MCG 3131 MIDTERM EXAMINATION June 2014

Open book. Calculators permitted. Attempt all questions. Time: 2hrs.

1- The figure shows a double action pump. The piston is driven by the force applied
through the connecting rod S-S which stays horizontal all the time. When the piston
moves to the right the maximum pressure in section 1 is 157 KPa and the pressure in
section 2 is zero. When the piston moves to the left the maximum pressure in section
2 is 550 KPa and in section 1 is zero. The connecting rod is made from 1010 HR steel
and has a diameter of 20 mm. The endurance limit (S e ) for the connecting rod is 100
MPa. The piston has a diameter of 110 mm. If the fatigue stress concentration factor
in the connecting rod is 3, find the factor of safety of the connecting rod for infinite
life. Use ASME elliptic fatigue theory.
(28 points)
in in

2
1 d = 110 mm
S
S

out out

2- In the figure shown, the steel bar has an area of 700 mm2 and length of 300 mm and
the brass bar has an area of 1500 mm2 and length of 250 mm. At room temperature
they fit between the fixed supports A and B without any loose space between them
or any stress on them. Determine the load in the bars when the temperature of the
bars is raised by 50 ºC. Thermal coefficient of expansion for steel is 10.8 × 10-6
m/m◦ C and for Brass is 18.7 × 10-6 m/m◦ C. (22 points)

A Steel, A = 700 mm2

α = 10.8 × 10-6
Brass, A = 1500 mm2 B
α = 18.7 × 10-6

300 mm 250 mm
3- The I beam shown is loaded with a 12000 N force. If it is made from 1010 HR steel,

a) Determine the factor of safety on the beam (no stress concentration factor is
needed and the maximum shear stress theory (Tresca) rules)
(25 points)
b) Determine the deflection at midspan M. (8 points)
c) Find the maximum deflection on the beam. (17 points)

F = 12000 N

A M
120 mm
B
1 mm
1.5 m

1m

2m 90 mm
10 mm

3m

The cross section of the beam

Solution 1:

1010 CD steel from table A-20, page 1040: Sy = 180 MPa, Sut = 320 MPa, (2)
Endurance limit for the part is given in the question as Se = 100 MPa
F 1 = P 1 A piston = 157 × 10-3 × π ×1102/4 = 1492 N
F 2 = P 2 A piston = 550 × 10-3 × π ×1102/4 = 5054 N (6)
From the figure it is clear that F 2 causes tension and F 1 causes compression in the connecting
rod SS.
σ 1 = KF 1 /A rod = 3 × 1492/( π × 202/4 ) = 14.25 MPa (in compression)
σ 2 = KF 2 /A rod = 3 × 5054/( π × 202/4 ) = 48.26 MPa (in tension) (6)

σ a = (σ max – σ min )/2 = (48.26 –(-14.25))/2 = 31.25 MPa

σ m = (σ max + σ min )/2 = (48.26 +(-14.25))/2 = 17 MPa (7)

ASME elliptic criterion:

(nσ a / Se )2 + (nσ m /Sy)2 = 1 then (31.25n / 100 )2 + (17n/180)2 = 1 then (4)

n2 = 9.38 and n = 3.06 (3)

Solution 2:

From inside the cover of text book:

E steel = 207 GPa and E brass = 106 GPa (1)
Gvien in the question and also in table 3-3 of textbook:

α steel = 10.8 × 10-6 m/m◦ C

α brass = 18.7 × 10-6 m/m◦ C
Because of temperature rise the length of the system will be increased by:

δlT st = lαδ T = 300 × 10.8 × 10-6 × 50 = 0.162 mm

δlT Br = lαδ T = 250 × 18.7 × 10-6 × 50 = 0.234 mm (6)

Because the system can not elongate force decreases the length by:

δlF st = Fl st /(A st E st ) = F × 0.3 /( 700 × 10-6 × 207× 109 ) = F×1.57 × 10-9 m (6)
δlF Brt = Fl Br /(A Br E Br ) = F × 0.25 /( 1500 × 10-6 × 106× 109 ) = F×2.07 × 10-9 m

The same force F exits in the brass and in the steel part (2)
And we must have δlT st + δlT Br = δlF st + δlF Brt (5)

In this equation F is the only unknown F = 107902 N (2)

Solution 3: a)
1010 CD steel from table A-20, page 1040: Sy = 180 MPa, Sut = 320 MPa,
R A = 12000 × 1 / 3 = 4000 N
R B = 12000 – 4000 = 8000 N

I = 2×(90×103/12 +90×10×552) +1× 1003/12= (7)

I = 5.543 × 106 mm4 = 5.543 × 10-6 m4
(3)
σ max = M max c/I = 8000 × 0.06 /5.543 × 10-6
σ max = 86.6 MPa A B

Factor of safety n = Sy/ σ max 4000 N

n = 180/86.6 = 2.08 at top V
(4)
τ max = V max Q/Ib -8000 N
τ = 8000×(90×10×55 + 50×1×25)/( 5.543 × 106 ×1)
τ = 73.2 MPa
8000 Nm
Factor of safety n = Sy/ 2 τ max
n = 180/2 × 73.2 = 1.23 at neutral axis M
(5)
At the junction of the web and the wing
σ max = M x c/I = 8000 × 0.05 /5.543 × 10-6
σ max = 72.16 MPa
τ max = V max Q/Ib
τ = 8000×(90×10×55)/( 5.543 × 106 ×1)
τ = 71.44 MPa
Using Mohr’s circle and finding the radius
τ max = ((72.16/2)2+71.442)1/2 = 80 MPa
n = 180/2 × 80 = 1.125 at the web and wing junction
(7)
The maximum normal stress happens at top and bottom of the I-beam and the maximum shear
stress happens at the web and wing junction. And for the whole beam n = 1.125 (1)

b)
From table A-9 beam #6
y m = Fbx(x2+b2-l2)/(6EIl) = 12000 × 1×1.5× (1.52+12-32)/(6×207× 109 ×5.543 × 10-6 ×3)
y m = -5.01 × 10-3 m (6)

c)
From the geometry of the beam we notice that the maximum deflection happens somewhere on
the left had side of the load. At that point we have dy/dx = 0. So getting the derivative of the
equation in part b) we have : (10)
2 2 2
dy/dx = Fb(3x +b -l )/(6EIl) = 0 and after putting b = 1 and l = 3 we find x = 1.633 m
y max = Fbx(x2+b2-l2)/(6EIl) = 12000 × 1×1.633× (1.6332+12-32)/(6×207× 109 ×5.543 × 10-6
×3)
y m = -5.06 × 10-3 m (7)