2004 EXAM ---Q1--CASTIGILANO ---Q2--The propellar and shaft of an aircraft engine are shown schematically.

The prope ller has a mass, m, and generates a forward force, F, relative to the aircraft a t a constant rotational speed of N rpm. The shaft has a diameter, d, where it jo ins the propeller and increases with a fillet of radius, r, to a diameter of D a t a distance, L, from the propeller centre of mass. The shaft transmits a power, P, to the propeller. i) Show that the effective mean stress,sigm, and alternating stress, siga, at th e fillet can be given by the following: siga=((32mgL)/(pi*d^3))*Kf(b) Kf(b) denotes bending stress. sigm=(2F/pi*d^2)*Kf(a)+sqrt((2F/pi*d^2)*Kf(a))^2+((480P)/(N*pi^2*d^3))*Kf(t))^2) Kf(a) denotes axial stress and Kf(t) torsional stress. (ii) Estimate the factor of safety for the following conditions: d=50mm, D=100mm , r=4mm,L=100mm,F=4000N,m=1000kg,P=50kW and N=3000rpm. Assume the shaft to be ma de from commercially polished steel with an ultimate tensile strength, Su, of 12 00 MPa. A2i) The system contains the following stresses acting at the fillet: 1) Alternating bending stress, siga(b), due to mg.From fillet figure in formula sheet. siga(b)=((32M)/(pi*d^3))*Kf(b) where; M=mg.L (sub this in) =>siga=((32mgL)/(pi*d^3))*Kf(b) 2)Constant axial stress, sigm(a) due to F. From fillet figures. sigm(a)=(4F)/(pi*d^2); F is axial stress force (pulling left and right) We need to take into account Kf for axial: =>sigm(a)=((4F)/(pi*d^2))*Kf(a) 3) Constant torsional stress, taum, due to P. P is torsional stress. (round and round) taum=(16T)/(pi*d^3) where T=(60/(2pi*N))*P. T is the torque. Sub into equation and factor in Kf(t).. taum=((480P)/(N*pi^2*d^3))*Kf(t)) We can obtain the equivalent mean stress, sigm, by assuming failure due to the m aximum distortion energy theory as follows: sigm=((sigx+sigy)/2)+sqrt(((sigx-sigy)/2)^2+tauxy^2) =>sigm=(2F/pi*d^2)*Kf(a)+sqrt((2F/pi*d^2)*Kf(a))^2+((480P)/(N*pi^2*d^3))*Kf(t))^ 2) A2ii) 1)Firstly we need to calculate the respective Kf values. From the Kt graphs. r/d=4/50=0.08, D/d=100/50=2.0: Kt(b)=1.82, Kt(a)=2.14, Kt(t) =1.53. 2)We also need to calculate the Peterson notch sensitivity factor, q (from graph ). r=4mm, Su=1200MPa => q(b)=0.93, q(a)=0.93, q(t)=0.95. 3)Now find surface finish, Cs from graph. Cs=0.88 4) Put findings into following equation: Kf=1+(Kt-1)*q*Cs therefore; Kf(b)=1+(1.82-1)(0.93)(0.88)=1.67 Kf(a)= 1+(2.14 1)(0.93)(0.88)=1.93 Kf(t) = 1+(1.53 1)(0.95)(0.88)=1.44 5)Plug into very first equation;siga=((32mgL)/(pi*d^3))*Kf(b) siga=((32*1000*9.81*0.1)/(pi*(0.05)^3))*1.671 siga=133.6 MPa. 6) sigm=(2F/pi*d^2)*Kf(a)+sqrt((2F/pi*d^2)*Kf(a))^2+((480P)/(N*pi^2*d^3))*Kf(t)) ^2) sigm=((2*4000)/pi*(0.05)^2)*1.933+sqrt(((2*4000)/pi*(0.05)^2)*1.933)^2+((480*500

