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MACHINE DESIGN

ASHISH AGARWAL
R.V.C.E, BANGALORE

Dr P R Venkatesh, Mech Dept,


RVCE, 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

Factors affecting selection of material


The major factors considered are;
(i)Availability: The material should be
readily available in the market, in large
enough quantities to meet the requirement.
(ii)Cost: The cost of material and the cost
of manufacturing will be a limiting factor for
the designer.
(iii) Mechanical Properties: Different
mechanical properties will be important for
different types of loading & service
conditions.
Ex: Connecting rod should have high endurance strength
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

Piston rings should have high wear

Factors affecting selection of


material (contd)
(iv) Manufacturing Considerations:
The manufacturing processes such as
Casting, Forging, Extrusion, Welding &
Machining govern the selection of
material.
Ex:
For high strength bolts, axles & shafts, free
cutting steels (with small % of sulphur) are
suitable as they have excellent machinability.
For complex shapes, castability or ability of
Dr P R Venkatesh,
Dept,
the molten metal
to Mechflow
into intricate
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

Six phases of machine design


(Shigleys Model)
According to Shigley, the process
of designing
Recognition of need
consists of six phases as follows;
1.Recognition of need
Definition of problem
2.Definition of the problem
Synthesis
3.Synthesis
4.Analysis & Optimization
Analysis & Optimization
5.Evaluation
6. Presentation
Evaluation

Presentation
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

Six phases of machine design


(Shigleys Model)
Recognition of need

Definition of problem

Synthesis

Analysis & Optimization

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.

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Six phases of machine design


(Shigleys Model)
Recognition of need

Definition of problem

Synthesis It is the
conceptualization
of
the component by the
designer.
Analysis:
iterative

Synthesis

Analysis & Optimization

It

is

process

Improvisation

the
of
of

design and redesign


Evaluation

Presentation

till

the

design
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

optimized
is

achieved

within the constraints

Six phases of machine design


(Shigleys Model)

Evaluation: It is concerned
with measuring the design

Recognition of need

against the specifications


established at the problem

Definition of problem

definition

phase.

This

often requires fabrication

Synthesis

and testing of a prototype


to

Analysis & Optimization

Evaluation

Presentation

assess

operating

performance,

quality,

reliability, etc.

Presentation:
documentation

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

existing

design

systems are adapted for a particular use.

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.

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Types of Design based on methods


Rational design:
This is based on determining the stresses and strains of
components using mathematical formulae of principle
of mechanics and thereby deciding their dimensions.
Empirical design:
This is based on empirical formulae which in turn is
based on practice & past experience.
Industrial design:
These are based on industrial considerations and
norms viz. market survey, external look, production
facilities, low cost, use of existing standard products.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

Factors to be considered in machine design


There are many factors to be considered while
tackling a design problem.
a)What device or mechanism to be used? This
would decide the relative arrangement of the
constituent elements.
b)Material
c)Forces on the elements
d)Size, shape and space requirements. The final
weight of the product is also a major concern.
e)The method of manufacturing the components
and their assembly.
f)How will it operate?
g)Reliability and safety aspects
Dr P R Venkatesh, Mech Dept,
h)Inspectability
RVCE, Bangalore

Standards and Codes


A standard

is a set of specifications for

parts, materials or processes intended to


achieve uniformity, efficiency and a specified
quality.
One of the important purposes of a standard
is to limit the variety, sizes & shapes.
A code is a set of specifications for analysis,
design,

manufacture

something.

and

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

construction

of

Standards and Codes


The organizations listed below have established
standards and design codes;
American

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

Design against Static Load


A static load is defined as a force that is gradually
applied to a mechanical component and which does not
change in magnitude & direction w.r.t time.
A ductile material will undergo a considerable
amount of plastic deformation before necking.
(cup & cone)
Ex: Steel, Aluminum, Copper, etc.
A brittle material undergoes little amount of
plastic deformation prior to fracture.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Selection of value for factor of


safety
The common range for factor of safety
is 1.25 to 4 for metals & 5 to 10 for
concrete, wood, etc.
The selection of an appropriate value of
FOS is based primarily on the following
factors;
a)Degree of uncertainty about the
loading.
b)Degree of uncertainty about the
material strength.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

