SOLUTION G.1D) Known: Definitions of the terms stress, strength, yield strength, ultimate strength, elastic limit, proportional limit, modulus of elasticity, and yield point int are given in Section 3.2. Find: Write definitions of the above terms -- see Section 3.2. Analysis: 1. The stress is the load divided by the cross-sectional area, 2. The strength is the maximum value of stress a material will carry before failure. 3. The yield strength, Sy, is the value of stress at which significant plastic yielding first occurs 4. The ultimate strength is the maximum value of stress a material will carry before fracture for nondynamic loading. 5. The elastic limit is the highest stress the material can withstand and still return exactly to its original length when unloaded. 6. The proportional limit is the stress at which the stress-strain curve first deviates (ever so slightly) from a straight line. Below the proportional limit, Hooke's law applies. 7. The modulus of elasticity (Young's modulus) E, is the constant of proportionality between stress and strain (which is the slope of the curve between the origin and the proportional limit). 8. The yield point of a material is a point for a material where appreciable yielding occurs suddenly at a clearly defined value of stress; for example, in soft steel. In other materials the onset of appreciable yielding occurs gradually, and the yield strength for these materials is determined by using the "offset method.” ‘This is illustrated in Fig. 3.1; it shows a line, offset an arbitrary amount of 0.2 percent of strain, drawn parallel to the straight-line portion of the original stress-strain diagram. Point B is the yield point of the material at 0.2 percent offset. If the load is removed after yielding to point B, the specimen exhibits a 0.2 percent permanent elongation. Yield strength corresponding to a specified (very small) offset is a standard laboratory determination, whereas elastic limit and proportional limit are not. 3-1SOLUTION (3.2D) Known: The materials to be selected have E greater than 207 GPa and Sy greater than 1378 MPa. Find: Identify five materials with (a) modulus of elasticity greater than steel, and (b) ultimate strength greater than 200 ksi Analysis: (a) From Appendix C-1, we attempt to select the following materials with higher E values than steel, but inspection of the materials listed in the appendix of the textbook, reveals no materials with E values higher than that of steel. . (b) From the textbook appendices, we select the following non-steel materials with Su values greater than 1378 MPa. Material (Pa) Steel 1378 MPa Leaded beryllium copper 1379 MPa (max) 17300 | (Appendix C-13) Duranickel 301 1448 MPa (max) CD aged bar |cappendix C-15) Rene 95, 1620 MPa Superailo} Comment: Inspection of the materials listed in the appendix of the textbook reveals that steel is a relatively strong and stiff material. 3-2SOLUTION (3.2D) -- alternate Known: The materials to be selected have E greater than 207 GPa and Sy greater than 1378 MPa. Find: Identify five materials with (a) modulus of elasticity greater than steel, and (b) ultimate strength greater than 200 ksi. Analysis: (a) From www.matweb.com we select the following materials with higher E values than steel: . Modulus of Elastiiy ksi, greater than 30x 106 pat Material [Steel [30000 ket Beryllium, Be 40020 ksi ‘Chromium, Cr 35960 ksi Recrystallized Iridium, Ir 75980 ksi Annealed Molybdenum, Mo F7850 ksi Annealed Osmium, Os 81200 ksi Annealed Rhenium, Re 68005 ksi Annealed Rhodium, Rh 32055 Ksi Annealed Ruthenium, Ru 60080 ksi Annealed Technetium, Te 76690 ksi ‘Annealed Tungsten, W 38000 ksi (b) We select the following non-steel materials with ultimate tensile strength Sy greater than 1378 MPa (200,000 psi) 7 Tensile Strength, Ultimate, psi, greater than 200 ksi Mat Su AIST Grade T8Ni (300) Maraging [293625 psi Steel Aged, round bar ‘Tested longitudinal, 75 mm Carpenter AerMet®-for-Tooling 300005 psi Tool Steel Double Aged 468°C BioDur™ 316LS Stainless Medical 223445 psi Implant Alloy 90% Cold Worked 33‘VascoMax® C-300 Specialty