ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

M1 – ANALYSIS OF NORMAL & BEARING STRESSES 𝐹 = Normal force (lb, N)

Course Outcomes
At the completion of the course module, the student will
be able to:
1. Apply the principles of machine elements and materials
engineering in the design of machine elements
2. Determine the design factor and design stresses, and be
able to apply these in the design of machine elements.
3. Solve problems involving different types of stresses.
Chapter Outcomes
At the completion of the chapter module, the student will
be able to:
1. Solve problems involving normal stresses.
2. Solve problems involving bearing stresses.
3. Solve problems involving strain and linear deformation.
4. Solve design problems involving normal stress and
bearing stress.
5. Determine the design factor and design stresses
involving normal stress and bearing stress.
1.0 Introduction
This module deals with normal and bearing stresses
including strain and linear deformation. It also includes design
of machine elements and its analysis.
1.1 NORMAL STRESS
The normal stress S develops when a force F is applied
perpendicular to the cross-sectional area A of the material.
𝐴 = Area of cross-section (in2, mm2)
Dimensional Homogeneity
Dimensional homogeneity is the quality of an equation
having quantities of same units on both sides. A valid equation
in Machine Design equations must be homogeneous, since
equality cannot apply between quantities of different nature.
BHN to Tensile Strength Conversion
3.55𝐵𝐻𝑁 (𝐵𝐻𝑁 ≤ 175)
(𝑀𝑃𝑎) = {
3.38𝐵𝐻𝑁 (𝐵𝐻𝑁 > 175)
515𝐵𝐻𝑁 (𝐵𝐻𝑁 ≤ 175)
(𝑝𝑠𝑖) = {
490𝐵𝐻𝑁 (𝐵𝐻𝑁 > 175)
1.2 BEARING STRESS
Bearing stress is the contact pressure between the
separate bodies. It differs from compressive stress, as it is
an internal stress caused by compressive forces.
A. Bearing Stress on Bolt:
In a bolted connection, the role of the bolts is
normally to press one parts on the other; the adherence
(friction) is opposed to the tangent forces and prevents
the parts from sliding apart. The bolts then play the role
of stops: the screws endure shear stress whereas the hole
endure bearing pressure. The magnitude of the bearing
stress can be calculated from the direct stress formula:
𝐹 𝐹
𝑆𝑏 = = .
𝐴 𝑑𝑡
Where:
𝑆𝑏 = bearing stress on the bolt (psi, MPa)
𝐹 = bearing force on the bolt (lb, N)
𝐴 = bearing projected area of the bolt (in2, mm2)
d = diameter of the hole (in, mm)
t = thickness of the plate (in, mm)

Fig. 1.1 Normal Stress (Tension and Compression)

If the force is going to pull the material, the stress is said

to be tensile stress. The compressive stress develops when
the material is being compressed by two opposing forces. The
magnitude of the normal stress can be calculated from the Fig. 1.2 Bearing stress on riveted connection1
formula:
𝐹 𝐹 B. Bearing Stress on Bushings
𝑆𝑡 = and 𝑆𝑐 =
𝐴 𝐴
Where:
𝑆𝑡 = Tensile stress (psi, MPa)
𝑆𝑐 = Compressive stress (psi, MPa)

1 Chegg.com
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

Where:
𝜀𝑇 = transverse, lateral or radial strain (in/in, mm/mm)
∆𝑟 = change in radius (in, mm)
r = initial radius (in, mm)

STRESS-STRAIN CURVE
A stress–strain curve for a material gives the relationship
between stress and strain.
These curves reveal many of the properties of a material,
such as the Young's modulus, the yield strength and the
ultimate tensile strength.
Fig. 1.3 Bearing Stress on Bushing

For negligible clearance and rigid bodies, the

magnitude of the bearing stress can be calculated from
the bearing stress formula:
Radial Load 𝐹 𝐹
𝑆𝑏 = = = .
Projected Area 𝐴 𝑑𝐿
Where:
𝑆𝑏 = normal stress (psi, MPa)
𝐹 = normal force (lb, N)
𝐴 = resisting area (in2, mm2)
𝑑 = inside diameter of bushing (in, mm)
𝐿 = length of bushing (in, mm)

1.3 STRAIN DEFORMATION Fig. 1.5 The stress-strain curvei

Strain is deformation of a solid due to stress; deformation
refers to the change in size or shape of an object; Modulus of Elasticity
displacements are the absolute change in position of a point The modulus of elasticity E is a measure of stiffness. The
on the object; deflection is the relative change in external magnitude of the modulus of elasticity E can be calculated as
displacements on an object. the ratio of stress to strain or
𝑆𝑡
𝐸= .
𝜀
Where:
𝐸 = modulus of elasticity (psi, MPa)
𝑆𝑡 = tensile stress (psi, MPa)
𝜀 = tensile strain (in/in, mm/mm)
Fig. 1.4 Deformation of bar under tension
Poisson’s Ratio
The longitudinal strain 𝜀𝐿 of a body is generally defined
The Poisson’s ratio (ν) is defined as the amount by which
as the change in length divided by the initial length.
the cross-sectional area reduces or increases is given by a
It can be expressed as
ΔL 𝛿 material property;
𝜀𝐿 = = . longitudinal strain 𝜀𝐿
𝐿 𝐿 𝑣= = .
Where: transverse strain 𝜀𝑇
𝜀𝐿 = longitudinal/lateral strain (dimensionless)
𝛿 = change in length (in, mm) Table 1.1 Poisson’s Ratio of common materials.
L = initial length (in, mm) Materials Poisson's ratio (v)
1. Aluminum 0.334
The transverse strain 𝜀𝑇 of a body is generally defined as 2. Stainless steel 0.30–0.31
the change in diameter divided by the initial diameter. 3. Steel 0.27–0.30
It can be expressed as 4. Cast Iron 0.21–0.26
∆𝑟
𝜀𝑇 = .
𝑟
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

