NAME: - Rupen N.

Amraniya
SUBJECT: - Machine Design (By Vijay Sir)

CHAPTER NAME PG NO.

1. STATIC DESIGN 001
2. PRINCIPLE STRESS 032
3. THEORY OF FAILURE 045
4. FLUCTUATING LOADS 082
5. BRAKES 111
6. DESIGN OF WELDED JOINTS 127
DESIGN OF RIVETED JOINTS 138
DESIGN OF THREADED JOINT 160
7. FRICTION CLUTCHES 172
8. BEARINGS 198
9. GEARS 226
10. SPRINGS 238
11. DESIGN OF SHAFT 248
1

CHAPTER 1 STATIC DESIGN

Page 1 of 253
1
-

CHAPTER 1. STATIC DESIGN

Ben-Zvi : A
diameter
cantilever beam
beam
of Midst is
it yield
loaded as shown .
Find

required
the safe
of strength 300 Mpa and the

F. O S
. . is 3
.

p =
to kN

÷ ④
iis⑧=M=¥ooFi!a
is 6--1=3002
A FOS ⑦

normal
stress -1
3002
SIM
MILT
.
B = =

↳
WENG ! !
Fos

: M = P X L Et 0×103×1×103
7-
← There are not principle
=
1×10 N .
mm
stress .

1×10
7-
X TM
da .

: D= too
ft compare Normal stress
LOO 62N mm
• .

= -

instead
.

of
.
-
Maximum shear
76494493 Stress .
( No Mentioned)
p = 1041W
1. How to differentiate between axial and
b. bending ?
=
2. Why transverse shear stress is not used in
the design ?
Er:i uieatitoonoierwrong
¥ 3. Why principal stresses are not calculated in .

this design ?
4. Why no theory of failure is used in this
design ?
T
←
-

BMD 5. Why normal stress is used in the design of

P L
ductile MS material here ?
.

Principle Stress:-
f -
n E

Mohr 's circle

- 6
-

,
Maximum principle stress
=

Bz = Minimum principle stress •

'

↳
=a *
tf
62=6×2-62 *
Y( )yZ . .
. Bp → Must

in
be

design
used

Theory of Failure:-
⑧

* Maximum Normal stress

theory → Brittle Material
Maximum
theory
no shear stress → Ductile Material

Page 2 of 253
1

TYPES OF STRESS:-
-

Pz
{ Tangential / Parallel -3

in:*:
" "
i
"

Pg

two types of stresses available

→
only are .

6x
Effy I
ELI I EF#z
= = =
,
,
I

* Tensile ( Normal ) Torsion { shear stress }

Compression ( Normal } Axial ( Normal }

Shear ( shear } Yield stress ( Normal stress }

Bending { Tension + compression ; Normal } ↳ obtained 6- e curve

" "
↳ UTM Machine

NOTATION OF STRENGTH AND APPLIED STRESS:-

÷ from
→
strength is obtained experiment .

S
strength Yield ← Yt Tension
strength
→

Syt =
yield in Tension of
strength ↳ yield
Syc in compression Yield
=
Yield strength of
strength
Ssy =
Yield strength in shear ore shear Yield strength
s
strength Yield
sat =
Ultimate in Tension er
strength Hut → Tension

Yield strength ↳
Sac =
Ultimate strength in compression er
strength ultimate

sus =
Ultimate strength in shear ore shear Yield strength

tox by 62 → Applied Normal stresses 01 Normal stresses due to applied load

, ,

Applied shear due to Load

Txy , Tyz ,
Tzx → shear stresses Er stresses applied
⑥ Normal stress
→
( NOT STANDARD ]
E → Shear stress

Stress Tensor:-
↳
622 TY "
byy Txy → shear stress

T f Y
=
big 8ji
.

different
•

⇐
I *
⑥** I
6xx
✓ ←
/ 6×× Normal stress

f
w
""

y gianni:
6ii=6
•

Ti : Tj;
622
=

Ayy
Page 3 of 253
1

÷÷¥÷¥÷
⇐

Stress - Strain Curve:-

-

② Ductile
-
Material :
-
M.s.
,
Aluminium
,
etc . . .

⑦
S€k=Spk=sy€
uoptiorinnatffsut )
^

¥ .÷÷÷÷÷:÷÷÷÷÷÷::
97%
37 ←→
I
.

V. Y k.
•
→ if which ever
given ,
we

E. e.
→
BE:{king take our elastic design
.
P k¥0
.
ooo
criteria .

"
a. x. a ( Sgt ) → Don 't cross yield Limit .

→ ductile Material →
yield stress is
limiting 3D 8$ By Sgt → Failure
.

criteria .

→ All the stresses on stress -

strain curve are

normal stresses .

For ductile material when ultimate

limiting criterion ?
→ is
,
strength the
Metal
Ans :
Forming operation
8*-5 Sat → safe

8*77 Sue → Failure

② Brittle Material : -

"÷÷÷÷¥÷:±÷
- -

• n

L
÷
.

#
←

Pfonewaaeking
.

.
.

.it?iiseastcos:: enssgim:.s.n.snngeQ
. Ductile Materials
elongate more before failure .
•
: Brittle

is:¥ii: :'t:*:iii. them :

" . high:b
. Ductile Materials -

gradual failure ,
static
loading
. Brittle Materials -

sudden failure

Page 4 of 253
1

:÷÷÷÷:!÷÷;÷;!÷,
' not
given " sackbut ,

i
.

tf not
given , Mutt =p Suell

AREA MOMENT OF INERTIA:-

-

I×a
B,Hz3 Iya
TIBI
• .

Iza Iya
. .

Ixat
=
:
o
. . = =

A YG

±#H
1$ &
POLAR
a-
MOTT

5¥
"
I'III. I :L:
'' '

#
= .

, Ix , = BHI
✓
Ya 3
f- # B
.
; I, D Ix

•
.
.
NITE :
-

Moment of inertia is lowest at centroid .

④→⇐
Az
?
D Ap

IIF
• .
.

mum .
.
:
is

More inertia → More Resistance

-

: Moo . I .
is means resistance to moment .

BENDING OF SCALE:-
-
I, = BHI
12

CM.o.IT , cm.o.az

"Bm
' >
Bm

, .

:( Resistance) , > ( Resistance)z

:
( Bending ) (
o

Bending )z
-

✓
,
air;

BI #¥ Iz = 1413-3
12

→ M O . .
I is minimum at centroid resistance also minimum at centroid
, .

rotate about centroid

Body
÷ .
So .

Page 5 of 253
1

"* Y 134

#
^
: I
Iyq
.
= =
× a-
"

'
*
.
: Iza = D

-
COMPONENT OF FORCE:-

QQ .
What is the component of Force F in vertical direction ?

Do
4-5=12
.

¥2 ¥
cos

a*:⇐
as ""

↳
By
F-
COS 450 = E
Foos 45
.

FIZ
Iz 2

9 .
What is the component of force F in the ox 9 OY directions ?

# ④
n yQ

045€ µ#
⇐ LOON

✓
R

9=200
* ④ 0=35

-P

o
: ( too )2 =
P2 + Q2 + ZPQ cos 35 .

:
•
122=102+012+2 PQ cos O

Q sin 35 Qsino
tan tana
. .

:
•
. .
.

. 20 =
-
= -

Pt Q COS 35 Pt Q cos O

P * Cf cos 35 = I .
576 Q

p = 0.757 Q

( 10032
Z
•

: =
( 0.757 9) t Q2 + 2 ( 0.757 Q) CQ) cos 350

59.62 KM
→ Q =

→ p = 45.13 kN

.
How much force is experienced by the
object shown ?

•
←→p
↳ section
*

*
E? !
Net Force
,
EF
7537mm
= + P -
.

P = O
• ←
① →

per

line
Page 6 of 253
1

Force B
→ For
any given object ,
on
any section is .

→ To determine how much force is experience by a section

,
take a cut
along that section

and refer any one side .

→ To determine how much axial force , bending moment , torque and shear force.
is

experienced by a section take a cut

along that sections and refer any one side .

Q will be if the
.
What stress induced in the
object object is
rigid ?

µ←→p
&
of a > ZERO of b > 8=1*2 so Book

srtigraidn - o
c, ← = , d > NOTA

µ
Resistance - ooo

AXIALSTRESI.to
Load
passing through the centroid .

• Load is perpendicular to the area . Then the load is axial .

*
¥
P p
b- Tension

* *

P ← p &=, Compression

Axial
-
-
stress Distribution
-
: -

.
•

: Uniform Distribution
> →

← ''
•• →
•
I
• -

#
66=1
A

⑤ AN points on the cross section will experience same amount of

axial stress PIA .

⑧ Air point are critical .

• In this case all points are critical .

Unit of stress
:L
Nlm 2 = I Pa =
1/106 N/mm2
I N/mm2 = I MPa

L Gpa = 103 Mpa = 103 N/mm2

Page 7 of 253
1

9 .
Find the axial
rumrunner strength of the circular
runner
rod as shown .

Efts
• =

←
=

fifty :

.P=f *I
Axial
strength CP) x
Sgt

Force
to
-

strength in terms of stress so you

do en 't diameter
P
→
to specify .

B → to

conclusion :
-

Resistance
-

Internal
•
Normal stress ,
6 =

cross-sectional
=

¥
• Either tensile or Compresiye tensile taken as positive
while compressive as
negative .

o
variation is uniform ; i.e .
each point on the cross section is

subjected to same stress 6 .

•
.
.
E = 29 ( Lt M ) = 3k ( It all)

•
Simple loading is also called as Pure
Loading , e.g . simple
tension means pure tension .

The amount load failure

•

of axial a member can sustain without

is caned as
strength of the member .
Axial
strength is
directly
to of diameter
proportional square the .

The axial independent of orientation of section

strength is cross
•
.

•
Direction of the axial stress is collinear with the direction

of corresponding axial force .

e. Uniaxial Tension compression Thermal

g . or
,
stresses , Initial

tightening in the bolts etc .

Page 8 of 253
1

If the axis
* of rotation is parallel to area
,
the moment is
bending moment .

If the axis of rotation is perpendicular the is

* to area
,
moment
Twisting Moment .

Yn- Torqued

a
z
Tangential / Parallel to
←

y
Area -• area ( B. M )

'

i:p :: ÷
. .
-

. .
I

Axis
Type of
run -
min

* How to decide the axis of rotation ?

Mo =
?
Y n

¥i¥÷
72 I' = LE + of ok +
→
Psino
cos OF + j OF
'
a F = P P since +

: I
=p :/
a'
'
. x'
.

Pcos O Psino O

V
M→=(pLsinO)k-
↳
Direction
about
of
2
moment
axis
magnitude f
axis of rotation
e. Exhaust fan Mo =
@ since) * b
g
.

-
La na t t t
Z x
x

Procedure:-
1. Locate the area ( Specified or Critical)

✓
←
!
r
2. Locate the area. TFIf Area is not

3. Draw 3 mutually perpendicular throughmentioned imam area

.

centroid.
.

rotate about 2- axis

4. Shift the load to the centroid.
•
Fan .

#
#

#
#

Casey case
b- B
-

// /
-

\I /
#

-4-7 Pz

t→ ?
•

ftp.af-spo
R

.
? . .

Axial Load Eccentric Axial load =

A. L .
+ B. M

B. M .
= O
-
B. M .
=
Pz X R
-

b lo lo
Z x Y
↳ Parallel to Assis ( B. MD
Page 9 of 253
1

Case 3 case 4

#
- -

÷
"
.
# #

II ftp.ns.f# /I /
-
> Paco so

*a Ps Ak -4

Hanners k¥9;
T.in#ers.e.n.s!F.m?adJ shear Load

F. S.k .
-
shear Load A B. M . :
'

B. M .
=
Pm x b F. M .
=
Pax R

→ B. M .
=
Ps Xk

Bending stress
→
Axial
* F) M I distance
.
←

Force z p > M =
Force x

.
:*:÷
A- ¥-4 a Y x

↳ Parallel to area ( B. M ).

µ
. . . . . . . . . .

← B- I

Bendingstres.ge
Dune
Simple Bending
bending →
only bending ( mo s .
F.
,
No IM .

,
No A. F.)

¥÷?
'
'

B. Mo M

}
EE
=

se .
- o Pure
Bending
⇐ D= ?
Axial force , o

* *

*
governing eqn of bending :

¥=¥=F * Kote : -
axis of rotation
6 about N A
where
bending stress
=
. .

Y = distance from Neutral Axis (N A.) .

( B. MD centroid
M
Bending moment about
=

I = M.O. I. about N A .
.

•=E GDma×=3£d
* circular ds
f-
-=÷Iµ
* :-

to *

Page 10 of 253
1

* Variation of Bending stress :O D=

III. y

:¥e÷ ¥÷:⇐¥"¥o
; P Xk
•

M =

M bmaxjaiean BHI
"
H
-
.
:
Izz
.
: Y = I
P 12 2
Tension Tension

: .

:*,.×=±x±
.

13113 3
←
# Lomax
b- Bt y -

12

*
Bending
Bending
stress

stress
maximum

zero at
at extreme

Natural
layers
layers .
.

max=4BP
* Extreme layers are critical .

A o S F =P
• ! . . . .

pr opera . =p . .

←k##B e
I> stress at point A :

°
Bb -

MIST
=

CP-II.tl ( Tension ) - 8*

The
fB
-

Pd-
stress at point B :

°
Bb ⇐

M÷Yy =
( compression) - 8*

NA¥¥¥#n→m£tress
A
•

*
Bending stress direction is
along the
length .

Compression stress
That's
why it is called longitudinal
← as stress .

:-#
B

Q of circular
.
Find the
bending stress the rod as shown .

K ⑥ How B. M sustained ? Do
Bending strength much . can be

Normal stress

mm
+

Yoram .
a -7¥
-

Etfs ÷r⑤
.
→→ If diameter is

.µ=?oyt*Jzd
stress
double
.

.
then

bending strength
* * will increase by
* section Modulus ,
8 times .

Gb I section
→ x modulus is
inversely proportional to
bending
ZZ stress .

Page 11 of 253
1

P
E
M =P
→
, , if
µ K
A Z Y

↳ Axis of rotation ( Noth )

.

✓
e

B Parallel to Area

[
( Moment)
# Bending

Bending Moment maximum at fixed end .

(B. M )
.

max
= pp . k

z!÷¥
p Iz = INA =
BHI
H 12

←
B -
bmaxlbenaing-M.fmax-P.ph:5 -

Y 12

paafferpsoinatseonn.fi?ca:ndcD.:c6Dmax--fzPnIQ
→

TRANSVERSESHEARSTRESS.io
'
"
←
Transverse road

* *

← ←→ ,
Transverse shear stress
,

E=FjA.÷
Rectangle section
, Wende ,
s=F= Shear force
b. = width of considered

'

II . .

n.
P I =
INA =
BHI
HK 12

I
A =
Shackled Area
1- BI
A
13×(112-7)
•

: =

so

.
.
I =
5×131×11 -

) x%(%*7)
Y

F- ICE D -ry=,¥+z
×,
-

:
.

2 : variation of transverse shear stress is parabolic .

Page 12 of 253
1

Conditions ,
i > 7=0 at N . A . T -
Imax

ii > Y =
Hk 7=0

÷÷÷÷÷iim¥ ←
←
←

Bending
Stress

At fibre is
but
bending maximum
→ extreme shear stress is zero moment .

At Axis is
Neutral shear stress is maximum but
bending moment zero .

:
max
>> Imax :
Bending stress are critical .

* *

For
Rectangular ,

C-maxt-3zx-avg-f-x.se#
For
Eieeudar , * *

Pg:S .fr?.bigtionEmax=IzTavgf
O.
→

÷
C-Transverse

It is Neglected in the design because,

1. It is very small value.
2. At the extreme layers, where bending stress is maximum while transverse shear
stress is zero.
3. In many cases, at the section where bending moment is maximum, shear force is
zero.

PURE-0RSION
"
"
→
only Torsion → simple Torsion
- -

# #

Hottie y¥F#"
-1=21312
-

→
Torque ? -
p

! a- M , =p x R

/T=2PR
- -

✓ ✓ [¥
→

Mz =
PXR

- -
Mz

*
every section subjected to same
magnitude of Torque TT .

Page 13 of 253
1

Net moment T =
Mr + Mz = 21012
,

* *

governing egn of Torsion

¥=¥=G
radial

Tj
where
,
R =
Radial distance g. distance
d- = Polar moment of inertia Tea
,
J Id't
•

: =

32

Varia sion of Torsion stress

u n - - m m

C- =
Ix R

Imax J
→

Linear ÷: c- a k EPT Rtt

Imax I
''
REENIE
←
m.
ii > if car
e-

# R Rmax So
.
-
-
. .
,

Imax
C- = Imax

* The points on the external Imax =

IR
circumference d-
are
subjected
to maximum torsional shear stress .
=
Tx dlz
- =

da JI d3

* At the center torsional Shea stress

Ema×=%
* *
will be zero .

Representation
mmmm
of
-
Torsion
-
stress
mm

• All sections are

subjected to same torque TT .

• The all surface point are critical .

* *

# T=I÷,=

//④tz
ALI ,

:
I a-
"

17=21012
,

Page 14 of 253
1

Cf . Find the torsional

strength of the circular rod as shown .

↳ Amount of torque the shaft is sustain .

yield

§⑦!
← shear
Emad
III Eggs
=
=

at strength
shear
stress
* *

%£s×y
T④** Torsional
strength or Torque
carrying capacity is
proportional
to cube of diameter .

→ Amount of twisting moment of shaft can endurance without failure

is called shaft
as
strength of .

* *

:PolorModulus⇐fT
•

Q .
Which are the critical points ?

µ
#

¥ .
P → Axial load .
.

..
All points on Cls
are critical .

A
-

\)
I . . .

8 Lip

ftp.#B
.
=

2
Tld

E.IT#dzEIy=EE?z=-cyz=o
at point A
,

I
e#
µ
-

A
i> M = Px d-

\#
/ §.?;Bmf#
•-
Z Y K

↳ Parallel to area CB.im ,

Maximum
B. ← a p bending moment farthest point
from N . A .
(A and B)

at point A
, Gb = 321 = 32101 = Gx ( Tension)
Ted 's Ted
's

.
.

by =
62=0 ; Txy =
Txz =
Tyz = O

Page 15 of 253
1

at point B
, 6b=6× =
-

32Pk_ (compression)
Ted 's
•

.
.

by =
62=0 ; Txy =
Txz =
Tyz = O

GATE 2020
Q. A body is subjected to ______ doest not undergo change in volume.
a.) Uniform Tension
b.) Pure Shear
c.) Pure Bending
d.) Hydrostatic Pressure

SOM .
Ev = 6×+4+62 ( t all) -

⇐
E-
Pure
Exy 16--1 6x=6y 62=0
• . '

=
-

→ .
- =

Torsion Tlds Pure Shean

Eu
'

O
-

. = ←

* Free vector Moment

:D
-

P EMA =p .
L (c. w )
OT

Ep o#
y EMB = P L-

( C. w)
A
E Mc ( )
Plz
PL
plz
=
+ = cue

←
42-4<-42 -sk- x-

C END = -
P.sc + PIL -13C) = + PL CC -
w )
.

Force 's
-

Efx = O

E
Fy =
p -

p =
O

Couple is two forces opposite

thing where are equal ,
and non -

collinear .

That's moment is constant where

→
why every .

1kW

HIS -
↳

B
# a - Im
Find
maximum
maximum
transverse
bending
shear .
stress and

1kW d. F.) ma ,
= 103 Ni

(B. M )ma×
.
= 103×103=106 N .
mm
-

P k
-

→ ④ = 32Mt = 32×1062=81.48
ma ,
A and B are £ Tlds TL x 503 MPa

critical .

Imax
CD line are
←
=

I Tang =

f- ×

constant =
O . 679 MPa
Page 16 of 253
1

( Imax)
&¥mmaa# @b) 120.018
8o!j5g
: 120.01
•
→ =
= =
max

NOTE :
-

The beams are

designed for bending stress they are checked for the

shear stress .

:
STANDARD #
RESULT OF
#
BEAM
#
#

:D Cantilever beam with Sof . =p

Point load .
B. M .
= P.sc

p
it G. F) max =P { Thought the beam .
}
I
✓

I
# BT k
¥x→
.

ii > (B. Mdma, = PL f At fixed end }

-
#

PIED critical point

: A B
°

and .

p .

if > Cantilever beam with Sof .

= 0

Moment .
B. M .
= M

f
E#¥→)Bm=m
=

-
c- r -
,
is (B. Mdma ,
=
M

Top and bottom layer of

o

:
g.p.cz#ine through
the beam is critical .

m m

iii > Cantilever beam with

UD b w Nlm 5. F =
W x x
w
.

WI

Aq-mmmmt.mn
B. M
wxxxxz
.
= =

€1
a
I l⇐x→
.

(s F.) ( At fixed end }

✓
i> .

max
= WL
B ←
- R
'T
ii > ( B. M ) .

max
=
WI ( At fixed end }

4
-

a
•

: critical points A and B

.

are .

2 [
Parabolic

Page 17 of 253
1

Tv) (S.F.) RA I
simply supported Beam =
=

2
with point load

(B. M ) Ra
Iz
qq.to
. =
-
x =
x

A B

K¥5,42 # 427¥ ,
i> (s F) max .
=
I
2
{ At air sections . }
RA
-

Pk 13,3=172

#
I
'
ii > (B. Mdma
Pfe { Atstheetomngdle
=
,

¥ critical
C and D point
- '

.
are .

t
F-

V>
simply supported Beam

with Ubb 5. F .
=
RA -
Wak

w Nlm B. M .
=
RA -
x -
WI
wa 2

mmmmm.no.mmmm
# (B. M )
A

¥¥:-b
B i> max
=

WGI ( At middle
section)

TRA -
wth RBI -
WI
-

s
'

critical points C and D .

2 L

#
WII
•

we
2

Vi > Pure Torsion :

-

Eatin:÷÷÷÷÷÷÷÷÷÷÷÷ ..

Page 18 of 253
1

n#¥µ¥q¥p
NFIB I> M =
Pz x k

-
z y x

A ↳
# ( B. MD
Tangential
↳
•

,
I p.
Axis of rotation Cmas
,

-
M¥7 Ii > P, →

taxi at
Axial

=
Tension load

( Tension)
Ik BA 6 axial 6
+
bending
=
t
( TOP )

ii. A ( Gb )
BB
3,26€ 32.132
6 axial 6 iii >
bending
= + -

max
=
=

( BOTTOM) Ted's

iii > Bc = * Coaxial

( N A.)
.

°
: point A is critical .

6x =
Coaxial + Gb

by =
62=0

Txy =
Txz =
Tyz = O

¢
i t
VII. I 'D is AN section are critical .

ii > P → Axial → all points are

If
-

y
A

:#
Critical
A
#
.

::÷:÷::i÷÷÷÷÷÷:÷: :::c:*:
i

point
Ia Ygz
* at A :O 6x= 6 axial =
=

Txy =
IGI -

.
'

by = 62=0 Txz =
Tyz = O
's
Ted

Px > -
i> M P Xk

X
=

:If ÷¥÷ti÷④
z y x

↳ Tangential B. M .

: : : :: .÷:::i¥i%:÷
" "

. . .

Iii > Moment External circumferential

-

Twisting = f- →

✓ fo
'
critical point
°

: A and B are .

p.sc
TM
-

=
T

Page 19 of 253
1

•
•
Point A
,
⑥* = 32PL_ Txy = 16€
Jed 's Ted 's

-0
.
.

by = Gz = O
•
: Txz =
Tyz = O

* §
-

pig
X
Pax L

ti
M =

Z Y K

? ↳ Tangential

I
-

! i÷
-
Noa ( B. M )
.

i:* :÷a:i :* : : :c:*:c:O::i:*

"
.

- Ivy Tom .
= T → Circumferential Points

✓
SF O
!
=

BM . p.sc
at point A 6A t 6 axial + 6
Trg
bending
-

=p
=
,

at point B 613 +6 axial 6

bending
= -

.
'

point A is critical .

→ Lx = 6a×iap t Gb
.

.
.

by = 62=0

C- =
TOI
. .

Tyz = Txz = O
xy
.

Tlds

X
Xia

ti÷÷÷
if > M =
pp * R
De
z y
↳

I
-

E
-
Bending Moment

..
:÷¥÷÷÷:÷÷:÷÷÷÷÷÷÷÷÷÷÷
✓
.

Paxial =P
ivy point A 6A taxi at +6
bending
=

,
BM = Mt
613=6axial 6
-

v> point B ,
-

bending
F- point → ÷
.

Air point on top layer are critical .

Goc =
taxi al t Gb :
by = 62=0

Txy Txz Tyz

•

: = = =
O

I>
. -

ti
xp i> M = P x R

z x Y

I
-

E
Moment
-
Bending .

! : .is#::o::::::i:i:::.i....
"

*. in
-
rift > B. M → Top and bottom points are

✓
.

Paxial =P critical .

BM = Mr
-
iv > Point A 6A 6axial 6
+
bending
= -

v> Point B 613=+6 axial + 6

bending
Ail points botom layer
•
: on are

critical .

Page 20 of 253
1

Ay M Paso R
* iii. I $
-
x
psino

#
=

:÷t÷÷:÷
If P a * x

El
>
↳ Tangential

It
( B MD
-

µ→_
Pcos
-

:÷:÷÷÷÷÷a: :::: ::c:*:c:

i

..

✓ Paxial
BM =
=

Mt
Paso iv > T

>
.

point
M .
→

A
circumference at point
6A t taxi al t b
.

v
bending
-
=

,
TM =
T
6A
.

B 46axial 6
Vi point
=
>
bending
-

: Point A are more critical .

ESE 2004
Q. A shaft is subjected to uniform twisting moment, Uniform bending moment and
axial thrust. Which one of the following are correct ?
a.) One extreme end of the vertical diameter fibre is subjected to maximum
compressive stress only.
b.) The opposite extreme end of the vertical diameter fibre is subjected to
tension/compression stress only.
c.) Every points on the surface of the shaft is subjected to maximum shear
stress only.
d.) Axial longitudinal fibre of the shaft is subjected to compressive stress only.
Got .

:÷::÷:÷::*
"

¥¥÷÷÷¥÷
A

longitudinal
.
.

GB Ga 6
f. bending
=
-
-

+ Tom
B
• EE Bc = -

Boxful
vertical
diameter

•
: bottom points are more critical .

GATE 2016
Q. A machine element XY, fixed at end X, is subjected to an axial load P, transverse
load F and twisting moment T at its free end Y. The most critical point from the
strength point of view is
* a.) a point on the circumference at location Y
a- !
F #

If
-

XX b.) a point at the centre at location Y

-

.
i

*c.) a point on the circumference at location X

. →

d.) a point at the centre at location X ,

↳ *
-

✓
Y
Gb = T M = O Ga # O Gb = T = htt
BM
.

-0
.

⑥axial
X
-

¥0 NO Maximum

Page 21 of 253
1

ESE 1999
Q. A hole is to be punched in a 15 mm thick plate having an ultimate shear strength
of 3 MPa. Allowable crushing stress is 6 MPa. Find the diameter of smallest hole
that can be drilled_____

50€ .

plate ,
7=1 :p =
THAT -_
Be # DK
.

4
F-
Idt

Pu h , K - B- : D= 3×15×42 = 30mm
' 6
xd

ESE 2020
Q. A punch is used for making holes in steel plates with thickness of 8 mm. If the
punch diameter is 20 mm and force required for creating a hole is 110 KN, the
average shear stress in the plate will be nearly_____
a.) 139 MPa 139×6 834 →
=

b.) 219 MPa 219×6=1314 →

→ 336×6=2016
c.) 336 MPa
d.) 416 MPa
E- =L
$012 =
8mm c-
D= 20mm Idt
5 5 5

F- = 710 kN 110×103 to XIOIXVOXVOX #

= =

C- =
? 7×20×8 Tx2XZXXXZ
=
1375g = 13752=219 Mpa
9×2 6.28

Q. A circular member is subjected to axial load of 10 Kn. The yield strength of

material is 200 MPa. Find the diameter if FOS is 2 and 3.

soph 10=10×103 N > FOS 2 Note f

: #
=
.
=

Sgt = 200hPa FOS PP

d2= 4×10×103×2
-
diameter 9$
⑤ I
Efts
= IX 200
max

gdz= o

: D= ii. 28mm

.
.
d2 4×P×F# it > FOS =3

Jlxsyt
d2= 4×10×103×3
-

7×200

d 13.819mm
'
-

- =

Page 22 of 253
1

→ 8 = Syt = Gallow able

Fog

F- OS 99 Goalmouth diameter 94 ← conservative Approach .

