VARIABLE STRESSES WITH STRESS CONCENTRATIONS

158. The load on the link shown (150) is a maximum of

10 kips, repeated and reversed. The link is forged from
AISI C020, as rolled, and it has a ¼ in-hole drilled on the
center line of the wide side. Let h = 2b and N = 5.1 .
Determine b and h at the hole (no column action) (a) for
indefinite life, (b) for 50,000 repetitions (no reversal) of
the maximum load, (c) for indefinite life but with a
ground and polished surface. In this case, compute the
maximum stress.

159. A connecting link as shown, except that there is a

1/8-in. radial hole drilled through it at the center section.
It is machined from AISI 2330, WQT 1000 F, and it is
subjected to a repeated, reversed axial load whose
maximum value is 5 kips. For N = 5.1 , determine the
diameter of the link at the hole (a) for indefinite life; (b)
for a life of 105 repetitions (no column action). (c) In the
link found in (a) what is the maximum tensile stress?
160. A machine part of uniform thickness t = b 5.2 is
shaped as shown and machined all over from AISI C1020,
as rolled. The design is for indefinite life for a load
repeated from 1750 lb to 3500 lb. Let d = b . (a) For a
design factor of 1.8 (Soderberg), what should be the
dimensions of the part? (b) What is the maximum tensile
stress in the part designed?
162. The beam shown has a circular cross section and
supports a load F that varies from 1000 lb to 3000 lb; it is
machined from AISI C1020 steel, as rolled. Determine the
diameter D if r = 2.0 D and N = 2; indefinite life.
164. The shaft shown is machined from C1040, OQT 1000
F (Fig. AF 1). It is subjected to a torque that varies from
zero to 10,000 in-lb. ( F = 0 ). Let r = 2.0 D and N = 2 .
Compute D. What is the maximum torsional stress in the
shaft?
165. An axle (nonrotating) is to be machined from AISI
1144, OQT 1000 F, to the proportions shown, with a fillet
radius r ≈ 25.0 D ; F varies from 400 lb to 1200 lb.; the
supports are to the left of BB not shown. Let N = 2
(Soderberg line). (a) At the fillet, compute D and the
maximum tensile stress. (b) Compute D at section BB. (c)
Specify suitable dimensions keeping the given
proportions, would a smaller diameter be permissible if
the fillet were shot-peened?
 170. The beam shown is made of AISI C1020 steel, as
rolled; e = 8 in . The load F is repeated from zero to a
maximum of 1400 lb. Assume that the stress
concentration at the point of application of F is not
decisive. Determine the depth h and width t if h ≈ 4t ; N
= 5.1 ± 1.0 for Soderberg line. Iteration is necessary
because Kf depends on the dimensions. Start by
assuming a logical Kf for a logical h (Fig. AF 11), with a
final check of Kf . Considerable estimation inevitable.

A smaller diameter is permissible if the fillet were shot-

peened because of increased fatigue strength.

166. A pure torque varying from 5 in-kips to 15 in-kips is

applied at section C. ( F = 0 ) of the machined shaft shown.
The fillet radius r = D 8 and the torque passes through the
profile keyway at C. The material is AISI 1050, OQT 1100
F, and N = 6.1 . (a) What should be the diameter? (b) If
the fillet radius were increased to D 4 would it be
reasonable to use a smaller D ?
171. Design a crank similar to that shown with a design
factor of 6.1 ± 16.0 based on the modified Goodman line.
The crank is to be forged with certain surfaces milled as
shown and two ¼-in. holes. It is estimated that the
material must be of the order of AISI 8630, WQT 1100 F.
The length L =17 in. , a = 5 in., and the load varies form +
15 kips to –9 kips. (a) Compute the dimensions at section
AB with h = 3b . Check the safety of the edges (forged
surfaces). (Iteration involves; one could first make
calculations for forged surfaces and then check safety at
holes.) (b) Without redesigning but otherwise
considering relevant factors, quantitatively discuss
actions that might be taken to reduce the size; holes must
remain as located.
 175. The link shown is made of AISI C1020, as rolled,
machined all over. It is loaded in tension by pins in the D
in 8 3 = holes in the ends; a in 16 9 = , t in 16 5 = , h in 8 1
=1 . Considering sections at A, B, and C, determine the
maximum safe axial load for N = 2 and indefinite life (a) if
it is repeated and reversed; (b) if it is repeated varying
from zero to maximum; (c) if it is repeatedly varies or F =
−W to F = 3W . (d) Using the results from (a) and (b),
determine the ratio of the endurance strength for a
CHECK PROBLEMS repeated load to that for a reversed load (Soderberg line).
173. For the crank shown, L =15 in , a = 3 in , d = 5.4 in , b
= 5.1 in . It is as forged from AISI 8630, WQT 1100 F,
except for machined areas indicated. The load F varies
from +5 kips to –3 kips. The crank has been designed
without detailed attention to factors that affect its
endurance strength. In section AB only, compute the
factor of safety by the Soderberg criterion. Suppose it
were desired to improve the margin of safety, with
significant changes of dimensions prohibited, what
various steps could be taken? What are your particular
recommendations?
179. A steel rod shown, AISI 2320, hot rolled, has been
machined to the following dimensions: D = 1 in. , . c =3/4
in , . e = 1/8 in A semicircular groove at the midsection
has . r = 1/8 in ; for radial hole, . a = 1/4 in An axial load
of 5 kips is repeated and reversed ( M = 0 ). Compute the
factor of safety (Soderberg) and make a judgement on its
suitability (consider statistical variations of endurance
strength – i4.4). What steps may be taken to improve the
design factor?

