Engineering Materials

• An engineering material is a material in the solid

state whose properties are technologically
useful.
• They can be metals or non metals.
Metals: Iron, Steel, Brass, Copper, Lead, Tin,
Aluminum, Titanium, Chromium, Nickel, etc.
Non Metals:
Plastics, Rubber, Metallic carbides and oxides,
etc.

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 Mechanical Properties
The mechanical properties to be considered while
selecting a material for a machine element are;
• Strength: Ability to resist failure or fracture
• Stiffness: Ability to resist deformation
• Ductility: Ability to undergo considerable plastic
deformation before failure.
• Resilience: Energy absorbed in the elastic range.
• Toughness: Energy absorbed in the plastic range.
• Hardness: Resistance to indentation or abrasion.
• Corrosion resistance: Ability to resist atmospheric
oxidation.
• Wear resistance: Ability to resist loss of material
while in relative motion with other components.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Factors affecting selection of material
The major factors considered are;
(i) Availability: The material should be readily
available in the market, in large enough quantities
to meet the requirement.
(ii) Cost: The cost of material and the cost of
manufacturing will be a limiting factor for the
designer.
(iii) Mechanical Properties: Different mechanical
properties will be important for different types of
loading & service conditions.
Ex: Connecting rod should have high endurance strength
Piston rings should have high wear resistance
Dr P R Venkatesh, Mech Dept, RVCE,
Clutch or brake lining should have high coefficient of friction
Bangalore
 Factors affecting selection of material (contd…)
(iv) Manufacturing Considerations: The
manufacturing processes such as Casting, Forging,
Extrusion, Welding & Machining govern the
selection of material.
Ex:
• For high strength bolts, axles & shafts, free cutting
steels (with small % of sulphur) are suitable as they
have excellent machinability.
• For complex shapes, castability or ability of the molten
metal to flow into intricate passages is the criterion.
• In fabricated assemblies of plates & rods, weldability
becomes the governing factor.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Machine Design
Machine design is defined as the “use of Scientific
principles, Technical information and imagination
in the description of a machine or mechanical
system to perform specific functions with
maximum economy & efficiency”.
Scientific Principles: Knowledge of physics, mathematics,
statics & dynamics, vibrations & heat transfer, etc.
Technical information: Information about fastening
devices, chain, belt & gear drives, Springs, bearings.
Imagination: Use of creative skills to produce a
configuration.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Six phases of machine design (Shigley’s Model)
According to Shigley, the process of designing consists of
six phases as follows;
Recognition of need
1. Recognition of need
2. Definition of the problem Definition of problem

3. Synthesis
4. Analysis & Optimization Synthesis

5. Evaluation
Analysis & Optimization
6. Presentation
Evaluation

Presentation
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Six phases of machine design
(Shigley’s Model)
• Recognition of need: It
involves the realization by
Recognition of need someone that a problem
exists for which some
Definition of problem
corrective action should
be taken.
Synthesis
• Definition of the
Analysis & Optimization
problem: It involves a
thorough specification of
Evaluation the item to be designed.
Ex: Physical and functional
Presentation characteristics, Cost, quality, &
operating performance.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Six phases of machine design • Synthesis It is the
(Shigley’s Model)
conceptualization of the
Recognition of need component by the designer.

Definition of problem
• Analysis: It is the iterative
process of Improvisation of
Synthesis
design and redesign till the
Analysis & Optimization optimized design is
achieved within the
Evaluation
constraints imposed by the
Presentation
designer.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Six phases of machine design
(Shigley’s Model)
• Evaluation: It is concerned with
measuring the design against the
Recognition of need
specifications established at the
problem definition phase. This
Definition of problem
often requires fabrication and
Synthesis testing of a prototype to assess
operating performance, quality,
Analysis & Optimization reliability, etc.
• Presentation: It includes
Evaluation
documentation of the design by
means of drawings, material
Presentation
specifications, assembly lists, etc.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Types of Design
There may be several types of design such as;

Adaptive design:

• This is based on existing design, for example, standard

products or systems adopted for a new application.

• Conveyor belts, control system of machines and

mechanisms or haulage systems are some of the
examples where existing design systems are adapted
for a particular use.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Types of Design
Developmental design:
• Here we start with an existing design but finally a modified design
is obtained.
• A new model of a car is a typical example of a developmental
design .
New design:
• This type of design is an entirely new one and requires creative
thinking to solve a problem.
• Examples of this type of design may include designing a small
vehicle for transportation of men and material on board a ship or
in a desert. Some research activity may be necessary.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Types of Design based on methods
Rational design:
• This is based on determining the stresses and strains of
components using mathematical formulae of principle of
mechanics and thereby deciding their dimensions.
Empirical design:
• This is based on empirical formulae which in turn is based on
practice & past experience.
Industrial design:
• These are based on industrial considerations and norms viz.
market survey, external look, production facilities, low cost, use of
existing standard products.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Factors to be considered in machine design
There are many factors to be considered while tackling a
design problem.
a) What device or mechanism to be used? This would decide
the relative arrangement of the constituent elements.
b) Material
c) Forces on the elements
d) Size, shape and space requirements. The final weight of
the product is also a major concern.
e) The method of manufacturing the components and their
assembly.
f) How will it operate?
g) Reliability and safety aspects
h) Inspectability
i) Maintenance, cost and aesthetics
Dr P R Venkatesh, of the designed product.
Mech Dept, RVCE,
Bangalore
 Standards and Codes
• A standard is a set of specifications for parts,
materials or processes intended to achieve uniformity,
efficiency and a specified quality.
• One of the important purposes of a standard is to limit
the variety, sizes & shapes.
• A code is a set of specifications for analysis, design,
manufacture and construction of something.
• The purpose of a code is to achieve a specified degree
of safety, efficiency, and performance.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Standards and Codes
The organizations listed below have established standards and
design codes;
American Gear Manufacturer’s Association (AGMA)
American National Standards Institute (ANSI)
American Society of Mechanical Engineers (ASME)
American Society of Testing & Materials (ASTM)
British Standards Institution (BSI)
Deutsches Institut fur Normung (DIN)
Indian Standards (IS)
International StandardsDr Organization
P R Venkatesh, Mech Dept, RVCE,
(ISO)
Bangalore
 Design against Static Load
• A static load is defined as a force that is gradually
applied to a mechanical component and which does
not change in magnitude & direction w.r.t time.

• A ductile material will undergo a considerable amount of

plastic deformation before necking. (cup & cone)

• Ex: Steel, Aluminum, Copper, etc.

• A brittle material undergoes little amount of plastic

deformation prior to fracture.

• Ex: Cast Iron, Glass, Concrete.

Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Selection of value for factor of safety
• The common range for factor of safety is 1.25 to
4 for metals & 5 to 10 for concrete, wood, etc.
• The selection of an appropriate value of FOS is
based primarily on the following factors;
a) Degree of uncertainty about the loading.
b) Degree of uncertainty about the material
strength.
c) Imperfect workmanship which leads to
variations in dimensions of components.
d) Human safety & economics.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 STRESSES IN MACHINE ELEMENTS
• Stress in a machine member is defined as the
intensity of internally distributed forces that resist
the external forces acting on that element.
• The unit commonly used is Mega Pascal (MN/m2)
or 106N/m2 which is numerically equal to N/mm2.
1 Pascal = 1N/m2
1 Kpa (Kilo Pascal) = 1000 N/m2
1 Bar = 100 Kpa =105 N/m2
1MPa (Mega Pascal) = 106 N/m2=1 N/mm2
1GPa (Giga Pascal) =109 N/m2=1000 N/mm2
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Mechanical properties of metals
CAST IRON: (2 to 4% carbon):
• It is classified on the basis of distribution of
carbon content in the microstructure.
• For example, ‘FG 300’ indicates it is cast iron
with carbon in the form of Free Graphite flakes
and its ultimate tensile strength if 300 MPa.
• ‘SG 450 ’(Spheroidal graphite cast iron) has
tensile strength of 450 MPa.
• For properties of Cast iron, refer Table 1.2 & 1.3
& 1.4, page 458-461.
• (Design Data book by Mahadevan)
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Mechanical properties of metals
STEELS:
(i) Low Carbon Steels (Or Mild Steel): < 0.3 % carbon
(ii) Medium carbon Steel : 0.3 to 0.5% carbon
(iii) High carbon Steels: (0.5 to 1% Carbon)
• It is designated by, 100 times the percentage of
carbon, the letter C, followed by 10 times the
percentage of manganese.
• For example, ’40C8’ or C 40 indicates the average
carbon percentage is 0.4% and average percentage
of manganese is 0.8%.
• For properties of carbon steels, refer Table 1.8,
page 463 & 464. (Design Data book by
Mahadevan) Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Rectangular cross section member under axial tension

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
Prob 1:
A link shown in fig is required to transmit a tensile
load of 60 KN. Determine the stresses induces at
sections 1-1 & 2-2.
 


50 mm
 

90 mm
60

 30
Section 1-1  mm
 
Section 2-2

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
  


50 mm
 

90 mm
60

 30
Section 1-1  mm
 
Section 2-2
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Prob 2:
A steel rod of circular cross section and length 200
mm is subjected to a compressive load of 40 KN. If
the safe stress in rod material is 80 MPa,
determine;
(i) Diameter of the rod
(ii) Contraction of the rod
Take the modulus of elasticity of the material as
207 GPa.

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
(i) Diameter of the rod
F
Compressive stress in the rod    Eq 1.1a Page 2
A
F 4 F 4  40 103
   80 
d 2
 d 2
 d2
4
 Diameter of the rod d  25.23 mm
(ii) Contraction in length of the rod
F l
  Eq 1.2b Page 3
A E
4 F l 4  40  103  200
 =  0.0773 mm
  d  E   25.23
2 2
Mech
Dr P R Venkatesh, 207Dept, 10
RVCE,
3
Bangalore
 Machine Elements subjected to lateral bending
• When a beam is subjected to a load in the
transverse direction, it is subjected to pure
bending moment.
• It results in tensile stresses on the convex side
and compressive stresses on the concave side
and zero stress on the neutral layer.

R M
M

N A
c

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 M  E
The bending equation is  
I c R
where M = Bending moment at the section under consideration
I  Moment of inertia about the neutral axis
c  Distance of the neutral axis from outer fibers
E  Elastic modulus of beam material
R  Radius of curvature of the deformed beam
The bending stress  may be written as;
Mc M M I
   where Z= is known as section modulus
I I Z c
c
R M
M

N A
c

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
Prob 1:
A short cantilever beam is of width 20 mm and
depth 40 mm supports a transverse load of 2 KN at
a distance of 200 mm from its fixed end.
Determine the maximum bending stress in the
beam.
2 KN
20
A

40

200

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 2 KN
20
A

40

200

The maximum bending stress occurs at the fixed point A

M  F  l  2000  200  4 105 N  mm
bh 2 20  402
Section modulus Z    5333.33 mm3
6 6
M 4 10 5
 Maximum bending stress   =  75MPa
Z 5333.33
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Prob 2:
A circular cross section beam of 50 mm diameter
and 1m length is supported between bearings.
Determine the bending stress induced in the beam
when it is subjected to a 5 KN transverse load at its
center.

5 KN

50 mm
1000 mm

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 5 KN

50 mm
1000 mm

The maximum bending stress occurs at the point of

application of the load.
F  l 5000  1000
M   1.25  106 N  mm
4 4
 D3   503
Section modulus Z    12271.85mm3
32 32
M 1.25 106
 Maximum bending stress   =  101.86 MPa
Z 12271.85
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Prob 3:
A steel saw blade 1 mm thick is bent into an arc of
a circle of 500 mm radius. Determine the flexural
stress induced and the bending moment required
to bend the blade if it is 15 mm wide. Take E=210
Gpa.
R 500

1 mm

15 1
x
section x-x

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 R 500

1 mm

15 1
x
section x-x

The bending equation is

M  E EI
  M   Eqn 1.3(a) Page 3
I c R R
bh3 15 13
Moment of inertia I    1.25 mm 4
12 12
210 103 1.25
Bending moment M   525 N - mm
500
Mc 525  0.5
 Maximum bending Drstress  
P R Venkatesh, Mech Dept, RVCE,
 210 MPa
Bangalore I 1.25
 Machine Elements subjected to Torsion
• When a rod or shaft is subjected to a twisting moment
about its axis, it is subjected to pure Torsion.
• It results in torsional shear stresses which vary linearly
with the radius of the shaft.

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
Prob 1:
A circular rod of 50 mm diameter is subjected to a
twisting moment of 1 KN-m. Determine the shear stress
induced in the shaft & the angular twist per unit length of
the shaft. Take rigidity modulus as 84 Gpa.
The shear stress at the extreme radii is  Eqn 1.1(d ), page 2
Tr
 
T D
2  

16  T

16  (1  10 6
)
 2

 
40.744N / m m
J  D4  D3  (50)3
32
The angle of twist per meter length  Eqn 1.3 (c), page 3
Tl (1106 ) 1000
   0.0194 rad

GJ 84 103    50 4

32 
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Machine Elements subjected transverse shear
• When a component is subjected to a force
perpendicular to its axis, so as to shear it at one or
more cross sections, it is said to be under transverse
shear.
• The shear stress in case of single shear is given by
F

A

• In case of double shear,   F

2A

Where F is the shear load and A is the area of resisting

cross section. Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Prob 1:
A knuckle joint is used to connect shafts of diameter D to
transmit a tensile load of 5 KN. Determine the diameter of
the shaft and the diameter of the pin required using
permissible tensile stress in the shaft as 60 MPa and the
shear stress in the pin as 40 MPa.

A knuckle joint is a
mechanical joint used to
connect two rods which
are under a tensile load,
when there is a
requirement of small
amount of flexibility, or
angular moment is
necessary.

