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Mechanical
Design of Machine
Components
by
ANSEL C. UGURAL
solutionS MANUAL FOR
Mechanical
Design of Machine
Components
by
ANSEL C. UGURAL
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CONTENTS
Section I BASICS
Chapter 1 INTRODUCTION 1
Chapter 2 MATERIALS 16
vi
NOTES TO THE INSTRUCTOR
The Solutions Manual to accompany the text Mechanical Design of Machine Components supplements
the study of machine design developed in the book. The main objective of the manual is to provide efficient
solutions for problems in design and analysis of variously loaded mechanical components. In addition, this
manual can serve to guide the instructor in the assignment of problems, in grading these problems, and in
preparing lecture materials as well as examination questions. Every effort has been made to have a solutions
manual that cuts through the clutter and is self –explanatory as possible thus reducing the work on the
instructor. It is written and class tested by the author.
As indicated in its preface, the text is designed for the junior-senior courses in machine or
mechanical design. However, because of the number of optional sections which have been included,
Mechanical Design of Machine Components may also be used to teach an upper level course. In order
to accommodate courses of varying emphases, considerably more material has been presented in the book
than can be covered effectively in a single three-credit-hour course. Machine/mechanical design is one of
the student’s first courses in professional engineering, as distinct from basic science and mathematics. There
is never enough time to discuss all of the required material in details.
The instructor has the choice of assigning problems using SI units and problems using U.S.
customary units. To assist the instructor in making up a schedule that will best fit his classes, major topics
that will probably be covered in every machine design course and secondary topics which may be selected
to complement this core to form courses of various emphases are indicated in the following Sample
Assignment Schedule. The major topics should be covered in some depth. The secondary topics, because
of time limitations and/or treatment on other courses, are suggested for brief coverage. We note that the
topics which may be used with more advanced students are marked with asterisks in the textbook.
The problems in the sample schedule have been listed according to the portions of material they
illustrate. Instructor will easily find additional problems in the text to amplify a particular subject in
discussing a problem assigned for homework. Answers to selected problems are given at the end of the text.
Space limitations preclude our including solutions to open-ended web problems. Since the integrated
approach used in this text differs from that used in other texts, the instructor is advised to read its preface,
where the author has outlined his general philosophy. A brief description of the topics covered in each
chapter throughout the text is given in the following. It is hoped that this material will help the instructor in
organizing his course to best fit the needs of, his students.
Ansel C. Ugural
Holmdel, N.J.
vii
DESCRIPTION OF THE MATERIAL CONTAINED IN
“Mechanical Design of Machine Components”
Chapter 1 attempts to present the basic concepts and an overview of the subject. Sections 1.1 through 1.8
discuss the scope of treatment, machine and mechanical design, problem formulation, factor of safety, and
units. The load analysis is normally the critical step in designing any machine or structural member (Secs.
1.8 through 1.9). The determination of loads is encountered repeatedly in subsequent chapters. Case studies
provide a number of machine or component projects throughout the book. These show that the members
must function in combination to produce a useful device. Section 1.10 review the work, energy, and power.
The foregoing basic considerations need to be understood in order to appreciate the loading applied to a
member. The last two sections emphasize the fact that stress and strain are concepts of great importance to a
comprehension of design analysis.
Chapter 2 reviews the general properties of materials and some processes to improve the strength
of metals. Sections 2.3 through 2.14 introduce stress-strain relationships, material behavior under various
loads, modulus of resilience and toughness, and hardness, selecting materials. Since students have
previously taken materials courses, little time can be justified in covering this chapter. Much of the material
included in Chapters 3 through 5 is also a review for students. Of particular significance are the Mohr’s
circle representation of state of stress, a clear understanding of the three-dimensional aspects of stress,
influence of impact force on stress and deformation within a component, applications of Castigliano’s
theorem, energy of distortion, and Euler’s formula. Stress concentration is introduced in here, but little
applications made of it until studying fatigue (Chap.7).
The first section of Chapter 6 attempts to provide an overview of the broad subject of “failure”,
against which all machine/mechanical elements must be designed. The discipline of fracture mechanics is
introduced in Secs. 6.2 through 6.4. Yield and fracture criteria for static failure are discussed in Secs. 6.4
through 6.12. The last 3 sections deal with the method of reliability prediction in design. Chapter 7 is
devoted to the fatigue and behavior of materials under repeated loadings. The emphasis is on the Goodman
failure criterion. Surface failure is discussed in Chapter 8. Sections 8.1 through 8.3 briefly review the
corrosion and friction. Following these the surface wear is discussed. Sections 8.6 through 8.10 deal with
the surfaces contact stresses and the surface fatigue failure and its prevention. The background provided
here is directly applied to representative common machine elements in later chapters.
