COMPLEX ENGINEERING PROBLEM

GROUP MEMBER REG NO

Haseeb Moghees 1032-FET/BSME/F21
Hamza ur Rehman 1036-FET/BSME/F21
Ahmed Nadeem 1054-FET/BSME/F21
Muhammad 1074-FET/BSME/F21

SUBJECT:
MECHANICS OF MATERIAL LAB

SUBMITTED TO:
ENGR. MOHSIN SAHAB

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Table of Contents

Problem Statement.................................................................................................................................................................. 3

Introduction................................................................................................................................................................................ 3

Apparatus..................................................................................................................................................................................... 4

Crack Analysis................................................................................................................................................................ 4

Free Body Diagram:.................................................................................................................................................... 5

Dimention and calculation................................................................................................................................................... 5

Fatigue Analysis............................................................................................................................................................... 8

Fatigue factor of safety (Nf ):.......................................................................................................................................... 9

Marin factor calculation........................................................................................................................................................ 9

Surface factor (Ka):.............................................................................................................................................................. 9

Size factor (Kb):..................................................................................................................................................................... 9

Loading factor (Kc):............................................................................................................................................................ 9

Temperature factor (Kd):.................................................................................................................................................. 10

Stress concentration factor (Kfs):.................................................................................................................................. 10

Factor of safety using failure theories.......................................................................................................................... 11

Modified Goodman Criteria............................................................................................................................................ 12

Gerber Criteria............................................................................................................................................................. 12

ASME-Elliptic Criteria............................................................................................................................................ 12

Number of cycles to failure.............................................................................................................................................. 13

Number of cycles with practically applied stress.................................................................................................... 14

Results and Discussion:...................................................................................................................................................... 14

References................................................................................................................................................................................ 15

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PROBLEM STATEMENT:
As every motorcycle need tuning for maintenance, in every month, in this the
mechanic loose and tight the bold applying cyclic loading due to which the bold
may fail. Metallurgical analysis of a large number of failed bolt have revealed
that all had failed from fatigue rather than overtightening.

LITERATURE REVIEW:
There has been a considerable amount of research into the
subject of wheel loss from commercial vehicles. A report from the Institute of
Road Transport Engineers in 1986 noted that based upon a large sample of
machines from the Institutes membership, a wheel stud failure rate of 3 per cent
per year and the average distance between failures is 123000 Km (although the
pattern is unpredictable). More than 6 per cent of hubs are affected each year.

INTRODUCTION:
A bolt is a form of threaded fastener with an external male thread requiring a
matching preformed female thread such as a nut. Bolts are very closely related
to screws. The distinction between a bolt and a screw is poorly-defined. The
academic distinction, per Machinery's Handbook, is in their intended design:
bolts are designed to pass through an unthreaded hole in a component and be
fastened with the aid of a nut, although such a fastener can be used without a
nut to tighten into a threaded component such as a nut-plate or tapped housing.
Screws in contrast are used in components which contain their own thread, or to
cut its own internal thread into them. Bolts are often used to make a bolted joint.
This is a combination of the nut applying an axial clamping force and also the
shank of the bolt acting as a dowel, pinning the joint against sideways shear
forces. For this reason, many bolts have a plain unthreaded shank (called the
grip length) as this makes for a better, stronger dowel. Where a fastener forms
its own thread in the component being fastened, it is called a screw. This is most
obviously so when the thread is tapered (i.e. traditional wood screws), precluding
the use of a nut, or when a sheet metal screw or other thread-forming screw is
used. A screw must always be turned to assemble the joint. Many bolts are held
fixed in place during assembly, either by a tool or by a design of non-rotating
bolt, such as a carriage bolt, and only the corresponding nut is turned.

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 PROBLEM ANALYSIS:
Crack Analysis:

Final Rupture

Crack propagation

Crack Initiation

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 FREE BODY DIAGRAM

FT
F’T
T’

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BOLT DIMENTION:
Bolt: M5×1mm×35mm Grad

4.6 Nominal Diameter = 5mm

Head Diameter = 8mm

Pitch = 1mm

Nominal Length = 35mm

Notch Radius = 1mm

CALCULATION:
Table 8-7 From Shigley’s Machine Design 10th Edition

Threaded Length: LT = 2d+6mm, L≤125mm, d≤48mm

= 2(5mm) + 6mm
= 16mm

Length of unthreaded portion in grip:

l d = L - LT
= 35 – 16 = 19mm

From Table 8-1: Tensile stress Area (At ):

