Woodruff School of Mechanical Engineering

Georgia Institute of Technology

ME 3180 Mechanical Design Spring 2008
st
1 Midterm Examination
If anything is unclear, make an assumption and proceed with it. Only reasonable
assumptions receive credits.

1. The following figure shows a key installed to enable the transmission of torque from
the shaft to the hub. It is tapered to prevent relative axial movement between the shaft
and the hub. You are asked to design the width (“w”) of the key so that there is an
equal possibility for the key to fail by shearing and to fail by bearing. Use von Mises
criterion for failure determination. (6 points)

hub
Taper 1mm in 30mm
key
3 mm
4 mm shaft
30 mm 45 mm
w

front view side view

2. The C clamp shown below uses a 1”-8UNC square double thread. For this power
screw application the thread depth is half of the pitch. The friction coefficients are 0.1
for the threads and for the collar. A clamping force as large as 250 lbf is desired, while
the force applied to the handle at a radius of 3” from the screw centerline is limited to a
9 lbf maximum. Specify the maximum allowable friction diameter of the collar, which in
this case is the anvil striker’s swivel joint, such that the desired 250 lbf can be achieved.
(6 points)

3”

3. Find the critical speed (in rad/sec) of a steel shaft (E=30Mpsi) with ½” diameter and
10” length as it spins while it is loaded as follows: The two ends are simply supported.
(6 points). Some beam deflection formulas are included for your reference.
 20 lbf 10 lbf 30 lbf

3” 10 lbf
4”
5”
8”
10”

4. The following figure shows an elbow part with one end built into a wall, while the
other end loaded by a varying load of F. The load F will first be 400 lbf, fully reversed,
to be applied for a period of 10,000 cycles. Subsequently the load will be varying
between 0 and 500 lbf until the part fails by fatigue. What is the number of total load
cycles, counting from the very start, that the part can go through to the point of fatigue
failure? It is known that the part material has an ultimate strength of 60 kpsi and a
modified endurance limit of 30 kpsi. Use Goodman curve without safety factor. Do not
consider any stress concentration factor. Use Von Mises if any combined loading
analysis is needed.(7 points)

F
d=1” y
z
x

5” 10”
 Woodruff School of Mechanical Engineering
Georgia Institute of Technology
ME 3180 Mechanical Design Spring 2008
Solution for 1st Midterm Examination

0.29S y dwA
1. Shear failure nshear =
T
The exit end of the key has a hight of 3+45(1/30)=4.5mm in the hub.
2T
nbearing S y Ad(7.5)
F d ⇒n
Bearing failure S y = = bearing =
A bearing A 1 3 + 4.5
( ) 4T
2
Same failure possibility, nshear = nbearing ⇒ w = 6.46 mm

1 1 1 15
2. d=1”, p= " , A = 2p = " , dm = d − p = " , α = 0
8 4 2 16
⎡ 1 15 ⎤
⎢ + π (0 . 1) ⎥
Fd ⎡ A + fπdm ⎤ Ffc 250(15 / 26) 4 16 ⎥ + 250 ⎛ 0.1 ⎞ d
T= m ⎢ ⎥ + d = ⎢ ⎜ ⎟ c
2 ⎣ πdm − fA ⎦ 2 ⎢ π ⎛ 15 ⎞ − (0.1) 1 ⎥
c
2 ⎝ 2 ⎠
⎢⎣ ⎜⎝ 16 ⎟⎠ 4 ⎥⎦
⎛ 0.1 ⎞
9 × 3 = 21.85 + 250 ⎜ ⎟ dc ⇒ dc = 0.41"
⎝ 2 ⎠

