PART B

SEMESTER : 3 SUBJECT : SOM SUBJECT CODE : CP-01

Question
Chapters Question Answers
No.

Why Does a Tool Designer Study Strength of The study of Strength of Materials helps the tool designer to determine the appropriate material for tooling, their
1
Materials? dimensions, and parameters of work-piece, tool geometry, and the processing methods.

List out the mechanical properties of materials

1.Tensile Strength
which a tool designer need to be considered while
2. Compressive Strength 3. Shear Strength 4. Hardness 5.Elasticity 6 Plasticity 7.Toughness
desinging.

The elastic limit of a material is the ratio of the maximum load that can be applied without producing a permanent
1 What is elastic limit?
deformation, to the cross sectional area.

Plasticity is the characteristic of a material to deform without breaking .The material will flow under a load before it
2 Define Plasticity
ruptures.

Define the following terms : a) Hardness :The ability of a material to resist scratching,wear , tear and indentation.
3
(a) Hardness (b) Elasticity b) Elasticity : It is the property of a material to recover its original size and shape when the applied force is removed.

4 What is toughness? Toughness is the energy that a material absorbs under an increasing force, before it fails.,

Tensile Load: When a body is subjected to two equal and opposite pulls, the body tends to elongate. These pulling forces
Write the difference between Tensile Load and are called as tensile loads.
5
Compressive Load Compressive Load: When a body is subjected to two equal and opposite pushing forces, the length of the body tends to
decrease. These pushing forces are called compressive load.

6 What is permanent set? The strain that does not disappear, on removal of the load that is causing the strain, is known as permanent set.
For any solid material loaded within the elastic limit, the ratio of the stress to the
corresponding strain is a constant.
This constant is called the Modulus of Elasticity of the material. It is denoted by E.
The modulus of elasticity is also called the elastic constant.

7 Explain Hook’s Law with neat sketch?

According to the hooks law stress is directly proposnal to the strain , in other words stress by stgrain is constant and it is
called as Young’s Modulus or modulus o elasticity and it is denoted as E According to hook’s law:

StressStrain
8 Derive the formula for Modulus of Elasticity
Stress  E  Strain E  Const
Stress
E
Strain
Convert the following Units : a)1 Pa to _1__ N/m2
a)1 Pa to ______ N/m2 b) 1 Gpa to __1 x 10^3_N/mm2
9 b) 1 Gpa to ________N/mm2
10 A rod of 150 cm long and diameter of 2 cm is Given data:
subjected to an axial pull of 20 KN. If the Modulus Length of the rod, = 150 cm = 1500 mm
of elasticity of the material of the rod is 2×10 5 Diameter of the rod, = 2 cm = 20 mm
N/mm², determine (a) Stress b) 5 Strain Axial pull, P = 20 KN = N
And (C) Elongation of the rod Modulus of elasticity, E = N/mm²

a) Stress p = load / area = P / A

Area, A = πd²/4 = 3.14 x 20 x 20 / 4
= 314 mm²
Stress P = 20000 / 314
Stress P = 63.662 N/mm²

b)Strain e = Change in length / orignal length = δl / l

E = stress / strain
Strain e = stress / E
e = 63.662 / 2 x 10^5
strain e = 0.000318

(c) Elongation δl = e x l
= 0.000318 x 1500
Elongation δl = 0.477 mm

Result :
Stress, p = 63.662
Strain, e = 0.000318
Elongation δl = 0.477 mm

Write the SI units of the following terms: a)Load, a) The Unit of load is Newton (N)
b) Modulus of elasticity and b)The Unit of Modulus of Elasticity E is N/m2
11 c) strain c) Strain has no unit

A Brass rod of diameter 16 mm and length 200 mm Given Data:

was subjected to a tensile load of P. The elongation Diameter , d = 16 mm
of the rod was found to be 0.24mm. The modulus of Length, L = 200 mm
elasticity of the material is 1x105 N/ mm2 . Calculate Elongation, dL = 0.24 mm
the Load P. Elastic modulus, E = 1x105 N/mm2

SOLUTION:

12 Area, A = π/4 x d^2

= 3.14/4 x 16^2
= 200.96 mm2
δl = PL/ AE
0.24 = P x 200 / 200.96 x 1x105
P = 24115 N

RESULT :
Load, P = 24.115 KN
A load of 4000 N is tied at the end of a steel wire. If Given data:
the unit stress in the wire must not exceed Axial pull, P = 4000N
80 N/mm². Diameter of the wire = d mm
(a) what is the minimum diameter required for the Stress limit, p = 80 N/mm²
wire? Length of the wire, l = 3.50 m = 3500 mm
(b) What will be the elongation of the wire, if its Young’s modulus, E =2 X 10^5 N/mm²
length is 3.50 m? Take E = 2 X 10^5 N/mm². Solution
(a) Minimum diameter of the wire

Stress, p = P/A
A = P/p
A = 4000 / 80
A = 50 mm²
Let the diameter of the wire be d m

A d2
4
3.14
50  d2
4
50  4
d2 
3.14
d 2  63.69
13
d  63.69
d  7.98mm
Pl
Elongation: l 
AE
4000  3500
l 
50  2.0 105

l  1.4mm
Result :
Diameter , d  7.98mm

Elongation , l  1.4mm

Wite the formula for calculating the Elongation of

wL2
wire due to self weight. a )WHen specific weight isgiven l 
a) If specific wieght is given. 2E
14 b) If total weight is given.
WL 2
b )When total weight is given l 
2AE
Given data :
Diameter = 1.5 mm
Length l = 30 m
= 30 x 10³ mm
Modulus Of Elasticity E = 90 Gpa
= 90 x10³ N/mm²
Specific Weight w = 89.2 kN/m3
A copper alloy wire of 1.5 mm diameter and 30 m
= 89.2 x 10³3N/m3
long is hanging freely 89.2 10
 N / mm3
15
from a tower. What will be the elongation due to the
self-weight of the 10 
3 3

wire? Take specific weight of copper and its  89.2 106 N / mm3
modulus of elasticity as 89.2 wl 2
kN/m3 and 90 GPa, respectively. l 
Solution : Elongation due to self Weight : 2E
89.2 10 6  (30 103 ) 2
l 
2  90 103
l  0.44mm
Result:
Figure shows a rod consisting of three sections. Given data
Find the stresses in the Axial pull = 40KN
three sections and the total elongation of the rod E = 2 x 10² N/mm² Solution
for an axial pull of 40 KN.
Stress on AB =P / A = 40000 / /4 X 30² = 56.62 N /mm² Stress on BC= P/L = 40000//4 X 20² =
Take E = 2 x 10^5 N/mm²
56.62 N / mm² Stress on CD = P/A = 40000 / /4 X 32..5² = 42.24
N/mm Elongation = stress/E x orignal length Adding
elongation in all section = 1/E (stress on AB X LAB + STRESS ON bc x LBC +
stress on CD x LCD)
16 = 1/2 x 10^5 (56.62 x 180 + 127.39 x 260 + 48.24 x 160)mm
= 1/2 x 10^5(10191.60 + 3312.40 + 7718.40)
= 1/2 x 10^5 (501031.40)
= Elongation = 0.26mm
Result : Elongation = 0.26mm
A member ABCD is subjected to point loads P1, P2, Given data:
P3, and P4 as shown
in the figure. Calculate the force P3 necessary for
equilibrium if P1 = 120
KN, and P2 = 220 KN and P4 = 160 KN. Determine
Young’s modulus, E = 2 x 10^5 N/mm²
also the net change in
length of the member.
Solution
Take E as 2 x 10^5 N/mm² For equilibrium, the forces acting in one direction must be equal to forces
acting in the opposite direction.
Therefore P1 + P3 = P2 + P4
P3 = P2 + P4 – P1
= (220 + 160 – 120) KN
= 380 – 120
P3 = 260 KN
If the force on a section is tensile, the section is elongated. If the force is
compressive, the section is constricted or shortened.
Section AB
Force on AB, p1 = 120 KN = 120 x 1000 N (Tensile)
Area of AB = 40 x 40 = 1600 mm²
Pl
l AB 
AE
120000  750
l AB 
1600  2 105
100000 1000
l AB  0.28mm 
706.5  2 105
Section BC
Net force on BC = (120 – 220)KN
17 = 100,000 N
Being compressive force, the section BC shortens by BC δl (ie - BC δl )

