Machine Design Chapter 8 Solutionsdocx PDF Free

Mechanical Design: An Integrated Approach - Ansel Ugural 1
Chapter 8, Problem 1
A structural steel bar of thickness t with full-fillets is loaded by reversed axial force P
(Figure P8.1). Calculate
(a) The maximum stress.
(b) The maximum fatigue stress concentration factor.
Given: P = 15 kN, t = 10 mm
Figure P8.1
Chapter 8, Solution 1
To determine the K t , we use Fig.C.1. Structural steel: Su  400 MPa (Table B.1).
At section C:
( a )  max  1.7 0.03(0.01)
3
d  30  1.267  85 MPa
D 38 15(10 )
 304  0.133
r
d ( b ) Figure 8.8:
 Kt  1.7 r  4 mm : q  0.78
K f  1  0.78(1.7  1)  1.55 (Eq.8.13b)
Similarly, at D:
( a )  max  1.8 0.034(0.01)
3
d  34  1.118  79.41 MPa

D 38 15(10 )
 342  0.059
r
d ( b ) Figure 8.8:
 Kt  1.8 r  2 mm : q  0.72
K f  1  0.72(1.8  1)  1.58
Abar with full-fillets is forged from a structural steel (Figure P8.1). Determine the value of the
endurance limit Se .
Copyright ©2004 The McGraw-Hill Companies Inc.

Assumptions: A survival rate of 95% is used. The operating temperature is 475C maximum.
Figure P8.1
Table B.1: Su  400 MPa, S y  250 MPa

Se  C f Cr Cs Ct 1
Kf Se'
where K f  1.58 at D (from Solution of Prob.8.1)

Se'  0.45Su  180 MPa
C f  ASub  272(400)0.995  0.7
Cr  0.87 (Table 8.3)
Cs  1 (axial loading)
Ct  1  0.0058(475  400)  0.565
Thus
Se  (0.7)(0.87)(1)(0.565) 1.58
1
(180)  39.2 MPa
A machined and full-filleted AISI 4140 annealed steel bar carries a fluctuating axial loading, as
shown in Figure P8.3. What is the value of endurance limit Se?
Given: b = 20 mm, D = 30 mm, r = 2 mm

Assumptions: A reliability of 90% is used.

Figure P8.3
Se  C f Cr CsCt (1 K f )Se' (a)
We have r
d 
 0.077,
2
26 d  1.154
D
Kt  2.5 (Fig.C.3)
Table B.4: Su  655 MPa, H B  197
Se'  0.45Su  294.8 MPa
Table 8.3: Cr  0.89
Fig.8.8: q  0.8, K f  1  0.8(2.5  1)  2.2
Table 8.2: C f  ASub  4.51(655)0.265  0.809
Use Cs  1 (axial loading) Ct  1
Equation (a) is therefore

Se  (0.809)(0.89)(1)(1)( 2.2
1
)(294.8)  96.48 MPa
A stepped cantilever beam of diameters d and D, machined from an AISI 1060 annealed steel
bar, is subjected to a fluctuating moment M, as depicted in Figure P8.4. Determine the modified
endurance limit Se .
Given: d = 25 mm, D = 35 mm, r = 4 mm

Design Assumption: Reliability is 90%.
Figure P8.4

Table B.4: Su  626 MPa H B  179

From Eq.(8.1):
Se'  0.5Su  313 MPa
(Note: by Eq.(2.22): Su  3500(179)  626.5 MPa. )
Using Table 8.3: Cr  0.89 Ct  1
From Eq.(8.9): Cs  0.85
By Eq.(8.7): C f  ASub  4.51(6260.265 )  0.819
For Fillet:
d  25  0.16 d  25  1.4
r 4 D 35
Hence, from Fig.C.9: Kt  1.45

From Fig.8.8, q=0.82
Equation (8.13): K f  1  0.82(1.45  1)  1.37
Thus
Se  C f Cr Cs Ct ( K1f ) Se'  (0.819)(0.89)(0.85)(1)( 1.37
1
)313  141.6 MPa
A notched beam, machined from AISI 1030 hot-rolled steel, is subjected to reversed bending.
Determine the endurance limit Se .
Assumptions: A survival rate of 98% and Cs = 0.7 are used. The fatigue stress concentration
factor is Kf = 2.5.
Table B.3: Su  470 MPa. We apply