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
The tensile stress in the rod is
4 F 4  5000
  60   D = 10.3 mm
D 2
D 2

The shear stress in the knuckle pin (double shear)

F 4  5000
  40   Dia of pin d  8.92 mm  9 mm.
2A 2 d 2

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 Prob 2: Determine the diameter of the rivet subjected to
(i) Single shear and (ii) Double shear due to a load of 5 KN.
The permissible shear stress in the rivet is 40 MPa.
F d
F
d
F
F
F

Single Shear
Double Shear
The shear stress in the rivet (single shear)
F 4  5000
   40   Dia of rivet 'd'  12.62 mm  13 mm.
A d 2

The shear stress in the rivet (double shear)

F 4  5000
  40   Dia of rivet 'd'  8.92 mm  9 mm
2A 2 d 2 Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Machine Elements subjected to eccentric
loading
• Many structural and machine members
are subjected to loads that are offset
from their centroidal axes.
• Such members may be considered as
elements subjected to an axial load
coupled with a bending moment.
• The stresses may then be added
e
algebraically to evaluate the total
F
stresses at the critical sections.
Fig 1.6, page 7
DDHB
Mahadevan The total stress in the critical section is
F M F Fe
     Eqn 1.10, page 7
A Z A Z
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Prob 1:
A steel bracket of rectangular cross section is loaded as
shown in fig. Determine the width ‘b’ at section A-A by
limiting the tensile stress to 80 N/mm2.

60 5 KN
b

60

A A

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 The direct stress at section A - A
60 5 KN
F 5 103 83.33
d  
b

60 A 60  b b
The bending stress at extreme fibers of A - A
F e
A A  bi   bo  where Z is the section modulus
Z
For rectangular section,
bh 2
Z= Table1.3, Sl no (a), column 5, Page 8
6
5 103  60 500
 b  
 b  60
 2

6
b

The max stress at the critical section is

F F e 83.33 500
   80  
A Z b b
 4  8 mm
Dr P R Venkatesh, Mech Dept, RVCE,
b = 7.35 Bangalore
Prob 2:
Determine the cross sectional dimensions for the wall
bracket shown in fig if the maximum stress in the material
of the bracket is limited to 120 MPa. Take the depth of the
section equal to three times its width.

0
30
b
600 mm
10 KN
h

1200 mm

fig 1 (c)

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 0
30
b 600 mm
10 KN
h

1200 mm

Horizontal component of force FH  F cos 300

 FH  (10 103 ) cos 300  8660.25 N
Bending moment due to horizontal component
M bH  FH  e  M bH  8660.25  600  5.196 10 6 N - mm
Vertical component of force FV  F sin 300
 FV  (10 103 ) sin 300  5000 N
Bending moment due to vertical component
M bV  FV  l  M bVDrP R500 0 Mech
Venkatesh, Dept, 
1200 6 ×10 6 N - mm
RVCE,
Bangalore
 0
30
b 600 mm
10 KN
h

1200 mm

Total bending moment M b = M bH + M bV

(As they are of same sense and tend to stretch
the top fibers & contract the bottom fibers)
 M b  (5.196 + 6) × 10 6 = 11.196 × 10 6 N - mm
 bh 2   b(3b) 2 
Section modulus Z   
    1. 5  b 3

 6   6 
M 11.196 106 7.464 × 10 6
Bending stress  b    N / mm 2

Z 1.5  b3 b3
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 0
30
b 600 mm
10 KN
h

1200 mm

FH 8660.25 2886.75
Direct Stress due to FH ;  d    N / m m 2

bh 3b 2 b2
Maximum stress σ max = σ b + σ d (occurs at top fibres)
7.464×106 2886.75
 120 = 3
+
b b2
 120b3 - 2886.75b -7.464×106 = 0
Solving, b = 40 mm, h = 3b = 120 mm

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
Prob 3: A C frame is subjected to a force of 15 KN
as shown in fig. It is made of grey cast iron FG 300
and the factor of safety is 2.5. Determine the
dimensions of the cross section of the frame.



5t

t
7.5t



Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 Bending moment M = 15  10 3 7.5t
= 112500 t N - mm

(It tends to stretch the inner fibers &
5t

t contract the outer fibers)

7.5t
 bh 2 
 Section modulus Z   
 6 
 t  (5t ) 2 
 Z    4.167 × t 3

 6 
M 112500t
Bending stress   
Z 4.167  t 3
27000
  2
N / mm 2

t
Dr P R Venkatesh, Mech
Bangalore
Dept, RVCE,
 F
Direct tensile stress  d 
 A
5t 15000 3000
t
  2
= 2
N / mm 2

7.5t 5t t

Total max stress (occurs at inner fibers)
 max   b   d
300  ut
But  max    120 MPa
FOS 2.5
27000 3000
 120  2
+ 2
t t
 120t 2  30000,  t = 15.81  16 mm
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Prob 4: Determine the normal stresses at the
extreme fibers of the cross section of a C-
clamp loaded as shown in fig.

80 KN

150
100

40
100
40

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 B=100
80 KN
d=40
c1
150 H=140
100 h=100
c2
40
100
b/2 a=40 b/2
40

Cross section area A = (100× 40 +100× 40) = 8000 mm 2

Bending moment M = 80×10 3 (150 + c1 )
aH 2  bd 2
where c1 = Table 1.3, Type d, Page 8
2(aH +bd)
40(1402 )  60(40)2
c1  = 55 mm
2 (40 140)  (60  40)
 c2  (140  55)  85 mm
Hence bending moment M = 80×10 3 (150 + 55)
 M = 16.40  10 5 NDr-P Rmm
Venkatesh, Mech Dept, RVCE,
Bangalore
 B=100
80 KN
d=40
150
c1
H=140
100 h=100
c2
40
100 b/2 a=40 b/2
40

 Bc13  bh3  ac23 

Moment of inertia I =  T 1.3, Type d,Page 8
 3 
where h = (c1 - d)= (55 - 40)= 15 mm
 100  553  60 153  40  853 
 I    13.667  10 6
mm 4

 3 
Mc1
 Bending stress at inner fiber  bi 
I
16.40 × 10 6 × 55
 bi  6
 66 N / mm 2
(Tensile)
Dr P R Venkatesh, Mech Dept, RVCE,
13.667 × 10 Bangalore
 B=100
80 KN

d=40
150 c1
100 H=140
h=100
40
c2
100
b/2 a=40 b/2
40

Mc2
Similarly Bending stress at outer fiber  bo 
I
16.40 × 10 6 × 85
 bo   102 N / mm (compressive)
2

13.667 × 10 6
F 80 103
Direct tensile stress  d    10 N / mm 2
A 8000
Total stress at inner fiber  i   bi   d  66 + 10 = 76 N / mm 2
Total stress at outer fiberDrP RoVenkatesh,
 Mech bo  
Dept, 
RVCE,
d -102 + 10 = -92 N / mm 2
Bangalore
Prob 5: For the member shown in fig, determine
the maximum load ‘F’ that can be applied if the
allowable compressive stress at cross section A-A
is 100 MPa.

