# Woodruff School of Mechanical Engineering Georgia Institute of Technology ME 3180 Mechanical Design Spring 2008 st 1 Midterm Examination If anything

is unclear, make an assumption and proceed with it. Only reasonable assumptions receive credits. 1. The following figure shows a key installed to enable the transmission of torque from the shaft to the hub. It is tapered to prevent relative axial movement between the shaft and the hub. You are asked to design the width (“w”) of the key so that there is an equal possibility for the key to fail by shearing and to fail by bearing. Use von Mises criterion for failure determination. (6 points)
hub Taper 1mm in 30mm 3 mm 4 mm w 30 mm 45 mm shaft key

front view

side view

2. The C clamp shown below uses a 1”-8UNC square double thread. For this power screw application the thread depth is half of the pitch. The friction coefficients are 0.1 for the threads and for the collar. A clamping force as large as 250 lbf is desired, while the force applied to the handle at a radius of 3” from the screw centerline is limited to a 9 lbf maximum. Specify the maximum allowable friction diameter of the collar, which in this case is the anvil striker’s swivel joint, such that the desired 250 lbf can be achieved. (6 points)

3”

3. Find the critical speed (in rad/sec) of a steel shaft (E=30Mpsi) with ½” diameter and 10” length as it spins while it is loaded as follows: The two ends are simply supported. (6 points). Some beam deflection formulas are included for your reference.

to be applied for a period of 10. Subsequently the load will be varying between 0 and 500 lbf until the part fails by fatigue. while the other end loaded by a varying load of F. that the part can go through to the point of fatigue failure? It is known that the part material has an ultimate strength of 60 kpsi and a modified endurance limit of 30 kpsi. fully reversed.20 lbf 10 lbf 30 lbf 3” 4” 5” 8” 10 lbf 10” 4.(7 points) F d=1” z y x 5” 10” . What is the number of total load cycles. counting from the very start. The load F will first be 400 lbf.000 cycles. The following figure shows an elbow part with one end built into a wall. Use Von Mises if any combined loading analysis is needed. Use Goodman curve without safety factor. Do not consider any stress concentration factor.

5 ) 2 Same failure possibility. 000 1/ 2 3. 2T nbearing S y d(7. nshear = nbearing ⇒ w = 6.5) 4 = 0. 400. 400.ME 3180 Woodruff School of Mechanical Engineering Georgia Institute of Technology Mechanical Design Solution for 1st Midterm Examination 0. 8 1 1 15 " . I = δ22 = δ 44 = ⎤ 1 ⎡1 = ⎢ ( W1δ11 + W2 δ22 + W3 δ33 + W4 δ 44 ) ⎥ ω ⎣g ⎦ ⎡ 1 =⎢ ( 20(1.1) ⎢ ⎥ Fd ⎡ + fπdm ⎤ Ffc 250(15 / 26) 4 16 ⎥ + 250 ⎛ 0.85 + 250 ⎜ ⎟ dc ⇒ dc = 0. 000 5.63 × 10 −4 in / lbf 6EI 5.31× 10−4 in / lbf 5.95 × 10−4 ) )⎤ ⎥ ⎣ 386 ⎦ ⇒ ω=255 rad/sec 1/ 2 .1 ⎞ 9 × 3 = 21. α = 0 4 2 16 ⎡ 1 15 ⎤ + π(0.46 mm 1 2.003)(10) = 5. 000 in3 64 bx (7)3(102 − 72 − 32 ) 2 2 δ11 = 1 1 ( 2 − b1 − x1 ) = = 1. 000 (6)4(102 − 62 − 42 ) (5)5(102 − 52 − 52 ) = 2. 6EI = 6(30E6)(0.1) 1 ⎥ ⎢ ⎜ 16 ⎟ 4⎥ ⎣ ⎝ ⎠ ⎦ ⎛ 0.13 × 10−4 in / lbf .5mm in the hub.29S y dw Spring 2008 1.41" ⎝ 2 ⎠ = 2p = π(0. dm = d − p = " .63 ×10−4 ) + 10(2. p= " .95 × 10−4 in / lbf 5.1 ⎞ d ⎢ + T= m ⎢ dc = ⎥ ⎜ ⎟ c 2 ⎣ πdm − f ⎦ 2 2 ⎝ 2 ⎠ ⎢ π ⎛ 15 ⎞ − (0. d=1”. 000 (2)8(102 − 22 − 82 ) = 0. Shear failure nshear = T The exit end of the key has a hight of 3+45(1/30)=4.13 ×10−4 ) − 10(2.31×10−4 ) + 30(0. 400. 400. 400.003 in4 . δ33 = = −2.5) F d ⇒n Bearing failure S y = = bearing = 1 A bearing 4T ( 3 + 4.

