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MAAE 4102 Part 6 - Solutions.

7.1

Beach Marks are the result of a period of loading that could contain several hundreds or
thousands of individual load cycles. These periods of loading usually correspond to each
time the component is started and stopped (for example, for fatigue of a motor shaft, each
beach mark may correspond to each time the motor was run). Beach marks are macroscopic and can usually be seen with the unaided eye or at low magnification.
Striations are much smaller fractographic features that can usually only be seen at high
magnifications using electron microscopy. Each striation corresponds to one load cycle.

6.1

(a)

maximum flaw size:

ac =
(b)

K1c = 55 MPam2

D = YS/ 2 = 1380/2 = 690 MPa

K2 =

55
= 0.002 m
2
690

2a = 25 mm

or a = 0.00125 m

da
= 1.1x 10 -39 K 4
dN
= 1.1x 10 -39 4 2 a 2
0.002
1
da
Nf=

- 39
6 4
2
1.1x 10 (690x 10 ) 0.00125 a 2
1
1
1

=
- 39
6 4
2
1.1x 10 (690x 10 ) 0.00125 0.002
5
N f = 1.22x 10 cycles

6.2

Internal pressure p = 75 MPa

maximum stress:

D = 7 cm

P D 75 7
=
= 262.6 MPa
2t
2
2
K = 1.1
a

24 = 1.1 262.5
a=

t = 1 cm

2
1
24

= 0.0054 m
2
1.12 22
262. 5

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Nf

1.14 (262.5x 106 ) 5x 10 -39

4

Nf=

0.0054

dN =

16

0.0025

da
a

1
1

16 0.0025 0.0054
1.14 (262.5x 106 )4 5x 10 -39
1

6
N f = 3.8x 10 cycles

6.3

2a = 0.2 mm
since:

= 180 MPa

da
dN
2
Ry K

Ry
2

K Ic = a
54 = 180 a
a = 0.0286 m

da
= 4x 10 -37 K 4
dN
= 4x 10-37 4 2 a 2

therefore:
Nf

1
dN =
- 37
4x 10 (180x 106 )4 2
6
N f = 2.4x 10 cycles

0.0286

0.0001

da
a

6.4

S-N curves do not provide sufficient information to separate crack initiation from crack
propagation. For damage tolerant design it is assumed that flaws, defects or cracks
already exist, so crack initiation is assumed to have already occurred. For damage
tolerant design information specific to crack growth is required.

6.5

Variation in the initiation of fatigue cracks is the primary reason for scatter in S-N data.
Fatigue cracks initiate at small defects such as inclusions, porosity, scratches or even
grain boundaries or from stress concentrations. The existing defects are not uniformly
distributed form one sample to another, thus a range of crack initiation values and
therefore variable fatigue lives are obtained.

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6.6

(a) 2a = 15 mm, = 180-60 = 120 MPa,

YS = 1200 MPa,

K1c = 60 MPam2

da
= A Km
dN
af
da
N=
m
C ( a )
ao
N=

at fracture:

af =
N=

(b)

1
2
1
- m/2-1
m
m/2 -1
m/2
(m - 2) C ( )
af
ao

1 K2

=
2

1 60 2
= 35.4x 10-3 m
2
180

1
1

(3 - 2) (6.9x 10 ) 120 0.075 0.0354
N = 1.88x 105 cycles
2

-12

3/2

striation spacing for dN = 1 da = 6.9x10-12 K3

at 2a = 15 mm,
so da = 0.043 m
at 2a = 25 mm,
so da = 0.093 m

6.7

(a)

K = 120 7.5x 10 -3 = 18.4 MPa m

K = 23.8 MPa%m

K1c = 18 MPam2,
since crack is small compared to size of connecting rod, use K=(a)2
64000
= 1.6 MPa
0.2x0.2
-2
K app = 1.6 2x 10 = 0.40 MPa m

no chance of brittle failure on start-up.

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(b)

da
= A Km
dN
da
= A 4 2 a2
dN
af
1
da
N=
4 2
A ao a 2
1 1

A 4 2 ao a f
1
1
1
N=
= 5.99x 106 cycles
-8
4
2

4.3x 10 1.6 0.02 0.03

=

(c)

safe to operate for 400 h?

400 h x 60 x 15 = 360,000 cycles n 5.99x106 cycles
even at a = 0.03m, K = 1.6( x 0.03)2 = 0.49 MPam2, which is still way below
K1c, so no problem to operate for 400 hours.

6.8

(a)

(b)

fatigue surface:

relatively flat due to limited plasticity

striations visible at high magnification
beach marks due to periods of fatigue loading

b fatigue area, a final fracture, d= 8 mm, P = 8kN, f = 600 MPa

Ao = 82/4 = 50.2 mm2,
area carrying load before final fracture Af = 50.2/3 = 16.7 mm2
= 8000N/16.7x10-6 m2 = 479 MPa < f so must have failed by fast fracture

(c)

a = 5 mm, min = 0, max = 479 MPa

K = 479 5x 10-3 = 60 MPa m

da
= 5x 10-39 (60x 106 )4 = 6.48x 10-8 m/cycle
dN

(d)

60 MPam2.

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6.9

max = 500 MPa, min = 0, K1c = 50MPam2, a = 25 mm, m = 4

da
= A Km
dN

da
= A ( a )m
dN
af
1
da
N=
4 2
A ( ) ao a 2

N=

1
A ( ) 2
4

1 1

ao a f

since for both options the value of A does not change and does not change,
so:

ao a f

for original case:

1 K 2Ic 1 50 2
=
= 3.18 mm
2max 500 2
1 1
1
1
- =
= 39685
-6
-6
ao a f 25x 10 3.18x 10

for option 1:

1 80 2
= 8.15 mm
500 2
1
1
= 39877
25x 10-6 8.15x 10-3

ac =

ac =

for option 2:

ao = 10x10-6 m

1
1
= 99685
-6
10x 10 3.18x 10-3

Changing to the material with higher K1c gives only about 1% increase in fatigue life, but
reducing ao from 25 to 10 m gives more than double the fatigue life. So chose option 2.
6.10

(a)

estimate of stress at final failure:

K =Y a
At failure:

a 12.7
=
= 0.5 _ Y = 0.75
2c 25.4
K = 0.75 a
K
91
= 607.6 MPa
=
=
0.75 a 0.75 12.7x 10 -3

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(b)

= 607.6 MPa
initially:

(c)

a 0.38
=
= 0.27 _ Y = 0.95
2c 1.4
K = 0.95x607.6 x0.38x 10-3
K = 19.9 MPa m

N = 15,503 cycles, a = 12.7 - 0.38 = 12.3 mm

12.3
da
8x 10 -4 mm/cycle
_ avg =
15,503
dN

(d)

a = 0.38 mm, K = 19.9 MPa%m

da
= 4.8x 10-9 19.93.3 = 9.3x 10-5 mm/cycle
dN
(e)

at last inspection

a 6.36
=
= 0.5 _ Y = 0.75
2c 12.7
K = 0.75 607.5 x6.35x 10-3 = 64.4 MPa m

da
= 4.8x 10-9 64. 43.3 = 4.5x 10-3 mm/cycle
dN

6.11

(a)
(b)

Disc was originally designed on a safe life basis. The design assumed that the disc
contained no defects and would be removed from service at a predetermined
interval without any requirement for inspection.
Disc is to continue in service based on a damage tolerant approach. Knowing the
crack growth behaviour, appropriate inspections will be undertaken to ensure the
disc can still be operated safely. Each individual disc is monitored and taken out
of service on an individual basis. Safe life approach mandates that all discs are
taken out of service after the same service life.