50


R1
A A

F
100

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 50


R1
A A

F
100

  502
Cross section area A = = 1963.5 mm 2
4
Bending moment M = F ×(150 +150)= 300 F N - mm
M 32M 32  300 F
Bending stress =    0.0245F N / mm 2

Z  D3   503
(It is compressive at inner fiber & tensile at outer fibers)
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 50


R1
A A

F
100

F F
Direct compressive stress =   0.5093 × 10 -3 F
A 1963.5
Max compressive stress occurs at inner fibers
 0.0245F  0.5093 10 F  100 -3

 F = 4000N
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Machine Elements subjected to Combined
Loading
• Many structural and machine members are
subjected to loads that are combinations of
axial, bending, & torsional types.
• Such members may be modeled as elements
subjected to uniaxial, biaxial & triaxial loadings
with or without shear loads.
• The principal stresses and the maximum shear
stress may be found and these values may be
used in the various theories of failure for design
of the machine members.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Also the expressions for maximum & minimum normal stresses
(Principal stresses) and max shear stress
The maximum & minimum normal stresses (Principal stresses) are

 x  y    x  y 
2

1        xy  Eq 1.8c Page 5
2

 2   2 
 x  y    x  y 
2

2         xy  Eq 1.8d Page 5
2

 2   2 
The maximum shear stress

  x  y 
2

 max       2
xy  Eq 1.8f Page 5
 2 

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
Prob 1: A point in a structural member is subjected
to plane stress as shown. Determine the following;
(i) Principal stresses
(ii) Maximum shear stress
30 MPa

25 MPa

40 MPa 40 MPa

25 MPa 30 MPa

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 Major & minor principal stresses

x  y    x  y 
2

 1,2         xy  Eq 1.8c & d Page 5

2

 2   2 
Hence major principal stress

 40  30   40  30 
2

1        25 2
 48.012N / mm 2

 2   2 
and minor principal stress

 40  30   40  30 
2

2        25 2
 38.012N / m m 2

 2   2 
  x  y 
2

The maximum shear stress  max       2

xy
 2 
 40  30 
2

  max    2

 P R Venkatesh, Mech Dept, RVCE,
25 43.012 N / mm 2

 2 
Dr
Bangalore
Prob 2: A circular rod of diameter 60 mm and
length 200 mm is fixed at one end. The free end is
subjected to a transverse load of 6 KN and a
torque of 400 N-m. Determine the stresses at the
critical points.

6 KN
A
400 N-m


B 200 mm

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 6 KN
A
400 N-m


B 200 mm

This is a member subjected to combined bending & Torsion.

Bending moment M = F  l = 6000  200 = 1.2  10 6 N  mm
M 32M 32  1.2  10 6
 Bending stress  =    56.59 N / mm 2

Z  D3   603
Twisting moment (given) T = 400 N  m = 400  10 3 N  mm
T 16T 16  400  10 3
 Shear stress  =    9.43 N / mm 2

Z p  D3   603
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 6 KN
A
400 N-m


B 200 mm
Maximum normal stress (or major principal stress) occurs at point A

   
2

 1         2  Eqn 1.5 a, page 3

2 2
2
 56.59   56.59 
1        9.432
 28.295  29.825  58.12N / m m 2

 2   2 
Minimum normal stress (or m inor principal stress) occurs at point B
2
 56.59   56.59 
2        9.432
 28.295  29.825  -1.5 3N / mm 2

 2   2 
 
2

The maximum shear stress  max      2  Eqn 1.5 b, page 3

2
2
 56.59 
 max     9.43 DrP R29.825
2
N / mm 2
Venkatesh, Mech Dept, RVCE,
 2  Bangalore
Prob 3: A circular rod of diameter 60 mm and
length 200 mm is fixed at one end. The free end is
subjected to an axial load of 10 KN, a transverse
load of 6 KN and a torque of 400 N-m. Determine
the stresses at the critical points.

6 KN
A
400 N-m 10KN


B 200 mm

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 6 KN
A
400 N-m 10KN


B 200 mm

This is a member subjected to combined bending , Torsion & axial load

Bending moment M = F  l = 6000  200 = 1.2  10 6 N  mm
M 32M 32  1.2  10 6
 Bending stress  b =    56.59 N / mm 2

Z  D3   603
(Tensile at top fibers A & compressive at bottom fibres B)
F 4F 4  10  10 3
Direct tensile stress  d =    3.54 N / mm 2

A  D2   602
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 6 KN
A
400 N-m 10KN


B 200 mm

Total normal stress at A ,

 A = (56.59  3.54)  60.125N / mm 2
& Total normal stress at B,
 B = (56.59  3.54)  53.05 N / mm 2
Twisting moment (given) T = 400 N  m = 400  10 3 N  mm
T 16T 16  400  10 3
 Shear stress  =    9.43 N / mm 2

Z p  D3   603
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 6 KN
A
400 N-m 10KN


B 200 mm

Major & minor principal stresses at point A

A  A 
2

 1,2@ A        2

 2   2 
2
 60.125   60.125 
 1,2@ A       9.432
 30.06  31.51
 2   2 
 61.57 N / mm 2 & - 1.45 N / mm 2
2
 60.125 
 max@ A     9. 4 3 2
 31.51 N / mm 2

 2  P R Venkatesh,
Dr Mech Dept, RVCE,
Bangalore
 6 KN
A
400 N-m 10KN


B 200 mm

Major & minor principal stresses at point B

B B 
2

 1,2@ B        2

 2   2 
 53.05   53.05 
2

 1,2@ B       9.432
 26.525  28.15
 2   2 
 -54.67 N / mm 2 & - 1.625 N / mm 2

 53.05 
2

 max@ B     9.4 3 2
 28.15 N / m m 2

 2  Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
Prob 3: Determine the maximum normal stress and the
maximum shear stress at section A-A for the overhung crank
shown in fig. when a load of 12 KN is assumed to be
concentrated at the center of the crank pin.
50 25 25 100

Web
12 KN

O 50
Pin
150

A
O 80

A
Dr P R Venkatesh,
Crank Shaft Mech Dept, RVCE,
Bangalore
 50 25 25 100

Web
12 KN

O 50
Pin
150

A
O 80

A
Crank Shaft

This is a member subjected to combined bending & Torsion.

Bending moment M = F  l = 12 103  (50  25  25) = 12  10 5 N  mm
M 32M 32  12  10 5
 Bending stress  =    23.87 N / mm 2

Z  D3   803
Twisting moment T = 12 103 150 = 18  10 5 N  mm
T 16T 16 18  10 5
 Shear stress  =    17.9 N / mm 2

Z p DrDP 3R Venkatesh,Mech
 80 3
Dept, RVCE,
Bangalore
Maximum normal stress (or major principal stress)

   
2

 max        2
2 2
2
 23.873   23.873 
 max       17.9 2

 2   2 
 max  11.94  21.52  33.46 N / mm 2

 
2

The maximum shear stress  max     2

2
2
 23.873 
 max    Dr PR Venkatesh,
17.9  21.52 N / mm
2 2

 2  Mech Dept, RVCE,

Bangalore
Prob 4: Determine the maximum normal stress and
the maximum shear stress at section A-A for the
overhung crank shown in fig. Neglect the effect of
transverse shear.
50 25 25 100
10 KN

30v
O 50
150

A
O 80

A Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 50 25 25 100
10 KN
F
Here, the bending moment

30v

arm remains the same

O 50
while the torque arm
150 y
becomes cos component

of the crank radius as the
A ycos  line of action of force is
inclined to the horizontal.
O 80

A T=F x ycos 

This is a member subjected to combined bending & Torsion.