Cost PP (More safe)

Q. A bracket has been loaded as shown in figure. Compute the top and bottom fiber
stress at section A-B.
A

¥¥÷:¥i¥
1- "m

4- to I
smog
-

- - . - .

/ 2000mm
e-
-

Sol .
M = 1000×103×500 Mmm ÷
.

M = Px 500
I
X
Y
P = -

1000×103 N
Z

↳ Tangential ( B. MI

Coaxial 1000×1032
Pz 25 MPa (comp )
:* =
=
=
.

@ 0012
%
.
6
y 03×500×1002×-12 ⇐ 375 Mpa
bending
= -
=

(20034

At Top GA =
Coaxial F B 25+375 350 Mpa ( Tensile)
bending
-

= -
=
,

At bottom 613 baxial 6 25 375 400 MPa (comp )

bending
= -
= -

=
-
- - .

for combined
Note : -
Locate NVA
I
loading .

6nA I baxial t Gb

NIA!!
= -

o== -
as -1M€
I

•
.
.

Y = 25 X I
=
25×60014
-

-1
Mf 12×1000×103×500

Y from
•
: = 6.67mm centroid .

: Art bottom layer point of horizontal critical

•

beam are .

Q. A circular cross section is loaded as shown below. Find a distance 'X' from where
the beam will start experience the compressive stress.

[
-_§"
Free end
B
-

BM
-

-
@
-
=

l
-

→
-

- .→P
-
-
.

I Ga Axial Force
only ( Tensile)
-
-
.
-
.

points
.

: All end under

°

on are
.

-
←

Cegmp .

tension only .

Page 23 of 253
1

⑨
⑥
321*1
f#az=
-6 axial t
•
: t
bending
=

1 Idk
* *

x=d
• bottom ⇐ HI • 32l =
O .

.
.

2
Tld Ted 's

Q. A circular cross section column is loaded by eccentric compressive load. Find the
maximum eccentricity of load such that the column will not experience the tesile
stress.

B ⑥ Tensile 6
Coaxial t

¥ bending
= -

{÷z+
32P

¥:÷÷2
o =

Let
-

Ted 's

. em .

What is the KERN

+
of section ? -

→ KERN of the region In which a compressive point load

may
be

applied without producing any tensile stress on the cross -

section .

↳ or vice versa

ESE 2017

Cf.
A Lo mm diameter bar of mild
of elastic modulus
steel
200×109 Pa is
subjected to tensile
loading of 50000 No ,

it
taking just beyond its yield point The elastic recovery of strain
.

that would occur

upon removal of tensile toad will be

-A 50M
200×109 Pa

§A÷÷÷i.I¥÷¥¥¥
.

→ DABC E =

! .p
,
.

UYL A AC =
200×103 MPa
tano -
-

. .
E =

e. as
.
f- Ep → It Eet
4-
=
0.00318 = 3.18×10-3

GATE 1991
Q. Strength to weight ratio for a circular shaft transmitting power is directly
proportional to the
a.) square root of the diameter
b.) diameter
c.) square of the diameter
d.) cube of the diameter
Page 24 of 253
1

strength
weight
=
¥¥×T¥x .cat#g-:.swtreeingHfaddf
i>
strength a- ii > weight =

Sgt
dab
=
sxgx
⇐
Iffy =
Sse
FOS

T = Ssy '
¥3
Fos 16

GATE 1993
Q. The outside diameter of a hollow shaft is twice it's inside diameter. The ratio of the
torque carrying capacity to that of a solid shaft of the same material and the
same outside diameter is_____

Sgt .
hollow shaft ,
do =
Idi
GI =

If

O ⑥
f- = Ex I = Tx Zp
R

T④
SID Hollow
D= do •
@ p) solid =
d
's
=

Iff X 8 dos
-

.
'

do = Idi

(4)
( Do4joDi→
•
Hollow =

t÷=E÷; -

÷ - ma

=÷e::
= t5i3
32

ISRO
Q. Two solid shaft 'A' and 'B' are made of the same material. The shaft 'A' is 50 mm
diameter and shaft 'B' is 100 mm diameter. The ratio of strength of shaft 'B'
compared to shaft 'A' is_____
Som .

da
=
50mm
strength Torte
=
→

dB =
100mm

TX Ip
: 'T ads

¥3 =

@ A)
3

100×100×100
=
8 Aris
=
50¥50 ⇐ .

Page 25 of 253
1

ESE 2019

A is
Cf .

rectangular strut 150 mm wide and 120 mm thick .

It

carries a load of 180 Knt at an

eccentricity of 10 mm in a plane
thickness in figure :
bisecting the as shown the

K¥150 #
-

T
The
the
maximum
section will
intensity
be
of stress in

¥7
.

Sol .
p → M =p x 10

180×103 N =P Z Y K

↳
* *
Tangential → B. M .

a #
bmax taxi al 6

..¥t6max=
Critical bending
= - -

⇐ or

A- 150 -
or y y

pal
l
-

fisoxd-L.io?.::gxoxIy
150×120

1180×1032
180×103×109150×12
Gma ,
)
= -
-

t
15×10×15×7
- -

15×12×10×10 2×12×10×150 X

= -

fro +4 ] =
-

14 Mpa CCCOMPDJ

ESE 2017
-

A bar
g .
rigid ACO as shown is
hinged at O and is held in a

horizontal position by two identical vertical steel wires AB and CD .

A point load of position shown The tensions in

20 kN is
hung at the .

wires AB and CD are

+ -

TAB = ? → To EMO = O

µ-
B D
Im
TCD =
? → T2 : (20×0.8) Tito .GE

-31
=
-

← 0.6M

#^•¢y0 I °

: Tpt 0.3672 = 06

{
=
a-
0.8M → 0.6
i
I. 361T = IG

20kW Tz 0.6 Te Ti I
°

ii. 8
.
. = = =

#-
A O 1.36 KN

T, ¥ Tz = 0.6×11.8

=
7.08 kid

Page 26 of 253
1

ISRO
-

P . A solid circular shaft needs to be

designed to transmit a torque
of 55 Nm .
If it allowable shear stress of the material is 280N 1mm ?
find the diameter ( in mm ) of the shaft required to transmit the

torque .
( Assume IT =
2217)

SOM .

I
-1=55×103 N mm
-
I =
16€
N/mmd Ted 's
Tallow able = 280

dd== ? .

; d3 =
-
16×55×1000×7

22×280
d
# fix 5×1000×71
d3
• .

• =
-
= 1000
Xx 21×71×14×10

.
.

d=t0mm@ E

ESE
Q. A rotating shaft is subjected to constant bending moment and constant twisting
moment. The shaft is subjected to_____
a.) Uniform Bending Stress and Uniform Torsion Stress
b.) Uniform Bending Stress and Varying Torsion Stress
c.) Varying Bending Stress and Uniform Torsion Stress
d.) Varying Bending Stress and Varying Torsion Stress
^ E

aNA#*
?
.az#.t--2seccase--:t=Iyse-(6b)max=3,2dMz-,6b--
^
¥ . .

'
.
.
.
.

• . com
.×=i÷i .
.
t=I
(G) (G)
32MW G
= O A
=

Tlds
✓ I (F) g = O (E) A
= 1Gt

Case 2 . Tlds
°⑥
+

to: : :÷±:÷: :÷÷:÷÷÷:

Now t = I see t =
2 Sec → Due to rotation ,
,

the distance from NA

y
-
o

is:: J J is not
changing so torsional

stress will not

change .

o but check at only one point ,

do not

considered two points .

don't follow case L

,
follow case 2 .

Page 27 of 253
1

E¥-fs
" "

NILE : static
loading
-

6 =
DAITO DI
/
-

DA

II :
' b

µ
-

point .

•
→
B Stress depend upon point thats

consider
why only point .

'
• Now
,
At point A and A

b) a = 32Mt → @b) max

Id 's

@ b) At = -

32Mt → @b) min

Tld 3

Qus
:Find
@
.
critical point

Case 1 :
mmmm

i > Ms ka
Ya =
Py X

X Y Z
p-42
""'
E. E'Indium
'
'

ii.

ft ¥ -
Ip /
i
y
-

,
Z

↳ Transverse
Y K

( B. MD N A . .

- , i v

¥
Ii:c :'nmcferemnotimuenitoints
m. -
'

"
lo py Mz →
Bending moment
are critical .

C and D point are critical .

Case 2 :

mum

i> M, = Px X L
y ^
NA
Y DE Z
Z

¥ . .
ii.
¥÷::::÷:
f All points critical
: are

=/
.

. .

✓ critical
.

i iiis M Moment
j
=
Bending
I. a layer : .
C and D are critical .

A
;i- Px in > Go = t taxi al t Gb

i
8D = +6axial -

Gb

.° .
16cL > 16dL
to
Layer belonging to point c is

critical .

Page 28 of 253
1

i> M Pzx Lz
Casey : =

Y Z K

Ya

May ( B. M )
↳ N.A.
Z
> " " "d " °" "" "" " " "" t "

c -

i
f
-
/ i
i
i

ipz

9¥ A 0.2 thick tape over a frictionless pulley of 25mm

mm
goes
.

diameter .
If E of the material is 200 Gpa . Then the maximum
stress induced in the tape is
-

bfYm#
¥
¢ 100×103
-
""
E
-

-p Mpa
.
.
.

o
: To make this type of

a-
f j
I
j -
a

N A
- -
bend

Bending
on pulley
stress
,

applied

100×1032×0
:

GI FE GOT → Gb) .
o
= .
= =

Max
12.5+0.1

¥
Gb 793.65 MPa 800 Mpa
Y
= =
=
:
-

(G) max
= Ymax

¥=¥=¥
''

÷/±¥E÷
"
:
'

"=± INA
bits
"
"
: =

a- a

-
N A - -

diameter 80mm is fixed

9¥ . A steel shaft of 1.5 m
length and

at both ends .
At an intermediate section at a distance of 0.5 m

from the left end ,

a torque 7358 N -
m is applied .

data :

ftp.IFEID
L 1.5 m 1500 MM
=
"
-

D= 80mm

-1=7358 iv. m ta

Page 29 of 253
1

Find : i> stress in the shaft in Ntmm Imax =

?

it > Angle of twist in

degree
: G 0.8 105 Nl Mmt
o

=
X

SEI TA TB T : Fac TA
•
= =
.
t

TCB =
FB
•

.
.

Compatibility egn ,

OAC =
OCB
•

: i. 5 TA = T

•
:
( Ta¥)ac= cB
TA =
4905.33 MPa
TB =
2452.67 MPa
•

;
FA @ 5) . - =
TB .

Imax 4905.33×103×402
"

try
"

=
= = 48.7g Mpa
TL
X ( 894
32

:9:%'¥¥÷÷.×'¥=⇐
•

#
O = Tk = 0.698
• a.

radar ↳ convert

radiant
degree

QIS .
The maximum stress induced in the Flat tie bar shown below is

:¥¥ ¥÷asmpa :t÷÷:&!.ae?..!n: !si:ea

's
Ii
'

asma

is 6=1
A

.
.

95 =
I s .
P =
95 Xue Xt

next

it >
Ein
p
6mm - -

→
| I L -
o
: Lomax = 95 X Witt
=
95×100
=
100 Mpa
¥ Es
←

v I

0¥ A tie bar has to load of 120 kN The thickness of the

carry a .
.

line bar is for tie bar is

Working
23 mm stress the 75 MPa . The
.

width of the bar

,
if there is a rivet hole 22mm diameter on its
center line is -
.

Page 30 of 253
1

"

÷÷÷÷÷÷÷÷
"

::
"

Lomax & Gallowable ( 6 working )

p
= Gallow able
Amin
120×103 = 75 w =
145.08 mm

¥23

Page 31 of 253
1

CHAPTER 2 PRINCIPAL STRESS

Page 32 of 253
1

CHAPTER 2 PRINCIPAL STRESS

* Principle
-
-
stress :-

CASE L : plane stress : Plane paper

edge
-
-

⑥=E=/¥;yE

sP"9e"as=÷÷;÷÷
Mechanical
Er
pipe cantilever
exam :
,

interview , •
A
beam at
Point load
E. g. gear
.

'

⑥ 2=0 ; T.cz =

Tyz = O tooth of B

point A
•
: →
bending stress

TO
by 62=0

8¥
× =

8 Exy =
Txz =
Eyz = O
,

v
•
This is point on component .

B
Exyc
x-p
by ✓
60 = Normal stress on inclined plane
To = Shear stress on inclined plane

T.ofoebxztGY-bxz-oycoszo-C-xy.sn
*

.
.

To =

6×-2642 . sin 20 -

Txy COS 20

Go =
f- ( Gx by , , Txy ,
O }
To = f ( bx by , , Txy ,
03
* *

←
6o.zt-62-6Y-EI.IE#YI2tTxy2 → Principle
stresses .
Normal

* *

tan2o=&Ix
6, 6x
• can be more than , by . 64 produced by applied stress .

↳ if 6 , 6x
>
, by
↳
design stress

indide plane experience but

Ef 6, → shear stress
-

→
g
we don't
applied shear stress . We

only provide normal stress .

No# g- Go ,
62 and 63 are 3 principle stresses ( normal) .

plane stress
,
62=0 Txz =
Tyz = O
o
: 63=0 ( by default)7

Page 33 of 253
1

Normal stress : -
be , by ,
62 ,
60 ,
bi ,
62,63
**

6max-maxfbi.62.bz
* Maximum shear stress :

Tse
=/ I ftTxy
• .

. =

I3
/# / : 723
/ /
= =

Shear stresses → Txy ,

Txz , Tyz ,
I2
,
C- 13
,
C-23 ,
TO
-

Applied Principal

tmax-e.az
* *

→ Absolute maximum shear stress

=/ / )2tTxyT
Tse =
→ Maximum in plane
-

shear stress
Imax

Note : -
Lomax & Imax should be used in the
design .

CASE 2
:#
Gx =
by = be F O
Tay F O

o=e=f÷E÷a8→
" = O Txz =
Eyz = O

* *

÷a
* *

TTyz=o :*

6r,z=6×ztE,/Ity
CA3
-
:
-

Fire Ffs:L then .co?.rincime

°
normal

•=e=/÷:E"j÷
,

•
: A - XI = 0

Tax Tzy A →
Eigen values

↳ by 62 63
↳ principle stress .
, ,

Page 34 of 253
1

Q. Which on of the following can not be a Mohr's Circle ?

# #
A B

It
DB

Sol ? n ok x2+y2= R2
=D # ,
Tait circle → center 10.03

.TO#o*.xix.niir::.::::::::....Exyc
To ×

µ 6×2-644 6×2--4 ②
B

=/ Thy sin 20
→
cos 20 +
-
-
=

by ✓

②
6×2--67 sin
20
Exy
20 cos
→ To
-

= -

•
: Square and add both ② and ② egn ,

( gg 6×2442-132=(6×2--64)
'
-

* exp
to
y

( 6¥64) ( 6×-24-12
' ' '
x -
t y = t
Txy

( x -

h } 't { Y -
k32 = R2
circle → center ( h .
K )
Radius R

( 6×2--64 )
•
: center = O → center must be on X axis .

16€
Z
: R
# Txy2 t
•
=

* Process to draw Mohr 's circle

:L . > Draw x -

Y axes ,
normal stresses on X axis while shear on Y axis .

2. B obtained & locate the two point coordinates as P ( Gx Txy)

,
and

Q ( by ,
-

Txy) .

3.D Joint P to Q take PQ as diameter and draw circle .

,
Page 35 of 253
1

* Uniaxial : -

one direction
loading .

"

x←¥→6x
^

'

: : ::÷¥:÷:%:
o

By = 8 62=0 83=0 u

*
Ps : -

AT
"

TEE
P
•

.
a

Pf tox
, Txy } =
P t O
,
+
Txy } ja
Q l by ,
-

Txy } =
Q to ,
-

Txy )

* : Biaxial#
Equi - -

loading In

¥¥¥o
by
⇐
Q' by
a.

u
on same line

Pf Gx , Txy } =P ( 6,03
Q { by ,
-

Exy } =
Q { 6,03

*
6 at

:÷÷!⇐ :
y
U

comp

:O:
.

6,0 } v

Q { by Cxy ) Q 16,03
-
=

81+62
loading ↳ BY
}
In 213 =
+
, " "
check point
In 3D
loading ,
Git 62+63 = bat by -162

Page 36 of 253
1

* Mohr circle in 3D are 3 Mohr circles

,

•
: fr & 62 ,
Br & 83 ,
62 & 63

* Uni -
Axial loading condition :*

:}
"

"%=¥s=o×;sy=o; =o
eE¥±e .

← ↳
P
A
•

Point A. B .

Loading Representation :

Bi
¥64 )
=
D A t

q←→8x
if

C B
: .
•µ ⇐

Azt ¥ = A

Bx Txy 0
Pz by
°

: =
; = 0 ;
=

82
6€ 621
Bs
'

• .
= = 0

ifTxfqy←spt%udI
-

'd
6, +62=6×-1 by
Gx tox
•
: =

*=i663=8=8* 83=0 °

: plane stress

NITE :
-
On principle stress there no shear stress .

Tre
1612-62-1 BE Tre
1612-62-1=12 Tn
1612-62-1=0
= = =
=
; ;

Tma×=MaX{Tr2,Ti3,T23}=&z
*

AT

,o§§µ↳gx
Ex *
Imax
pop
=

2
Every point on Mohr 's circle is a

plane in a material .

8=6×+6 y plane AB Gx , Txy =O

plane 4=0 . Txy - o

(g
→ T plane AB * The angles on Mohr circle
plane CB
plane CD
twice
plane DA
to
Imax
are the actual
angle .

g-6× -

* *

→iortnisnawna.÷÷÷÷:::÷÷÷"= ✓• Imp
urticaria .

Page 37 of 253
1

txuowmucnistha.gs?rm:on:.,.sntereIaIze7YIPI * *

* How to represent 135

degree angle ?
{mmaa×_
4¥ ↳ Uni axial

÷÷÷⇐
-

case

Pure
*
-
shear
Loading Condition
-
: . .
.

-
Txy example :

is:S::* :O:* :c: :*:÷ue

.

ex ↳
-

65-0
Pure shear
Loading Represent
•
.
-

**
•

.
.

T×ytO6×=6 8, =
Imax

t×y
62
6×2+-4
Gr =
-

Imax
,
2 =
I
63 = 0

•
; Go , 2 = I Txy

: bi t 62 = 6×-1 by Txy -

Tay = O → checked

Co2
61-2-62 Txy{ TXY Tiz
-2¥ 723
:
-

Tg Ig
= = = =
=

**

:s÷::÷:÷ * *

NITE : in case of pure shear

{mma÷
-

Page 38 of 253
1

Txy=%÷:6x=0:t
Ex . on
Twisting moment on shaft :

•
: lomax = Imax =
1Gt
Ted's

AIma.jo?.pso,-uygh5Tmax=Txy-O=o..&t35
.

ID 6ma× = *
Exy → 0=45
z

¥=£µ-¥¥÷
Plane
Verticle plane .

↳ In "

000
lo Exy)
tu Q
-

Plane
.
CB

GATE

Q .
In a two dimensional stress analysis ,
the state of stress at point p is

6
fg;; qq.gg
=

The necessary and sufficient condition for existence of state of pure shear
at the point P
,
is
in pure shear
I
A.) 6x× .

byy -
T
Ky = o ,

B.) Txy = O Txy to bx =

by = O

C.) 6x× t byy = O

D.) ( 6×× -

byy ) 't 4 Thy = 0

GATE 2014

Q The of point is 6x= by

state stress at a
given by G Mpa =
H MPa
-

.
,

and Txy = -
8 MPa .
The maximum tensile stress ( Mpa) at the point is .
=

So In .

6×tz ty
=

Go ,
z
=
I

-612 ±f¥8K
= -

p -19.434
* Bp =
8.434 MPa F-

62 =
-

10.434 MPa

63 = 0

Page 39 of 253
1

ESE
Q The normal stresses the two perpendicular
. on
mutually planes at a

point are 120 MPa ( Tensile) and 60 MPa ( Tensile) .

If the shear stress across

these planes is 3014Pa the principle will be

,
stresses
nearly
A.) 124 MPa ( Tensile) and 24 MPa ( compressive
)
B.) 13214Pa ( Tensile) and 24 MPa ( compressive
)
C.) 124 Mpa ( Tensile) and 48 MPa ( Tensile)

d.) 13214Pa ( Tensile) and 48 MPa ( Tensile)

50€ .
. .

.
6× =
120 MPa :
.

6×-1 by = bit 62=180

#

by = 60 MPa opt . DD bi = 132 MPa

62 =
48 MPa

ESE

Q At point in material planes

acting two
right angle
.
a a the stress on at
,

to each other are : 62 =

120 MPa and by = -
200 MPa and
Try = -

80 MPa

The maximum stress the

shear on element will be
nearly
A.) 142 MPa

Mpa
B.) 155

C.) 167 Mpa

D.) 179 MPa

Sol .

62=120 Mpa =
6*

Tzy = -
8014Pa =

Txy Trick :

by = -

200hPa 2.12 = 4.41

2.22 =
4.84

Imax
tTy= 2.33 5.29
=
=

=
¥+805
=
80¥ =
801-5 = 80×2.2=176 Mpa

GATE 2019

Q The state of stress component is represented

. at a point in a

by a Mohr 's circle of radius 100 MPa centered at 200 MPa on the
axis
normal stress .
On a plane passing through the same
point ,
the
is The the
normal stress 260 Mpa .

magnitude of the shear stress on

same plane at the same point is 8-0 Mpa .

Page 40 of 253
1

I
^ 260 MPa
ABZ-tc.BZ ACZ
Sol
#
=
.

1¥32
-

A AB =

pump
" MPa

#
/
GOMPA

v leggins
( ←
20014Pa →

Further :
at
-

6g = 300M Pa

62=100 Mpa

6-3=0

÷:÷÷:
→
"

Tr3 =
150 MPa

723 = 50 MPa v

→ Imax =
Coz = 150 MPa

QIU . A simply supported beam length ,

800 mm and diameter 80 mm is

supporting a flywheel of weight 4 kid at its centre .

The flywheel
transmits 24 kW at 240 RPM . Find principle stresses in MPa .
-

SOM

##,,④¥
.

F-

A
• Loading : BM & TM

g- =
601 = 60×24×1032 Nom
A & B are critical LJLN 2 IT X 240
V

w point .
=
954.93 X 103 N mm.

Ema , =
= 16×954.93×1032 =
9.499 Mpa
's
Tld TL X ( 8013

@b) may =
321 = 32×41×103×8002 = 15.9ps Mpa
3
Id XX XX ( 8033

→ be @ b) max
6%2=6×21642 tY
=

I
o
:

by = O

IF
Txy Imax
9.42992
=
=
I

=
4.7495 I 16.6086
•

.
.

top = 21.358 MPa

62 = -
ii. 8591 MPa

Page 41 of 253
1

QUS . In a plane stress

loading , principal stresses are 400 and 300 MPa.

Find normal stresses on a

planes of 450 to principle stress .

Soth .
en T> Normal stress on a plane of 45
€

& = 300-150=350 MPa

Es .

D
← 6= ? →

GATE 2020

9 . The stress state at a point in a material under plane stress

If
condition is equi -

biaxial tension with a

magnitude of 10 MPa .
one

unit on the 6 -
T
plane is I MPa ,
the mohr 's circle representation
of the state of stress is
given by
A.) A circle with a radius equal to principle stress and its center

at the origin of the 6 -

T plane .

B.) A
point on the 8 axis at a distance of 10 units from the origin
C.) A circle with a radius of 10 units on the 6 -

t plane
D.) A point on the Taxis at a distance of Lo units from the origin
In
Sot
€
.

gaby
o
.
→ ax
a- POMPA -0A

* by
F- qui biaxial Gx =
by = LO MPa

Txy =
o * Air
planes are the

( 6xz )
Center
,
o =
fro 03 , principal planes .

* spherical pressure
TXT
-

g) (6×2--64)
2
•

: Radius = + = O vessel
•
: Bx =
by =
Pd
HE
; Tay O
•
=

ESE

9 . In plane stress condition ,

find condition when 62=0 .

82=6×2+-64 -

,/¥6y)F = o Txy=n6xy

Page 42 of 253
1

Uni
Eg .
-

axial loading
6×1=0 ; by = 0 ; Txy =O

Gx *
by = O

•
:
167*4=0 =
Exy
Io . tox = O

Ben-Zvi : A cantilever beam of Midst is loaded as shown .

Find the safe
diameter of beam it yield
strength 300 Mpa and the required
F. O S . . is 3
.

p =
to kN

÷¥ #
th =L m
-
.

SIM
MILT 3001=05
.
B = =

: M = P X L ETO X 103×1×103
= 1×107 N .
mm

TB 7-
. .

. 1×10×92 = 100
.

: D= too .
62N mm -

% 494493

*
why principle stress are not calculated ?

* critical point A- & B Point A Gb 62--0

3,2%12=6 ; 4=0 ;
=
x

Txy = O

6,
6xzt
•
: =
t

:&
6L 6x Lomax IM 62=0 63=0
•

= = = ; ;
's
Ted

ANI :
-

To avoid this steps to save the space ,

this avoid this step to
reduce time . You can not avoid the principle stresses .

Page 43 of 253
1

Failure of Material:-

Ii :/ .ie/:l:::::s:::l
•

Maximum
Loading Material Failure stress

Angle at failure Angle

③

Uniaxial Ductile 450 Shear stress

:÷ ::÷
Torsion Brittle 45 Normal stress

NOITE :
- i> ductile materials fails by shear stress .

ii > Brittle fails stress

materials
by normal .

Page 44 of 253
1

CHAPTER 3 THEORY OF FAILURE

Page 45 of 253
1

CHAPTER 3:-THEORY OF FAILURE

Theories of failure are those theories which help us to determine the safe
dimensions of a machine component when it is subjected to combined stresses due to
various loads acting on it during its functionality.

Theory of failure are the relation ship between multi-axial loading and UTM
test data. The parameters used for relation are stress, strain and strain energy.

Some examples of such components are as follows:

1. I.C. engine crankshaft
2. Shaft used in power transmission
3. Spindle of a screw jaw
4. Bolted and welded joints used under eccentric loading
5. Ceiling fan rod

Theories of failure are employed in the design of a machine component due

to the unavailability of failure stresses under combined loading conditions.

Theories of failure play a key role in establishing the relationship between

stresses induced under combined loading conditions and properties obtained from
tension test like ultimate tensile strength (Sut) and yield strength (Syt).

→
Directly we
get Cd ) without
using any
P failure theory because
only uniaxial load CD .

↳ Syt = 200 MPa 6, f

Syt
Sue = 300 MPa 41 f
:
Syt
.

'
Jed

→ Member is subjected to both

tnweinteingc.mg?neenat%ada..nugn:axiai
P road

↳ Syt = 200 MPa

Sue = 300 MPa → we cannot determine (d) directly in

this case because failure stresses under

combined
loading conditions are unknown .

Page 46 of 253
1

MAXIMUM NORMAL STRESS THEORY [MNST]

" "

* → For brittle material

MAXIMUM PRINCIPAL STRESS THEORY [MPST]
RANKINE'S THEORY

This theory is suitable for the safe design of machine components made of
brittle materials under all loading conditions (tri-axial, biaxial etc.) because brittle
materials are weak in tension.

This theory is not suitable for the safe design of machine components made of
r

ductile materials because ductile materials are weak in shear.

