ME 423

Instructor: Ramesh Singh

HW#2
Assigned: September 10, 2023
Due: September 21, 2023

1. The composite properties are a combination of those of the components. The rule of
mixtures predicts that there exists an upper limit of the elastic modulus of the composite
given in terms of the elastic moduli of the matrix (Em) and the particulate (Ep) phases.
Please list all the assumptions and derive the value of elastic modulus of the composite (Ec)
for the upper limit as given in the following relationship.

𝐸! = 𝐸" 𝑉" + 𝐸# 𝑉#

where Vm and Vp are the volume fraction of the two phases.

Also prove that the lower bound of the elastic modulus is given by:
$! $"
𝐸! = $
" %! &$! %"

2. Derive the material indices that give highest strength and stiffness at the lowest mass for
tie rods and beams.

3. You have to design a mirror for a large telescope. the mirror is a circular disc, of diameter
2a 90
andMaterials
mean thickness
Selection int Mechanical
, simply supported
Design at its periphery (Figure 1).

Figure
Fig. 6.3 The mirror of a large optical 1. The istelescope
telescope geometry
modelled as a disc, simply supported at its periphery.
It must not sag by more than a wavelength of light at its centre.
When horizontal, it will deflect under its own weight m; when vertical it will not deflect
Table 6.3 Design requirements for the telescope mirror
significantly. This distortion (which changes the focal length and introduces aberrations
Function Precision mirror
Objective Minimize the mass
Constraints (a) Radius n specified
(b) Must not distort more than S under its own weight
(c) High dimensional stability: no creep, no moisture take-up,
low thermal expansion
 into the mirror) must be small enough that it does not interfere with performance; in
practice, this means that the deflection 𝛿 of the midpoint of the mirror must be less than
the wavelength of light. Additional requirements are: high dimensional stability (no creep),
and low thermal expansion. r is the density of the material of the disc. The elastic deflection,
𝛿, of the centre of a horizontal disc due to its own weight for a material with Poisson's ratio
of 0.3 can be looked from simply supported disc deflection solutions.

The objective is to minimize the mass. The constraints are as follows:

o Radius a specified
o Must not distort more than 𝛿 under its own weight
o High dimensional stability: no creep, no moisture take-up, low thermal expansion

We can treat the remaining constraints as property limits, requiring a melting point greater
than 1000K to avoid creep, zero moisture take up, and a low thermal expansion coefficient
(a < 20 x 10-6/K).

Identify the material index for this condition and make a table with following columns: 1.
Material; 2. Material index; mass in tons given the radius is 6m and provide your comments
and identify some right candidates from the appropriate property chart. Provide a rationale
behind the recommendation.

4. You have to design an elastic spring. The constraints are: No failure (𝜎 < 𝜎' at every
location in the spring). The objective functions are: (a) maximize the stored elastic energy
per unit volume and (b) maximize the stored elastic energy per unit weight. The only free
variable is the choice of material.

Identify the material indices separately for both these objectives and make two tables (one
for each objective) with following columns: 1. Material; 2. Material index and identify
some right candidates from the appropriate property chart and provide a rationale behind
the selection.

5. Derive the closed form solution for crack propagation from ai to af after Nf cycles based
on fracture toughness and Paris Law.

6. A steel rotating-beam test specimen has an ultimate strength of 1600 MPa. Estimate the
life of the specimen if it is tested at a completely reversed stress amplitude of 900 MPa.

7. A solid round bar with diameter of 50 mm has a groove cut to a diameter of 45 mm, with a
radius of 2.5 mm. The bar is not rotating. The bar is loaded with a repeated bending load
that causes the bending moment at the groove to fluctuate between 0 and 2825 Nm. The
bar is hot-rolled AISI 1095, but the groove has been machined. Determine the factor of
safety for fatigue based on infinite life and the factor of safety for yielding (a) Using
Modified Goodman; (b) ASME Elliptic.

8. The cold-drawn AISI 1040 steel bar shown in Figure 1 is subjected to a completely reversed
axial load fluctuating between 28 kN in compression to 28 kN in tension. Estimate the
fatigue factor of safety based on achieving infinite life, and the yielding factor of safety. If
 6–23 Repeat Prob. 6–20 but with an alternating torsional stress of 30 kpsi.
6–24 Repeat Prob. 6–20 but with an alternating torsional stress of 15 kpsi and a steady bending stress
of 15 kpsi.
6–25 The cold-drawn AISI 1040 steel bar shown in the figure is subjected to a completely reversed
axial load fluctuating between 28 kN in compression to 28 kN in tension. Estimate the fatigue
infinite life is not predicted, factor of safety based on achieving infinite life, and the yielding factor of safety. If infinite life is
estimate the number of cycles to failure.
not predicted, estimate the number of cycles to failure.

6-mm D.
25 mm

Problem 6–25

10 mm
Fig. 1. Cold drawn steel bar under reversed axial loading
6–26 Repeat Prob. 6–25 for a load that fluctuates from 12 kN to 28 kN. Use the Modified Goodman,
Gerber, and ASME-elliptic criteria and compare their predictions.
9. In Figure 2, shaft A, made of AISI 1020 hot-rolled steel, is welded to a fixed support and
6–27by equal
is subjected to loading Repeat and
Prob. 6–25 for each
opposite of the following
forces loadingB.
F via shaft conditions:
A theoretical stress-
(a) 0 kN to 28 kN
concentration factor Kts of 1.6 is induced by the 3 mm fillet. The length of shaft A from the
(b) 12 kN to 28 kN
fixed support to the connection at kN
(c) –28 shaft BkN
to 12 is 1 m. The load F cycles from 0.5 to 2 kN. Find
the factor of safety for infinite life using the modified Goodman and Gerber fatigue failure
6–28 The figure shows a formed round-wire cantilever spring subjected to a varying force. The hard-
criteria. ness tests made on 50 springs gave a minimum hardness of 400 Brinell. It is apparent from the
mounting details that there is no stress concentration. A visual inspection of the springs indicates
that the surface finish corresponds closely to a hot-rolled finish. What number of applications is
likely to cause failure? Solve using:
(a) Modified Goodman criterion.
(b) Gerber criterion.
Fmax = 40 lbf
12 in Fmin = 20 lbf

Problem 6–28
3
8
in D.