Machine Design EML 4501 Exam 1: Important Material

General Guidelines The exam will be open book, closed notes. Extra sheets of paper will be treated as cheating. Bring pencils and a calculator to class. Nothing else will be required. You may use the back of the test as scratch paper or obtain additional paper from the instructor. All other items should be left at the front of the room or at home. Please arrive on time. The exam will begin promptly at 12:30 PM and the exams will be collected at 1:50 PM. Below are some guidelines to aid your preparation for the exam. This is intended to identify the most important concepts that will be tested, but I do not guarantee that other material not listed here might be included. Test Taking Suggestions If you explain your thinking clearly and state your assumptions explicitly, I can better evaluate the level of your understanding and give you partial credit where appropriate. If time is short, you can also explain how you would solve the problem if more time were available. The test will consist of some questions short answer questions and analytical questions of varying complexity. Chapter 2 Know important vocabulary. Some of the most important vocabulary includes Ductile, Brittle, Even material, Uneven material, isotropic, orthotropic, anisotropic, homogenous, heterogeneous Concepts: Hardness and strength relationships Dont worry about the formulas but know how they could be used.

Basic Material Characteristics for: Steel,Cast Iron,Aluminum,Stainless Steel,Ceramics, thermpoplastics, thermosets, composites Heat Treatment Quenching Tempering Normalizing Annealing Know relative ductility and strength. (Currently in order of decreasing strength and increasing ductility)

Chapter 3 Important Concepts Free Body Diagrams Be able to use free body diagrams to solve for forces and moments in the system. Superposition You can always analyze the effects of different loads separately and then sum them as long as the equations and models are linear.

Conservation of Energy You may need to recognize situations in which this principle could be used to help solve for unknowns. Think falling objects and impacts. Definition of Spring Constant k = F/deflection

Beam Deflections Solve for reactions, use beam tables to find the moment, shear, and deflection

Chapter 4 Important Concepts Stress distribution for common loading types. Where are the peak stresses and how do you calculate them for the following cases: Axial loading Torsional loading Bending Loading Direct shear Tearout failure Direct Bearing Stress Deflections for axial, torsional, and bending. Principal Stress Concept Depending on what coordinate system you use for expressing the stresses, there can be shear and normal stresses or just normal stresses. The principal stresses is the stress state when there are only normal stresses and no shear stresses. The first principal stress is the largest principle stress and the third principle stress is the smallest. Mohrs circle is graphical technique for representing the variation in stress states with coordinate system. Deflection Properties Deflection depends only on geometry and modulus of elasticity and not on strength (as long as it is below the yield strength). If you are designing to limit deflection, you dont need a high strength material just a high modulus material. Torsion Loading Always use a closed section in torsion if you want to minimize the deflection.

Stress Properties Stress depends only on the geometry of the part and its loading characteristics. Design for stress by increasing the strength of the material or modifying the geometry to reduce the stress. Stress Concentration Changes in the profile of a part create stress concentrations that raise the local stress level. Know how to use a chart to calculate a stress concentration. Which cross section properties should you use? Stress Superposition Generally, stress analysis is linear and so you can apply superposition. Meaning, you can analyze different loads separately and add their effects. Remember cases we discussed in which superposition would not apply. Columns Column failure is generally due to buckling unless the columns are very short. Because column failure is deflection dominated, the important material property is the modulus of elasticity, not the strength. However, strength does play a role in intermediate columns. Know which end conditions make for stronger columns (fixed) and weaker columns (pinned or free). You are not responsible for calculating eccentric columns on the test. What is eccentric loading? Know what happens when loading is eccentric. (does the columns load capacity increase or decrease?, Is it a small effect or large?)

Chapter 5 Static Failure

You will be given a material and asked to calculate the safety factor. You must select the appropriate criteria based on brittle or ductile material. You will also be asked to estimate the safety factors for a given stress level. You should know whether larger or smaller safety factors are more desirable. Summary: Ductile Materials: Distortion Energy (Von Mises) - Most accurate Brittle Materials: Modified Mohr Most Accurate Linear Elastic Fracture Mechanics (LEFM): Know when you should consider using LEFM analysis. Know how to do simple calculations for edge cracks and cracks in large plates. Which materials should you apply stress concentrations to in static loading? (generally brittle, pg 273 (4th edition).

Chapter 6 Fatigue Failure

Understand what is fatigue failure and what types of stress cause it and what dont. (compressive vs. tensile) Know the difference in behavior between materials with an endurance limit and those without. You should be describe the difference with a graph or in words. Also know which materials have an endurance limit and which do not. Know when you would use the LEFM approach to fatigue analysis Know when strain-life approach should be used. Be able to do calculations with the stress-life approach and when to apply it. Be able to explain how to approximate the fatigue properties of a material or perform the calculation if the necessary information is provided. Also know about methods that can be used to improve the fatigue properties of the materials. Be able to estimate the life of a part from an S-N curve for a material and the applied stress information for fully reversed loading. Be able to answer questions about the life of a part from a modified Goodman diagram Be able to calculate the alternating stress and the mean stress. Stress concentration factors in fatigue loading: Apply to all alternating stress for all materials Calculate a Kf from the Kt and q (notch sensitivity factor) Apply to mean stress for brittle materials

Chapter 7: Surface Failure

Know the basic types of surface failure (adhesive, abrasive, corrosive, fretting, surface fatigue) and how they can be reduced or eliminated through changes to the design, materials, or operating conditions. No calculations required on Chapter 7 material.