Tutorial - 1: Machine Design I: Design for static and fatigue strength

1. A bar of steel has Sut = 700 MPa, Sy = 500 MPa, and a fully corrected endurance limit Se = 200
MPa. For each of the cases below find the factors of safety which guard against static and
fatigue failures.
(a) m = 140 MPa
(b) m = 140 MPa, a = 70 MPa
(c) xym = 100 MPa, xa = 80 MPa
(d) xm = 60 MPa, xa = 80 MPa, xym = 70 MPa, xya = 35 MPa
Ans. (a) 2.06 (b) n(static) = 1.37, n (fatigue) = 1.64 (c) n (static) = 2.62, n (fatigue) = 1.56
(e) n (static) = 2.18, n (fatigue) = 1.45
2. Tests on a particular melt of cast iron gave Sut = 150MPa and Suc = 600 MPa. Find the factor of safety for
each of the three failure theories for brittle materials for the following stress states:

= 50 MPa, = 30 MPa cw
(b) = - 80 MPa, = - 40 MPa, = 20 MPa ccw
(c) = 40 MPa, = 30 MPa, = 10 MPa ccw
(d) = 30 MPa, = - 60 MPa, = 30 MPa cw
(a)

xy

xy

xy

xy

3. A 25-mm-diameter shaft is statically torqued to 230 N m. It is made of cast 195-T6 aluminum, with a
yield strength in tension of 160 MPa and a yield strength in compression of 170 MPa. It is machined to
final diameter. Estimate the factor of safety of the shaft.

4. The figure 1.1 shows a round bar subjected to the vector moment M = 1.75i+1.10k kN.m. The
material is 5052-H38 aluminium alloy. A stress element A located on top of the bar is oriented in
the xz plane as shown. Using the stresses on this element, determine the factor of safety
guarding against a static failure by using the maximum shear stress theory and the distortion
energy theory.

Fig.1.1

5. A lever subjected to a downward static force of 1.8 kN is keyed to a 25-mm round bar as shown
in Figure 1.2.
(a) Find the critical stresses in the round bar.
(b) The round bar is made of steel with Sy = 1020 MPa. Based on static loading, find the factor
of safety using maximum shear stress theory and the distortion energy theory.

Fig.1.2
Ans: (a) x= 205 MPa, xy = 132 MPa
(c) 3.05 and 3.32

6. The cantilevered tube shown in Fig. 1.3 is to be made of 2014 aluminum alloy treated to obtain a specified
minimum yield strength of 276 MPa. Use a design factor nd = 4. The bending load is F = 1.75 kN, the axial
tension is P = 9.0 kN, and the torsion is T = 72 N m. What is the realized factor of safety?

Fig. 1.3

7. A steel ship deck plate is 30 mm thick and 12 m wide. It is loaded with a nominal uniaxial tensile stress of
50 MPa. It is operated below its ductile-to-brittle transition temperature with KI c equal to 28.3 MPa. If a
65-mm-long central transverse crack is present, estimate the tensile stress at which catastrophic failure will
occur. Compare this stress with the yield strength of 240 MPa for this steel.

8. A thin-walled pressure vessel is made of 3003-H14 Aluminium alloy tubing. The vessel has an
OD of 60 mm and a wall thickness of 1.50 mm. What internal pressure would cause the material
to yield.
Ans: 8.38 MPa.
9. A spherical pressure vessel 600 mm in diameter is made of cold drawn sheet steel having Sut =
400 MPa, Sy = 370 MPa, and a thickness of 3 mm. The vessel is to withstand an infinite number
of pressure fluctuations from 0 to pmax.
(a) What maximum pressure will cause static yielding?
(b) What maximum pressure will eventually cause a fatigue failure? In any case, assume that the
joints and connections are adequately reinforced and do not weaken the vessel.
Ans. (a) pmax = 7400 kPa, (b) pmax = 5280 kPa
10. The figure 1.4 is an idealized representation of a machine member subjected to the action of an
alternating force F which places the member in completely reversed bending. The material is
hardened tempered to 190 Bhn. All surfaces are ground. Based on 50 percent reliability, infinite
life, and no margin of safety, determine the maximum value of alternating force F which can
probably be applied.
Ans. 1.06 kN

Fig.1.4

11. The shaft shown in figure 1.5 rotates at 1720 rev/min and is to have a life of 3 min at 50 percent
reliability. The steel used has the following properties: Sut = 610 MPa, E = 207 GPa, HB = 178.
The shaft is finished by grinding. It is simply supported in bearings at A and B and is loaded by
the static forces F1 = 8.9 kN and F2 = 13.4 kN. Find the factor of safety guarding against failure.

