Sultanate of Oman

Ministry of Manpower
Directorate General of Technological Education
Al Musanna College of Technology
QUESTION BANK
DESIGN FOR VARIABLE LOADS
1. A bar of circular cross section is subjected to alternating tensile forces varying from a
minimum of 200 kN to a maximum of 500 kN. It is to be manufactured of a material with an
ultimate tensile strength of 900 MPa and endurance strength of 700 MPa. Determine the
diameters of bar using safety factors of 3.5 related to ultimate tensile strength and related
to endurance limit. [ANS: 59.5mm]
2. Determine the diameter of a circular rod made of ductile material with fatigue strength
(complete stress reversal). Take σe = 265 N/mm2 and σy = 350 N/mm2. The member is
subjected to a varying axial load from Wmin = - 300 kN to Wmax = 700 kN and has a stress
concentration factor = 1.8. Use factor of safety as 2.0. [ANS: diameter, d = 100.5 mm]
3. A steel rod is subjected to a reversed axial load of 180 kN. Find the diameter of the rod
for a factor of safety of 2. Neglect column action. The material has an ultimate tensile
strength of 1070 N/mm2 and yield strength of 910 N/mm2. The endurance limit in
reversed bending may be assumed to be one – half of the ultimate tensile strength. Other
correction factors may be taken for: axial loading = 0.7; machined surface = 0.8; size = 0.85;
stress concentration = 1.0 [ANS: 42.5mm]
4. A 50 mm diameter shaft is made from carbon steel having ultimate tensile strength of
630 MPa. The shaft is subjected to a torque which fluctuates between + 2000 N-m to – 800
N-m. Using Soderberg equation, determine the factor of safety to be used for the design.
Assume ultimate strength, σU = 630 MPa, Yield stress, σY = 510 MPa; τe = 0.55σe; σe = 0.5 σU;
τY = 0.5 σY; [ANS: Factor of safety, FS = 1.85]
5. A circular bar of 500 mm length is supported freely at its two ends. It is acted central
concentrated cyclic load having a minimum value of 20 kN and a maximum value 50 kN.
Determine the diameter of bar by taking a factor of safety of 1.5, size surface finish factor of
0.9. The material properties of bar are given by: ultimate strength of 650 MPa, yield
strength of 500 MPa and endurance strength of 350 MPa.

1
 [ANS: diameter, d = 62.1 mm]
DESIGN OF HELICAL SPRINGS
1. A coil spring has stiffness of 90 N/mm. The load on the spring causes a total deflection of
8.5 mm. Take the permissible shear stress as 450 MPa, Shear modulus as 80 kN/mm², and
spring constant as 6. Determine the spring wire diameter and number of turns.
(Ans: 5.3mm, 3 turns)
2. The spring of a spring balance elongates by 150 mm when subjected to a load of 400 N.
The spring constant is 6. The permissible shear stress for spring material is 540 MPa and
shear modulus is 84 kN/mm². Design a suitable spring.
(Ans: 4 mm, 21 mm, 64 turn)
3. Design a compression helical spring for operating range of 100 N to 135 N. The axial
deflection of spring is 5 mm. The spring constant is 8. The permissible shear stress is 330
MPa. Take the design stress 25% excess of permissible shear stress for service condition.
Take shear modulus as 84 kN/mm2. (Ans: 8 mm, 24 mm, 9 turns)
4. Design a spring for a balance to measure 0 to 1000 N over a scale of length 80 mm. The
spring is to be enclosed in casing of 25 mm diameter. The approximate number of turns is
30. The modulus of rigidity of spring material is 85 kN/mm². Also calculate the maximum
shear stress induced. (Ans: 1018.2 MPa)
5. A spring loaded safety valve for a boiler is required to blow at a pressure of 1.2 N/mm².
Diameter of the valve is 65 mm. The maximum lift of the valve is 17.5 mm. Design a helical
compression spring for the safety valve. If the spring index is 6 and spring has set for an
initial compression of 30 mm. Take the shear stress as 450 MPa, and G as 84 kN/mm² for
the spring material. (Ans: 13 mm, 78 mm, 8 turn)