Hooke’s Law states that “within the proportional limit the 1.11 (ME BD., APR. 2000) The ratio of strain to the original
stress in the material is directly proportional to the strain or S length.
∝ ε. A. Modulus of elasticity C. Stress
𝑆 = 𝐸 ·𝜀 B. Strain D. Unit length
𝐹 𝛿
=𝐸· 1.12 The frictional forces depend on the coefficient of
𝐴 𝐿
Linear Deformation friction and this ______. (Similar to ME Bd. Exam April,
This can be stated in the formula 1998)
𝑆 = 𝐸 ·𝜀 A. Torque C. Weight
𝐹 𝛿 B. Normal force D. Tangential force
=𝐸·
𝐴 𝐿
Solving for the linear deformation 𝛿, therefore, 1.13 A type of stress that acts coplanar with cross section
𝐹𝐿 of material. (Similar to ME Bd. Exam, April 1998)
𝛿= . A. Shearing stress C. Bearing stress
𝐸𝐴
Where: B. Compressive stress D. Bending stress
𝛿 = linear deformation under axial load (in, mm)
F = axial load (lb, N) 1.14 What is the derivative of the shear equation of a
L = original total length of the member (in, mm) beam? (ME Bd. Exam, April, 1997)
E = modulus of elasticity of the material (psi, MPa) A. Bending moment C. Tensile strength
A = cross-sectional area of the member (in2, mm2) B. elastic curve (slope) D. Load

Factor of Safety 1.15 The ability of the material to resist deformation

The factor of safety N is given by the formula2: under stress. (Similar to ME Bd, April, 1997)
(ductile material) (brittle material) A. Plasticity C. Stiffness
𝑆𝑦 𝑆𝑢 B. Toughness D. Malleability
𝑁= 𝑁=
𝑆𝑑 𝑆𝑑
Where: 1.16 The ratio of unit lateral deformation to unit
𝑆𝑢 = ultimate-stress (psi, MPa) longitudinal deformation. (Similar to ME Bd. Oct. 1996)
𝑆𝑦 = yield-stress (psi, MPa) A. Deformation C. Stiffness
𝑆𝑑 = design/working/allowable stress (psi, MPa) B. Poisson’s ratio D. Shear modulus
N = factor of safety/margin of safety/design factor
1.17 The maximum load that a material can support
Table 1.2 Factor of Safety3, N
without fracture when being stretched, divided by the
Steel Cast Iron original cross-sectional area of the material. (Similar to
Timber ME Bd, Oct. 1993)
(Ductile) (Brittle)
Type of Load A. Tensile strength C. Stress
𝑆𝑢 𝑆𝑦 𝑆𝑢 B. Elasticity D. Strain
Dead load 3-4 1.5-2 5-6 7
1.18 A mechanical property of metal that is the degree to
Repeated,
which a material may be bent, stretched, or compressed
Gradual, 6 3 7-8 10
before it ruptures. (Similar to ME Bd Exam, Apr. 1993)
one direction
A. Elastic limit C. Strain
Repeated,
B. Elongation D. Stiffness
Reversed, 8 4 10-12 15
Gradual
1.19 The ratio of stress to strain within the elastic limit.
Shock 10-15 5-7 15-20 20
(ME Bd Exam, Apr. 1993)
A. Creep C. Modulus of rigidity
ILLUSTRATIVE EXAMPLES
B. Poisson’s ratio D. Modulus of elasticity
NORMAL STRESS 1.20 The ability of a material to resist being crushed. (ME
Bd Exam Apr. 1992)

2 3
Machine Design by R. H. Creamer p. 16 Design of Machine Elements by V. M. Faires, p. 20
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

A. Bending strength C. Fatigue strength A. SAE 1015 C. SAE 1040

B. Compressive strength D. Torsional strength B. SAE 1030 D. SAE 1080
SOLUTION:
1.21 The total resistance that a material offers to an Mott (p.49), AISI 1015 is used for formed sheet-metal
applied load. (ME Bd Exam, Jun 1990) parts and machined parts; AISI 1030 is used for general-
A. Compressive force C. Stress purpose like bar-shaped parts, levers, links, keys, etc; AISI
B. Rigidity D. Friction torque 1040 for shaft and gears; AISI 1080 used for springs;
agricultural equipment parts subjected to abrasion like
1.22 Forces that act in a single plane; thus, the forces are rake teeth, disks, plowshares, mower teeth. A.
parallel to the plane and their points of application are in
the plane. (ME Bd Exam, Oct. 2020) 1.31 If the weight of a 4-in diameter shaft, 96-in long SAE
A. Resultant C. Coplanar 1045 shaft is 343 lb, then what is the weight of a shaft of
B. Couple D. Resolution of forces similar dimension made of SAE 4640? (Similar to ME Bd
EXAM, April, 2002)
1.23 A simple term for force. (ME Bd, Apr. 2003) A. 1396 N C. 1495 N
A. Concurrent force C. coplanar force B. 1455 N D. 1526 N
B. Push or pull D. Linear momentum SOLUTION:
The main component of SAE 1045 & SAE 4640 is iron, the
1.24 The ratio of the ultimate stress with the allowable density is the same; W = 343(4.44822) = 1526 N. D.
stress.
(ME Bd Exam, Nov. 1998) 1.32 Which of the following defines the factor of safety for
A. Strain C. Poisson’s ratio ductile materials as a ratio of?
B. Modulus of elasticity D. Factor of safety A. ultimate stress to allowable stress
B. yield stress to working stress
1.25 The greatest unit pressure the soil can continuously C. safe working stress to ultimate stress
withstand. (ME Bd, Apr. 1996) D. allowable stress to permissible stress
A. Yield point C. Bearing strength NOTE: In ductile materials, when the stress exceeds
B. Ultimate strength D. Point of rapture the yield strength of the material, there is a small
amount of plastic deformation that does not put the
1.26 Separate forces which can be combined (forces that component out of service. The factor of safety N is
intersect through a single point). (ME Bd, Oct. 2006) calculated with the yield stress of a materialii.
A. Parallel forces C. Couple
B. Concurrent forces D. Coplanar forces

