15

Part (II)
Sheet (1): NORMAL STRESS PROBLEMS
1. A uniform vertical steel rod, having an original length of 2.0 m and a cross
section area of 4.0 cm2, is loaded by a concentric tensile force P of 3000 Kg
(Neglecting the effect of gravity and the rod weight), determine the tensile
stress σt in MPa and the elongation δ = Δl in mm. [ take the steel modulus of

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elasticity Est = 210 GPa]

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2. A circular uniform bar made of aluminum with 50 mm diameter and 1.0 long
is subjected to a concentric axial load P of 8.0 kN. If the aluminum modulus of

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elasticity EA1 is 80 GPa, determine the total elongation δ.
3. Two solid cylinder rods AB and BC are welded together at B and Loaded as
.L
shown in fig.1. Knowing that the average normal stress must not exceed 140
MPa in either rod, determine the smallest allowable values of d1and d2.
M
y
m
Sa
r.
D

4. In problem 22, determine the magnitude of the force P for which the tensile
stress in the rod AB has the same magnitude as the compressive stress in rod
BC.

Appendix
 16

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5. Define the following terms:

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a) Thermal expansion coefficient

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6. A bar of copper 40 mm diameter is completely enclosed in a steel tube 50 mm
external diameter; a pin of 18 mm diameter is fitted transversely to the axis of
the bar near each end to secure the bar to the tube. Calculate the shear stress
.L
induced in the pins when the temperature of the whole system is raised to 100oC
ECu = 110 GPa αCu = 1.7 X 10-5 K-1
M
Est = 210 GPa αst = 1.17 X 10-5 K-1
7. A weight of 20 ton is supported by three short pillars each of 1.0 in2 cross
y

section area, the central pillars is of steel and the outer of copper. The pillars
m

are adjusted that at a temperature of 15°C. Estimate the in each pillar at 15°C
and at 15°C.
Sa

Ecu = 6.5 X 106 t.f / in2 αcu = 9.5 X 10-6 1 / °F

Est = 13 X 106 t.f / in2 αst = 6.2 X 10-6 1 / °F
8. A bar of copper 1.5 in diameter is completely enclosed in steel tube 2.5 in
r.

external diameter. A pin of 0.75 in diameter is fitted transversely to the axis of

D

the bar near each and to secure the bar to the tube. Calculate the intensity of
the shear stress induced in the pins when the temperature of the whole system
is raised to 100 °F.
Ecu = 6.5 X 106 t.f / in2 αcu = 9.5 X 10-6 1 / °F
Est = 13 X 106 t.f / in2 αst = 6.2 X 10-6 1 / °F

Appendix
 17

Sheet (2): Tensile STRESS PROBLEMS

1. Define the following terms:
a) Elasticity
b) Plasticity

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c) Ductility

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d) Brittleness
e) Resilience and modulus of Resilience

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f) Toughness and modulus of Toughness
g) Ultimate strength
h) Yield strength .L
i) Proportional limit
j) Elastic limit
M
1. A tensile test was carried out on a steel specimen of 50 mm2 cross sectional
area. The following data were obtained for the load P in N, and the extensions
y

in mm on a gage length of 10 cm.

m

P (N) 0 600 800 1000 1300 1500 1650 1750 1700 1500
Sa

δΔ 0 0.06 0.08 0.10 1.5 3.5 6 9 11 15

(mm)
Draw the Stress – Strain diagram and determine:
r.

a) Tensile strength
D

b) The stress to produce 0.1% non proportional strain

c) Elongation percentage
d) Modulus of elasticity and modulus of toughness
e) Then, show if the material is ductile or brittle

Appendix
 18

2. The following results were obtained in a tensile test carried out on a mild steel
specimen, 15.9 mm diameter and 100 mm gauge length, the following data
were obtained.

P (Ton) 2.4 5.6 5.6 6.4 7.2 8 7.6 6.8

Δl (mm) 0.06 0.14 1.0 4.0 10 24 30 32
Draw the Stress – Strain diagram and determine:

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a) Proof stress

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b) Elongation percentage

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c) Yield strength
d) Ultimate strength

Sheet (3): shear stress problems .L

1. Determine the shear stress in the rivets shown. The rivet diameter is 28 mm
and made of steel 34 with allowable shear stress 9.7 kp/mm2. The force F equal
M
4000 kp. Is the joint safe?
F
y
m
Sa
r.
D

Prob. 3

Appendix
 19

2. Shear test was carried out on copper pin with pin diameter 15 mm and the head
diameter and thickness are 30 mm and 5 mm, respectively. A steel sleeve with
inner diameter 15 mm and outer diameter 35 mm is used. It is found that the
failure occurs at load 60 KN by shear. Calculate the shearing and bearing stress.