Gma ,
=
Suit → Failure
b. l.

Normal Normal
stress stress

[ Applied maximum Normal stress ] Eeg .

Sat = 300hPa

* * FOS = 2

→6max=?out→safedesig : Gallow
quote
o

brittle at •

: Gallow = bmax = 150 MPa

is from
It multi axial
loading .

y
* lomax or
6I{ t
= =
t
-

only exam point of view :

This theory can be suitable for the safe design of machine components made
of ductile materials under following state of stress conditions.

: Not applicable in practical application

•

bmax =
Syt →
Yielding
→ Plastic deformation
→ Failure .

* *

eue%°m"=E→safedesig€
* If EOS = I → Failure

Fos > I → Safe

Intermediate principle is
NIST :
-
stress
ignored in this theory .

Page 47 of 253
1

* Plane stress condition :-( For ductile material )

mm mmmm mmmm

B, 62 63 lomax MNST Failure ( Fos =L )

1 . 100 O O 61=100 6g = Sit 6, =
Syt
FOS

L . 100 200 O 62=200 62 = Syt 62 =

Syt
FOS

3 .
-100 O O 6, = -
100 6, = SYL bi =
Syc
FOS

4 .
-

100 -
200 O 62=-200 62 =
Sys 62 =
Syc
FOS

i#÷*m:÷:÷÷÷÷
Ductile Material
Loading Linear ,
62362g g. loading
*
Fore
#.
re
syt line for A
lsytl =
15yd
* Point A is safe point .

:c: :* '

* Point C is Failure point

Loading B
Line 6,
: Syt
o
a =

For B { 4,62} -

syc
✓

* NOTE : -
All point inside rectangle are safe .

Page 48 of 253
1

MAXIMUM SHEAR STRESS THEORY [MSST]

"
ductile Material
"
* → for

TRESCA'S and GAUEST THEORY →

used for simple calculation
conservative
Most
theory
→

Txy ,
Txz , Tye ,
TO ,
Tiz ,
Tis ,
C-23 ↳
Results into maximum
# # dimension .

" "

shear stress
" "

Applied principal

( ) ( 160-26-21 161-63=1 162-263-1 )

Imax =
Max Tiz Trs 723 =
Max
, ,
, ,

MSST used for ductile material.

M.S.S.T and M.P.S.T will give same results for ductile materials under uniaxial state
of stress and biaxial state of stress when principal stresses are like in nature.

Multi -
axial = UTM Test

Loading 9 Data
TOF

Imax f- Sylt
←
P Normal stress )

shear stress Normal strength

Imax =
Ssy → Failure

* *

→Tmax=SszI→safedesig
Shear Yield strength Issy } : -

Uni Axial For ductile Material #

Loading :B At
yielding
-
•

•' Go
at
Imax =
# =
Sgt
→

6¥
How much g, snow , be for yt
failure ?
ANS : Gx =

Syt (yielding )
g-
Normal I ↳ Normal
=
Sy't
stress strength
; at yield point
•

so.shearsetsrenyqth-E-max-gysggar
!g¥*h streng.tn
Imp .
•

: Normal strength
←
8x=8max =
Syt → yield Tensile strength
⇐

Page 49 of 253
1

As

MSST7.agsyssyzt-o.gs#**.:Ssy
per

Permissible yield
-
= shear
strength
FOS

Syt Permissible yield tensile

:
strength
•
=

FOS

* If yield strength =
20014Pa ( if normal or shear not mentioned)
↳ Syt = 20014Pa

MSST * *

Tmax=ss=f¥
,
←

* Plane stress condition :

-

( For ductile material )

mm ummm mmmm

B, 62 63 PTI 21 ITCH tTz3f Imax

1 . 100 O O 50 50 O Erg =

Bitsy =
61
2
= Imax

61--62
82g
O 100 50 O 50 ⇐2
2 .
O = = = Imax
2

25
75 50 ⇐2 61-62
=
3 .
-100 -

50 O = Imax
2

=sy,÷¥,,;¥±⑦
: IX Imax
6oz SI Go Sylt Syt
•

Ssy : X
-

= = = =p = =

it > Imax =

BI =
Ssy =
Syt → 82 =
Sgt :
y =
Syt

µ ; , em ..
.az#=ssy=zsyz g. ↳

82 4=0 X
Syt
= -

.si#jsa.stn: :tae:g7na9refgI.:e:ymaieesangiee--
S"

Hexagone first and third quadrant safe areas

/
a
,
TB
shape of Normal stress shear
theory and

syc
450 with x-axis and passes through
second and fourth quadrants . Shear
v

diagonal represent pure shear case .

•
Disadvantage : -

Hydrostatic stress state .

Page 50 of 253
1

* MAXIMUM DISTORTION ENERGY THEORY [MDET]

VONMISES, HUBER and HENCKY'S Theory → Use for
SHEAR STRAIN ENERGY THEORY
" "
Ductile Material .

:
.
Basics -
Total strain
energy
U =
strain energy

✓
If by Ei t
I 62 Ez
Iz 63 E3
=
Total t

→ E, =
Go -
U (62+63)
-

→
ez =

→ Ez =

E * *

Utotal-GZ-622-632-zfzuki.bz-62.63-br.bz
•

:
Eu
6it6zt¥DCt-# D÷ C6xt6yt¥z)li-2#
•

=
= =

Eu E, t Ezt Ez
°

: =

: Basic -
Pure shear

AT

÷.t÷
"

"

I> Txy to ; tox = 0 ; by =o ; 62=0

ii > 6, = t
Tay ; 6z= -

Tay ; 63=0

iii y 6×-1 by t 62 = bit 62+63=0

in >

Eu
6rt6zt¥3)ll O → No
change
in volume
= =

V > Distortion is present shear stress

Page 51 of 253
1

: Basic Hydrostatic loading :

°
-
-

7pm
pro #6 p P

6←e÷→6
-

- ooo -

%,,
-

: Hydrostatic loading
✓
<
.

.
.

6× =
by =
62=6

6
µ
VV
Txy =O 1×2=0 Tyz=O

6.
[80 8]
6, 62--63=8 stress tensor
%
: :
o
=
,

g =

Tx ( bi -162+63) ( r au)
to
O O f
Eu
-

e-
:
Eigen value
°

Eu to volume is
;
changing . D= 6. 6,6

" ' '

Mohr 's circle : -
Point
mm

a
E- o

: shear stress are not in

"
II::" instating
.

.
6g ,
62 , 63

Basic Uni Axial

Loading
•

: -
-

"

x←¥→6x
^

<§#
•

Gx

↳ *o q=o ↳ = ,

Eu =
Kx + by -162 ] Cr -

su)
-
E

Ev to → Volume is changing .

: shear stress is present distortion is

°

present .

Concept :
-

U Total = Uvolume t U distortion

→ Uni - Axial

Utotal =
Uvolume t O → Hydrostatic Loading
✓ Total =
O t U distortion → Pure shear

in distortion U distortion
NOTE :
-

energy theory use

only .

* The distortion is due to shear stress .

Page 52 of 253
1

The theory states that the mechanical component subjected to bi-axial or

tri-axial stresses occurs when the strain energy of distortion per unit volume at any
point in component, because equal to the strain energy of distortion per unit volume
in the standard specimen of tension test, when yielding starts.

Multi -
axial → UTM Test data

Loading 16
Distortion
energy Theory

{ U distortion 3 Multi -
axial
=
{ U distortion
} UTM

loading TEST

von-MisesstressC6×m)=Iy+6I×z{¥yz# it

Gym =
Sylt → Failure { Gum ) UTM → 6×1=0

* * → bum = 6x

→8vm=SI→sa# FOS
→
yielding
.
: bx =
point
Sylt
bum =
Syt
case 17 Uniaxial
loading
. .
.
6×1=0 •

:
6vm=
case 2 > Bi axial
-

loading
o
:

bgxztyoo
.
:
byiy-62-bx.br/t#

Pure 8vM=nT3XT
.

:
Txy I 0
.

Case 3 > shear %

case a > Principle stress

§÷¥fo bvmi-ftzfk-642-CI-%7f.pe#
.
: ÷
.

cases >

Pdoannediftorness
:

6g! # ooo :6vm=f6R-6r6zt6

o

failure ?
8×← b×
* How much 6x required to

:8×=SyQ →
yielding
Failure .

Page 53 of 253
1

Exy for failure ? Txy

①µ
* How much should be -

y
ty → Failure

yielding Tay T

pure shear M D. E. To
•

: → .

) /
al ↳ bx.ir#.=Syt
Txy # O → Failure

V L

Gung = IT x
Txy =
Sylt → Failure ,
yielding
: At
yielding Exy =
Ssy
o

* *

°:Ssy=SyY =0.577Sy÷ M D E. T
→ - . .

Syt
Ssy M.s.s.tl
•

: = →

-2
* *

{Ssy}D⇐+D{SsY3ms# dpqsst >

DDET
•

Mr

l
.

Conservative
Now
, Coaxial = HI = Syt
Tld 's
FOS ↳ "
More safe
' "

¥ bpermissible MSST is more conservative

÷ = o

DET
theory than .

'
6
4¥ = d X
permissible

6permissiblelldiameterb.to
'

type
:* d

Distortion is for
o
energy theory the most accurate or best
theory
ductile material .

^
62

<s#
Plane stress
loading ,
Sgt .
→ DESI
→ 6, to 62 to 63=0

÷ a, "=ya+* 6,

x2 yd
-

x.
y + =
Sylt + •

to
" ' '
Erripse Sgc
Ellipse v

Page 54 of 253
1

* *

Udistortion-1ztxf-xbvmZ-fv.TL
Strain
energy ,

: semi minor axis

Ig
°
= x
Sgt

axis it Syt
semi major =
×

This is the best of most accurate theory for ductile materials because actual

shear strength of material is ar round 57% of Syt .

Combined :
-

TT
^

¥¥.÷÷÷ FY
X-D
" "

Ii angle

M.D E. T
.

:
"

9.II.is?:::Iq...+..z+s.z-co....o.a-rao.i#.azaii :

Page 55 of 253
1

B-QQ.us A cantilever beam of Midst is loaded as shown Find the safe

.
.
.

diameter of beam it yield and required

strength 300 Mpa the

F. O S
. . is 3
.

p =
to kN

A
•

.
.
.
# 1×10 X
da
100%494493
. .

1=1 m
-
.
-
=

Moy
7¥
Sol ? B = =

÷ D= too
.

TI
=

.
62N mm-

: M = P X L ⇐ i 0×103×1×103
= 1×107 N .
mm

.to#..f*i:*: *oD
at point A ,

Tiz
Gb 321 6x bi
621 621
= =
= =
=

's
ad

by 0 62 TB I GI
- '

= =
.
=
=

2 2
-

.
'

62=0
C-23 =
0

i> lomax = Gx Ii > Imax = E iii > bum =6x

2
MNST DET

÷i÷÷÷
• a.
•
32M
=

FOS

→ In this case all type of T.O.to are

giving same result
,
that's

why here mentioned of any of

T.0.F.TT
no
process

#¥÷ f -

µ
Page 56 of 253
.gg?inngPointaresametorauo-.o.e
.
1

to
DESIGN OF SHAFT

Gb
shaft → Rotate → →
varying ↳
Go = Y Dynamic loading
It
↳ Fatigue Theories

( °

: First choice of )
answer

if fatigue loading is not there ,

means static theory of failure for shaft .

i> M.N.si .
→ Brittle Material { cast iron }

it > Mos . S . -1 .
→ conservative

Ductile Material

simple calculation

iii > M . D. E. T . → Ductile Material

Best for most accurate
theory
complicated calculation .

Q . Which TOF is used for shaft ?

A > steel
.
MINST Shaft Made by me
.

B >
. MISS T to
C >
.
IYDET Ductile Material

:
if nothing is mentioned which theory used
•

beth prefare
MSS T or MD ET , always M.s.si .

simple calculation
→ Safe Design due to Conservative .

Page 57 of 253
1

ESE

Q Syt is 200 MPa FOS Find in

.

,
is 2
,
the permissible stress steel

shaft subjected to torque by

i > MNST
↳ Sheer stress
ii > MSST
iii > DET

Soth .

loading →
Twisting moment

I .

Txy =
IGI Txy =
? 6x=0 by = O 62=0
's
Id

Gp = t
Txy ; 62 = -

Txy
{ 6, t
62--6×+4=0 }

i. 7 Maximum normal stress theory :

Gma , = Max { 61 ,
62,633
Lomax =
Txy

lomax
Spyot 20,1=100%4132
:
•

=
=

Ii > Maximum shear stress

theory :

Imax =
-
Sgt Imax = MAX { Tiz ,
Tiz ,
C-23 } Gp = Imax

L FOS
62 =
-

Imax

2=1%2--621
= Imax

from Trz=Tma×= -
200

2×2 Tiz Imax Izz Imax

;
= =
-
-

=
50 MPa 2 2

fit > Maximum Distortion Energy Theory :

6×=O by = O
Txy to

buy = IJX Txy

°
: bum, =
Syt
-

FOS

IT
Tay 2002
X =

:
Txy 57.74 MPa
-

Page 58 of 253
1

IT
ANS : a

too MPa
MNST Txy =

→
Ii .SE: EI;
' "

ampa

F-
"

angle

Loading → Twisting → M.D E. T

.

÷÷÷÷:
"

÷÷÷÷÷÷÷
:

D
-

line
MSS T S M DET > MN SF
→ loading
J
µ
°

: In MSST ,
6 permissible is minimum .

did 1-
tbpermissible
6permissible X
I 0¥
d2

.
"

MISS T is most conservative

theory .

}
6290 4th quadrant
" ' '
•
: 6, > 0 ; → ESE 1998
M SST is most conservative .

¥ A shaft is
subjected to BM and Trai . The design is most

conservative
by which
theory mm
.

GATE

.z=↳t±f⇐
-

1988 Soth

§;÷÷
road :b .
-
=
÷÷: : :
.

.
.

6g =
+ Ve

quadrant 4 62 ve
°

: no .
=
-

↳ most most
conservative .
( Tresca 's)

GATE 2019

¥ . At a critical point in a component ,

the state of stress is
given as

6××= 100 MPa

,
byy = 220 MPa
, bxy =
byx = 80M Pa and all other stresses

components are zero .

The yield strength of the material is 468 MPa . The factor
of safety on the basis of MSST is
.

-7 Soth Gx =
100 MPa
-

by = 220 MPa

Txy =
Tyx =
80hPa

Sgt = 488 MPa

Page 59 of 253
1

Go ,
2 =

6×1-264--1,1 As
per
MSST ,

Sit
10012220--1
= Imax =

, 2 FOS

= 160 I 100

46862
°

: 6, = 260 MPa 130 =

= 6014Pa 2 FOS

T FOS = 1.8

Imax -_
max

( 16262-1,14263-1,162263-1 }
=
Max { 100
,
130
,
303
Imax = 130 MPa

by MNST ,
°

: Gma , = SI
Lomax = Max { Go , 62,633 FOS

Lma x 260 260

4,6% FOS=
o

= : =

IT
^

.#f÷÷÷:÷÷÷÷÷:÷:÷÷÷
-
A { 260 , 603
M No S T
✓
.
. .

:* .

#
" MNST same
E
.

.
ago .

SO
,

fog is same .

GATE 2016

Cf .
6g = 100 MPa ,
62=100 MPa and 63=0 MPa .
Yield strength is 200 MPa
rumrunner

Find factors of safety by MSST and DET .

to

Nothing mentioned
i> MSST
,
Imax = 50 MPa
by default Syt run
'

Gr = 100 MPa

62 = 100 Mpa Imax =

Syt
63 = 0 LFOS

50 = 200

CT2 = O 2705
Iz = 50 MPa .

.
'

Fos = I
C- 23=50 MPa

Page 60 of 253
1

ii. y DEF ,
-

: 64M =
2/42 -

61.62+622
Gum = Syf
-

Fos =
#
pool 1002+1002
-

-
: 100 = 200 = 100 Mpa
#

FOS

:
F0S
o

IT
^

Gp = 100 MPa

- B 62=100 Mpa
M No S T
T
.
. .

÷÷÷÷::
"

€
E. sifixagon
. ""

f -

ESE

of Cls 100×10-6 m2 is tensile load

g. A rod area
subjected to ,
use

tresca 's Syt 20059Pa find the failure road

theory ,
=
, .

SOM .

→
Imax = Gt r

: Failure toad
p p 21--05 FOS =L
.

.
.

P =
200
-
-

Gx = I = 8 ,
Coz = I 2A 2

A 2A
200×100×06
' s
"
p 20 KIN
'

: = =

-
run

I3 I
by =
0 = 62 =
106
2A
Txy = 0

Izz = O

ESE

Q .
Use Miss -1 .
Go = 60 and 62=-60 MPa .
The yield strength is 360 Mpa

Find FOS .

SI .
61=+60 MPa .

: Tiz =
60 MPa ←
Imax =
60 MPa

62=-60 MPa 43 = 30 MPa

633--0 723 = 30 MPa

Imax = Syt : . 60=360

-

2 FOS 2 XFOS

:
.F0S⑦
Page 61 of 253
1

ESE

9 .
A solid rod of circular cross section made of brittle material ,
when

subjected to torsion fails 45 axis of the rod

,
along plane at to the

* i > Distortion is maximum on this 45 plane

energy
* ii > shear stress is maximum on this 450 plane → M and N point
Iii > Normal stress is maximum this 450 prone T=O 6*0
Mfg on

which of correct
? 0=45
.
one above are

SI .
Txy =
loading TMI
az

o¥
Tld 's pf AB
•

6×= by
•

; = O

" '
"

t
¥ , jQ

conclusion g- At 0=450
-

→ point are M and N .

7=0 bnormal FO
'

SI ,
at us T is not maximum
but bnormal are maximum

Now 9 → at 0=00

6vm#
-

Ud =
Txy # O o
: d) D { Ud }
ooo @ ago
IJX Txy
⇐

GXG Gum =

: Distortion energy maximum

'

÷ (Ud) 0=00 = 3xTxy2 at 0=450 at 0=0

.

TXG 6, =
Txy
r
:
( Ud) 0=450 =
-
Txy2 bum = bi =
Exy
GXG

GATE 2015

Cf . The uniaxial yield stress of a material is 300 Mpa .

According to Von

Mises criterion ( in MPa) of material is

,
the shear yield stress the
w
•

( ssy ?)
SIM . Shear yield stress -=

Sgt
spohaedgrng.az directormake
300hPa :
°

→
A> bum IT Txy SYE fit Syt
Ssy
= × =
=

TJ
:
Txy Ssy Syt
o

= = = 300
- -

UJ UJ

=
300 = 173.205 = 173.205 MPa
-

UJ MPa
Page 62 of 253
1

GATE 2012

QIU . The homogeneous state of stress for a metal port undergoing

plastic deformation is

a
.IE O
:
O -
:] 10

Where the stress component value in MPa misses

are .

Using Von

yield criterion ,
the value of estimated shear yield stress in MPa
-
.

→
6. = 10 Mpa Tay = 5 MPa

by = 20 MPa Txz = O MPa

Lz = -
to Mpa
Eyz = O MPa

form =

6x-6y)2t6x6zt6y6z)Tt6(Txy2tTxztTy}
=

,
)£f(io-20)2_C10tI0)T_(2Ot10)t6(52tO
Bum =
27.838 Mpa
•
: Bvm =
IT x
Txy

" "

Ssy
Sitz 27.8£
o
: =
= = 16.07 MPa

¥
mmmm

GATE 2017 ME .

Pg . 164 [ Q .
5]

bi 180hPa Mises condition

QUE +
Following von * :
=
.
,

62=-100 MPa Syt =

? Material just start
63=0
yielding

SII Gung Syt Sgt Gum 245.76 Mpa

°

= : = =
.

FOS

when
yielding ,
Fos =L

Gum
2 =
6,2 -

by .bz t 622

= ( 1802) t ( 180×100) t C -

10072
bum =
245.76 MPa

GATE 2017 Moe 104 (Q ]

.

Pg .
- G

QI Gi = 60 Mpa Syt =
200M Pa

62=5 Mpa Using NISST ,

63 = -

40 Mpa FOS =
?
Page 63 of 253
1

Imax = Max { Tiz ,

TB ,
C-233
•

: Ema , = Syt
-

Tiz = 27.5 Mpa 2x FOS

Tpz = 50 MPa ← Imax Fos = 2002 = 2

2×50
Izz = 22.5 MPa

GATE 1997 M . E .

Pg .
25219.7]
critical section
of Fos - L

B, = 360 MPa

62=140 MPa

Lomax = Imax = ?

Using DEF
,

fell . bum =

-
Syt 6vmE 6,2 -
( 61.62) of 622
FOS =L
6vM2= 3602 -
(360×140) t 0402

frm =
Syt bum =
314.32 MPa

GATE-2014M.IE .
Pg . No .
253 [ 9. b. is]

E
46 46

AEI #
! X

*
''

16 16
Gx = O Txy
-

- O Gx = O Txy = O

by = 6 Tx 2=0 by = 6 Txz = I

62=0 Iyz = I 62=0 Iyz =

O

⇐ ,z¥Ztk in bum ② bum ②

= =

so
yielding is
simultaneously .

462+3 EZ
-

=
G t IJF

GATE 2015 M . E .
Pg .
No . 254 19.1.20]

data : Gx = 80 MPa

by =
20 Mpa Imax =
Ssy Fos =
100 = 2
Aris
-

62=0
-

-50
FOS

Exy
802720--1 #tH
=
40 MPa 6, =
,z

Ssy = 200hPa

= 50 I 50

6, = TOO 62=0 63=0

TC 2=50 To 3=50 723--0
Page 64 of 253
1

GATE 2020

data
-

Asg .
= 90×40 = 1600 Mmd
D= do mm

Ssy = 20 MPa MSST

Imax
④ Ssg
=

② I > and Ii > Fos

p = 80×103 N

A =
402 Mmd =
8600 mind
③ ⑨
⑥ =
I = 80×-103 = 50 MPa
A 1600

I =

By = 25 MPa > 20hPa

Failed
#

Tv) iii > Imax II

III. y
=
Bb =

Tld 3

320×103×20 16×64×91×103
-

: I = -6 =
-
= -

2 TIX ( 4033
CHOI
12 IG MPa 20 MPa
=
IS Mpas 20M Pa =
C

safe =
30hPa Safe
-=

GATE 2014 M.E. Pg . No .

253 (Q .
L .
LG ]

Loading Twisting Moment I shear Force ] bum = IT

xcxy
=
Syt
-

Imax = 100 Mpa FOS

Syt = 300 Mpa : FOS

°
=
3002
Sat =
450 Mpa IT X 100
FOS =
? ( use DET) :
'

FOS = 1.732

ESE

9 .
Permissible B. M .
due to MNST is Mi Find the permissible B. M .
,

due to for
MSST same shaft .

Case i > MNST

"
Loading
. ↳ =
BM

=
- M

↳ = ,
"

6m"=a=¥2=¥oy -

's
Id

:
by 0=62
°

.
: 63=0

Txy = O
Page 65 of 253
1

case if > Mst

B. M =M
"
Tiz be Imax Syt
Loading
= =
→ .

z
2x FOS

Gb bi CTS 6£
6£
=
32Mt = 6× = = .

.
.

= Syt
's 2
Tld / 2/4=05
To
by
,33,2ff_=§f ②
= 0=62 = O .
: -

Gz = 0 =
63

1×4=0
from 1 and 2
, M=⑦
ATE

" Point

iii.
are same

f -

ESI .

P Permissible
. torque is torsion due to MSST is T .
Find the

permissible torque in the same shaft due to MNST .

'÷÷÷i:÷÷÷÷÷÷: /÷÷÷÷÷
Case i> MSST Case it > MNSF
"
TM T IM T
Loading Loading
→ =
→
-
→

T if Tay Txy t÷I 6x=0 4=0

-

= =
; ;
-

3
Tld

Gx
:*
= O

÷ :O
ATE

,±⇐#§
Imax =
Txy = Syt

F)
-

E
2 FOS

÷;
'

i÷s=s
-
②

A•
prom , and , ,± ,

Tld
's
Tid 's

TE
-

:
•

Page 66 of 253
1

Pies . Proportional limit = 300 MPa

6, =
150 MPa

62=75 MPa Find FOS

by MSST ?
63 =
-

30 MPa

I Tiz 37.5 MPa

Sol Spr Mpa Syt
=
.
= 300
I

Tiz = 90 MPa ←
Imax

Imax =
Sit C-
23 = 52.5 MPa

2 FOS

Fos = St = 301 = 1.67

nm

2X Emax 2×90

GATE XE 2005

Syt = 180 MPA

i> Find in
how much shear stress can be applied pure shear by MNST
,

which will causing yielding .

Loading → shear stress Txy to

Gx O 61,2 I
Tay
= =

MNST ,
by =O 6, = +
Txy
lomax =
It 62 = -

Txy
FOS

: .

6ma×=T×y=Syt=t80MP
ii > How maximum normal need to be in uniaxial
much stress applied
?
loading to cause
yielding by MSST

Uni axial 6×40 Go ,z=6x Tiz

Loading → - =
O

M SST , by = O
Tiz =
6£ 723=61
2
Imax =
Sit Exy = O 2

Syt
# =

2 FOS

:
6x=Syt=L80MP#
GATE XE 2016

Plane stress condition → 6x= 6 Go -18 Tiz = to

,z=
-

Gx =
-
6
, by = 6
,
Txy = O by = 6 Ers =
612
permissible shear stress is 200hPa Ex
-1=0 Izz -_ 42

Find maximum permissible value of 6 o

:
Ssy =
200hPa

as per MSST ?
Ema , do
?g 6=2ooM
•

: = =

Page 67 of 253
1

ES → 6, f =

62=-2 f
Cf .
Principle stress f ,
-
2f ,
fk
F- 05=2 63 He
Syt 300 Mpa
=
=
,

Find maximum value of f by

Rankine ,
MSS -1 ,
DET

T > Rankine ,

it 6ma× = 62 = -

25 Imax =
Syt
-

ii > Tiz = i. 5 f 2 FOS

Tiz 0.25£ 1.25 f-

300%3
=
=

f = 1.25 → Imax 2×2

iii > 6vm2=

Lz { ( 6, -642 + ( bi -
6332 t ( 62-635 } f- = 50 MPa

Iz f gf2 + tyg + 2514ft ) ii >

MIST
Gmax =
Syc
-

£ .
bum = 2.783 f Fos

f- = 301 = 75 Mpa
4

iii > DIET

but =
Syt
FOS

2. 783
f = 300
f- =
53.89
2- MPa

ISRO
=

Find von -
Mises stress .

Gx = 100 MPa
150 Mpa
-

300 MPA
177 by +150hPa

q
=

y§-
Gz = + 300 Mpa

qq.gg
soo Mpa
gym =
,
-
g,> 2+6×-62,2+16 , -

fogy

← =

Lz 12502+4002+1502)
p
ON

10£ (252+402+152) =

1201/625+1600+225)
102×1225
1201×2450
=
=

bum 10×35=350 MPa

° -

.
=

ESE

Cf .
A steel specimen is subjected to the
following principal stresses : 120hPa

tensile 60 MPa tensile and limit

, 30hPa compressive . If the proportional
for the specimen is 250 MPa ; The Fos as per MSST will be ?

Page 68 of 253
1

Sol? 61=120 MPa bph =

Syt =
250 MPa
=

62=60 MPa

63=-30 MPa As pes MSST ,

Tiz = 30 MPa Imax =

Syt
TC 's 2 FOS
= 75 MPa ← Imax
45 MPa
3×5,07=2,55010 ZE
C-↳ = FOS = = =

ISRO

¥ steel machine element at the critical

loading is in biaxial stress state

with two principal being 300 NIMMZ and 300 Nlmmz (equal Magnitude) .
Find the

von mises stress ( in Nlm m2) in the member

£01 . 6, = 300 NIMMZ

62 = 300 Nlm m2

bum 2=42-61.621-622
(30072
=
( 30032 -1 -
(30032

•:6vm=300MP#
GATE 2019 M.E.
pg.no .
570 [ 9.3.93] .

