Académique Documents
Professionnel Documents
Culture Documents
ASHISH AGARWAL
R.V.C.E, BANGALORE
Engineering Materials
An engineering material is a material in
the solid state whose properties are
technologically useful.
They can be metals or non metals.
Metals: Iron, Steel, Brass, Copper, Lead,
Tin, Aluminum, Titanium, Chromium,
Nickel, etc.
Non Metals:
Plastics, Rubber, Metallic carbides
and oxides, etc.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Mechanical Properties
The mechanical properties to be considered
while selecting a material for a machine
element are;
Strength: Ability to resist failure or
fracture
Stiffness: Ability to resist deformation
Ductility: Ability to undergo considerable
plastic deformation before failure.
Resilience: Energy absorbed in the elastic
range.
Toughness: Energy absorbed in the
plastic range.
Hardness: Resistance to indentation or
abrasion.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Machine Design
Machine design is defined as the use of
Scientific
principles,
Technical
information and imagination in the
description of a machine or mechanical
system to perform specific functions with
maximum economy & efficiency.
Scientific Principles: Knowledge of physics,
mathematics, statics & dynamics, vibrations &
heat transfer, etc.
Technical information: Information about
fastening devices, chain, belt & gear drives,
Venkatesh, Mech Dept,
Springs, bearings.Dr P R RVCE,
Bangalore
Presentation
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Definition of problem
Synthesis
Evaluation
Presentation
Recognition of need:
It
involves
the
realization
by
someone
that
a
problem exists for
which
some
corrective
action
should be taken.
Definition
of the
problem: It involves
a
thorough
specification of the
item to be designed.
Definition of problem
Synthesis It is the
conceptualization
of
the component by the
designer.
Analysis:
iterative
Synthesis
It
is
process
Improvisation
the
of
of
Presentation
till
the
design
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
optimized
is
achieved
Evaluation: It is concerned
with measuring the design
Recognition of need
Definition of problem
definition
phase.
This
Synthesis
Evaluation
Presentation
assess
operating
performance,
quality,
reliability, etc.
Presentation:
documentation
It
includes
of
the
Types of Design
There may be several types of design such as;
Adaptive design:
This is based on existing design, for example,
standard products or systems adopted for a
new application.
Conveyor belts, control system of machines
and mechanisms or haulage systems are some
of
the
examples
where
existing
design
Types of Design
Developmental design:
Here we start with an existing design but finally a
modified design is obtained.
A new model of a car is a typical example of a
developmental design .
New design:
This type of design is an entirely new one and requires
creative thinking to solve a problem.
Examples of this type of design may include designing
a small vehicle for transportation of men and material
on board a ship or in a desert. Some research activity
may be necessary.
manufacture
something.
and
construction
of
Gear
Manufacturers
Association
(AGMA)
American National Standards Institute
(ANSI)
American Society of
Mechanical Engineers
(ASME)
American Society of Testing & Materials
(ASTM)
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Prob 1:
A link shown in fig is required to transmit
a tensile load of 60 KN. Determine the
stresses induces at sections 1-1 & 2-2.
60
30
Section 1-1
mm
Section 2-2
90 mm
50 mm
60
30
Section 1-1
mm
Section 2-2
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
90 mm
50 mm
Prob 2:
A steel rod of circular cross section and
length 200 mm is subjected to a
compressive load of 40 KN. If the safe
stress in rod material is 80 MPa,
determine;
(i)Diameter of the rod
(ii)Contraction of the rod
Take the modulus of elasticity of the
material as 207 GPa.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
80
2
2
d
d
d2
4
Diameter of the rod d 25.23 mm
(ii) Contraction in length of the rod
F l
L L Eq 1.3 Page 2
A E
4 F l
4 40 103 200
=
0.0773 mm
2
2
3
d E Dr25.2
3 2Mech
07Dept,
10
P R Venkatesh,
RVCE, Bangalore
A
c
M E
The bending equation is
I
c R
where M = Bending moment at the section under consideration
I Moment of inertia about the neutral axis
c Distance of the neutral axis from outer fibers
E Elastic modulus of beam material
R Radius of curvature of the deformed beam
The bending stress may be written as;
Mc M M
I
A
c
Prob 1:
A short cantilever beam is of width 20
mm and depth 40 mm supports a
transverse load of 2 KN at a distance of
200 mm from its fixed end. Determine
the maximum bending stress in the
2 KN
beam.
