MACHINE DESIGN I FINAL EXAM

1. Which of the following joining methods is stronger (welding or Bolting)? Perform an

adequacy assessment.
Bolting Configuration
4 M24 Grade 8.8 Bolts
F=30 kN
20 cm BLOCK

3 cm
ARM
15 cm

10 cm Square
L=1 m
15 cm
2 cm
Welding Configuration
Welding 8x8x200
F=30 kN
BLOCK
Welding 8x8x150

ARM

L=1 m

20 cm

Yield strength of Bolt is 440 MPa

Yield Strength of Block Material is 250 MPa
Yield Strength of Welding is 150 MPa

Bolting Solution:
V  15kN M  15kNx 0.6m  9kNm r 50 2  50 2  70.71mm
Primary shear load per bolt F’=15kN/4=3.74 kN
Secondary Shear load per bolt F”=Mr/4r2 =9kNm/4*0.07071 m=31.82 kN

D A

r
C B
FA  Fa'  Fa" vectorial addition by parallelogram law
2 2
FA  Fa'  Fa"  2 Fa' FA" cos( )  3.74 2  31.82 2  2 x3.74 x31.82
FA  FB  34.5682kN

2 2
Fc  Fc'  Fc"  2 Fc' Fc" cos( )  3.74 2  31.82 2  2 x3.74 x31.8
Fc  Fd  29.29kN

F 34.5682 kN
    76.434 MPa
Ar  (24) 2 / 4

0.557 x 440
Factor of Safety n   3 .2
76.434

Block is thinner than arm (2 cm < 3 cm) Therefore Bearing stress on the block
F 34.5682kN
b    72.011MPa
Ar 24 x 20

250
Factor of safety n   3.47
72.011

Assuming Critical Bending -Stress occurs at the section passing from Bolt A
M=15kNx0.55m=8.25 kNm

30(150) 3 15( 24) 3

I=Ibar-2(Ihole+Ad2)=  2(  24 x30 * 50 2 )  4.802 x10 6 mm 4
12 12
Then

Mc 8.25kNmx(75mm)
 bending    128.85MPa
I 4.802 x10 6 mm 4

Mc
So critical stress is  bending   128.85MPa
I

250
Factor of safety n   1.94
128.85

Welding Assessment:
 b=200 mm =72.72 mm

d=150 mm

G =4.955x106 mm3
d/2

C b=200 mm A
=30.51 rA=147.72 rc=104.47
75
rA =30.51
=45.84
200-72.72=127.27
G 72.72

D B

V 15kN
'    4.82MPa
A 2 x 200 x(0.707 x8)  150 x (0.707 x8)
 " 
Tr
J

(15kN x (500  127.27)(
0.707 x8 x 4.95 x
147
10 6

Using parallelogram law Stress at the points A and B

   '2
  "2  2 x ' " cos(180  30.51)  53.85MPa

Using parallelogram law Stress at the points C and D

   '2
 "2
 2 x ' "
cos(45.84)  46.41MPa

0.557 x 200
Factor of Safety n   1.8
46.41

Result : The lowest factor of safety is 1.8 for welding so bolting is better for this
configuation.
2. A steel rod of diameter d=50 mm (Sy=260 MPa) supports an axial load P=50R,
vertical load of 0.2R at the midspan of 2m long cylindrical bar and vertical load R
acting at the end of an 0.8 m long arm as shown in figure. Given of a factor of safety
n=2, compute the largest permissible value of R using the following criteria:
a. Maximum shearing stress and
b. Maximum energy of distortion

0.2R

F Mc 50 R ( 2 Rx10 3 x1) x 25 80000R 51200R 131200R

x         41745R
A I  (50E 3 ) 2 / 4  50 4 / 64   
Tr 0.8 Rx 25
 xy    32581.81R
J  50 4 / 32
x
 1, 2   ( x / 2) 2   xy2  20872R  38694 R
2
 1  59567 R
 2  17821.5R

a) Maximum shearing stress criterion

Sy 260MPa
1   2  59567 R  ( 17821.5 R ) 
n 2

R=1679.83 N

b) Maximum distortional energy criterion

Sy
2 x2  6 xy2  2
n

R=1851.97 N
3. A propped cantilever beam AB subjected to a uniform load of intensity p shown in
figure. Determine
a. The reactions
b. The equation of the deflection curve and,
c. The slope at A

p
MB

A
B

RA RB

Reactions Ra , Rb and Mb are statically indeterminate because there are only two
equilibrium equations. (  Fy  0 and  M z  0 ), the beam is staticallt
indeterminate to the first degree. With the origin of coordinates taken at the left
support, the equations for the beam moment is

px 2
M   Ra x 
2
2
px
EIy "
  Ra x 
2

aAnd successive integrations yield

1 px 3
EIy '   Ra x 2   c1
2 6
1 px 4
EIy   Ra x 3   c1 x  c2
6 24

There are three unknowns Ra, c1 and c2 and three boundary conditions
y(0)=0 y(L)=0 y’(L0)=0

a) introducing boundary conditions in the deflection equations

at x=0 y=0 so c2=0 and c1=pL3/48EI and
3
Ra  pL
8
Now we can determine the other reactions from the equilibrium equations
5
Rb  pL
8
1
M b  pL2
8
b) Substituting Ra, c1 and c2 in the deflection equations
 P
y (2 x 4  3Lx 2  L3 x )
48EI
c) differentiating the deflection equation with respect to x, the equation of angle of
rotation is obtained
P
  (8 x 3  6 Lx  L3 )
48 EI
Setting x=0 we have the slope at A

PL3
A 
48 EI
4. Consider a thin walled cylindrical tank of radius r=120 mm and thickness
t=5 mm, subjected to an internal pressure varying from a value of –p/4 to
p. Employ the distortional strain energy theory together with the
Soderberg criterion to compute the value of p producing failure after 108
cyles. The material tensile yield strength (Sy) is 300 MPa and the fatigue
strength (Se) is 250 MPa at 108 cycles. (Assume n=1)
Pr Pr
Tangential stress T  Axial stress  A 
t 2t
Von Mises failure criterion in polar coordinates

 eq   T2   A T   A2

Solution: The maximum and minimum values of the tangential and axial principal
stresses are given by
Pr (  P / 4) r
 T ,max   24 p  T ,min   6 p
t t
Pr (  P / 4) r
 A,max   12 p  A,min   3 p
2t 2t

The alternating and mean stresses are therefore;

 T ,max   T ,min    T ,min

 T ,alternating   15 p  T ,mean  T ,max  9p
2 2
   A,min    T ,min
 A,alternating  A,max  7.5 p  A,mean  T ,max  4.5 p
2 2
The equivalent stresses for alternating and mean stresses
 eq ,alternating   T2   A T   A2  225 p 2  112.5 p 2  56.25 p 2  12.99 p
 eq,mean   T2   A T   A2  81 p 2  40.5 p 2  20.25 p 2  7.794 p

Soderberg relation then leads to

A B
 1
Se S y
12.99 p 7.794 p
6
 1
250 x10 300 x10 6

P=12.82 MPa