1.27 Finding the resultant of two or more force. (ME Bd,

Oct. 2006)
A. Composition of forces C. Couple
B. Coplanar forces D. Parallel forces

1.28 A law stating that the strain in a solid is proportional

to the applied stress within the elastic limit of that solid.
(Similar to ME Bd, Oct. 2005)
A. Ohm’s law C. Kirchhoff’s law
B. Hooke’s law D. Poisson’s law

1.29 (ME BD., AUG. 2021) The magnitude of springback is

proportional to the _________, yield strength, and work
hardening of the sheet metal. 1.33 What is the value of strain at yield point of ASTM A36
A. Load applied C. Modulus of rigidity steel in the stress-strain curve?
B. Modulus of elasticity D. Strain rate A. 0.0012 C. 0.0021
B. 0.0016 D. 0.0025
1.30 (ME BD EXAM) What is the most common material SOLUTION:
for sheet metal? In ASTM A36 steel, Sy = 36000 psi
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

𝑆 36000 1.37 A steel tie rod on a bridge must be made to withstand

𝜀= = = 0.0012.
𝐸 30000000 a pull of 5 kips. Find the diameter of the rod assuming a
factor of safety of 5 and yield stress of 64,500 lb/in2. (ME
1.34 A 12000-lb hammer of a mechanized pile driver is BOARD APR ‘96)
lifted by 3 ft in 2.618 sec, what is the theoretical power A. 3/8 in C. 3/4 in
delivered? B. 1/2 in D. 1 in
A. 15 hp C. 25 hp
B. 20 hp D. 30 hp
SOLUTION:
Power = (weight)(height)/(time)
P = (12,000 lb)(3 ft)/2.618 sec)/(550 ft-lb/hp-sec)
12000(3/2.618)/550 = 25 hp. C.

1.35 A 1.00-in diameter steel bar is under a tensile load of

5,000 lb, if the yield stress of the shaft is 310 MPa (AISI Fig. 1.7 Tie Rod for suspension bridge4
1045), find the factor of safety based on yield strength. SOLUTION:
A. 4 C. 6 Let D = the nominal diameter of the tie rod (in).
B. 5 D. 7 𝐹 = 5 kips = 5,000 lb.
SOLUTION: 𝑆𝑦 64,500
Conversion: 1 MPa = 145 psi. 𝑆𝑑 = = = 12,900 lb.
𝑁 5
𝑆𝑑 = F/A = 5000/(π/4)(12) = 6,366 psi The dimensions are homogeneous, we apply the formula:
6366/145 = 43.9 MPa. 𝐹 𝐹
N = 𝑆𝑦 /𝑆𝑑 = 310/(43.9) = 7. 𝑆𝑑 = = 2
𝐴 (𝜋/4)𝐷
5,000
1.36 A 12-ft long wide flange beam I-beam (W 12 × 30) is 12,900 =
(𝜋/4)𝐷 2
subjected to a compressive load of 200 kN; if the area of
𝐷 = 0.71 in. C
the section is 8.85 in2, find the magnitude of the
compressive stress.
A. 4.11 MPa C. 5.08 ksi 1.38 An S12 × 40.8 steel I-beam5 has a cross-sectional
B. 4.65 MPa D. 6.63 ksi area = 12 in2. If the beam is 10 ft, find the compressive
load applied perpendicular to the web area where the
allowable stress is 16,530 psi.
A. 198,360 lb C. 201,525 lb
B. 199,440 lb C. 203,767 lb

Fig 1.6. A wide-flange I-beamiii.

SOLUTION:
F = 200 kN = (200,000 N)(1 lb/4.448 N) = 44,964 lb
A = 8.85 in2.
The dimensions are homogeneous, we apply the formula:
𝐹 44,964 lb
𝑆𝑐 = = = 5,080 2 = 5080 psi Fig. 1.8 An I-beam with S-sectioniv.
𝐴 8.85 in SOLUTION:
𝑆𝑐 = 5.08. ksi.
An S12 x 40.8 means 12-in of nominal height and weighs
40.8 lb/ft of length. An I-beam can be bought with W-
section or an S-section, in this case it is the S-section. The
dimensions are homogeneous, we apply the formula:
F = SA
F = (16,530)(12) = 198,360 lb. A.

4 5
https://www.dreamstime.com/stock-images-metal-bridge-tie-rod-coupling- https://amesweb.info/Profiles/Standard-Steel-I-Beam-Sizes-Chart.aspx
threaded-screed-blurred-background-buildings-sky-image40306734
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

1.39 A 2-in diameter Aluminum schedule 40 pipe has D = A. 61,400 N C. 51,670 N

2.375 in and d = 2.067 in. If the 2-ft long pipe is subjected B. 58,540 N D. 42,165 N
to a tensile force of 500 lb, find the tensile stress.
A. 201 psi C. 281 psi
B. 241 psi D. 321 psi

Fig. 1.11. A bronze thrust washer under bearing loadvi.

