NEW ZEALAND DIPLOMA IN ENGINEERING

(Mechanical)
DE5302: Strength of Materials 1
June 2018: Final Examination

Three (3) hours plus 10 minutes’ reading

Time Allowed:
time
Total Marks: 80

Please Note:
1. This examination will be held in accordance with institutional examination procedures and in conjunction with the
rules and regulations imposed by The Board.
2. Any candidate who aids, attempts to aid, obtains aid or attempts to obtain aid from another candidate will be
disqualified and further dealt with under the institutional disciplinary procedures for cheating. This could result in the
offender’s expulsion from the institution.
3. Candidates are permitted to use non-programmable calculators. This explicitly excludes lap-top computers, cell
phones, i-phones, i-pads or any other device capable of connecting by wireless to the Internet or other electronic
media, or source of potential aid. Violations of this rule will also be dealt with as acts of cheating.
4. This is a CLOSED BOOK examination. You may not be in possession of books, notes memoranda or reference
materials other than those supplied in the examination.
5. You may make use of the information in the Data, Formulae and Tables booklet handed out with this paper.
Instructions:
1. All answers must be written in the answer book supplied, and on extra sheets (including graph paper) as you may
request during the examination. Enter your Student ID in the space provided on the front cover.
2. Write your student ID and the question number on each loose page, including graph paper, and enclose such extra
sheets in the book.
3. CROSS OUT any work that you do not wish to have marked.
4. Show ALL working in calculations to obtain full marks. In any question that does not ask for numerical answers to a
specified accuracy, answers should be rounded appropriately.
5. Answer EIGHT (8) questions from the available ten (10). Each question is worth 10 marks.

NZDE (Mechanical Examination) Strength of Materials 1 Examination June 2018

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Question One [10 marks]

A component made from a composite fibre material is under load. The element below shows the
stresses that exist at a point on the surface of the component. The fibres are oriented at an angle of
30o with respect to the x axis.

Figure 1.

(a) Determine the principal stresses and the principal directions at this point. (4 marks)
(b) Sketch the principal stress element, indicating clearly the principal stresses and their directions.
(2 marks)
(c) Determine the maximum shear stress and the associated direct stress at the point. (2 marks)
(d) Determine the shear stress along the fibre direction. (2 marks)

Question Two [10 marks]

A block of mass 5 kg as shown below is moving with a velocity 4 m/s just before it strikes the
Aluminium stepped cylindrical bar 6061-T6. The Young’s modulus of Aluminium is 68.9 GPa and
the yield strength is 225 MPa.

Figure 2.

(a) Determine the maximum displacement developed in segment AB (6 marks)

(b) Determine the maximum force developed in segment AB (1 mark)
(c) Determine the maximum normal stress developed in the cylinder. (1 mark)
(d) Briefly describe two modes of failure in beams. (2 marks)

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Question Three [10 marks]

A bar of length 350 mm and width 150 mm has a load P applied as shown below. A fillet weld
group as shown connects the bar to a plate.

Figure 3.

(a) If the weld height is 7 mm, calculate the throat thickness of the weld. (1 mark)
(b) Determine the maximum load per unit length of weld if the allowable shear stress in the weld is
135 MPa. (1 mark)
(c) Determine the maximum load P before failure will occur. (8 marks)

Question Four [10 marks]

A 100 x 100 x 5 SHS steel beam is used to make a cantilever to support loads as shown in Figure 4.
Determine the factor of safety using allowable stress design philosophy. Use the average shear
stress in the section and ignore the self-weight of the beam.
Use A = 1810 mm2 I = 2.66×10-6 m 4 , Z = 53.1×10-6 m 3, σtensile ≤ 165 MPa, τ ≤ 62.5 MPa, deflection
≤ 1/250 span, and E = 200 GPa.

Figure 4.

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Question Five [10 marks]

A beam cross section has the dimensions as shown in Figure 5 is subjected to a shear force (V) of
45 kN.

Figure 5.

(a) Determine the web’s shear stress at A and B. (6 marks)

(b) Determine the max shear stress value. (2 marks)
(c) Sketch the variation of the shear-stress distribution over the beam’s cross-sectional area.
(2 marks)

Question Six [10 marks]

A 4 m length of 410 UB 53.7 steel beam is used to span simple supports. It supports a uniformly
distributed load of 10 kN/m and two-point loads of 20 kN each located 1 m inwards from the end
supports. Ignore the self-weight of the beam and Assume E = 200 GPa for the beam.

Figure 6.

(a) The deflection under the point loads (5 marks)

(b) The bending stress at mid-span (5 marks)
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Question Seven [10 marks]

A hydraulic ram actuator arm has 60 mm bore and 10 mm thickness. When fully extended it is 1.8
m long. One end can be treated as rigidly fixed and the other as pin jointed.

Figure 7.

