CRN: 32718 and 32712

UNIVERSITY OF SALFORD
School of Computing, Science and Engineering

SEMESTER TWO EXAMINATION

AIRCRAFT STRUCTURES / STRUCTURAL MECHANICS E2

May 2018

Instructions to Candidates

Exam Duration: THREE HOURS

Full marks may be obtained for correct answers to Five full questions.

Answer TWO questions from SECTION A and TWO questions from SECTION B.
The FIFTH question may be answered from either SECTION A or SECTION B.

Answer ONLY a total of five questions (only the first five questions will be marked)

Selected Equations are included at the back of this Exam Paper.

Approved electronic calculators may be used.

1
 d4 d4 Mr Tr
I J
64 32 I J

2
2
1,2
2 2

2 2 2
S1 Y S1 S3 Y S1 S2 S2 S3 S3 S1 2Y 2

FL F'
Q =
j
members AE Qj

d 2v m( x )
dx 2 EI

GJ
k
b

9
 Section A

1. A circular shaft 12 cm in diameter is subjected to a bending moment and a twisting

torque simultaneously; the bending moment being three times the twisting torque.
The material yielded at a stress of 300 N/mm2 in direct tension, and if a factor of
safety of 2.5 is to be used, calculate the allowable twisting torque according to the
following:

a) maximum principal stress criterion

(12 marks)

b) maximum shear stress criterion (Tresca)

(4 marks)

c) the maximum shear strain energy criterion (VMH)

(4 marks)

2. The pin-jointed framework, which is shown in Figure 1, is constructed from members

of stiffness EA = 20000 kN. The framework is loaded with a horizontal force of 25
kN at joint D. Ignore the weight of the bars.

(a) Demonstrate that the pin-jointed framework is statically determinate.

(2 marks)

(b) Calculate the reaction forces at A and B and the loads in each member.
(10 marks)

(c) Calculate the vertical and horizontal deflection of point D and hence, calculate
the magnitude and direction of the resultant displacement of the loaded joint.

(8 marks)

Figure 1

2
3. Figure 2 shows a uniform simply supported beam of bending stiffness 800 Nm2.
Using singularity functions, determine an expression for the bending moment at any
point along the beam. Hence, determine the slope of the beam at A and the deflection
of the beam at the point of application of the 25 N load.
(20 marks)

Figure 2

4. A shaft of total length 1000 mm is firmly held at both ends and carries two
comparatively thin discs at a distance of 250 mm and 750 mm from the left-hand end
as shown in Figure 3. The left-hand disc carries a torque of 10x103 N.mm while the
other carries a torque of 20x103 N.mm in the same direction. The diameter of the
shaft between the discs is 20 mm, and that of the other two portions is 30 mm. The
material of the shaft has a modulus of rigidity of 80x103 N/mm2.

Determine the following:

a) the rotation of each disc

(12 marks)

b) the reaction torques at the ends of the shaft

(2 marks)

c) the internal torque and maximum sheer stress in the left-hand portion of the
shaft
(6 marks)

10x103 N.mm 20x103 N.mm

mm

30 mm 30 mm
20 mm

250 mm 500 mm 250 mm

Figure 3

3
 Section B
5.
(a) Age hardening was carried out on two aluminium-copper alloy samples. The
first sample reached the maximum hardness after 12 hours at an aging
temperature of 120 0C, while it took 30 hours for the second sample to reach
the maximum hardness at an aging temperature of 80 0C. Determine the aging
time for an identical aluminium-copper alloy, that is required to reach
maximum hardness for an aging temperature of 95 0C. Use 0 0C = 273 K.
(8 Marks)

(b) The plane strain fracture toughness value, KIc was determined for a titanium
alloy, using a three point bend test. Determine the value of KIc and find if the
test is valid.

Use the following information, related to specimen properties and test results.