STRESSES IN MACHINE ELEMENTS


Stress in a machine member is defined as
the intensity of internally distributed forces
that resist the external forces acting on that
element.
The unit commonly used is Mega Pascal
(MN/m2) or 106N/m2 which is numerically
equal to N/mm2.
1 Pascal
= 1N/m2
1 Kpa (Kilo Pascal) = 1000 N/m2
1 Bar
= 100 Kpa
=105 N/m2
1MPa (Mega Pascal)
= 106 N/m2=1
N/mm2
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

Mechanical properties of metals


CAST IRON: (2 to 4% carbon):
It is classified on the basis of
distribution of carbon content in the
microstructure.
For example, FG 300 indicates it is
cast iron with carbon in the form of Free
Graphite flakes and its ultimate tensile
strength if 300 MPa.
SG 450 (Spheroidal graphite cast
iron) has tensile strength of 450 MPa.
For properties of Cast iron, refer Table
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

Mechanical properties of metals


STEELS:
(i)Low Carbon Steels (Or Mild Steel): <
0.3 % carbon
(ii)Medium carbon Steel : 0.3 to 0.5%
carbon
(iii)High carbon Steels: (0.5 to 1%
Carbon)

It is designated by, 100 times the


percentage of carbon, the letter C, followed
by 10 times the percentage of manganese.
For example, 40C8 or C 40 indicates
the average carbon percentage is 0.4%
and average percentage of manganese is
0.8%.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Rectangular cross section member under axial tension

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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

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

(i) Diameter of the rod


F
Compressive stress in the rod L L Eq 1.1 Page 2
A
F
4 F
4 40 103

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

Machine Elements subjected to


lateral bending
When a beam is subjected to a load in
the transverse direction, it is subjected
to pure bending moment.
It results in tensile stresses on the
convex side and compressive stresses
on the concave side and zero stress on
M
the neutral
layer. R
M
N

A
c

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

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

where Z= is known as section modulus


I
I
Z
c
c
M

A
c

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

2 KN
20
A
40
200

The maximum bending stress occurs at the fixed point A


M F l 2000 200 4 105 N mm
bh 2 20 402
Section modulus Z

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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

5 KN
6 mm
1000 mm

The maximum bending stress occurs at the point of


application of the load.
F l 5000 1000
M

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

The bending moment equation is


M E
EI

M
L L L Eqn 1.16 Page 3
I
c R
R
bh3 15 13
Moment of inertia I

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

Machine Elements subjected to


Torsion
When a rod or shaft is subjected to a twisting
moment about its axis, it is subjected to pure
Torsion.
It results in torsional shear stresses which
vary linearly with the radius of the shaft.

Dr P R Venkatesh, Mech Dept,


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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Machine Elements subjected


transverse shear
When a component is subjected to a force
perpendicular to its axis, so as to shear it at
one or more cross sections, it is said to be
under transverse shear.
The shear stress in case
of single shear is
F

given by
A
F

2A

In case of double shear,


Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

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

The tensile stress in the rod is


4 F
4 5000

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

Prob 2: Determine the diameter of the rivet


subjected to
(i) Single shear and (ii) Double shear due to a
load of 5 KN. The permissible shear stress in
F
d
F
the
rivet isd 40 MPa.
F

F
F

Single Shear

The shear stress in the rivet (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

Machine Elements subjected to


eccentric loading
Many structural and machine
members are subjected to loads
that are offset from their centroidal
axes.
Such
members
may
be
considered as elements subjected
to an axial load coupled with a
bending moment.
The stresses may then be added
algebraically to evaluate the total
The total
stresscritical
at the critical
section is
stresses
at the
sections.
F Fe
L L L Eq1.17, Page 3
A Z
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

The direct stress at section A - A


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)

