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TUTORIAL 5

Design of Machine Elements


ME 351 (09/02/17)

NOTE: MARKS ARE SHOWN AGAINST EACH STEP MM:35

Q1. A cold drawn AISI 1040 steel bar shown in the figure is subjected to a
completely reversed axial load fluctuating between 4.45 kN in compression to
4.45 kN in tension. Estimate the fatigue factor of safety based on achieving infinite
life, and the yielding factor of safety. If infinite life is not predicted, estimate the
number of cycles to failure.

Sol. 1. Given Fmax = 4.45 kN, Fmin = -4.45 kN, and from Table A-20: Sy = 490
MPa, Sut = 590 MPa (AISI 1040, CD).
Check for yielding: (In computing the stress, the section at the hole governs):
F 4450 Sy 490
max max 37.08 N/mm2 = 37.08 MPa. n y 13.21 . [2]
A 6(40 20) max 37.08
Ans.
Determine the fatigue factor of safety based on infinite life:

Eq. (6-8): S e 0.5590 295MPa. [1]
Eq. (6-19): k a 4.51590
0.265
0.8315 . [1]
Eq. (6-21): kb 1 . [1]
Eq. (6-26): k c 0.85 . [1]

Eq. (6-18): S e k a k b k c S e 0.835(1)(0.85)(295) 209.37 MPa. [1]
Fig. (6-20): q 0.83 . [1]
d 20
Fig. A-15-1: 0.5 , K t 2.16 . [1]
w 40
K f 1 qK t 1 1.96 . [1]
Fmax Fmin
a K f 72.678 MPa. [2]
2A
Fmax Fmin
m K f 0 MPa. [2]
2A
1 a m
n f 2.88 . Infinite life is predicted. [1]
nf S e S ut
Ans.

Q2. This problem illustrates that the factor of safety for a machine
element depends on the particular point selected for analysis. Here you
are to compute factor of safety, based upon the distortion energy theory,
for stress elements at A and B of the member shown in the figure. This
bar is made of AISI 1006 CD steel and is loaded by the forces F = 0.55
kN, P = 4.0 kN, and T = 25 N-m.
Sol. 2. From Table A-20: S y 280 MPa (AISI 1006, CD):
At point A:
4P 16T 4 F
x 2 22.63 MPa. xy 3 38.75 MPa. [2]
d d 3 A

1

x 2 3 xy 2 2 70.82 MPa. n
Sy

3.95 . [3]

At point B:
32Fl 4 P 16T
x 2 188.62 MPa. xy 3 37.72 MPa. [2]
d 3
d d


x 2 3 xy 2
1
2
199.61 MPa. n
Sy

1.40 . [3]
Ans.

Q3. A threaded steel rod is subject to a mean tensile stress of 210 MPa. The ultimate strength for the material is 900
MPa, and Kf for the threaded section is 2.6. Estimate the maximum alternating stress that can be applied.

e
Sol. 3. For a Ferrous metal: 0.5 (infinite life, m 0 ).
ult
From the Fig. on right:
173.07
a (210) 173.07 132.68 .
900

[5+5]
Ans.