Bending moment M = F  l = 12 103  (50  25  25) = 12  10 5 N  mm
M 32M 32  12  10 5
 Bending stress  =    23.87 N / mm 2

Z  D3   803
Twisting moment T = 12 103 150  cos 300 = 15.59  10 5 N  mm
T 16T 16 15.59  10 5
 Shear stress  =    15.51 N / mm 2

Z p DrDP 3R Venkatesh, Mech

 Dept,80RVCE,
3
Bangalore
Maximum normal stress (or major principal stress)

   
2

 max        2
2 2
2
 23.873   23.873 
 max       15.512

 2   2 
 max  11.94  19.57  31.51 N / mm 2

 
2

The maximum shear stress  max     2

2
2
 23.873 
 max    Dr PR Venkatesh,
15.51  19.57 N / mm
2 2

 2  Mech Dept, RVCE,

Bangalore
Prob 5: A 50 mm diameter steel rod supports 9 KN
load in addition to a torsional moment of 100 Nm
as shown in fig. Determine the maximum tensile
and maximum shear stress.

9 KN
A

100 N-m


Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 9 KN
A

100 N-m


This is a member subjected to eccentric & Torsion.

Bending moment M = F  l = 9 103  28 = 252  10 3 N  mm
M 32M 32  252  10 3
Bending stress  b =    20.535 N / mm 2

Z  D3   503
F 4F 4  9  10 3
Direct tensile stress  d =    4.584 N / mm 2

A  D2   502
∴ Total maximum normal stress σ = σ b + σ d
 σ = 20.535 + 4.584 = 25.12 MPa
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Twisting moment T (given ) = 100 Nm = 100 103 = 10 5 N  mm
T 16T 16  105
 Shear stress  =    4.074 N / mm 2

Z p  D3   503
Maximum principal stress

   
2

 max         2
2 2
2
 25.12   25.12 
 max       4.074 2
 25.764 N / mm 2

 2   2 
 
2

The maximum shear stress  max      2

2
2
 25.12 
  max     4.074 2
= 13.2 N / mm 2

 2  Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 Theories of failure
• The design of machine parts subjected to
combined loads should be related to
experimentally determined properties of
material under ‘similar’ conditions.
• However, it is not possible to conduct such tests
for different combination of loads and obtain
mechanical properties.
• In practice, the mechanical properties such as
yield strength, ultimate strength and
percentage elongation are obtained from a
simple tension test.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Theories of failure
• Theories of failure provide a relationship
between the strength of the machine
component subjected to ‘complex state of
stress’ with the mechanical properties obtained
from tension test.
• With the help of these theories, the data
obtained in tension test can be used to
determine the dimensions of the component,
irrespective of the nature of stresses induced in
the component due to complex loads.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Theories of failure
• Several theories of failure have been proposed,
each assuming a different hypothesis of failure.
• The important theories are;
1. Maximum Principal Stress theory (Rankine’s theory)
2. Maximum strain theory (St. Venant's theory)
3. Maximum shear Stress theory (Coulomb, Tresca &
Guest’s theory)
4. Distortion energy theory (or) Shear energy theory
(Hencky Von Mises theory)
5. Maximum total strain energy theory (Haigh’s theory)

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
1. Maximum principal stress theory or Rankine's theory
It states that " the failure of a specimen subjected to combined
loading occurs when the maximum principal stress at any point in the
specimen reaches the yield or ultimate strength as detemined from a
simple tension test". i.e. Failure occurs when  e   1

x  y   x  y 
2

 e         xy  Eqn 2.8(a), Page 21
2

 2   2 
σ yt
For safe design, σ e = for ductile materials &
n
σ ut
σe  for brittle materials where n = factor of safety
n
* Experimental investigations suggest that Rankine's theory gives good predictions for
brittle materials and not recommended for ductile materials.

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
2. Maximum principal strain theory or St.Venant's theory
It states that " the failure of a specimen subjected to combined
loading occurs when the maximum normal strain at any point in the
specimen reaches the principal strain as detemined from a
simple tension test".
e ( 1   2 )
Failure occurs when    e  ( 1   2 )
E E
x  y    x  y 
2

 e  (1   )    (1   )     xy  Eqn 2.8(b), Page 22

2

 2   2 
σ yt
For safe design, σ e = for ductile materials &
n
σ ut
σe  for brittle materials where n = factor of safety
n
* St.Venant's theory predicts smaller value of stress than maximum
Dr P R Venkatesh, Mech Dept, RVCE,
principal stress theory & hence not widely used.
Bangalore
3. Maximum Shear stress theory or Tresca's theory or Guest's theory
or Coulomb's theory
It states that " the failure of a specimen subjected to combined
loading occurs when the maximum shear stress at any point in the
specimen reaches the shear yield stress as detemined from a
simple tension test".
e
We know that shear stress at yield,  e =
2
e (   2 )
Failure occurs when   max  1   e  ( 1   2 )
2 2

 
2
 e  x   y  4 2
 Eqn 2.8(c), Page 22
σ yt
For safe design, σ e = for ductile materials
n
where n = factor of safety
* Max shear stress theory is widely used for predicting the failure of
Dr P R Venkatesh,
ductile materials such as transmission Mech Dept, RVCE,
shafts.
Bangalore
4. Shear energy theory or Hencky -Von Mises's theory
It states that " the failure of a specimen subjected to combined
loading occurs when the shear energy of distortion per unit volume
at any point in the specimen reaches the shear energy of distortion
at yield point as detemined from a simple tension test".
 1   2
As shear energy at yielding in tension is U     e & that under
 3E 
 1   2
combined loading is 
 3E 

 1    2   1 2  , failure occurs when;
2

 e2   12   22   1 2  OR  e   12   22   1 2
  e   x2   x y   y2  3 2  Eqn 2.8 d, Page 22
σ yt
For safe design, σ e = for ductile materials
n
where n = factor of safety
* Experiments have shown that distortion energy theory is in better agreement for
Dr P R Venkatesh, Mech Dept, RVCE,
predicting failure of ductile componentBangalore
than any other theory of failure.
5. Maximum Total strain energy theory or Haigh's theory
It states that " the failure of a specimen subjected to combined
loading occurs when the total strain energy per unit volume at any
point in the specimen reaches the total strain energy at yield point
as detemined from a simple tension test".
Failure occurs when;
 e   12   22  2 1 2  Eqn 2.8e, Page 22
σ yt
For safe design, σ e = for ductile materials &
n
σ ut
σe  for brittle materials where n = factor of safety
n
* As the experimental investigations do not support predictions
as per this theory, is not used widely as other theories.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Prob 1
A machine member C 40 steel is loaded in the following
ways;
(a) x = 40 MPa and y = 20 MPa
(b) x = 60 MPa and xy = 40 MPa
(c) x = 60 MPa , y = -20 MPa and xy = 30 MPa
Determine the factor of safety in each type of loading by
using;
1. Maximum Principal Stress theory (Rankine’s theory)
2. Maximum shear Stress theory (Coulomb, Tresca &
Guest’s theory)
3. Distortion energy theory (or) Shear energy theory
(Hencky Von MisesDr Ptheory)
R Venkatesh, Mech Dept, RVCE,
Bangalore
 From Table 1.8, Page 464, for C 40 steel, yt =324 MPa
Consider  a  σ x = 40 MPa and σ y = 20MPa
1. Maximum principal stress theory or Rankine's theory
   