SOLUTION:
Let D = outer diameter of the washer and d = inner
diameter of the washer and 𝑆𝑏 = 2 MPa = 2 N/mm2. The
Fig. 1.9 Aluminum pipes schedule 40v dimensions are homogeneous, we apply the formula:
𝐹 𝐹
SOLUTION: 𝑆𝑏 = ⇒ 𝑆𝑏 =
D = 2.375 in, d = 2.067 in and F = 500 lb. The dimensions 𝐴 (𝜋/4)(𝐷2 − 𝑑 2 )
are homogeneous, we apply the formula: 𝐹
25 =
𝐹 𝐹 (𝜋/4)(752 − 502 )
𝑆𝑡 = = 𝜋 𝐹 = 61,359 N. A
𝐴 ( ) (𝐷 2 − 𝑑 2)
4
500
𝑆𝑡 = 𝜋 1.42 From the above problem, for a design factor of 4
(4 ) [(2.375)2 − (2.067)2 ] based on the ultimate strength, what is the maximum
𝑆𝑡 = 320.85 lb/in2 ≈ 321 psi. D allowable load?
A. 16 kips C. 21 kips
B. 18 kips D. 24 kips
1.40 The link shown is made of AISI C1020 annealed steel
SOLUTION:
(𝑆𝑢 = 57 ksi & 𝑆𝑦 = 42 ksi), with b = 0.75 in and h = 1.5
𝑆𝑢 = 57 ksi = 57,000 psi, b = 0.75 in and h = 1.5. The
in. What force will cause the breakage?
A. 36 kips C. 64 kips dimensions are homogeneous, we apply the formula:
B. 52 kips D. 80 kips 𝐹 = (𝑆𝑢 /𝑁)𝐴
57,000
𝐹=( ) (0.75)(1.5) = 16,000 lb
4
𝐹 = 16 kips. A

1.43 What is the yield strength of an A36 steel plates?

A. 224 MPa C. 248 MPa
B. 236 MPa D. 260 MPa
Fig. 1.10. A tensile specimen under load. SOLUTION:
An A36 steel plates indicates that the yield strength is
SOLUTION:
36,000 psi. So, convert the unit psi to MPa.
𝑆𝑢 = 57 ksi = 57,000 lb/in2, b = 0.75 in and h = 1.5. 1 MPa
The dimensions are homogeneous, we apply the 𝑆𝑦 = 36,000 psi × = 248 MPa. 𝐶.
145 psi
formula:
𝐹𝑢 1.44 A soft steel specimen has a BHN of 100, find the
𝑆𝑢 = ⇒ 𝐹𝑢 = 𝑆𝑢 × 𝑏ℎ = (57)(0.75)(1.5)
𝐴 equivalent tensile strength in MPa. (Similar to ME BOARD
𝐹𝑢 = 64 kips. C EXAM)
A. 265 C. 355
1.41 A thrust washer6 has an inside diameter of 50 mm B. 305 D. 405
and an outside diameter of 75 mm. If the allowable SOLUTION:
bearing stress is 25 MPa (Sy = 150 MPa), how much axial This is not a design problem but a tough question if you
load can it sustain? (Similar to #6, p. 156 Creamer) are not familiar with Machineries HB. The book of Faires

6“Thrust washers are flat washers that are located between a rotating surface on to which a bearing is supported.”-
surface and a stationary component. The thrust washer provides a https://www.amgindustries.com/Thrust-Washers.html
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

gave this steel BHN estimate, 𝑆𝑢 ≈ 500(BHN) psi [200 < L = ?, d = 4 in, 𝑆𝑏 = 200 psi, and F = 6,400 lb
BHN < 400] which is not applicable. The dimensions are homogeneous, we apply the formula:
The Machineries HB, 26th Ed., p. 521 gave these 𝐹
𝑆𝑏 =
approximations: 𝑑𝐿
6,400
𝑆𝑢 = 490 (BHN) psi for BHN > 175 200 =
(4)(𝐿)
𝑆𝑢 = 515 (BHN) psi for BHN ≤ 175
𝐿 = 8 in. B
Therefore,
𝑆𝑢 = 515(BHN) psi = 515(100) psi = 51,500 psi
1.48 What is the L/D of the previous problem?
𝑆𝑢 = (51,500 psi)(1 MPa/145 psi)
A. 0.8 C. 1.5
𝑆𝑢 = 355.2 MPa. C.
B. 1.0 D. 2.0
SOLUTION:
1.45 From the above problem, for a design factor of 2.5
L/D = 8/4 = 2.0. D.
based on the yield strength, what is the maximum
allowable load?
A. 17.9 kips C. 21.9 kips 1.49 A shaft is supported with two sleeve bearings and is
B. 18.9 kips D. 22.9 kips subjected to a radial load of 30 kN. Permissible bearing
SOLUTION: pressure is 1.5 MPa. The diameter of the shaft is 100 mm.
𝑆𝑦 = 57 ksi = 42,000 lb/in2, b = 0.75 in and h = 1.5. find the length of the bearings.
The dimensions are homogeneous, we apply the A. 100 mm C. 150 mm
formula: B. 125 mm D. 175 mm
𝐹 = (𝑆𝑦 /𝑁)(𝐴) SOLUTION:
42,000 D = 100 mm, F = (30 kN)/2 = 15 kN = 15,000 N, permissible
𝐹=( ) (0.75 × 1.5) stress 𝑆𝑏 = 1.5 MPa = 1.5 N/mm2. The dimensions are
2.5
𝐹 = 18,900 lb homogeneous, we apply the formula:
𝐹
𝐹 = 18.9 kips. B 𝑆𝑏 =
𝑑𝐿
(15,000)
1.5 =
(100)(𝐿)
BEARING STRESS EXAMPLES
L = 100 mm. A
1.46 A 2.5 in diameter by 2 in long journal bearing is to
carry a load of 5,500 lb at 3,600 RPM using SAE 40 lube 1.50 A journal bearing with diameter of 60 mm is
oil at 200 °F through a single hole at 2 psi. Compute the subjected to a force of 5,000 N while rotating @ 1,200
bearing stress. (ME BD, OCT ’95) RPM. If the coefficient of friction is 0.02 and L/D = 1.5,
A. 1,100 psi C. 1,300 psi find the projected area under pressure in mm2. (Similar
B. 1,200 psi D. 1,400 psi to ME BOARD APR ’96)
SOLUTION: A. 4,300 C. 5,400
D = 2.5 in and L = 2 in, and F = 5,500 lb, other data given B. 4,900 D. 5,800
are irrelevant to the solution of the problem. The SOLUTION:
dimensions are homogeneous, we apply the formula: The L/D ratio is in consonance with current standards7,
𝐹 5,000 other given information is irrelevant, then
𝑆𝑏 = = = 1,100 psi. 𝐴
𝐷𝐿 (2.5)(2) 𝐴 = 𝐿𝐷 = (𝐿/𝐷) · 𝐷 2 = (1.5)(60)2 = 5,400 mm2 . C

