IIT Madras Failure Analysis and Design(ME6225) Maximum Marks: 90

Assignment-2

Question: 1 2 3 4 5 6 7 8 9 10 11
Points: 2 5 5 4 2 2 2 4 2 2 10
Score:

Question: 12 13 14 15 16 17 18 19 20 Total
Points: 4 5 2 6 10 5 4 8 6 90
Score:

1. The length of the Burgers vector in a hypothetical FCC metal is 0.25 nm. The radius of (2)
the metal atom in this unit cell (rounded off to three decimal places) is
nm.
2. A hypothetical FCC crystal has a dislocation density of 10 × 1011 cm−2 , typical of a (5)
highly deformed metal. The shear modulus of the material is 50 GPa and the lattice
parameter of the material is 0.45 nm. The stored energy density in the dislocations
(rounded off to two decimal places) is MJ/m3 .
3. A tensile test is performed on a metal specimen, and it is found that a true plastic strain (5)
of 0.17 is produced when a true stress of 400 MPa is applied. Assume the material to be
a power-law hardening type, with power-law coefficient K equal to 900 MPa. The true
strain that results from the application of a true stress of 655 MPa (rounded off to two
decimal places) is .
4. It is found that there are 2.5 × 1023 vacancies in a cubic meter of a Cu at 400 K. The (4)
atomic weight and density of Copper at 446 K are 63.5 g/mol and 8.4 g/cm3 , respectively.
The vacancy formation energy for this system (rounded off to two decimal places) is
eV/atom.
The following data may be used if needed:
Avagadro’s number: 6.022 × 1023 atoms/mol
Boltzman’s constant: 8.62 × 10−5 eV/atom-K
5. The stress-strain response of a linear elastic materials is described by its elastic modulus (2)
E=200 GPa, yield strength σy =300 MPa and an ultimate strength of σu =450 MPa. The
resilience of the material (rounded off to nearest integer) is kJ/m3 .
6. An FCC single crystal material is subjected to a stress of 250 MPa along [232]. The (2)
resolved shear stress (rounded to nearest integer) for the slip system (111) and [110] is
MPa.
7. The true stress-strain relation for a ductile material in the plastic deformation regime is (2)
given by σt = Kn−1
t . For this material, K = 150 MPa and n = 1.6. The true strain at
the onset of necking (rounded off to two decimal places is) is .

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IIT Madras Failure Analysis and Design(ME6225) Maximum Marks: 90

8. If the lattice parameter of a hypothetical BCC element is 0.2345 nm, the largest radius (4)
(in nm) of an atom that can fit in the tetrahedral void site of the unit cell (rounded off
to 5 decimal places) is nm.
9. The Miller index representation for the plane AGE (given a = 0.250.25 nm) shown in (2)
the fig. 1 is

Figure 1: A hypothetical unit cell

A. [1̄11]
B. (1̄11)
C. (111)
D. (11̄1)
10. In a tension test, a steel rod which was initially 1 m long is pulled at a constant rate of
0.0001 m s−1 . After one minute,
(a) the engineering strain (rounded off to 3 decimal places) is (1)
−1
(b) the engineering strain rate (rounded off to 4 decimal places) is s (1)
11. The non-zero stress state at a point in a material are given as σx = 120 MPa, σy =
−120 MPa, σz = 100 MPa and σyz = 100 MPa. The yield strength of the material is
450 MPa.
(a) The maximum principal stress at this point is MPa. (1)
(b) The minimum principal stress at this point is MPa. (1)
(c) The factor safety according to distortion energy theory (rounded off to two decimal (3)
places) is .

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IIT Madras
Failure Analysis and Design(ME6225) Maximum Marks: 90

(d) the

factor of safety using Maximum Shear Stress(MSS) theory (rounded off to two (3)

decimal places) is .

(e) The second invariant of the deviatoric stress tensor at the point is (2)

2
MPa

12. A specimen

shown in Figure 2 is loaded in constant load mode. The out of plane thickness

of the specimen (B = 30 mm) remains constant. If the energy release rate (GI ) is to

remain
constant with the growth of the crack, the relationship between depth (h) and

crack length (a) is expected to follow a relation given by h = Cam . The initial crack

length
is 50 mm, elastic modulus is 208 GPa and the depth of each cantilever is 12 mm

up to the initial crack length.

(a) The value of C (rounded off to three decimal places) is . (2)

(b) The

value of m (rounded off to 2 decimal places) is . (2)

2h

P a

Figure 2: A

double cantilever specimen with variable cross-sectional area ahead of the crack.