Steel]285070 psi Heat Treatment: 927°C (1700°F) + Age W-25 Re Tungsten Rhenium Alloy /580000 psi Deformed AISI A6, Type Tool Steel 345100 psi Austenitized 830-870°C (1525- 1600°F) AIST A9, Type Tool Steel 319000 psi ‘Tempered at 500°C Titanium Ti-15Mo-5Zr 246500 psi ST 730°C, Aged 400°C ‘AISI Type W2 Tool Steel 361000 psi Water quenched at 775°C (1425°F), and tempered ‘AISI Type S5 Tool Steel 323550 psi Austenitized 855-870°C (1575- 1600°F) Oil quenched to 55 HRC Mo-47.5 Re Molybdenum 464000 psi Rhenium Alloy Deformed Trdium, Ir 250000 psi Cold-Drawn Rhenium, Re 304500 psi Deformed Rhodium, Rh 299860 psi Hardened Technetium, Te 218950 psi As-Rolled Pt-20% Ni Alloy 250125 psi Hard 79Pt-15Rh-ORW 300150 psi Alloy 851 Pt-8% W Alloy 300150 psi Hard Comment: Matweb is an award winning web site. 3-4SOLUTION (3.3) Known: The critical location of a part made from a known steel is cold worked during fabrication. Find: Estimate Su, Sy and the ductility Schematic and Given Data: Stress Strain Assumption: After cold working the stress-strain curve for the critical location starts at point G Analysis: 1. Atpoint G in Fig. 3.2, the part has been permanently stretched to 1.1 times its initial length. Hence, its area is 1/1.1 times its original area Ao. On the basis of the new area, the yield strength is Sy = 62(1.1) = 68.2 ksi. ll The ultimate strength is Su = 66(1.1) = 72.6 ksi. a At fracture, R increases to 2.5 on the graph. R=2.5/1.1 = 2.27 Using Eq. (3.3) and Eq. (3.2) auReDN 35SOLUTION (3.4) Known: The critical location of a part made from a known steel is cold worked during fabrication. Find: Estimate Sy, Sy and the ductility. Schematic and Given Data: Stress Hot Rolled 1020 Steel Strain Assumption: After cold working the stress-strain curve for the critical location starts at point J Anal 1 QUAD lysis: ‘The area ratio at J is R = Ao/Af = 1.2. The initial area is thus 1/1.2. ‘The yield strength is Sy = 65(1.2) = 78 ksi The ultimate strength is Sy = 66(1.2) = 79.2 ksi At fracture, R increases to 2.5 on the graph. R= 25/12 = 2.08 Using Eq. (3.3) and Eq. (3.2) 0.519 R - 1 = 2.08 - 1 = 1.08 or 108% @ aL R 3-6SOLUTION (3.5) Known: A tensile specimen of a known material is loaded to the ultimate stress, then unloaded and reloaded to the ultimate stress point. Find: Estimate the values of 6, , Gt, €r for the first loading and the reloading. Schematic and Given Data: Stress Hot Rolled 1020 Steel Strain Assumption: After unloading the stress-strain curve starts at point H for the new specimen. Analysis: For the initial sample, o = 66 ksi, € = 30%. / For Figure 3.2, R = 1.3 at point H. From Eq. (3.4), GT= OR = (66)(1.3) = 85.8 ksi . From Eq. (3.5), er=In(1 + €) = In 1.30 = 0.26 = 26%. . . : For the new specimen; 6 = 66(1.3) = 85.8 ksi. The new specimen behaves elastically, so € = G/E = 85.8/30,000 = .00286. Within the elastic range, or ~ 6 and er ~€. Therefore oT = 85.8 ksi and eT = 0.29%. a NAWRYHA Comment: Note also that 7 = In(1 + €) = In(1.0029) = 0.29%. 37SOLUTION (3.6) Known: A tensile specimen of a known material is loaded to a known stress, then unloaded and reloaded to the same stress point. Find: Estimate the values of 6, €, or, €r for the first loading and the reloading. Schematic and Given Data: Stress Hot Rolled 1020 Steel Strain Assumption: After unloading, the stress-strain curve starts at point G for the new specimen. Analysis: 1. For the initial sample, 6 = 62 ksi, € = 10% / For Figure 3.2, R = 1.1 at point G. From Eq. (3.4), r= OR = (62)(1.1) = 68.2 ksi. . From Eq. (3.5), er=In(1 + €) = In 1.10 = 0.095 = 9.5%. : For the new specimen; 6 = 62(1.1) = 68.2 ksi. . The new specimen behaves elastically, so € = G/E = 68.2/30,000 = .00227. Within the elastic range, or ~ 6 and er ~€. Therefore or = 68.2 ksi and er = 0.23% . AAUWEYN Comment: Note also that ey = In(1 + €) = In(1.0023) = 0.23%.SOLUTION (3.7) Known: A tensile specimen of a known material is loaded to a known stress, then unloaded and reloaded to the same stress point. Find: Estimate the values of 6, €, Gr, er for the first loading and the reloading. Schematic and Given Data: Stress Hot Rolled 1020 Steel Strain Assumption: After unloading the stress-strain curve starts at point J for the new specimen. Analy: 1. For the initial sample, 6 = 65 ksi, € = 20%. . 