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

600 mm

30

10 KN
h

1200 mm

Horizontal component of force FH F cos 300


FH (10 103 ) cos 300 8660.25 N
Bending moment due to horizontal component
M bH FH e M bH 8660.25 600 5.196 10 6 N - mm
Vertical component of force FV F sin 300
FV (10 103 ) sin 300 5000 N
Bending moment due to vertical component
6
M bV FV l M bVDrP R500
0

1200

610
N - mm
Venkatesh, Mech Dept,
RVCE, Bangalore

30

600 mm

10 KN
h

1200 mm

Total bending moment M b = M bH + M bV


(As they are of same sense and tend to stretch
the top fibers & contract the bottom fibers)
M b (5.196+6) 10 6 11.196 10 6 N - mm
bh 2 b(3b ) 2
3
Section modulus Z

1.
5

6
6

M 11.196 106 7.464106


2
Bending stress b

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

Prob 3: A C frame is subjected to a


force of 15 KN as shown in fig. It is made
of grey cast iron FG 300 and the factor
of safety is 2.5. Determine the
dimensions of the cross section of the
frame.

5t
t
7.5t

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

5t
t
7.5t

Bending moment M = 15 10 3 7.5t


= 112500 N - mm
(It tends to stretch the inner fibers &
contract the outer fibers)
bh 2
Section modulus Z

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

Determine the normal


stresses at the extreme fibers of the
cross section of a C-clamp loaded as
shown in fig.
Prob

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/2 a=40 b/2

Cross section area A = (100 40 +100 40) = 8000 mm 2


Bending moment M = 8010 3 (150 + c1 )
aH 2 bd 2
where c1 =
L Table 1.3, Type d, Page 8
2(aH +bd)
40(1402 ) 60(40) 2
c1
= 55 mm
2 (40 140) (60 40)
c2 (140 55) 85 mm
Hence bending m oment M = 8010 3 (150 + 55)
R Venkatesh, Mech Dept,
M = 16.40 10 5 NDr-Pmm
RVCE, Bangalore

B=100

80 KN

d=40
150
100

h=100

H=140

40
100

c1
c2

b/2 a=40 b/2


40

Bc13 bh3 ac23


Moment of inertia I =
L T 1.3, Type d,Page 8
3

where h = (c1 - d)= (55 - 40)= 15 mm


100 553 60 153 40 853
6
4
I

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

b/2 a=40 b/2

40

Similarly Bending stress at outer fiber bo

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

Prob 5: For the member shown in fig,


determine the maximum load F that
can be applied if the allowable
compressive stress at cross section A-A
is 100 MPa.

A
F

100

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

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

Machine Elements subjected to


Combined Loading
Many structural and machine members
are subjected to loads that are
combinations of axial, bending, &
torsional types.
Such members may be modeled as
elements subjected to uniaxial, biaxial &
triaxial loadings with or without shear
loads.
The
principal
stresses
and
the
maximum shear stress may be found
and these values may be used in the
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

Also the expressions for maximum & minimum normal


stresses (Principal stresses) and max shear stress

The maximum & minimum normal stresses (Principal stresses) are

1,2

x y x y
2

xy L L Eq 1.11a Page 2
2
2

x y
x y
2

2
2

The maximum shear stress

xy2 L L Eq 1.11 b Page 2

max

x y
2

xy
2

L L Eq 1.12 Page 2

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Prob 1: A point in a structural member


is subjected to plane stress as shown.
Determine the following;
(i)Principal stresses
(ii)Maximum shear stress
30 MPa

25 MPa
40 MPa
25 MPa

40 MPa
30 MPa

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Major & minor principal stresses


2

x y
x y
2
1,2

xy L L Eq 1.11a & b Page 2


2
2

Hence major principal stress


2

40 30
40 30

2
2
1

25

48.012N
/
m
m

2
2

and minor principal stress


40 30
40 30

2
2

252 38.012N / mm 2
2

The maximum shear stress max


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

Prob 2: A circular rod of diameter 60


mm and length 200 mm is fixed at one
end. The free end is subjected to a
transverse load of 6 KN and a torque of
400 N-m. Determine the stresses at the
critical points.
6 KN

400 N-m

200 mm

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

6 KN

400 N-m

200 mm

This is a member subjected to combined bending & Torsion.