 yt    x  y 
2 
For safe design,   x y
 
2 
   xy  Eqn 2.8(a), Page21
n  2   2  
 
324  40  20  40  20  
2

       0   factor of safety n = 8.1
n  2   2  
 
2. Maximum shear stress theory Tresca's theory
 yt
   y   4 2  Eqn 2.8(c), Page 22
2
For safe design,  x
n
324
   40  20   0  factor of safety n = 16.2
2

n
3. Shear energy of distortion theory or Hencky's theory
 yt
For safe design,   x2   x y   y2  3 2  Eqn 2.8d, Page 22
n
324
  402  (40  20)DrP R20 2
0 
Venkatesh, Mechfa ctorRVCE,
Dept, of safety n = 9.35
n Bangalore
Consider  b  σ x = 60 MPa and  xy = 40MPa
1. Maximum principal stress theory or Rankine's theory
   
 yt    x  y 
2 
For safe design,   x y
       Eqn 2.8a, Page 22
2

n  2   2  
 

324  60  0   60  0 
2 
       40   factor of safety n = 4.05
2

n  2   2  
 
2. Maximum shear stress theory Tresca's theory
 yt
 x   y   4 2  Eqn 2.8c, Page 22
2
For safe design, 
n
324
   60  0   4  402  factor of safety n = 3.24
2

n
3. Shear energy of distortion theory or Hencky's theory
 yt
For safe design,   x2   x y   y2  3 2  Eqn 2.8d, Page 22
n
324
  602  0  02  3 Dr40 2
 facto
P R Venkatesh, MechrDept,
of RVCE,
safety n = 3.535
n Bangalore
Consider c  σ x = 60 MPa, σ y = - 20 MPaand  xy = 30MPa
1. Maximum principal stress theory or Rankine's theory
   
 yt    x  y 
2 
For safe design,   x y
 
2
    Eqn 2.8a, Page 22
n  2   2  
 

324  60  20   60  20 
2 
       30   factor of safety n = 4.63
2

n  2   2  
 
2. Maximum shear stress theory Tresca's theory
 yt
   y   4 2  Eqn 2.8c, Page 22
2
For safe design,  x
n
324
   60  20   4  302  factor of safety n = 3.24
2

n
3. Shear energy of distortion theory or Hencky's theory
 yt
For safe design,   x2   x y   y2  3 2  Eqn 2.8d, Page 22
n
324
  602  (60  20) Dr20 2
 3  30
P R Venkatesh,  factor of safety n = 3.645
2 Dept, RVCE,
Mech
n Bangalore
 Prob 2
A steel shaft is subjected to a bending moment of 9 KNm
& a twisting moment of 12 KNm. The yield strength of
steel is 360 MPa & factor of safety is 2.
Determine the permissible diameter of the shaft by
using;
1. Maximum Principal Stress theory (Rankine’s theory)
2. Maximum shear Stress theory (Coulomb, Tresca &
Guest’s theory)
3. Distortion energy theory (or) Shear energy theory
(Hencky Von Mises theory)

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 Data : M = 9 KNm, T = 12 KNm, σ yt = 360MPa,n = 2
This is a shaft subjected to combined bending & Torsion.
Bending moment M = 9 KNm = 9  10 6 N  mm
32M 32  9  10 6
Bending stress  = 
D 3
  D3
91.673 × 10 6
  3
N / mm 2

D
Twisting moment T = 12 KNm = 12  10 6 N  mm
T 16T 16 12  10 6
 Shear stress  =  
Zp  D 3
  D3
61.11× 10 6
  N / mm 2

D3 Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
1. Maximum principal stress theory or Rankine's theory
   
 yt    x  y 
2 
For safe design,   x y
 
2
    Eqn 2.8a, Page 22
n  2   2  
 
360 106  91.673  0   91.673  0 
2 
  3      61.11 
2

2 D  2   2  
 
 Diam eter of shaft D = 87.89  90 mm
2. Maximum shear stress theory Tresca's theory
 yt
   y   4 2  Eqn 2.8c, Page 22
2
For safe design,  x
n
360 106
  3  91.673  0   4  61.112
2

2 D
 Diameter of shaft D = 94.68  95 mm
3. Shear energy of distortion theory or Hencky's theory
 yt
For safe design,   x2   x y   y2  3 2  Eqn 2.8d, Page 22
n
360 106
  3 91.6732  0  0 2  3  61.112
2 D Dr P R Venkatesh, Mech Dept, RVCE,
 Diameter of shaft D = 91.97 Bangalore
95 mm
 Prob 3
A mild steel shaft of 60 mm diameter is subjected to a
bending moment of 2.5 KNm & a twisting moment ‘T’. If
The yield strength of shaft material in tension is 200 MPa,
find the maximum value of torque at which the shaft just
begins to yield, according to;

1. Maximum Principal Stress theory

2. Maximum shear Stress theory

3. Distortion energy theory

Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Data : M = 2.5KNm = 2.5×10 6 N mm, D = 60 mm,
T (at yielding) = ? (  factor of safety need not be taken)
32 M 32  2.5 106
Bending stress     117.89 N / mm 2

 D3   603
Let the shear stress induced be equal to ' '
1. Maximum principal stress theory or Rankine's theory
       x  y 
2 
For yielding,  yt   x y
       Eqn 2.8a, Page 22
2

 2   2  
 
 117.89  0   117.89  0 
2 
i.e. 200       
2

 2   2  
 
 141.05  3474.51   2 Squaring both sides,
19895.1  3474.5   2   = 128.15N / mm 2
16T 16T
But shear stress    128.15 
 D3   603
 Max torque to cause yielding shaft
Bangalore
T 
Dr P R Venkatesh, Mech Dept, RVCE,
of 5.435  10 6
N - mm
2. Maximum shear stress theory Tresca's theory

 
2
For yielding,  yt  x   y  4 2
 Eqn 2.8c, Page 22

 200  117.89  0   4  2
2

 200  13898  4   2 Squaring both sides,

40000  13898  4   2  τ = 80.78 N / mm 2
16T 16T
But shear stress    80.78 
D 3
  603
 Max torque to cause yielding of shaft T  3.43  10 6 N - mm

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
3. Shear energy of distortion theory or Hencky's theory
For yielding,  yt   x2   x y   y2  3 2  Eqn 2.8d, Page 22

 200  117.89   0  0  3 2
2

 200  13898  3 2 Squaring both sides,

40000  13898  3 2   = 93.28 N / mm 2
16T 16T
But shear stress    93.28 
D 3
  603
 Max torque to cause yielding of shaft T  3.956  10 6 N - mm

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 Prob 4
Determine the diameter of the shaft loaded as shown in fig
based on maximum shear stress theory. Take yield point as
380 MPa and factor of safety as 2.







Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
Data : This is a shaft subjected to combined bending & Torsion.
From the fig, M = 1000  250 = 2.5  10 5 N - mm &
T = 1000  500 = 5  10 5 N - mm,
σ yt = 380MPa,n = 2
32 M 32  2.5  10 5 2.5465 × 10 6
Bending stress  =   N / mm 2

 D3   D3 D3
16T 16  5  10 5 2.5465 × 10 6
Shear stress     N / mm 2

 D3   D3 D3
Maximum shear stress theory Tresca's theory
 yt
 x y
2
For safe design,      4 2
 Eqn 2.10, Page16
n
380 106
  3  2.5465  0   4  (2.5465) 2
2

2 D
 Diameter of shaft D = 31.06  35 mm
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Stress Concentration
• In the basic stress equations for tension,
compression, bending & torsion, it is
assumed that there are no discontinuities in
the cross section of the machine
component.
• But while designing a machine component
it is necessary to have changes in cross
sections such as hole, notch, keyway, etc.
• Such discontinuities will alter the stress
distribution and are called stress raisers.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Internal force lines are
denser near the hole
 Theoretical Stress concentration factor
• A theoretical or geometric stress concentration
factor kt is used to relate the actual maximum
stress at the discontinuity to the nominal stress.
 max  max
kt  for normal stress & kts  for shear stress
 nom  nom
• The values of kt for various geometries and type
of loading are known in Peterson’s charts
plotted on the basis of dimensionless ratios. (Fig
2.11 to 2.31, Page 36 to 46, Design Data
Handbook, Mahadevan)
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Methods of reducing stress Concentration
• It is rather impossible to avoid stress
concentration, but care can be taken to
reduce it.
• In a machine element, the force flow lines
must be uniformly spaced and the number
of flow lines at any cross section must be
same.
• The same may be achieved by using fillets
at steps, by drilling additional holes or
making additional notches, by using
symmetrical shapes, etc.
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Prob 1
A steel plate of width 50 mm, thickness 10 mm,
with a hole of diameter 10 mm drilled at its center
is subjected to a tensile load F. Determine the load
‘F’ the material can withstand by taking the stress
concentration into account. The maximum stress
in the member is 60 N/mm2.

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 Data: Width of plate B = 50 mm, hole dia ‘a’ or ‘d’ =10
mm, Thickness of plate t=10 mm, max= 60 MPa
t

F F
B a

a 10
From fig 2.12, page 36, for   0.2, stress concentration factor kt = 2.5
B 50
 max 60
But kt   2.5  , ∴ σ nom = 24MPa
 nom  nom
F F
Also,  nom   24  ∴ F = 9600 N
( B  a)t (50  10) 10
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
Bar in tension or compression with a transverse
hole. A=(w-d)t where t= thickness of plate

Fig 2.12 , Page 36, Mahadevan DDHB

Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Prob 2

Determine the maximum stress induced in the

notched plate as shown in fig.

9 KN 9 KN
B =80 b
r10

10

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
Notched bar in tension or compression with a
transverse hole. A=tb where t= thickness of plate

Fig 2.14, Page 37, Mahadevan DDHB

 9 KN 9 KN
B =80 b
r10

10
From the fig,
B = 80 mm, r = 10 mm , b = (B - 2r) = 80 - (2 × 10) = 60mm ,
F = 9000 N, t = 10 mm.
From the fig 2.14, Page 37,
r 10 B 80
for   0.167, and   1.333, k t = 2.12
b 60 b 60
F 9000
 nom   15 MPa
t  b 10  60
 max  max
But kt   2.12  ∴ σ nom = 31.8 MPa
 nom 15
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Prob 3

A rectangular plate as shown in fig is subjected to an axial

pull of 200 KN. Determine the thickness of the plate if the
plate material is made of C 60 steel and the factor of
safety desired is 2.

200 KN 200
200 KN
 50  50
r 10

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
  

200 KN 200
200 KN
 50  50
r 10

 

For C 60 steel, from table 1.8, Page 464,

 yt
412
σ yt = 412MPa  max    206MPa
n 2
a 50
Considering the hole section (1 - 1), for   0.25, kt = 2.45
B 200
(fig 2.12, page 36)
 max 206
But kt   2.45  ∴ σ nom = 84.1 MPa
 nom  nom
F 200 103
 nom   84.1   t = 15.85  16 mm
( B  a)  t Dr P R  50)  t
(200Bangalore
Venkatesh, Mech Dept, RVCE,
  

200 KN 200
200 KN
 50  50
r 10

 

Considering the fillet section (2 - 2),

B 200 r 10
for   1.11 & =  0.055, kt = 2.5 ( fig 2.14, page 37)
b 180 b 180
 max 206
But kt   2.5  ∴ σ nom = 82.4 MPa
 nom  nom
F 200 103
 nom   82.4   t = 13.48  14 mm
bt 180  t
Select higher value for safe design, i.e. t = 16 mm
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Prob 4
Determine the diameter of the hole shown in
fig, if the stress concentration factor at the hole
is to be same as that at the fillet.

r5
50

85

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r5
50

85

Fig 2.12, Page 36,

Mahadevan DDHB

Fig 2.16, Page 38,

Mahadevan DDHB

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r5
50

85

At the fillet section, (fig 2.16, Page 38, for stepped bar in tension)
B 85 r 5
  1.7,   0.1,  k t = 2.18
b 50 b 50
At the hole section, (fig 2.12, Page 36, for plate with a hole)
a
Corresponding to kt  2.18, = 0.5
B
a
  0.5 ∴ Diameter of the hole = 42.5 mm
85 Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Prob 5
A shaft is stepped down from 80 mm diameter to 40 mm
with a fillet radius of 6 mm. Determine the maximum
stress induced in the shaft when subjected to;
(i) Bending moment of 200 Nm.
(ii) Twisting moment of 400 Nm.

r6

 

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r6

 

Fig 2.25, Page 43,

Mahadevan DDHB

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r6

 

(a) When subjected to bending moment of 200 Nm :

(fig 2.25, Page 43, for stepped bar in bending)
D 80 r 6
  2,   0.15,  kt = 1.55
d 40 d 40
32 M 32  200 103
 nom    31.83 N / mm 2

d3   403
 max
But k t    max  k t   nom  1.55 × 31.83 = 49.34
 nom
∴ Max stress induced in the shaft =
Dr P R Venkatesh, Mech Dept, RVCE,
49 .34 N / mm 2

Bangalore
 r6

 

Fig 2.27, Page 44,

Mahadevan DDHB

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r6

 

(b) When subjected to twisting moment of 400 Nm :

(fig 2.27, Page 44, for stepped bar in torsion)
D 80 r 6
  2,   0.15,  kts = 1.34
d 40 d 40
16T 16  400 103
 nom  3   31.83 N / mm 2

d   403
 max
But kts    max  kts   nom  1.34 × 31.83 = 42.65
 nom
∴ Max shear stress induced in the shaft
Dr P R Venkatesh, Mech Dept, RVCE,
= 42.65 N / mm 2