Syt =
300 Mpa FX Imax =
SI
Gx = GOMPA ( comp ).
LEOS

Exy = O bi 62 -

= 6x = I Syt
2-
-

started
yielding ,
FOS =L L 2. FOS

As Tresca 's Lx by Syf

Theory
.

: -
=
,

by = ? o
: -40 -

by = 300

62=0
by = -
340 Mpa ( com perceive]
↳
Forging operation so comp .

Stress applied .

④ ji > Gr -

63 6×-62 Isxt
↳ Not 2-
=
2-
=

2 . .

. Ez = o = 62 -
U (6×+6-1)
Valid FT
: 40+20 o
-s6y I 300
.
- - =
.

from opt . •
: 62 = U (6×+4)
A> by = 640 MPa ( Tensile) o
: 62 = 0.5 f -

40 t
by) : U -

-
0.5

B>
by = -

560 MPa ( comp) -

: 62=-20+0.5 by ↳ No volume

change

Page 69 of 253
1

* Equivalent Bending Moment IF

mum mm mm

bmax are same in

to
both case
Find equivalent subjected to B. M by MNST .

.
•
mmmm

→ The shaft is subjected to

bending moment and
twisting moment .

If the load shaft ( BM ) replaced equivalent

on and TM are
by only bending
moment ( Me) .

"m .
"t ! .
on .

t.m.me
.
Me

G B. M
→
Loading B. M . TM .

Loading .

fb 32M_ 6× : Gb 32mg 6× =6p

-

= =
= =

's Tlds
Tld

Txy =
IGI by = 0 =
62
Jed 's
Txy = O

by = O

6ma×=4=3,Y -

②
G. a
=

# ±
,/¥yz
¥ien:t¥i:n:e÷e
NOTE :
-

lomax = top

:*
=

6max=I÷fMtI¥# -

②
compare ②
and ,

Me=IfM+y÷**
if 6, → + ve

62 → -
ve

63 E O

Imax Tiz
2/16×2--6432 Txyt
= =
+

**

Tma×=y¥y Page 70 of 253

1

* Equivalent Twisting
nv m mm
Moment
nv m
:
-

Imax are same in both cases

ya
.

Find equivalent Twisting moment by MILT .

→ The shaft is subjected to

bending moment and
Twisting moment .

→ If the road on shaft ( BM and TM ) are replaced by only equivalent Twisting

moment (Te) .

on
! 't ! "
. .

-max=¥¥ Loading TM Te
° .
.
=
.

② Txy =

3
,
6x=O , by = 0

Jed

6, =
+
Txy 62 = -

Txy 63=0

Ema×=TCz=Txy=!f# -

②
Compare ② and ② ,

NEIEI.o.to#ig,smse.n.tionedQ
**

a=tsm
if I > lomax → Tom . and B. M .

÷:÷÷÷i:÷÷÷÷÷**
B. M and IM
Suppose
* shaft .
.

)
,

( M) ( T) 6ma× 300 MPa

shaft safe
=

Imax =
200 MPa

Me

Te
=

=
4¥92
2- ( Mt ,/M2tTT }
> T → Imax
> r't

= 200 Mpa
lomax =
300 MPa

t¥g÷
→ The maximum bending moment that shaft can sustain equivalent bending
moment .

→ The maximum twisting moment that shaft can sustain equivalent

bending
moment .

Page 71 of 253
1

ESE 2004

* M = 400 Nm and f- = 300 Nm .

Find Me and Te .

1¥ } Te 1M¥
f- {
Me = Mt =

{ 400 240¥00 } 214¥02 500 Nom

{
= =
=
t

1400+5003 Te > Me
f- Nm :
.

= = 450

ESE Me Te

Cf .
M =3 . 4G kN -
m Fa > .
7.73 and 12 kN .m ; Te > Me
,
Te > T ,
Me > M
T =
11.5 kN om Xb > .
14.96 and 22 kN m -
; Te s Me

Find Me and Te .
X Col 7.73 and 8.04 kN m -
; Te > Me ,
Te ET

Xdr ? 14.96 and 8.04 kN m -

; Tes Me

ESE

9 of Length L
weight unit
. cantilever beam ,
W per length ,
is subjected to M

Find Te
bending moment and torque Tat free end .
.

W Nlm
✓

¥EaIFimp
i>
"" gear Bom .

=Cw×y+µ×÷ ,
M =
WL t WI
c- L - 2

ii > TM = T

YMZ-TI.o.FI/fNLtwzIJT#
Te =

ISRO

M =
G kN om The maximum torque that the shaft can

-1=8 kN om sustain is Te .

Maximum Torque that the

shaft can resist when Te = 1¥72 =

16¥82 = 10 kN -
m

applied alone is =
.

ESM
Different sections of shaft of subjected P Q R S

to B. M .
and T M . . as below .
Find B. M .
10 40 20 15

Which T.nl 45 30 50 40
section is critical .
.

Page 72 of 253
1

SIM .

Shaft As per
MSST,

f la
Brittle
×
1
Ductile
is
Imax =

,÷znM=,÷d ,
-
Te

MSST DET has maximum Te is the

NOTE : -
which section
b -

More critical section .

Conservative
#

:{ Te }pe > Help { Te }g -1402-1302=50

{ Te ) > { Tele ( Te } ¥02750
k ,z =
)
°

critical
M.E. ( 9. 1.6] Section
GATE 2996 Pg .
No .
254

data : M =3 kN -
M

T = 4 kN .
m Te =
ITF

Torque Maximum → Te =
¥2 =
5KN.in

ESE 2017

Cf . P= 20kW Exy =
= Imax = Ssu
N =
200 rpm
Tld ' Fos
Ultimate
S,g
shear stress 360 MPa
4%3×6012×103 Nim
=
:
.

F- 05=8 LIN
100 104
8 y
o

: dice . = ? .

.
.
d
's
= 161×61×101×201 X 103×10/3×8 -
8×107×87
-
=

b > 45 C. 748 d > 51 2x a 2×36/0×2007 101×03

A. 742 .

TV
.

66×101

331×104 10.67×104
'
d = = = 106700

/d=48mmT
-

ESE

Qus
I
.
TM =
1000 Nm Sor . Te
?
= ( Kb 131432
X t ( Ktx -11432
-1
500 Nm 3M=
=
{ i. 5×50032 + { 2×100032
bending fatigue factor ,
Kb = 1.5 =
7502 t 20002
Torsion fatigue factor ,
Kt = 2 =
1000210.752+223
Find equivalent B. M .
=
? = 10002×4.5625
Te =
103175625
A > 2000 N.m Opt . 2100 Te = 2136 NM

b > 2050 N.me 2.1×0000

4.41×103
C) 2100 Nim

4-4154.56
d) 2136 Nrm

Page 73 of 253
1

* Ellipse size : -

Murr www

if
•

^
62 OA ×
Sylt

<%.at±#t÷
• .
⇐

semi axis
Sgt
→
major
• DIII

÷maior±isz×
{ ,a3
Br
-
a

v . : OB = semi minor axis

<

I •
o : OB =
IT x a

Erripse Sgc 6,62+622 Sfp

" "

Gp2 - =
→
DEI
V
q2 Shyt
2
q2
o

: f + a =

: 392 Shyt
•

: a = Sylt

i.minoraxis-2.IT#xSytf
CRPQ

/ 1.
- -

) ¥2
( Pg 12]
# Imax
No
9. L . .
6, ,
2 =

± t Tay
2 °

: bi =

Bx = 60 MPa , Lomax =
Syt

5; % :'m:
"⇐
EH Fos

Principal 80
Maximum bi ,
2 = 30 I go
Stress ? 6, 80 Mpa FOS =
4.125
theory
=
=

{ MNST) 62 = -

20 Mpa

)
CRPQ

/
-

9. 2 .
( Pg No . 12] .

.
.
6× = HO Tiz = 35 MPa ←
Imax
by = -

30 Tis =
20 MPa

/ Hoo Igo )
Is MPa
6 =
Txy =
0 = 15

=q ,÷÷
s. em. .
¥; ; ÷ ;g;÷,
. =
.
±

3506g
5 I 35
= . .

.
FOS =

2×35
= 40 Mpa

62=-30 MPa
FOS

Page 74 of 253
1

QUI .
A machine member 50mm diameter ,
250 mm
Pong and supported at one

end as a cantilever will be used for axial tensile load 235 kN .

The

Ultimate tensile strength of member material is 480 Mpa .

The design FOS

to
according MSST is
~
.

I
→ p Tiz =
4-622 =
61 = I
2 2A
2

C- I3 = I
2A
A- It points are critical .

•
: tox =
I = 6g 723 =
0
A

÷÷ ,
=
, am . .
.gg#.....=os=...y
63 =
0 .
.

.
235×103
=
480
-

21×1×502 EX FOS

CRPQ

.rs#Exi/.:so:I :osFos--?lMssT3
-

9.33 .
( Pg No . 12]
6× = 48×10-3 = 80 Mpa Tiz = 50 MPA

600 45 MPa
Tiz =

Loading → Tensile load ( Pr) by = 0 723=5 MPa

shear load ( Pa) Txy = 18×1032 = 30 Mpa

Pr =
48×103 N 600
Ema , = Syt
#

I;¥÷÷:÷:
'

=¥
=

821 ± F0s
Go =
90 MPa

62 = -
to Mpa

) |
CRPQ
-
For pressure vessule Tiz =
-
Pd Ema , =
Pd
,

( Pg No 12] 8T Ht
9.4 . .

Gong .
= Pd
di = 4. Gm 4T Tiz = PI
" and
it 3%77,2=0.2 Ift
-
.

, Mpa a, ,
.

Syt =
260 MPa tox =
brong .
= Go Htt

Fos =
? { MSST } by =
btang .
=
62

Txy = O

Imax = Syt
Fos :

0.24×1.66×1032 =

22,6¥ ,
.:F0s=8o6⑦

Page 75 of 253
1

CRIQ Iz = 150 Mpa ÷

.

Fos = 5002 = 2.67

un
2×150
Cf .
5 . ( Pg .
No .

]
12 C-i3 =
100 Mpa

6, = -1200 MPa Izz =

50 Mpa

62 =
-
100 Mpa

Syt =
500 MPa Imax = Syt
Fos = ? ( Tresca 's } 2 FOS

CRIQ Gx = 55 Mpa Gz = 41.82 MPW

9. 66 . ( Pg .
No .
12
] by = O Etz = 34.66 MPa

Txy =
284 MPa Izz = 7. LG MPa

Gb = 55 MPa
-

2=525--1,1152-12×31.52 SI
T =
31.5 MPa bi Imax =
,

Syt = 284 MPa 2 FOS

FOS =
? ( MST ) Gi =
69.32 Mpa Fos = 2842 = 3.396
rum

62 =
-

14.32 Mpa 2×41.82

:/
CRPQ Gx = 20×103
- -

( Pg No 12] A
9. F. .
.

15×1035
Noh .
Pp 20×103 N
Txy =

A
13=15×103
. L .
N

÷÷÷ 's:÷ .me#iox-xir+a: l

G
bum
Iz X
{202+202+(6×152)}
s

: =
=

2
FOS

bum = 3-60 i20 =

3 A

bum = 120 Mpa

°

: A = 273.23 MMZ

of = 18.65 mm

EEP Q : . All surface point are

P=40j*Fp→p=
( Pg ] critical
9. 8 .
- 12
go kN
.

DET

Fos -
2

Syt -_
310hPa 6× =
I =
#
40×103×4 .
.

. bum =
f¥TxyT =
Syt
-

A Tl × ( 2072
Paxia , = do kN FOS

.fr#2t3ffo,fT=3!z0-max--
D= 20mm 6x= 127.324 MPa :

Txy =
IGI = t
Jed 3
IT l20)3 F 80165 NMM
.

. . =

-1=80.17 Nom

Page 76 of 253
1

CRPQ
9. 9 { Pg .NO 123 -

dd== poem I > Mr = Px 500

"
"
Y 2 K

↳ Perpendicular to area ( F. M ) .

# it >
50cm
Mz = PX 2500
r2 L
x Y

' →
aanacarefrii.fi:i .
""

&
Loading → Tom . B. M .

TM = 5000×500 N mm
I
-
.

B. M .
= 5000×2500 N .
mm

As per tresca theory ,

Imax = Syt =
I'¥t

24,7¥ *!÷p 475000×572+15000×25007

:
°

:F0S=3.
CRPQ Gx = 100 MPa

f. LL { Pg - No .
133 by = 40hPa

Txy = 40 MPa

[ !
6 =
LOO 40 62=0
40 40

)
6vM2=
Iz f ( 6x by )2t ( 6×-6212 ( by 6212
MPa
Syt = 360 -

* -

Fos =
? ( DET] t Tty t t z3

Iz { )
⇐ ( too -

4012 t 1002 t 402 t 614032

:
bum 111.36 MPa
•
=

Efts ,3⇐=
' '
"

bum Fos
:
EE
o
=
=

CRPQ
rn

g. LO ( Pg .NO
.
- B ) :
"

= EMO
Y # 1500 mm - * goomm -4

↳t.ee//d/U=o,T--Tz
M2 i
- -

a
- -

t ↳ frictionless
b→
i pulley
i
←

pym
500mm
.

- - - - -
i . . . . - . . . -
- - - -
I
Y - - -
*& M

Z
'
=P

Y
"
" 500+123
X
"" " M"

Z
"

K
1500
Y
-

R }

↳ N.A. and B. M .
↳ B. M .

y 13=5 kN

Page 77 of 253
1

Resultant B. M . M =
Mit Mz Gamp .
= = -
5000
M ,z= 200010 A b. d

M Y
→ 6b=
.

ttop = -

bcomp .
+ bb I
6 bottom =
-

bcomp .
-

bb =
107×42 =
6×107 :
1=2
-
-

bd2 b
(: Bottom point are critical
) bdl
12 Gx pot D= 2b
=

°
: lobottom =
Lomax = -

bump -
lob F
o

.
.
SYC = -
5000 -
6×107 =
-201
-
-
-

2.5
Fos 2b 'd
4b3 FOR C. I .

Syt
25,020-+1.5×-107=80 Syc
: >
°

3
b.
SYCE Syt
Solve
by put opt in eqn ,
b=gy.yzmmy
CRPQ
9. 12 .
( Pg . No . 13 )
-1=10 kN M - T = 5 KN.in From case I & 2
,

M = LO kN M -
M = 6 kN m -

Fos =
1.5 Fos =
? { MSST } 4¥02 ( i. 5) =
IF ( FOD

case i > M =
T =
LO kN -
m

:
FOSz=2.7€T
°

case ii > M=6 Krim & f- = 5 kN m -

Imax = I + M2 =
-
Ssy
3 FOS
Tld
-

•
°

.
I MZ t T2 × FOS =
Ssyx d3
.

16

Page 78 of 253
1

* MAXIMUM STRAIN ENERGY THEORY

TOTAL STRAIN ENERGY THEORY
BELTRAMI AND HAIGH THEORY

The theory states that the failure of the mechanical component subjected
to bi-axial or tri-axial stresses occurs when the maximum strain energy per unit
volume reaches the yield or ultimate strength of the material.

Multi axial
loading = UTM test data

{ U Total ) multi -
axial = { U Total } UTM

U =
strain energy

✓
Igbo Er t
£62 Ez Iz 63 E3
=
Total t

→ E, =
Gr -
U (62+63)
-

→
Ez =

↳
G -
U ( 62 t bi )

.to#==+bzz+6z2-z2pu(6r6z-6z-63+bi-b**Mfflatd gal
→ =

{ UTM } Test : -

At
yielding { UTM } Test =
61=521
6×1=0--6 , =
Syt 2E 2E
* *

&! 9=62
63=0 .sn/It6z#6st6s6D-=?o4t
Application E- Thick cylinder of ductile material

^
62

mn<s#o
Sgt •
TD
M SET

I •

Erripse Sgc
v

Page 79 of 253
1

* MAXIMUM STRAIN THEORY

St. VENANT'S THEORY

The theory states that the failure of the mechanical component subjected to
bi-axial or tri-axial stresses occurs when the maximum strain reaches the yield or
ultimate strength of the material.

{ Emax } multi -
axial ⇐ { Email very

Maximum strain in Multi axial

→ -

loading :

Ep 61 -

U (62+63)

}
=

E-

Ez = 6z-UC6rt# Principal strain

E

63 U ( 621-63 )
Ez
-

E-

÷Ema×=max{Ei,E2,E3 - ②

Maximum strain in axial

→ Uni -

loading :

6×40

by = 0
=

=
61

62
: Er -_
I
E Ema×=Eo=t÷=S¥ -

Tay Ez=Ez= MEI

= O o . -

63=0

If Ep 7 Ez > E3 ,

Er = Syt
-

: 6, - U ( 62+63 ) = Syt
# E

* *

6z-uCGt6D=s
.

:
E, → max 61 -
U (62+63) =
SI
FOS

EN max

Ez → Max 63 - U ( 6, + 62) =
Sit
FOS

Page 80 of 253
1

62
n
.
→
good ri suit for brittle

material , but not used

•
b' coz some time its
← Parallelogram

so .
in
:÷÷÷÷÷÷ :* .
.

V
•

Page 81 of 253
1

CHAPTER 4:- FLUCTUATING LOADS

Page 82 of 253
1

CHAPTER 4:- FLUCTUATING LOADS

* Terms :
-

→ Mean or
Average stress ,
Gm =
6max-6m
2

Amplitude
=/ / Always
→ stress Ga → Positive
,

→ stress Ratio
,
R = Comin
bmax
→ Amplitude Ratio =
I
6M

{mmIbgaI{mma
"
"

condition
checking
" →

static
Loading :6ma× = + LOO MPa
^

i
stress Comin = t 100 MPa

6M = 100 Mpa

Ga = O MPa

Fatigue
rn rn Loading
u r

^
loading

Hi¥
stress Fatigue → Dynamic
loading
%
•

>
time

Page 83 of 253
1

Reversed
mm
Loading
-
Kmart = 16 mint
Lomax 4321
= -
comin
A → § =

Tld 's
^
Stress .

e.
I
g .

in

A
•

→ Gb =
-
32M
-

Ted 's
v

shaft → B. M .
and Tom .

i> bmean = 0 Gb →
veering
C-Torsion → constant
it > 6amplitude =
tbmaxl -
I bminl
Pain A 6mA , -132Mt

)
:
°

=
=
,

iii > '

R 6mi Tld
pyexersed
=
= -
I

bmax Sending
.

.
.
Comin = -
32Mt
y
Loading
-

Tlds

NN
Mr
TE : -

if direction are
change then its repeated loading .

Casey gear
-

^ I

fr
stress

a-

ion

#
Comin time From points are contact

v B → A is 6=10
A → B is 6=0

bmaxbmin
lomax to .
: Gm =

Z
= o

o
: Ga =

6max2
GATE {
2014 ME .
Pg .
No . 253 } { 9. i. is }

6mi
Gmax
=

=
200 MPa

400 Mpa
6g
=/ 6maxz6min_ I
Ga =
?

14002-200-1 MPa
= 200
=

Page 84 of 253
1

GATE 2015 { Moe .

Pg .
No . 2533 ( 9.1.19 )
data

=/ 6ma×z6min_ /
6a= ? Gamp .

Stress ratio ( R) =

lomax
bmax = +250 Mpa =
250 -

50 =
100 MPa
-

2
Comin =
+50 Mpa

: stress Comin
←

Ratio ( R) =
= 51=-0.2
Lomax 250

GATE 2018 ( Moe Pg . . No . -259 } { Q . 2.133

( fully) lomax Gamp
Reversed
loading
: =
.

O 15
{ posy
-
-

Gmax , a
= 1100 x

" ' 5
6g
-

= 1100N ⇐
195.61 Mpa

N = 1×105

GATE 2019 { M E .
.

Pg . No . 259 } I 9. i. is }

tmaxtbminbmin
Gm + 140 Mpa 6M
= =

2
= -

70 Mpa

: 6ma× (2×140)+70
•

= =
350 MPa

R = Comin = -
-70
=
-
0.2
-

lomax 350

GATE stress . .

.
6max =
50
^

Cf . Comin =
-
100

=gmm'÷=
" :
z
-

= -

one

tamp
=/ /
:
°

Z
-
100 - - - - - - - -
- - - - - - - - - - - - - -
- - -

/ 50+2100-1 1502
=
=

Find :
-

stress Ratio
-

Amplitude Ratio .

: 6m=6max-6m
2

50-1002
502
-

= =

Amplitude ratio
÷ t5gI =-3
:
• -

= =

Page 85 of 253
1

Gus .
lomax = -

10 MPa

To
6mi n = -
100 MPa
#

/
bmax time
I

=↳"¥m
Lo
"
- -
-

" " "

stress
= -10-1002 = -

55
2
-
100 - - - - - - - - - - -
FIT

Gamp
=/ 6max-6min_ /
:
•

Find :
-

stress amplitude =
-
to -1100 = 45 MPa
-

Mean stress 2

Stress Ratio . .
. Stress ratio = Comin = -10L = 10

Amplitude Ratio lomax -10

gray ÷g
Ratio 0.818
: Amplitude
° -

= = =

Prismaticpsars →
cross section area is uniform through length .

ro.I.ro "
I

BM Bm →
6b=M
y T.at?emcaaI?Ibg!!! for

g
t
→ e=

Non -
Prismatic Bar → cross section are not uniform throng length .

- mm -

lomax = Pe
Amin

¥Eskmax3 actual

→ b

9)
Fos T

dimension when don't know

-

Cost is about stress -

=/Lp (
concentration

€¥
I
.

soth

(
* in
century Photo elastic
µ
→
P -
w
d

"
TB Technique

o:{6ma×3actua,$cw€
Epoxi -.

"
Rasim
"

Material "
Page 86 of 253
1

* stress concentration factor ( Kt ) :

-

mm mum we r

Nominal stress ,
too = I =
p

# E
•
°

6me ,
might > z

•
:
stressconcentrationtactor.kt-t.mg#--Tmfo**
Go To → Nominal stresses calculated base upon minimum area .

due to
→
change of area that stress concentration takes place .

Kt Theoretical stress concentration ( Not Practical)

Fatigue factor ( Kt)

⑦
* stress concentration .
-

n un un un

* *

Notcnseqgitivity-YI.IT#
:
Kf g. ( Kt L
) t I
•
= -

if i 9=1 kit
> →
Kf =
→
Nothing mention so select this case .

ii > 9=0 →
kg -
= I

60
H

engine
circular hate :

¥÷a×¥÷^:i¥ic
-

:*.

↳
.s÷€
B°→ lomax
"
ta ¥7
:
-

¥
I
Pi to =

Amin
=

{ w d) t-

d
'
•
>
0.2
lomax = too x Kt
dfw
i> if dlw = 0.2 → Kt =
2.5

lomax to
•

• .
= 2.5 X

→
(k=3 D= O → No stress concentration,

↳→¥=° we =
infinite → width >s> diameter

infinite width

Page 87 of 253
1

Plate with elliptical

run
hole
~
:
-

w
we r

A →
Major Axis

¥¥
B Minor Axis don't take this

JB ego :
→

* * circular

,
*=↳o
to B a-

gi.en.mm.yg.q.p.g.z.w.r.sn
ESE .

F-

If the ratio of minor axis to major axis is 42 ,

for a plate with
elliptical hole .
Determine the stress concentration factor .

=L I -

212) = 5
mi

P
a
: Go = I = -

Amin (w - A } t

: lomax = box Rt

* Failure
me
by fatigue Loading
u w w un
:

Defect to
crack expands in a direction perpendicular
! a.TK
Ho

¥¥±¥E¥÷:÷¥
to maximum tensile stress

§
.

EP IP
Compressive load F will reduce the

: :::S:O: :::e.int :i:ei :c:c:

e

,
Hot to

crack to →
fatigue life will increase .

Freaking / Rupture
toad
Residual applied reduce
propagation
→
compressive to crack .

* Auto -

freitag e
→ Pressure Vessel

→ Smaller cylinder is put on pressure vessel

→ residual compression stress

→ expansion of crack will reduce

→
More strength & More life .

→ Produce residual
shot
mm
peening
mm
compressive stress .

k
↳ 9 Fatigue Loading
small steel
Hammering
balls

Page 88 of 253
1

Set up : -

Rotating Beam Test f. Fatigue Experiment :

-

* *
E-
-
- -
ra
←
How to load applied ? Reversed

R.Rrey : -

Bend
→
Bending stress

wk 42

Comin Gm
lomax
3! 9 32Mt
=
+ - → = o
=

Tld 's
6g = 32Mt
Tld 's

* S N -
curve :S
ur urn

log of Ga} tow cycle X →

Fatigue rife

lsut3.IT#ighcycefatigue
N
fatigue

.gg#j.q. . . .p. n
,

stress Y Fatigue { Sf )
s → →
strength
N → No .
of cycle doggo +
+
+
+
+
+

dog pot 0.9 Sat )

*

µ
t
-

+
t

ng ..
,

>
6
lomean is zero ,
tamp .
is non
L 3 No .
of cycles
↳ Intine life
Zero in fatigue loading .
rog old },

"÷¥:: :.:÷: : :÷.

tog ro
't =

togpo -10 =

log ooo ,
= o
+
Se → Endurance
strength

÷ : : : :!:÷:÷ : :c
"

..

it is
strength of component which
→
at

iiis 106 cycles

dog port =
6 N =
the component Wiss sustain infinite
no .
of cycle .

.
.

Sf =
Se N BIOG cycle
ga f se → Life of component is • .

Sf =
0.9 Sat N - 003 cycles

Page 89 of 253
1

S N becomes after 106 cycles

NOTE : curve
asymptotic
-
-

Fatigue is Y axis
→
strength on
,
but endurance strength for particular
point when life is infinite .

Set endurance for Test specimen

→
strength
Se endurance for Actual specimen
strength
→

SeE④ → Actual specimen fails first .

Seisnotmaterialproperty

Mild steel * *
,

Set =
0.5 X Sat it sat E 2400 Mpa

set =
70014Pa Sat > 0400 MPa

cast Iron ,

set = 0.4 X Syt

%5e-kaxkbxkcxkdxke.is
AD surface Finish Factor ( ka) :
-

r u m r u n n e rs

td② ② Surface
w w w. r m m
Isen > lsek

→ Made
by COLD
working → Made
by HOT
working
Ise } > Ise )
cold Hot
worked worked

2> Size Factor ( Kb)

÷:::
"

deflect are more

less
strength is .

→ If we increase the size of test specimen ,

size 9 No of defects 19 cracks P self

Page 90 of 253
1

37
Reliability Factor ( Kc) :
-

Indention →
size & finish
specimen are same .

← Made from same batch .

a O → we can 't defined where the

strength are come or not in

( se } , # { 542 same
manufacturing process .

reliable
→
Fatigue test data is only 507 .
.

→
Expected reliability more than 50% .

specimen
'
Let
,
Se = 200 MPa → Test
R = 507 .

Actual ,
→ R > 507 .

→ Ise ) else's
→ Se = 50hPa
strength

4> stress concentration factor ( Kt) :

9=¥I Kt = It Ellett D

'
se e se
i> 9=0 →
Kf =L * *

kf= Kt { Kt
:se=¥
ii > 9=2 → > I }

:ty⑤
57 Miscellaneous Factor ( ke )
-

Temperature factor
-

Humidity factor

: Se =
Ka X Kb X Kc X kex Kf X Set
°

: ka ,
Kb ,
Kc - a less
than one

Se = ka x Kb X Kc X ke p
-
x Se
Modified \ Kf

Id=L÷¥D
stress L :
Kf > I
o

concentration

* * q → Notch sensitivity
steel
,

se=kaIIbgqµt¥Ixo.5xS
Ses se
' 1 > It factor less it set
: is than
multiply to
•
.
a one ,
.

2.7 If a factor is more than one ,

divide Se
'
by it .

Page 91 of 253
1

Need of TOF

:# B In case of fatigue ,
we do the test and
get endurance
strength ( se)

from Reversed
bending toad .