2. For Figure 3.2, R = 1.2 at point J 3. From Eq. (3.4), or= OR = (65)(1.2) = 78.0 ksi. / 4. From Eq. (3.5), er=In(1 +€) = In 1.20 = 0.18 = 18%. . 5. For the new specimen; 6 = 65(1.2) = 78 ksi . 6. The new specimen behaves elastically, so € = G/E = 78/30,000 = 0026. 7. Within the elastic range, ot =~ and er =. Therefore or = 78 ksi and er = 0.26% . Comment: Note also that ey = In(1 + €) = In(1.0026) = 0.26%. 3-9SOLUTION (3.8D) Known: A steel is to be selected from Appendix C-4a Find: Estimate Sy and Sy from the given value of Brinell hardness for the steel selected. Schematic and Given Data: Decision: Select ANSI 1020 annealed. Assumptions: The experimentally determined relationship of ultimate strength to hardness is sufficiently accurate. 2. The experimentally developed relationship of yield strength to ultimate strength is sufficiently accurate for our purposes. Analysis: Appendix C-4a shows that ANSI 1020 annealed steel has Sy= 57.3, Sy = 42.8, and Bhn =111. 2. Using Eq. (3.11), we can estimate Sy from the Brinell hardness using: Su=KpHp where Kg ~ 500 for most steels. Su = 500(111) = 55,500 psi 3. Sy can be estimated by using Eq. (3.12). Sy = 1.05 Su - 30,000 psi = 1.05(55,500) - 30,000 = 28,275 psi. . Comments: 1. Equation (3.12) is a good estimate of the tensile yield strength of stress-relieved (not cold-worked) steels. Note that the estimated value of Sy from the Brinell hardness of 55.5 ksi is close to the value given in Appendix C-4a of Sy = 57.3 ksi. 2. Experimental data would be helpful to refine the above equations for specific steels. 3-10SOLUTION (3.9D) Known: A steel is to be selected from Appendix C-4a : Estimate Sy and Sy from the given values of Brinell hardness for the selected Schematic and Given Data: AIST 1040 Steel oO annealed Decision: Select ANSI 1040 annealed steel. Assumptions: 1. The experimentally determined relationship of ultimate strength to hardness is sufficiently accurate. 2. The experimentally developed relationship of yield strength to ultimate strength is sufficiently accurate for our purposes. Analysi 1. Appendix C-4a shows that ANSI 1040 annealed steel has Sy = 75.3 ksi, Sy = 51.3 ksi, and Bhn = 149. 2. Using Eq, (3.11), we can estimate Sy from the Brinell hardness value using: Su = KpHe where Kp = 500 for most steels. Sug = 500(149) = 74,500 psi 3. Sy can be estimated by using Eq. (3.12). Sy, = 1.05 Sy - 30,000 psi = 1.05(74,500) - 30,000 = 48,225 psi . 4. Ratio of strength (Appendix C-4a values to Brinell hardness based values) 53-101 Comments: 1. Equation (3.12) is a good estimate of the tensile yield strength of stress-relieved (not cold-worked) steels. 2. The Brinell hardness based strength values are slightly less than the Appendix C- 4a strength values. 3-11SOLUTION (3.10D) Known: A steel is to be selected from Appendix C-4a. Find: Estimate Sy and Sy from the given values of Brinell hardness for the selected steel Schematic and Given Data: AISI 1030 Steel oO as-rolled normalized annealed Decision: Select ANSI 1030 steel. Assumptions: 1. The experimentally determined relationship of ultimate strength to hardness is sufficiently accurate. 2. The experimentally developed relationship of yield strength to ultimate strength is sufficiently accurate for our purposes. Analysis: 1. Appendix C-4a shows that for ANSI 1030 the strengths are as follows: (1) as- rolled Sy = 80.0 psi, Sy = 50.0 psi, Bhn = 179; (2) normalized Sy = 75.5 psi, Sy = 32.0 psi, Bhn = 149; (3) annealed Sy = 67.3 psi, Sy = 31.2 psi, Bhn = 126 2. Using Eg. (3.11), we can estimate Sy, Su= KsHp where Kg = 500 for most steels. 3. Sy can be estimated by using Eq. (3.12). 