Section CD
Force on CD = 160 KN (Tensile)
= 160 KN (Tensile)

Total elongation:

Result :

Force P3 = 260000 N
Total elongation:
Section BC
Net force on BC = (120 – 220)KN
17 = 100,000 N
Being compressive force, the section BC shortens by BC δl (ie - BC δl )
Pl
lBc  
AE
100000 1000

706.5  2 105
lBC  0.70mm

Section CD
Pl
Force on CD = 160 KN (Tensile) lCD 
= 160 KN (Tensile) AE
160000 1200
lCD 
900  2 105
lCD  1.07mm

Total elongation: l  l AB  lBC  lCD

l  0.28  0.70  1.07
Result :
l  0.64mm
Force P3 = 260000 N
Total elongation: l  0.64mm
Find decrease in length of the steel rod loaded as Given data:
shown in figure. Take E = 2 x 105 N/mm² The length of the rod BC, l1 = 180 mm
The length of the rod AB, l2 = 200 mm
Young’s modulus, E = 2 x 105 N/mm2
Diameter of the rod AB, d2 = 15 mm
Diameter of the rod BC, d1 = 10 mm
Load on BC = 2 KN = 2000 N
Load on AB = 7 KN = 7000 N
Solution
Elongation of AB Pl
l AB   A
3.14
152  176.6mm2
AE 4
7000  200
l AB  
176.6  2 105
18
Elongation of BC:  l AB   0 . 039 mm
Pl 3.14
lBC   A 102  78.5mm2
AE 4
2000 180
lBC 
78.5  2 105
lBC  0.022mm
Total Elongation :
l  l AB  lBC
 0.039  0.022
l  0.061mm
What do you mean by Composite Bar A bar made from two or more different materials joined together and acting as one member is known as composite bar.

19

Define Lateral strain? The strain caused to a body, at right angles to the direction of the applied load is known as lateral strain.
20

Define Longitudinal strain? When a body is subjected to an axial tensile or compressive load, there is a change in the length of the body.
The ratio of this change in length to the original length of the body, is known as longitudinal strain.
21

Write the formula which relates E, G and K?

9 KG
22 E 
3K  G
Define Poisson’s ratio with its units This is the ratio of lateral strain to the longitudinal strain, when material is stressed within elastic limitic, This
ratio is called a poisson's ratio Therefore, Poisson's ratio= 1/m or µ = Lateral strain / longitudinal strain.
23
Unit : No unit

Write the formula for the Poisson’s ratio Poisson's ratio= 1/m or µ = Lateral strain / longitudinal strain
24
Define Bulk Modulus
25

Write the formula which relates Young’s modulus,

shear modulus and Poisson’s ratio 1
young' s mod ulus E  2G(1  )
26 m

Write the formula for the Volumetric Strain.

V
27 Volumetric Strain 
V
Define the following terms with formula: Lateral strain:-The strain caused to a body, at right angles to the direction of the applied load is known as lateral
(a) Lateral strain strain. δb d
(b) Poisson’s ratio ela  or
b d
28 Poisson's ratio:- This is the ratio of lateral strain to the longitudinal strain
Poisson's ratio = 1/m or µ = lateral strain / longitudinal strain
Define tensile stress? This the ratio of tensile load to the area is known as tensile stress . Tensile Stress = tensile load / Area
29

Explain the Tensile Test of M.S specimen with neat * Tensile tests are conducted on test specimens of the material to be tested. Test pieces are standardized in
sketch. order that results are reproducible and comparable. Figure 11 indicates standardized test specimens.

* Gauge length is the length of the parallel portion of the test piece over which elongations are measured. For a
cylindrical test piece, the gauge length used for calculation of percentage elongation is a function of the cross-
section area or the diameter of the test bar.

*The specimen is held between grips fixed to platens on the two crossheads of the tensile test machine. The
specimen is subjected to a pulling load by gradually moving one grip away from the other by moving of the cross
head of the machine (Figure 12). As the grips move apart the tensile load on the test specimen increases and the
30
specimen elongate. The load is increased till the specimen breaks.