Se  C f Cr CsCt ( K1f )Se'
where
K f  2.5, Se'  0.5Su  235 MPa
Cr  0.84 (Table 8.3), Cs  0.7 , Ct  1
0.718
C f  AS  57.7(470)
b
u  0.696
Thus
Se  (0.696)(0.84)(0.7)(1)( 2.5
1
)(235)  38.5 MPa

A stepped cantilevered beam, machined from steel having ultimate tensile strength Su, is under
reversed bending (Figure P8.4). Determine the maximum value of the bending moment M, using
the Goodman criterion.
Given: d = 1 in., D = 1.5 in., r = 0.05 in., Su = 100 ksi

Design Assumptions: A survival rate of 95% is used. The factor of safety n = 1.5.
Figure P8.4
Equation (8.10):
C f  ASub  2.7(100)0.265  0.797
Also
Table 8.3: Cr  0.87 Ct  1
Equation (8.9): Cs  0.85
Equation (8.1): S e'  0.5(100)  50 ksi
From Fig. C.9, with D d  15 ., r d  0.05:

Kt  2.1
By Fig.8.8: q  0.77
and K f  1  0.77(2.1  1)  1.85
Hence
Se  C f Cr Cs Ct ( K1f ) Se'
 (0.797)( 0.87)( 0.85)(1)( 1.185 )(50)  15.9 ksi
Thus, Eq.(8.24):
n  Sea ; 1.5  10
15, 900
.2 M
or
M  1.039 kip  in.

A cold drawn AISI 1020 annealed steel link is subjected to axial loading (that fluctuates from 0
to F) by pins that go through holes (Figure P8.7). What is the maximum value of F with a factor
of safety of n, according to the Goodman criterion?
Given: R = 10 mm, r = 4 mm, t = 2.5 mm, n = 1.4

Assumption: A reliability of 99.99% is used.
Figure P8.7
Table B.3: Su  470 MPa H B  131  Se'  0.45Su  211.5 MPa

Tensile area through the hole:
2( R  r )t  2(10  4)(2.5)  30 mm2
and  m   a  2FA  2(30)
F
 60
F
(a)
We have
Cr  0.70 (Table 8.3) Ct  1
0.265
C f  AS  4.51(470)
b
u  0.88
From Fig.C.5:
D  0.4, Kt  2.8
d
By Fig.8.8: q  0.8
Hence K f  1  0.8(2.8  1)  2.44
Therefore,
Se  C f Cr CsCt (1 K f )Se'
 (0.88)(0.7)(1)(1)(1 2.44)(211.5)  53.4 MPa
By Eq.(8.20):
 m  4704701.4  34.25 MPa (b)
(1)( ) 1
53.4

From Eqs.(a) & (b):

34.25  60F
or
F  2.06 kN
A cold drawn AISI 1050 steel plate with a central hole is under a tension load P that varies from
5 kN to 25 kN (Figure P8.8). Based on the Goodman criterion, determine the factor of safety n
(a) Against yielding.
(b) Against fatigue failure.
Given: D = 25 mm, d = 5 mm, t = 10 mm

Assumption: A reliability of 98% and Cr = 0.7 are used.
Figure P8.8
A  10(25  5)  200 mm
Pm  12 (5  25)  15 kN , Pa  10 kN
( a ) Stress concentration factor is neglected for ductile materials under static loading.
Thus
 max  Pmax
A  25(103 )
200(106 )
 125 MPa
n   maxy  125  4.64

S 580
( b ) We now have
D  0.2, Kt  2.45 (Fig.C.5)
d

Su  690 MPa, S y  580 MPa, H B  197 (Table B.3)

q  0.83 (Fig.8.8)
K f  1  0.83(2.45  1)  2.2
Cr  0.84 (Table 8.3) Ct  1
C f  ASub  4.51(690)0.265  0.798
Se'  0.45Su  310.5 MPa
Hence
Se  (0.798)(0.84)(1)(1)( 2.2
1
)(310.5)  94.61 MPa
We have
 m  PAm  200(10
15(103 )
6  75 MPa,
)
 a  50 MPa
Equation (8.22) gives

n 690
690  1.57
75  (50)
94.61
Resolve Problem 8.8 for the condition that the load varies from –5 kN to 25 kN.
Assumption: Buckling does not occur.
Chapter 8. Problem 8
A cold drawn AISI 1050 steel plate with a central hole is under a tension load P that varies from
5 kN to 25 kN (Figure P8.8). Based on the Goodman criterion, determine the factor of safety n
(a) Against yielding.
(b) Against fatigue failure.
Given: D = 25 mm, d = 5 mm, t = 10 mm

Assumption: A reliability of 98% and Cr = 0.7 are used.

