3.

A hanger (or a conveyor system) extends outward from two supports as shown in figure P3. The load at the right end varies from 600 lb to 3800 lb. Design the hanger.

A
Given:

A Hanger extending outward from two supports Minimum load, Pmin = 600 lb Maximum load, Pmax = 3800 lb Required: Design the hanger Initial design decision: Steel bar with rectangular cross-section having its long dimension vertical. Cylindrical holes drilled on the neutral axis of the bar at points A, B, and C. Cylindrical pins at holes A and B to attach the bar to the conveyor. Thickness should be fairly large to provide good bearing surface for the pins and to ensure stability upon subjection to stress. Thickness, t Height, h = = 1 in 4 in

Dimensions of the bar :

Proposed material

AISI 1050 OQT 400 Steel Properties (from Appendix 3): Ultimate strength, SU Yield strength, SY = = 143 ksi 110 ksi

Design Factor

N = 4; Since the actual use pattern for the system is uncertain and shock loading is likely to occur

Horizontal Bar:
NEUTRAL AXIS

C
h t

Analysis: >> Solving for the mean and alternating Forces, Pm and Pa :
P max + P min 2 P max P min 2 3800 lb + 600 lb 2 3800 lb 600 lb 2

Pm = Pa =

= =

= 2 200 lb = 1 600 lb

>>

Free-body diagram of the horizontal bar:

24

36

FA

FB

Solving for the reaction forces at A and B:

MB = 0 Fy = 0

24FA 36P = 0 FA FB + P = 0

; ;

FA =

36 24

FB = FA + P

Considering minimum load, Pmin = 600 lb: FA =

36

P 24 min

36 24

600 lb = 900 lb

FB = FA + P = 900 lb + 600 lb = 1500 lb Considering maximum load, Pmax = 3800 lb: FA =

36

P 24 max

36 24

3800 lb = 5700 lb

FB = FA + P = 5700 lb + 3800 lb = 9500 lb

>> Shear and Moment diagrams Considering the minimum load

24

36

FA

FB
600 lb

Pmin

SHEAR DIAGRAM - 900 lb MOMENT DIAGRAM - 21 600 lb-in

Mmin = 21 600 lb in

Considering the maximum load

24

36

FA

FB
3800 lb

Pmax

SHEAR DIAGRAM -5700 lb MOMENT DIAGRAM

- 136800 lb-in

Mmax = 136 800 lb in

>>

Solving for the mean and alternating moment, Mm and Ma :

Mm = Ma =
>>

M max + M min 2 M max M min 2

= =

136 800 lb in + 21 600 lb in 2 136 800 lb in 21 600 lb in 2

= 79 200 lb in = 57 600 lb in

Solving for actual endurance strength, Sn :

Sn = Sn (CS )(CM )(CST )(CR )

Theoretical endurance strength, Sn From figure 5-8, for machined steel with Su = 143 ksi, Sn 50 ksi Size factor, CS For the equivalent diameter, DE for rectangular cross-section, DE = 0.808 ht = 0.808 4in 1in = 1.616 in

From figure 5-9, for diameter = 1.616 in, CS 0.831 Material factor, CM For wrought steel, Type-of-stress factor, CST For repeated bending stress, Reliability factor, CR For a reliability of 99.9%, So, CR = 0.75 CST = 1.0 CM = 1.0

Sn = (50 ksi) (0.831)(1.0)(1.0)(0.75) = 31.1625 ksi

>> Determining the size of the hole in the horizontal bar (size of pins) Since the pins will experience fluctuating shear stresses (Case H), the following equation will be used for the analysis:

1 m a = + N Ssu Ssn
Where:

m =

Pm 2A

a m = 2A

Ssu = 0.75Su
Pa 2A

Ssn = 0.577Sn

1 N

m S su

a S sn

Pm 2A

0.75S u

0.577S n

1 2A

Pm 0.75S u

Pa 0.577S n

Solving for the cross-sectional area of the pin: A =

N 2 Pm 0.75S u

Pa 0.577S n

4 2

2 200 lb 0.75 143000

lb in 2

1600 lb 0.577 31162 .50

lb in 2

A = 0.2190 in2 Solving for the minimum allowable diameter of the pin: A = 0.2190 in2 = D =
4A 4

D2 = 0.5281 in

4 0.2190 in 2

Since the diameter is quite small considering the loads and other stress like the bearing stress and wear at the surfaces that contact the tabs of the bar, a larger diameter would be preferred. Specification: >>
Stress concentration factor, k t

Use D = 0.75 in

From figure A15 3, for flat plate with a central hole, d Assuming h 0.50, Use k t = 1.0 >>
Determining the section modulus of the cross-sectional area of the bar

Solving for the minimum section modulus, Smin:

Since the bar will experience fluctuating normal stress due to bending (Case G), the Goodman Method is applicable. The following equation will be used for the analysis:

1 m k t a = + N Su Sn
Where:

m =
1 N
Mm S min ktM a S min

Mm Smin
1 S min

and

m =
kt Ma Sn

Ma Smin

Su 1 N

Sn

=
kt Ma Sn

Mm Su 1 4

Smin =

Mm Su

79 200 lb in 143000
lb in 2

1.0 57 600 lb in 31162 .50

lb in 2

Smin = 0.6006 in3 Solving for the required height section, h: For solid rectangular section, S = h =
6S t th 3 6

6 0.6006 in 3 1.0 in

= 1.8983 in 1.90 in

The table of preferred basic sizes in the decimal-inch system, Table A2 1, recommends h = 2.0 in.

Since the actual height is not identical to the assumed height, h = 4 in, the solution is not acceptable. Recalculating the height with all the related parameters:
DE = 0.808 ht = 0.808 2in 1in = 1.14 in ; CS 0.865

Sn = (50 ksi) (0.865)(1.0)(1.0)(0.75) = 32.4375 ksi Smin =

1 4 79 200 lb in 143000
lb in 2

1.0 57 600 lb in 32437 .50

lb in 2

= 0.5824 in3

h =

6S t

6 0.5824 in 3 1.0 in

= 1.8693 in 1.87 in

Hence, for the actual height, use h = 2.0 in Recalculating the pin diameter: A =
4 2 2 200 lb 0.75 143000
lb in 2

1600 lb 0.577 32437 .50

lb in 2

= 0.2120 in2

D =

4A

4 0.2120 in 2

= 0.5195 in

Use D = 0.75 in
Solving for the actual ratio of the diameter and height at point C, to check if the
d h

earlier assumption
d h

< 0.50 is correct,

0.75 in 2 in

= 0.375

Since the actual value satisfies the assumed value, then the earlier assumption k t = 1.0 , is acceptable. Solving for the actual section modulus of the cross section with the holes in it, S =
t h3 d3 6h

1 in

2 in 3 0.75 in 3 6 2 in

= 0.6315 in3 0.63 in3

Since the actual value is larger than the minimum required value, the size of the cross section is satisfactory with regard to stress due to bending. >> Therefore, The following are the final design decisions for the horizontal bar of the hanger (or conveyor system):

Material Size

: :

AISI 1050 OQT 400 Steel Rectangular cross-section Section Modulus, S = Thickness, t = Height, h = Hole diameter = 0.63 in3 1 in 2 in 0.75 in

(for the pins)