±:* :c: : .
i :::n:
" "

se can 't
directly
→
be used .

Multi -
axial =
Fatigue Test
loading ↳ TOF
ur

Fatigue Strength Formulation :#

^
6m=o
ya
→ Reversed
Loading stress

↳gaq=qo
A

100 MPa

lomax = -1100
1$
.
, .

g , .± ,
.
g. me , para , ,µ ,
ga .
#
+ +
. od man line time
¥
*
Stress A

*
:÷÷¥÷¥i¥÷
+
line
Soderberg

→ Gerber 's contains failure point inside the

parabolic some curve .

is theory
→
Soderberg more conservative .

→ For fatigue loading all TOF aeiye same result .

it Soderberg line :
-

Normal loading : -

I
Gynt
=L
a +
is
Ga Se

↳
Se .

÷÷¥÷
"

* *

sie om -
>

{F7t¥==
Page 92 of 253
1

Shear
Loading :
-

* *

gT÷=÷ Sse → shear endurance

strength

is Ssy = 0.5 X
Syt → MISS T

MSS T, Sse = 0.5 X Se

=

Tm
¥5
2
+ =

Tye jig Ssy = 0.577 x Syt → DET

Sse = 0.577 X Se

Tft t
¥ 27705 =

NOTE
-
:
- If
nothing mentioned then

MST is used .

DET ,
=

iBgyfI +
ITIL =L
Se FOS

ask.tt#--LiT3XFOS
ii > Good men 's Line : Gud man
+
sat Normal stress :
p a
**

E÷t÷=¥Q
•a

↳
Se

it
shear Stress :*
* *

¥T¥=¥Q
.

If
→
nothing mentioned then used
goodman theory .

for brittle ductile is used

Here and ,
any theory .

Cf . 2.12 . Sat = 600 NIMMZ

[ GATE 2017 ] Se =
250 N Imm 't

$g
M E
}
. .

a
* = 10000 cycles

,og,y€µ÷
.
No .
258 BABE ,

A d. 8 Sat =
480 MPa tano = 109,0480-109,0125032
G 3
C
log
-

D
PO

i
,

yg.gg?gpog,o#
i
i
i

tog pom
i
>
3 4 6

Page 93 of 253
1

• .
109,0480 -

109,01250) 109,0480 -
10910 ( Sf)
@
#
= #

G -
3 4-3

( Sf) dog 109,0250

log log
480
480
-

:
•
=
ro
-

,o ,o
3-

:
doggo (Sf ) 2.587 Sf 386.195 MPa
°
=
=

GATE 2020

⑥ Go Cos ( 8TH) All will for

give
→ TOF
= •
same results

reversed
loading .

I> 6mg = t bo
e

: cos 0=1
,

6M¥ ÷
Comin ba cos o L
Soderberg pots
:
'

= -

= -

+ =

60
¥5
:
Gm O
-

= 0 . .

.
+ =

6a=6o- = ⑥o -350
2
÷6o=L00MP#
9. 2.6 .

Syt = 2X Se
{ GATE 19933
( Pg . No . 258 } Torque → shear stress (Soderberg)

I =L
3÷{T¥et IF }=i¥
°
+ :

Ssy Sse Fos

{ )
Ssy Syt Tld3×Se_
Tgi
MSST, 0.5 X
°

:
=
Fos x + Ta =

Se 32
Sse = 0.5 X

→ Fos will be minimum when

Im
,{T÷ { Tze }
I
=
; Ia = Kota + Ta is maximum .

Jed 's

→ Minimum FOS means critical

f¥{ o.IS#t-o.IaseY-- ÷s
÷ condition .

;÷{ 7¥ Taz } Es
:
÷ -
+

Page 94 of 253
1

Tmax Tmin Tm Ta TfL f- Ta

66

EE i> to -

T O T
⑦ → Critical

Loading
' '

pig I T
'

-
1- T 3T 7T
- -

2 -

4 4 8

T T 3T
iiis 1- T o -
- -

2
2 4
T
Iv > f- T t T 3T 5T
12 -
- -

4 He 8

9.1.13 .

Rotating shaft
( GATE 2014 ) ↳ same fiber under point load at the

ME Pg . No -
253 center of rotating steel shaft supported
at ends is
subjected to reverse l of
stresses .

lomax = t 100 MPa

comin will
Loo MPa → All TOF
give some results
= -

o
: Gm = O
'

: 6g = 100 Mpa Goodman Line ,

EIzt6Ie-fFs.a.EotEoIo-rIsiF0S-2@Cf.2.L
GATE 1987
Se
Syt
=

=
196

294
Nlmmz
N/mm2
Se =
ka×kb×kcx
Kf
× Set

( Pg
?§{_
258 ] lomax
5k¥
. No .
= 147 Nlm m2 .

: Se =
=
= 148.48 MPa
comin =
49 N/mm2
Kf = i. 32
6 9

Fos =
? Syt given →
Soderberg Theory
-

gtryhtgbea
Gm
14712492=98 =L
:
°

=
Mpa
FOS

ba
=/ 9/ =
49hPa
Lady T÷%=¥s
+

F0S=1.5⑦
ISRO 2020

Q A metal is to
fluctuating tensile
.

alloy machine component subjected

stress from 200 Nlm m2 to 200 Nlmm ? The material has yield and endurance

Nlmm
'

strength of 450 and 200 respectively . Find the FOS of machine component .

Page 95 of 253
1

6ma× Nlm m2
Sol .
= 200 Syt →
Soderberg
-6mi n = 100 N/mm2
Syt 6M
÷ ÷
= 450 MPa :
+ =

Se =
200 Mpa Tye
Fos =
?
→ 6m= 2007100L 150 Mpa :
Lg5÷ 5€ I
o
=

+ =

2 / 20/0 FOS

12002-100-1=50
3 4
6a= MPa

:# PLos F0s=t
.
=

* Modified Goodman 's diagram :

-

^ ^

µ*÷i÷÷÷÷÷÷
Stress
q syt
G
•
be a-

Iida : ineetgeosoignm.sase.ge;
-
.
se .

O
t •
A
A- •
←

•
66

Goodman
mmmm
' '

)
→
Comin
Gm
Ga
=

=
=

200
99 Mpa

L Mpa
MPa

Syt Sat

6.mea back 6M
v. Almost static
loading .

i> Point A is safe

according to
goodman theory .

As 6ms Syt →
yielding → Failure .

Area A B
O C O
Modify ied goodman diagram
-

→
-
- -

US .
GATE 2016

In structural member under fatigue loading ,

the minimum and maximum stress

developed at the critical point are 50 Mpa and 150 MPa , respectively .
The endurance
,

Yield and ultimate strengths of the material are 200 MPa

,
300 MPa and 400 MPa

respectively .
The Fos using modified good men criteria is .

Comin = 50 MPa 6M = 100 Mpa

Gmax = 150 MPa Ga = 50 Mpa

Page 96 of 253
1

8a a

€o⇐
tan O = 50 = I
Syt
-

100 2

> loading
Line
Se

i> yield line

{ 6m.ba } = { ' 00,2003 -

,g÷, ÷
.

,
= ,

,
A
go
-_
Gmt Ga Syt ②
-

: = -

>
sat Bm
Syt
ii > Goodman line
on
: 6mi 69=300 .
:
tom +
be =L

Gm t 26g = 400 Sat Se

-
-

tom ta
-

=L
- '

+
r

6g = 100 400 200

Gm 200 6mi 2.ba 400 ②

=
:
-

= -

: tan x = too =L if 9=0 ,

passing through both lines ,

200 2

i > Goodman
- -
I,

:
°

ETI t
# =¥s
°

:
1%00-+502 200
=
2
FOS

* *
F0
ESE

Qus . A machine component is subjected to a f- texture stress which fluctuates

,

beth and MNIM ?

300 MNIMZ 150
Taking the yield strength 0.55 of the
-

ultimate 0.50 of the ultimate and Fos to be 2

strength strength
=
,

the of minimum modified

value ultimate strength according to
goodman
relation will be

A .
> 1100 MNIMZ B > .

1075 MNIMZ
C .
> 1050 MNIMZ d. 7 1025 MNIMZ

Sod .
lomax =
300 MNIMZ tan O = das = -225 =3

bmin = - 150 MN/m2 Gm 75

Syt = 0.55 Sat

Se = 0.50 Sat

F- 05=2

min sat =
?
,

6M = 75 MPa

6g =
450/2 = 225 MPa
Page 97 of 253
1

€%÷gq,,,,
i> yield line

Syt

\
torn +
be = L

Syt Syt
Se -

: 6mi ba =
Syyt -

②
. . ,
,m ,. . ,, gu,
I
, , . .

>
Iis Goodman
•

Sue line
Syt

6mi 26A = Sat 6m_ + be = I -

②
Gmt Sat Se
Ga = 0.55 Sat

6M 6a_
-
- -

=L
.

:
+
gut
-

: Ba = 0.45 Sat
0.5 Sat

: Gm = o . I sat : tom t 26g = Sat

fan x
0-45-sut-4.50.rs
:
•

at

tan x x tan O

i>
Yield line : -

¥ -1¥ ÷
-

.
.

Gm 6g 0.5 Sat
-

:
+ =

FOS

( 75 ) 2- Sat
°

: t 225 x =

0.55

12000 2090.90 Mpa 1100 MPa

sat 2 100
-

: =
300 X X = -
= =
-

55 LL

Q . 2.14 . Pma , =
+60490 = 150 kN lomax =
150×102 N/mm2
GATE 2018 A
Pm in = t 60 -
10 = 50 kN

( Pg .
No . 259 ] Se =p go Mpa Emin = 50×1032 NIMMI
A
Syt = 480hPa

Sut = 600 Mpa

°

: Gm = 1009002 N/mm2
A
FOS = 2

Value of side ,
a =
?
-

: ta =
50×-103 N/mm2
A

•
: tan D= ba = 50 =L
- -
-

too 2
Gm

Page 98 of 253
1

i > yield line :

Syt

be
loading line
Emf
> + =L
Se
Syt
-

÷: : : :
" " " -
°

"
-0

Syt Sat
Gm + I =
L

Gmt 46g = 600 sat Se

Gm Ga 6M
t = 480 .

:
*
I = L

Too
-
-

150
-

36g = 120 :
'

Gm t 46g =
600 - ②
: Ga = 40 MPa

Gm 440 MPa
'

:
=

tan 4=41 = I
440 LI

: tan O tant
-

i> Goodman line

stunt ÷=÷s
100×103 50×11032
:

LAX
.

t =

050 2

: ( too x 103 ) t 4 (50×103) = 300 A

: A = 1000
A=3t.62mm

* Combined
Loading : -

mum mum

(G)
Bending } ¥; } Together ¥7,711
Moment min
→ →
(
Twisting moment
-
. min

(6dm Gx)a ,
( Txy ) m
,
( Txy ) a
,

Let { 6×3 max = 200 16×3 min = 100

e¥ ,

{ Txy } max
= 100 ( Txy ) min = -
200

→ ( bx) =
150 Mpa (Txy) m
= -
50 Mpa

(G) ma = 50 Mpa (Txy) a = 150 MPa

Page 99 of 253
1

Reference of most accurate

theory ,
{ DET }

6hm =

Lex { (6×-6/1) 't ( 6×-6/25-1 CHI 6/212+61 Exit

-

THE t THE })
Gx to Try to

6vm2 = 6×2 t 3
T×y2 bum =
Y¥TxyT
i> Mean stress
, -

Gm =
! @ ) m2 x + 3 ( txyrn

=
#
1502 3 f 5032 t -
= 173 . 21 MPa

%; > Amplitude stress

; a =
y⇐¥LLxyF
=

g)¥105032 = 264 . 58 MPa

→ Then
go according to gus ,
which theory is used mentioned in gas .

9. 1.9 .
thin spherical vessel
,
→ spherical Pressure Vessel ,

GATE 2007 d =
200mm Gx =
by =
Pd
( Pg .
No .
252 ] t = I mm 4T

Pm in = 4 MPa Pmax → 6.c. max =

by ,
max
=
Pmaxid
Pmax hit
= 8 Mpa

Syt = 600 Mpa Pmi n → tox ,

min =
by ,
min =
Pmin .
d
#

Sat =
800 MPa Ht
Se =
400 MPa

Fos =
? as per

{ Goodman 's Theory }

(6×-6/2) 6/572
6vm2=
Lzf }
'

EET , (6×-64) 't t ( by -

'
6vmZ
Iz ( 6×2 26 x.
by + by +6×2+642
)
= -

6vm2 = 6×2 -

6x.by t 6y2
6x ,
m
=
61 =
by ,m
at

Gx , a =
21 =
by ,
a

at

Page 100 of 253

1

•
: Gm =
#
(6%2 ( 6x)m( by)mt (G) m2
- : → Goodman
theory ,

6m2= 6×5 Gin

gaff ÷ I
.

÷ =
t =

•
: 6m== Gd FOS

Ft .
:
-
6×200 2×200

4×1 4×1
-
t -
= I
•
:
692=6%92 =
by ,a2
800 400 FOS

•
: 6g =
2dg I
F0S=
Let

* Cumulative Damage :
-

Mmm mm

A specimen is subjected to cyclic roads as :

Gi for no cycles then no → for -6, only

.

:
,

62 for nz cycles , then Ni → Total Number

63 for Of cycle
nz cycles ,
then repeat of loading .

total of cycles failure for load bi alone

Let ,
Ni = number
up to

Nz total number to failure for road 62 alone

=
of cycles up
Nz = total number
of cycles up to failure for load 63 alone
↳
damage = too % = I
damage

log ,ot6a } A
Applied on one
single

:€#¥+++i*s : : ;"
specimen .

"

+
+
+
+
* Disadvantage :
-

+
if 6,
logar)
+ = LOO MPa
te
-

t 62=200 Mpa
+

Yogi e
's: : :p:S,
first damage is more .

→ 62 apply large stress '

Nr Nz Nz damage will more then

toapply so damage will
→
Damage by 61 for nr cycle ,
magnified .

only bi → failure will take place Nr cycle

damage = 100% =L

I .

damage done by 6,
=
L
-

in one cycle Nr

damage done by 6, hi
.

. .
=

in Nr cycle
'
Nd

done
damage by 62 I
.
e .
=

in Nz cycle Nz
Page 101 of 253
1

cumutativedamage-nwi-nzq-nw.ee
" "
: .
→ Minors Equations

N = Total no .
of cycles before failure
•

• •
N = hit nztnz

Fraction of time for which 6, is applied a =

Ni
hp

Fraction of time for which 62 is applied 92=12

N 2

Fraction of time for which 62 is applied q=N→

N
3

: 4, +42+43=1
°

* *

Fi-f÷+÷
"

I:P:c .
9:÷¥÷÷÷÷÷"
"" d
.no .
. '

¥
.

Sy 440 MPa
,
=

0.8
9 =

kg = 0.67 Kc =
O -

9 kt =
2.35 FOS = 1.5

Kb =
0.85 Kd = 0.897

kaxptgbxkcxkd
Se =
x se
'
Kf = It 91kt -
i )

= 0.67×0.85×0.990.897-5 et steel ,
set = 0.5 Sat
1 -10.812.35 t) -

= 0.221 X 0.5 X 440 = 48.628 MPa

.GG#t.+bgae-=L-
: Fm O
:
o

FOS 16kW
Fa =

4
4-00 6g =Fa_ 1/60002
4004×48.628
°
:
-
=
1 . . = =
.

410kt i. e5
Cw d) it - t

t=

Page 102 of 253

1

4 A

,↳
NOTE * static
:ga .ba
- #
:
loading
-

¥
-

Se .
i> FOS E I → Failure
C ii >
• Fos > L → Safe
"

s • >
* ,

I> FOS D
ng

L
,

Point B
Syt Gm -
→

→ bas se

→ infinite life
it > Fos =L → Poin A

→ 6g = Se

→ infinite life
iii > Foss I → Point C

→ 6g > be
→ Finite
length

CRPQ -
to
M

9.2 ( Pg . No .
203
go , B -
so kN
p
y
R = 3.75mm

Sat =
300 MNIMZ i> Se = Set = 2002 = 133.79

Set = 200 MNIMZ Kf L t 0.9 ( i. 55

-
t ) MNIMZ

Kt = 1.55

ti ) 50×102
9 faxia ,
Gz
0.8
= =
= = 101.86 Nt

M =
? ( constant speed ) h ( 2512
Nominal
-

a stress
Minimum -

Area
ii ) stress Gb 32Mt 32XM_
bending
= =
,

's
Jed TL X ( 2573

Ga lob
As & are
acting direction this is not of combined
•

: in x a case
,

loading .

: A and B are critical point .

at point A , given time or as shown in figure

6A = t 6g -
Gb → For point A
,

6max = bat Gb

after half rotation ,

°
: 6A=t6at6b Comin = Ga -

6b

Page 103 of 253

1

Gm = 6at6b-6a =
baxial .

Ga =
6at6b-6at6b_ =
b
bending
2

Sat given
→
, goodman theory .

6M
suit
=

#
101.864mm
'
.
: 32 M = I f : FOS =L
-
t - -

300 xx (2533×133.79 I
↳ infinite life

M = 135548 .
43 N . mm

MIV35.55N.MY

CRPQ 61 , max = 150 Mpa Se =

Set
9. 3 .
( Pg .
No 21
.
) Gd ,
min = -50 Mpa Lt 9 ( Kt -
L )
62 ,
Max =
r > 5 Mpa 250 = 135.14 MPa
-

62 ,
min = 25 MPa L t 2x ( i. 85 -
i
)
Sy = 500 Mpa

set = 250 Mpa . .

6mg , = 50 Mpa Ga , i =
100 MPa
.

Kt = 1.85 Gm ,z = 200 Mpa Ga

,
z = 75 Mpa

DET,
•

:
=

6vm2 = 6,2 -
6,62+622

.
"

6mL =
( 5012 -

(50×100) + ( 10032 °

: 692=110072-(100×75) + ( 7572
6M 86.603 MPa La 90.139 Mpa
-
=
: =

{mzt # to
.

: sat → given =

I
a
: 86.603
-
+
90.139
-
= -

500 135.14 FOS

1--05--1.19=1.21
CRPQ
9. 4 and 9.5 data : Se = 280 MPa

Sy = 600 MPa

cycles 103 → 0.9 Sat

Page 104 of 253

1

A
togro ( 540)

!€¥
04$ fan O =

-
-

log oG80)
,
E-

G -
3

=
logo ( 5h03 -

tog ( Sf)
ro

5¥
/0gpo( 0.95€
logo (420)
log ,o( Sf)
!! ! ! logo
:
( 540)
e

r Ino -

togoland

>
3C? ) 5.301 6

og > tano = togro ( 540)

-
-

109,0680) = -
logo ( 540) -

dog ,o( 420)

G -
3 N -

Nz-3_ 0.382 N 4.148

=
=

logo ( 4.148) 14058.52 Cycles

•

: =

= i. 41×104 cycles
mum

CRPQ ( cumulative damage}

9. 8. ( Pg .
No .2D

I Load
→
Heavy Ni = 10 hrs
2 → Normal Load Nz =
?

Combined
loading ,
N = 18 hr
{N -= nrtnz }
Np = 9.8 hr

Nz = 8.2 hr

F.
'
+ =L + = '

iNz-4i0hrs@CRPQ9.6.lPg.No.
21 ]
②
66

500
N( Failure

IX iOS
) n ( cycles)
to
&

1%8 No = 105
② 600 0.4×105 5 548 Nz = 0.4×105

③ 700 0.15×105 3 3/18 Nz = 0.15×105

ogerm.eng.stgosmeicngtetime.com
n÷÷E
Levin
Insider.am
: -

N 18
④
=

→ Failure after 18 cycle

Page 105 of 253
1

IT +
Iz IT + =

# life in combined
loading
a-

to 5 3
t t = I 30 Sec → is cyc
- - -

18×105 18×0.4×105 18×0.15×105 N 60 Sec → 36 Cyc .

: 42352.94 Cycles
°

N =

of hr 42352.94
°

: No . =

-
= 19.6 hr
-

36×60
-

Em
¥
D=
¥0
CRPQ 50mm →
+ =

9. 7 ( Pg .
. No . 21] Tma , = 2×006 Nmm Tsy
Tmin
¥503) { 725
0.8×106 16×106
4¥ } ¥
= -
NMM 0 . 6
+ =

Ssy = 225 Mpa

Sse = 150 Mpa

i

:F0S=2

→ C- =

Td 's

: Tm = 0.6 KNIMZ
Ta = I. 4 KNIMZ

CRPQ Data : 6ma×= 030M Pa Imax = 57 MPa

-

Q . 09 & 10 Comin = -
130hPa Emin =
IG MPa

sat =
1400 MPa

Ksar = 0.76 krei = 0.867

Ksize = 0.85 kt =
t 85
-

9=0.95

'
097 Ksar X Krell k size
Se =
-
x
X Se
Lt 91kt -

D
0.76×0.85×0.897 O 5 X 224.41 Mpg 225 Mpa
=

-
X -
1400 = I

L -10.954.85 -
t )

107 6µm = O 6× ,
a
= 130 MPa

Exy , m =
36 Txy ,
a
=
20.5 MPa

2
÷
6vmZ = 6×2+3 ( txy ) m
m
:
'

692=6492-1 3( Ixy ,a)

Gm 692=(13032+3120.5) 2
'

62.35
'
•

: =
-

Ga = 134.76 MPa

tom
Sat
-o§ea_ =

pots 9%305-+13242362 =

,÷s Fos=i55f

Page 106 of 253

1

9. I. LL d =
30mm Lomax =

-
160×103 = 226 .
35 MPa

(GATE 2009 ] Pmax = 160 kN Thy x (3032

Pg No 253 Pm in = -
40 kN
Comin 40×103
=
-
= -

56.59 Mpa
Sy = 600 Mpa % x ( 3032

Sy =
420 MPa

Se 240 Mpa
Gm 226.35 56.59
'
i
=
84.88 MPa
-
.

= =
-

6g
1226.352+56.59-1
- '

142.97 Mpa
:
Soderberg
° .

= =

bignyt # =

Eos
°
:

844%8-+14,2%72
=

÷g F0s=to253=rT

9. 100×1032
10£01
I 12 Fma ,
.
= 100 kN Gma , = =
N/mm2
GATE 2013 Fm in = 20 KN
A

( Pg ] Sy fmin
20×-103=2%001
No 253 240 Mpa
N/mmZ
. .
=
=

A
Se = 160 Mpq

Area ? Gm 60000
N/mm2
=
=

FOS =
2 A-

Ga = 400002 N/mm2
A

long t
# =

ITS
÷ -
60000
t -
40000 =L
AT 240 AX 160 2

÷
.

A=1000MM①

In:# fasten :O: times , :* :

"

teaming
'

son . . -
→ r
.

..
.

of rivets ,

•
:
fornax) I # per .

tensile

: F
T Sf
¥)t
* *

tminzqf
'
"

Page 107 of 253

1

Cf .
1.22 .
Comin = -
50 Mpa Gm = 6m6mi = O

[ GATE 2017 ] Gma , = 50 MPA

Z

Pg . No .
254 Set = too MPa
fa = 6max-6m = 50 Mpa

2
Sy = 300 MPa

FOS = ?

¥=÷s
:b

;
*

"

}÷=e÷ Fo

.io#n..=o......=in=s.us
9.2.10 .
tano = 10%0490 togro 70 -

( GATE ) d0gpo(490) #

:i #
2006

10%019,03-10910400319 =

3
>
3 N G
cycles → 281903.59 Cycles

GATE

*
Fatigue behaviour of an aluminium alloy is shown in S N
-

plot .
A piston rod made of
this material is
subjected to :

i > 1000 Cycles at 420 MPa

Ii > 1000 at
Cycles 300hPa

Using minor 's rule of cumulative

damage ,
the
remaining fatigue life ( in terms of no . of
cycle) at stress of 250 MPa at .
-

:¥t¥
^
5

420 -

MPa

300 -

2000 5000 ht

Soo 6 n Nt Minner 's eqn ,

TNz=2
I
-

420 2000 2000

hi
M¥
5000

Ngf
300 1000 =L
t -1

250 no =
? 8800 NT

1000

}°÷
B-
.
÷
=L
+ +
Tooo 8800
Page 108 of 253
1

Axial
Endurance
strength in
Loading
:L
*

> Axial Ise 's axial less strength

.
•

±p•#o.w±P →

2.7 Fatigue Test → Endurance

strength ( se } Fatigue Test

lomax

¥1
.

BM =
IM BM = IM
⇐
Lomax

{ { Se }
Selam.ae &
fatigue loading

toadingfactor-0.cl#
* *
→ →
given only in aus

then used .

Eg .

toad factor =
0.9 given

• .

• Se = ka X Kb X Kc X ke x 0.9×0.5 × Sat
-

It 91kt -

Stress concentration factor

* In static
loading
:# I> lomax =
Kt X Bo

¥÷¥÷÷÷¥
IX
AA & 1133 are

a
.
critical .

" "
Est
' '
'
"

,
→

Tooo °
: bmax 3 Sat →
yielding
↳ Failure

Page 109 of 253

1

Safety Measures
,
I
→ lomax should be reduced .

→ So either increase width or

thickness
•

: lomax s Syt
but increase cost and
- '

efficient .

and B
→
only A

points will yield

99
↳ local
yielding o
strain
hardening →
strength of Material
Resistance of Material TP
•
increase strength can sustain lomax .

→ so
,
No requirement of increasing size of
component .

NII : -
static
loading ,
Ductile Material stress concentration effect is not -

harmful
& it can be
neglected .

brittle material
hardening
→ For there no have strain so there considered
,

stress concentration factor .

Page 110 of 253

1

CHAPTER 5:- BRAKES

Page 111 of 253

1

CHAPTER 5:- BRAKES

from Mls Mls in seconds the
9£ A car increase its speed 10 to 20 20
,
at

constant acceleration

Find distance in these

covered
by car 20 Sec .

→ y =
so m/s V =
20 mls t = 10 Sec .

i> a = V -
U =
20
-
-

10 = L MIS
-

t LO

ii > '
s = ut t
Iz at

(10×10) (r )
Lz
=
t x ro = 150 m
€

velocity

#
second : -

V = ds
I -

20ms dt

✓ yds =p dt
-

②
so
displacement
-194%1 :{Imo ! 77,1mm
•
>
ios
t -7

÷÷:÷t i÷÷÷÷÷÷÷÷
* V =
y t at ② eg .
② → displacement not given

:*
:÷
.

( 24 t at )
2-

I Cutlet )
= at

) ④
tz (
s = Utv

*ra ionmotion:-:÷÷÷:÷÷÷÷÷
Page 112 of 253
1

* Sheldrake :-

"÷¥
""'

i÷÷÷÷¥:÷÷÷÷÷
Kanti
case -2
*arm
.

ke

FBD of Peter :

f-drum f-shoe U M
t c

-4
= =
. -

braking Torque
¥¥IaE¥¥ :*
r

:
.

.
.
e I

EM = O
hinge

(Nxb) ( tsnoexa) (Pic)

°
: t =

p=(Nxb)t(fsnoe effort
-

: →
Breaking

case 2

ciockwise

÷¥÷÷¥¥÷÷÷÷÷÷÷*nn÷÷: ÷¥÷ ke

FBD of Peter :

Braking Torque I c

-4
-

T=fd
,

#
- Mo - o
1@aIatHt7sn.e :$
(pic) ( fshoexa) @ Xb)
•

: t =

÷p=CNxb)zCfshoe →
Breaking effort

Neet : -

[ B) ⇐ ( P]
crock wise Anticlockwise

Page 113 of 253

1

*:: :÷:÷→÷÷÷÷÷÷÷:÷:
Seif locking condition K Beso) for self
; condition
locking
•
←
, .

condition .

* Seif locking is not desirable conditions .

* For the given arrangement ,

self
locking is possible for only clockwise

rotation .