Figure P8.8
Refer to Solution of Prob.8.8
n   maxy  125  4.64

S 580
(a)
( b ) We now have
Pm  12 [25  (5)]  10 kN , Pa  15 kN
Hence  a  75 MPa,  m  50 MPa
Thus
n 690
690  1.16
50  (75)
94.61
A machined AISI 4130 normalized steel bar of diameter D carries an axial load P, as shown in
Figure P8.10. Calculate the value of
(a) The static force P to produce fracture.
(b) The completely reversed force P to produce fatigue failure.
Given: D = 2 18 in.
Assumptions: The survival rate is 95%. The operating temperature is 900°F maximum.
Figure P8.10

A   D4  3.547 in.2
2
( a ) Su  97.17 ksi H B  197 (Table B.4)

and P  Su A  97.17(3.547)  344.7 kips
( b ) Se  C f Cr CsCt (1 K f )Se'
where
Kf 1
Cr  0.87 (Table 8.3)
Cs  1 (axial load)
C f  ASub  2.7(97.17)0.265  0.803
Ct  1  0.0032(900  840)  0.81
Se  0.45Su  43.73 ksi
and
Se  (0.803)(0.87)(1)(0.81)(43.73)  24.75 ksi
Thus
P  ASe  (3.547)(24.75)  87.79 kips
Redo Problem 8.10 for the case of a grooved shaft shown in Figure P8.11.
Given: D = 2 18 in., d = 2 in., r = 0.05 in.
Figure P8.11
A machined AISI 4130 normalized steel bar of diameter D carries an axial load P, as shown in
Figure P8.10. Calculate the value of

(a) The static force P to produce fracture.
(b) The completely reversed force P to produce fatigue failure.
Given: D = 2 18 in.
Assumptions: The survival rate is 95%. The operating temperature is 900°F maximum.
Figure P8.10
Refer to Solution of Prob.8.10. We now have A   d 2 4  3.142 in.2

( a ) For a static fracture of a ductile material, the groove has little effect. Hence,
P  Su A  305.3 kips
( b ) dr  0.025, d  1.063
D
 Kt  2.6 (Fig.C.10)
From Fig.8.8, with Su  97.17 ksi and r  0.05 in.  q  0.75
and K f  1  q( Kt  1)  1  0.75(2.6  1)  2.2
We now have
Se  24.75 2.2  11.25 ksi
Thus
P  ASe  3.142(11.25)  35.35 kips
A stepped shaft ground from AISI 1040 annealed steel is subjected to torsion, as shown in Figure
P8.12. Determine the value of
(a) The torque T to produce static yielding.
(b) The torque T to produce fatigue failure.
Given: D = 50 mm, d = 25 mm, r = 1.25 mm

Assumption: Reliability is 98%.

Figure P8.12
From Table B.4: Su  519 MPa, S y  353 MPa, H B  149

By Eq.(7.20), S ys  0.577 S y  203.7 MPa
( a ) Thus, S ys  16T  d 3 :
T   (0.025) 16
(203.7 10 )
3 6
 624.9 N  m
( b ) Ses  C f Cr CsCt (1 K f )Ses'

where
Cr  0.84 (Table 8.3) Ct  1
Cs  0.85 (Eq.8.9)
C f  ASub  1.58(519)0.085  0.929 (Eq.8.7)
Se'  0.29Su  150.5 MPa (Eq.8.4)
From Fig.C.8, with dr  0.05 and Dd  2  Kt  1.72
From Fig.8.9: q  0.9, K f  1  q( Kt  1)  1.65
Hence
Ses  (0.929)(0.84)(0.85)(1)( 1.65
1
)(150.5)  60.5 MPa
Refer to Eq.(8.24): Ses  16T  d 3 .
Thus
T   (0.025) 16(60.510 )  185.6 N  m
3 6
Repeat Problem 8.12 for the condition that the shaft is subjected to axial loading and no torsion.

