MAE 203_31957 Lab Report 1 Failure Michael Foch UIN: 00920537

123 ABC Street, Norfolk, VA 23529

2/6/2012 Mechanical Equipments Inc. 123 ABC Street, Norfolk, VA 23529

Client Client Address Norfolk, Va, 23529

Greetings Valued Client Recently I received your letter concerning the failure of a mechanical component manufactured by Mechanical Equipments Inc. More specifically the problem involved the failure of a bolt. Upon observation the bolt is manufactured from mild steel and failure occurred when a certain torque was applied. This information was deduced from a torsion test. The torsion test subjects the specimen to tensile and compressive forces. Mild steel is a ductile material, and when subjected to a high torque the fracture is vertical. This was true for your case. The fracture occurred due to extensive plastic deformation. When the ultimate tensile strength of the bolt was reached it caused the bolt to fracture. The cavities in the neck coalesce into a crack in the center of the bolt and propagated towards the surface perpendicular to the applied stress. This is way the fracture was vertical. Ductile fractures are infrequent and are caused from an overload on the bolt. Improper design, fabrication, and/or abuse can be contributed to the overload failure. It is believed that you exceeded the load level specified for this particular bolt. Mild Steel is an improper choice of material for a component that will be subjected to large loads and stresses. I would suggest you replace the bolt with one made from a stronger material. The fracture occurred at the shoulder of the bolt and this is the point where the stress concentration is the highest. Alterations to the shoulder of the bolt can be made in order to prevent failure as well. A simple chamfer at the shoulder continuing outwards to the head, will achieve this. The most cost effective solution to this problem could be making modifications to the bolt, as opposed to using a more expensive material. Enclosed are some drawing/dimensions of a modified bolt. I look forward to your response and chosen solution. Mechanical Equipments value your business and look forward to helping with any other problems.

Mechanical Equipments Inc. 2

123 ABC Street, Norfolk, VA 23529

Best Regards, Michael Foch

Mechanical Equipments Inc. [Type the sender title] 123 ABC Street, Norfolk, VA 23529

References Lab Handout, Lab 2 Failure, ODU. William F. Smith and Javad Hashemi, Foundations of Material Science and Engineering, 5th ed., Mcgraw Hill, 2006.

Mechanical Equipments Inc. 3

123 ABC Street, Norfolk, VA 23529

Mechanical Equipments Inc. 4