2. Good surface condition

3. Presetting
186. A stock stud that supports a roller follower on a
needle bearing for a cam is made as shown, where a =
5/8 in , b = 7/16 in , c = ¾ in . The nature of the junction
of the diameters at B is not defined. Assume that the
inside corner is sharp. The material of the stud is AISI
2317, OQT 1000 F. Estimate the safe, repeated load F for
N = 2 . The radial capacity of the needle bearing is given
as 1170 lb. at 2000 rpm for a 2500-hr life. See Fig. 20.9,
p. 532, Text.
F = 0.370 kip = 370 lb < less than radial capacity of the
needle bearing. Ok.
187. The link shown is made of AISI C1035 steel, as rolled,
with the following dimensions . a = 3/8 in , . b = 7/8 in , c
=1in. , . d = ½ in , L =12 in., . r = 1/16 in. The axial load F
varies from 3000 lb to 5000 lb and is applied by pins in
the holes. (a) What are the factors of safety at points A,
B, and C if the link is machined all over? What are the
maximum stresses at these points?
 Example 6.6. Determine the diameter of a circular rod
made of ductile material with a fatigue strength
(complete stress reversal), σe = 265 MPa and a tensile
yield strength of 350 MPa. The member is subjected to a
varying axial load from Wmin = – 300 × 103 N to Wmax =
700 × 103 N and has a stress concentration factor = 1.8.
Use factor of safety as 2.0.

6.7. A steel rod is subjected to a reversed axial load of 180

kN. Find the diameter of the rod for a factor of safety of
2. Neglect column action. The material has an ultimate
tensile strength of 1070 MPa and yield strength of 910
MPa. The endurance limit in reversed bending may be
assumed to be one-half of the ultimate tensile strength.
Other correction factors may be taken as follows: For
axial loading = 0.7; For machined surface = 0.8; For size =
1. Determine the thickness of a 120 mm wide 0.85; For stress concentration = 1.0.
uniform plate for safe continuous operation if the
plate is to be subjected to a tensile load that has
a maximum value of 250 kN and a minimum
value of 100 kN. The properties of the plate
material are as follows: Endurance limit stress =
225 MPa, and Yield point stress = 300 MPa. The
factor of safety based on yield point may be
taken as 1.5.

6.8. A circular bar of 500 mm length is supported freely

at its two ends. It is acted upon by a central concentrated
cyclic load having a minimum value of 20 kN and a
maximum value of 50 kN. Determine the diameter of bar
by taking a factor of safety of 1.5, size effect of 0.85,
surface finish factor of 0.9. The material properties of bar
are given by : ultimate strength of 650 MPa, yield
strength of 500 MPa and endurance strength of 350 MPa.
 6.10.A cantilever beam made of cold drawn carbon steel
of circular cross-section as shown in Fig. 6.18, is
subjected to a load which varies from – F to 3 F.
Determine the maximum load that this member can
withstand for an indefinite life using a factor of safety as
2. The theoretical stress concentration factor is 1.42 and
the notch sensitivity is 0.9. Assume the following values:
Ultimate stress = 550 MPa Yield stress = 470 MPa
Endurance limit = 275 MPa Size factor = 0.85 Surface
finish factor = 0.89

6.9. A 50 mm diameter shaft is made from carbon steel

having ultimate tensile strength of 630 MPa. It is
subjected to a torque which fluctuates between 2000 N-
m to – 800 N-m. Using Soderberg method, calculate the
factor of safety. Assume suitable values for any other
data needed.

6.11. A simply supported beam has a concentrated load

at the centre which fluctuates from a value of P to 4 P.
The span of the beam is 500 mm and its cross-section is
circular with a diameter of 60 mm. Taking for the beam
material an ultimate stress of 700 MPa, a yield stress of
500 MPa, endurance limit of 330 MPa for reversed
bending, and a factor of safety of 1.3, calculate the
maximum value of P. Take a size factor of 0.85 and a
surface finish factor of 0.9