Given: D = 50 mm, d = 25 mm, r = 1.25 mm

Figure P8.12
Refer to Solution of Prob.8.12.
( a ) A   d 2 4   (25)2 4  490.874 mm2 , and S y  353 MPa . Thus

P  S y A  490.874(353)  173.3 kN
( b ) We now have with

d  0.05, 2
r D
d
From Fig. C.7: Kt  2.52

Figure 8.8: q  0.7 and
K f  1  q( Kt  1)  1  0.7(2.52  1)  2.06
By Eq.(8.3): Se  0.45Su  233.6 MPa
Hence
Se  (0.929)(0.84)(0.85)(1)( 2.06
1
)(233.6)  75.22 MPa
Thus
P  Se A  (75.22)(490.874)  36.92 kN
Redo Problem 8.12 for the case in which the shaft is machined from an AISI 1095 hot-rolled
steel.

Given: D = 50 mm, d = 25 mm, r = 1.25 mm

Figure P8.12
From Table B.3: Su  830 MPa, S y  460 MPa, H B  248

By Eq.(7.20),
S ys  0.577 S y  265.4 MPa
Refer to Solution of Prob.8.12.
 d 3S ys
  (0.025) 16
(265.410 )
3 6
(a)T  16  814.2 N  m
( b ) C f  ASub  4.51(830)0.265  0.76

Ses'  0.29Su  240.7 MPa
and
Ses  C f Cr CsCt (1 K f )Ses'
 (0.76)(0.84)(0.85)(1)(1.65
1
)(240.7)  79.16 MPa
Therefore
 d 3 Ses  (0.025)3 (79.16 106 )
T 16  16  242.9 kN  m

A shaft with a transverse hole ground from AISI 1095 annealed steel is under bending moment
M that varies from 0.5 to 1.4 kip in. (Figure P8.15). Determine the factor of safety n against
fatigue failure, using the Goodman criterion.
Given: D = 1 in., d = 18 in.

Assumption: A reliability of 99% is used.
Figure P8.15
Su  95.43 ksi H B  192 (Table B.4)

Se  C f Cr CsCt (1 K f ) Se'
where
Cr  0.81 (Table 8.3) Cs  0.85 (Eq.8.9)
0.085
C f  AS  1.34(95.43)
b
u  0.91 (Table 8.2)
S  0.5Su  47.72 ksi
'
e
D  0.125, Kt  2.18 Fig.C.13)

d
and
From Fig.8.8: q  0.79, K f  1  0.79(2.18  1)  1.93
Thus
Se  (0.91)(0.81)(0.85)(1)( 1.93
1
)(47.72)  15.49 ksi
We have
M m  12 (1.4  0.5)  103  950 lb  in., M a  450 lb  in.
 m  ( D 3
Mm
32) ( dD2 6)
  (1)3 32950
[(1 8)(1)2 6]
 12.28 ksi (Fig.C.13)
 a  12.28( 9.5
4.5
)  5.817 ksi
Equation (8.22):
n 95.43
95.43  1.98
12.28 (5.817)
15.49
Resolve Problem 8.15 for the condition that shaft is ground from AISI 1060 HR steel and is

under axial loading varying from 5 to 15 kips.
A shaft with a transverse hole ground from AISI 1095 annealed steel is under bending moment
M that varies from 0.5 to 1.4 kip in. (Figure P8.15). Determine the factor of safety n against
fatigue failure, using the Goodman criterion.
Given: D = 1 in., d = 18 in.

Assumption: A reliability of 99% is used.
Figure P8.15
Refer to Solution of Prob.8.15. We now have

Su  98.62 ksi, H B  201 (Table B.3)
q  0.8 (Fig.8.8)
Also
d
D  0.125 Kt  2.65 (Fig.C.13)
K f  1  0.8(2.65  1)  2.32
Se'  0.45Su  44.38 ksi
and Se  (0.91)(0.81)(0.85)(1)( 2.32
1
)(44.38)  12 ksi
We write
Pm  12 (15  5)  10, Pa  5 kips A   D 2 4  Dd (Fig.C.13)
and
 m   (1) 2
10
4 (1)(1 8)
 15.14 ksi,  a  7.57 ksi
Equation (8.22) is therefore
n 98.62
98.62  1.27
15.14  (7.57)
12

A thin-walled cylindrical vessel of diameter d is subjected to an internal pressure varying from

60 to 300 psi continuously. Apply the maximum energy of distortion theory incorporated with
the Soderberg relation to design the vessel.
Given: d = 80 in., Sy = 40 ksi, Se = 30 ksi, n = 2.5
1  pr
t , 2  pr
2t ,  3  0. pm  180 psi, pa  120 psi
a
  .
pa 2
m pm 3
Replace S u with S y in Eq.(8.30):