Explain the stress strain diagram for mild steel 1.The strain is directly proportional to the corresponding stress from O to A. Beyond A, the strain is not directly
specimen. proportional to the stress. The line O A is called the line of proportionality. Hook’s law is valid in this range. The
stress at A is known as the Proportionality Limit.
2. If the load is increased beyond this, elongation increases more rapidly as indicated in the diagram from A to C.
At a point B, between A and C, the elastic limit for the material is reached and thereafter a permanent set or
deformation takes place.
3. C is the point of sudden large elongation, known as the Yield Point. Beyond the Yield point, the piece
elongates further — the strain increasing at a higher rate as shown in the diagram from C to D.
4. In this range, owing to plastic deformation of the material the stress may initially drop with further increase in
stress. From D to E, the specimen elongates further and, the point E of maximum load or ultimate strength is
reached.
5.With further increase in stress, plastic flow of the material begins. A local reduction in cross-section (necking)
of the specimen takes place. With plastic flow a drop in stress and increased elongation takes place till the
31
specimen fractures.
6.The breaking load, if divided by the actual cross section area of the necked specimen, is the actual stress at
rupture, and is greater than the stress at F in the stress- strain diagram. The actual stress at rupture is greater
than the ultimate stress (at E).
Draw a neat sketch of stress strain diagram for mild Answer is same as ( Q. No 31 )
32 steel specimen and explain the different areas.

Draw a neat diagramof the Tensile Testing

experiment.

33

Define the following terms : Modulus of Resilience

(a) Modulus of Resilience Let us consider a volume of a material which is subjected to a tensile load. When the tensile load is gradually
increased, at a specific value of this load, the limit of proportionality between stress and strain is reached. The
(b)Modulus of Toughness stress per unit volume for this load at the proportionality limit is known as modulus of resilience of the test
material.
(c)Strain Hardening
Modulus of Toughness
Let us consider a volume of a material which is subjected to a tensile load. When the tensile load is gradually
34 increased, at a specific value of this load, the test piece ruptures after proportionality limit between stress and
strain is reached. The stress per unit volume for this load at rupture is known as modulus of toughness of the
test material.
Strain Hardening
If a ductile material can be stressed considerably beyond the yield point without failure, its hardness increases.
This phenomenon is called strain hardening. Structural materials can be strain hardened.

Write the formula which relates E and K?

 2
35 E  3 K 1  
 m
Explain Compressive Test. Microscopic cracks are present in all metals. In brittle materials, tensile stresses tend to widen these
microscopic cracks, oriented perpendicular to the axis of tension, leading to fracture at lower stresses. Under
compressive loads, microscopic cracks tend to close up, allowing the brittle material to withstand higher
compressive stresses than tensile stresses.
Hence, brittle materials are mainly used in applications to withstand compressive loads.
Figure 15 shows a comparison of the stress-strain properties of brittle cast iron, under tensile and compressive
loads.
36

2 Compare shear stress to normal stress Shear force causes stress in a material along a plane that is parallel to the direction of force. The axial force causes stress in a
material along the axial direction.
The shear force causes angular deformation of the material, whereas the axial force causes linear deformation of the material.
37 The shear force can produce a sliding failure, whereas an axial force can make the material fail across a section perpendicular
to the direction of the force (break).