20
A
40
200
2 KN
20
A
40
200
5333.33 mm3
6
6
M
4 105
Maximum bending stress
=
75MPa
Z
5333.33
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Prob 2:
A circular cross section beam of 50 mm
diameter and 1m length is supported
between
bearings.
Determine
the
bending stress induced in the beam
when it is subjected to a 5 KN transverse
load at its center.
5 KN
6 mm
1000 mm
5 KN
6 mm
1000 mm
1.25 106 N mm
4
4
D 3 503
Section modulus Z
12271.85mm3
32
32
M
1.25 106
Maximum bending stress
=
101.86 MPa
Z
12271.85
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Prob 3:
A steel saw blade 1 mm thick is bent into
an arc of a circle of 500 mm radius.
Determine the flexural stress induced
and the bending moment required to
bend the blade if it is 15 mm wide. Take
E=210 Gpa. R 500
1 mm
x
15
x
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
section x-x
R 500
1 mm
x
15
x
section x-x
1.25 mm 4
12
12
210 103 1.25
Bending moment M
336 N - m m
500
Mc
336 0.5
Maximum bending stress
=
134.4 MPa
Dr P R Venkatesh, Mech Dept,
I
1.25
RVCE, Bangalore
Prob 1:
A circular rod of 50 mm diameter is subjected
to a twisting moment of 1 KN-m. Determine
the shear stress induced in the shaft & the
angular twist per unit length of the shaft. Take
rigidity
modulus
asextreme
84 Gpa.
The shear
stress at the
radii is
D
Tr T 2 16 T 16 (1106 )
2
40.74
4N
/
mm
J
D3
(50)3
D4
32
The angle of twist per meter length
Tl
(1106 ) 1000
0.0194 rad
4
GJ 84 103 50
32
given by
A
F
2A
Prob 1:
A knuckle joint is used to connect shafts of
diameter D to transmit a tensile load of 5 KN.
Determine the diameter of the shaft and the
diameter of the pin required using permissible
tensile stress in the shaft as 60 MPa and the
shear stress in the pin as 40 MPa.
A knuckle joint is a
mechanical joint used to
connect two rods which
are under a tensile load,
when
there
is
a
requirement of small
amount of flexibility, or
angular
moment
is
necessary.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
60
D = 10.3 mm
2
2
D
D
The shear stress in the knuckle pin (double shear)
F
4 5000
40
Dia of pin d 8.92 mm 9 mm.
2
2A
2 d
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
F
F
Single Shear
Double Shear
F
4 5000
40
Dia of rivet 'd' 12.62 mm 13 mm.
2
A
d
The shear stress in the rivet (double shear)
F
4 5000
40
Dia of rivet 'd' 8.92 mm 9 mm
2 Dr P R Venkatesh, Mech Dept,
2A
2 d
RVCE, Bangalore
e
F
F
Fig 1.4, Sl no 5
page 13 DDHB
Mahadevan
Prob 1:
A steel bracket of rectangular cross section is
loaded as shown in fig. Determine the width b
at section A-A by limiting the tensile stress to
80 N/mm2.
60
5 KN
b
60
5 KN
b
60
F 5 103 83.33
d
A 60 b
b
The bending stress at extreme fibers of A - A
F e
bi bo
where Z is the section modulus
Z
For rectangular section,
bh 2
Z=
L Table1.3, Sl no (a), column 5, Page 8
6
5 103 60 500
b
2
b
b 60
6
The max stress at the critical section is
F F e
83.33 500
80
A
Z
b
b
Dr b
P R=Venkatesh,
Dept,
7.354 Mech
8 mm
RVCE, Bangalore
Prob 2:
Determine the cross sectional dimensions for
the wall bracket shown in fig if the maximum
stress in the material of the bracket is limited
to 120 MPa. Take the depth of the section
equal to three times its width.
0
30
600 mm
10 KN
h
1200 mm
fig 1 (c)
600 mm
30
10 KN
h
1200 mm
1200
610
N - mm
Venkatesh, Mech Dept,
RVCE, Bangalore
30
600 mm
10 KN
h
1200 mm
1.
