King Fahd University of Petroleum & Minerals

College of Engineering Sciences

Mechanical Engineering Department

1st Semester (2011-2012) (111)

ME 307: Machine Design I

Second Major Exam

Date: November 27, 2011

Name: ______Solution____________

(
(
(
(

ID #: ____________________________

Sec
) 01
) 02
) 03
) 04

Time: 120 minutes

Instructor
Pasha
Mahir
Mahir
Bashmal

Lec. Time
08:00-08:50
09:00-09:50
10:00-10:50
11:00-11:50

General Instructions
1.
2.
3.
4.
5.

Open Book Exam.

A4 size formula sheet is allowed.
Read each question carefully.
Be neat and clear in your presentation, and show all work for full credit.
Do NOT WRITE on the BACK sheets because your work will not be looked at.

Marks
Problem 1

30

Problem 2

30

Problem 3

40

TOTAL

100

Grades

This exam has eleven pages including this title page.

Mechanical Engineering Department

King Fahd University of Petroleum & Minerals

PROBLEM # 1:

(30 marks)

The 90 elbow rod shown in the sketch is made of AISI 1040 steel
(Hot Rolled) and the dimensions of its two sections are a = 300 mm,
b = 250 mm. The rod is fixed at one end to a wall and its free end is
subjected to force P = 450 N along the z-axis and torque T = 35 N-m
about the y-axis as shown in the figure.
a) Draw the Free Body Diagrams (FBD) of the two sections of
the rod, and calculate all the reaction forces and moments.
b) Show the critical point on the elbow (use a separate drawing
to show that point).
c) Use the MSS failure theory to determine the minimum rod
diameter (dmin) for a safety factor of 2 at the critical point.
a) Recalculate (dmin) using the DET failure theory for a safety
factor of 2.

Second Major Exam

2/10

1st Semester 2011-2012 (111)

Mechanical Engineering Department

King Fahd University of Petroleum & Minerals

Solution:
a) and b)

Second Major Exam

3/10

1st Semester 2011-2012 (111)

Mechanical Engineering Department

King Fahd University of Petroleum & Minerals

c)

Second Major Exam

4/10

1st Semester 2011-2012 (111)

Mechanical Engineering Department

King Fahd University of Petroleum & Minerals

d)

Second Major Exam

5/10

1st Semester 2011-2012 (111)

Mechanical Engineering Department

King Fahd University of Petroleum & Minerals

(30 marks)

PROBLEM # 2:

The grooved bars shown in both figures are made of brittle ASTM 30 Cast Iron and have the
following dimensions D = 10mm, d = 9.5mm, and L = 1m. In both figures the round groove is located
at x = L/2 and has a radius r = 0.95mm.
b) Use the Brittle Coulomb-Mohr theory to find the maximum allowable torque T in Figure (a) that
can be applied before static failure of the bar. (factor of safety n =1)
c) Use the Brittle Coulomb-Mohr theory to find the maximum allowable force P in Figure (b) that
can be applied before static failure of the bar at the groove. (factor of safety n =1)

(a)

Second Major Exam

(b)

6/10

1st Semester 2011-2012 (111)

Mechanical Engineering Department

King Fahd University of Petroleum & Minerals

Second Major Exam

7/10

1st Semester 2011-2012 (111)

Mechanical Engineering Department

King Fahd University of Petroleum & Minerals

PROBLEM # 3:

(40 marks)

A rotating stepped shaft is supported at its ends (A and D) on bearings. A non-rotating weight of 3 kN
is carried by the shaft by bearings at points C and B as shown in the sketch. All bearing supports can
be considered as simple supports (only reaction forces at bearing). The shaft is made of steel with
Sut=700 MPa, Sy=580 MPa and has a ground surface finish. The reliability requirement is 99%.

All Dimensions are in mm.

The fillet radius at each step (i.e. point B and C) is equal to 3.5 mm.
40

40

40

40

35.7
A

C
34

35
3 kN
250

75

100

125

(a) Calculate the stress at points B and C and identify which one is the critical point.
(b) Calculate the endurance limit (Se) at the critical point.
(c) Assuming that a steady tensile stress of 50 MPa (already corrected for Kf) is added to the shaft,
determine the von Mises stresses a and m at the critical point.
(d) Estimate the fatigue factor of safety using modified Goodman criteria.
(e) Determine which type of failure will occur first: fatigue failure or first cycle yielding failure.

Second Major Exam

8/10

1st Semester 2011-2012 (111)

Mechanical Engineering Department

King Fahd University of Petroleum & Minerals

Second Major Exam

9/10

1st Semester 2011-2012 (111)

Mechanical Engineering Department

King Fahd University of Petroleum & Minerals

Second Major Exam

10/10

1st Semester 2011-2012 (111)