Setfenerggingconditon : -

→ The moments of braking force P and the frictional force f are in same

directions then
about hinge the brake is called as the self
emerging
brakes .

in
"
condition
energiging clockwise direction
"
: self only possible
•

effort is less
braking
°

: .

shoe
¥¥¥Ei÷¥ EE
:*:*

long and short brake

:/
*

O contact
- c- =
angle
y

¥x¥¥#¥
if 05400 ,
short shoe brake { Take it is given )
°
"" Sh " brake
' 9
↳ '
equivalent coefficient of friction
they U

w=ug:si÷co
* *

→ don't use equivalent coefficient of friction in exam if not asked .

Page 114 of 253

1

CRPQ .
0=900 µ
'
=
µ 2-
9. 3 U =
0.3 O t since
I

Pg No . 80 = 0.3 X 4×51%90/22 = 0.33

mm

( ft
90 sin 90

* simple
=
Band Brake : -
→ when one end of belt is connected to the
hinge ,

it's a
simple band brake .

→ clockwise :t

7¥f!"
A
←
-

Drum

"
" " "
9

i¥¥÷÷
lever
breaking torque .

Band / →
Belt
i T= IT, -
Tz } x R

'

c - -

E Mo = O

•
: (Pxb ) = (Tzxa )

p=T2 Self
locking is not clockwise
: rotation
. →
possible in ,

for given brake .

→
Anticlockwise :

:i:¥÷÷
-
breaking Torque ,

A
← Drum

is:c
Belt

oi¥ so
. .

::÷÷÷:
I
"

c - -

E Mo = O

•
: (Pxb ) = (Tr Xa )

p=Tr Self locking is not Anticlockwise rotation

: . →
possible in ,

for given brake .

Page 115 of 253

1

* Differential band brake :-

when no end of belt is connected to

-

the differential band brake

hinge ,
it's a .

Clockwise
-

;¥
.

; FBD of lever ,

→
← Drum

slack
Tight A B
⇐ x c) t ( Fxb) = ( Tzxa)

ppg,,q
,
fever ⇐ × ,, = , ,×a , .
, ,× ,

Tif ft (Hb )
Tzfa ¥ }
:
o

o
M.
= -
.
c

i÷÷÷÷÷."
" "
" " " "

Antickwise

;#¥
A
a- Drum .
: FBD of lever
,

stack A B

ever ⇐ xc) * crab) =

i. xa )
Bana ,
Belt :
.
F. b =
Tra -
I. c
Tf TF

i÷÷÷÷.÷! C Z q ell
O

* tinepressure :-( P }
¥

¥ .. "
.

6Tensile=?
Page 116 of 253
1

E-
.÷¥¥
¥

t.at

↳
From
"
② & ②
eg ,

i > line pressure

, p=_m
do b R .
-

i p R do b T do
-

. . . = .

b ②
.

. .
N =P . R . do - -

p=,T
.

ji > EFy=O

doz { Ttd -13

sindzo
P=T,tigh
+ N =
Tsin :
+

→ Nt =
12T too} sin de
2
b = width of the shoe
DI
sin
doz R Radius of shoe
°
: = =

N =
12T t DT } de
2

0 (
Negligible)
: N = Todo t
dt.dz#
°

•
: N = F. do -
②

Page 117 of 253

1

stack T
÷
T

"
2
.

: T, > Tz
T2
→
↳
'
← t v
s÷: :: : .

-
p T, Upper is stag
Driver Ta ↳ Driven
side .

pulley
Paley

:t÷ frictionless
o

If pulley is
Machine
Design → the driver ,
then the side of belt which is pulled
the the side
on
pulley is tight .

If is driver of belt
Engineering Mechanics → the belt the then the side which tries

to create motion is the tight side .

9.1¥ (Fi Fz) R

¥
Q 8.14 tight Torque
emo
°

. . : =
-

↳ =

GATE 2016 Torque =

(3.248-1)×2
( Pg No 278 ] = 2.248 Nm

3¥
.
.

w
0.25 x
stack
ofI =
e.

µ = 0 . 25
°
: Fa > Fz

O
35£ radian
Tights FL 3 248 No
o
= " , : = .
.

Fz = LN

Torque of drum =
-
( Nm)

R =
Im

9. 6. to
Tight tdr.am " ""
raping angle
" w
-

→
"
"
Yp:!÷?:3, ← berton the drum

stack
f Fz
µ T wrap angle .

FE
a
f
-

D= 0.5M tbert '

O = I 800 I TL

EMO ( E)
2¥
U = 0.25 T= Fr -
or
=

Torque = ? =
( 400 -

182.38 ) X OI
O -
25 XTC z
•
: HOO = e
-

Fz TT =
54.405 N -
m

Fz 182.38 N
•
; =

Page 118 of 253

1

9aia.EE :# Is
" '⇐

0=2 > ox radian .

180
[ Pg ]

|
.
No .
275

¥
ftp.OON
13=200 mm =o.2m

0=2700 O

%#U=
F-
I -1
= LOON

0.5
← Lm → -
Im

¥¥¥t
A "
A
"""

¥
.

¥
.

• pasta o
pot
¥2 ¥
' '

1
- Lm → I -
Im - I /a- Lm → I -
Im -1
" "
Anticlockwise
" "
clockwise

To > Tz To > Tz

lever FBD ,
lever FBD ,

EM 0=0 EMO -_ O

(100×2) =
(72×1) 100×2 =
Tp Xi

T2 = 200N To = 200 N

Fr 7 200 N Fak 200 N

→ clockwise maximum value ,

rotation give

O
T
ell
-

⇐
=

O
Tt ell
-

:
Ex
'

O - 5 X 270 X TY, go
=
200 × e
"

To
"
=
2r4N → Maximum Tension
#

: Maximum Torque = ( Tr -
E) XR
=
Cairo -

200 ) x 2002 = 382 Nam

#
1000

Page 119 of 253

1

9.6.18 P Two conditions

!
a- i. sa :
p ago
- -

. -

GATE 201g

.¥t
r . > Rotation of drum
-
( Pg . No .
279 ) g 2.7 Force Apply
%:*

#
orum.sn

¥¥
.

.mu .
.

tank:O:7w7se rotating to

N =
100 RPM

µ = 0.25
was
P = 2000N
P

-#¥⇐#¥b
?
H
a a- i. 5g
p
=

at
-
-

Lever FBD
,
EE

EYnIa8-icu.n.aya-pxs.s@fsn.e
N ( t tht) = 2000×2.5
4

N = 4705.88 M -
②

Torque U Nxaa
°

: =

250 = 0.25×4705-88 X A

A = 0.2125 m I 212.5mm

¥m
9.4.16 .

- Energy Absorbed = Total energy lost

| by the bract
by sysm
ftp.tno.7:3}
@ e) brake

|
* E) of * *
9-
-
mass drum

-
g- (p
of mass

:
2m/sf ⑨ E) brake '

IA 4- Lz Iwl
i
MV t
mgh
=
.
we +
÷ -_
-

: @ E) brake =

/
x
2000×2*3 ( f- +
i
× BOX
(E))
t
{2000×9.81×0.5}
=
their O J = the . it KJ

Page 120 of 253

1

CRPQ

€4
15200 → -
200 go
and 2
FBD of drum :

( Pg No 80 ]
/ / tfw

¥→¢soo:mn=%m←¥
.
.

F - 300N

TT

II :O: :p .

£ 100 RPM

FBD of lever :

EMO = 0

FX 500 N X 200

// /
=
ft 200
.

2007
.
.
→ -

t o

300*500 750¥
Hp F¥-
N = =

300N
0

f-drum
t-q-dfpge.gg
Torque MTF
- -

= × R = UN
=
µ x N X R

= 0.24 X 750×1502 = 27 Nom

#
1000

€7 Heat
generated =
Energy absorbed
by brake

=
TX O

Wth
tax two
=
Tx *

2K¥ {2%100-+0}
=

=
706.86 Joules
mm

( Wo WE}
'
Heat lost by sysm
Lz
AKE T IN
°

= x I x -
: =
,

Lzx Ig two ) :

4=Wf-Wot
o

=
x -
o

I Word
Lz
=
×
×
f-Wolf ) : f- = -
27 Nom

→
breaking Torque

tzx T × ago
= -

)
5g f
2J%I
27
706.86in
=
x x
-
-
=

Page 121 of 253

1

CRPQ T =
CT -

Tz) th

1509
; ?n !! :O;
at 150mm
°

: 450 ( Tr Tz) X

)
-

:-O:O

µ#¥qµ
b : o. ta oooo
.

-
-

Tre Tz
8=450 N f lo
-

m
stack 220N
Tight Emo = O

, µ, go , , ,w , ,
zoo
# I
#

f- go → A- soo a- 100 -
=
( Tzxroo)
-

.
'

AN dimension in mm .
Tr t 880=272
i
Tt -

282 = -

880 -

②
EMO
÷
.

: Tt -
Tz = 6000 .

:
=

Tr 21-2 880 : 0=180

.
=
-

X I
-

(
t t 180
12880
-

i pm
'

-
UO =

Tz = 6880 µ

Tp = 12880N - '

µ O 1995

0.2--5.3
I
-

=
.

.¥÷
F
Ey
BB at 150mm 2- Mo O
Antic lock
=

peg

iii. " "

÷ :# Iii : ::
"

↳€.f
.
f 2

220N
iis
¥=euo
0.4 x TL

-4 I Tp
#

f- 5o→k-
.

e
.

.
=

soo soo
¥
-
-

Tt = 3.514 Tz -
②
from ② and ② ,

:
( 3.514 Tz) Tz ( Tr Tz)
o

2 - =
880 .

: Fma , = -
.
R

Tz =
145.985 N =
( 512.993 -
145.985) X 150
-

2000
Tp = 512 .
993 N

=
27 . 53 Nam
r u

e
CRPQ F- =
300N
T
is.io:::
"

¥÷÷÷ :
' ""

T=

800
( Ti

= ( Ti
-
Te ) R

300 ) X 0.5
Tight
µ it
,
't

r÷
-
=3 00
~Fz

N
,
stack

.
IT = 2900 N

Page 122 of 253

1

→ Fr = emo
I
0.45×0
.
:
1900
-
=
e
300

O 4.101 rad 4. rot

xl¥ 235dm
°

: =
.
= =

98 Line 6=30 mm
pressure p :
= .

R -
b

P 2900 0.026 MPa

•
=
: =
-

500×30 = 226 kPa

CRPQ
Cf 1091L Find
:µ=o.s③
.

→ •" N

¥¥Y
[
-

Normal Force exerted beth

F- = 600N drum and shoe ?

400
② torque ( Nm)
"" breaking
dramas . .

.
.

¥µ⑦
-

350

t.d.IE
+drum
to > . EMO -=O

.
: (NX 350
) t ( UNX 40) =
(600×750) Lever of FBD : -

: 362N 450000 a- → 600N

¥-¥
-

: N =
1243.09 No = 1243N
r u n I
400
It > .
TE UX N x R ntshoe
=
o . ,×µ , .ae .

=
59.66 Nm = 60 Nom
mm
350*-40
I ←
-⑨% ,
mm

Page 123 of 253

1

-4
IT
ftoo
"
9.6.19 500mm T= forum XR

GATE 2019

#o¥
UNXR

#u=o.ss
Its
=

[ Pg No 279 ] " " "" "

% ? !! 'm"m°
.
.

" mm
drum

c- 1000mm
←

#
0500mm
-

:
(fshoex
EMO

200 )
=

+
O

( 100×2000)

=
(N X 500 )
( ll NX ) (100×1000) 500N
-

: -
200 t =

: 430N = 200000

N =
232.58 N

T.CC#:: :sl/ .im*. : : : :xi*oEMx=0fI-00N

/
← 300mm -
g. 6. if Torque =
f-drum x R
← 200mm →
[ GATE 2018] = µ . N .
R

Y
/ :
( U.N .
300 ) t (100×300) =
( Nx )
200

#
: 110N 30000
-

= " = "" " "

+drum
Oren

Cf .
6.13 m =

2000kg
GATE 2014 Wo =
10 rad Is
( Pg . No .
278] r = 0.2M

* =
LOS

Breaking Torque in each wheel ?

Up 10×0.2=2 m/s Force

.

→ her : Acceleration
.
= = =
mass ×

=
1000×0.2

# = Ui - at ( de -
acceleration) =
200 Nom

at Force

2002=9×10
Up wheel
.

on
•

: = : each
-

9=0 .IM/s2 F =
50 Nam

Fx
'

Torque
-

-
= r

= 50×0.2 =
LO Nam

Page 124 of 253

1

p- 800 #
9.6.12 Torque fdrum R

!
2000N = X
f- ago p
.

GATE 2014

.se#0,. u.nqygo;g,n.a,g=,. .o.goo

an IE =
Ux Nx 0.2

( Pg . No .
278 ] = 0.2×1600×0.2

I
/ f drum
←

tshoe f- = 64 Nom

o
: u=o

,
ya
N = 1600N

9. 6.9 .
W =
80mm .
; F- (Tp -

Tz) .
R

GATE 2070 d = 250mm Ti -

Tz =
10002=8000 Nt

(Pg . No .
278 ] U = 0.25 0.125

0=2700
f- = 1000 Nom .

: PT UO
-
=
e

Maximum Tension =
? ( kN) 72
25×270×54180
EO
2¥
-

: Ti -

Tz = 8000N

3.2481-2 Tz 8000N Tt 3.248 Tz

'

= :
=
-

r
: Tz =
3558.42 N
FL = 11557 . 75 = 01.56 kN
mmr

Cf .
6.7 .

@ om)

#¥
GATE ← 200 400ha ?
breaking torque
→ a-
2007 =

/ /
( Pg .
No . 2776-3
N
f-drum
*

#*tshoe
F -
400N T= XR

÷¥tdrum④¥
o

q
I III. 7375
µ=o 25 .

. 0300mm

IT
£ =
8200×0.0375

A- =
45 Nom

EMO = O

: ( 400×600 ) =
( NX 200 )
: NE 1200
"

Cf . 6.3 . It =3

GATE T2 ENO
T÷
°
:
2003 =

( Pg . No . 275 ] 0--1800 =
1809 = ST
180 JT.lt
3=e
-

i
U =
?
-

.
'

µ = O . 349
'

0.35
#

Page 125 of 253

1

CRPQ

Q .
06 & 07

brake
6 .
> Energy absorbed by =
Energy absorbed by flywheel

( Wf WE} flywheel
Lz
:
cylinder
°
=
II -
→

2- ( Ro Rig
I = 't

I M€2 coz
=
,

2502×20×42512
+4%500-12
TL
= 1- X 7200 X X

¥¥00x÷'T
=
} ,

5. 69 Joule .

/
7. 7 Torque Capacity =
? ( T) * T =
I. X

DE = T . O = IX WIE w
,

t
75 =

Txtzxfw ,
+ wz )

,×µ,=
=m , ayy ×
-

o÷
* = , .
,

60
C -
ve) → Acceleration retardation
" "
: T 7.162 Nm
tracking torque
°
=

Page 126 of 253

1

CHAPTER 6:- DESIGN OF WELDED JOINT

Page 127 of 253
1

CHAPTER 6:- DESIGN OF WELDED JOINT

*
Button ÷

Area of weld for design

A=h
-

Weide

ha Int:! Ise's doingthe

nforcement where ,
'
.

or
-

h Weld size
er
-6
of weld
Leg
→ Reinforcement act as reservoir ,

i > Reinforcement part is not

considering in the
design .

ii > the weld

Hand Peening →

piaammer
↳ Residual compression

case L strength 99
I

"
or

( use design )
l ductile )
I¥¥
weld steel this
→
I.

: .

Tensile = Gx = Go → As MSST
,
Imax =

Spg =

{¥Iog

:÷÷÷ ::

Page 128 of 253

1

Casein •pz\M-_ Pix ha

.ie#onsot.:.omenTxy--P2-
:
s

r - e. - .

ftp.resnear %;
M TO

ooh
" ' 4=0
. .

E;
Imax
Txy ={¥Ios
=

Pfz={¥g=Eos
÷

Casein :

"
" .

f- tho -

÷ :÷÷¥*v
" :* ..

÷÷:÷÷
.
.

62 = -

ve
: Imax =

,J¥z×y
63 =
0

:f¥5-=s¥s=F÷I
a

Page 129 of 253

1

* Lap Joint or
-
Fillet Joint :
-

⑦÷i ±→ •
: Transverse weld
o
: Parallel weld
.

→ The line of action of toad is Line of action of toad is parallel

perpendicular to the weld line .
to the weld line .

Parad-Deri:#y
*

→ Neglected a. o

"
a) l =
length of each weld

gyp I . Total weld

L = htt
length ,

L
t
:
.

h → weld thickness

g-
I
i= 45% Do
ppc
K- to -4
weld

h of weld size of
.
: =
leg &
•
: ABCD → BC =
CD
°

: AD = Act CD weld
DAB C → AC = t cos O h =
too so t t Sino

BC =
t since * *

tsino
t=g;noh+
°
: BC = CD = :

Area of weld plane :

o
: Area = 2X txt ( weld on both side)

×⑥ It since 03
Eo
Pf
A + cos
•

:
o

:
=
f- =
= a-
shear stress
↳ L = 2L hk

: A = ht
since f- cos O

Page 130 of 253

1

For maximum plane ,

DEO
It
= cos O - since } = o

go

: . cos @ = since

i .
tano =L

0=450 → shear stress max at 0=4-5

N
f-
• .

=
•
- -

sin 45 f- cos 45

* *

z → ( throat distance }

Imax
Pt
°

: =

.
L
* *

Emax=¥
important result :

tax parallel weld * *

Ema×=T2P-=P# b. b t.lk
•

: Imax = LP
h.lk

÷ it =
I → throat
angle
52

0=4-5 → throat plane

L Total weld
length
°
: =

AND Transverse weld * *

Ema×=L.2tP=# h .
k th

: t =
I → Throat thickness
1. 21

'

: 0=67 -5 .
→ Throat plane

:
(Emax) ZZ (Emad → parallel weld
experiencing more stress .

trans
parallel ,erse
.

→ parallel weld will fail first .

i÷÷÷÷÷÷÷÷÷÷÷÷
:÷÷÷÷÷÷÷:÷÷÷÷÷÷÷:÷ Page 131 of 253
..
.
1

Both weld Transverse

&
designed by weld
Theory
•

:
parallel are parallel .

mentioned
→
Anything ,
use parallel weld
theory .

weld is conservative
→
parallel theory more .

Q .
3.6

GATE 2006 data : D= 60mm

262 h
Pg . No .
=
6mm

P = 15 kN =
15×103 N

Ssy = 200 Mpa

Imax = VI. p =
Ssy
-

Noth FOS

o
: VIX 15×103 200
-
= -

6×60 FOS

Y FOS = 3.39 I 3.4

CRPQ data : h = 20mm

9. L E = 80 Mpa

Pg . No . 48

C- =
IIP
-

h k .

80×202 N_
Pz
: mm
°
"
x
=
a
N asked
Tm
YZ
mine
565
÷
If =

Npm =

506.5g =
-.65KNImn

±i→
CRPQ data : P = 400 kN
-

g;÷ . . .
II. = 80 ""

.
Total length = ?

hh= romm
V - l -

Sol
-
.
C- = II.
-
P =
-
Ssy
h .
R FOS

: k = 52×400×1032 = 707 . it mm 2707mm

↳ x 80

CRPQ

i→
9.4

"÷÷:*:÷:÷÷:*:÷ : :
.

Porno .
.

: : : ::
.

: . 180 KN load can be taken by ,

Page 132 of 253

1

•
; k = 181 = 45 cm = 450 MM

4
o

: 450 =
100 -12L

L=L75m#T

10=340×103 UZI
CRPQ N
Twerking =

h th
9. 3
Twerking
-

= 80 Mpa

Pg h
52×340×8031
NO 48 :L
25mm
- - .

= =

=
? 15×80

: the = 400 mm

CRPQ tox 6, Imax Syt

I
.
= =

foin:
2. FOS
-

.. a. = .. .

:c. .=e. .

4. t 8. t

f- Exy
P Syt
= LO mm =o .
: =

2
d = 15 mm 63=0
85 MPa Pxi5x
Syf
858
= in
=

X LO 2

:P=O.227Ml#
CRPQ . Circumference.at fillet → circular weld

9. OF .
Tokyo Joint

( Pg No .
49 ] F =P x
( GI
x dat
} = Px x ( 20032 -
②

% Imax =
nT2 .

.
.
L =
Total weld length
h . the

I#

// )
L =
a. dm -

"
= Thx 207.5mm

gomm
I ,
=
205mm

D= Dr + 2h
-
I
210=205-12 ( h ) #
v .
: h = 2.5mm

::::÷÷÷÷i÷÷
→ For hollow cylinder take mean Area .

'
Fe All 05)
°

: 2
110 = : A = -

alto 2. 5)
2. 5×207.5 X TL =
518.75A MMZ

F- = 141972.32 N

. ×⇐u
. .. .
n

: P = 4.518 Mpa 518.75A > 512.5 A 257×102-5=205 TT

P = 4hPa

Page 133 of 253

1

*
Axially loaded Unsymmetrical wedded Joint :

•
: I = II. P
-

Rio
h - L

P, let #
* →
Ppp = 0.707 NRF
to
a

Pz = 0.707 N LIL
yL

"

ici's::::" nori . . .
⇐ x BE
Pz #z→ .
force equal to

zero .

→ since the moment of forces about the center of gravity equal to zero .

: Pry, =
Pzyz
•

: hi Y , . = 12 Yz
-

Assuming total
length of weld as l
,

°
: Ip t lez =L

QUI .
An 200×100×10 angle is welded to a steel plate by means of fillet
welds shown in figure .
The angle is
subjected to a static force of 150 kN

and permissible shear stress for the weld is 70 Nlmm? Determine the lengths
of weird at top and bottom .

data :

←÷ini→sokN2mfmµ±
P,
P =
150 KN
let #
B
FIT N/mm2
'
a- T =
70

h -
-
10mm
"""

⇐ # e III.Omm
Pz # z→
← 100 -4
mm

step : Total length of weld ,

P =
0.707 x h x Lx T

: L 150×103
=
-
= 303.09 MM

0.707×10×70

step weld lengths do and 12 ,

lzyz : dr Iz =L
°

:
try , t
•
=

Kp ( 128.2) 12170.8) ti
.

÷ = t i. 786 do = 303.09

:
dz I 786dL hi 108.81
•

= .
= mm

12 =
194.33 MM

Page 134 of 253

1

CRPQ
9. 08 & Og Given : Imax = 75 N/mm2

10mm weld
+
Lay TL =
I
O h the.

p
" '
a' zoo . .
"
h=t×9;
55mm
L =
377.124 MM
t
-
← Lbt •

: da .

( 145 ) =
Lb (55)
•

: lb = 2.636 da
•

: Force at top weld ,

Pa = 0.707 X Lx h x E
'

: L = lat lb
a

=
0.707 X 103.7 X to X 75 377.124 = da t 2.636ha

54,991 75 55 kN
da=103.7mmT Ans 08
'

N
-

=
.
I -
-0

T
Ca Ans 09

Welded joint subjected to Torsional Moment

:T=
*

Torsional

fF⇐÷t¥
Moment

d = dice of shaft
Y

.
I.i¥± since
*
*
*

: DA = rdoxt .
•
: t = throat size

/ : t I
o -

( rdoxt) ( r since)2
: dI×× DA
.y2 Y IZ
-

=
=

= tr 's sin 20 do . ht size of weld

MOI of annular fillet weld ,

2t.rs/ in2o.doTl=2tr3/L-zC0S2O-dO0- 2tr3f Ef

Ixx 2 for? sin 20 do
= =

! finger ) ! ) of
-
=2tr3 .
-

:
I××=Itr3T
•

Page 135 of 253

1

by symmetry '

Iyy=Iod
Polar moment of Inertia ,

d- =
Ixx t Iyy

:
J=2Ft
Torsional shear stress
,

T =

: I
.

zsttr '
* *

T=z¥
.
:

ESE

Gus . In the welded joint shown in the given figure ,

if the weld at B

has thicker fillets that the toad P

than A the
carrying
-

at
, capacity ,

of the
joint win

A > .
increase g
p•fB
µ ! 1/13
.
> Decrease

C .
> Remain constant T
E
D .
> exactly get double BHap

¥€
case A :
-

case 2
=

Area are

µ 1/1 µ .IE/4weidBis
same in
y
both case thicker
+ y more
. -

x x
E w
-

Happ y
tip
direct shear stress Direct
only shear stress
→
.

Twisting Moment
→

→
.

:( strength) ,
> (strength) z
.

: m = Pxe

Load of decrease ②
:
carrying capacity P is xxx
°

(
.

perpendicular to
plane
CRPQ

Pg .
No . 47 C- = I

#/ °

: T =
2atr2

Tx 2atr2

"
Ei
= "" ""

Foa
¥ .
=
2332.51 Nim

Page 136 of 253

1

CHAPTER 7:- DESIGN OF RIVET JOINT

Page 137 of 253

1

CHAPTER 7:- DESIGN OF RIVET JOINT

"

! automatic header →

in
shneaand.isytoupmsd.in;
a machine
Yess

closing head is

n⇐ . is:* .

±.

Hammering Method
→
.

rivet specified diameter of rivet

by Shank .

:
Eg 20 rivet means rivet
having 20 mm the Shank dice
°
. mm a as .

16
Standard size of rivet : -

12 ,
14 , , 18,20 ,
22
,
24 ,
27
,
30 ,
33
,
36 ,
39 ,
42 and 48 mm .

*
length of rivet Shank is
given by ,

÷÷÷÷÷ :*
'
*
~
:÷ :
.
in
Shank
a =
length portion
necessary to from the
head ( mm,

→ adt sing

°
: d =
dice . of Shank riyet Cmm)

* Used of riveted
terminology in
joint :
-

② Pitch ( p) :-
The pitch of the rivet is defined as the distance beth the center of
rivet in
one to the center of the adjacent rivet the same row .

p=3d⑦

② Merging cm) :
-

The
margin is the distance beth the
edge of the plate to

the centerline of rivets in the nearest row .

m=L.5⑦

Page 138 of 253

1

't÷7
y ±
±

¥1 I
' '

i:-#
-

Ifi Hmm to tammt

. - . - .

-
It
( a.) single ( b.) tap joint
riveted tap joint Double -
riveted with

chain pattern

i:-p # -

Hmm -4
i .

-
It
CC ) Double
.
riveted Lap joint with

zig -

zag pattern

③ Transverse Pitch ( Pt) :

-
Transverse pitch ,
also called back pitch or row

pitch ,
is distance between two consecutive rows

of rivets in the same plate .

(
It %Pp riveting )
For chain

( For
zigzag riveting )

Page 139 of 253

1

⑨ Diagonal Pitch ( Pd) : -

Diagonal pitch is the distance between the

center of one rivet to the center of adjacent

rivet located in the adjacent row .

NOI ,
→
deep joint always subjected to

Mb eccentric
bending moment due to

'• ' "

* II: bending moment causes

distortion of the plate .

← " "
drawback of lap joint .

Mb = Pxt

*
tuft :-
This
arrangement called
butting
yea
.

Strap
t¥

÷ ±÷ i÷ ÷ ÷ :÷÷÷÷÷i÷÷
e.
I
i

9.) b.) riveted double strap

single riveted single strap single
-
-
- -

butt butt joint

joint

The line of action of force joined butt

acting on two plates , joint lies

in the plane Therefore there

same .

,
no
bending moment on the
joint and
no
wrapping of the plates .

Page 140 of 253

1

n =
no . of rivets under consideration

ct-6.04xttmmifts.sn#Impen.::,dpo-r-mupahankdia
.

* If no other data is available .

L . If total number of rivet are known ,

then all rivets should be

considered for design .

2 . If total number of rivets are not known ,

then design is done for per

pitch length .

strength equation
* :-

i>
Tearing of plate / Tensile strength of plate : -

Pt Pt
TT TT TT it TTTTTTT T → Tensile failure of the

¥pmmmnn#
-

at
e.
plate between two

live rivets in
gong:
-

'
-

cp-dsxttttttttti.tt
area =

-
"

A=÷
, +
Pt
Pt →
If Gt → permissible stress

Pt → permissible tearing
Tearing toad
, Pt road

ji >
shearing of rivet A shear strength of rivet :
-

→ shear failure in the rivet of a

= .
single riveted tap joint ,

Ps

↳for .
'=÷ nx

Where ,
Ps = shear resistance of rivet per

pitch length ( m)
d = Shank dice of rivet Cmm)

c- =
permissible shear stress for
rivet .