Fig.1.5

12. The rotating shaft shown in figure 1.6 is machined from a 50-mm bar of cold-drawn steel. The
shaft is designed for an infinite life and a reliability of 99.99 percent. What factor of safety guards
against a fatigue failure if the force is 3.0 kN?
Ans.1.55

Fig.1.6

13. The figure 1.7 shows a rotating shaft loaded by two bending forces having the bearing reactions
R1 and R2. Point A is a shaft shoulder which is required for positioning the left-hand bearing. The
grinding-relief groove at B is 2.5 mm deep (given to get geometric Stress Concentration Factor).
The surface AB is ground, but the groove is machined. The material of the shaft is hardened and
tempered steel to Sut = 1300 MPa. Determine the factor of safety corresponding to a life of 0.35
(10)6 revolutions of the shaft.
Ans. 1.50

Fig.1.7

14. A plate of width 1.4 m and length 2.8 m is required to support a tensile force in the 2.8-m
direction of 4.0 MN. Inspection procedures will detect only through-thickness edge cracks larger
than 2.7 mm. The two aluminum alloys AA2024 and AA7178 are being considered for this
application. The KIc is equal to 26 and 33 MPa(m)1/2 respectively and Sy is equal to 455 and
490 respectively. The geometry factor for stress intensity factor, KI is 1.1. For this application the
safety factor must be 1.3 and minimum weight is important. Which alloy should be used?
15. A bar of steel has the minimum properties Se = 276 MPa, Sy = 413 MPa, and Sut = 551 MPa. The
bar is subjected to a steady torsional stress of 103 MPa and an alternating bending stress of 172
MPa. Find the factor of safety guarding against a static failure, and either the factor of safety
guarding against a fatigue failure or the expected life of the part. For the fatigue analysis use:
(a) Modified Goodman criterion.
(b) Gerber criterion.
(c) ASME-elliptic criterion.
Ans: Yield: ny = 1.18. Fatigue: (a) nf = 1.06, (b) nf = 1.31, (c) nf = 1.32
16. Repeat Prob. 12 but with a steady torsional stress of 138 MPa and an alternating bending stress of
69 MPa.
17. Repeat Prob. 12 but with a steady torsional stress of 103 MPa, an alternating torsional stress of 69
MPa, and an alternating bending stress of 83 MPa.
18. Repeat Prob. 12 but with an alternating torsional stress of 207 MPa.
19. Repeat Prob. 12 but with an alternating torsional stress of 103 MPa and a steady bending stress
of 103 MPa.
20. A bar of AISI 1020 cold-drawn steel is subjected to following plane stress states. Using the
distortion-energy and maximum-shear-stress theories determine the factors of safety:
(a) x = 180 MPa, y = 100 MPa
(b) x = 180 MPa, xy = 100 MPa
(c) x = 160 MPa, xy = 100 MPa

(d) xy = 150 MPa

Ans: (a) MSS: n = 2.17, DE: n = 2.50, (b) MSS: n = 1.45, DE: n = 1.56, (c) MSS: n = 1.52, DE: n
= 1.65, (c) MSS: n = 1.27, DE: n = 1.50
21. A cylinder subjected to internal pressure pi has an outer diameter of 350 mm and a 25-mm wall
thickness. For the cylinder material, KI c = 80 MPa m, Sy = 1200 MPa, and Sut = 1350 MPa. If
the cylinder contains a radial crack in the longitudinal direction of depth 12.5 mm determine the
pressure that will cause uncontrollable crack growth.
Ans: p = 29.2 MPa
22. A shaft shown in Figure 1.8 must transmit a torque of 1000 N m, with superimposed torsional vibration
causing an alternating torque of 250 N m. A safety factor of 2 is to be applied to both loads. A heat-treated
alloy steel is to be used, having Su = 1.2 GPa, and Sy = 1.0 GPa (unfortunately, test data are not available
for Sus or Sys). It is required that the shaft have a shoulder, with D/d = 1.2 and r/d = 0.05 (as shown in
Figure 4.35). A good-quality commercial ground finish is to be specified. What diameter is required for
infinite fatigue life?

Fig.1.8

23. Figure 1.9 given below pertains to the shaft of a disk sander that is made of steel having Su = 900 MPa, and
Sy = 750 MPa. The most severe loading occurs when an object is held near the periphery of the disk (100mm radius) with sufficient force to develop a friction torque of 12 N m (which approaches the stall torque
of the motor). Assume a coefficient of friction of 0.6 between the object and the disk. What is the safety
factor with respect to eventual fatigue failure of the shaft?

Fig.1.9

24. A 10-mm-diameter steel bar having Su = 1200 MPa and Sy = 950 MPa has a fine ground surface.
Estimate the bending fatigue strength for (1) 106 or more cycles and (2) 2 x 105 cycles.
25. When in use, the shaft shown in Figure 1.10 experiences completely reversed torsion. It is
machined from steel having a hardness of 150 Bhn. With a safety factor of 2, estimate the value
of reversed torque that can be applied without causing eventual fatigue failure.
[Ans.: 55.8 N m]

Fig.1.10

26. A straight round shaft is subjected to a torque of 565 N-m. Determine the required diameter
using steel with tensile yield strength of 400 MPa and a safety factor of 2 based of initial yielding
according to the (i) Maximum shear stress theory and (ii) Distortion energy theory. Discuss
briefly the relative validity of the two predictions.