M.S Ramaiah School of Advanced Studies: Postgraduate Engineering and Management Programme (PEMP)

PT09 AME514
M.S RAMAIAH SCHOOL OF ADVANCED STUDIES
Postgraduate Engineering and Management Programme [PEMP]
Department: Automotive Design and Engineering

Course: Automotive Engineering
Module Code: AME514
Module Title: Structural Fatigue and Reliability Analysis
Module Leader: Chidambar D. Kulkarni and Dr. Vinod K. Banthia
Assignment
1. This assignment has three parts

2. The weightage of the three parts are – Part A (20), Part B (40) and Part C (40)
3. The assignment should be word processed confirming to the format prescribed in the template
provided by the ARO
4. The length of the assignment report should be limited to 35 pages in your writing
5. The assignment should be submitted to the ARO’s office on or before 09-Oct-10
6. Finite element software ANSYS and Fe-Safe should be used for the simulation based
problems
7. All the units of measurement wherever applicable should be SI Units only
8. Method of evaluation
9. Whether group work is permitted and method of evaluation under such circumstances.
10. IMPORTANT: It essential that all the sources used in preparation of the assignment must be
suitably referenced in the text.
< August 2010>
Form – 43 Ver: 2 Date: 01-08-2009

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PT09 AME514
Introduction: In the present module, students have learnt the fundamental concepts of
fatigue, fracture mechanics and reliability design, and the application of the same to
engineering problems. The aim of this assignment is to make the student use this knowledge
to an engineering design problem.
Problem statement
Part-A
Fatigue in materials is a complex phenomenon. For prediction of fatigue life at the design
stage, numerous methodologies are used. Each of these methodologies has their own pros and
cons and limitations.
Inlight on this, debate on the topic, “Even though the stress-life approach for fatigue life
prediction has a number of approximations built into it, it is still the best methodology for
most of the engineering applications.”
Debate this statement taking “For” or “Against” stand. List your arguments, backing them
with examples and references, to support your stand. Limit your debate to three (3) pages.
(8+7+5) marks
PART- B:
Connecting rods for automotive applications are typically forged from either wrought steel or
powdered metal. Since these are subjected to high cyclic loads, which range from high
compressive loads during power stroke, to high tensile loads due to inertia, consideration of
fatigue life of this component is of critical importance in design.
Figure 1(a) Connecting rod for a Figure 1. (b) Axial, normal, and the resultant force
four cylinder diesel engine at the piston-pin end at crank speed of 5700 rev/min.
i. Explain, in detail, different types of loads coming on connecting rod. Comment on the
critical loads and critical locations considering fatigue failure.
(04+03) Marks
ii. Using the geometrical model of a connecting rod provided (Figure 1a), develop a finite
element model with appropriate loading and boundary condition to find the critical stress.
Discuss the analysis through stress and deformation plots. Simplify the boundary
conditions by considering only axial forces, as normal forces are very little compare to
axial forces in static condition. Provide appropriate justification for assumptions and
decisions made in FE modelling.
(08+05) Marks
iii. Through literature survey, gather information about
a. Designed fatigue life of connecting rods
b. Different Manufacturing Processes used for connecting rods and their effect on its
fatigue life
c. Different means of improving fatigue life of connecting rod
Restrict your discussion on all three parts, (a), (b) and (c) to a total of 600 words
Form – 43 Ver: 2 Date: 01-08-2009

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PT09 AME514
06 Marks
iv. Find, using Fe-safe, fatigue life and critical site for crack initiation for connecting rod.
Fatigue loading coming on the connecting rod is shown in figure 1. (b). Comment on the
fatigue life predicted by the analysis. If fatigue life is infinite, discuss how the design can
be improved, if fatigue life is finite explain which parameters in design can be adjusted to
make the fatigue life infinite.
(06+05+03) Marks
PART-C:
A machine component which is in the form of a wide thin plate, subjected to uniform stress
(σ), contains a circular hole of diameter D (Figure 2). Consider the plate as very wide
compared to any crack that may be present in it.
i) (a) If there is a small crack of length,

‘a’, growing from the surface of the
hole, as shown in Figure 2, what would
be a suitable approximate expression for
the geometric stress intensity factor?
Clearly explain the applicability of the
expression. (b) If the crack in part (i.a)
becomes long (compared to the zone of
influence of the notch), what would be a
suitable approximate expression for the
geometric stress intensity factor?
Clearly explain the suitability of the
expression and the difference between
this and the expressions considered in
part (i.a).
(03+03) Marks
ii) Develop a finite element model to
obtain stress intensity factor for the plate
with a hole and a crack and compare the
simulation and analytical results for
crack lengths of 1.0 mm to 7.0 mm in
steps of 2.0 mm.
20 Marks
iii) Plot curves of crack length versus stress
intensity factor and discuss.
04 Marks
iv) Explain relevance of assignment to the learning outcomes.
10 Marks
**NOTE: Value of diameter of hole D, and material of the plate have to be decided in
consultation with the module leader.
Guidelines for Submission

• The report should have a short introduction to the assignment and all the parts of the
assignment should be presented in different chapters.
• Justifications for the decisions made for the type and size of elements used and
validation of methodology used for application of loads and boundary conditions
should be clearly explained.
• Include analytical calculations used and results obtained in validation studies.
• Wherever appropriate, include JPEG images of the analysis results.
Form – 43 Ver: 2 Date: 01-08-2009

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PT09 AME514
• All the graphs should have appropriate axis notations with proper units.
• All the analysis work done using software should be saved for possible
demonstration.
• Results obtained should be critically reviewed and discussed.
Marking Scheme
Section Description Marks

A(i) Arguments 08
A(ii) Organisation 07
A(iii) Language, presentation and referencing 05
Total (Part A) 20
B(i) Types of loading, critical locations and loads 04+03
B(ii) Finite element modelling, BC application, solution and discussion 03+05+05
B(iii) Discussion up-to 300 words, understanding, language, presentation 06
B(iv) Fatigue life, and discuss the results 06+05+03
Total (Part B) 40
C(i) Suitable approximate expression for the geometric stress intensity 03+03
factor in both conditions, and difference between them
C(ii) Selection of suitable elements and Finite Element Modelling, Grid 20
independence study, Application of suitable boundary conditions and
justification for the same, Determination of stress intensity factor for
different values of crack length
C(iii) Plot and discuss curves of crack length versus stress intensity 04
factor
C(iv) Comments on Learning Outcomes and Formatting 10
Total (Part C) 40
Total 100
Form – 43 Ver: 2 Date: 01-08-2009

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PT09 AME514
Form – 43 Ver: 2 Date: 01-08-2009

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PT09 AME514

M.S RAMAIAH SCHOOL OF ADVANCED STUDIES

Postgraduate Engineering and Management Programme [PEMP]

Department: Automotive Design and Engineering

1. This assignment has three parts

< August 2010>

Form – 43 Ver: 2 Date: 01-08-2009

Form – 43 Ver: 2 Date: 01-08-2009

i) (a) If there is a small crack of length,

Guidelines for Submission

Form – 43 Ver: 2 Date: 01-08-2009

Section Description Marks

Form – 43 Ver: 2 Date: 01-08-2009

Form – 43 Ver: 2 Date: 01-08-2009

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