467=16.500 psi.800 psi. σ σ 1 = a + m ⇒ Sf = σa since σm = 0 S f Sut S-N curve: a = ⎛S ⎞ ⎛ 40.F2=0~500 lbf σm=σa=102(250)=25.000+6. σx = Mc F(5)(1/ 2) Tr F(10)(1/ 2) F F = = 51F. τ xy = = = 51F.F1=-400~400 lbf σm=0.467 27.085 ⎛ 44.9(60) ⎞ = 97.2.348 psi Sf Sut Sf 60 1/ b −1/ 0.2 ⎠ ⎝ a ⎠ Stage 2 -. τ xy = = = 1.5 25.250 cycles ⎟ ⎝ 97.467 .27F ≈ 0 4 4 I J ( π(1) ) / 32 A ( π(1)2 ) / 4 ( π(1) ) / 64 σ ' = σ2 + 3τ2 = 102F x xy (0.log ⎜ ⎟ = −0.4. σ σ 25.2 ⎠ −1/ 0.8 ⎞ N1 = ⎜ f ⎟ = ⎜ = 27. b=.250 10.5 1= a + m = + ⇒ S f = 44.217 Number of total cycles = N1+N2= 10.000 + ⇒ n2 = 6.085 30 3 ⎝ 30 ⎠ State 1 -.3 ⎞ N2 = ⎜ ⎟ ⎝ 97.085 = 10.9 × 60)2 1 ⎛ 0.217 cycles Minor’s rule: 1 = n2 10. σa=102(400)=40.

000 lbf. The bolt proof strength (60 kpsi) is the same as the nut proof strength. θ=4.000 lbf 1/4 in-12 UNC 1 1/2” 1/4” 4. The figure shows a square-threaded bolt holding a hook to a ceiling.000 lb. The bolt diameter and the preload are all carefully selected so that the bolt yielding.6. and b=1. The vertical load on the joint is 4. (6 points) 1/2” 1/2” 3/4” 1” 4. Find the factors of safety for the failure modes of bolt shearing and bolt bearing. The members are cold-drawn bars of AISI 1020 steel (57 kpsi yield strength). and thread stripping can take place only simultaneously. Note that the effective load P should be calculated as P=XVFr+YFa with X and Y given in the following table. Consider the joint constant to be 0. (7 points) F 3. A radial ball bearing is used under rotating outer ring condition with 800 lb axial load and 3. The nut length is 11/16 inch. Calculate the load (F) that causes these failures to happen.ME 3180 Woodruff School of Mechanical Engineering Georgia Institute of Technology Mechanical Design nd 2 Midterm Examination Spring 2008 1. The figure shows a clamped joint that employs three identical bolts of SAE grade 5 bolts (92 kpsi yield strength).459.02. which is the same as the bolt major diameter. what should be the basic dynamic load rating (C10) of the bearing selected for this purpose? Note that the published Weibull parameters are x0=0. Use distortion energy theory when necessary. plates separation.483 and assume the bearing selected has a basic static load rating (Co) of 22. If the expected life is to be 5 × 108 revolutions with 95% reliability.000 lbf 1/8” 2. (6 points) .100 lb radial load.

028 0.99 0. What is the amount of force (F. The torsional spring shown in the figure has an angular spring constant of 15.00 0 1.22 0.Fa/Co 0.56 1. and its wire has E= 30 × 106 psi and G= 11.00 0 Fa/VFr>e X Y 0.34 Fa/VFr<e X Y 1. in lb) that can buckle the coil spring? Assume that the 10 inch beam is infinitely stiff.31 4.63 0.00 0 1. (6 points) 10 inch F free end spring constant 200 lb/in fixed end angular spring constant 15.070 0.56 1.5 × 106 psi .000 lbin/rad and the coil spring has a spring constant of 200 lb/in. The coil spring has a free length of 3 inches and a diameter of 1 inch.56 1.17 e 0.000 lb-in/rad .27 0.

