5.

Analysis
a) Discuss how a fatigue limit is used in estimating the tensile strength.

To determine the fatigue strength of a material it is necessary to test the material to

failure in a very different way from that used to determine its ultimate strength in
tension.
i. Steel
At higher strength/hardness levels, materials lose fatigue strength due to increased
notch sensitivity and brittleness. With the addition of compressive stresses from
shot peening, however, metal fatigue strength increases proportionately to
increasing strength/hardness. The cyclic stress level of the first set of tests is some
large percentage of the Ultimate Tensile Stress (UTS), which produces failure in a
relatively small number of cycles. Subsequent tests are run at lower cyclic stress
values until a level is found at which the samples will survive 10 million cycles
without failure. The cyclic stress level that the material can sustain for 10 million
cycles is called the Endurance Limit (EL).
 iii. Copper
Soft copper has a tensile strength of about 200 MPa, yield strength of 40-80 MPa,
and a breaking elongation of over 40%. With cold forming, the tensile strength can
be increased to at least 350 MPa and the yield strength at least 320 MPa, then the
breaking elongation is lowered to values below 5%.

Pure copper does not become brittle under warmer temperatures and thus can be
shaped easily. At the same time, copper does not turn brittle under colder
temperatures.

Because copper has considerable fatigue-strength, it is also an ideal material for

oscillating stresses without the danger of it becoming brittle and breaking.

Even with slight variations in the purity of copper the physical properties will not
very much. The creep tensile strength can be enhanced through the creation of
copper alloys such as copper-silver.

With alloys, a greater strength of up to 700 MPa can be achieved and, in some
cases, even up to 1500 MPa. The disadvantage is that the conductivity of such
alloys decreases significantly.

iv. Brasses set the standard by which the machinability of other materials is judged and
are also available in a very wide variety of product forms and sizes to allow minimum
machining to finished dimensions. Brass does not become brittle at low temperatures
like mild steel.

Brass also has excellent thermal conductivity, making it a first choice for heat
exchangers (radiators). Its electrical conductivity ranges from 23 to 44% that of pure
copper.
b) With the help of sample calculation, compare stress σ between experimental and
theoretical result. Evaluate your answers.
σ = F/A
σ = 20N/20 mm2
σ = 1 N/mm2

Stresses and strains for a load of 20N,

Cross-sectional area 20 mm2
Experimental Theoretical Value
Material Value stress σ stress σ
in N/mm2 in N/mm2

Steel 1120434 1

Copper 902254.2 1

Brass 839168 1

Aluminium 1012285,2 1

This is because in experimental we can calculate value of stress precisely using a

device instead of using the theoretical value.

c) The shear modulus G of 80000 N/m2 and section modulus Wp of 196.3 mm3.
Calculate torsional moment for a load 5N.

2
Mt = . 𝐺. 𝑊𝑝. 𝑈𝐴
𝑈𝐵
𝑘
2
Mt = 2.05 ∗ 80000 ∗ 196.3 ∗ 0.035

Mt = 536234.1463 Nm
d) With the help of calculation compare the differences between measured and
calculated values of torsional moment.
γ = rd θ / dLds
𝛕=γ.G
γ = 0.005(0.01)45/0.01(0.5)
𝛕 = 0.45 * 80000
γ = 0.45
𝛕 = 7066800
Ε = 1/k * Ua/Ub
γ=2E Ε = 1/k * Ua/Ub
E = 0.45/2
Ua/Ub = 2.05(0.225)
E = 0.225
2 Ua/Ub = 0.46125
Mt = . 𝐺. 𝑊𝑝. 𝑈𝐴
𝑈𝐵
𝑘

2
Mt = 2.05 ∗ 80000 ∗ 196.3 ∗ 0.46125

Mt = 7066800 Nm