Bending moment M = F l = 6000 200 = 1.2 10 6 N mm
M 32 M 32 1.2 10 6
2
Bending stress =

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

Maximum normal stress (or major principal stress) occurs at point A

L L Eq 1.11a & b Page 2


2
2
2

56.59
56.59

2
2
1

9.43 28.295 29.825 58.12N / mm


2
2

Minimum normal stress (or minor principal stress) occurs at point B


56.59
56.59

2
2

9.432 28.295 29.825 -1.53N / mm 2


2

The maximum shear stress max


56.59

2
2

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

9.432 29.825 N / mm 2

Prob 3: A circular rod of diameter 60


mm and length 200 mm is fixed at one
end. The free end is subjected to an
axial load of 10 KN, a transverse load of
6 KN and a torque of 400 N-m.
Determine the stresses at the critical
points.
6 KN
A

400 N-m

10KN

200 mm

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

6 KN

400 N-m

10KN

200 mm

This is a member subjected to combined bending , Torsion & axial load


Bending moment M = F l = 6000 200 = 1.2 10 6 N mm
M 32M 32 1.2 10 6
2
Bending stress b =

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

Total normal stress at A ,

A = (56.59 3.54) 60.125N / mm 2


& Total normal stress at B,
B = (56.59 3.54) 53.05 N / mm 2
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
3
3
Zp D
60
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

6 KN

400 N-m

10KN

200 mm

Major & minor principal stresses at point A

1,2@ A
1,2@ A

A
A

2
2

2 L L Eq 1.11a & b Page 2

60.125
60.125

2
2

9.432 30.06 31.51

61.57 N / mm 2 & - 1.45 N / mm 2


2

max@ A

60.125
2
2

9.43

31.51
N
/
mm

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

6 KN

10KN

400 N-m

200 mm

Major & minor principal stresses at point B

1,2@ B
1,2@ B

B
B

2
2

2 L L Eq 1.11a & b Page 2

53.05
53.05

2
2

9.432 26.525 28.15

-54.67 N / mm 2 & - 1.625 N / mm 2


2

max@ B

53.05
2
2

9.43

28.15
N
/
mm

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Prob 3: Determine the maximum normal stress


and the maximum shear stress at section A-A for
the overhung crank shown in fig. when a load of
12 KN is assumed to be concentrated at the
center of the crank
pin.
25 25
50
100

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

This is a member subjected to combined bending & Torsion.


Bending moment M = F l = 12 103 (50 25 25) = 12 10 5 N mm
M 32M 32 12 10 5
2
Bending stress =

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

Maximum normal stress (or major principal stress)

max
max




2
2

2 L L Eq 1.11a & b Page 2

23.873
23.873

2
2

17.92

max 11.94 21.52 33.46 N / m m 2


2

The maximum shear stress max


2

max


2
2

23.873
2
2

17.9 21.52 N / mm
2 Dr P R RVCE,
Venkatesh, Mech Dept,

Bangalore

Prob 4: Determine the maximum normal


stress and the maximum shear stress at
section A-A for the overhung crank shown in
fig. Neglect the effect of transverse shear.
50

25

25

100

O 50

10 KN

150

O 80

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

50

25

25

100
10 KN

F
O 50

150

ycos

O 80

Here, the bending moment


arm remains the same
while the torque arm
becomes cos component
of the crank radius as the
line of action of force is
inclined to the horizontal.

T=F x ycos

This is a member subjected to combined bending & Torsion.


Bending moment M = F l = 12 103 (50 25 25) = 12 10 5 N mm
M 32M 32 12 10 5
2
Bending stress =

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

Maximum normal stress (or major principal stress)

max
max




2
2

2 L L Eq 1.11a & b Page 2

23.873
23.873

2
2

15.512

max 11.94 19.57 31.51 N / mm 2


2

The maximum shear stress max


2

max


2
2

23.873
2
2

15.51 19.57 N / mm
2 Dr P R RVCE,
Venkatesh, Mech Dept,

Bangalore

Prob 5: A 50 mm diameter steel rod


supports 9 KN load in addition to a
torsional moment of 100 Nm as shown in
fig. Determine the maximum tensile and
maximum shear stress.
9 KN

100 N-m

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

9 KN
A

100 N-m

This is a member subjected to eccentric & Torsion.