4. Inas-rolled condition: Su = 500(179) = 89,500 psi 1.05 Sy - 30,000 psi 5. In normalized condition: Su = 500(149) = 74,500 psi. 1.05Sq ~ 30,000 psi = 48,225 psi. 6. In annealed condition: Su = 500(126) = 63,000 psi. Sy = 1.058q - 30,000 psi = 36,150 psi. 7. Ratio of strength (Appendix C-4a values to Brinell hardness based values): 1.05(89,500) - 30,000 = 63,975 psi. 3-12as-rolled: = 39.5 7 894 ee 781 normalized: = - 743 = 101 ‘annealed: = = 213 = 1068 . Comments: Equation (3.12) is a good estimate of the tensile yield strength of stress-relieved (not cold-worked) steels. Experimental data would be necessary to refine the above equations. 1 2. 3-13SOLUTION (3.11) Known: An AISI 4340 steel part is heat treated to 217 Bhn. A second AISI 4340 steel part is heat treated to 363 Bhn. Find: Estimate values of Sy and Sy for both parts. Schematic and Given Data: AISI 4340 Steel Part 1, 217 Bhn Part 2, 363 Bhn s Sy =? Gao Assumptions: 1. The experimentally determined relationship of ultimate strength to hardness is sufficiently accurate 2. The experimentally developed relationship of yield strength to ultimate strength is sufficiently accurate for our purposes. Analysis: 1. Using Eq. (3.11), we can estimate Sy. Su = Kale where Kp = 500 for most steels For Part 1, Su = 500(217) = 108,500 psi; for Part 2, Su = 500(363) = 181,500 psi . 2. Sy can be estimated by using Eq. (3.12). Sy = 1.05 Su - 30,000 psi. For Part 1, Sy = 1.05(108,500) - 30,000 = 83,925 psi. For Part 2, Sy = 1.05(181,500) - 30,000 = 160,575 psi / Comments: 1. Equation (3.12) is a good estimate of the tensile yield strength of stress-relieved (not cold-worked) steels. 2. Experimental data would be helpful to refine the above equations for specific steels. 314SOLUTION (3.12) Known: An AISI 1020 steel part is heat treated to 111 Bhn. Find: Estimate Sy and Sy Schematic and Given Data: AISI 1020 Steel O tee Treated Sus? Sy =7 111 Bhn Assumptions: 1. The experimentally determined relationship of ultimate strength to hardness is sufficiently accurate. 2. The experimentally developed relationship of yield strength to ultimate strength is sufficiently accurate for our purposes. Analysis: 1. Using Eq. (3.11), we can estimate Sy, Su=KeHp where Kp ~ 500 for most steels. Su = 500(111) = 55,500 psi 2. Sy can be estimated by using Eq. (3.12) Sy = 1.05 Su - 30,000 psi = 1.05(55,500) - 30,000 = 28,275 psi. Comments: 1. Equation (3.12) is a good estimate of the tensile yield strength of stress-relieved (not cold-worked) steels. 2. Experimental data would be helpful to refine the above equations for specific steels. 3-15SOLUTION (3.13) Known: An AISI 3140 steel part is heat treated to 210 Bhn. Find: Estimate Sy and Sy Schematic and Given Data: AISI 3140 Steel O Heat Treated to Suz? Sy =? 210 Bhn Assumptions: 1. The experimentally determined relationship of ultimate strength to hardness is sufficiently accurate 2. The experimentally developed relationship of yield strength to ultimate strength is sufficiently accurate for our purposes. Analysis: 1, Using Eq. (3.11), we can estimate Sp So =KeHs where Kg ~ 500 for most steels. Sy = 500(210) = 105,000 psi 2. Sy can be estimated by using Eq. (3.12). Sy = 1.05 Su - 30,000 psi = 1.05(105,000) - 30,000 = 80,250 psi Comments: 1, Equation (3.12) is a good estimate of the tensile yield strength of stress-relieved (not cold-worked) steels. 2. Experimental data would be helpful to refine the above equations for specific steels. 3-16SOLUTION (3.14) Known: The hardness versus distance curve for a Jominy end-quench test of AISI 4340 steel is given. Find: Sketch similar curves for low-alloy steel and for plain carbon steel Schematic and Given Data: 4340) () Low attoy ) ()) Plain Carbon 58Re 58Re 58Re dae 4340 So cot ( 2 sot 3 — Low Alloy & 4+ 8 304 5 = 20+ \ pain Carbon 10+ o——+—_+—_—_1 0 10.20 30. «40,50 Distance From Quenched End (mm) Assumption: We assume that the hardness for the non heat treated end of the Jominy test specimen properties are similar to 4340 steel Analysis: From Appendix C-4a, for 1040 Normalized, HB = 170 and for 4340 Normalized, Hp = 363. We would expect at the end of the Jominy bar that the hardness of the 1040 would be approximately 50% of the 4340 hardness. Comment: The Jominy curves show the effectiveness of the alloying elements in imparting hardenability to steel. 