2.094 in2 .81 . Considering bolt shearing: S ⎡ π(1/ 4)2 ⎤ 92 / 3 F 4 2 = 1.720 ⎟ ⎝ ⎠ 3 3 2 ⎡ ⎛ C2 ⎞1/ 2 ⎤ 4.Woodruff School of Mechanical Engineering Georgia Institute of Technology ME 3180 Mechanical Design Spring 2008 nd Solution for 2 Midterm Examination 1.5) 16 1 1 ⎡ 1 11 ⎤ Also.21 A 0.215 < e (since e>0.66 A b 0.37 in2 For simultaneous bolt yielding and member separation (thread stripping also).2)(3.21 kpsi .685 inch.100)=3. Fa/VFr=800/(1.95 = 27. P=VFr=(1. SA 1 = n = p t ⇒ F = Sp A t = (60 × 103 )(0. C2 = = =6 6 D 1 2G + E 2(E − G) 2(30 − 11.147 ⎣ 4 ⎦ (Note the distortion energy theory is used to calculate Ssy above) Considering bolt bearing: S 92 F 4 ⎛ 1 ⎞⎛ 1 ⎞ = 2.000=0. The buckling force F = LoC1 ⎢1 − ⎜ 1 − 2 ⎟ ⎥ K λ ⎠ ⎥ ⎢ ⎝ ⎣ ⎦ C1 = αL o 2(3) 2π2 (E − G) E 30 × 106 = 6.95) x o + ( θ − x o )( − lnR ) L10 8 × 108 ⎛ C10 ⎞ ⎛ C ⎞ = ⎜ 10 ⎟ ⇒ = ⇒ C10 = 34.02 + (4.89 . Y=0. σb = σb 42.5) × 10 ⎡ ⎛ 6.533lb 1× 106 ⎝ 3. λ = = = 0.483 0. n = y = A S = 3 ⎜ ⎟ ⎜ ⎟ = 0. n = sy = AS = 3 ⎢ ⎥ = 0.02)( − ln0.66 kpsi .720 ⎠ 1× 106 ⎜ 3.036. A t = πd2 = π ⎢dm − (D − dm ) ⎥ with D = t 4 4 ⎣ 2 16 ⎦ The above two give dm = 0.81) ⎢1 − ⎜ 1 − 2 ⎟ ⎥ (200) = 49 lb 6 ⎠ ⎥ ⎢ ⎝ ⎣ ⎦ . V=1. Fa/Co=800/22.147 in .89 ⎞1/ 2 ⎤ F = (3)(0. which leads to At=0.720 L 5 × 108 = = 8 × 108 L10 = 1/ b 1/ 1. τS = = τs 27.459 − 0.22) X=1.094 ⎝ 4 ⎠⎝ 8 ⎠ 2.200 lbf F 3.37) = 22.2)(3.100)=0.16 = = 42. To have simultaneously bolt yielding and thread stripping: 11 A S = 2A t = πdmqw = πdm ( )(0.

Some beam deflection formulas are provided for your reference.ME 3180 Woodruff School of Mechanical Engineering Georgia Institute of Technology Mechanical Design Final Examination Spring 2008 1. in lb) that can buckle the coil spring? Assume that the 10 inch beam is infinitely stiff. What is the amount of force (F. and its wire has E= 30 × 106 psi and G= 11. (10 points) 10 lbf 20 lbf 4” 6” 8” 10” 10 lbf 20 lbf 2” 2.000 lb-in/rad spring constant 200 lb/in pivoted ends . Find the critical speed (in rad/sec) of a steel shaft (E=30Mpsi) with ½” diameter and 10” length as it spins while it is loaded as follows: The two ends are simply supported.000 lbin/rad and the coil spring has a spring constant of 200 lb/in.5 × 106 psi . The torsional spring shown in the figure has an angular spring constant of 10. The coil spring has a free length of 3 inches and a diameter of 1 inch. (10 points) 10 inch F angular spring constant 10.

and lead of 0. for the bolts to survive this application? Use the maximum shear stress theory and a load safety factor of 3. What is the maximum possible weight (in lb) that can be lifted with the use of 50 lb-in torque. Two identical bolts (with a proof strength of 500 MPa and a stress area of 58 mm2) are used to fasten two flat plates as shown.5 inch. Assume that the collar bearing friction is negligible. F 2m 3m 5m . A square-threaded bolt with major diameter of 0.3. minor diameter of 0.077 inch is used in a self-locking screw jack application.4 inch. F. (10 points) 4. What is the maximum allowable load.