 [1  12  14 ]2 1e  0.8661e
Sy 1
1e  0.866 n
Sy
or (a)
Similarly, Eq.(8.25):
1e  1m  S 1a  rt ( pm  S pa )
Sy Sy
e e
 (180   120) 
40
t
4
3
13,600
t (b)
By Eq.(a) and (b):
(0.866)2.5  t , t  0.736 in.
40 13.6
A thin-walled cylindrical vessel of diameter d and thickness t is under internal pressure varying
from 0.6 to 2.8 MPa continuously.
Given: d = 1.5 m, t = 25 mm, Su = 350 MPa, Se = 150 MPa

Design Decision: Use the maximum energy of distortion theory incorporated with the Goodman
relation. Determine the factor of safety n.
1  pr
t , 2  pr
2t ,  3  0. pm  1.7 MPa, pa  1.1 MPa
Refer to Solution of Prob.8.17:

1e  0.866
Su
n (a)

Use Eq.(8.25):
1e  1m  SSue 1a  rt ( pm  SSue pa )  30[1.7  15
35
(1.1)]  128 MPa (b)
From Eqs.(a) and (b):

0.866 n  128, n  3.16
350
A small leaf spring, 10 mm wide • 100 mm long and h mm deep, is subjected to a concentrated
center load P varying continuously from 0 to 20 N. The spring may be approximated to be a
simply supported beam (Figure P8.19). Calculate the required depth for a factor of safety of 4.
Given: Su = 980 MPa, Se = 400 MPa

Design Decision: Apply the Goodman theory, based on the maximum normal stress.
Figure P8.19
b  0.01 m, L  0.1 m, M  PL 4.
M max  14 (20)(0.1)  0.5 N  m, M min  0
M a  M m  0.25 N  m,  m   a
We have,  m  6bhM  6(0.25)
m
2
0.01h
 150
2
h 2
Equation (8.20) gives

 m  98098 4  71.01 MPa
(1) 1
40
Thus
h 150
71.01106
 1.45 mm

Redo Problem 8.19 using the Soderberg criterion and yield strength of Sy = 620 MPa.
A small leaf spring, 10 mm wide • 100 mm long and h mm deep, is subjected to a concentrated
center load P varying continuously from 0 to 20 N. The spring may be approximated to be a
simply supported beam (Figure P8.19). Calculate the required depth for a factor of safety of 4.
Given: Su = 980 MPa, Se = 400 MPa

Design Decision: Apply the Goodman theory, based on the maximum normal stress.
Figure P8.19
From Solution of Prob.8.19, we have

 a   m  150
n2
. (a)
Equation (8.20) by replacing S u with S y :
m 
Sy n
a Sy
1
 m Se
Substituting the given data gives

 m  62062 4  60.78 MPa (b)
(1)( ) 1
40
By Eqs.(a) and (b),

60.78(106 )  150
h2
or
h  1.57 mm

An electrical contact includes a flat spring in the form of a cantilever, 18 in. wide  1.5 in. long
and h in. deep, is subjected at its free end to a load P that varies continuously from 0 to 0.5 lb
(Figure P8.21). Compute the value of h for a factor of safety n = 1.2.
Given: Su = 150 ksi, Se = 72 ksi

Design Decision: Employ the Goodman criterion, based on the maximum normal stress.
Figure P8.21
At fixed end M max  PL  0.5(1.5)  0.75 lb  in. Hence

M max  M min
M  Mm  Ma  2  0.375 lb  in.
 m   a  6bhM 
2
6(0.375)
0.125 h2
 18
h2
Equation (8.20): m  150 1.2

150  40.541 ksi
(1) 1
72
Thus
18
h2
 40,541 psi, h  0.021 in.
A cantilever spring is subjected to a concentrated load P varying continuously from 0 to Po

(Figure P8.22). What is the greatest allowable load Po for n = 4?
Given: Sy = 850 MPa, Se = 175 MPa, b = 5 mm, h = 10 mm, Kf = 2

Assumption: Failure occurs due to bending stress at the fillet.
Design Decision: Use the Soderberg criterion.