Bending moment M = F l = 9 103 28 = 252 10 3 N mm
M 32 M 32 252 10 3
2
Bending stress b =

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

Twisting moment T (given ) = 100 Nm = 100 103 = 10 5 N mm


T
16T 16 10 5
2
Shear stress =

4.074
N
/
mm
Z p D 3 503
Maximum principal stress

max




2
2

2 L L Eq 1.11a & b Page 2


2

max

25.12
25.12
2
2

4.074

25.764
N
/
mm

2
2

The maximum shear stress max


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

1. Maximum Principal stress theory or Rankine's Theory


It states that " the failure of a specimen subjected to combined
loading occurs when the maximum principal stress at any point
in the specimen reaches the yield or ultimate strength as
detemined from a simple tension test".
i.e. Failure occurs when e = 1
2
1
1
2
e x y

L Eqn 2.8, Page16

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

for brittle materials and not recommended for ductile materials.


Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

2. Maximum principal strain theory or St.Venant's theory


It states that " the failure of a specimen subjected to combined
loading occurs when the maximum normal strain at any point in the
specimen reaches the principal strain as detemined from a
simple tension test".

e ( 1 2 )
Failure occurs when

e ( 1 2 )
E
E
2
1

e (1 )( x y ) (1 ) x y 4 2 L Eqn 2.9, Page16


2

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

3. Maximum Shear stress theory or Tresca's theory or Guest's theory


or Coulomb's theory
It states that " the failure of a specimen subjected to combined
loading occurs when the maximum shear stress at any point in the
specimen reaches the shear yield stress as detemined from a
simple tension test".

e
We know that shear stress at yield, e =
2

( 2 )
Failure occurs when e max 1
e ( 1 2 )
2
2
e

L L Eqn 2.10, Page16

x
y
2

For safe design, e =

yt

n
where n = factor of safety

for ductile materials

* 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

4. Shear energy theory or Hencky -Von Mises's theory


It states that " the failure of a specimen subjected to combined
loading occurs when the shear energy of distortion per unit volume
at any point in the specimen reaches the shear energy of distortion
at yield point as detemined from a simple tension test".
1
2
As shear energy at yielding in tension is U

e & that under


3E
1
2
2

2 1 2 , failure occurs when;


1
3E

combined loading is

e2 12 22 1 2 OR e 12 22 1 2

e x2 x y y2 3 2 L Eqn 2.11a, Page16


For safe design, e =

yt

for ductile materials

n
where n = factor of safety

* Experiments have shown that distortion energy theory is in better agreement for
Dr P R Venkatesh, Mech Dept,

predicting failure of ductile component


any other theory of failure.
RVCE, than
Bangalore

5. Maximum Total strain energy theory or Haigh's theory


It states that " the failure of a specimen subjected to combined
loading occurs when the total strain energy per unit volume at any
point in the specimen reaches the total strain energy at yield point
as detemined from a simple tension test".
Failure occurs when;

e 12 22 2 1 2 L Eqn 2.11b, Page16


For safe design, e =

yt
n

for ductile materials &

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

From Table 1.8, Page 419, for C 40 steel, yt


=324
Consider a x = 40 MPa
and MPa
y = 20MPa
1. Maximum principal stress theory or Rankine's theory
yt 1
2