5
6
6
N
/
mm
3
3
Z Dr P R Venkatesh,
1.5 bMech
b
Dept,
RVCE, Bangalore
600 mm
30
10 KN
h
1200 mm
FH 8660.25 2886.75
2
Direct Stress due to FH ; d
N
/
mm
bh
3b 2
b2
Maximum stress max = b + d( occurs at top fibres)
7.46410 6 2886.75
120
3
b
b2
120b3 - 2886.75b - 7.46410 6 0
Solving, b = 40 mm, h = 3b = 120 mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
5t
t
7.5t
5t
t
7.5t
6
t (5t ) 2
3
Z
4.167
M
112500
Bending stress
Z 4.167 t 3
27000
2
N
/
m
m
3
t Dept,
Dr P R Venkatesh, Mech
RVCE, Bangalore
5t
t
7.5t
F
Direct tensile stress d
A
15000 3000
2
=
N
/
mm
5t 2
t2
Total max stress (occurs at inner fibers)
max b d
ut
300
But max
120 MPa
FOS 2.5
27000 3000
120
+ 2
3
t
t
3
120t 3000t 27000 0
t = 7.434 8 mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
4:
80 KN
150
100
40
100
40
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
B=100
80 KN
d=40
150
h=100
100
H=140
40
100
40
c1
c2
B=100
80 KN
d=40
150
100
h=100
H=140
40
100
c1
c2
13.667
10
mm
Mc1
Bending stress at inner fiber bi
I
16.40 10 6 55
2
bi
66
N
/
mm
(Tensile)
6
Dr P R Venkatesh, Mech Dept,
13.667 10
RVCE, Bangalore
B=100
80 KN
d=40
150
100
h=100
40
100
H=140
c1
c2
40
Mc2
16.40 10 6 85
2
bo
102
N
/
mm
(
compressive)
6
13.667 10
F 80 103
Direct tensile stress d
10 N / mm 2
A
8000
Total stress at inner fiber i bi d 66 + 10 = 76 N / mm 2
2
Total stress at outer fiberDrP oR Venkatesh,
bo Mech
Dept,
-102
+
10
=
-92
N
/
mm
d
RVCE, Bangalore
A
F
100
A
F
100
502
Cross section area A =
= 1963.5 mm 2
4
Bending moment M = F (150 +150)= 300 F N - mm
M 32M 32 300 F
2
Bending stress =
0.0245F
N
/
mm
3
3
Z D
50
(It is compressive at inner
fiber
&
tensile
at
outer
fibers)
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
A
F
100
F
F
Direct compressive stress =
0.5093 10 -3 F
A 1963.5
Max compressive stress occurs at inner fibers
0.0245 F 0.5093 10-3 F 100
F = 4000N
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
1,2
x y x y
2
xy L L Eq 1.11a Page 2
2
2
x y
x y
2
2
2
max
x y
2
xy
2
L L Eq 1.12 Page 2
25 MPa
40 MPa
25 MPa
40 MPa
30 MPa
x y
x y
2
1,2
40 30
40 30
2
2
1
25
48.012N
/
m
m
2
2
2
2
252 38.012N / mm 2
2
max
x y
2
xy
2
40 30
2
2
25
43.012
N
/
mm
Dr P R Venkatesh, Mech Dept,
2
RVCE, Bangalore
400 N-m
200 mm
6 KN
400 N-m
200 mm
56.59
N
/
mm
Z D3
603
Twisting moment (given) T = 400 N m = 400 10 3 N mm
T
16T 16 400 10 3
2
Shear stress =
9.43
N
/
mm
Z p D3
603
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
6 KN
400 N-m
200 mm
2
2
2
56.59
56.59
2
2
1
2
2
56.59
2
2
9.432 29.825 N / mm 2
400 N-m
10KN
200 mm
6 KN
400 N-m
10KN
200 mm
56.59
N
/
mm
Z D3
603
(Tensile at top fibers A & compressive at bottom fibres B)
F
4F
4 10 10 3
2
Direct tensile stress d =
3.54
N
/
mm
A D2
602
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
6 KN
400 N-m
10KN
200 mm
9.43 N / mm
3
3
Zp D
60
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
6 KN
400 N-m
10KN
200 mm
1,2@ A
1,2@ A
A
A
2
2
60.125
60.125
2
2
max@ A
60.125
2
2
9.43
31.51
N
/
mm
6 KN
10KN
400 N-m
200 mm
1,2@ B
1,2@ B
B
B
2
2
53.05
53.05
2
2
max@ B
53.05
2
2
9.43
28.15
N
/
mm
O 50
Web
150
Pin
O 80
A
Dr P RShaft
