TABLE OF CONTENTS

LIST OF FIGURES ............................................................................................................................................ 1

BACKGROUND ............................................................................................................................................... 2
INVESTIGATION ............................................................................................................................................. 2
Tensile Test ............................................................................................................................................... 2
Procedure .............................................................................................................................................. 2
Results ................................................................................................................................................... 3
Bend Test Without a Notch....................................................................................................................... 4
Procedure .............................................................................................................................................. 4
Results ................................................................................................................................................... 4
Bend Test with Notch................................................................................................................................ 7
Procedure .............................................................................................................................................. 7
Results ................................................................................................................................................... 7
CONCLUSION................................................................................................................................................. 8
REFERENCES .............................................................................................................................................. 8

LIST OF FIGURES
Figure 1: Graph of Tensile stress vs Tensile strain……………………………………………………………………………….3

Figure 2: Ductile fracture……………………………………………………………………………………………………………………..3

Figure 3: Table of results of bend test without notch……………………………………………………………………………4

Figure 4: Graph of Load (kg) vs Deflection (mm)…………………………………………………………………………………..5

Figure 5: Table of results for bend test with notch……………………………………………………………………………….7

Figure 6: Graph of load (kg) vs deflection (mm) for both bend tests with and without a notch…………..7

1
DESIGN FAILURE ANALYSIS- CASE STUDY
BACKGROUND
A user of a broomstick, which had a tubular aluminum handle, claims that, while he was sweeping leaves
outside using the broom, it snapped right in the middle and cut his hand.

The user is claiming it as an accident and would like the insurance company to cover his medical cost.
However, the insurance company needs to be sure whether this really was an accident or was the users
own doing.

To prove this, a tensile test, a bending test without a notch and one with is required so as to certify the
actual amount of force that would be required to snap the broom handle. This information can then be
used to certify or deny the users claim.

This report aims to present exactly that by detailing how the tests were carried out their results and
their consequence on the users claim.

INVESTIGATION
After further inspection of the broom handle, I noticed that it had snapped right at the center. It also
had staining, dirt, scratches and pits evident on its surface.

Tensile Test
A tensile test is an easy and effective method to quantify a materials actual strength and evaluate
properties such as the materials Ultimate Tensile Strength, yield stress and percentage elongation.

The ultimate tensile strength of a material is the maximum stress it can withstand before yielding when
being pulled. The yield stress is the stress where the material no longer acts elastically. The percentage
elongation is the maximum elongation of the gage length divided by the original gage length.

Procedure
The tensile test was carried out using a Universal Testing Machine.

First the diameter and thickness of the tube was measured and found to be:

D = 23 mm Outside Diameter t = 0.9 mm Wall Thickness

To allow for proper gripping of the tube during the tensile test, two mandrels had to be used. The
mandrels were turned to a diameter of 22.5 mm to provide a snug fit into the tube. The ends of the
mandrel were tapered 60°.

2
The mandrels were secured to the aluminum tube using a Permabond two-part epoxy adhesive that has
a typical bond strength of about 20 N/mm2.

Results
From the graph that was printed the following data was collected:

Figure 1: Graph of Tensile stress vs Tensile strain

Ultimate Tensile Yield Stress (MPa) Percentage Elongation

Strength (MPa)
Specimen 1 200 170 6.75%
The aluminum tube experienced ductile fracturing as a large plastic deformation was observed before
the tube yielded. Also, the fracture had a dimpled, cup and coned fracture appearance, which is unique
to ductile fracturing.

Figure 2: Ductile Fracture

3
Bend Test Without a Notch
Bend tests deform the material at its midpoint to cause a deflection in the specimen without fracturing
it. Such a test is usually performed to determine the ductility or resistance to fracture of a material.

The test was carried out on a lathe bed, supporting the tube length on knife edges while it was loaded at
the center (simply supported beam).

Procedure
The outer diameter and thickness of the tube was measured:

D = 23 mm Outside Diameter t = 0.9 mm Wall Thickness d = 21.2mm Inside Diameter

The length of tube between the supports was measured and found to be:

L = 1m

The digital display was setup and the beam was carefully loaded. The deflections were then measured
and recorded. From which a graph was plotted.

Results

Bend test without notch

Load(kg) Deflection(mm)
5 4.33
10 8.81
15 13.32
20 17.82
25 22.22
30 28.08
35 34.99
37 37.04
39 40.64
40 45.03
43 50.6
45 55
47 buckled

Figure 3: Table of results of bend test without notch

4
 Load (kg) vs Deflection(mm)
50

45

40

35

30
Load (kg)

25

20

15

10

0
0 5 10 15 20 25 30 35 40 45 50 55 60
Deflection (mm)

Figure 4: Graph of Load (kg) vs Deflection (mm)

We can see that the maximum load before buckling is 47kg. And the limit of elasticity is reached at
about 26kg.