Sections 9.1 through 9.4 of Chapter 9 treat the stresses and design of shafts under static loads.
Emphasis is on design of shafts for fluctuating loading (Secs. 9.6 and 9.7). The last 5 sections introduce
common parts associated with shafting. Chapter 10 introduces the lubrication as well as both journal and
roller bearings. As pointed out in Sec. 8.9, rolling element bearings provide interesting applications of
contact stress and fatigue. Much of the material covered in Secs. 11.1 through 11.7 of Chapter 11 deal with
nomenclature, tooth systems, and fundamentals of general gearing. Gear trains and spur gear force analysis
are taken up in Secs. 11.6 and 11.7. The remaining sections concern with gear design, material, and
manufacture. Non-spur gearing is considered in Chapter 12. Spur gears are merely a special case of helical
gears (Secs. 12.2 through 12.5) having zero helix angle. Sections 12.6 through 12.8 deal with bevel gears.
Worm gears are fundamentally different from other gears, but have much in common with power screws to
be taken up in Chap. 15.
viii
Chapter 13 is devoted to the design of belts, chains, clutches, and brakes. Only a few different
analyses are needed, with surface forms effecting the equations more than the functions of these devices.
Belts, clutches, and brakes are machine elements depending upon friction for their function. Design of
various springs is considered in Chapter 14. The emphasis is on helical coil springs (Secs. 14.3 through
14.9) that provide good illustrations of the static load analysis and torsional fatigue loading. Leaf springs
(Sec. 14.11) illustrate primarily bending fatigue loading. Chapter 15 attempts to present screws and
connections. Of particular importance is the load analysis of power screws and a clear understanding of the
fatigue stresses in threaded fasteners. There are alternatives to threaded fasteners and riveted or welded
joints. Modern adhesives (Secs. 15.17 and 15.18) can change traditional preferred choices.
It is important to assign at least portions of the analysis and design of miscellaneous mechanical
members treated in Chapter 16. Sections 16.3 through 16.7 concern with thick-walled cylinders, press or
shrink fits, and disk flywheels. The remaining sections introduce the bending of curved frames, plate and
shells-like machine and structural components, and pressure vessels. Buckling of thin-walled cylinders and
spheres is also briefly discussed. Chapter 17 represents an addition to the material traditionally covered in
“Machine/Mechanical Design” textbooks. It attempts to provide a comprehensive introduction to the finite
element analysis in mechanical design. A variety of case studies illustrate solutions of problems involving
structural assemblies, stress concentration factors in plates and disks, and thick-walled pressure vessels.
Finally, case studies in preliminary design of the entire crane with winch and a high-speed cutting machine
are introduced in Chapter 18.
ix
SAMPLE ASSIGNMENT SCHEDULE MACHINE/MECHANICAL DESIGN (3 credits.)
TEXT: A. C. Ugural, Mechanical Design of Machine Components, CRC Press (T & F Group).
Prerequisites: Courses on Mechanics of Materials and Engineering Materials.
4 Fatigue Criteria and Surface failure 7.1 to 7.15, 8.1 to 8.10 7.6,7.17,7.28,7.32,7.34
8.3,8.8, 8.14, 8.21
5 EXAM # 1 - - - - - - - - - -
Shafts and Associated parts 9.1 to 9.12 9.7,9.14,9.19,9.24,9.28
9 EXAM # 2 - - - - - - - - - -
Belt and Chain Drives 13.1 to 13.6 13.1,13.8,13.9, 13.10,13.13
12 EXAM # 3 - - - - - - - - - -
Power Screws and Fasteners 15.1 to 15.12 15.2,15.6,15.14,15.19,15.30
14 Miscellaeneous Mechanical
Components* 16.1 to 16.5, 16.8 16.6,16.17,16.25,16.38
to 16.11
* Secondary topics. The remaining, major, topics constitute the “main stream” of the machine design
course.
x
Section I BASICS
CHAPTER 1 INTRODUCTION
SOLUTION (1.1)
Thus
RB = (5.9) 2 + (19.8) 2 = 20.7 kN
and
α = tan −1 20.7
5.9
= 15.9o
F A
5.9 B
20 in. 15 kN 4.8 kN
19.8
RBx B
C
6.4 kN α
RB
Figure S1.1 10 in. 10 in.