1.47 What is the length of a bearing for a 4-in diameter

1.51 A 22-mm shaft is supported by sleeve bearings in an
shaft if the load on the bearing is 6,400 lb and the
arrangement as shown below. The load is 4,000 lb. The
allowable bearing pressure is 200 psi of the projected
sleeve bearings have an L = 1.5D. Find the maximum
area? (Similar to FAIRES, #1.13)
bearing stress. (Similar to #4.3 Creamer, p. 154)
A. 6 in C. 10 in
A. 1.8 MPa C. 2.9 MPa
B. 8 in D. 12 in B. 2.6 MPa D. 3.3 MPa
SOLUTION:

7https://www.daidometal.com/wp-
content/uploads/2017/10/Metal_bushing.pdf
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

1 − 𝐴𝑓
0.7 = ⇒ 𝐴𝑓 = 0.3.
1
𝐴𝑜 1
𝜀𝑡 = ln ( ) = ln ( ) = 1.1. 𝐵.
𝐴𝑓 0.3

1.54 What modulus of elasticity in tension is required to

Fig. 1.12. Load diagram of a simply supported shaft. obtain a unit deformation of 0.0015 m/m from a load
producing a unit stress of 44,500 psi? (ME BD., OCT ’95)
SOLUTION: A. 29,500 ksi C. 30,000 ksi
The maximum force in the bearing occurs where the load B. 30,500 ksi D. 31,000 ksi
is nearest to it. Take summation of moments at the right SOLUTION:
bearing (@ R2): The dimensions are homogeneous, we apply the formula:
𝑆 44,500 psi
(200 + 300)(R1) – (300)(F) = 0, 𝐸= =
500R1 – 300(4000) = 0, 𝜀 0.00105
R1 = 300(4000)/500 𝐸 = 29,500 ksi. A
R1 = 2,400 N.
We apply the bearing load formula: 1.55 The diameter of a brass rod is 6 mm. What force will
𝑅1 𝑅1 2400 N stretch it by 0.20% of its length where E is 90 GPa.
𝑆𝑏 = = 2 = 2 = 3.3 = 3.3 MPa.
𝐷𝐿 1.5𝐷 1.5(22) mm2 A. 5,450 N C. 5,090 N
B. 6,500 N D. 6,900 N
SOLUTION:
1.52 The lap joint is fastened by four 3/4-in.-diameter
D = 6 mm = 0.006 m,
rivets. Calculate the bearing load that can be applied if
𝛿 = 0.20% of length 𝐿 = (0.20/100)𝐿 = 0.002𝐿
the bearing stress in the plates is limited to 8 ksi. Assume
the applied load is uniformly distributed among the four 𝐸 = 90 GPa = 90,000 MPa = 90,000 𝑁/m2 .
rivets. The plate is 7/8-in thick. The dimensions are homogeneous, we apply the formula:
A. 18,667 lb C. 25,500 lb 𝐹𝐿 𝐹𝐿
𝛿= =
B. 21,000 lb D. 28,333 lb 𝐸𝐴 𝐸 · (𝜋/4)𝐷 2
SOLUTION: 𝐹𝐿
0.002𝐿 =
𝑆𝑏 = 8 𝑘𝑠𝑖 = 8,000 𝑝𝑠𝑖 = 8,000 lb/in2 (90,000) · (𝜋/4)(0.006)2
𝐴𝑏 = 4bt = 4(3/4 in)(7/8 in) = 21/8 in2 𝐹 = 5,089.4 N ≈ 5,090 N. C
The dimensions are homogeneous, we apply the formula:
F = 𝑆𝑏 𝐴𝑏
1.56 A piston assembly has the following information: a =
F = (8,000)(21/8) = 21,000 lb. B cylinder block length = 8 in, b = deck clearance = 0.025 in,
c = target compression height of piston = 1 in, and d =
Strain and Deformation Problems stroke of engine = 3.25 in. Additionally, the chrome
1.53 A test specimen under tensile load suffered a plated C1045 piston rod has 𝑘 = 12.5 × 10−6 m/m/
reduction in area of 70%. What is the true strain at °C, 𝑆𝑦 = 45,000 psi & 𝐸 = 30,000 ksi; if the piston rod
failure? (ME BD., AUG. 2021) underwent a temperature change of 400 °C, then
A. 0.7 C. 1.5 determine the thermal elongation.
B. 1.1 D. 2.0 A. 0.0319 in C. 0.0358 in
Calculate the change in diameter of a circular steel rod B. 0.0333 in D. 0.0372 in
axially loaded in compression, where D = 2 in ε = SOLUTION:
−0.00025, and ν = 0.28 (steel). SOLUTION: We use the empirical formula from the internet for the
The percentage reduction in area of a steel test specimen approximate piston rod length8, then
ranges from 40% to 70%. L = a – b – (c + 0.5d).
𝐴𝑜 − 𝐴𝑓 L = 9.025 – 0.025 – (1.0 + 0.5(3.25)) = 6.375 in.
%𝑅𝐴 = × 100% 𝑘 = 0.0000125 m/m/°C.
𝐴𝑜
The dimensions are homogeneous, we apply the formula:
𝛿 = 𝑘𝐿(𝑇2 − 𝑇1 )

8
http://www.wiseco.com/Calculators.aspx
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

𝛿 = (0.0000125)(6.375)(400) 1.60 An Aluminum, 6061-T6 (v = 0.35) bar with length 10