13. An un-notched member of AISI4340 steel is subjected to uniaxial cyclic stressing at zero
mean stress. The material properties for this material and constants for stress-life curves
at zero mean stress are given below:
Yield strength: 1103 MPa, Ultimate strength: 1172 MPa, and the fatigue stress-life data
for AISI4340 steel at zero mean stress is given by S = 1643N −0.0977 .
(a) The number of cycles to failure at 517 MPa is . (1)
(b) The number of cycles to failure at 444 MPa is . (1)
(c) The number of cycles to failure at 550 MPa is . (1)
(d) The member is at first subjected to a stress amplitude of σa = 517 MPa for 31,280 (2)
cycles, followed by σa = 444 MPa for 84,620 cycles. If the stress amplitude is then
changed to 550 MPa, the number of cycles that can be applied at this third level
before fatigue failure is expected is .
14. The stress state at a point in a material is given by (2)
 
100 30 40
σ =  30 150 60 .
40 60 80
The first invariant of the deviatoric part of the above stress state is .

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IIT Madras Failure Analysis and Design(ME6225) Maximum Marks: 90

15. A circular tube made of ASTM A514 (T1) structural steel (yield strength of 720 MPa)
with a wall thickness of 3 mm and an outer diameter of 90 mm must support a bending
moment of 4.5 kN · m and a torque of 7 kN m.
(a) The factor of safety against yielding based on distortion energy theory (rounded off (3)
to two decimal places) is .
(b) The factor of safety against yielding based on maximum shear stress theory (rounded (3)
off to two decimal places) is .

16. A solid square rod with cross section area of 9 cm2 is cantilevered at one end. The rod
is 0.8 m long and supports a completely reversing transverse load at the other end of
±0.85 kN. The material is AISI 1045 hot-rolled steel with Sut = 570 MPa and Sy =
310 MPa . The theoretical stress concentration factor at the support end is 1.35 and the
notch sensitivity factor is 0.85. Use the relevant data given below for your calculations.

Figure 3: Data for correction factors in fatigue design

(a) The fatigue stress concentration factor (rounded off to two decimal places) is (1)
(b) The maximum bending stress is MPa. (2)
(c) The corrected endurance strength is MPa. (3)
(d) The factor of safety in stress for the rod to support this load for 3 × 104 cycles (4)
(rounded off to two decimal places) is .

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IIT Madras Failure Analysis and Design(ME6225) Maximum Marks: 90

17. A strain gauge rosette as shown in Figure 4 is applied to the surface of a component
made of AISI 1020 steel. Assume that no yielding has occurred, and also that no loading
is applied directly on the surface, so that σz = τyz = τxz = 0 MPa. Strains are measured
as follows: x = 290 × 10−6 , y = −860 × 10−6 , and 45 = −190 × 10−6 . The elastic
modulus is 210 GPa, Poisson’s ratio of the material is 0.3 and the yield strength is
260 MPa.
(a) The shear strain at the point is ×10−6 . (3)
(b) The strain z at the point is is ×10−6 (2)

Figure 4: Configuration of a strain gauge rosette for measurement of strain in three directions.

18. The cantilever rod of length 120 mm and a diameter of 30 mm is made of grey cast iron (4)
having tensile strength of 300 MPa and compressive strength of 900 MPa. The bending
load is F = 1.75 kN, the axial tension is P = 9 kN and the torsion is T = 83 N m.
The factor of safety (rounded off to two decimal places), using Coulumb-Mohr theory is
.

Figure 5: A cantilever rod subjected to static loads.

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IIT Madras Failure Analysis and Design(ME6225) Maximum Marks: 90

19. A flat leaf spring has fluctuating stress of σmax = 420r MPa and σmin = 140r MPa for
r = 1.02 applied for 5 × 104 cycles. The material is AISI 1040CD steel and has a
yield strength of 490 MPa, ultimate strength of 590 MPa and a fully corrected endurance
strength of 200 MPa.
(a) Using Goodman’s criteria , the spring is expected to survive for (4)
cycles.
(b) After 5 × 104 cycles, the load changes to σmax = 350 MPa and σmin = −200 MPa. (4)
The spring now is expected to survive for cycles. (Hint: Use Miner’s
method)
√
20. Martensitic steel with Su = 1482 MPa, Sy = 1379 MPa, KIc = 81 MPa m is used for a
plate with rectangular cross section, 9 mm thick by 36 mm wide. The plate is subjected
to a completely reversed cyclic axial force of 78 160 N amplitude, following the initiation
of a fatigue crack. It may be assumed that the length of the newly initiated fatigue
crack is 1.3 mm, the geometric factor to be 1.5 and the Paris law parameters to be
C = 3.03 × 10−10 and m = 2.25 in SI units.
(a) The crack length that leads to catastrophic failure (rounded off to 2 decimal places) (2)
is mm.
(b) The number of cycles of continued loading that could be applied before catastrophic (4)
fracture would occur for this plate are .

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