Engineering failure digital assignment 2

Koushik gupta
19BME0941
Q1) Detail the procedure for conducting the bi-axial tension testing of metallic and alloyed
materials. Evaluate the bi-axial states of stress and list out the possible applications of
biaxial tests.
In the biaxial test a specimen is loaded via two load axes. The load can be applied through a
torsional moment in addition to the tensile or compression test (tension-compression-
torsion test). To generate the biaxial tensile stress field, either four drive axes are required,
which are individually controllable and adjustable, or two drive axes each in master-slave
operation.
Case study
instrumented with 52 strain gages. All of the gages were back-to-back with the odd
numbered gages on the front of the specimen and the even numbered gages on the back.
In biaxial testing all cruciform specimens had a 0.08-in.-thick gage section and were An 80-
channel data acquisition system with a collection rate of 30 data points per second was
used to collect the data at 5 second intervals. The tests were performed on a four- actuator
servo-hydraulic test stand in stroke control with a constant ratio between longitudinal (L)
and transverse (T) displacement.
Procedure:

 Biaxial stress states can be achieved by the axial

loading of UD coupons with the fiber at an angle to the
loading direction.
 Loading at off-axis angles between 30 ° and 90 ° allows
arbitrary combinations of shear strain and transverse
normal strain, with negligible strain in the fiber direction.
 At an off-axis angle of about 8 ° for CFRP and 15 ° for
GFRP, the transverse normal strain is zero, but the shear
strain is three to four times that in the fiber direction.
 Hence the interest in 10 ° off-axis specimens for testing in
 plane shear strength
 The biaxial tensile stresses were produced in a specially
designed testing machine by subjecting a thin-walled tubular
specimen to axial tension and internal pressure.
 Plastic stress-strain relations for various biaxial stress
conditions were obtained using a clip-type SR-4 strain gage.
 Three types of tests were made: Constant-stress-ratio tests,
variable- stress-ratio tests, and special tests.
 Finally, special tests were conducted to check specific
 assumptions made in the theories of plastic flow.
 The constant-stress-ratio tests show that the deformation
theory based on the octahedral, effective; or significant stress-
strain relations is in approximate agreement with the test
results.
 The variable-stress-ratio tests show that both the deformation
and flow theory are in equally good agreement with the test
results

Condition for test

Tests were conducted at a constant displacement rate of 0.005 in./second on the major
loading axis until a strain level of 12,000 micro-strain was obtained in the gage section.
Next, the specimens were unloaded (in stroke control at 0.005 inch/second) by 20-40 kips to
allow the determination of unloading compliance. The specimens were then loaded at a
displacement rate of 0.003 in./second until failure. Other than a single test at -320°F, all
biaxial tests were performed at room temperature (75 °F).
This test concludes that the yield load loci for 0.45-in.and1.75-in.-thick 2195-T8 plates show
a significant increase in strength when compared to the 2219 results for the same
displacement ratio. Both plate thicknesses of 2195-T8 showed similar results. The yield load
at 320°F was 20% higher than the value at room temperature for the 0.45-in.-thick2195-T8
plate at a 1:2 biaxial displacement ratio.

Evaluation:

A biaxial tensile state can be derived starting from the most general constitutive law for
isotropic materials in large strains regime:

The simplest biaxial configuration is the equi-biaxial configuration, where each of the two
direction of load is subjected to the same stretch at the same rate.

A strip biaxial test is a test configuration where the stretch of one direction is confined, namely
there is a zero displacement applied on that direction
Application of biaxial tension testing

 Biaxial tensile test generally allows the assessment of the mechanical properties. it is
particularly suitable for understanding the mechanical properties of biomaterials, due
to their directionally oriented microstructures.
 Biaxial test is done to examine the plastic behaviour.
 Biaxial test results can help manufacturers find the right material at the right
quantity without quality loss in their products.

Q2)
A. Illustrate the Bursle-Pugh model for stress corrosion cracking of metallic
materials.

Schematic representation of crack growth rate under different

combinations of static and dynamic loading in inert and corrosive
environments. Crack growth rate depending on stress intensity factor in
(a) pure corrosion fatigue (CF),
(b) stress and
(c) time-stress dependent SCC and CF combinations
 B. Briefly describe what is meant by liquid metal-embrittlement.

Liquid metal embrittlement (LME)

Is a phenomenon in which ductile metals experience drastic loss in tensile ductility or
undergo brittle fracture when exposed to specific liquid metals. A tensile stress
induces this embrittlement. There is a specific combination of liquid metals and
stressed metals or alloys that can lead to catastrophic intergranular cracking.
Few example are
carbon steels and stainless steels are susceptible to liquid metal embrittlement by
zinc and lithium
aluminum and aluminum alloys are susceptible to liquid metal embrittlement by
mercury and zinc
copper and copper alloys are susceptible to liquid metal cracking by mercury and
lithium.

In this process of liquid metal embrittlement, the liquid metal atoms when adsorbed
on a susceptible metal or alloy reduces the metal bond strength within the grain
boundary regions of the susceptible metal. Under tensile stress, crack initiates and
propagates rapidly along the grain boundaries.

C. Determine the K1scc ( Fracture Toughness of stress corrosion cracked

specimen) of a metallic sample through a compact tension standard test
method. Take a corroded Ti, Al or Steel alloyed sample as a case study.

Materials like high-strength steels and titanium alloys, exhibit a rather well-defined
KIscc limit after a reasonable test time period. An ASTM standard test method which
is applicable to aqueous and other aggressive environments, utilizes fatigue
 precracked cantilever beam [SE(B)] or compact fracture [C(T)] specimens that are
subjected to constant-load testing.
For the determination of a material’s KIscc value, it is necessary that SE(B) and/or
C(T) specimen dimensions satisfy those corresponding to plane strain condition

To determine K1scc engage the bolt thread to produce a given crack-opening

displacement and place the specimen in the environment. Samples should be
examined periodically to determine when the crack stops growing. The KIscc value is
then defined by the residual applied load remaining after the crack has ceased
growing and the final crack length as seen on the fracture surface.

influence of loading rate on KIscc in 4340 steel. Data bar corresponds to data from
modified compact samples.

Q3) What are the FMEA ( Failure Mode Effect Analysis) issues associated with the medical
devices manufacturing industries ? Discuss the product liability issues and how does
conducting an FMEA will improve the product safety
 Failure mode Hazard Failure sev occ detection Control RPN
effect measure
Failure in Stopping Treatment 9 6 4 Thorough 216
sample testing of cannot be testing of
during medical provided devices
manufacturing device before mass
while production
using
Failure in Faulty Delay in 8 6 4 Material of 192
using good supplies treatment medical
quality delivered process supplies/
material to devices
hospitals should be
tested and
then finalized
Using out of Improper Wrong 9 4 8 keep 288
date working results of information of
components of patient improvements
in medical devices in component
devices
Ignoring the Device (x Side 9 6 8 Potential side 432
side effects of ray effects on effects should
device machine) patient be mentioned
can emit by
harmful manufacturer
radiations

Medical products liability issue arises when a person is injured from a defective medical
product and did not receive adequate warning about the product’s potential defects or
dangerous side effects. The person can file legal action against the manufacturer if he/she
is able to prove that the damaged caused is due to the product.

FMEA lists all the potential failures that can be caused thus preventive measure can
be taken before actual failure occurs.
The cost of correcting the faulty product is saved.
Health risks associated with the use of devices is reduced.