π(0.5) 4
3. I = = 0.003 in4 , 6EIA = 6(30E6)(0.003)(10) = 5, 400, 000 in3
64
(7)3(102 − 72 − 32 )
δ11 = 1 1 ( A 2 − b12 − x12 ) =
bx
= 1.63 × 10 −4 in / lbf
6EIA 5, 400, 000
(6)4(102 − 62 − 42 ) (5)5(102 − 52 − 52 )
δ22 = = 2.13 × 10−4 in / lbf , δ33 = = −2.31× 10−4 in / lbf
5, 400, 000 5, 400, 000
(2)8(102 − 22 − 82 )
δ 44 = = 0.95 × 10−4 in / lbf
5, 400, 000
1/ 2
1 ⎡1 ⎤
= ⎢ ( W1δ11 + W2 δ22 + W3 δ33 + W4 δ 44 ) ⎥
ω ⎣g ⎦
1/ 2
⎡ 1 ⎤
=⎢
⎣ 386
( 20(1.63 × 10 −4 ) + 10(2.13 × 10−4 ) − 10(2.31× 10 −4 ) + 30(0.95 × 10 −4 ) ) ⎥
⎦
⇒ ω=255 rad/sec
4.
Mc F(5)(1/ 2) Tr F(10)(1/ 2) F F
σx = = = 51F; τ xy = = = 51F; τ xy = = = 1.27F ≈ 0
I ( π(1) ) / 64
4
J ( π(1) ) / 32
4
A ( π(1)2 ) / 4

σ ' = σ2x + 3τ2xy = 102F

(0.9 × 60)2 1 ⎛ 0.9(60) ⎞
S-N curve: a = = 97.2; b=- log ⎜ ⎟ = −0.085
30 3 ⎝ 30 ⎠
State 1 -- F1=-400~400 lbf
σm=0, σa=102(400)=40,800 psi,
σ σ
1 = a + m ⇒ Sf = σa since σm = 0
S f Sut
1/ b −1/ 0.085
⎛S ⎞ ⎛ 40.8 ⎞
N1 = ⎜ f ⎟ = ⎜ ⎟ = 27,250 cycles
⎝ a ⎠ ⎝ 97.2 ⎠
Stage 2 -- F2=0~500 lbf
σm=σa=102(250)=25,500 psi,
σ σ 25.5 25.5
1= a + m = + ⇒ S f = 44,348 psi
Sf Sut Sf 60
−1/ 0.085
⎛ 44.3 ⎞
N2 = ⎜ ⎟ = 10,217 cycles
⎝ 97.2 ⎠
10,000 n2
Minor’s rule: 1 = + ⇒ n2 = 6,467
27,250 10,217
Number of total cycles = N1+N2= 10,000+6,467=16,467
 Woodruff School of Mechanical Engineering
Georgia Institute of Technology
ME 3180 Mechanical Design Spring 2008
nd
2 Midterm Examination

1. The figure shows a clamped joint that employs three identical bolts of SAE grade 5
bolts (92 kpsi yield strength). The vertical load on the joint is 4,000 lbf. The members
are cold-drawn bars of AISI 1020 steel (57 kpsi yield strength). Find the factors of
safety for the failure modes of bolt shearing and bolt bearing. Use distortion energy
theory when necessary. (6 points)

1/2” 4,000 lbf

1”
1/4 in-12 UNC
1/2”

3/4”

1 1/2” 1/4” 1/8”

4,000 lbf

2. The figure shows a square-threaded bolt holding a hook to a ceiling. The bolt proof
strength (60 kpsi) is the same as the nut proof strength. The nut length is 11/16 inch,
which is the same as the bolt major diameter. The bolt diameter and the preload are all
carefully selected so that the bolt yielding, plates separation, and thread stripping can
take place only simultaneously. Calculate the load (F) that causes these failures to
happen. Consider the joint constant to be 0.6. (7 points)

3. A radial ball bearing is used under rotating outer ring condition with 800 lb axial load
and 3,100 lb radial load. If the expected life is to be 5 × 108 revolutions with 95%
reliability, what should be the basic dynamic load rating (C10) of the bearing selected for
this purpose? Note that the published Weibull parameters are x0=0.02, θ=4.459, and
b=1.483 and assume the bearing selected has a basic static load rating (Co) of 22,000
lb. Note that the effective load P should be calculated as P=XVFr+YFa with X and Y
given in the following table. (6 points)
 Fa/VFr<e Fa/VFr>e
Fa/Co e X Y X Y
0.028 0.22 1.00 0 0.56 1.99
0.070 0.27 1.00 0 0.56 1.63
0.17 0.34 1.00 0 0.56 1.31

4. The torsional spring shown in the figure has an angular spring constant of 15,000 lb-
in/rad and the coil spring has a spring constant of 200 lb/in. What is the amount of force
(F, in lb) that can buckle the coil spring? Assume that the 10 inch beam is infinitely stiff.
The coil spring has a free length of 3 inches and a diameter of 1 inch, and its wire has
E= 30 × 106 psi and G= 11.5 × 106 psi . (6 points)