𝛿 = 0.0319 in. A m and radius 100 mm is stretched 5 mm. Calculate the
radial contraction (Δ𝑟).
1.57 Calculate the change in length of a steel bar that is A. 0.0135 mm C. 0.0165 mm
heated to 250 °F from 0 °F, k = 6.5 × 10−6 in/in/°F, and L = B. 0.0145 mm D. 0.0175 mm
9 ft. SOLUTION:
A. 0.15 in C. 0.21 in Δ𝑟
B. 0.18 in D. 0.24 in 𝑣=− 𝑟 .
Δ𝐿
SOLUTION: 𝐿
k = 6.5 × 10−6in/in/°F, L = 9 ft, 𝑇2 − 𝑇1 = 250 °F, we apply Rearranging to solve for Δ𝑟,
the formula: 𝑟 · Δ𝐿 · 𝑣
Δ𝑟 = −
𝛿 = 𝑘𝐿(𝑇2 − 𝑇1 ) 𝐿
𝛿 = (0.0000065)(9)(250) = 0.015 ft = 0.18 in . B With Poisson's ratio for aluminum 0.33 - the contraction
can be calculated as
100 · 5 · 0.35
1.58 A 3/8×16×5 hex bolt is made of AISI Type 304 Δ𝑟 = − = −0.0175 mm. 𝐷.
10,000
Stainless Steel hex bolt (𝑆𝑦 = 50,200 psi & 𝐸 =
30,000 ksi) has an effective grip length of 5 in. The bolt 1.61 Determine the load in kN on a 25-mm diameter and
is to be loaded by tightening until the tensile stress is 80 1,200 mm long steel shaft if its maximum elongation
% of the yield strength, as determined by measuring the exceeds 1 mm. Use E = 206,786 MPa. [ME BOARD, OCT
total elongation. What should be the total elongation? 2000]
(Similar to FAIRES, # 1.10) A. 74.4 C. 91.5
B. 84.6 D. 99.9
SOLUTION:
The dimensions are homogeneous, we apply the formula:
Fig. 1.14. Hex bolt under tensile load.9 𝐹𝐿 𝐹𝐿
A. 0.011 in C. 0.0033 in 𝛿= =
𝐴𝐸 (𝜋/4)(𝐷2 )𝐸
B. 0.007 in D. 0.0002 in 𝐹(1,200)
1=
SOLUTION: (𝜋/4)(252 )(206,786)
The hex bolt is 3/8 in in diameter, 16 threads per inch and 𝐹 = 84,588.2 N. B
5.0 inch long. https://pinoybix.org/2014/10/mcqs-in-strength-of-
𝑆𝑑 = 0.8𝑆𝑦 = (0.8)(50.2) = 40.16 ksi = 40,160 lb/in2 materials-part1.html
E = 29,000,000 lb/in2
L = grip length = 5 in. A. FORMATIVE ASSESSMENT PROBLEMS
The dimensions are homogeneous, we apply the formula:
𝐹 𝐿 𝐿 (5)
𝛿 = · = 𝑆 · = 40,160 · Normal Stress Problems
𝐴 𝐸 𝐸 29,000,000
𝛿 = 251/(36250) = 0.007 in. B 1.62 A 6-in long steel has a cross-section area of 0.25 in2;
if the load applied is 5,000 kg, what would be the stress?
[3,100 kg/cm2 - ME BOARD EXAM, OCT 2003]
1.59 Determine the estimated weight of an A-36 steel
1.63 Find the force on a 1/2-diameter round bar subjected
plate size 3/16′′ × 4′ × 8′. (Similar to ME BOARD EXAM)
A. 242 lb C. 305 lb to an induced compressive stress of 8 ksi. [1,571 lb]
B. 274 lb D. 339 lb 1.64 A 3-in diameter Aluminum pipe (ANSI10 schedule 40)
SOLUTION: with D = 3.50′′ and d = 2.90′′ is subjected to a tensile force
An A36 has a density of 7,800 kg/m3 (0.284 lb/in3). Also of 800 lb; find the tensile stress developed if the length
given are: L = 3/16′′, W = 4′ = 48 in, H = 8′ = 96 in. of pipe is 4ft. [265 psi]vii
Weight = density × volume = ρLWH 1.65 An S5×10 steel I-beam has a stress area of 2.94 in2. If
Weight = (0.28)(3/16)(48)(96) = 241.92 lb. A the beam is 12 ft, find the tensile load if the allowable
stress is 114 MPa. [48,600 lb]