Figure P8.22
Pm  Pa 
P0
2 , M m  0.2Pm  0.1P0 , Pa Pm  1 a m  1
Eq.(8.20): m  850 4
85  36.28 MPa
(1) 1
17.5
Also  m  6bhM  0.0056(0.1)

m P
100(10 )
2  1.2(106 ) P0
0
6
Thus
1.2P0  36.28, P0  30.23 N
Resolve Problem 8.22 for the load varying from Po/2 upward to Po downward, n = 2.
A cantilever spring is subjected to a concentrated load P varying continuously from 0 to Po

(Figure P8.22). What is the greatest allowable load Po for n = 4?
Given: Sy = 850 MPa, Se = 175 MPa, b = 5 mm, h = 10 mm, Kf = 2

Assumption: Failure occurs due to bending stress at the fillet.
Design Decision: Use the Soderberg criterion.
Figure P8.22
M max  0.2P0 , M min  0.2(0.5P0 )  0.1P0

Mm  (0.2  0.1)  0.05P0 , M a  (0.2  0.1)  0.15P0

P0 P0
2 2
Equation (8.20): m  850 2

85  35.629 MPa
1.5(3) 1
35
Also  m  6bhM  0.0056(0.05

m
2
P)
100(10 )
0
 0.6(106 ) P0
6
Thus
0.6P0  35.629, P0  59.38 N
A 24-mm wide, 4-mm thick, and 3-mm long leaf spring, made of AISI 1050CD steel, is straight
and unstressed when the cam and shaft are removed (Figure P8.24). Use the Goodman theory to
calculate the factor of safety n for the spring.
Given: Se = 250 MPa, E = 200 GPa,  = 0.3

Assumption: The cam rotates continuously. Leaf spring is considered as a wide cantilever
beam.
Figure P8.24
24(4)3
I  bh12   128 mm4 . Table B.3: Su  690 MPa
3
12
For a wide cantilever beam (see Secs 4.4 and 4.10, and Case 1 of Table A.9):
  (1   2 ) 3PLEI  0.91 3PLEI
3 3
12
 min  3(2000.91(0.3)
10 )(12810
9
This gives Pmin  3 EI
0.91L3 3
)
(0.01)
 31.26 N and hence Pmax  62.52 N
Thus
Pm  46.89 N , Pa  15.63 N and

3
10 )
 m  46.89(0.3)(2
0.128(10 )
 219.8 MPa
9
 a  219.8( 15.63
46.89 )  73.27 MPa
Eq. (8.22):
n   1.63
Su 690
S 690
m  u a 219.8 (73.27)
Se 250
Repeat Problem 8.24 for the case in which the cantilevered spring is made of normalized AISI
1095 steel and employing the Soderberg criterion.
A 24-mm wide, 4-mm thick, and 3-mm long leaf spring, made of AISI 1050CD steel, is straight
and unstressed when the cam and shaft are removed (Figure P8.24). Use the Goodman theory to
calculate the factor of safety n for the spring.
Given: Se = 250 MPa, E = 200 GPa,  = 0.3

Assumption: The cam rotates continuously. Leaf spring is considered as a wide cantilever
beam.
Figure P8.24
Table B.4: S y  500 MPa
Refer to Solution of Prob.8.24. Replacing S u by S y in Eq.(8.22):
n   1.36
Sy 500
Sy 500
m  a 219.8 (73.27)
Se 250

Figure P8.26 shows a circular aluminum bar having two shoulder fillets supporting a
concentrated load P at its midspan. Determine the allowable value for diameter D if stress
conditions at the fillets are to be satisfactory for conditions of operation. Dimensions shown are
in millimeters.
Given: Su = 600 MPa, Sy = 280 MPa, n = 2.5, Kf Se = 150 MPa

Assumptions: The load P varies from 2 kN to 6 kN. The Soderberg relation is employed.
Figure P8.26
I  4 (0.03) 4  0.636  106 m4 , Pm  4 kN , Pa  2 kN

 m  MI c  2000(0.5)(0.03)
m
0.63610 6 47.2 MPa
 a  23.6 MPa
Eq. (8.16), with replacing S u by S y :

 m  a;  47.2  150280K f (23.6)
Sy Sy 280
n Se 2.5
Solving K f  1.47 .
From Fig.8.8: q=0.8
and K f  1  q( Kt  1); 1.47  1  0.8( K t  1), K t  1.59
Then from Fig. C.9:

Kt  1.59  D
 3
r
d  9
60  0.15 d

and
D  3d  3(60)  180 mm
The filleted flat bar shown in Figure P8.27 is made from 1040 steel OQ&T at 650C. What is the
factor of safety n, if the bending moment M varies from 0.6 to 3 kN· m?
Given: Kf Se = 400 MPa, D = 120 mm, d = 60 mm, r = 4 mm, t = 20 mm