Venkatesh, Mech Dept,
Crank
RVCE, Bangalore
12 KN
50
25
25
100
O 50
Web
12 KN
Pin
150
O 80
A
Crank Shaft
23.87
N
/
mm
Z D3
803
Twisting moment T = 12 103 150 = 18 10 5 N mm
T
16T 16 18 10 5
2
Shear stress =
17.9
N
/
mm
Z p DrDP3R Venkatesh,
Mech
803Dept,
RVCE, Bangalore
max
max
2
2
23.873
23.873
2
2
17.92
max
2
2
23.873
2
2
17.9 21.52 N / mm
2 Dr P R RVCE,
Venkatesh, Mech Dept,
Bangalore
25
25
100
O 50
10 KN
150
O 80
50
25
25
100
10 KN
F
O 50
150
ycos
O 80
T=F x ycos
23.87
N
/
mm
Z D3
803
Twisting moment T = 12 103 150 cos 300 = 15.59 10 5 N mm
T
16T 16 15.59 10 5
2
Shear stress =
15.51
N
/
mm
3
Z p DrDP3R Venkatesh,Mech
80Dept,
RVCE, Bangalore
max
max
2
2
23.873
23.873
2
2
15.512
max
2
2
23.873
2
2
15.51 19.57 N / mm
2 Dr P R RVCE,
Venkatesh, Mech Dept,
Bangalore
100 N-m
9 KN
A
100 N-m
20.535
N
/
mm
Z D3
503
F
4F
4 9 10 3
2
Direct tensile stress d =
4.
5
84
N
/
mm
A D2
502
Total maximum normal stress =b +d
= 20.535 +4.584 = 25.12 MPa
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
4.074
N
/
mm
Z p D 3 503
Maximum principal stress
max
2
2
max
25.12
25.12
2
2
4.074
25.764
N
/
mm
2
2
max
2
2
25.12
2
2
4.074
=
13.2
N
/
mm
2
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Theories of failure
The design of machine parts subjected
to combined loads should be related to
experimentally determined properties of
material under similar conditions.
However, it is not possible to conduct
such tests for different combination of
loads and obtain mechanical properties.
In practice, the mechanical properties
such as yield strength, ultimate strength
and percentage elongation are obtained
from a simple tension test.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Theories of failure
Theories
of
failure
provide
a
relationship between the strength of the
machine
component
subjected
to
complex state of stress with the
mechanical properties obtained from
tension test.
With the help of these theories, the data
obtained in tension test can be used to
determine the dimensions of the
component, irrespective of the nature of
stresses induced in the component due
to complex loads.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Theories of failure
Several theories of failure have been
proposed, each assuming a different
hypothesis of failure.
The important theories are;
1.Maximum Principal Stress theory
(Rankines theory)
2.Maximum strain theory (St. Venant's
theory)
3.Maximum
shear
Stress
theory
(Coulomb, Tresca & Guests theory)
4.Distortion energy theory (or) Shear
Dr P R Venkatesh, Mech Dept,
energy theory (Hencky
Von Mises theory)
RVCE, Bangalore
x
y
2
2
yt
For safe design, e =
for ductile materials &
n
ut
e
for brittle materials where n = factor of safety
n
* Experimental investigations suggest that Rankine's theory gives good predictions
e ( 1 2 )
Failure occurs when
e ( 1 2 )
E
E
2
1
yt
For safe design, e =
for ductile materials &
n
ut
e
for brittle materials where n = factor of safety
n
* St.Venant's theory predicts smaller value of stress than maximum
P Rwidely
Venkatesh,
Mech Dept,
principal stress theory & henceDrnot
used.