At= 14.2mm2 = 14.2×10-6 m2
Area of unthreaded portion (Ad ):
Ad = πd2 /4 = 19.6mm2 = 19.6×10-6 m2
Mechanical Properties of AISI 1020 CD Steel:
Modulus of Elasticity = 205GPa
Yield Strength = 350MPa
Ultimate Tensile Strength = 420MPa
Stiffness of Bolt:
Ad×At×E
𝐾𝑏 = Ad×lt+At×ld

𝐾𝑏 = 97.9 k N/m

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Standard Torque For bolt M5 Grad 4.6, T = 2.20 N/m
Polar moment of inertia (J):
J = πd4 /32 = 6.12×10-11 m4

To calculate stress concentration factor (Kts ):

r/d = 1/5 = 0.2
D/d = 8/5 = 1.6

From Figure A-15-8 from Shigley

Kts = 1.2

Maximum shear stress produced in the bolt (ℸmax):

𝐾𝑡𝑠 𝜒 𝑇 𝜒 𝑟 1.2 𝜒 2.2 𝜒0.0025
τ 𝑚𝑎𝑥 = 𝐽 = 6.14 𝜒 10−11

τ𝑚𝑎𝑥 = 107.6 MPa

According to MSST:

Yielding F.O.S Ny = Sy/2 =350/2

τ𝑚𝑎𝑥 107.6

= 1.626 >1 so, no yielding will occur.

Now calculations for torque practically applied:

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Applied Torque = T = 9 Nm

Max. shear stress produced:

𝐾𝑡𝑠 𝜒 𝑇 𝜒 𝑟 1.2 𝜒 9 𝜒0.0025

τ𝑚𝑎𝑥 = 𝐽
= 6.14 𝜒 10−11

= τmax = 440.1 MPa

Now according to MSST:

Sy/2
Ny = τ𝑚𝑎𝑥

350/2
= 440.1

= 0.397 < 1 so, Yielding will occur.

FATIGUE ANALYSIS:

Standard tensile force that can be applied, Fmax = 4090N

Tensile Area, At = 14.2mm2

Minimum force, Fmin = 0N

Max. stress, 𝜎𝑚𝑎𝑥= 288MPa

Min. stress, 𝜎𝑚𝑖𝑛 = 0

Fatigue factor of safety (Nf ):

Ny = Se
𝐾𝑓𝜒 σmax

Where,

Se = endurance limit

Kf = notch sensitivity

σmax = max. stress

Calculations for Se :

Se = Ka.Kb.Kc.Ke.Kf×S’e

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Surface factor (Ka):

Ka= a𝑆b𝑢𝑡

From table 6-2, ch#06 , Shigley’s BOOK

a = 4.51 , b = -0.265

Ka = (4.51)×420-0.265

Ka = 0.91

Size factor (Kb):

Kb = 1.24d-0.107 2.79<d≤51mm

Kb = 2.24(5)-0.107

Kb = 1.044

Loading factor (Kc):

Kc = 0.59 for torsion

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Temperature factor (Kd):

Kd = 1

Now for 𝑆′𝑒:

𝑆′𝑒 = 0.5Sut if Sut ≤ 1400MPa

𝑆′𝑒 = 0.5(420) = 210MPa

Now for Se:

Se = Ka.Kb.Kc.Kd.𝑆𝑒′

Se = 0.91×1.044×0.59×1×210 = 117.1MPa

Stress concentration factor (Kfs):

K𝑓𝑠=1+𝑞(K𝑡𝑠−𝑎)

Notch sensitivity ‘q’ from graph 6-21:(shigley)

q = 0.7

K𝑓𝑠= = 1+0.7(1.2-1) = 1.14

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Now fatigue factor of safety (Nf ):

Se
N𝑓 = 𝐾𝑓 × σmax

117.71
N𝑓= 1.14×288 = 0.358<1 so, finite life is predicted

Factor of safety using failure theories:

σ𝑚𝑎𝑥= 288MPa

σ𝑚𝑖𝑛 = 0MPa

Mean stress:

σ𝑚 = σmax + σmin
2
288+0
σ𝑚 = = 144𝑀𝑃𝑎
2

Alternating stress:

σmax − σmin
σ𝑚 =
2

σ𝑎 = 288− 0
= 144𝑀𝑃𝑎
2
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Modified Goodman
Criteria:

σ𝑎 + σ𝑚 = 1
s𝑒 s𝑒 𝑛

144
117.71 144 1
+ =
420 𝑛

n = 0.638<1 so, finite life is predicted.