10 inch F
free end
spring constant
200 lb/in

fixed end

angular spring constant

15,000 lb-in/rad
 Woodruff School of Mechanical Engineering
Georgia Institute of Technology
ME 3180 Mechanical Design Spring 2008
nd
Solution for 2 Midterm Examination
1. Considering bolt shearing:
⎡ π(1/ 4)2 ⎤ F 4 S 92 / 3
AS = 3 ⎢ ⎥ = 0.147 in ; τS = = = 27.21 kpsi ; n = sy = = 1.95
2

⎣ 4 ⎦ A 0.147 τs 27.21
(Note the distortion energy theory is used to calculate Ssy above)
Considering bolt bearing:
⎛ 1 ⎞⎛ 1 ⎞ F 4 S 92
A S = 3 ⎜ ⎟ ⎜ ⎟ = 0.094 in2 ; σb = = = 42.66 kpsi ; n = y = = 2.16
⎝ 4 ⎠⎝ 8 ⎠ A b 0.094 σb 42.66

2. To have simultaneously bolt yielding and thread stripping:

11
A S = 2A t = πdmqw = πdm ( )(0.5)
16
2
1 1 ⎡ 1 ⎤ 11
Also, A t = πd2t = π ⎢dm − (D − dm ) ⎥ with D =
4 4 ⎣ 2 ⎦ 16
The above two give dm = 0.685 inch, which leads to At=0.37 in2
For simultaneous bolt yielding and member separation (thread stripping also),
SA
1 = n = p t ⇒ F = Sp A t = (60 × 103 )(0.37) = 22,200 lbf
F

3. V=1.2, Fa/Co=800/22,000=0.036, Fa/VFr=800/(1.2)(3,100)=0.215 < e (since e>0.22)

X=1, Y=0, P=VFr=(1.2)(3,100)=3,720
L 5 × 108
L10 = = = 8 × 108
x o + ( θ − x o )( − lnR ) 0.02 + (4.459 − 0.02)( − ln0.95)
1/ b 1/ 1.483

3 3
L10 ⎛ C10 ⎞ 8 × 108 ⎛ C10 ⎞
= ⇒ = ⇒ C10 = 34,533lb
1× 106 ⎜⎝ 3,720 ⎟⎠ 1× 106 ⎜⎝ 3,720 ⎟⎠

⎡ ⎛ C2 ⎞1/ 2 ⎤
4. The buckling force F = LoC1 ⎢1 − ⎜ 1 − 2 ⎟ ⎥ K
⎢⎣ ⎝ λ ⎠ ⎥⎦

E 30 × 106 2π2 (E − G) αL o 2(3)

C1 = = = 0.81 ; C = = 6.89 ; λ = = =6
2(E − G) 2(30 − 11.5) × 10 2G + E
6 2
D 1
⎡ ⎛ 6.89 ⎞1/ 2 ⎤
F = (3)(0.81) ⎢1 − ⎜ 1 − 2 ⎟ ⎥ (200) = 49 lb
⎣⎢ ⎝ 6 ⎠ ⎦⎥
 Woodruff School of Mechanical Engineering
Georgia Institute of Technology
ME 3180 Mechanical Design Spring 2008
Final Examination

1. Find the critical speed (in rad/sec) of a steel shaft (E=30Mpsi) with ½” diameter and
10” length as it spins while it is loaded as follows: The two ends are simply supported.
Some beam deflection formulas are provided for your reference. (10 points)

10 lbf 10 lbf 20 lbf

20 lbf
2”
4”
6”
8”
10”

2. The torsional spring shown in the figure has an angular spring constant of 10,000 lb-
in/rad and the coil spring has a spring constant of 200 lb/in. What is the amount of force
(F, in lb) that can buckle the coil spring? Assume that the 10 inch beam is infinitely stiff.
The coil spring has a free length of 3 inches and a diameter of 1 inch, and its wire has
E= 30 × 106 psi and G= 11.5 × 106 psi . (10 points)

10 inch F

angular pivoted ends

spring
spring constant constant
10,000 lb-in/rad 200 lb/in
3. A square-threaded bolt with major diameter of 0.5 inch, minor diameter of 0.4 inch,
and lead of 0.077 inch is used in a self-locking screw jack application. What is the
maximum possible weight (in lb) that can be lifted with the use of 50 lb-in torque.
Assume that the collar bearing friction is negligible. (10 points)