9
https://shop.theelectricbrewery.com/pages/3-8-16-x-5-hex-bolt
10 https://www.engineeringtoolbox.com/ansi-steel-pipes-d_306.html
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)
1.66 A 5/8-in steel tie rod is made to withstand a pull of 4
kips. Find the factor of safety if the yield stress is 64,500
lb/in2. (Similar to ME BOARD APR ‘96 ) [N = 5]
2. A 1/8-in diameter wire is used in a chain link. The tensile
stress is 540 MPa, what is the breaking load of the chain?
3. A rectangular metal bar has a width of 10 mm and can
support a maximum compressive stress of 20 MPa;
determine the minimum breadth of the bar loaded with
a force of 3 kN. [15 mm – ME BOARD APR. 2004]
4. A 16-in long hollow square tube is made of Aluminum
material, the outside diameter is 2.25 in and a wall
thickness of 0.120 in. What axial compressive force would
cause the tube to shorten by 0.004 in? [2,556 lb]
Fig. 1.12 An Aluminum steel tube11
5. From the above problem, compute the resulting
compressive stress in the aluminum. [2,506 psi]
6. Compute the stress in the middle portion of rod AC in
The figure below if the vertical force on the boom is
2,500 lb. The rod is rectangular, 1.50 in by 3.50 in.
(Similar to MOTT, #3.8) [595 psi]
7. A tensile force of 9500 N is applied to a round bar. If the
direct tensile stress in the bar is 84 MPa, find the
diameter of the bar. [12-mm]
8. A steel steel has a BHN of 250, find the equivalent tensile
strength in MPa. [845]
9. A 2-in diameter Aluminum pipe (ANSI schedule 40) is
subjected to a tensile force of 600 lb; find the tensile
stress developed if the length of pipe is 10 ft.
11https://www.homedepot.com/p/Everbilt-1-in-x-96-in-Aluminum-
Square-Tube-with-1-20-in-Thick-802537/204273939
10. The rectangular section is made of AISI C1020 annealed
steel (Su = 57 ksi), with b = 0.5 in and h = 1.5 in. What
tensile force will cause the breakage? [42.75 kips]
Situational Problem: An A36 structural steel has 𝑆𝑦 = 36,000
psi. The tensile stress is 6,000 psi. (ME BD, APR. 2004)
11. What is the equivalent yield strength in MPa?
A. 160 C. 220
B. 190 D. 250
12. What is the factor of safety based on yield strength?
A. 4 C. 6
B. 5 D. 7
13. If the induced tensile stress is 4,500 psi, what is the factor
of safety?
A. 6 C. 8
B. 7 D. 9
14. What is the elongation break of a rod specimen with a 50
mm gauge length and 8.0 mm diameter?
A. 15 % C. 20 %
B. 18 % D. 23 %
15. What is the Poisson’s ratio of A36 structural steel?
A. 0.24 C. 0.26
B. 0.28 D. 0.30
16. What is the Young's modulus for A36 steel in GPa?
A. 180 C. 200
B. 190 D. 210
Bearing Stress Problems
17. A 36-mm shaft uses a sleeve bearing that sustains a load
of 3,575 N. If the allowable bearing pressure is 1.38 MPa,
find the L/D ratio. [2 – Similar to Creamer #4.1]
18. A shaft is supported with two identical sleeve bearings
and is subjected to a radial load of 37.5 kN. Allowable
bearing pressure is 5 MPa. The diameter of the shaft is 50
mm. find the length of the bearings. [75 mm]
19. A sleeve bearing has an outside diameter of 1.50-in and a
length of 2 inches. The wall thickness is 3/16-in. The
bearing is subjected to a radial load of 450 lb. find the
bearing pressure. [200 psi – Creamer #4.4]
20. A thrust washer has an inside diameter of 80 mm and an
outside diameter of 100 mm. If the axial load it can
sustain is 5 kN, then find the bearing stress induced.
[1.768 MPa]
21. A circular shaft uses a pair of sleeve bearings. The total
load per bearing is 2000 N. An L/D = 2.5 is desired. If the
allowable bearing pressure is 2 MPa, find the diameter of
the shaft. [20 mm - Similar to #4.2 of Creamer]
22. A 20-mm-diameter rivet joins the plates that are each 110
mm wide and a thickness of 10 mm. The allowable
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

bearing stress of the rivet is 60 MPa. Determine allowable

bearing load of the rivet. [12,000 N] M1B – ANALYSIS OF NORMAL & BEARING STRESSES
DESIGN PROBLEMS

1.41 The link shown, made of AISI C1045 steel, as rolled, is

23. A bushing with an internal diameter of 150 mm is
subjected to a force of 30,000 N. If L/D = 0.8, find the
projected area under pressure in cm2. [180]
subjected to a tensile load of 8,000 lb. Let h = 1.5b. If the
load is repeated but not reversed, determine the
dimension b of the section with the design based on
ultimate strength. (Similar to Faires, #1.1)

Strain and Deformation problems

24. What is the decrease in lateral dimension due to an axial
tensile force of 50,000 lb in a steel bar 3 inches on each
side and 6 feet long? [0.000185 in/in – ME BOARD, APR
2003]
25. An aluminum rod is made in the form of a hollow square SOLUTION:
tube. 2.25 in outside, with a wall thickness of 0.120 in. Its For AISI C1045 steel, as rolled (Table AT 7) 𝑆𝑢 = 96 ksi and
length is 16.0 in. What axial compressive force would E = 30,000ksi; N = 6 for repeated but not reversed load
cause the tube to shorten by 0.004 in? [2,556 lb] (Table 1.1).
26. From the previous problem compute the resulting 𝑆𝑢 𝐹
compressive stress in the aluminum. [2,506 psi] 𝑆𝑑 = =
𝑁 𝐴
27. A wire of length 2.5 m has a strain of 0.012% when loaded lb
96,000 2
with a tensile force. Find the extension of the wire – ME in = 8,000
BOARD APR 2004. [0.30 mm] 6 (𝑏)(1.5 𝑏)
28. It is the resulting cross-sectional area of the tensile test b = 0.577 in
specimen divided by the specimen original area. [% The next std. dimension is 5/8 in, use b = 5/8 in.
elongation; likely, it’s % reduction area]
29. An Aluminum, 2024-T4 (v = 0.32) round bar with length of 1.42 From #1.6, determine the dimension h of the section
4 m and radius 50 mm is stretched by 8 mm. Calculate the with the design based on yield strength. (Faires, #1.1)
radial contraction (Δr). [0.032 mm] SOLUTION:
30. A test specimen under tensile load suffered a reduction For AISI C1045 steel, as rolled (Table AT 7) 𝑆𝑦 = 59 ksi, and
in area of 90%. What is the true strain at failure? [2.3] E = 30,000ksi; N = 3 for repeated but not reversed load
31. Compute the load in kN on a 3-cm diameter and 100-cm (Table 1.1).
long steel rod if its maximum elongation exceeds 0.12 𝑆𝑦 𝐹
cm. [175.4 kN – ME BOARD, OCT 2000] 𝑆𝑑 = =
𝑁 𝐴
32. Calculate the length of a steel bar that is exposed to the lb
sun (ΔT = 20 °F), where k = 6.5 × 10−6in/in · °F (steel) and 59,000 2
in = 8,000 lb
elongation of 0.01872 in. [12 ft] 6 (𝑏)(1.5 𝑏)
33. It is a problem of expansion and shrinkage of steel b = 0.521 in.
material so that the slightly bigger shafting of 2′′ diameter The next std. dimension for b is 9/16 in and the height h
can be inserted/fitted to the slightly smaller hole of a = 1.5b = 1.5(9/16 in) ⇒ h = 27/32 in.
steel bushing of 1.999′′ diameter with the following
process/material/data to apply: 1.43 If this link, which is 15 in. long., must not elongate more
a) Coefficient of expansion of carbon steel = 0.0000068 than 0.005 in., what should be the dimensions of the
in/in/°F. cross section? (FAIRES, #1.1)
b) Temperature raised by gas heating = 24.5 °F. B. 1/2 in & 3/4 in C. 3/4 in & 9/8 in
c) Cooling media to use dry ice with boiling point of – C. 5/8 in & 15/16 in D. 7/8 in & 21/16 in
109.3 °F (–78.5 °C). SOLUTION:
d) Shrinkage rate below boiling point is 0.00073 in/in. Apply the elongation formula:
Determine the final clearance between the expanded 𝐹𝐿
steel bushing hole against the shrinkage of the steel shaft. 𝛿= .
𝐸𝐴
(Similar to ME Board Exam) [0.000793 in]
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)