SOLUTION (1.2)
Free Body: Beam ADE (Fig. S1.2)
∑M A = 0 : − W (3.75α ) + FBD (2a) = 0,
E FBD = 1.875W ↑
D W ∑F x = 0 : RAx = 0
FBD
A
∑F y = 0 : − RAy + FBD − W = 0,
1
SOLUTION (1.3)
2 kip/ft
24 kip ⋅ ft
∑ M = 0: A RB = 2.5 kips ↓
C
D A E
B ∑ F = 0:
y RA = 10.5 kips ↑
2’ RA RB
4’ 8’ 8’
Segment CD
2 kip/ft
M D = 12 ( 2 )( 2 2 ) = 4 kip ⋅ ft
C MD VD = 4 kips
2’ D VD
Segment CE
8 kips VE
2’
M E = 8( 6 ) − 10.5( 4 ) = 6 kip ⋅ ft
C ME VE = 2.5 kips
4’ A 4’ E
10.5
SOLUTION (1.4)
(a)
1m
∑M B = 0: 0.8 RC ( 6) − 0.6 RC ( 2) − 24( 4) = 0
8 kN m 2m
10 kN ∴ RC = 26.667 kN
RCx = 16 kN , RCy = 21334
. kN
C
RC 3m D B 2m
RBx Then
4
RBy 2m ∑F x = 0: RBx = 16 kN
∑F
3
A y = 0: RBy = 12.66 kN
( b ) Segment CD
8 M D = 21334
. (3) − 12(15
. ) − 6( 2) = 34 kN ⋅ m
4 MD FD = 16 kN
16
FD VD = 21334
. − 18 = 3334
. kN
C 3m D VD
21.334
2
SOLUTION (1.5)
3m
(a)
A
∑M A = 0: RCx = 23 RCy
2 2m
3
C
RCy 4
RCx
3
SOLUTION (1.6)
P A T 6” ∑M C = 0: RA ( 28) − T = 0
T = 28 R A
C
RA 20” 8”
(b) ∑F x = 0: 4− 20
20.88 FAB = 0, FAB = 4176
. kips
SOLUTION (1.7)
Free Body: Entire Crankshaft (Fig. S1.7a)
120 mm
120 mm ( a ) From symmetry: RA = RB
y
∑ F =0 : R = R = 2 kN ր
z A B
∑ M = 0 : − 4(0.05) + T = 0,
A 70 mm
D T x
B
T = 0.2 kN ⋅ m = 200 N ⋅ m
RA = 2 kN
z RB = 2 kN x
50 mm C
4 kN (a)
(CONT.)
3
1.7 (CONT.)
My
D ( b ) Cross Section at D (Fig. S1.7b)
Vz Vz = 2 kN ր
(b) T = 200 N ⋅ m
T
Figure S 1.7 M y = 2(0.07) = 0.14 kN ⋅ m
= 140 N ⋅ m
SOLUTION (1.8)
30 kN
1.8 m 4
∑ F = 0 : − F + 60 = 0, F = 69.11 kN
x
7
65 CD CD
C FCD
7
∑ F = 0 : R − F − 30 = 0, R = 64.3 kN ↑
y A
4
65 CD A
M A = 72 kN ⋅ m
60 kN
1.8 m
A
MA
RA
SOLUTION (1.9)
B 4’ C
Free body entire frame
30 kips
3’ 3’ 4’
8’
∑M A = 0: − 30(3) − 12 RDy ( 4 ) + RDy (10 ) = 0
2 RDy = 1125
. kips, RDx = 5.625 kips
A 1
D 1
2 RDy
RDy RD
RBy
B C Free body BCD
RBx 4’ ∑F x = 0: RBx = 5.625 kips
∑F
8’
y = 0: RBy = 1125
. kips
D 5.625
RB = 5.6252 + 1125
. 2 = 12.58 kips
11.25
4
SOLUTION (1.10)
y
RAy 4 kN 3 kN
A
RAz 0.3 m T REy 5 kN
z
C
E
1m D
REz 2 kN
1m B x
0.5 m
0.5 m
(a) 0.3 m
∑M x = 0: . ) − 4( 015
3( 015 . ) + T − 5( 015
. ) + 2( 015
. )=0
or T = 0.6 kN ⋅ m
(b) ∑ M = 0: z ( 4 + 3)(1) + REy ( 2.5) = 0, REy = −2.8 kN
∑ M = 0: y − REz ( 2.5) + (5 + 2 )(3) = 0, REz = 8.4 kN