Fracture Load, PQ = 43.5 kN

Yield stress = 750 MPa
Width, W = 50 mm
Breadth, B = 25.2 mm
Fracture length, a = 23.25 mm
(including fatigue pre crack)

a/w 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009

Stress intensity factor coefficient (Compliance factor)Y1

0.450 9.10 9.13 9.15 9.18 9.21 9.23 9.26 9.29 9.32 9.35
0.460 9.37 9.40 9.43 9.46 9.49 9.52 9.54 9.57 9.60 9.63
0.470 9.66 9.69 9.72 9.75 9.78 9.81 9.84 9.87 9.90 9.93
0.480 9.96 9.99 10.03 10.06 10.09 10.12 10.15 10.18 10.21 10.25
0.490 10.28 10.31 10.34 10.38 10.41 10.44 10.48 10.51 10.54 10.58
0.500 10.61 10.65 10.68 10.71 10.75 10.78 10.82 10.85 10.89 10.93
Table 1
Part of the Stress intensity factor coefficients for three point bend specimen

(6 marks)

(c) A circular metal bar, with a diameter of 150 mm is subjected to a tensile load
of 5.25 MN. Determine if the bar will fracture if, using non-destructive
techniques, a 4 mm diameter, circular crack, was detected in the cross
sectional plane, at the centre of the bar. Calculate the factor of safety if the bar
does not fracture. Assume that the bar is thick, and use the fracture equation
with plastic zone size correction

Use the following information for the bar material;

Yield stress = 600 MPa

Fracture Toughness, KIC = 40 MPa m1/2
Flow shape parameter = 2/
(6 marks)

4
6. (a) (i) A Nimonic alloy component, is required to operate at three different creep
combinations. Determine if the component can survive these creep loading
combinations. The three creep combinations are shown in Table 2, and the
Larson Miller Parameter, LMP, for the alloy is presented in Figure 1.

Stress Temperature Time Required

(MPa) (0C) (hours)
Combination 1 440 480 2500
Combination 2 390 450 35000
Combination 3 250 400 100000
Table 2 Creep combinations for the alloy (0OC = 273K)

Stress (MPa)
440
390 Figure 1
250 Larson Miller Paramet
200 for the Nimonic Alloy
(not to scale)

18.0 18.5 19.0 19.2 LMP

The Larson Miller Parameter, LMP, for the Nimonic alloy may be expressed
by the following empirical relationship;

LMP = T (20 + log10tr)×10-3 where; T = Temperature (K)

tr = Rupture Time (hours)
(12 marks)

(ii) If the above component survives the required creep conditions, determine how
many more hours it can survive, if it is to operate at a constant stress of 200
MPa, and a temperature of 5000 C.
(3 marks)

(b) An engineering component is required to safely withstand a mean stress of 50

MPa, at a stress amplitude of 40 MPa. Two possible alloys are considered for
the manufacture of the component. Use the Soderberg equation to determine
(if any) the suitability of these alloys. Apply a factor of safety of two to the
stress amplitude and mean stress. The table below includes the material
properties for the two alloys.

Alloy Yield Stress (MPa) Endurance Limit (MPa)

A 350 140
B 300 100
(5 marks)

5
7. (a) (i) Sinusoidal fatigue tests were carried out on two identical aluminium alloy
specimens. The first specimen was tested at a stress range of 400 MPa and
failed after 106 cycles. The second specimen was tested at a stress range of
270 MPa and failed after 1010 cycles.
for the alloy. Assume that the mean stress is zero.

logC1, to four decimal places)

(8 marks)

(ii) Determine the number of cycles to failure for a component, made from the
same material in section 7. (a) i), undergoing a sinusoidal fatigue loading at a
stress range of 350 MPa (about a zero mean stress).

(2 marks)

. (b) An edge crack with length, ao, of 1.6 mm was discovered on the surface of a
flat plate component, during a routine non destructive test inspection. The
component is expected to operate under a repeated, fatigue, stress with a
maximum tensile value of 250 MPa.

(i) Determine the remaining fatigue life (residual life) of the component.

Use the following data;

KIc = 50 MPa m1/2

The Paris law constants for the component are; A = 3.8x10-12 and m = 3
-1/2
( and crack length, a, in m.).

(8 Marks)

(ii) The next inspection is scheduled after 300 days for the above component.
Determine whether the component should be replaced now or retained in
service, if it is required to sustain a stress (with a maximum tensile value of
250 MPa) that fluctuates at a rate of 9500 cycles per day.

(2 Marks)

6
8. (a) Describe and discuss, using sketches, the Resin Infusion process for the
production of reinforced fibre composite structures.
(6 Marks)

(b) A laminate composite system is made of epoxy resin reinforced with long
continuous length Aramid fibres.