(1,000 lb)(15 in) lb lb

0.005 in = . 134,000 (20 in)2 · 125 2
lb in2 = in
30,000,000 2 (𝑏)(1.5𝑏) 4 𝑑2
in
b = 0.73 in d = 1.2216 in
The next std. dimension for b = 3/4 in and the height The next standard piston rod diameter d is 1 and 1/4 in.
follows to be Design Problems
h = 1.5(3/4 in) ⇒ h = 9/8 in. 34. The link shown, made of AISI C1045 steel, as rolled, is
subjected to a tensile load of 6,000 lb. Let h = 4b. If the
1.44A piston rod, made of AISI 3140 steel, OQT 1000 F (Fig. AF load is repeated but not reversed, determine the
2), is subjected to a repeated, reversed load. The rod is dimension b of the section with the design based on yield
for a 20-in. air compressor cylinder, where the maximum strength. (Similar to FAIRES, #1.1)
pressure is 125 psig. Compute the diameter of the rod
using a design factor based on ultimate strength. (Faires,
#1.4)

SOLUTION:
From Fig. AF 2 for AISI 3140, OQT 1000 F, then
𝑆𝑢 = 153 ksi and E = 30,000 ksi. From
Table 1.1, 𝑁𝑢 = 8.
For the piston: F = Bore × 𝑝𝑚𝑎𝑥 35. A short hollow compression member with D/d = 2 is to
𝜋 support a dead load of 20 tons. The material is to be 4130
𝐹 = 𝐷 2 · 𝑝𝑚𝑎𝑥 steel, WQT 1100 °F. Calculate the outside and inside
4
For piston rod: 𝐴 = piston rod area diameters on the basis of (a) yield strength, (b) ultimate
𝜋 strength. (FAIRES, #1.6) [a) 5/8 in and 1-1/4 in & b) 7/8 in
𝐴 = 𝑑2
4 and 1-3/4 in]
𝐹 36. A hollow, short compression member, of normalized cast
𝑆𝑑 =
𝐴 steel (ASTM A27-58, 65 ksi), is to support a load of 1500
𝜋 2 kips with a factor of safety of 8 based on the ultimate
𝑆𝑢 4 𝐷 · 𝑝𝑚𝑎𝑥 𝑆𝑢 𝐷 2 · 𝑝𝑚𝑎𝑥
= 𝜋 2 ⇒ = strength. Determine the outside and inside diameters if
𝑁 𝑑 𝑁 𝑑2
4 D = 2d.
The dimensions are homogeneous, we apply the values: 37. A round, steel tension member, 55-in long, is subjected
153,000 (20)2 · 125 to a maximum load of 7000 lb. (a) What should be its
=
8 𝑑2 diameter if the total elongation is not to exceed 0.030 in?
d = 1.617 in. (b) Choose a steel that would be suitable on the basis of
The next standard dimension is 1 and 5/8 in. yield strength if the load is gradually applied and
repeated (not reversed).
1.45 From the previous problem, compute the diameter of
the rod using a design factor based on yield strength. PLATE #1.
(Faires, #1.4) 38. A piston rod, made of AISI 3140 steel, OQT 1100 F (Fig. AF
SOLUTION: 2), is subjected to a repeated, reversed load. The rod is
𝑆𝑦 = 134 ksi, and E = 30,000 ksi. for a 20-in. air compressor cylinder, where the maximum
From Table 1.1, page 20, 𝑁𝑦 = 4. pressure is 150 psig. a) Design the piston rod using a
𝜋 design factor based on yield strength, b) make a
𝐹 = Area of Bore × max. pressure = 𝐷 2 · 𝑝𝑚𝑎𝑥 mechanical drawing showing necessary details. (See
4
𝜋 FAIRES, #1.4)
𝐴 = cross − sectional area of piston = 𝑑 2
4
𝑆𝑦 𝐹
=
𝑁 𝐴
𝜋 2
𝑆𝑦 4 𝐷 · 𝑝𝑚𝑎𝑥
= 𝜋 2
𝑁 𝑑
4

i_https://en.wikipedia.org/wiki/Stress%E2%80%93strain_curve#/media/

File:Stress_strain_ductile.svg
 ISAT U ME: MACHINE DESIGN 1 – LECTURE NOTE 2022-2023 (2ND SEM)
ii
https://testbook.com/question-answer/which-of-the-
following-defines-the-factor-of-safet--
6165498a269498d91c3714ff
iiihttps://www.istockphoto.com/photos/wide-flange
iv https://www.steelbeamsdirect.com/product/universal-beams/
v https://www.oilandgaspipingmaterials.com/aluminum-pipes-tubes-
suppliers.html
vi https://www.cseoffroad.com/j8134037-cluster-gear-thrust-washer-
race
vii
The Error corrected by Onate & Avelino 02/15/2021