(a) Determine the maximum safe end load before buckling will occur using a factor of safety 1.5.
(7 marks)
(b) Determine the maximum safe end load using a factor of safety 2.5 if the ends are both pin
jointed. (3 marks)
σ y =250 MPa , σ C =320 MPa , σ ult =350 MPa , E=200 GPa

Question Eight [10 marks]

A stub axle is to be made from steel. The axle begins with a diameter of 25 mm, which is reduced to
diameter “d” across the 150 mm length, as shown in the figure below. At the point of reduction
there is a fillet radius of 2 mm. The shaft carries a fluctuating load bending of +150 N to +500 N
acting at the outer limit of the reduced section of the shaft and in the vertical plane. Use a stress
concentration factor (K) of 1.5 for the fluctuating load only. Using Goodmans or Soderberg method,
determine a suitable diameter “d” for the reduced end of the shaft if a factor of safety of 2 is
applied. Use these values: σyield  = 250 MPa, σuts = 600 MPa, σe = 225 MPa.

Figure 8.

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Question Nine [10 marks]

A wooden beam is simply supported at A and B as shown. The beam is supported at B by a rod, nut
and washer. The diameter of the rod is 8 mm. The inside diameter of the washer is 8 mm and its
outside diameter is 16 mm. The support at A consists of a cylindrical aluminium block of diameter
15 mm. There is a vertical downward point load P acting 500 mm from A. The allowable tensile
stress in the bolt is 200 MPa and the allowable bearing stress in the wood is 30 MPa. The
aluminium block can withstand a compressive stress of 120 MPa.

Determine the maximum allowable load P such that failure does not occur in the system.

Figure 9.

Question Ten [10 marks]

A 45o strain rosette is mounted on the surface of a machine component under load. The following
readings are obtained from each gauge: ε a = 650x10-6, ε b = -300 x10-6, ε c = 480 x10-6. Young’s
modulus E=200 GPa; Poisson’s ratio ν=0.3; σyield=300 MPa; σuts=500 MPa.

Figure 10.

(a) Determine the principle strains and their direction relative to ε a. (8 marks)
(b) Determine the principal stresses at the point. (2 marks)

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Formulary

Complex Stresses
σ x + σ y σ x −σ y −σ x −σ y
σ θ= + cos 2 θ+ τ xy sin 2θ τθ= sin2 θ+ τ xy cos 2 θ
2 2 2

√( )
σ +σ σ x −σ y
2
2 τ xy σ 1 −σ 2
σ 1,2= x y ± + ( τ xy )2 tan2 θ P= τ max=
2 2 σ x −σ y 2

Strain

1 1 γ
ε θ= ( ε x + ε y ) + ( ε x −ε y ) cos 2 θ+ xy sin2 θ
2 2 2
2 2
ε a=ε x cosθa + ε y sinθ a + γ xy sinθ a cosθ a

√( )( )
ε x+ ε y ε x −ε y
2
γ xy
2
γ xy
ε 1,2= ± + tan2 θ P=
2 2 2 ε x −ε y

E E
2( x
σ x= ε +ν εy) σ y= 2( y
ε + ν εx )
1−ν 1−ν

1 1
ε x= (σ +ν σ y)
E x
ε y= ( σ +ν σ x )
E y

Failure Theories

Maximum shear stress

σ yield
2
Factor of safety =
τ max

Maximum deformation energy theory

σ yield
Factor of safety =
{ }
1 /2
1
2
[ ( σ 1−σ 2) 2+ ( σ 2−σ 3 )2 + ( σ 3 −σ 1 )2 ]
Maximum normal stress theory
σ UTS/UCS
Factor of safety =
max {|σ 1| ,|σ 2|,|σ 3|}

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Second moment of area

3 4 4
bd πd πd π ( D −d )
4 4
I NA = I NA = J= I =I ¿ + A h2 I = A k2 I =
12 64 32 64
π 2 π 3
A= d Z= d
4 32

Stress

F ΔL σ ε LAT
σ= ε= =E =ν
A L ε ε LON

My T τ Gθ
σ= = = τ=
VA y
q=
VA y
I NA J r L Ib I

Fatigue
σa σm 1 σa σm 1
Goodman: + = Soderberg + =
σ '
e
σ UTS FoS σ '
e
σ yield FoS

K f −1
q=
K t −1

Energy and impact

1 1 1 2 1 2
U= F∆ L U = Tθ KE= m v KE= I ω PE=mgh
2 2 2 2

Buckling
le
Slenderness ratio=
k

le =
{l: pinned/ pinned
0.5 l:
¿
/¿ ¿ 0.7 l : pinned/¿ ¿ 2 l : ¿ ¿ free ¿

()
le
k limit
=
√ 2 π2 E
σ yield

π 2 EA
Pcrit =
Euler:
()
le 2
k

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σ yield A
Pcrit = σ yield
()
2
Rankine-Gordon: l where a=
1+a e π2E
k

( ( ))
2
σ yield l e
Johnson: Pcrit =σ yield A 1−
4 π2 E k

Welded joints

P M Tr
F d= F T= F T=
Weld length Zw Jw

height =√2 ×throat

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Stress concentration factor for round bar with fillet

NZDE (Mechanical Examination) Strength of Materials 1 Examination June 2018