Assignment 1

DEPARTMENT OF MECHANICAL ENGINEERING
S7 ME MACHINE DESIGN I Assignment No.1 To be submitted on 22-09-2014

1. A cylindrical bar of Cast Iron is subjected to a twisting moment of 4.5 kNm and a bending
moment of 3.5 kNm. Determine the minimum diameter of the bar based on a factor of safety of
2.25 if the loading is static.
2. A spherical shell 2.5 m diameter and 4 mm thick, is subjected to an internal pressure p. Suggest
the maximum 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 theory
(b) Maximum distortion energy theory
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 4.
3. A machine frame is made of steel with a yield point of 350 MPa in tension and 190 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 6 kN test load, the stresses at these points were:
(a) Point A - 1 = 240 MPa ; 2 = 100 MPa
(b) Point B - 1 = 180 MPa ; 2 = 110 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 tensile stress of 70 MPa with a superimposed shear stress of
60 MPa due to torsion. What is your best estimate of the safety factor with respect to initial
yielding if the material has its tensile yield strength of 450 MPa.
5. A hollow shaft 8 m long made of cold rolled steel is used to transmit a static torque of 700 Nm.
The shaft is simply supported at its ends on bearings. The ratio of inner to outer diameter of the
shaft is 0.75. 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 3 and a yield
stress of 280 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 380 MPa and the required factor of safety is 3.0, check whether the design is
safe or not, by the maximum distortion energy theory of failure.
105 40 25
40 80 30
25 30 70
ij
MPa
7. A static force F is applied at D near the end of the 375 mm lever shown in figure1. Using Von-
Mises theory of failure, determine the maximum force F that can be applied if the critical section
is at A. Yield strength of the material is 340 MPa. Use a factor of safety of 2.2.

Figure 1 Figure 2
8. Figure2 shows a shaft mounted in bearings at A and D and having pulleys at B and C. The forces
shown acting on the pulley surfaces represent the belt tensions (treated as static forces). The shaft
is to be made of 20 Mn 2 alloy steel, hot rolled. Using a factor of safety n of 2.8 and neglecting
stress concentration effects, determine the diameter of the shaft.
9. By modern standards, the shaft design of Problem-8 is poor because it is too long. Suppose the
shaft is redesigned by halving the lengths of each section between A and D. Using the same
material and factor of safety as in Problem-8, find the new shaft diameter.
10. A camshaft 20 mm diameter, mounted on ball bearings, carries a cam mid-way between the
bearings. Distance between the bearings is 240 mm. The follower which weights 800 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 0.5 mm. Determine the maximum stress induced in the shaft and the corresponding
deflection if the material of the camshaft is mild steel.
11. A 400 N load drops from a height of 200 mm and impacts the free end of a horizontal cantilever
beam 500 mm long. The beam has a rectangular cross section with depth to width ratio of 0.8. If
the maximum allowable bending stress is 180 MPa, find the cross section of the beam. Also
determine the maximum deflection if the Youngs modulus of elasticity is 210 GPa.
12. A mild steel connecting rod of square cross section is subjected to a completely reversed axial load
of 120 kN. Suggest a suitable size of the rod using a factor of safety of 2.4, if the suggested life of
the rod is 210
5
cycles only. Take a surface finish factor of 0.8. Choose the other factors suitably.
13. A hot rolled steel shaft 600 mm long and supported between bearings at its ends, is subjected to a
torsional load that varies from 2.8 kNm clockwise to 1.4 kNm anticlockwise and a central
concentrated load that varies from 3.5 kN to 1.8 kN. The shaft is of uniform cross section.
Determine the required shaft diameter if the material has an ultimate strength of 640 MPa and a
yield strength of 420 MPa. Assume a factor of safety of 2.2.
14. Find the value of factor of safety if the part in figure-3 is made of C-40 steel and of uniform
thickness of 40 mm.

Figure-3 Figure-4
15. A simply supported beam 40 mm diameter and 600 mm 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 2.4. Use a size factor of 0.85 and a surface
finish factor of 0.9.
16. The general proportions of a shaft for an idler pulley with a constant overhung load are shown in
figure-4 with dimensions in mm. The material is an oil-quenched and normalized alloy steel with
ultimate tensile strength of 810 MPa and yield strength of 500 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. Assume the pulley to be keyed
to the shaft.
17. Bearing reactions R1 and R2 are exerted on the shaft shown in figure5, which rotates at 1200
r.p.m. and supports a 45 kN bending force. Use S.A.E. 1095 steel. Specify the diameter d using a
design factor of n = 1.6 for a life of 8 hours. The surfaces are machined.

Figure 5

10040 kN
60 mm
100 mm
10 mm radius
20 mm dia

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DEPARTMENT OF MECHANICAL ENGINEERING

S7 ME MACHINE DESIGN I Assignment No.1 To be submitted on 22-09-2014

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