Define rigidity modulus. Modulus of rigidity deifned as the ratio of shear stress to the shear strain.
38
Consider the bolted joint shown in the figure below. In the absence of any additional information, we can assume that force
The force P is 30 KN P will tend to shear the bolt. This is resisted by shear stresses
and the diameter of the bolt is 10 mm. Determine developed equally across sections a-a and b-b.
the average value of Given Data :
shearing stress existing across either of the planes
Force, P = 30 KN = 30000 N
a-a or b-b.
Diameter of the bolt, d = 10 mm
To Find :
Shear Stress fs
Shear Force: P
F s 
2
30000
Fs 
39 2
F s  15000 N
Area Of Cross section: 
A d2 3.14 10 2 A  78.6mm2
4 A
Shear Stress : 4
Fs
Shearstres s 
A
15000
shearstres s 
78 .6
Result :
shearstress  191N / mm 2
Define shear stress with its units The resisting forces acting parellel to the surface per unit area is called as shear stress
40
Unit : N/mm²
Define Temperature Stress An increase in the temperature of body makes it to expand cooling results in contraction.
3 41
Thermal stress is the stress created by any change in temperature to a material.
A rod is 2 m long at 10°C. Find the expansion of the Given data:
rod when the temperature is raised to 80°c. If this Rise in temperature, T = 80 - 10 = 70 ° c
expansion is prevented, find the stress on the E = 1 x 10^5 N/mm²
material. Take E = 2 X 10^ 5 N/mm² and a
= 0.000012 per °c
=0.000012
Solution
per *c
42 Free expansion = Tl
= 0.000012 x 70 x 2000
= 1.68 mm
Temperature stress, =  T E
Pt = 0.000012 x 70 x 2 x 10^5
Temperature stress = 168 N/mm²

Write the formula for thermal stress if the thermal

43 expansion is fully prevented. Thermal stress ( p t )   TE
A rod of steel is 20 meters long and is at a
temperature of 20°c. (a) Find the free expansion of Given data:
the length when the temperature is raised to 65°c. Length of the rod = 20 m = 20000 mm
Find the temperature stress caused (b) when the Rise in temperature, T = 65 - 20 = 45 ° c
rod is fully prevented from expansion. Take a = 12
a = 12 x10^-6 per °c
x10^-6 per °C and E = 2 X 10^5 N/mm²
E = 2 X 10^5 N/mm²
Solution
(a) Free expansion in length of the rod = aTl
= 12 x10 ^-6 x 45 x 20000
Free elongation = 10.80 mm

(b) Thermal stress when expansion is fully prevented

Temperature stress, = a T E
Pt = 12 x10 ^-6 x 45 x 2 x 10^5
44
Temperature stress = 108 N/mm²
Temperature stress when expansion is fully prevented = 10.8 N/mm2
(c) Thermal stress when the rod is permitted to expand only by 5.8 mm

 Tl   
ThermalStress, pt  E   
 l 
 12106  45 20000 5.8 
Stress, pt  2 105   
 20000 
Result :
t p  50 N / mm 2
Free elongation = 10.80 mm
Temperature stress when expansion is fully prevented = 10.8 N/mm2
Temperature stress = 50 N/mm2

Write the thermal stress formula if the expansion is

 Tl   
45
partially prevented.
ThermalStress, f t  E   
 l 
A brass rod 2 m long is fixed at both ends. If the
thermal stress is not to exceed 76.5 MPa, calculate Given data:
the temperature through which the rod can be Given Length, l = 2 m = 1000 mm
heated. Take the value of α and E as 17x10^-
Limiting thermal stress, pt = 76.5Mpa
6/degree celsius and 90GPA respectively.
pt = 76.5 N/mm²
a = 17 x 10^-6/°c
E = 90GPa = 90 x 10 ^3 N/mm²
46 Solution
Let T = Temperature by which the rod should be heated
pt = 76.5
76.5 = aTE
76.5 = (17 x 10^–6 ) x T x (90 x 10^3)
76.5 = 1.53 T
T = 50°c
Temperature by which the rod is to be heated = 50°c
A rod is 2 meters long at 10°c. find the expansion of
the rod when the temperature is raised to 80°C. If Given data:
this expansion is prevented, find the stress on the Length of the rod, l = 2m
material. Take
Increase in temperature, T = 80-10 = 70°c
E = 1X10^5 N/mm²and a = 0.000012 per degree c.
E = 1X10^5 N/mm²
a = 0.000012 /°c

Solution
47 Free elongation, = aTl
= 12 x10 ^-6 x 70 x 2000
Free elongation = 1.680 mm

Temperature stress = a T E
Pt = 12 x10 ^-6 x 45 x 1 x 10^5
Temperature stress = 84 N/mm²
Free elongation = 1.68 mm
Temperature stress = 84 N/mm2
State the difference between column and strut with If the member of the structure is vertical and both of its ends are fixed rigidly while subjected to axial compressive load, the
neat sketch. member is known as column.
For example a vertical pillar between the roof and floor is an example for Column.

