MOI UNIVERSITY DEPARTMENT OF MECHANCIAL AND PRODUCTION ENGINEERING MPE 451 ~ FRACTURE MECHANICS TUTORIAL 1 A sheet of glass measuring 2 m by 200 mm by 2 mm contains a central slit parallel to the 200 mm side. The sheet is restrained at one end and loaded in tension with a mass of 500 kg. What is the maximum allowable length of slit before fracture occurs? ‘Assume the following material property values: E = 60 GPa, surface energy is 0.5 J/m?, Poissons ratio = 0. and the fracture stress of sound glass is 170 MPa. If the fracture stress of a large sheet of maraging steel , which contains a central crack of length 40 mm, is 480 MPa, calculate the fracture stress of a similar sheet containing a crack of length 100 mm. Athin sheet of maraging steel has a tensile strength of 1950 MPa. Calculate the percentage reduction in strength due to the presence of a crack in the sheet, which is 4 mm long and orientated perpendicular to the stressed direction. For this steel, E can be taken as 200 GPa, the energy of fracture surface as 2.J/m’, and the work of plastic deformation of each crack tip is 2x104 J/m* A rectangular perspex plate 600 mm by 300 mm by 6 mm thick is scribed into two equal squares by a knife, leaving a uniform cut of depth 0.3 mm. What is the bending moment required to break the plate if the perspex has a work to fracture of 500 I/m'? Note that E = 2.5 GPa for perspex. A Class 20 grey cast iron has an average graphite flake size about nine times as long as Class 60 type. The fracture strength of the latter is about 140 MPa. Using arguments that follow the Griffith analysis, what would you predict to be the fracture strength of the Class 20 iron? Griffith postulated that brittle fracture occurred when the energy release rate during crack growth le material exceeded the rate that energy was required. His original analysis was performed for a brit (glass). a) Sketch curves showing how the changes in surface energy required, and potential energy released, as a crack extends. bb). Sketch the changes in their differentials (rates R and G) with respect to crack length extension. Label the sketches and define the parameters R and G. ¢) State what the critical condition is for fracture, in terms of R and G. 1MOI UNIVERSITY DEPARTMENT OF MECHANCIAL AND PRODUCTION ENGINEERING MMPE 451. — FRACTURE MECHANICS TUTORIAL 2 1. Along pipe has an outer diameter (0D) of $0 mm, an inner diameter (10) of 70 mm and works ata pressure (p) of 40 MPa. Valve failure downstream in the pipe caused a pressure surge which burst the pipe. Examination of the fracture surface revealed a metallurgical defect at the inner surface of the pipe which ‘was semielliptical in shape with a depth of 1.6 mm and a surface length of 4.5 mm. This flaw was orientated perpendicular to the hoop stress in the pipe. ‘What pressure would have caused this failure? Note that the formula for hoop stress from thin walled theory is p(ID)/2t, while from thick walled theory it is pl(t2 + 1)/{L -1)] where tis the wall thickness of the pipe and L is the ratio OD/ID. Which formula would you use and why? The plane strain fracture toughness of the pipe alloy is 25 MPa m*, and the geometry correction factor can be found from the graph below. 3.0 25 20 15 1.0 05 Geometry Correction Factor Y 0.0 L 1 L L 00 02 04 06 08 10 K = Yona ‘Anew pipe was manufactured from the same alloy and subjected to NDT prior to installation. This showed that the pipe contained a similarly orientated flaw, 1.5 mm deep, but with a semicircular shape. ‘Assuming normal operating conditions, .e. no pressure surges and a daily evacuation to zero pressure, will the pipe last for its desired lifetime of 30 years? ‘Assume that the geometry correction factor has a constant value of 0.7 in this second part of the question and note that a fatigue crack growth rate of 6.25x10* mm/cycle corresponds to an applied delta K value of 410 MPa m’ The Paris law exponent m is 4.3 Acylndrical pressure vessel, wth a diameter of 6.1 mand a wall thickness of 25.4 mm, underwent catastrophic fracture when the internal pressure reached 17.5 MPa. “The steel of the pressure vessel had E = 210 GPa, a yield strength of 2450 MPa a value of G-= 131 ki/m* a) Show that failure would not have been ‘expected if the von Mises yield criterion had served for design purposes: i 2 2 2 ie.(q - a) +(2- a) +(- a) ¥ 207, 'b) Based on Griffith's analysis determine the size of crack that might have caused this failure, stating assumptions that you have made, Grinding wheels are fabricated, typically, from alumina powder, which is compacted and sintered at high temperature and pressure. The powder is sieved before compacting to remove impurities which may later act as defects in the grinding wheel. Hence residual impurities are related in size to the sieve mesh dimension. One particular type of alumina wheel has a density of 3800 kg/m’, a bore diameter of 140 mm and an outer diameter of 1.0 m. It spins at 3000 rpm. ‘The maximum stress the wheel is given by: ‘ia = R44 RI] Nine Where: (p = density of the wheel material © = rotational speed in radians v = Poisson's ratio = 03 R, = bore radius R, = outer radius Calculate the allowable size of the sieve mesh if the wheel is to have a factor of safety of two on critical defect size when operating at 3000 rpm. Note that, for alumina, the fracture toughness R = 0.10 ki/m? and E=371 GPa. You may assume plane strain conditions.