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at
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prob. 4
M
3. Two identical plates are riveted by 2 rivets. The plate thickness and width are
y

10 mm and 200 mm, respectively. The rivet diameter is 12 mm. If the

m

connection is loaded by 100 KN, calculate the stresses in the rivets and the
plates.
P (load)
Sa

P (load)
20 20
r.
D

Appendix
 20

y
at
Fig. P1.9

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4. A steel shaft 120 mm diameter and 0.8 m long transmits a mechanical power
P of 120 kW at a rotational speed n of 250 rpm. Taking the steel modulus of
rigidity G as 80 GPa, calculate: .L
a. the torque transmitted by the shaft T in N.m.
b. the maximum shear stress induced Tmax in MPa,
M
c. the angle of twist for the whole length 8 in degrees, and
d. the shear stress 't at a radius of 30 mm in MPa.
y

5. A steel shaft of a hollow circular cross-section is required to transmit 96 kW at

m

a rotational speed n of 1200 rpm. The outer diameter is 1.25 times the inner
diameter. The twisting angle θmax must not exceed 0.85° in a length of 3.0
Sa

meters. The allowable shear stress Tall for the shaft material should not exceed
80 MPa. The steel modulus of rigidity G is 80 GPa. You are required to
calculate the shaft outer and inner diameters.
r.

6. A steel shaft 120 mm diameter and 25 m long is subjected to a pure twisting

D

moment. It is driven at one end while the power is taken off at the other end.
One end of the shaft moves 6° in advance of the other end. Taking the steel
moduli of elasticity and rigidity as 206 and 84 GPa, respectively; You are
required to calculate:
a. The maximum shear stress induced in MPa,

Appendix
 21

b. The Subjected twisting moment in N.m, and

c. The power transmitted in kW, if the rotational speed n is 120 rpm

Sheet (4): Impact test problems

1. A Charpy impact test was carried out on cast iron specimen, having the
dimensions of 10X10x55 mm and notch depth of 2 mm, the angle of fall was

y
170° while the angle of rise was 166° without the specimen. When the

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specimen was fixed on the anvil, the angle of rise registered 146°. The
pendulum mass and arm length are 30 kg and 1.2 m respectively. You are

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required to determine:
i. Energy consumed due to friction and other resistances in Joules,
ii.
iii.
.L
Energy consumed in rupturing the specimen in Joules, and
The impact factor k in Joules per square millimeter.
M
2. A Charpy impact test was carried out on cast iron specimen, having the cross
section dimensions of 10x10 mm and notch depth of 2 mm. The angle of fall
was 160° while the angle of rise without specimen was 153°. The pendulum
y

mass and arm length are 30 kg and 1.2 m respectively. After the specimen has
m

been ruptured, the angle of rise was registered as 42°. You are asked to
determine:
Sa

i. Energy consumed due to friction and other resistances in Joules,

ii. Energy consumed in rupturing the specimen in Joules, and
r.

iii. The impact factor k in Joules per square millimeter.

3. Following is tabulated data that were gathered from a series of Charpy impact
D

tests on a tempered 4140 steel alloy.

Temperature (°C) Impact Energy (J)
100 89.3
75 88.6
50 87.6
25 85.4

Appendix
 22

0 82.9
–25 78.9
–50 73.1
–65 66.0
–75 59.3
–85 47.9
–100 34.3
–125 29.3
–150 27.1

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–175 25.0

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a) Plot the data as impact energy versus temperature.

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b) Determine a ductile-to-brittle transition temperature as that temperature
corresponding to the average of the maximum and minimum impact energies.
c) Determine a ductile-to-brittle transition temperature as that temperature at
.L
which the impact energy is 70 J.
M
Sheet (4): Hardness test problems
1. Mention briefly the different kinds of metal hardness.
y

2. Give a brief comparison between the three most common types of indentation
m

hardness [Brinell, Vickers, and Rockwell].

3. In a Brinell hardness testing machine for a mild steel specimen, the following
Sa

data were recorded: the ball diameter = 5 mm, the applied load = 15 KN and
the indentation diameter = 3.163 mm. Calculate the specimen Brinell
r.

Hardness Number, BHN

4. Explain the meaning of 350 HB 10/3000/30 W, then determine the diameter
D

and depth of impression, and estimate the tensile strength of that material.
5. On a brinell hardness testing machine for a specimen made of mild steel, the
following data were recorded: the ball diameter is 10 mm, load applied is 3000
kg and the indentation diameter is 3.163 mm:
I. Determine the specimen BHN

Appendix
 23

II. Draw the Brinell Hardness Machine

6. Explain the meaning of:
I. 60 HB 10/1500/30 W
II. 75 HB 10/500/30 S
III. 356HBW
IV. 2500 HK 25 (or HV25)

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V. 250 HVN 10

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VI. 450HK0.5
VII. 50 HRB

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.L
M
y
m
Sa
r.
D

Appendix