4. Two identical bolts (with a proof strength of 500 MPa and a stress area of 58 mm2)
are used to fasten two flat plates as shown. What is the maximum allowable load, F, for
the bolts to survive this application? Use the maximum shear stress theory and a load
safety factor of 3.
F

2m

3m

5m
 Woodruff School of Mechanical Engineering
Georgia Institute of Technology
ME 3180 Mechanical Design Spring 2008
Solution for Final Examination
π(0.5) 4
1. I = = 0.003 in4 , 6EIA = 6(30E6)(0.003)(10) = 5, 400, 000 in3
64
(8)2(102 − 82 − 22 )
δ11 = 1 1 ( A 2 − b12 − x12 ) =
bx
= 0.95 × 10 −4 in / lbf
6EIA 5, 400, 000
(6)4(102 − 62 − 42 ) (4)6(102 − 42 − 62 )
δ22 = = −2.13 × 10 −4 , δ33 = = 2.13 × 10 −4
5, 400, 000 5, 400, 000
(2)8(102 − 22 − 82 )
δ 44 = = 0.95 × 10 −4
5, 400, 000
1/ 2
1 ⎡1 ⎤
= ⎢ ( W1δ11 + W2 δ22 + W3 δ33 + W4 δ 44 ) ⎥
ω ⎣g ⎦
1/ 2
⎡ 1
=⎢ (10(0.95) − 20(2.13) + 10(2.13) + 20(0.95) ) × 10−4 ⎤⎥
⎣ 386 ⎦
⇒ ω=14,912 rad/sec

⎡ ⎛ C2 ⎞1/ 2 ⎤
2. The buckling force on the coil spring F1 = LoC1 ⎢1 − ⎜ 1 − 2 ⎟ ⎥ k1
⎣⎢ ⎝ λ ⎠ ⎦⎥

E 30 × 106 2π2 (E − G) αLo 1(3)

C1 = = = 0.81 ; C2 = = 6.89 ; λ = = =3
2(E − G) 2(30 − 11.5) × 10 6
2G + E D 1
⎡ ⎛ 6.89 ⎞1/ 2 ⎤
F1 = (3)(0.81) ⎢1 − ⎜ 1 − 2 ⎟ ⎥ (200) = 250 lb
⎢⎣ ⎝ 3 ⎠ ⎥⎦
The linear spring constant of the torsional spring (including the beam) is
k1 = k a / r 2 = 10,000 /102 = 100 lbf / in
Since the coil spring and the torsional spring are in parallel, the required total force to
k +k ⎛ 100 + 200 ⎞
buckle is F = F1 1 2 = 250 ⎜ ⎟ = 375 lbf
k1 ⎝ 200 ⎠

A 0.077
3. Self locking screw : μ > tan λ = = = 0.054
πdm π( 0.5 + 0.4 )
2
Fd ⎛ μ + tan λ ⎞ 2T ⎛ 1− μ tan λ ⎞
T= m⎜ ⎟ ⇒ F= ⎜ ⎟
2 ⎝ 1 − μ tan λ ⎠ dm ⎝ μ + tan λ ⎠
 2(50) ⎛ 1− 0.054(0.054) ⎞
at μ=0.054, maximum F = ⎜ ⎟ = 2, 051 lb (4 points) . Any
1
(0.5 + 0.4) ⎝ 0 . 054 + 0 .054 ⎠
2
greater F would require a smaller μ which makes the screw not self-locking.

F F
4. On the top bolt, which is the critical one, the direct shear stress is V1 = = ,
58(2) 116
F(4000) F
and the torsional shear stress is V2 = =
(58)(2000 2 ) 41
The resultant shear stress is
2 2
⎛ 1 ⎞ ⎛ 1⎞ ⎛ 1 ⎞⎛ 1 ⎞
V = V + V − 2V1V2 cos θ = F ⎜
1
2 2
2 ⎟ + ⎜ ⎟ − 2⎜ ⎟ ⎜ ⎟ cos 135 = F(0.113)
0

⎝ 116 ⎠ ⎝ ⎠41 ⎝ 116 ⎠⎝ ⎠

41
S 500
Maximum shear stress theory: p > nV ⇒ F < = 735 N
2 (2)(3)(0.113)