∑ F = 0: y RAy + 4 + 3 + REy = 0, RAy = −4.2 kN
∑ F = 0: z RAz + REz − 5 − 2 = 0, RAz = −14
. kN
Thus RA = 4.2 2 + 14
. 2 = 4.427 kN
RE = 2.8 2 + 8.4 2 = 8.854 kN
SOLUTION (1.11)
(a) Free-body Diagrams, Arm BC and shaft AB
y C T
x B
z M
A
T V T V
M
M V
Figure S1.11 B T
(b) At C:
V = −2 kN T = −50 N ⋅ m
At end B of arm BC:
V = 2 kN T = 50 N ⋅ m M = 200 N ⋅ m
At end B of shaft AB:
V = −2 kN T = −200 N ⋅ m M = −50 N ⋅ m
At A: V = 2 kN T = 200 N ⋅ m M = 300 N ⋅ m
5
SOLUTION (1.12)
0.15 m 200 N
D
y
C 36 N ⋅ m
T Ry
Rx A 0.2 m
Rz
Mz
z My
0.3 m B x
SOLUTION (1.13)
C 36 N ⋅ m
Ry
Rx WCD
T WAB 0.2 m
WBC
Rz A
Mz
My
z
0.3 m 0.15 m
B x
(CONT.)
6
1.13 (CONT.)
SOLUTION (1.14)
RCy 1.6 kN 150 mm
(a)
RAy 0.5 m D y C RCx
1m Bx B
0.25 m
RAx A D Dx B Bx E 1.6 kN 1.6 kN
By D 0.15 m By
Dx Dy
Free body pulley B
∑F x =0: Bx = 16
. kN →
∑F y = 0: B y = 16
. kN ↑
Free body CED
∑ M =0: D RCx ( 0.4) − 16 . ) = 0,
. ( 015 RCx = 0.6 kN ←
∑ F =0:x − Dx − 0.6 + 16
. = 0, Dx = 1 kN ←
∑ F =0:y RCy = D y
Free body ADB
∑ M =0: A D y ( 0.5) − B y (15
. ) = 0, D y = 4.8 kN , RCy = 4.8 kN ↑
∑ F =0:x − R Ay + D y − B y = 0, R Ay = 3.2 kN ↓
(CONT.)
7
1.14 (CONT.)
MG VG 0.6 m B
(b)
1.6
M G = 16
. ( 0.6 ) = 960 N ⋅ m, VG = 16
. kN
FG G
1.6
FG = 16
. kN
SOLUTION (1.15)
SOLUTION (1.16)
Segment ABE
y
A B
Vy
0.175 m x
192 N E
z Mz
At point E:
M z = −192( 0175
. ) = −33.6 N ⋅ m
V y = 192 N
8
SOLUTION (1.17)
F2
50 mm
F2
B D
C
Td
100 mm 50 mm
F1 Figure (a) Figure (c)
150 N ⋅m
A
50 mm F1 Figure (b)
SOLUTION (1.18)
4 kips 3 kips
3ft C
9 ft
B
Rx
A Ry 3
18 ft 12 ft 4
R
Free body-member BC
∑M C = 0: Rx (9) − R y (12) = 0
and
Rx = 43 (3.4 ) = 4.533 kips
Thus
FBC = R = ( 4.533) 2 + (3.4 ) 2 = 5.666 kips
9
SOLUTION (1.19)
P Free body-member AB
A E 40 o a
B
∑M A = 0:
RAx
4a 2a RE ( 4a ) − P cos 40 o ( a ) − P sin 40 o ( 6a ) = 0
RAy RE ∴ RE = 1156. P
Free body-member CD
RE
C 2a 4a D ∑M D = 0: RE ( 4a ) − RCy ( 6a ) = 0
RCx ∴ RCy = 0.771P ↑
E 30 o
RCy RD
∑ M = 0: R C D sin 30 o ( 6a ) − RE ( 2a ) = 0, RD = 0.771P
∑ F = 0: R
x Cx = RD cos 30 o = 0.668 P →
SOLUTION(1.20)
( a ) Power= P=(pA)(L)(n/60)
= (1.2)(2100)(0.06)( 1500
60 ) = 3.78 kW
Power required = P
e = 3.78
0.9 = 4.2 kW
( b ) Use Eq.(1.15),
T= 9549 kW
n = 9549(4.2)
1500 = 26.74 N ⋅ m
SOLUTION (1.21)
10
1.21 (CONT.)