RVCE, Bangalore
e
We know that shear stress at yield, e =
2
( 2 )
Failure occurs when e max 1
e ( 1 2 )
2
2
e
x
y
2
yt
n
where n = factor of safety
* Max shear stress theory is widely used for predicting the failure of
Dr P R Venkatesh,
ductile materials such as transmission
shafts.Mech Dept,
RVCE, Bangalore
combined loading is
e2 12 22 1 2 OR e 12 22 1 2
yt
n
where n = factor of safety
* Experiments have shown that distortion energy theory is in better agreement for
Dr P R Venkatesh, Mech Dept,
yt
n
ut
e
for brittle materials where n = factor of safety
n
* As the experimental investigations do not support predictions
as per this theory, is not used widely as other theories.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Prob 1
A machine member C 40 steel is loaded
in the following ways;
(a) x = 40 MPa and y = 20 MPa
(b) x = 60 MPa and xy = 40 MPa
(c) x = 60 MPa , y = -20 MPa and xy = 30
MPa
Determine the factor of safety in each
type of loading by using;
Maximum Principal Stress theory
(Rankines theory)
Maximum shear Stress theory (Coulomb,
Dr P R Venkatesh, Mech Dept,
Tresca & Guests
theory)
RVCE, Bangalore
324 1
2
n
2
2. Maximum shear stress theory Tresca's theory
yt
2
For safe design,
x y 4 2 L Eqn 2.10, Page16
n
324
2
324 1
2
n
2
2. Maximum shear stress theory Tresca's theory
yt
2
For safe design,
x y 4 2 L Eqn 2.10, Page16
n
324
2
324 1
2
n
2
2. Maximum shear stress theory Tresca's theory
yt
2
For safe design,
x y 4 2 L Eqn 2.10, Page16
n
324
2
Prob 2
A steel shaft is subjected to a bending
moment of 9 KNm & a twisting moment
of 12 KNm. The yield strength of steel is
360 MPa & factor of safety is 2.
Determine the permissible diameter of
the shaft by using;
1.Maximum Principal Stress theory
(Rankines theory)
2.Maximum
shear
Stress
theory
(Coulomb, Tresca & Guests theory)
3.Distortion energy theory (or) Shear
energy theory (Hencky Von Mises theory)
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
3
D
D3
91.673106
2
N
/
mm
3
D
Twisting moment T = 12 KNm = 12 10 6 N mm
6
T
16T 16 12 10 6
Shear stress =
3
Zp D
D3
61.11106
2
N
/
mm
D3
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
yt 1
2
360 1 106
2
2
2 D
Diameter of shaft D = 87.89 90 m m
2. Maximum shear stress theory Tresca's theory
yt
2
For safe design,
x y 4 2 L Eqn 2.10, Page16
n
360 106
2
3 91.673 0 4 61.112
2
D
Diameter of shaft D = 94.68 95 mm
3. Shear energy of distortion theory or Hencky's theory
yt
For safe design,
x2 x y y2 3 2 L Eqn 2.11a, Page16
n
360 106
3 91.6732 0 02 3 61.112
2
D
P R Venkatesh,
Mech Dept,
Diameter of shaft D = Dr
91.97
95 mm
RVCE, Bangalore
Prob 3
A mild steel shaft of 60 mm diameter is
subjected to a bending moment of 2.5 KNm & a
twisting moment T. If The yield strength of
shaft material in tension is 200 MPa, find the
maximum value of torque at which the shaft
just begins to yield, according to;
1.Maximum Principal Stress theory
2.Maximum shear Stress theory
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
117.89
N
/
mm
D3
603
Let the shear stress induced be equal to ' '
1. Maximum principal stress theory or Rankine's theory
2
1
1
2
i.e. 200 (117.89 0) 117.89 0 4 2
x
y
2
2
117.89
117.89 0 0 3 2
2
Prob 4
Determine the diameter of the shaft loaded as
shown in fig based on maximum shear stress
theory. Take yield point as 380 MPa and factor
of safety as 2.
N
/
mm
D3
D3
D3
16T 16 5 10 5 2.5465 106
2
Shear stress
N
/
mm
D3
D3
D3
Maximum shear stress theory Tresca's theory
yt
2
For safe design,
x y 4 2 L Eqn 2.10, Page16
n
380 106
2
3 2.5465 0 4 (2.5465) 2
2
D
Diameter of shaft D = 31.06 35 mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Stress Concentration
In the basic stress equations for
tension, compression, bending &
torsion, it is assumed that there are
no discontinuities in the cross section
of the machine component.
