the S-N curve for a certain steel are:
Stress
(MN/m2)

Fatigue endurance (cycles)

350
380
410

2,000,000
500,000
125,000

If a component manufactured from this steel is subjected to 600,000 cycles at 350 MN/m2
and 150,000 cycles at 380 MN/m2, how many cycles can the material be expected to
withstand at 410 MN/m2 before fatigue failure occurs, assuming that Miners cumulative
damage theory applies?

Problem Set
Page 3 of 8

MAAE 4102 Strength and Fracture

Strain Life
1.

It has been determined that a certain steel (E = 30 x 103 ksi) follows the following true
stress, , true plastic strain, p, relation:

= ( 350ksi)(P ) 0 .11
The true plastic strain at fracture was found to be 0.48. Determine:
a)
True fracture strength, f
b)
Total true strain at fracture
c)
Strength coefficient, K
d)
Strain hardening exponent, n
e)
Strength at 0.2% offset, Sy
f)
Percent reduction in area, % RA
g)
True fracture ductility, f
2.

The following stress-strain and strain-life properties are given for a steel:

a)
b)

c)
d)
e)
f)

E = 30 x 10 ksi

K = 137 ksi n = 0.22

f = 120ksi

b = -0.11

f = 0.95

c = -0.64

Draw on log-log coordinates the elastic strain-life, and total strain-life curves.
Determine the transition life (2Nt).
Draw the hysteresis loops corresponding to strain amplitude (/2) values of
0.05, 0.00125 and 0.0007. Determine the fatigue life in reversals at these three
strain levels.
Determine the elastic, plastic and total strain amplitude for a life (2Nf) of 2 x 106
reversals.
Determine the elastic, plastic, and total strain amplitude for a life (2Nf) of 500
reversals.
Determine the cyclic stress amplitude corresponding to fatigue lives of 500 and 2
x 106 reversals.
A component made from this material is required to have a life of no less than 104
reversals. The loading on the component causes a total strain amplitude of 0.008.
Determine if the component will meet the life requirements.

Problem Set
Page 4 of 8

MAAE 4012 Strength and Fracture

3.

Smooth aluminum specimens are subjected to two series of cyclic load-controlled tests.
The first test (level A) varies between a maximum stress value, max, of 21.3 ksi and a
minimum value, min, of -30.1 ksi. The second test (level B) varies between 61.5 and
10.1 ksi. Predict the life to failure, in reversals, at the two levels. Use the Morrow,
Manson-Halford and Smith-Watson-Topper relationships for the predictions. Assume
that there is no mean stress relaxation. The material properties for the aluminum are
E = 10.6 x 103 ksi

K = 95 ksi

f = 160 ksi

b = -0.124

f = 0.22

c = -0.59

n = 0.065

Listed below are actual test results at the two levels. Three tests were run at each of the
levels. Compare the predictions to these values.
Level

Test Results: Lives in Reversals, 2Nf

5.4 x 105

5.5 x 105

7.2 x 105

5.6 x 104

6.4 X 104

6.9 X 104

Problem Set
Page 5 of 8

MAAE 4102 Strength and Fracture

Fracture Mechanics

1.

A large plate made of AISI 4340 steel contains an edge crack and is subjected to a tensile
stress of 40 ksi. The material has an ultimate strength of 260 ksi and a Kc value of 45 ksi
in. Assume that the crack is much smaller than the width of the plate. Determine the
critical crack size.

2.

3.

A large cylindrical bar made of 4140 steel (y = 90 ksi) contains an embedded circular
(penny shaped) crack with a 0.1 in. diameter. Assume that the crack radius, is much
smaller than the radius of the bar, R, so that the bar may be considered infinitely large
compared to the crack. The bar is subjected to a tensile stress of 50 ksi. Determine the
plastic zone size at the crack tip. Are the basic LEFM assumptions violated?
A very wide late made from Al 7075-T651 (KIc = 27 ksi in., y = 80 ksi) contains an
edge crack. Plot the allowable nominal stress (ksi) as a function of crack size, (in
inches), if the design requirements specify a factor of safety of 2 on the critical stress
intensity factor. If the plate specifications were changed so that Al 7050-T73651 was
used (KIc = 35 ksi in., y = 70 ksi), re-plot the curve. For a nominal stress of one-half
the yield stress, determine the increase in allowable flaw size by changing from the Al
7075 alloy to the Al 7050 alloy.