00)/(3000*pi^2*(0.05)^3))*1.443)^2) sigm=11.53 MPa 7) Determine CL, CD and Cs. CL=1, CD=0.9, Cs=0.88. 8)Construct Goodman line. Need to determine Sn=CL*CD*Cs*Sn' Sn'=0.5Su Sn=1*0.9*0.88*0.5*1200 Sn=475.2 MPa 9)This forms the point on the y-axis of the goodman diagram (0,475.2) (siga) and x-axis (sigm) is Su (1200MPa) 10)Other points on the goodman are siga and sigm found in step 5&6. (ie (0,133.6 )&(11.53,0)). 11)Find the point these intersect and extrude the line to hit the goodman line. 12)By substitution, determine new values of sigm. siga=475.2-(475.2/1200)*sigm =>siga=475.2-0.396*sigm (eqn 1) siga=(133.6/11.53)*sigm =>siga=11.59*sigm (eqn 2) 13)Solving these equations gives: sigm=39.66 MPa, therefore Factor of safety=39.66/11.53 =>Factor of Safety =3.44 ---Q3--The shaft shown in Figure 3 contains two fillets and one groove. The shaft is ma chined from alloy steel heat-treated to 320 BHN and rotates at high speed, whilst the impose d loads remain static. If the loading is sufficiently great to result in eventual fatigue fract ure, use the following conditions to determine where failure would most probably occur. The shaft contains a fillet on the lhs, a groove close to the rhs, and another f illet the same as the first on the rhs. d=25mm, D=30mm, L1=140mm (distance from point force to end both ends of shaft, i e in the middle), L2=90mm (distance from centre point to fillets), L3=70mm (dist ance from force to groove) R1=0.5mm (LHS Fillet), R2=3.0mm (Groove), R3=1.0mm (RHS Fillet). The shaft is su pported at both its ends by F/2. (Centre force is "F"). A3i) Determine Cl=1, CD=0.9. BHN<=350, therefore Su(MPa)=3.45*BHN, Su=3.45*320=1104MPa. From Chart, determine Cs=0.68. 2)Determine Kt at fillets: for 0.5mm fillet. D/d=30/25=1.2 r/d=0.5/25=0.02, Kt=2.47. for 1.0mm fillet: D/d=30/25=1.2, r/d=1/25=0.04, therefore, Kt=2.03 3)Determine peterson notch sensitivity, q, from graph. for 0.5mm fillet: q=0.83, for 1.0mm fillet: q=0.87. 4) Determine Kf for both fillets: Kf=1+Kt-1)qCs, for 0.5mm radius; Kf=1.830, for 1.0 mm fillet, Kf=1.610 We only need to consider the larger Kf value as this will give the lowest infini te cycle stress. 5)Sn=(CL*CD*Cs*Sn')/Kf, Sn'=0.5*Su. Sub in values, Sn=184.6 MPa 6) Determine nominal stress; sig(nom)=32M/(pi*d^3) where M=(F/2)*(L1-L2); sig(nom)=(32(0.05(F/2))/(pi*(0.025)^3) =>sig(nom)=F*0.01630 MPa. Therefore, the allowable load for infinite life=184.6/ 1.630x10^-3=11.33kN 7) Now repeat steps 2->6 for the groove. 8)Hence, for the groove: sig(nom)=32M/pi*d^3. sig(nom)=(32(0.07(F/2))/(pi*((30-2*3)x10^-3)^3). Therefore load for infinite lif

e =226.1/2.579x10^-2=8.767kN 9)Also, need to check fatigue at the centre span. 10)Find Sn=(1*0.9*0.68*0.5*1104)/1=337.8 MPa. 11)once again find nominal stress (sig(nom)). sig(nom)=32M/pi*d^3 sig(nom)=32(0.140*F/2)/(pi*(0.03)^3) sig(nom)=F*0.02641 MPa 12) Allowable load for infinite life=337.8/0.02641=12.79 kN 13) Therefore the failure point would be at the groove (lowest force point). ---Q4--A solid square cross-section steel post AB of width d1=50mm, is fixed at the bot tom and free at the top as shown in the figure. A cable passes through a welded eyelet on the post at a height of L=5m from the ground with the angle between the cable and ground being theta=50degrees. The distance between the pla ne of the cable and the post centre d2=40mm. Assuming a factor of safety of 2.0, what is the maximum allowable tensile force in the cable to prevent failure of the column due to buckling? (E=220 GPa, sigy=400 MPa) Figure shows a post support by 2 cables that makes up a triangle. Also a distanc e of d2 is the distance from the wire eyelet to the centre line of the post (ima gine side view). A4i) Let the maximum force in the cable be F and that in the post be P. Due to non-linearity between P and sigmax, the factor of safety has to be applie d to P rather than sig. First we need to calculate the slenderness ratio. We use the supplied equation f or a solid square section: I=b^4/12=Ar^2 =>r=b/sqrt(12), r=0.05/sqrt(12). Therefore, r=0.01443m. The effective length, Le, is 2L as one end is fixed whilst the other is free. The slenderness ratio is thus (2*5)/(0.01443)=692.8 We can calculate I using the supplied equation: I=b^4/12, I=(0.05^4)/12=>I=5.208x10^-7m^4 Using the supplied equation: sigmax=(P/A)[1+(ec/r^2)*sec((1/2r)(sqrt(P/EA))] The critical value of force, Pc, will be obtained when sigmax=sigy sigy=(Pc/A)[1+(ec/r^2)*sec((1/2r)(sqrt(Pc/EA))] The value of A can be obtained from: A=b^2, A=0.05^2 =>A=0.0025m^2 The value of eccentricity, e, is simple d2 on the figure: e=d2 e=0.04m To obtain the value of c we need to use the following: sig=Mc/I c=b/2 c=0.25m We need to iterate Pc in order to reach sigy. So set Pc values of 5,10,10.5,10.6,10.55,10.58 to get as close to 400MPa as poss ible. Or just go backwards... therefore, =>Pc=10.58 Taking into account the factor of safety, FoS: P=Pc/FoS P=10.58x10^3/2 P=5.29 kN Resolving forces to obtain F, sin(theta)=(P/2)/F rearrange; F=(P/2)/sin(theta) F=(5.29/2)/(sin(50)) =>F=3.45kN