Solving,
R f = 1.722 kips
and
∑F y = 0 : Rr − 3.2 + 1.722 = 0
or
Rr = 1.478 kips
(b)
We have V = 0, Fd = 0, F = 0.
See Fig. P1.21:
∑M A = 0 : Wa + R f L = 0
Thus
R f = La W = 110
60
(3.2) = 1.745 kips
So, ∑F y = 0 gives
Rr = W − R f = 3.2 − 1.745 = 1.455 kips
SOLUTION (1.22)
Refer to Solution of Prob. 1.21. Now we have Wt = 3.2 + 1.2 = 4.4 kips and friction force
F = 103.4 lb acts at point A.
(b) V = 0, Fd = 0, F = 0, as before,
∑M A = 0 : R f = aL Wt = 110
60
(4.4) = 2.4kips
and
Rr = Wt − R f = 4.2 − 2.4 = 1.8 kips
SOLUTION (1.23)
11
1.23 (CONT.)
TDE A
TAC
F
D
rD rA
F
Figure S1.23
SOLUTION (1.24)
SOLUTION (1.25)
= 3,125 lb ⋅ in. s
SOLUTION (1.26)
12
SOLUTION (1.27)
= 0.00225 = 2250 µ
SOLUTION (1.28)
2π ( r + ∆r ) − 2π r
(a) εc = 2π r = ∆r
r
( εc ) i = 0.3
150 = 2000 µ
(εc ) o = 0.2
250 = 800 µ
∆ro − ∆ri
(b) εr = ro − ri = 0.3− 0.2
250−150 = 1000 µ
SOLUTION (1.29)
(b) [
L AB ' = LCB ' = d 2 + (1.0012d ) 2 ]1
2
= 1.41506d
ε AB = ε BC = 1.41506 −1.41421
1.41421 = 601 µ
SOLUTION (1.30)
13
SOLUTION (1.31)
We have
L2BD = L2AB + L2AD
2 LBD ∆LBD = 2 L AB ∆L AB + 2 LAD ∆L AD
or
∆LBD = ∆L AB + ∆LAD
LAB LAD
LBD LBD (1)
= [ 150
250 (120 ) +
200
250 ( 200)]10 −3 = 0.232 mm
SOLUTION (1.32)
SOLUTION (1.33)
13.1 in.
C'
Therefore
− δ BE
ε BE = LBE = 0.049
40 = −1225(10−6 )
= −1, 225 µ
14
SOLUTION (1.34)
End of Chapter 1
15
CHAPTER 2 MATERIALS
SOLUTION (2.1)
SOLUTION (2.2)
Normal stress is
σ = PA = π
500
= 4744 ksi
(1 8)2
4
This is below the yield strength of 50 ksi (Table B.1).
We have
ε = δL = 18.50.3×12 = 0.001351 = 1351 µ
Hence
E = σε = 135(10
40,744
−6 = 30 × 10
)
6
psi
SOLUTION (2.3)
σ a = A = 0.125
P 4.8
= 38.4 ksi
Because σ a < S y (See Table B.1), Hooke's Law is valid.
( b ) Modulus of elasticity,
E = σεaa = 1324(10
38,400
−6 = 29 × 10
)
6
psi
16
SOLUTION (2.4)
SOLUTION (2.5)
We obtain
L AC = LBD = 152 + 152 = 2121
. mm
∆LAC
εx = LAC = . − 21.21
2117
21.21 = −1886 µ
∆LBD
εy = LBD = 21.22 − 21.21
21.21 = 471 µ
σx 100 (10 6 )
(a) E= εx = −1886 (10 − 6 )
= 53 GPa
εy
(b) ν= εx = 471
1886 = 0.25
(c) G= 53
2 (1+ 0.25 ) = 212
. GPa
SOLUTION (2.6)
Then, Eq. (1) becomes ε = 1−E2ν σ . Since σ and ε must have identical signs:
1 − 2ν ≥ 0 or ν = 12
SOLUTION (2.7)
We have σ x =
100 (103 )
3( 2 ) = 16.67 ksi
(CONT.)
17