Page 141 of 253

1

°
: n = number of rivet per pitch length
For
single riveted joint ,
n =L

For double riveted joint / chain

joint / zig-zag joint ,
n = 2

* *

ps=÷d ( For single shear ]

•

:÷::÷
"

iii) of plate / effect

Bearing strength Bearing
: -

→ occurs when the

T T T T T TRY T T TT Typ y f
Pe compressive
between the
stress

Shank

t⇐¥¥f¥:÷:÷÷÷÷÷:ne
-

at
to
of the rivet and the

ft
t.tt t.tt t t t t t t t t t
- -

tip
n

:÷÷ in:&::
hole in the

loosening
.

plate
of the
and

joint .

c
Pc

:
Pc=dt6 where ,
Pc =
crushing resistance of prate per

pitch length (N)

Gc =
permissible compressive stress of
plate material ( Nlm my

* efficiency :-

→ ratio of strength of riveted joint to the strength of un riveted solid

plate .

Strength of rivet =
lowest value of Ps ,
Pc ,
Pt
Where
→
strength of solid prate = F=p.t
'

tf Ptihtichkness
BE = Tensile stress
Page 142 of 253
1

=LowestofµPs,PtandPc
y

d ) t.tt
Pus
F- (p
3.2 0.25
Pt
. .
.
= =
-

GATE 1996

P
tearing efficiency =
? =p t.ba .

°
: (r 0.25 ) p t.GE 0.75 75%
q
I
-

= =
-

Mr

ptt.GE

CRPQ d- = 0.5
p
Q . OL

Pg
Ppt CP-dj.t.btp.tt
No 27
Me
- . =
=

bit

Mt = L -
0.5 = 0.5 I 50%

ESE

9 .
16 mm
plates are
joined together by single riyerted tap joint in

of which of the two will

one the
following ways .
Calculate
ways
give a
stronger joint :

i> rivets
24 mm at 60 mm pitch
it > 30mm rivets at go mm pitch

Giiyen E- Pt = 150 Mta

Ps = 102.5
Sa
Pb = 236 Mpa

SOM n =L
+

case 1 :
f-
Pt =
(p - d) .
t.tt
-
case 2 : -

Pt =
( p d) xtx be
-

=
(60-24)×16×150 = (90-30)×16×150
=
86400 N = 86.4 kN =
144000N a 144 kN

-
Ps = nxtxdxe Ps = nx xd XE

( 2473×102.5 TIX ( 3032×102.5

YE
= I × X = Ix

=
46369.91 N = 46.369 kN = 72452.98 N = 72.45kW
runner

Pb = dt.be on Pb = d. t.be .
n

= 1×24×16 X 236 =
30×16×236×1

= 90264 W e 90.26 kN
=
113280N =
113.28 kN

strength of joint :
strength of joint
.

:
46.369 Is 72.45 kN
°

= =

Page 143 of 253

1

Gus .

GATE 2020

{ PI )
2 location
shearing
"
at

double
shearing
' '

I = F
#

2x d2
k a
double shear .

I = 2 F
-

JTDZ
mm
* *

mm
.

:d=,¥
CRPQ D= 30mm lot = 4014Pa

us .
02 to 04 10=90 mm Gs =
3014Pa

Gc 55
Pg .
No 27 t = 22.5 mm = Mpa

'
Ps nx xd Pt
Me
→ =
x I → =

4 p

L ( 3012×30 21205.75 N 300002

66.67%45000
= =
x x = =

→ Pt =
( p -
d) .
t.tt →
Ms = Ps
=
(90-30)×12.5×40 = 30000 N P

→ Pc = nxdxtx 6C =
21205.752 = 47.12%
45000
= 1×30×12.5 X 55 = 20625 N

→ p =
pot Be . → M = minlps.pt#
45000 N joint p
=
90×12.5×40 =

= 20625 45.834
-
= .

I>
strength of joint = min { Ps Pt ,
Pc} 45000
,

= 20625 N

27 Strength of rivet = min ( Ps ,

Pc }
=
20625 N

CRPQ . A = 15 mm n =L

9. 09 D= 20 MM

Pg . 27 .
p =
60mm
BE = 120 Mpa
E = 90 Mpa

Gc = 160 MPa

Page 144 of 253

1

→ Ps =

nxstqxdxe strength of rivet joint

= min .
( Ps ,
Pt ,
Pc )
=L ( 2032×90 28274.33 Nt
x
28274.33€ 28.27kt
=
X = I

Pt =
( p d) -
xtx lot
=
(60-20)×15 × 120 = 72000 N

Pc =
n . d. t.be

=
1×20×15×160 = 48000 N

Aus .
Two plates each 5 mm thick ,
are connected
by means of four
,

rivets shown in figure . The permissible stress for rivets and

plates in tension ,
shear and compression
are 80 ,
60 and 120 Nlm m2 respectively .

A B c

///
calculation :

I > dia .

of rivet
2> width of plate
efficiency of joint
A 3
B c >

"
som t =
5mm known no . of rivets
"

n = 4
p = 15 kN

by crushing failure
dice of rivets
t >
by shearing : 2 .
> dia .

P = n x TI x d2 x E
'

:
P = nxdxtxbc
4
15000 =
4 Xd x 5×120

15000 4 Xd 2x 60 d 6.25 mm
'

=
X
-

-
=

d =
8.92mm a 9mm

safe dice should select higher value

, d=gmmX
Iii > width of prate by tearing :

P =
(p -

d) t.tt
13000 ( p 9)
-

= -
x 5×80 * *

:p = 46.5 mm ← width of rivet w=5om⑦

I> Ps xd 2x 4 ( 9)2X
Tf 15268.14 N
= n x I = X x 60 =

it > Pc = n × d x t x bc = 4×9×5×120 = 21600 N

Page 145 of 253

1

(50-9)×5×80
iii >
Ptl = (p -
d) t.BE = = 16400 no
AA

th PHB ,
= (p - 2nd ) - t .
bit ⇐

{(50-18)×5×80} tf GI x 92×60
}
=
16617.04 N

strength of joint min 16C Bs }

=
,

=
min { 15268.5 , 21600 }

= 15268.5 MN

P
=p f. be
50×5×80
°
: . = = 20000N

"
M = 15268.52 = 0.7634 I 76.34%
joint 20000

Note : It load is not given then egute two formula which is

any
-

suitable for as per question .

CRPQ t= toad
given
7mm → not .

Q . 05 I = GO Mpa

No 27 Bc
Pg = 120 MPa

: Ps = Pc

Thx xd # E Thx # tx Go
Ig
=

: d tx6c×4
•

IT X I

=
5×120×42 = 17.83 mm x 88 mm
TL X 60

A B c

¥¥f¥
CRPQ t
④Tx
= 7 mm n =3
-

:÷.÷÷÷÷÷ .

: Ps =
Pt =
Pc

II d 't ( p d) rt bit n d. t be
= - . .
= .

:
(p -

d) oft = n . d. be
-

: (p -

183×80 =
3×88×120
: 100mm
p =
99mm =

Page 146 of 253

1

t= 6mm Ps Pt Pc
°

CRPQ : -_ =

9.07 n =
4

Pg D= ? Ps Pc
°

. No 27 .
: =

Bt = 90 Nlm m2 thx xd I =
XI # t x Bc
I =
75 NIMMZ 2

6C = 150 N Imma D=
-
6×1570×4 = 15.27 MM I 15 mm
-

FT X 757

US . 1.21 n = 2

GATE 2017 6 =
I
Pg
!
.
No . 254

gy
.

:t=gfF
9.3.12 and 3.13 data 's n =-3
=

GATE 2013 w = 200 mm

Pg No .
263
t =
5mm lot = 200 MPa

dr= 10mm Gs = too MPa

dh = 17 mm Gc = 150 Mpa

i> To avoid Pc nxdrxtxbc

crushing strength
=

=3 X LOX 5×250

=
22500 N I 22.5 kN
mm

it > To avoid failure Pt (w )

tearing in plate 3d t lot
=

!
-
-

=
{ 200 -
C X11 ) ) X 5×200

=
167000 N = 167 kN
rum

Types
mm
of
-
rivet :
mm
-

Page 147 of 253

1

Loaded Riveted Joint

*
Eccentrically :
-

→ line of action of external force does not pass through the center of

gravity of these rivets , the joint is called eccentrically loaded joint .

let ,
I

Iet
4

ee

¥
YA
step
#
. I

? m¥::::;÷¥.
?÷±
⇐

. .

3
.
4

I 0 ! O AY, Aziz Asks + A 444

g-
t +
→ =
!
t
-

# Art Az + Ast Aq
I -4
ta -

r , step eccentric force can be considered as

Pr P
equivalent to
imaginary force
-

: an
L 2
.

at the center of gravity .

1¥ @ "i?
-

-
-
ri

Pi PI force
direct stress
primary
→
poor shear
shear
,
" stress
p
"
L 2
Pz B

#
' ' ' P
g pi =
Pz =
B = Put =

B
trivets
-

13
µ
'
'
(No of .
boots
i.
'

Pi:÷
-

ri

p;
.
: a
is )
st¥3 Take moment at cog xe
P
.

4
At both rivet center ,

M -
secondary shear force ,
→ T.M. ,
shear stress

're
'

Pa"rzt Pg rz
" ''
Pxe = P, + + Py ray

step 4 It is assumed that the shear force at bolt A rivet

=
.

secondary any
is proportional to its distance from the cool .

P,
" Poe
Carp ; C
so
= =
#

h2trz2_rg2_ry2
' '
Pz = Cxrz
''
B = Cx Rz

Pm
"
=
cxrg
°

:{ Shea force X Radius }

o

; pm = C# A
Page 148 of 253
1

Pz

Is
>
P
"
o

: P, =
R

h2+k2trz2try2 # p,
O

erz 122=132+132
't P
p,
°
.

and : + zpppzcoso
=
-
as soon .

rf+rz2trg2_ry2 i>
if five)
.

O < go cos @ →

Ii > O > 900 cos @ → C ve)

-

step
=
-
5 .

Primary and
secondary shear force are added by vector addition

method to
get resultant shear force .

#
40mm
Pus .
3.17 .

400N
GATE 2015

-
* "
"" " " ]
•¥
/ 4 I 3
) µ =p , e

2
Y x

500 ↳ Perpendicular to
plane (Twisting)

Find : -

Magnitude of load on the worst loaded rivet :

"
pp,
' ' ' '
II ← 500N 22 Pr =
Pz =
Pg =
Pg = 500Mt = 125 ng

Ttp AT
⇐

a
R
T
! p 13
"

pi
'
pi 're '

?
B' rst
'
go p×e = r, t t Pu 'm

/ purr ra
p .
B
' '

$3 Pi
:
o

= Cxr.

H
T Bri #7
45
.
Pa
' '
=
cxrz
Pg
'
'
B ' '
Pg =
Cxrz

"
f- 40 -

/ Pari =
Cxrq

" f.
55
¥ '
.
-

So /
28.28mm

r,
due to

rz=rz= By
symmetry
= 28.28mm
,
o

; C =
-

r, Z
t
Pie

rz2 t rzZ try

2
"
=
mm

¥
T
°

: C =
-
400×500

40mm 4 X
( 28.28)2

' ' " ' ' "

pp
N=
Pa Pg Pa 62.5
°

28.28 C 62.5
•

: = = = = x : =

mm
1767.5 Nd

For Joint 2
,
132 = Part 1392 t 213
'
.
pz
''
cos 45

132=42572 t ( 1767 5) 2+2 ( 125) ( 1767

. . COS 45
" " "

Pz
"
•

: B = =
1857 .
9g no -
criticallpoint → wworst loaded rivet

Pr 1681.43 N
Pay
-
: = =

Page 149 of 253

1

÷::::÷÷÷÷÷÷:
Note : -

design of Rivet 2 ,

=q÷
Txy ,
6x=0
, by = O '
: Pz → Resultant load on

rivet .

Pz
f
• .

.
- =

Faz LEOS

holes of M 20×2.75 mm bolts

9¥ .
3.7 .

g-

¥#
n.a-romm.tn/./ o/t#ot....
GATE 2007 20mm F = LO KNT * Maximum shear stress

[ Pg No .
262 ] (MPa) in the bolts A- and B .

C
40mm

trot A
i. clap
2 2
.

#
20mm
"
* Btp !
F. e

sso -
n

#f
,
mm
'
Pi
Pp 's 131=13 '
1030-00 3333.331W A
=
= '
p,

Pxe 10×103×150
q C 468.75 N
.

= =
-
= -

rift re 2x ( 4032 mm

" 't
:
Pp Pz
°

= = 468.75 × 40 = 18750 IN

Pp Pz 4M¥72 44333.3372+-4875072
•

: 19043.99 IN
=t9.04kNm
= = = =

Pz =
¥2 = 3333.33 N

P, Pz shear stress at A and

°

: = → C

Pz → shear stress at B

(Imax) Pi 19043.492
•

: =
Ema , = = 242.47 MPa

YI d2
A. C 2
× ( a) = 242.6 MPa

÷÷z
'

:
⇐ max ) =
= = 42.44 MPa = 42.5 MPa
,

Page 150 of 253

1

GUS . 3. LO .
Direct shear stress ( MPa)
,

GATE 2010

'
D= Pr
Pg 104002
6mm =
= No = 250 N

Le =
22mm

qI.gg
" "

C-
EEIIa
°
:
primary
= =
= .

QUS .
3.8 and 3.9 .

data : - A = 10×50 MMZ

GATE 2008 db = 12mm

P = 4 kN
m m

f
¥1 < Le kN

v.

' '
Pi Pa
4021
=2kN-
°

: -_ = 2000N

Pigs g.
=

pzr ,
pzr
,

c=

'tI H2 -irz2
r
. re
'
P
4000×20002
NP
, p
=
= LOO
M
20032 2 (
←
''
P.ee
°

: P, =
Pz
' '
=
too x 200 = 20000N

: pr"=20

: Pine (P,
'
)2+ ( PI 'T +
'
2113 ) Cpi ) cost
'
80

Pi = 18000 Nt

°
: C-resultant =
Pi =
-
18000 = 159.15
-
Mpa

£ ( iz)2
gTI×
Resultant I d2
Shear stress on bolt P
4

\
I LOO MPa
CRPQ =

#
L

9. 8 D= 20mm

Pg No 27 100
z

#
.
.

100

#
4
→ for

Page 151 of 253

1

design load for critical rivet

→
Always a .

#→
' t ' '
p, p,

Rivet 2 and 3 are same

k¥-13
" s

: O > 90 R will less .

0590 R will high

a¥→pJ '
Poe .

#
Bro B 3 So Rivet 4 are critical
, .

'

# I
pyo
. Pa ' 4
pp
'
=
Pz
'
=
Pz =
Py
'
=

4
•

: e =
Px LOO
-

(30032 f- ( 10012 f- ( 10032+130032

C =
13×1002 I
200000 mm

part = Cx ray

23×300 31¥ N
=
=

Pq 3210 2032
:
•

+ =
100 x x (

: P =
78539.82 N = 78.54 kN

Us .
3.18 .

GATE 2015

:÷÷:÷÷÷ ties: : " .

'

301€
* mm
,

40
-
I
.

t
.

F-
"

250mm -
/
I
' ' '
por Pg Pz B
903002 3000 N
= = =
=

p p
. -

pro °

: C = Pxe
Pin
H
-

Q rft re

9000×2502
42250 kN mm
NB 1250
.

µ
= =

'
( 3032 ( 3032 MM

¥
Re t
-
,
" ' '
Pg .

.
.

P, =
1250×30 = 37500 N

Cpr ) 't (B )2
' "
P, =
-
'

C- 37619.80 332 632 MPa

boot p
.
= = .

=
Z
( 300032 t ( 37500 ) 2
=
× ( i 2)

= 37619 . 81 No

Page 152 of 253

1

9.3.20 .

anew "

#¥¥#m→µ
'
Pfe Pz
603002 2000 N
n →

pit
= =

' '
p, B

-4¥
2

Pie 6000×2502
Nrp
→ c = =
= 300
.

# 2x rz2
502+15032 ( MM

P
, p ' '
Cxrz
pz = =
300×50=15000 N

÷
Pz2= (PI ) ( Pz ) 't
' '
243 ) CPI ) 0
' ' '
t cos

Z
=
( p ooo )2 x ( 15000) t 211000) ( r -5000) cos 0

Pz = 17000 N =
t7kNm -

ppm
II f p 22
→

P ' # Ant
Trip .
"

100
t

/ Pa "

?¥
4T
Pa .

!÷ Brr #^
.

+ LOO -
-

/
P, ' =P, ' =P, ' -_
Py
'
= I
4

pzt
1004002
.
÷ = =
2500 N

: Pie
o

C =

4×432

=
20000×400

¥70132
=
200 Ne
mm

pz2= (Pz )2+ ( Pz ) 450

- ' ' '
Pz
'
243 ) ( pi ) cos
" ' i
• .

. + : = 200×70.71

= ( 250032 t (14142.1332+212500)/14142.13) cos 450 = 14142.13 N

P2 = 16007.805 N =
16.00kt
'

I 16 EM
Page 153 of 253
1

2
US . 3.19 A = 25 mm

GATE 2016 T = 200 Nom

¢uasrµ#
ri = rz = B =
By = 50mm

f- purr

: C =
200×103 ( N - mm )
-

4×150)2
2
" mm
"

some
c
-

''
✓
Pr ' ' '
=p!
" ' '
p, = Ps = Pa = 20×50

=
1000 N

#
' ' ' '
part Pr =
13 =p, -
Py =o

12=1000 ht
-

: due to
only torque there

force Emax
Rf 10,0¥ N/mm2
°

:
only shear 40
=

secondary
= =

mum

Ies . A steel plate subjected to force of 5 KN and fixed to a

Channel by means of three identical bolts .

The bolts are made

of plain carbon steel 30C 8 ( syt = 400 NIMMZ) and F. S . =3 .

The

diameter of the Shank for the bolt ,

i
L
# l
.

F-
250mm

I
' '
Pzl
por Pr Pg
50301 1666.67
= = = =
N

p p
. -

pro r, = rz = 75mm

Pip a
# t 1250 kN mm .

#
1250×00313
Pie
MZ
'

TZZ )
Skov
C =
=

Z
p t 2X ( 75
¥B
R
-
,
"
'

Ne
°

.
C =
111.11
mm

" ' '

: Pr Pg 75 8333.33N
-

= = iii. ri X =

: RE Cpp )2t '

( pi
'
)2
'

:
Txy =
I = Syt A = 127.48 mme
A
=
( 1066.6732 + ( 8333.3372 2 FOS
D= 12.74 mm

R M 8498.37×22×3 d
°

: A i3 mm
8498.37 :
s

= = x

400
Page 154 of 253
1

concept g-
e-

pz
-

J D-
-

J -
⑧
f
hear)

/
Pa
( normal)

" "

Py ( shear) Py ( shear)

! Pz2
PIA P.IN by
°
Z
: 6×
R
Py t
°

Txy
= : = =
= 0

I .

Txy =

PAL = C-max =
SYL
2x FOS
.

: Emax =
Tiz =

,/¥YtTy = SYI
2. FOS

* Eccentric toad perpendicular to axis of boit : -

E- e

L L
I
I
-4
O_O
to
!
I
I -

.
I

¥0
I 122

Eoc

→ Force P results in direct shear

=
I force on the bolts .

- ⑨a
- . - since the bolts are identical the
←

!
,

E shear force on each bolt is

pi:pi=÷÷
' ""

-
②
.

I
Es → Moment ( Pxe) tends to tilt the

bracket
-
-

about the edge C .

Ec each bolt stretched by an amount

(8) which is proportional to its

vertical distance from point C .

Page 155 of 253

1

: Sp X de Ato Force x stress

o

82 A 12 Stress a strain

strain a stretch

bolt
→ let it conclude that
resisting force induced in any ,
due to
tendency
of the bracket to tilt under the moment ( Pxe) is proportional to its distance
,

from tilting edge .

"
P, e, : Pi
''
Cle
°

a =

.,p,µ=p.e.e÷
'
Pz
"
X Lz Pd =
Cdz .

.
.
P, "
=
P .
e. do

2¥51
Ergo
÷ ope .

,
zp.me , + zp.me , -

②
-

: Pe = 2 ( Cli ) hi t 2 ( Cle) lz 211,2+122 ]

Pe Clf 2422
°
: = 2 t

•
:
Pxe
C =
-

211,2 t tf)

→ Bott denoted by I are

subjected to maximum force .

located farthest distance from

→ A bolt which at the the
tilting edge ;

it subjected to maximum stress .

eg ② and ② give shear and tensile forces that act on the bolt due

to eccentric road perpendicular to the axis of the boot .

Primary shear stress → direct shear stress

Axial
Secondary shear stress → stress

Tip A
A- = Cls
diameter
area of the boot at minor or core

8t=Pi
→ bolt can be designed on basis of Principles or Principal
Khan Kine)
shheoy .

( Tresca 's )

4¥42
-

It
'
or
O D

.
=
+ t t

Imax
,/({I}2
' '

Page 156 of 253

1

°
: 6, = Syt o

: Imax = Ssy =
-
Syt
-

FOS FOS 2 FOS

→ The bolt are made from ductile ,

so
appropriate to use maximum shear stress

theory of failure .

⇐ A wall bracket is attached to the wall

by means of four
identical bolts ,
two at A and two at B .

held
Assuming that the bracket is
-

I #y 500mm
against the wall and prevented from
four
¥ by
125km
A
a- ÷ .
-

tipping about point C all

|
boots and allowable tensile
-
using an

I # Stress in the bolts are 35 N/mm2

-

I
÷÷÷÷÷÷:÷÷÷÷÷÷÷:÷:÷ .

B
-

=
50 mm -

-
c

Given P 25000 N
SI .
=

e = 500 mm

( Gt) max = 35 N/mmZ

'
Pp
'
= Pa = P 25000 6250
→
=
= N
g-
-

No of bolts

direct shear
62n.SC#N/mm2
: stress
.

,
C- =

↳diameter
core area .

→ C =
Pie →
µ and lz from point C .

2. left 122 )

25000×500

NZ
=
-
= 20.49

( 5502 502 ) t
mm

' '
pp = Cx dip ← bolt A resist maximum load
=
20.49 X 550

=
11270.49 N

→ Tensile stress
,
be =N270 N/mm2
A

Page 157 of 253

1

According to MPSF
,

6,
It -1,1¥) 't T2
→ =

=mzon t
,/tF
6, .
A =
5635.25 t 8415.37
6, 14050.62
Nfmm
.

: =
2
A-

-→ Gma , = SI °

: d =
22.60mm EE
FOS * *
D= 30mm As
design
←
per .

: 14050.622 =
35
A

→ A = 401.45 MMZ
* *
As per Standard Are 561mm 'd
,

CRPQ 5kW
I

9. H <250m# n -
4

-y
-

75 P=
Pg .
No - 39 5000N
A
- - - - -
→ -

e = 250mm

" mm .
÷:
'

75
do = 0.8 d
T
-

bgtt
'

504002=1250
'
pi = Pz = N 6, =

N/mm2
I
t2a50
•

: =

Go 801.28 1484.78
=
- t -

A A

p,
"
Pxextr
•

: =

211ft 122)
¥Y¥
: 2286.06
=

5000×250×3752 = pgoz.gg N
At
=

213752 t 752) .

: A = 30.87 MMZ

dc= 6.188 mm

→
Lot =
PIE = 1602.56
N/mm2
A A- → .

: dc =
0.8 d
→ D= 6.1-88 = 7.7mm
=
0.8

Page 158 of 253

1

→ 1751i 250 I: 75ft

p pox 103 N

47¥
=

÷iq
i i

\
syt= a -00 Mmm '
FOS = G

nomiifaldqao.glaborted )
" kN -

omm-l
-

f.
'
'
Pz
104002
→ P, = =
=
2500 N

C-
Prat 25*002 N/mm2
= =

't
→ p, = Pxexlp =
10000×550×3-25 =
8033.71 No
-
-

211ft LE] 2 [3252-1 752]

bit
=Pgf =

8033g.IN/mm2
#

6.
# TIKI) 't
=
T2

=
8033.31
Ta +4803¥
¥42 { 25A0 2 t

Gi Syt dc
8741.782
: 8D
°
=
= = o .

FOS D= 16.16mm a
i8mm ←
An⇐
8747.78 400
= -

A-
c
G

MMZ
:
AI
°

131.22

d = 12.98 MM
c

Page 159 of 253

1

CHAPTER 7:- DESIGN OF THREADED JOINTS

Page 160 of 253
1

CHAPTER 7:- DESIGN OF THREADED JOINTS

*
Terminology of screw thread / bolt and Nut thread : -

→
Right hand thread always use
,
instead of left hand thread .

is Diameter :-( d)
Major
crest for → external dice .

root for → internal dice

Toto
.

→ Nominal diameter

it > Minor Diameter ( dc) : -

root for → external thread

crest for → internal thread

→ core or root diameter

iii > Pitch Diameter ( otp) : -

→ width of threads equal to the width of the spaces cut by the surface

of the
cylinder .
It is called effective dice . of thread .

Iv ) Pitch ( p) : -

→ it is distance between two similar points on

adjacent threads measured

parallel to the axis of the thread .

V> head :

→ head is the distance that the nut moves parallel to axis of the

screw
,
when the nut is gives one turn .

Vi > thread Angle :

→
Angle included between the sides of the thread angle is the

angle included between the sides of thread measure in an axial

plane .

Thread angle = 600 for ISO

* -
Uniform Bott :
-

pen h
ante read Part

P←①7tm/→p
Header
k-hs-sk-L.ms/
.

:D

( 6) Shank
> do

e (6) threads

( ) Shank
U 3 ( U ) threads

↳ Failure of threads is
more
likely .

Page 161 of 253

1

→ strain
energy =

÷ x P x SL

Pish
=
Lz ×

AXL
x AXL

Ly
: U
°
=
x 6 x E X A X th

: U
Lz 6
f¥X AX k
°
=
x X

* *

÷u=g÷×a
* Uniform : -

A bolt is made uniform

strength by :

② Reducing the Shank diameter

② Drilling hole inside the Shank

③ Increasing the Shank

length .

Eh ante In read Part

← ←

Fiat
- - - - -

← . .
- - - - - t

Headed

k-hs-sk-h.ms/Bshank= 6th read

p p
-
E -

F- { din)
¥xdf
'
d -

:
dh2=d2_dc⑦

Page 162 of 253

1

D= 12mm

aa¥E%ii ←J-②mmgmf→p
A- threaded =
84.3 mm2

hthread -
- 30mm

-
mmmm Lnormal =
8mm

E = 200 Gpa

Find : -
effective stifness of the bolt ( MN IMD =
.

zoon .

Axial
loading
Bankim mkmi→p
,

s =
PI -

AE
Ke
Pammi p
Anginal stiffness Egg AET
-

→
.
: K = =

in series ;
spring
°
: 8, =
I Sz = I •

:
8e= I o
: Pr =Pz= Pe =P
ki K2 ke : sit 82 = Se

Se Sit 82
°

: =

Xd 2)2X 200×103 06
NITE
K, The

II. It
. .

.
= = 2.83 xp
= *
mm

84.3×200×103 0.56×106 I
the Fe ¥2
•

: = t
Kz = =

, T o mm

"

the -_

.se#.-o-tmhmrooom
a 0.56×106

1000 NIN
ke = 467492.62 N_ ×

mm to -m

ke=¥
* *
* Initial ing Pretensions
Tightening -
Preload
Head
Cylinder
# Assembly Bott

¥%'ygPT
# p
P P

-1¥
,
Connected Member

i#µ¥ '

j
'
← Cylinder

Page 163 of 253

1

→ due to initial
tightening the boot is elongated and the
connecting
members are compressed .