We found the radius of curvature, maximum bending stress and Young’s modulus using the bending
equation, which is:

𝑀 𝜎 𝐸
= =
𝐼 𝑦 𝑅
Where: M=bending moment at the center point

I = second moment of area

σ = bending stress

y = distance from neutral axis

E = Young’s Modulus

R = radius of curvature

From the data that we have, we can see that:

𝑀𝑦
𝜎= 𝐼

5
And therefore: 𝜎𝑚𝑎𝑥 = 𝑀𝑚𝑎𝑥
𝐼
𝑦

𝐿
Where: 𝑀𝑚𝑎𝑥 = max 𝑙𝑜𝑎𝑑 ∗ = (47kg x 9.81m/s2) x (1m/2) = 230.535Nm
2

𝐷 23𝑚𝑚
𝑦= = = 11.5𝑚𝑚
2 2

Second moment of area for a thin tube is given by:

𝜋 𝜋
𝐼 = (𝑅 4 − 𝑟 4 ) = (11.54 − 10.64 ) = 3821.192𝑚𝑚4 = 3.821 ∗ 10−9 𝑚4
4 4

𝑀𝑚𝑎𝑥 𝑦 230.535𝑁𝑚∗11.5𝑚𝑚
Therefore: 𝜎𝑚𝑎𝑥 = = = 693.84𝑀𝑃𝑎
𝐼 3.821∗10−9
To find the Young’s modulus, E we use the deflection formula for elastic materials:

𝑑2 𝑦
𝐸𝐼 = = 𝑃𝑥
𝑑𝑥2
Where P = load at yield stress

𝑥 𝑑2 𝑦 𝐿
We integrate the equation: 𝐸𝐼 = ∫0 = ∫0 𝑃𝑥
𝑑𝑥2

𝑃𝐿3
Which gives: 𝑦=
48𝐸𝐼
Making E the subject of the formula:

𝑃𝐿3 (26𝑘𝑔∗9.81)∗13
𝐸= = = 120.93𝐺𝑃𝑎
48𝐼𝑦 48∗3.821∗10−9 ∗0.0115
Using the bending equation, we can find the radius of curvature from:

𝐸𝑦 120.93𝐺𝑃𝑎 ∗ 0.0115𝑚
𝑅= = = 2.093 ∗ 10−9 𝑚
𝜎 664.3𝑀𝑃𝑎

Considering our calculated Young’s Modulus of 120.93GPa, where as Aluminum usually has a Young’s
modulus of about 69GPa. The large discrepancy might be due to the fact the aluminum used to make
the broom handle might be an alloy. This can also be explained by experimental errors like parallax
when measuring the diameter of the tube or when placing the weights on the tube.

6
 Bend Test with Notch
This is similar to the above bend test; however, a file is used to make a small notch on the tube before
loading. The depth of the notch should be at least half of the wall thickness.

Procedure
Make a notch on the tube, and measure its depth:

Notch depth = 0.5 mm

With the notch on the underside of the tube, place the loads and record the deflections. Plot these
results on the same graph as the bend test without a notch.

Results
Bend Test with Notch
Mass Deflection
(kg) (mm)
5 4.2
10 8.58
15 13.01
20 17.5
25 buckled
Figure 5: Table of results for bend test with notch

Load (kg) vs Deflection(mm)

50

45

40

35

30
Load (kg)

25
Bend test without notch
20 Bend test with notch

15

10

0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
Deflection (mm)
Figure 6: Graph of load (kg) vs deflection (mm) for both bend tests with and without a notch

From the table we can see that the max load that buckled the tube was 25kg.

7
We calculated the maximum bending stress , 𝜎𝑚𝑎𝑥 and the notch stress concentration, Kt using the max
stress from bend test 1.

We know that: 𝜎𝑚𝑎𝑥 = 𝑀𝑚𝑎𝑥

𝐼
𝑦

𝐿 1𝑚
Therefore: 𝑀𝑚𝑎𝑥 = max 𝑙𝑜𝑎𝑑 ∗ = (25𝑘𝑔 ∗ 9.81) ∗ = 122.625𝑁𝑚
2 2

Y and I are the same as before as we are dealing with the same tube.
𝑀𝑚𝑎𝑥 𝑦 122.625𝑁𝑚∗11.5𝑚𝑚
So: 𝜎𝑚𝑎𝑥 = = = 369.062 𝑀𝑃𝑎
𝐼 3.821∗10−9
Notch stress concentration is given by the formula:

𝜎𝑚𝑎𝑥 693.84
𝐾𝑡 = = = 1.88
𝜎𝑛𝑜𝑚 369.062

CONCLUSION
From the results obtained from the experiments above, the material that was used to make the broom
handle was a very rigid one. In fact, one could say it was overly rigid for its use. The material was also
noticed to perform better under bending loads rather than tensile loads. Also, the pits and scratches
seen on the tube are fairly reminiscent of a brittle fracture of the tube, which could only be caused by
lateral uniaxial loading. Therefore, in retrospect the broom handle could not have snapped due to the
simple act of sweeping leaves, as it was far too strong. This, therefore, puts in doubt the users claim of it
being an accident.

In recommendation, I suggest the following materials to be better suited for the broom handle.

i. Wood: It is cheaper and more flexible, therefore allowing for easier sweeping. It also can be
stained or varnished, eliminating wear due to weather and making it easier to clean.
ii. Plastic: In this case any polymer like polypropylene or nylon would do. They are cheap and easy
to manufacture. They are flexible but rigid enough to withstand large durations of physical
fatigue. And they are weather proof and very easy to clean.

REFERENCES
Ferdinand P. Beer, Russel Johnston., John T. DeWolf, David F. Mazurek. Mechanics of Materials, sixth
edition.

http://www.permabond.com/2017/07/21/metal-bonding-epoxy-adhesives-strongest-glue-metal/

https://www.engineeringtoolbox.com/young-modulus-d_417.html