Master of Science in Mechanical Engineering

Politecnico di Milano
Course of Machine Design 2
(Prof. S. Beretta, Prof.ssa L. Vergani)

Written test – 07.07.2015

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Exercise 1.

Consider a thin rotating disk with external radius equal to Re.

Requests:
1) Consider that the disk has variable rotational speed from 0 to n (rpm).
Perform the fatigue assessment (in the most stressed point) neglecting the
inertia effect (i.e. consider stress state only at 0 and n state).
2) Determine the strain values obtained from 2 rosettes placed in the centre
and at the border (by considering the stress exactly at the border). Consider
0°-45°-90° type, with 0° aligned along the radial direction.
3) Determine the maximum axial strain value.
4) Perform the static assessment considering also an external pressure pe acting
on the border of the rotating disk.

Data
Re=500mm Radius of the disk
n=4'000 rpm Rotational speed
pe= -50 MPa

Material of the disk: Fe510

Rm=510 MPa
Rsn=360 MPa
=7860 kg/m3 volumic mass
Exercise 2.

Data

z=2 m
v=1m
M=15kNm
HE180B
h=180mm
b=180mm
a=8.5mm / e=14 mm / r=15 mm
Ix=3831cm4
Material of the beam/welding: Fe510

A HE180B beam is over constrained.

Requests:
1) Plot diagrams of the internal forces;
2) Design and assess a proper welding joint at the clamp.

Exercise 3.

Let us consider a component, made of Al alloy, subjected to a cyclic stress with

Smin=100 MPa and Smax=200 MPa. The component, with a thickness of 30 mm, can
be treated as simply subjected to axial loading.
A defect with a depth ai=2mm (to be treated as a semicircular crack) has been
detected on the component.
Fracture toughness of the material is 30 MPa√m.
Coefficients of Paris law are: m=3.70, C=1.42e-11 [m/cycle]. These parameters are
given for the considered stress amplitude.
Under the hypothesis that the crack propagates with a semicircular shape and
that the geometric factor can be expressed as:

Determine:
1) the critical crack size for static fracture acrit;
2) the number of cycles for "safe life" of the component (propagation from ai to ap,
where ap=acrit/2)