But while designing a machine
component it is necessary to have
changes in cross sections such as
hole, notch, keyway, etc.
Such discontinuities will alter the
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Stress Concentration
In the basic stress equations for
tension, compression, bending &
torsion, it is assumed that there are
no discontinuities in the cross section
of the machine component.
But while designing a machine
component it is necessary to have
changes in cross sections such as
hole, notch, keyway, etc.
Such discontinuities will alter the
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Prob 1
A steel plate of width 50 mm, thickness
10 mm, with a hole of diameter 10 mm
drilled at its center is subjected to a
tensile load F. Determine the load F
the material can withstand by taking the
stress concentration into account. The
maximum stress in the member is 60
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
F
w
a 10
max
60
2.5
, nom = 24MPa
nom
nom
F
F
Also, nom
24
F =9600 N
( w a )t
(50 10) 10
But kt
Prob 2
Determine
the
maximum
stress
D=80
9 KN
d
R 10
10
9 KN
D=80
9 KN
d
R 10
10
1.333, kt = 2.12
d 60
d 60
F
9000
nom
15 MPa
t d 10 60
max
max
But kt
2.12
nom =31.8 MPa
nom
15 Mech Dept,
Dr P R Venkatesh,
RVCE, Bangalore
Prob 3
A rectangular plate as shown in fig is subjected
to an axial pull of 200 KN. Determine the
thickness of the plate if the plate material is
made of C 60 steel and the factor of safety
desired is 2.
200 KN
200
200 KN
50
50
R 10
200 KN
200
200 KN
50
50
R 10
206MPa
n
2
a 50
Considering the hole section (A - A), for
0.25, kt = 2.45
w 200
(fig 2.8, page 33)
max
206
But kt
2.45
nom =84.1 MPa
nom
nom
nom
F
200 103
84.1
t =15.85 16 mm
Dr (200
P R Venkatesh,
(w a) t
50)Mech
t Dept,
RVCE, Bangalore
200 KN
200
200 KN
50
50
R 10
1.11 & =
=0.055, kt = 2.5. (fig 2.4, page 31)
d 180
d 180
max
206
But kt
2.5
nom =82.4 MPa
nom
nom
F
200 103
nom
82.4
t =13.48 14 mm
d t
180 t
Select higher value for safe design, i.e. t =16 mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Prob 4
r5
85
50
r5
85
Fig 2.8, Page 33,
Mahadevan DDHB
50
r5
85
At the fillet section, (fig 2.6, Page 32, for stepped bar in tension)
D 85
r
5
1.7,
0.1, kt = 2.18
d 50
d 50
At the hole section, (fig 2.8, Page 33, for plate with a hole)
a
Corresponding to kt 2.18,
=0.5
w
a
Prob 5
A shaft is stepped down from 80 mm
diameter with a fillet radius of 6 mm.
Determine the maximum stress induced
in the shaft when subjected to;
(i)Bending moment of 200 Nm.
(ii)Twisting moment of 400 Nm.
r6
r6
r6
2,
0.15, kt =1.55
d 40
d 40
32 M 32 200 103
2
nom
31.83
N
/
mm
d3
403
max
But kt
max kt nom 1.55 31.83 49.34
nom
2
Max stress induced
in
the
shaft
=49.3
4
N
/
mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
r6
r6
2,
31.83
N
/
mm
d
403
max
But kts
max kts nom 1.34 31.83 42.65
nom
2
Max shear stress induced
in
the
shaft
=
42
.65
N
/
mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Prob 6
A grooved shaft of larger diameter 60 mm has
a semicircular groove of radius 5 mm.
Determine the maximum stress induced in the
shaft taking stress concentration into account
when subjected to;
(i)An axial load of 40 KN.
(ii)A bending moment of 400 Nm.