1. A rectangular plate 50 mm × 10 mm with a hole
10 mm diameter is subjected to an axial load of
10 kN. Taking stress concentration into account,
find the maximum stress induced.
2. A stepped shaft has maximum diameter 45 mm
and minimum diameter 30 mm. The fillet radius
is 6 mm. If the shaft is subjected to an axial load
of 10 kN, find the maximum stress induced,
taking stress concentration into account
3. A leaf spring in an automobile is subjected to cyclic
stresses. The average stress = 150 MPa; variable stress =
500 MPa; ultimate stress = 630 MPa; yield point stress =
350 MPa and endurance limit = 150 MPa. Estimate,
under what factor of safety the spring is working, by
Goodman and Soderberg formulae
13. A steel cantilever beam, as shown in Fig. 6.21, is
subjected to a transverse load at its end that varies from
45 N up to 135 N down as the axial load varies from 110
N (compression) to 450 N (tension). Determine the
required diameter at the change of section for infinite life
using a factor of safety of 2. The strength properties are
as follows: Ultimate strength = 550 MPa Yield strength =
470 MPa Endurance limit = 275 MPa

The stress concentration factors for bending and axial

loads are 1.44 and 1.63 respectively, at the change of
cross-section. Take size factor = 0.85 and surface finish
factor = 0.9.

15. A pulley is keyed to a shaft midway between two anti-

friction bearings. The bending moment at the pulley
varies from – 170 N-m to 510 N-m and the torsional
moment in the shaft varies from 55 N-m to 165 N-m. The
frequency of the variation of the loads is the same as the
shaft speed. The shaft is made of cold drawn steel having
an ultimate strength of 540 MPa and a yield strength of
400 MPa. Determine the required diameter for an
indefinite life. The stress concentration factor for the
keyway in bending and torsion may be taken as 1.6 and
1.3 respectively. The factor of safety is 1.5. Take size
factor = 0.85 and surface finish factor = 0.88. [Ans. 36.5
mm] [Hint. Assume σe = 0.5 σu ; τ y = 0.5 σy ; τ e = 0.55
σe ]

14. A steel shaft is subjected to completely reversed

bending moment of 800 N-m and a cyclic twisting
moment of 500 N-m which varies over a range of ± 40%.
Determine the diameter of shaft if a reduction factor of
1.2 is applied to the variable component of bending
stress and shearing stress. Assume (a) that the maximum
bending and shearing stresses are in phase; (b) that the
tensile yield point is the limiting stress for steady state
component; (c) that the maximum shear strength theory
can be applied; and (d) that the Goodman relation is
valid. Take the following material properties: Yield
strength = 500 MPa ; Ultimate strength = 800 MPa ;
Endurance limit = ± 400 MPa.
VARYING STRESSES – NO CONCENTRATION

DESIGN PROBLEMS

141. The maximum pressure of air in a 20-in. cylinder

(double-acting air compressor) is 125 psig. What should
be the diameter of the piston rod if it is made of AISI
3140, OQT at 1000 F, and if there are no stress raisers and
no column action? Let N = 75.1 ; indefinite life desired.
How does your answer compare with that obtained for
4?

143. The same as 142, except that, because of a

corrosive environment, the link is made from cold-
drawn silicon bronze B and the number of reversals of
the load is expected to be less than 3 x 107 .

142. A link as shown is to be made of AISI 2330, WQT

1000 F. The load F = 5 kips is repeated and reversed. For
the time being, ignore stress concentrations. (a) If its
surface is machined, what should be its diameter for N =
40.1 . (b) The same as (a), except that the surface is mirror
polished. What would be the percentage saving in
weight? (c) The same as (a), except that the surface is as
forged.
145. A shaft supported as a simple beam, 18 in. long, is
made of carburized AISI 3120 steel (Table AT 10). With the
shaft rotating, a steady load of 2000 lb. is appliled
midway between the bearings. The surfaces are ground.
Indefinite life is desired with N = 6.1 based on endurance
strength. What should be its diameter if there are no
surface discontinuities?
 147. The same as 146, except that the reversal of the
146. (a) A lever as shown with a rectangular section is to load are not expected to exceed 105 (Table AT 10).
be designed for indefinite life and a reversed load of F =
900 lb . Find the dimensions of a section without
discontinuity where b = 8.2 t and L =14 in . for a design
factor of N = 2 . The material is AISI C1020, as rolled, with
an as-forged surface. (b) compute the dimensions at a
section where e = 4 in .

148. A shaft is to be subjected to a maximum reversed

torque of 15,000 in-lb. It is machined from AISI 3140
steel, OQT 1000 F (Fig. AF 2). What should be its
diameter for N = 75.1 ?
149. The same as 148, except that the shaft is hollow
with the outside diameter twice the inside diameter.

151. The same as 150, except that the link operates in

brine solution. (Note: The corroding effect of the
solution takes precedence over surface finish.)

150. The link shown is machined from AISI 1035 steel, as

rolled, and subjected to a repeated tensile load that
varies from zero to 10 kips; h = 2b . (a) Determine these
dimensions for N = 40.1 (Soderberg) at a section without
stress concentration. (b) How much would these
dimensions be decreased if the surfaces of the link were
mirror polished?