For safe design,


( x y ) x y 4 2 L Eqn 2.8, Page16
n
2

324 1
2

(40 20) 40 20 0 factor of safety n = 8.1

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

40 20 0 factor of safety n = 16.2


n
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
324
2

402 (40 20) Dr20


0 factor
of safety n = 9.35
P R Venkatesh,
Mech Dept,
n
RVCE, Bangalore

Consider b x = 60 MPa and xy =40MPa


1. Maximum principal stress theory or Rankine's theory
yt 1
2

For safe design,


( x y ) x y 4 2 L Eqn 2.8, Page16
n
2

324 1
2

(60 0) 60 0 4 40 2 factor of safety n = 4.05

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

60 0 4 402 factor of safety n = 3.24


n
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
324

602 0 02 3 402 factor of safety n = 3.535


Dr P R Venkatesh, Mech Dept,
n
RVCE, Bangalore

Consider c x = 60 MPa, y = - 20 MPaand xy =30MPa


1. Maximum principal stress theory or Rankine's theory
yt 1
2

For safe design,


( x y ) x y 4 2 L Eqn 2.8, Page16
n
2

324 1
2

(60 20) 60 20 4 30 2 factor of safety n = 4.63

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

60 20 4 302 factor of safety n = 3.24


n
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
324

602 (60 20) 202 3 302 factor of safety n = 3.645


Dr P R Venkatesh, Mech Dept,
n
RVCE, Bangalore

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

Data : M = 9 KNm, T = 12 KNm, yt = 360MPa,n = 2


This is a shaft subjected to combined bending & Torsion.
Bending moment M = 9 KNm = 9 10 6 N mm
32 M 32 9 10
Bending stress =

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

1. Maximum principal stress theory or Rankine's theory

yt 1
2

For safe design,


( x y ) x y 4 2 L Eqn 2.8, Page16
n
2

360 1 106
2

3 (91.673 0) 91.673 0 4 61.112

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

3.Distortion energy theory

Data : M = 2.5KNm= 2.5 10 6 N mm, D = 60 mm,


T (at yileding) = ? ( factor of safety need not be taken)
32 M 32 2.5 106
2
Bending stress

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

For yielding, yt ( x y ) x y 4 2 L Eqn 2.8, Page16


2

1
2
i.e. 200 (117.89 0) 117.89 0 4 2

282.11 13898 4 2 Squaring both sides,


79586 13898 4 2 =128.15N / mm2
16T
16T
But shear stress
128.15
3
D
603
Max torque to cause yielding of shaft T 5.435 10 6 N - mm
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

2. Maximum shear stress theory Tresca's theory


For yielding, yt
200

L Eqn 2.10, Page16

x
y
2

2
117.89

200 13898 4 2 Squaring both sides,


40000 13898 4 2 =80.78 N / mm2
16T
16T
But shear stress
80.78
3
D
603
Max torque to cause yielding of shaft T 3.43 10 6 N - mm

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

3. Shear energy of distortion theory or Hencky's theory


For yielding, yt x2 x y y2 3 2 L Eqn 2.11a, Page16
200

117.89 0 0 3 2
2

200 13898 3 2 Squaring both sides,


40000 13898 3 2 =80.78 N / mm2
16T
16T
But shear stress
93.28
3
D
603
Max torque to cause yielding of shaft T 3.956 10 6 N - mm

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

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.

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Data : This is a shaft subjected to combined bending & Torsion.


From the fig, M = 1000 250 = 2.5 10 5 N - mm &
T = 1000 500 = 5 10 5 N - mm,
yt = 380MPa,n = 2
32 M 32 2.5 10 5 2.5465 106
2
Bending stress =

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

Internal force lines are


denser near the hole

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Methods of reducing stress


Concentration
It is rather impossible to avoid stress
concentration, but care can be taken
to reduce it.
In a machine element, the force flow
lines must be uniformly spaced and
the number of flow lines at any cross
section must be same.
The same may be achieved by using
fillets at steps, by drilling additional
holes or making additional notches,
by using symmetrical shapes, etc.
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

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

Data: Width of plate w = 50 mm, hole dia a


or d =10 mm, Thickness of plate t=10 mm,
max= 60 MPa
t
F

F
w

From fig 2.8, page 33, for

a 10

0.2, stress concentration factor kt = 2.5


w 50

max
60
2.5
, nom = 24MPa
nom
nom
F
F
Also, nom
24
F =9600 N
( w a )t
(50 10) 10

But kt

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Bar in tension or compression with a transverse


hole. A=(w-d)t where t= thickness of plate
Fig 2.8, Page 33, Mahadevan DDHB
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