Bangalore
 Prob 6
A grooved shaft of larger diameter 60 mm has a
semicircular groove of radius 5 mm. Determine the
maximum stress induced in the shaft taking stress
concentration into account when subjected to;
(i) An axial load of 40 KN.
(ii) A bending moment of 400 Nm.
(iii) A twisting moment of 500 Nm.
r5

D  d

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r5

D  d

Fig 2.18, Page 39,

Mahadevan DDHB

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r5

D  d

(a) When subjected to an axial load of 40KN :

(fig 2.18, Page 39, for grooved shaft in tension)
D 60 r 5
  1.2,   0.1,  kt = 2.17
d 50 d 50
4 F 4  40 103
 nom  2   20.372 N / mm 2

d   502
 max
But kt    max  kt   nom  2.17  20.372 = 44.2 N / mm 2
 nom
∴ Max stress induced inDr Pthe shaft = 4 4.2
R Venkatesh, Mech Dept, RVCE,
N / mm 2

Bangalore
 r5

D  d

Fig 2.20, Page 40,

Mahadevan DDHB

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r5

D  d

(a) When subjected to bending moment of 400 Nm :

(fig 2.20, Page 40, for grooved shaft in bending)
D 60 r 5
  1.2,   0.1,  kt = 1.89
d 50 d 50
32 M 32  400 103
 nom    32.595 N / mm 2

d3   503
 max
But k t    max  kt × σ nom = 1.89 × 32.595 = 61.6
 nom
 Max stress induced in the shaft =
Dr P R Venkatesh, Mech Dept, RVCE,
61.6 N / mm 2

Bangalore
 r5

D  d

Fig 2.22, Page 41,

Mahadevan DDHB

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r5

D  d

(a) When subjected to twisting moment of 500 Nm :

(fig 2.22, Page 41, for grooved shaft in torsion)
D 60 r 5
  1.2,   0.1,  kts = 1.46
d 50 d 50
16T 16  500 103
 nom  3   20.372 N / mm 2

d   503
 max
But kts    max  kts  nom  1.46  20.372  29.74
 nom
 Max stress induced in the shaft =
Dr P R Venkatesh, Mech Dept, RVCE,
29.74 N / mm 2

Bangalore
 Prob 7
A shaft of diameter ‘1.5d’ is stepped down to
diameter ‘d’ with a fillet radius of d/8. It carries a
transverse load of 60 KN as shown in fig. Find suitable
diameter ‘d’ if the shaft is made of SAE 1045 annealed
steel. Assume factor of safety 2.5.

r=d/8 60 KN

D=1.5 d d

200
300

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r=d/8 60 KN

D=1.5 d d

200
300

Fig 2.25, Page 43,

Mahadevan DDHB

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
This component is subjected to bending moment :
For SAE 1045 steel,  yt = 310 MPa (T 1.18, page 473)
 yt 310
 max    124MPa
n 2.5
M (at critical section) = 60  10 3  200 = 12  10 6 N - m m
d
D 1.5d r
For   1.5,  8  0.125,  kt = 1.58
d d d d
(fig 2.25, Page 43, for stepped shaft in bending)
 max  max 124
But k t    nom    78.48 N / m m 2
 nom kt 1.58
32 M 32 12 106
But  nom   78.48 
d 3
 d3
 d = 116 mm, D = 1.5d = 174Mech
Dr P R Venkatesh, mmDept, &
RVCE,r = 0.125d = 14. 5 mm
Bangalore
 Prob 8
A shaft of diameter 60 mm has a semicircular groove
of radius 5 mm & is made of steel having allowable
shear stress of 60 MPa. Determine the safe power that
can be transmitted at 900 rpm.
r5

D  d

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 r5

D  d

Fig 2.22, Page 41,

Mahadevan DDHB

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
Grooved shaft subjected to twisting moment 'T' :
(fig 2.22, Page 41, for grooved shaft in torsion)
D 60 r 5
  1.2,   0.1,  kts = 1.46
d 50 d 50
 max  max 60
But kts    nom    41.1 MPa
 nom kts 1.46
16T 16  T
Also  nom   41.1 
d 3
  50 3

T  1008.64 × 10 3 N - mm = 1008.64 Nm
2 NT 2  900 1008.64
P =  95.1 KW
60000 60000
Power that can be transmitted by the shaft = 95.1 KW
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Prob 9
A stepped shaft shown in fig is subjected to a
transverse load. The shaft is made of steel with an
ultimate strength of 400 MPa. Determine the
diameter ‘d’ based on a factor of safety of 2.

8 KN
d/5
A d/10 B

d 2d d

250 100 125 25

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 8 KN
d/5
A d/10 B

d 2d d

250 100 125 25

This is a simply supported beam subjected to bending moment :

(Refer Table 1.4, Sl No 5, page 16, Mahadevan DDHB)
F  b 8000 150
Support reaction at A , RA   = 2400 N
l 600
F  a 8000  350
Support reaction at B , RB   = 5600 N
l 600

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
 8 KN
d/5
A d/10 B

d 2d d

250 100 125 25

Fig 2.25, Page 41,

Mahadevan DDHB

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
There are two critical sections at left fillet & right fillet.
(i) Considering left fillet :
Bending moment M  RA  250  2400  250  6 105 N - mm
d
D 2d r
For   2,  10  0.1, kt = 1.74
d d d d
(fig 2.25, Page 41, for stepped shaft in bending)
 max  ut 400
But kt  , Here,  max    200 MPa
 nom n 2
 max 200
  nom    114.94 N / mm 2
kt 1.74
32M 32  6 105
But  nom   114.94   d  37.6  40mm
d 3
Dept,
Dr P R Venkatesh, Mech  dRVCE,
3
Bangalore
(i) Considering right fillet :
Bending moment M  RB  25  5600  25  1.4  105 N - mm
d
D 2d r
For   2,  5  0.2, k t = 1.44
d d d d
(fig 2.25, Page 41, for stepped shaft in bending)
 max  max 200
But k t  ,   nom    138.9 N / mm 2
 nom kt 1.44
32 M 32  1.4 105
But  nom   138.9   d  21.73  25 mm
d 3
 d 3

Selecting the higher of the two values for safe design,

d = 40 mm, D = 2d = 80 mm ,
r (left fillet) = 4 mm, r (right fillet) = 8 mm
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 Prob 10
An infinite plate with an elliptical cut out having
major diameter 60 mm and minor diameter 30 mm is
subjected to uniaxial tension. Determine the stress
concentration factor when;

(i) Load is at right angles to the major axis

(ii) Load is parallel to the major axis

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore
F F

Note: From Table 2.1, Page 30, Sl No 5 & 6,

Kt = 1+2b/c when load is perpendicular to major axis
30 60
Kt = 1+2c/b when load is perpendicular to minor axis
60
where b= semi major axis & c=semi minor axis.
30

F F Here, major axis 2b = 60 mm  b = 30 mm &

minor axis 2c = 30 mm  c = 15 mm
(i) When load is perpendicular to major axis :
 2b   60 
kt   1     1    5
 c   15 
(ii) When load is parallel to major axis :
 2c   30 
kt   1     1    2
 b   30 

Dr P R Venkatesh, Mech Dept, RVCE,

Bangalore