3-17SOLUTION (3.15D) Known: Four given applications require steel Find: Choose between (a) 0.1% C and 0.4% C, and between (b) plain carbon and alloy steel Schematic and Given Data: (a) Machine Frame (b) Round Rod tL cc (©) Irregular Shaped Part (4) Rail Car Wheel Assumption: Material is of usual quality. Analysis: (a) Machine frame. All steel materials provide approximately the same rigidity (30 x 106 psi). In this application, since stresses are low and we also want the cost to be low, we would select plain carbon because of low price and 0.1% C because of low strength. () Small round rod. For high bending and torsional stresses we select 0.4% C and to keep cost down we select steel. () Large irregular shaped part. For high stress we select 0.4% C and for ease in heat treating we select alloy steel. (@_ Rail car wheel. For low cost we select carbon steel and for low interior strength we choose 0.1% C. If we carburized the 0.1% C steel we can obtain a high strength wear surface. Comment: In summary, (1) alloy steel is more expensive but it is more easily heat treated than plain carbon steel, and (2) 0.4% C steel has greater strength than 0.1% C steel 3-18SOLUTION (3.16D) Known: The site http://www.matweb.com provides the properties of aluminum 7075-0. Find: Compare the material properties for aluminum 7075-0 from the web to those given in Appendix C-10 of the textbook. Anal 1 lysis: From www.matweb.com we obtain for aluminum 7075-0. Key Words: Aluminum 7075-O; UNS A97075; ISO AIZn5.5MgCu(A); Aluminium 7075-0; AA7075-O; PHYSICAL PROPERTIES Density, g/cc 2.81 Hardness, Brinel! 60 500 kg load with 10 mm ball Hardness, Knoop 80 Converted from Brinell Hardness Value Hardness, Vickers 68 Converted from Brinell Hardness Value MECHANICAL PROPERTIES Tensile Strength, Ultimate, MPa 220, 31,900 psi Tensile Strength, Yield, MPa 95, 13,775 psi Elongation %:; break 17, In 5 cm; Sample 1.6 mm thick 17 % Modulus of Elasticity, GPa 72, Average of Tension and Compression. In Aluminum alloys, the compressive modulus is typically 2% greater than the tensile modulus, 10,440 ksi Poissons Ratio 0.33 Shear Modulus, GPa 26.9, 3,901 ksi Shear Strength, MPa 150, 21,750 psi THERMAL PROPERTIES, CTE, linear 20°C, um/m-°C, 23.6, 20-100°C, 13 pin/in-°F CTE, linear 250°C, um/m-°C, 25.2, Average over the range 20-300°C, 14 ptin/in- F Heat Capacity, J/g-°C, 0.96, 0.23 BTU/Ib-°F Thermal Conductivity, W/m-K, 173, 1,201 BTU-in/hr-ft2-°F Melting Point, °C, 477, Solidus, 891 °F Solidus, °C, 477, 891 °F Liquidus, °C, 635, 1,175 °F ELECTRICAL PROPERTIES Electrical Resistivity, Ohm-cm 0.0000038 From Appendix C-10 of the textbook for 7075-0 aluminum we find: Aluminum 7075-0 Brinell Hardness 60 Tensile Strength, Ultimate, 38 ksi, MPa 230 Tensile Strength, Yield, 15 ksi, MPa 105 Elongation in 2 in %; 16 . 3-19Comments: 1. The web wins again, providing a vast amount of information. 2. The tensile strength and the yield strength values from Appendix C-10 are higher than those from www.matweb.com. SOLUTION (3.17D) Known: A designers favorite materials are 1020 steel, 1040 steel, 4340 steel, 2024- T4 aluminum, nylon 6/6, and acetal. Find: Compare the specific material properties for each material. Assumptions: The material properties presented in Appendix C are sufficient for comparison purposes. Decision: The material properties compared will be tensile strength, yield strength, elongation, and hardness. Analysis: 1. From Appendix C-4a, we obtain properties for normalized stee! in 1 inch round sections. 2. From Appendix C-10, we obtain properties for wrought aluminum alloy for 1/2 inch sizes. 3. From Appendix C-18a, we obtain mechanical properties of plastics. MATERIAL |Tensile Strength] Yield Strength | Elongation (%) Brinell (MPa) (MPa) Hardness 1020 steel 441.3 346.5 35.8 131 normalized 1040 steel 589.5 374.0 28.0 170 normalized 4340 steel 1279.0 861.8 a 363 normalized 2024-T4 470 325, 19 120 aluminum Nylon 6/6, 83 60 Acetal 60.7 oan one aoe 4. Inspection of the table provides a comparison of the properties of the six materials. Comments: The site http://www.matweb.com will provide additional material property information. 3-20