If the member of the structure is not vertical and one or both of its ends are hinged or pin joined, the bar is known as strut
For Example : connecting rods, piston rods etc.
4 48

Differentiate strut from column with neat sketch. Answer same as ( Q.No 48 )
49
Define the following terms: Post — is a general term used for a member under compressive load
a) Post b)Strut c) Boom d) Stanchion Strut — is a member of a truss under compressive load
50
Boom — is a principal member subjected to compressive load in a crane
Stanchion — is another name for a column
51 Define Crippling load. The load at which the column just buckles is known as buckling or crippling load.
52 Define Buckling load. Answer same as ( Q.No 51 )
Define column If the member of the structure is vertical and both of its ends are fixed rigidly while subjected to axial compressive load, the
53 member is known as column.
For example a vertical pillar between the roof and floor is an example for Column.

What are the Four types of End conditions for the 1.Both ends of the column hinged (or pinned)
columns. 2.One end fixed and the other end free
54 3.Both the ends fixed
4.One end fixed and the other hinged
An MS pillar 0.5 m long, 20 mm diameter is used as
a strut with both ends hinged. Find the collapsing Given data:
load . Take E=2.1x10 5 Nmm2. d = 20 mm
l = 0.5 m = 500 mm
E = 2.1 x 105 N/mm2
Solution:  2 EI
CripplingL oad 
l2
d 4 3.14  204
MomentOfInertia , I  I  7850mm4
64 64

55 For both ends hinged : Length of column, l = 500 mm

3.14 2  2.1105  7850
The collapsing load CL 
500 2
1.62 1010
CL 
250000
CL  65014.2 N
CL  65KN
Result:
Write the formula for Slenderness ratio?
fc  A
P 2
56  l
1 α  
k
Write the assumptions made in Euler’s Theory of 1. The column is initially perfectly straight and the load is applied axially.
columns? 2. The cross-section of the column is uniform throughout its length.
3. The column material is perfectly elastic, homogeneous and isotropic and obeys Hooke's law.
57 4. The length of the column is very large as compared to its lateral dimensions.
5. The direct stress is very small as compared to the bending stress.
6. The column will fail by buckling alone.
7. The self-weight of column is negligible.
A steel rod, 4 m long and 30 mm diameter is used
as a column, with one end fixed and the other end Given data:
free. Determine the crippling load by Euler’s Internal diameter, d = 30 mm
formula. Take E = 2 x 10 5 N/mm2 External diameter, D = 30 + 2 x 4 = 38 mm


Solution
Moment of Inertia of section, I D
64
4
d4 

I
64
38 4
 30 
4

I  62561.3mm4
58
Since the both ends of the column are hinged,
the effective length, L = 4000 mm
 2 EI
Crippling load, Criticallo ad 
l2
3.142  2.1105  62561.3
CL 
4000 2
CL  8095.8 N
CL  8KN
Write the formula for crippling load of a column Both ends are fixed :
 2 EI
CripplingL oad 
when both ends are fixed.
59
l2
Define Factor of Safety? The ratio of the critical load to the safe load on a column is called the factor of safety. Factor of safety is denoted as FOS
and is given by :
60
FOS - ultimate load / safe load

61 What is Slenderness ratio? The ratio of effective length to the least radius of gyration for a given column is called as slenderness ratio.
A steel rod, 5 m long and 40 mm diameter is used
as a column, with Given data:
one end fixed and the other end free. Determine the Length of the rod, l = 5m = 5000mm
crippling load by Diameter of the rod, d = 40mm
Euler’s formula. Take E as 200Gpa. E = 200Gpa
E = 200,000
E = 2 x 105 N/mm2
Solution
(a) The moment of Inertia of the column section,
d 4
MomentOfInertia , I 
64
  604
I  635850mm4
62 64

Since the column is fixed at one end free and at the other end, equivalent length of the column,
L = 2 x l = 2 X 5000
= 1 x 10^4  2 EI
The Critical Load : Criticallo ad  2
l
3 . 14 2  2  10 5  635850
CL 
1 x10  4 2

CL  2480 N
CL  2.48KN