4.

Design a pressure vessel that is capable of withstanding a static pressure of 1000 psi and
that will leak-before-burst. The required material has a fracture toughness of 60 ksi
in. and a yield strength of 85 ksi. The diameter of the vessel is specified to be 4 ft. A
crack with surface length of 1 in. can reliably be detected. Since the cost of the vessel is
related directly to the amount of material used, optimize the design so that the cost is
minimized.

5.

A component made from 7005-T53 aluminum contains a semi-circular surface crack (a/c
= 1) and is subjected to R = 0.1 loading with a stress range, , of 250 MPa. (Refer to
Example 1 for an expression for the stress intensity range, K.) the following crack
growth data were obtained in laboratory air environment. Using these data:
a)
b)
c)

Plot crack length, (mm), versus cycles, N

Plot da/dN versus K. Identify the three regions of crack growth.
Determine the Paris law constants, C and m, for the linear region of crack growth.

Problem Set
Page 6 of 8

MAAE 4012 Strength and Fracture

________________________________________________________
N (cycles)
a (mm)
da/dN (mm)
_________________________________________________________
95,000
0.244
100,000
0.246
7.00 x 10-7
105,000
0.251
3.920 x 10-6
110,000
0.285
9.665 x 10-6
115,000
0.347
1.053 x 10-5
125,000
0.414
1.230 x 10-5
130,000
0.490
2.063 x 10-5
135,000
0.621
4.661 x 10-5
140,000
0.956
9.565 x 10-5
145,000
1.577
3.964 x 10-4
147,000
2.588
1.105 x 10-3
147,400
3.078
1.554 x 10-3
147,500
3.241
8.758 x 10-3
147,500
3.445
__________________________________________________________

KI =

Problem Set
Page 7 of 8

1
1.12 a
Q

MAAE 4102 Strength and Fracture

6.

Calculate the critical defect size for each of the following steels assuming they are each
subjected to a stress of 0.5y. Comment on the results obtained.
Yield Strength y
(MN/m2)

Fracture Toughness
(MN-3/2)

Mild Steel

207

200

Low-alloy Steel

500

160

Medium Carbon Steel

1000

280

High-carbon Steel

1450

70

18% Ni (Maraging)
Steel

1900

75

Tool Steel

1750

30

Steel

7.

A sheet of glass 0.5 m wide and 18 mm thick is found to contain a number of surface
cracks 3 mm deep and 10 mm long. If the glass is placed horizontally on two supports,
calculate the maximum spacing of the supports to avoid the fracture of the glass due to its
own weight. For glass KIC = 0.3 (MN-3/2) and density = 2600 kg/m3.

8.

The accident report on a steel pressure vessel which fractured in a brittle manner when
the internal pressure of 19 MN/m2 had been applied to it shows that the vessel had a
longitudinal crack 8 mm long and 3.2 mm deep. A subsequent fracture mechanics test on
a sample of the steel showed that it had a KIC value of 75 MN-3/2 . If the vessel diameter
was 1 m and the thickness was 10 mm, determine whether the data reported are consistent
with the observed failure.

9.

An aluminum alloy plate with a yield stress of 450 MN/m2 fails in service at a stress of
110 MN/m2 . The conditions are plane stress and there is some indication of ductility at
the fracture. If a surface crack of 20 mm long is observed at the fracture plane calculate
the size of the plastic zone at the crack tip. Calculate also the percentage error likely if
LEFM was used to obtain the fracture toughness of this material.

Problem Set
Page 8 of 8