Prob 2

Determine

the

maximum

stress

induced in the notched plate as


shown in fig.
9 KN

D=80

9 KN

d
R 10
10

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

Notched bar in tension or compression with a


transverse hole. A=td where t= thickness of plate
Fig 2.4, Page 31, Mahadevan DDHB

9 KN

D=80

9 KN

d
R 10

From the fig,

10

D = 80 mm, r = 10 mm , d = (D - 2r) = 80 - (2 10) = 60mm ,


F = 9000 N, t = 10 mm.
From the fig 2.4, Page 31,
r 10
D 80
for
0.167, and

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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

200 KN

200

200 KN
50

50

R 10

For C 60 steel, from table 1.8, Page 418,


yt 412
yt = 412MPa max

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

Considering the fillet section (B - B),


D 200
r
10
for

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

Determine the diameter of the hole


shown in fig, if the stress
concentration factor at the hole is
to be same as that at the fillet.
50

r5

85

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

50

r5

85
Fig 2.8, Page 33,
Mahadevan DDHB

Fig 2.6, Page 32,


Mahadevan DDHB
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

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

0.5 Diameter of the hole =42.5 mm


85
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

r6

Fig 2.16, Page 37,


Mahadevan DDHB
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

r6

(a) When subjected to bending moment of 200 Nm :


(fig 2.16, Page 37, for stepped bar in bending)
D 80
r
6

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

Fig 2.18, Page 38,


Mahadevan DDHB
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

r6

(b) When subjected to bending mom ent of 400 Nm :


(fig 2.18, Page 38, for stepped bar in bending)
D 80
r
6

2,

0.15, kts =1.34


d 40
d 40
16T 16 400 103
2
nom 3

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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

r5

Fig 2.9, Page 33,


Mahadevan DDHB
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

r5

(a) When subjected to an axial load of 40KN :


(fig 2.9, Page 33, for grooved shaft in tension)
D 60
r
5

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

Fig 2.11, Page 34,


Mahadevan DDHB
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

r5

(a) When subjected to bending moment of 400 Nm :


(fig 2.11, Page 34, for grooved shaft in bending)
D 60
r
5

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

Fig 2.13, Page 35,


Mahadevan DDHB
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

r5

(a) When subjected to twisting moment of 500 Nm :


(fig 2.13, Page 35, for grooved shaft in torsion)
D 60
r
5

1.2,

0.1, kts =1.46


d 50
d 50
16T 16 500 103
2
nom 3

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

Fig 2.16, Page 37,


Mahadevan DDHB
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

This component is subjected to bending moment :


For SAE 1045 steel, yt = 310 MPa (T 1.18, page 428)

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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

r5

Fig 2.13, Page 35,


Mahadevan DDHB
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

Grooved shaft subjected to twisting moment 'T' :


(fig 2.13, Page 35, for grooved shaft in torsion)
D 60
r
5

1.2,

0.1, kts =1.46


d 50
d 50
max
max
60
But kts
nom

=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

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

25

8 KN
A

d/5

d/10
d
250

2d
100

d
125

25

This is a simply supported beam subjected to bending moment :


(Refer Table 1.4, Sl No 5, page 11, Mahadevan DDHB)
F b 8000 150
Support reaction at A , RA

= 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

Fig 2.16, Page 37,


Mahadevan DDHB
Dr P R Venkatesh, Mech Dept,
RVCE, Bangalore

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

(i) Considering right fillet :


Bending moment M RB 25 5600 25 1.4 105 N - mm
d

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

Note: From Table 2.1, Page 23, Sl No 4 & 5,


60

30
60
F

30
F

Kt = 1+2b/c when load is perpendicular to major axis


Kt = 1+2c/b when load is perpendicular to minor axis
where b= semi major axis & c=semi minor axis.

Here, major axis 2b = 60 mm b = 30 mm &


minor axis 2c = 30 mm c = 15 mm
(i) When load is perpendicular to major axis :
2b
60

kt 1 1 5
c
15

(ii) When load is parallel to major axis :

2c
kt 1
b

30

1 2
30

Dr P R Venkatesh, Mech Dept,


RVCE, Bangalore

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