DEPARTMENT OF MECHANICAL ENGINEERING

S6 PE

DESIGN OF MACHINE ELEMENTS

Assignment No.2

23-01-2009

1. A cylindrical bar of Cast Iron is subjected to a twisting moment of 3000 Nm and a

bending moment of 1000 Nm. Determine the minimum diameter of the bar based on a
factor of safety of 2.5.
2. A spherical shell, 4.0m diameter and 3mm thick is subjected to an internal pressure p.
Suggest a suitable value of the internal pressure, if the failure of the shell is to be
prevented according to the following theories of elastic failure:
a. Maximum shear stress
b. Maximum distortion energy
The yield point of the material of the shell in simple tension is 280 MPa and the
Poissons ratio is 0.3. Assume the factor of safety to be 3.
3. A machine frame is made of steel with a yield point of 420 MPa in tension and 260
MPa in shear. When loaded in a test fixture, the stresses were found to vary linearly
with load. Two points on the surface were found to be most critical. With a 4 kN test
load, the stresses at these points were:
a. Point A - 1 = 250 MPa ; 2 = 100 MPa
b. Point B - 1 = 180 MPa ; 2 = -100 MPa.
Compute the test load at which the frame will experience initial yielding according to :
(i)
Maximum normal stress theory
(ii)
Maximum shear stress theory
(iii)
Maximum distortion energy theory
Discuss briefly the relative validity of each theory for this application. Considering all
the information available, what is your best judgment of the value of test load at which
yielding would actually be expected to begin?
4. A round steel rod is subjected to axial tension of 50 MPa with a superimposed shear
stress of 120 MPa due to torsion. What is your best estimate of the safety factor with
respect to initial yielding if the material has a tensile yield strength of 500 MPa.
5. A cold rolled steel shaft 6m long is used to transmit 40 kW at 900 rpm. The shaft is
simply supported at its ends on bearings. The shaft experiences bending owing to its
own weight also. Determine the required shaft diameter using different theories of
failure. Use a factor of safety of 2.5 and a yield stress of 300 MPa.
6. A triaxial state of stress is given by the tensor shown below. If the material is cold
drawn steel with yield stress of 386 MPa and the required factor of safety is 3.0,
determine if the design is safe by the maximum distortion energy theory of failure.
ij

70
30
25

30
80
40

25
40 MPa.
95

7. A camshaft 20mm diameter, mounted on ball bearings, carries a cam mid-way between
the bearings. Distance between the bearings is 250 mm. The follower which weights
1500 N is out-of-adjustment due to which an impact is produced when it is contacted by
the cam. The height of fall of follower is 0.25 mm. Determine the maximum stress
induced in the shaft and the corresponding deflection.

8. A 500 N load drops 250 mm and impacts the free end of a horizontal cantilever beam
300 mm long. The beam has a hollow circular cross section with a diameter ratio of
1.25. If the maximum allowable bending stress is 180 MPa, find the outer diameter of
the beam. Also determine the maximum deflection if the Youngs modulus of elasticity
is 200 GPa.
9. A mild steel connecting rod of square cross section is subjected to a completely
reversed axial load of 125 kN. Suggest a suitable size of the rod using a factor of
safety of 1.8, if the suggested life of the rod is 4104 cycles only. Take a surface finish
factor of 0.8. Choose the other factors suitably.
10. A hot rolled steel shaft is subjected to a torsional load that varies from 360 Nm
clockwise to 120 Nm anticlockwise and an applied bending moment at a critical section
that varies from 400 Nm to 180 Nm. The shaft is of uniform cross section. Determine
the required shaft diameter if the material has an ultimate strength of 560 MPa and a
yield strength of 400 MPa. Assume a factor of safety of 2.
11. Find the value of factor of safety if the part in figure-1 is made of C-35 steel and of
uniform thickness of 80 mm.
12. A simply supported beam 50mm diameter and 400mm long is subjected to a central
concentrated load which varies from W to 3W. The material of the beam is cold rolled
steel. Determine the maximum value of W, if the design factor is to be 1.8. Use a size
factor of 0.85 and a surface finish factor of 0.9.
25050 kN

60 mm
10 mm radius
20 mm dia
100 mm

Figure-1

Figure-2

13. The cover of a pressure vessel is held in place by ten M20 bolts. The internal pressure
is 1.4 MPa and the effective area of the cover exposed to the pressure is 0.2 m 2. The
ratio of the stiffness of the bolts to the connected parts is 4. Each bolt is tightened
initially, before the pressure is applied, to 27 kN. (a) Will the joint separate as a result
of the load due to internal pressure? (b) If the joint does not separate, determine the
tensile stress in each bolt due to the axial load.
14. A mild steel bracket is connected to a vertical member by eight bolts of equal
diameters, as shown in figure-2. A vertical force of 50 kN acts in the plane of the bolts
at a horizontal distance of 300 mm from the centre of the bolt arrangement. Suggest
the suitable size of the bolts for a permissible shear stress of 50 MPa.

15.

16.

The general proportions of a shaft for an idler pulley with a constant overhung load are
shown in figure-3 with dimensions in mm. The material is an oil-quenched and
normalized alloy steel with ultimate tensile strength of 828 MPa and yield strength of
517 MPa. From the right, let the diameters be 85, 100 and 120 mm. All surfaces are
machined. The fillet radius at a-a is restricted by ball bearing to 2 mm, but the fillet
radius at b-b can be more generous, with perhaps r/d =0.075. Estimate the factors of
safety at planes a-a and b-b.
The pulley bracket shown in figure-4 is to be fastened to the back of the vertical
channel stanchion by five bolts in single shear, spaced as shown. A horizontal rope
passes over the pulley and supports a counter-balance weight weighing 12 kN. The
rope force may be assumed to act in the plane of the bolted joint. Select a suitable bolt
size using an allowable shear stress of 65 MPa.

Figure - 3

Figure 4