400.89 ⎞1/ 2 ⎤ F1 = (3)(0.003 in4 .4 ) 2 Fd ⎛ μ + tan λ ⎞ 2T ⎛ 1− μ tan λ ⎞ T= m⎜ ⎜ ⎟ ⎟ ⇒ F= dm ⎝ μ + tan λ ⎠ 2 ⎝ 1 − μ tan λ ⎠ = .5) × 10 2G + E ⎡ ⎛ 6. 400. 000 in3 64 bx (8)2(102 − 82 − 22 ) 2 2 δ11 = 1 1 ( 2 − b1 − x1 ) = = 0. 000 5.95 × 10 −4 5.13 × 10 −4 .003)(10) = 5.5 + 0.89 .81) ⎢1 − ⎜ 1 − 2 ⎟ ⎥ (200) = 250 lb 3 ⎠ ⎥ ⎢ ⎝ ⎣ ⎦ The linear spring constant of the torsional spring (including the beam) is k1 = k a / r 2 = 10.000 /102 = 100 lbf / in Since the coil spring and the torsional spring are in parallel. 000 δ22 = δ 44 (6)4(102 − 62 − 42 ) (4)6(102 − 42 − 62 ) = −2. δ33 = = 2.ME 3180 Woodruff School of Mechanical Engineering Georgia Institute of Technology Mechanical Design Solution for Final Examination Spring 2008 1. C2 = = 6.13) + 10(2.054 πdm π( 0.077 = 0.13) + 20(0. The buckling force on the coil spring F1 = LoC1 ⎢1 − ⎜ 1 − 2 ⎟ ⎥ k1 λ ⎠ ⎥ ⎢ ⎝ ⎣ ⎦ αLo 1(3) 2π2 (E − G) E 30 × 106 = =3 C1 = = = 0. 000 1/ 2 ⎤ 1 ⎡1 = ⎢ ( W1δ11 + W2 δ22 + W3 δ33 + W4 δ 44 ) ⎥ ω ⎣g ⎦ ⎡ 1 =⎢ (10(0.5) 4 = 0.13 × 10 −4 5. 400. 400. the required total force to k +k ⎛ 100 + 200 ⎞ buckle is F = F1 1 2 = 250 ⎜ ⎟ = 375 lbf k1 ⎝ 200 ⎠ 3.95) ) × 10−4 ⎤ ⎥ ⎣ 386 ⎦ ⇒ ω=14.81 . 400. 6EI = 6(30E6)(0. Self locking screw : μ > tan λ = 0. λ = 6 D 1 2(E − G) 2(30 − 11.95) − 20(2.912 rad/sec 1/ 2 ⎡ ⎛ C2 ⎞1/ 2 ⎤ 2. I = π(0. 000 (2)8(102 − 22 − 82 ) = = 0.95 × 10 −4 in / lbf 6EI 5.

Any 1 ⎝ 0. at μ=0. 58(2) 116 ⎛ 1 ⎞ ⎛ 1⎞ ⎛ 1 ⎞⎛ 1 ⎞ 0 V = V + V − 2V1V2 cos θ = F ⎜ ⎟ + ⎜ ⎟ − 2⎜ ⎟ ⎜ ⎟ cos 135 = F(0. 051 lb (4 points) .054(0.5 + 0.113) 2 1 2 2 2 . maximum F = 4.054 + 0. On the top bolt.054 ⎠ (0.054) ⎞ ⎜ ⎟ = 2. which is the critical one.054. the direct shear stress is V1 = and the torsional shear stress is V2 = The resultant shear stress is F(4000) F = (58)(2000 2 ) 41 2 F F = .113) 116 ⎠ ⎝ 41 ⎠ 116 ⎠ ⎝ 41 ⎠ ⎝ ⎝ S 500 Maximum shear stress theory: p > nV ⇒ F < = 735 N 2 (2)(3)(0.4) 2 greater F would require a smaller μ which makes the screw not self-locking.2(50) ⎛ 1− 0.