Design Assumption: The Goodman criterion of fatigue failure is applied.
Figure P8.27
Table B.4: Su  634 MPa, H B  192

3
I  bh12  0.02(0.06)  0.36  106 m4
3
12
M m  1.8 kN  m M a  1.2 kN  m
Figure C.2:
d  60  2 
D 120
 Kt  2.1
r
d  4
60  0.067 

Figure 8.8: q  0.82 and K f  1  0.82(2.1  1)  1.902. Se  1.902

400
 210.3 MPa
We have
 m  MImc  1800(0.03)
0.36106
 150 MPa
 a  150( 1.2
1.8 )  100 MPa
Equation (8.22):
n  Suu   1.4
S 634
634
m  a 150 (100)
Se 210.3


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Mechanical Design: An Integrated Approach - Ansel Ugural 1

(a) The maximum stress.

(b) The maximum fatigue stress concentration factor.

d  34  1.118  79.41 MPa

Copyright ©2004 The McGraw-Hill Companies Inc.

Table B.1: Su  400 MPa, S y  250 MPa

where K f  1.58 at D (from Solution of Prob.8.1)

Given: b = 20 mm, D = 30 mm, r = 2 mm

Copyright ©2004 The McGraw-Hill Companies Inc.

Se  C f Cr CsCt (1 K f )Se' (a)

Equation (a) is therefore

Given: d = 25 mm, D = 35 mm, r = 4 mm

Copyright ©2004 The McGraw-Hill Companies Inc.

Table B.4: Su  626 MPa H B  179

Hence, from Fig.C.9: Kt  1.45

Table B.3: Su  470 MPa. We apply

Copyright ©2004 The McGraw-Hill Companies Inc.

Given: d = 1 in., D = 1.5 in., r = 0.05 in., Su = 100 ksi

From Fig. C.9, with D d  15 ., r d  0.05:

Copyright ©2004 The McGraw-Hill Companies Inc.

Given: R = 10 mm, r = 4 mm, t = 2.5 mm, n = 1.4

Table B.3: Su  470 MPa H B  131  Se'  0.45Su  211.5 MPa

Copyright ©2004 The McGraw-Hill Companies Inc.

From Eqs.(a) & (b):

(a) Against yielding.

(b) Against fatigue failure.

Given: D = 25 mm, d = 5 mm, t = 10 mm

n   maxy  125  4.64

Copyright ©2004 The McGraw-Hill Companies Inc.

Su  690 MPa, S y  580 MPa, H B  197 (Table B.3)

Equation (8.22) gives

Assumption: Buckling does not occur.

(a) Against yielding.

(b) Against fatigue failure.

Given: D = 25 mm, d = 5 mm, t = 10 mm

Copyright ©2004 The McGraw-Hill Companies Inc.

Refer to Solution of Prob.8.8

n   maxy  125  4.64

(a) The static force P to produce fracture.

(b) The completely reversed force P to produce fatigue failure.

Copyright ©2004 The McGraw-Hill Companies Inc.

( a ) Su  97.17 ksi H B  197 (Table B.4)

Copyright ©2004 The McGraw-Hill Companies Inc.

(a) The static force P to produce fracture.

(b) The completely reversed force P to produce fatigue failure.

Refer to Solution of Prob.8.10. We now have A   d 2 4  3.142 in.2

(a) The torque T to produce static yielding.

(b) The torque T to produce fatigue failure.

Given: D = 50 mm, d = 25 mm, r = 1.25 mm

Copyright ©2004 The McGraw-Hill Companies Inc.

From Table B.4: Su  519 MPa, S y  353 MPa, H B  149

( b ) Ses  C f Cr CsCt (1 K f )Ses'

Copyright ©2004 The McGraw-Hill Companies Inc.

(a) The torque T to produce static yielding.

(b) The torque T to produce fatigue failure.

Given: D = 50 mm, d = 25 mm, r = 1.25 mm

Refer to Solution of Prob.8.12.

( a ) A   d 2 4   (25)2 4  490.874 mm2 , and S y  353 MPa . Thus

( b ) We now have with

From Fig. C.7: Kt  2.52

Copyright ©2004 The McGraw-Hill Companies Inc.

(a) The torque T to produce static yielding.

(b) The torque T to produce fatigue failure.