(i) Determine the longitudinal and and Shear Modulus

of the composite laminate.
(4 Marks)

(ii) A tensile stress of 50 MPa is acting on the above composite system, at angle of
+ 230 to the direction of the fibres. Determine the Transformation Matrix and
stresses acting on the principal axes (parallel and perpendicular to the direction
of fibres) of the laminate.
(4 Marks)

(iii) Use the information from the above section to determine the Compliance
Matrix and strains acting on the principal axes of the composite laminate.

(6 Marks)

Use the following information;

Fibre reinforcement (by volume) = 41 %

the Aramid fibres = 105 GPa
s of the Epoxy matrix = 7.20 GPa
Shear Modulus of Aramid fibres = 25 GPa
Shear Modulus of Epoxy matrix = 3.50 GPa
12 = 0.25

7
FORMULA SHEET (SECTION A)

8
 SELECTED FORMULAE (SECTION B)

FRACTURE

Plane Strain Fracture Toughness;

Leak-Before-Break Condition :

Fracture Toughness with crack tip correction; Plain strain condition (thick sections),

2 2
KIc
KIc a ry a 1
6 y2 6 y
2

Three Point Bend Fracture Toughness; , and For Validity; B 2.5(KIc/ y)2

FATIGUE
a
Basquin Equation; N f C1

Miner's Rule; f = N1/Nf1 + N2/Nf2 +N3/Nf3

ac
1 da
Paris law; Nf m2 m m
A a0
am 2
Nf = Number of cycles to failure, between a0 and ac
a = Crack length
ao = Initial crack length
ac (or acrit) = Final, critical, length
imum fatigue stress in tension)
A and m are material constants
Flow shape parameter

f FOS
Soderberg Relation; a 1 m

FOS y

a = Stress amplitude
m = Mean stress
y = Yield stress
f = Fatigue limit (or Endurance limit or Fatigue strength, when applicable)
FOS = Factor of Safety
CREEP

; t t1 + t2 + t3
tr tr1 tr2 tr3

AGE HARDENING

Rate = 1/t = Ae(-Q/RT) , where, t, is in hours and, T, in Kelvin.

10
 LONG CONTINUOUS COMPOSITE LAMINATES

Vf + Vm = 1

Ec = E1 = EmVm + E V

1 = 1 = Vm + V
Etc E2 Em E

1 = Vf + Vm
G12 Gf Gm

COMPOSITE LAMINATES (Strains)

The strain law for an orthotropic material under plane stress conditions, referred to the
material axis (1 and 2), has the following form;

1 1

2 S 2

12 12

Where, [S], is termed the Compliance matrix, written in the form;

S11 S12 S13

S S 21 S 22 S 23

S 31 S 32 S 33

Where; S11 = 1/E1 S22 = 1/E2 S33 = 1/G12 S21 = -

12 = S12 = - 21
E1 E2
And, S13 = S23 = S31 = S32 = 0, for an orthotropic material under plane stress conditions.

Also; 12 = 21
E1 E2

Where;
G12 = In-plane shear modulus
E1
E2 s Modulus in the 2 direction
12
21 =

11
 COMPOSITE LAMINATES (Stresses)
The stress law for an orthotropic material under plane stress conditions, referred to the
material axis (1 and 2), has the following form;

1 1

2 Q 2

12 12

Where, [Q], is termed the Stiffness matrix (which is the inverse of [S]). In general, the
stiffness matrix is written in the form;

Q11 Q12 Q13

Q Q21 Q22 Q23

Q31 Q32 Q33

E1 E2
Where; Q11 Q22 Q33= G12
1 12 21 1 12 21

21 E1 12 E2
Q12 = Q21
1 12 21 1 12 21

And, Q13 = Q23 = Q31 = Q32 = 0, for an orthotropic material under plane stress conditions.

COMPOSITE LAMINATES (Arbitrary Orientation)

If the principal materials axis, or material axis (1 and 2) of the lamina do not coincide with
the reference axis, or laminate axis (x and y), at some arbitrary orientation wit
use the following relations to transform the stresses and strains;

1 x x 1
1
2 T y and y T 2

12 xy xy 12

1 x x 1
1
2 T y and y T 2

12 xy xy 12

Where, [T] is the transformation matrix and [T]-1 is the inverse of [T], written in the form;

c2 s2 2cs c2 s2 2cs
and
T s2 c2 2cs T
1
s2 c2 2cs

cs cs ( c 2 s2 ) cs cs ( c 2 s2 )

12