Gerber Criteria:

1 𝑆𝑢𝑡( 2σ𝑚𝑠𝑎 2
2
𝜎
𝑛𝑓 = 2 𝑆𝑒 ) [−1 + √1 + ( )]
𝑠𝑒 𝑠𝑢𝑡𝑠𝑎

2 144 2 × 144 × 177.71 2

𝑛𝑓 = 1 420
( ) √
[−1 + 1 + ( ) ]
2 144 117.71 420 × 144

𝑛𝑓 = 0.762 < 1 so, finite life is predicted.

ASME-Elliptic Criteria:

Factor of safety is given by

𝑛𝑓 = 1
√
𝜎 2 2
( 𝑎) + (𝜎 𝑚)
𝑆𝑒 𝑆𝑦

𝑛𝑓 = √ 1
144 2 144 2
( ) + ()
117.71 350

𝑛𝑓 = 0.779 𝑠𝑜, 𝑓𝑖𝑛𝑖𝑡𝑒 𝑙𝑖𝑓𝑒 𝑖𝑠 𝑝𝑟𝑒𝑑𝑖𝑐𝑡𝑒𝑑

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Number of cycles to failure:

1
𝜎𝑟𝑒𝑣 𝑏
𝑁=( )
𝑎

Where,

(𝑓.
𝑎=
𝑆𝑢𝑡)2
𝑆𝑒

𝜎𝑚,𝑟𝑒𝑣 = 288𝑀𝑃𝑎

From figure 6-18 ( Shigley CH no 06)

Fatigue strength fraction, f = 0.89

Sut = 420MPa

Se = 117.71MPa

(0.89.420)2
𝑎= = 1213.86
117.71

1 𝑓. 𝑠𝑢𝑡
𝑏 = − 𝑙𝑜𝑔 ( )
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3 𝑠𝑒

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 1 0.89 × 420
𝑏 = − 𝑙𝑜𝑔 ( ) = −0.1689
3 117.71

Now,

1
288 0.1689
𝑁=( ) = 4998.28 𝑐𝑦𝑐𝑙𝑒𝑠
1213.86

𝑁 ≈ 5000 𝑐𝑦𝑐𝑙𝑒𝑠

Number of cycles with practically applied stress:

Fmax = 6250N

At = 14.2mm2

𝜎𝑚𝑎𝑥 = 440.14𝑀𝑃𝑎

a = 1213.86

b = -0.1689

f = 0.89

1
𝜎𝑟𝑒𝑣 𝑏
𝑁=( )
𝑎

1
440.14 0.1689
𝑁=( ) = 405.98 𝑐𝑦𝑐𝑙𝑒𝑠
1213.86

RESULTS AND DISCUSSION:

In this study a M5×1mm×35mm AISI 1020 CD Steel bolt was studied. There are
two analysis performed one with standard stresses and the second with
practically applied stresses. With standard stresses the yielding does not occur
but the bolt has limiting number of life cycles. Modified Goodman Criteria,
Gerber Criteria, and ASME Elliptic Criteria are applied and the results have
shown that factor of safety is less than 1 which means finite life of the bolt
material at stress 288MPa. When the analysis performed with maximum

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practically applied stress of 440MPa by applying torque (T=9Nm) the life cycles
reduced from 5000 to 405 cycles also this maximum stress is beyond ultimate
tensile strength due to which yielding is produced and the bolt was therefore
failed. Another important aspect is that maybe the sudden max. force was
applied which exceed the yield point and the failure was occur.

 References:
 "Article on fatigue Failure of Bolts by Bill Eccles
 Text book of machine design by RS Khurmi and JK Ghupta
 Text book of Mechanical Engineering Design, by Shigley’s ninth Edition
 Mechanics of material by Beer and Johnston, 7th edition
 Alex Hudgins*Brad James,*FASM Exponent Failure Analysis Associates Menlo
Park, Calif

 http://www.matweb.com/search/DataSheet.aspx?MatGUID=10b74ebc27344380ab16
b1b69f1cffbb&ckck=1
 https://blog.maxprocorp.com/examples-of-bolt-failure

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