(iii)A twisting moment of 500 Nm.
r5
r5
r5
1.2,
0.1, kt = 2.17
d 50
d 50
4 F 4 40 103
2
nom
20.372
N
/
mm
d2
502
max
But kt
max kt nom 2.17 20.372 44.2
nom
2
Max stress induced
in
the
shaft
=44.2
N
/
mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
r5
r5
1.2,
0.1, kt =1.89
d 50
d 50
32 M 32 400 103
2
nom
32.595
N
/
mm
d3
503
max
But kt
max kt nom 1.89 32.595 61.6
nom
2
Max stress induced
in
the
shaft
=
61.6
N
/
mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
r5
r5
1.2,
20.372
N
/
mm
d
503
max
But kts
max kts nom 1.46 20.372 29.74
nom
2
Max stress induced
in
the
shaft
=
29.74
N
/
mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Prob 7
A shaft of diameter 1.5d is stepped down
to diameter d with a fillet radius of d/8. It
carries a transverse load of 60 KN as shown
in fig. Find suitable diameter d if the shaft
is made of SAE 1045 annealed steel.
Assume factor of safety 2.5.
r=d/8
D=1.5 d
d
200
300
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
60 KN
r=d/8
D=1.5 d
60 KN
d
200
300
yt 310
max
124MPa
n
2.5
M (at critical section) = 60 10 3 200 = 12 10 6 N - mm
d
D 1.5d
r
For
1.5,
8 0.125, kt =1.58
d
d
d
d
(fig 2.16, Page 37, for stepped shaft in bending)
max
max 124
But kt
nom
78.48 N / mm2
nom
kt
1.58
32 M
32 12 106
But nom
78.48
3
d
d3
d =116 mm, D =1.5d
mm
& r =0.125d =14.5 mm
Dr P =174
R Venkatesh,
Mech Dept,
RVCE, Bangalore
Prob 8
A shaft of diameter 60 mm has a
semicircular groove of radius 5 mm & is
made of steel having allowable shear stress
of 60 MPa. Determine the safe power that
5
can be transmitted at r900
rpm.
D
r5
1.2,
=41.1 MPa
nom
kts 1.46
16T
16 T
Also nom
41.1
3
d
503
T 1008.64 10 3 N - mm=1008.64 Nm
2 NT
2 900 1008.64
P
=
95.1 KW
60000
60000
Power that can be transmitted by the shaft =95.1 KW
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Prob 9
A stepped shaft shown in fig is subjected
to a transverse load. The shaft is made of
steel with an ultimate strength of 400 MPa.
Determine the diameter d based on a
factor of safety of 2.
8 KN
A
d/5
d/10
d
250
2d
100
d
125
25
8 KN
A
d/5
d/10
d
250
2d
100
d
125
25
= 2400 N
l
600
F a 8000 350
Support reaction at B , RB
=5600 N
l
600
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
8 KN
A
d/5
d/10
d
250
2d
100
d
125
25
There are two critical sections at left fillet & right fillet.
(i) Considering left fillet :
Bending moment M RA 250 2400 250 6 105 N - mm
d
D 2d
r
For
2,
10 0.1, kt =1.74
d
d
d
d
(fig 2.16, Page 37, for stepped shaft in bending)
max
ut 400
But kt
, Here, max
200 MPa
nom
n
2
nom
max 200
114.94 N / mm2
kt
1.74
But nom
32 M
32 6 105
114.94
d 37.6 40mm
3
3
d
dDept,
Dr P R Venkatesh,
Mech
RVCE, Bangalore
D 2d
r
For
2,
5 0.2, kt =1.44
d
d
d
d
(fig 2.16, Page 37, for stepped shaft in bending)
max
max 200
But kt
, nom
138.9 N / mm2
nom
kt
1.44
32 M
32 1.4 105
But nom
138.9
d 21.73 25 mm
3
3
d
d
Selecting the higher of the two values for safe design,
d =40 mm, D = 2d =80 mm ,
r( left fillet)= 4 mm, r( right fillet) = 8 mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
Prob 10
An infinite plate with an elliptical cut out
having major diameter 60 mm and minor
diameter 30 mm is subjected to uniaxial
tension. Determine the stress concentration
factor when;
(i)Load is at right angles to the major axis
(ii) Load is parallel to the major axis
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore
30
60
F
30
F
kt 1 1 5
c
15
2c
kt 1
b
30
1 2
30