Loading due to initial

Tightening Pr Initial
Tightening Load
.
=

Loading due to External

Loading ,
P =
External Load per bolt assembly
Pb = Force on bolt due to External Load P

Pcm = Force on connected member due to

external load P

Resultant
Loading ,
Rb =
Resultant load on bolt due to external Load P

initial
and
tightening
Rcm =
Resultant load on connected members due to
and initial
external load P
tightening
Rb→= Pit PT & Rcm→ = Pit pcm→

Kb =
stiffness of boot
Kem =
stiffness of connected member .

:c=µt# combination stiffness factor

•

force dikyinder
Total Px
tax
÷ =

N -_ no . of bolts

Force bolt Totalforce

on each assembly , p =

No .
of bolts

Force in bolt
assembly
P =
Pbt Pcm - - - - - - Ct ) → indeterminate case
,

* Sb =
8cm

fail t :#Im ÷=¥÷

'
-

% Pcm = Pb .
Kerry . . . . .
(2)
Kb

② and ② Pbt
kcmkb
combined eg . P = Pb
,

Page 164 of 253

1

Pb =P
Kbkbttkcm
:
°
*

|Pb=p
**

: Pcm
--Pf*IIm×¥÷ )
.

* *

Pcm=Cr-c)×#
* Resultant Force IR }

:::::s:r
i

L . > { i -

c) xp > Pi → Rcm is tile

Tension

Leakage will happen

2 > . Pi > ( t -

c) xp → Rcm is -
Ve

compression
Leakage win not happened

"
→ leak proof condition "

Rcm €0
( t -
c } xp g pi

* Minimum condition
,

{ r -

Cf P =
Pp
.

CRPQ Pr 5.3 kN
.

Cf . 04 C = 0.25 kN

Pg No . 38 P = 9.6 kno

Rb = Pi t C P -
Ram = ( r -
C ) P -
Pi

= 5.3 t (0.25×9.6) =
{1-0.25}×9.6 -
5.3

Rb =
7.7kW = 1. g kN

Rcm, Ctve) is happened

* → value →
leakage

clues .
The ratio of toad required to open the bolted joint to the

load with stiffness part is

initial
tightening of the
matting
equal to four times stiffness of bolts is
mm
.

Page 165 of 253

1

Soo . P → road required

-

pi →
initially tightening toad
Kem =
4 x Kb

:c = kb_ =
Kb_ =.
I = 0.2

kbtkcm Kb t 4 Kb 5

To open the boot joint →

separating the plates
: Rcm Z O
.

Rcm = O

( r c) -
p -
Pi = O

66 33
P
# 2%-2
;
•

off 1.25in
=
= = =

PT .

CRPQ d cylinder E 500 MM

9. 06 ME 8

Pg .NO . 38 P =
20bar =
2 MPa

{ t bar = 105Pa = o.o MPa }

Kem =
3 X Kb
Kb
C =

FEM
=

÷ = 0.25

External toad on Total external road 2x × (

50032=49087.39 no
B =
-
= -

8
,
each bolt of boots
assembly No .

→ua rooF7n:
heatproof joint → Rcm SO * More Pi PP

c.
PIT , o

pi = Pcr -
C ) are more .

= 49087.38 ( t -
0.25 )

=
36785.54 N I 36.79
mmmm
kN

CRPQ .
L =
40mm { two 20 mm thick plate )
9. 08 & 09
Kem = i. 7×106 N Imm

Pg .
No . 39

i > Kb =
AI
k

N5X25 0.575×006
NUO
=
=
mm

C =
Kb 0.557×106 0.246 I 0.25
=
- = - -

F.
Kb t Kem 10.557 f- i.
71×106

Page 166 of 253

1

hi >
safety → No leakage create proof joint )
Yielding of bolts

L . Leak proof joint Piz tr -

C } P
,

minimum
,
Pi =
(i -
c ) p
.

0.8
Syt X A = (r -
0.25 ) XP

0.8×650×185 = ( r -

0.25 )x P

P =
79.7 kN = 80 kN
r u n

2 . Avoid yielding of boots ,

Gb f Syt
minimum lob =
Syt
,

Gb =
Rts =
Syt
A

Pit Cp
:
Syt
°

=
-

: 0.8 Syt At 0.25 P Syt A

°
. = .

P =
59800 N
P I 60 kN
+

→ if p= 80 kN select
,
so leaking is not happened but
yielding of boot

take place .
So at 60 kN both are safe .

* Bolted Joint -
simple Analysis : -

de =
core diameter ( weakest portion)

Maximum tensile stress in the bolt at

this Cts is given by ,

8max=¥× mum

'

h
'

→ The height of nut can be determined

boot
by equating strength of the in tension

with in shear
strength .

Shear in bolt ,

P de SI
QI ②
=
:
•
. . . . . -

FOS * I =
B-
Ix d2
4
→ threads of the bolt in contact with
the nut are sheared at core diameter do .

Page 167 of 253

1

A- shear = IT .
do h .

: p = IT .
do h . .
SI
( Fos)

P = IT .
do h . .
Syt . . . . ②
ZCFOS)

comparing both ed '

doe q.io#=Ttd/oh ?I
→
.

: do 2h
•

: h = 0.5 do
but
,

dc÷°h8fo.i
Assuming ,

QIU .
Two plates are fastened by means of two boots .
The bolts are

made of plane carbon steel ( syt =

400 Nlm m2 ) and Fos is 5 .

Determine size of bolts if toad is 5kW .

Soph . P = 5 KN T = P_ =
-
Ssy
A
e-

Syt =
400 N/mm2 FOS

Fos = 5 5×1032 = 400

2×5
N = 2 2x TL x d2
4-
: D= 8.92mm
•

→ Nearest size MIO •

_#

Q 3. the n =3 T =

¥ ÷gz
.
=

n
GATE 2014 Ssy = 200 Mpa

€103
Fos 2
20202
= :
=

D= ? 3x Ex d2
4
P = 19×103 N

"
D=
"
•

: 8.97mm standard
→
MII
if we select
,
D= 8mm Jarrow = 100 MPa

Td = 8mm
=
126 MPa > Farrow = 100 MPa → Fails
=

* Gasket
:#

without gasket
y ,

plate

7%4
£

2 plate

Fi
÷m=÷ty
Page 168 of 253
1

T with gasket ,

Jt

ai://i.io
I prate

÷=¥¥+i- y
Rcm = -
pit (I -
c) p

introducing gasket ,
If
Kem
Kant

: .
C 9 : . { i -
C ) ta
: . Rcm to →
leakage change will decrease .

/
Case :
I
-
if Pi More
,
#

: Rb =
Pit C. P let Kem >7 Kb
,

Assume Kam = 4 Kb

Pmax =
Pit C. p
-

i
'

C = I
5
Pm in = Pi

:÷÷÷÷
"

::
"

:÷±:*
→

2 LO

: .
Pm e pi D Paro

C kb_ G AI
•

: =
K =

kcmtkb k Goodman theory o

,

IMI # Fos
Kam >> Kb
t =

→ static design
Fos pays

Advantagedg
:L . > It secure parts tightly .

2 > . It avoids leakage .

3 .
> It reduces the amplitude of fluctuation in load there by improves
the fatigue road .

4 > . Pre
tensioning helps to seal 1 prevents the leakage from the pressure
vessel .

5 .
> It is increase fatigue life .

G .
> It increase tensile stress in bolt .

> .
> It decrease stress amplitude .

Page 169 of 253

1

increase
8.7 It stiffness of bolted joint .

9 > . Pre -

loading in
fluctuating loads improves FOS .

* stresses in Bost : -

RB A- =
( d? at

T "
airing Area
Bearing tcrushing
f ?
,

¥¥¥⇐E¥÷
,µµµµ
I f I

I 1- →
shearing
:* .

"
thread
b- -
. -
d-
9
.
.
-
.
-
. -

A- = B. JL .
do
•

: D=
major dice
+
.

RB de = minor dice

B = width of thread

N = No .
of thread in constant

→
Height of each thread = 2B

For square threads ,

→ Height of nut = N X 2B : . B = I
2

→ Tensile stress Gt = p= pitch

,

de

→ shear stress at the root of thread ,

I =

N x xx dc x B

±yY%gµ-
&
→
bearing ( crushing of thread
, bearing
=

CRPQ D= 36 mm

9. 02
Syt =
280 Mpa

Pg .
No . 38 FOS = 2.5

do =
0.84 d

ft Syt
'

: =

FOS

¥3gE 38¥
.

: P 134066.49 N
134k€
= =

Page 170 of 253

1

CRPQ Rotation work = Linear force

Us .
03 T X O =
Pi X S

Pg .
No . 38

One rotation 0=2 lead

→ a → 8 = =
pitch =
4mm

1.4 2x Pix 4
'

X
-

.
=

Fi, =P ; = 2.2 KM

Page 171 of 253

1

CHAPTER 9:- Friction Clutches

Page 172 of 253
1

CHAPTER 9:- Friction Clutches

→ clutches is mechanical device which is used to connect or dis -

the of from
connect source
power the
remaining parts of power
transmission sysm at the win of operator .

Clutch the to without

can permit engine run
driving the car .

basic difference beth clutches and

*
couplings :
-

→ A is
coupling ,
such a
flange coupling ,
a permanent connection .
The
driving
driven shaft of it is
and are
permanently attached by means
coupling and

not possible to disconnect the shaft ,

unless the
coupling is dismounted .

→ clutch can connect or disconnect the

driving or driven shaft ,
as and when

required by the operator .

* Basic difference between initial and final condition in clutch and brake

operations : -

.ae/:ti:IE: : : : : : : :./
clutch
-
Brake
-

L . Initial
-
condition L . Initial
-
condition

is is
→
driving member
rotating and → one member such as brake drum

the driven member is at rest .

rotating and the
braking member

ioitmnionisrot.in .
"

same speed and have no relative relative motion .

motion .

* classification of clutches :
-

③ Positive contact clutches :-

I> square jaw clutches

2> spiral jaw clutches

37 toothed clutch .

→ Power transmission archived by means of interlocking of jaws or teeth .

→ Main
advantage is positive engagement and once coupled they,
can

transmit large torque without slip .

Page 173 of 253

1

② Friction crutches
1 .
> single and Mutti plate clutches

2.7 cone clutches

3 . > centrifugal clutches

transmission is archived by of friction between

→ power means
contacting
surface .

③ Electromagnetic clutches :

L . > Magnetic particle clutches

2 .
> Magnetic hysteresis clutches

3.7 eddy current clutches .

→ Power transmission archived

by magnetic fields .

→ Those are rapid response time ,

ease of control ,
smooth start and absorb

shocks .

* Square jaw clutch :

-

→ simplest form of
positive contact clutch .

Socket → Jaw clutches can be

EI
? I
.
Used

shaft
,
when

is
the
driving
stationary or

low speed
rotating at a .

Jaws
← n .

Square Spiral
1.
engage at

slightly high
speed without

clashing .

Shift
← →
levers → Frequently engagement
results in wear of jaws .

Advantages 3- 1.) do not slip and

engagement is positive .

2.) No heat generated during engagement or disengagement .

Uses in
→ power press ,
rowing mins .

Page 174 of 253

1

single Plate Friction clutch

:*
*

why springs in parallel connection ?

i > in series connection ,

force are critical
at all sections but in parallel connection

force are distributed on each of the

springs .

27 In series connection if one

spring is

→ springs broken so all the connection are

in parallel
disengage but in parallel connection

it is not possible .

37 in clutch we required radially force

so that why we
go for parallel
connection .

engagement force is provided by friction

→
.

engagement force is axial .

→ Friction force creates torque .

f- = UN

p > f →
pressure cross the friction limiting force
↳ slip creates → non positive type clutch .

*
Advantage of friction clutch :

L is smooth
.

engagement .

2 .
slip occurs
only during engaging operation and once the clutch is

engaged ,
there no slip between the
contacting surface .
Therefore power toss

and consequent heat generation do not create problem ,

unless the operation
required frequent starts and stops .

3 .
In certain cases ,
friction clutch serves as a
safety device .
It

slips when the torque transmitted through it exceeds a safe value .

This prevents breakage of parts in transmission chain .

Page 175 of 253

1

Torque Transmitting ( carrying ) capacity :

-

÷÷÷÷÷÷÷
.

// //
Pa = Axial Force

: BP → PNP → Pap
K
Friction Torque 99
- d -→

c - B -

B =
outer diameter of friction disk ( mm )
d = inner diameter of friction disk Cmm)

@ 1mm )
'

intensity
' '

p =
of pressure at radius r

P Force required to the clutch ( N )

engage
=

T =
Torque carrying capacity by the clutch ( N - mm )

'

intensity of be
' '
→ radius be constant
'

p at r
may may
or
pressure
variable .

For the
ring ,
element area = 2 arr . dr

axial force rdr ) Cpr

element =
µ ( 2x = 2x . dr )

element friction force =

ii.
p
.
( 2x )
rdr

element friction torque = ii.

p -
( 2 Ttrdr) -
r = 2AM ( pr 'd r )

→ P =
J 2x
( prod r ) → T =
I 2am
( pm . dr )
** * *

P=2r.dr T=2auo%?pr2
Dt2
. . .. . ② . . . .
②
dt2 dt2

I> Uniform Pressure Theory :-

→ In case of neueciutches employing a number of springs ,

the pressure
remain constant over the entire surface area of the friction disk .

Assumed , p=consta
Page 176 of 253
1

DIZ
P =
2K
) D. r dr
.

#
to
=3 -
dk

ax.p.IE/Iii
ro =

**

K¥0 P=ajpfD
-

. . . . . ③

0/2
↳
1- = 2am .

dlz
J por
? dr

p=¥d
13/2
2x M Po
Idk
= - -

;
T=µ.P.R
23 ( DJ ¥)
=
a.
U.p . -

Rf =
friction Radius

* *

( ⑨
Rf=÷÷d}
'
]
Tju
T = 103 -
d . . . . .

* *

t=u . . . . .
⑤

→ This derivation for single pair of contacting Surface .

Z=1①
if > Uniform Wear Theory : -

Assumed is
that
uniformly
→
the wear distributed over the entire surface
area of the friction disk .

→ Used for worm out clutches -

( old clutch) .

→ Axial wear of friction disk is proportional to friction work .

→ work done
by the friction force at radius
'
r
'
is proportional to friction force
( RN)
( up) and
Rubbing velocity 2x .

N =
RPM .

WearX(Up)(2ar
Assume ,
Speed and coefficient of friction are constant .

Page 177 of 253

1

wearier
wear is uniform
,
pr=constan
→ x I
p
→ A

¥7

¥!q
-
Pmpn → outer radius

Pmax → inner radius

x-P
,
qq.yyya.eparesggrepainten.it
→
, at the inner radius

Pale
-

where
,
pa
=
permissible intensity of pressure .

Pax d-
:
o

pr
=

13/2
→ P =
2x
J por dir.

d 12
Dt2

P
( Pax dz) )
= 2K dir

dlz
**

P=Tl.pzaCD-# . . . . ⑥

17/2
→ IT = 2 IT .
U
f p r2 dr
. .

dlz Dlz

T = 2 Thou .

( Pax dz) ) r .
dr

dk

**

T=TloUjPa(D2-d . . . .
⑦

⑦ ⑥
comparing egn ,
and ,

pI =

TUjPa
TT
to
( D2 -
d2) x #
* plan # CD
. -
d)

CD
=

F- ( D -

d)
Page 178 of 253
1

* *

tMgCl ⑧
/Rf=D-o
r

. - - - -
:

* Two phase of mechanism in friction lining

:L
wear

. > when the friction lining is neue

,
uniform pressure theory is applicable .

p= constant
since a : wear a
'
r
,
wear
pin .

→ The wear at the outer radius will be more .

Since pressure plate is rigid ,

this will the

wear release pressure at the outer edge .

2 >
.
since the pressure is released there will be no further wear at the outer
,

The
edge . wear will now take place at the inner edge due to contact of
the pressure plate .
This will release pressure and stop further wear at the

inner edge This of and

.
process wear mechanism alternatively at the outer

inner radius will continue till the pressure is adjusted in such manner that
,

'
the is
'

product in uniform at radius

Pr constant
resulting wear any .

Observation
:#

② The uniform -

pressure theory is applicable only when the friction lining

is new .
When
lining is put into services ,
wears occurs .
The fore ,
a

major portion of the life of friction lining comes under the uniform
wear criterion and it more
logical to use uniform wear
theory in design
of crutches .

t.io/::/:::::/s:/
I

② d
¥ f- )
D ( Dtd

200 180 95.09 95

-

( Rt ) ( Rt ) → difference is two small .

new crutch oped crutch

(F) crutch > (F)

new old clutch

→ use of uniform wear

theory ,
we are on the safe side and assume lower

torque dimensions Such crutch will have little

carrying capacity for given .
a

it is
more torque carrying capacity when new .

Page 179 of 253

1

From eqn ⑧ ,
Torque carrying capacity
Mg (
I Dtd ) will increase
=
by ,

µ PP

T = it .
P .

tz{ Dz +
dz } plate pressure ( P) 99

Mean radius
of clutch
-0T = U.p .
Rm ( Rm) PP

Cpus .
Compare friction radius by both
theory .

ESE 2018
-

Clutch 1 : -
Rr = 90 mm d = 180 mm
#

Rz = LOO mm D= 200mm

Clutch : -
Ri = 25mm
d = 50mm

Rz = 100 mm D= 100mm

Sold
uniform pressure theory , Rf =

I
03-1 "
( Rt ) > ( Rt)
DZ pressure wear
-
d2

(200)2980332 T
Rf
§ Rf
,
I =
, = 95.08 mm
=
µ .
p .

( 20012 8012
(T ) IT]
Cr
>
-

wear
pressure
Rf , z
= 1- ×
120033-150132 = 70 mm
3 ( 20032 -

( 5012
Torque
carrying capacity
→

of wear
theory is less
,

Theory Rf
Ly ( Dtd ) theory most
wear = so wear is
,

conservative .

Rf
4- ( ) 95mm
=
,
I 200 t 180 =

Rf
Ly (200+50) 62.5mm
,
2 = =

Note : -

→
designing clutch based on wear
theory is safer and conservative .

→ If not mentioned and for same

design uniform wear
theory should be
,

used .

→ Torque transfer capacity and friction power

is more in
pressure theory .

Tapplied Soo-5 - F- 105 Nm 7=180 Nm ←

Tapplied & 180

5- 200 Nm Pressure wear

" "
Rt
Neue More safe
m u r m u rs

Actual
clutch

old
slipping as

F- 100 Nom

Page 180 of 253

1

* Muttidskcutch : -

set A → hardened steel

set B → bronze

set A ( 3 disks)

Tl
v u v

lfiffffffffe
00000
i t
:*:ii÷:
surface

¥312disks)

* uniform theory
: -

pressure
:
of contacting surfaces
°

2 = no . .

→ T
MPzf¥
=

No .
of = no .

of pair of + t

disks
contacting surface
→ P =
"5 - d2 )

uniform
nagt=2 -

* wear
theory : -

Lr
suppose ,
=
no .

of disks on
driving
T
UjPo2 ( Dtd ) shaft
→ =

Zz = no . of disks on driven

shaft

p
T.Pza.de (D d )
→ =
-

; ( z, + za ) = number of pair of t L

surface
contacting
-

(2)
* *

"
2=q*z€
It should be noted that two disks have surface
contacting
→
outer

side
on one
only

"÷÷÷÷÷÷÷÷÷÷i÷÷
.

"

¥÷÷÷÷÷÷÷::÷÷:i : :*
'
'

Page 181 of 253

1

:÷ ÷ ÷ ÷ :÷ ± f
-

clutches Multi plate clutches

single
=
→ Number of pairs are one or at → More number of contacting surfaces

the most . in the multi disk clutch .

of surfaces is torque capacity

→e Number
contacting → For a
given ,
the size

:÷÷÷±÷÷÷÷÷÷÷÷÷÷÷÷÷÷÷
:
"
:

coefficient of friction coefficient of friction decrease due

is
high .
→

to lubricant .

Used as where large radial space → used in application where compact

is available ,
such as cars and construction is desirable e.
g .
scooter

truck .
and motorcycle .

II
Dry clutches I wet crutches

I :/
=

Dry clutch has higher coefficient → wet clutches the coefficient of friction
of friction .
is reduce due to oil .

U L O . I U 30.3

→
Torque carrying capacity is
high .
→ Torque carrying capacity is less .

:÷÷÷÷:÷÷:÷÷÷÷÷÷÷:i÷÷: : ÷:÷:÷÷÷:÷÷::::÷
→ Rate of wear is far less in wet → wear rate in wet clutches is about

clutches compared dry clutches .

19 .
of the rate expected in
dry
clutches .

→ is not smooth is
engagement engagement smooth
→
. .

Page 182 of 253

1

9.6.16 Ri = 20mm
single plate
GATE 2017 Ro = 40 mm

µ = o . or r →
varying
T = 18.85 kN .
mm

T =
12 Ill ( por ) dr
'

Ro

2
) dr
= 's
ax 0.01 X x r
p

Ri

18.85×103 (N 204 ]
) f 404
Ly
mm 2x xx O or X
p
=
x
-
-
-

.:P=O.5M
GATE 2020

-
- -
-
-
-1
/Pa=Pn
-

-
-

-
-

D= 250 MM

d = 50mm M = M wear
pressure

Fr Rf Motz Rf
"

µ
-

. . = .

Fr → Neue clutch

CD2
Fz → old clutch
FIZ =

g- ( Dtd ) X 3 X

( 133 -

d
's
)

GI ( 250450) X 3 X

(2502-502)-(2503-503)
=

EI=
Clas . Find ratio of inner dice .
to outer dice . for maximum power transmission
IESE capacity .
Use uniform wear
theory .

-501 . T =/ 2 Ill -

Pr ? dr as per wear theory ,

pr= constant

Jrcdr
T = 2 a it
por
. .
-

"

"
.
: x = d- =
RI
k
T = TL U d D Ro
p
. -
.

dlz

Page 183 of 253

1

T [ D2 d2 )
dy
Thou
°

:
p
= . - -

T.gu-opfd.DZ )
'
T = -
d

T
=HujPo { dy -

dis )
:
t.u.p.DZ { x3 }
e

T =
x -

→ For maximum power capicity will be when torque capacity is maximum .

DT = O =
{ L - 3×2
}

)} 0.57in
° =
: x =

CRPQ booth side effective ,

2

9. Ol Ps = 2000N

Pg -
NO 73 Ri = 100 mm

Ro = 150 MM

µ =
O .
-5

Assume wear
theory
:
.

T (
= 2. U
-
-

PN Dtd )
4

=
2×0.5×1000
-
I 300 +200 ]
4

=
125000 N -
mm

= 125 Nom
-7

CRPQ Two active surface ,

n
-

- 2 Not to exceed
PN ↳ Maximum
9. 02 and 03 = 0.85 bar = 0.085 Mpa pressure

Pg . No .
72 D= i. 25 d

U = 0.3

1- = 100 Nom

13/2 100×003 =
2×190.3×0.085×12 ( ( i. 25 d)
2
-
d2)

J
8
T =
n . 2. a -

it .

prz . dr

D=258.82M①
•

: D= 207.05 MM
2

plz

pmax.dz/rodrd/z
=
4Th -
U .

-
2- IT .
U .
Pmax d f D2 -
d2]
8

Page 184 of 253

1

DIZ

pwn = 2 TL
) por dr .
PN = Tl×0-085×208_
Z
( 260 -
208 )

DIZ Diz

= 2x -

pma×x
dz / dr
PN=i.U4T
dlz

=
IT .
Pmax d -

( D -
d)
=
2

CRPQ 2=5 T = 2 .
Hope ( Dtd )
9. 04 f- = 0.4 kN M -
H

Pg . NO .
04 it = 0.5 0.4 X 106 = X ( 300-1200]
Ro = 150 mm 4
Di = 200mm PN = 1600N

Springs =
Lp

Load per 1001=400 N

Spring
=

4
: No of contacting 5-1=4
°

.
=

surface

CRPQ Df = 120 mm let

,
Ip = MOI of input shaft
=
07 and 08
.
Do P
200mm =
Iz = MOI of output shaft
n = 2

No =
0 RPM Equivalent or effective MOI

N 200 RPM
F =

EE-%eEg.ms iEe=¥i¥①
U =
0.3

i> T =
Ie .
X

: . T =
Ie X
-

Wz -

Wp
#

it

¥1
= 20 × 21×200--0

T 83.8
°

: = Nom

3
ii > T =
n x Ux Pnx I 133 -
d
-

3 D2 -
d2

83.8×103 = 2 × 0.3 × Pn ×
2003-12033
I×
2002 -
1202

PN = Ps =
1710.21 N a 0704 Nt

Page 185 of 253

1

Q .
6. Tl µ -0.3 13/2

GATE 2014 Pmax

D= 200
= i. 5

MM
MPa T =
2 Ill
J pr ? dr

dlz
d = 100 mm
13/2
Assume wear
Theory 2 all
Pma dy ( IL) q
: =
x X
,

Tmax =
? (
Nim ) ,

TL.U.pmax.de/Dg2-
=
-

Fmax ( ]
'
= .
D2 -
d

=
9×0.3×1.5×1002 (2002-1002)
8

Tmax =
530143.76 N .
mm a 530.143 Nom

Q .
6.8 .
D= 100mm Assume : Uniform pressure theory
GATE 2008 d =
40mm P= constant

10=2 Mpa Dk

U 0.4 f- 2am
f. p r2 dr
= = -
.
.

T =
? N m -

dlz
D1d
= 2x .ee . P -

( %

ax.u.pl?I-dIaI--TljuzoP(D3-d3
=

=
TLXO.MX#fp0O3 -
403 )
12

T N
= 196035.38 -

mm =
196N.im

Q . 6.6 .
P = 5kW =
5000W Assume :
p
-

- constant

GATE 2006 N = 2000 rpm 13/2

r
=

=
0.25

25mm → d = 50mm
T= 2x -
U .

p
) r2 dr.

dlz
p =L MPa

?
1¥) !!!
D= mm = 2x M - -

P -

d3 )
TpzU (
→
p =
Zant A- = D3 -

60

f- = 5000×60
-
→ 23.87×103×12 =
( DS - 503 ]
-

2x XX 2000 TLX 0.25×2

•
: T = 23 . 87 Nom d =
78.57 mm R=39.28mmF
Page 186 of 253
1

* :#
Cone clutch
→ conical surface result in

-91£ considerable friction force

even with a small
engaging
force due to the
wedge
shifting collar action .

f-
-5*-8 Semi angle ( ) -
cone x = 12 .

←pdg
Note : -

Spring broken
to
Two prates di
engage
suddenly .

Leather ,

Cork or asbestos
of =
friction angle of friction
pad e
*** ESE 2019 prelims
to sliding will hapenes
-
← i . a * →

m m

u
prates separate
~
disengagement
-

self disengagement

working condition
~

ii. Be 950 → No motion

No Sepe ration
engaged -
self rocking condition { Not safe

working condition )

5¥
mjvttt.tt
¥HH¥
dr

It 11
c -
-

B
d

-
-→
"
¥
"
! .

Page 187 of 253

1

dr
"" d " =
"
t.r.sn
"

=,
Normal force =p .

( Area )
i a,
i
t p

d r i
'
fo=p DA p .
= .
2x or .

r Sind
t . -
= . -

Friction force =
it ( Normal force)
Ped A. sing
P DA

dr¥t
2 x. r
.

µ
p
= . . .

sina

Pda -
Cosa

Friction Torque = r ( friction force)

**

Frictiontoraue-2xr2.u.p.gr
Axial force = d. p =p SA since .
.

12 dg,÷
Axial force =p .
arr . . Sina

* *

Axialforce-p.2JL.r.cl#D/z
* * :

±:÷%
→ p = 2 I
f por . dr

" - - - -

dlz

i> Uniform Pressure

Theory :
-

P= constant
I 13/2

.µ¥
-

→ P = 2 a
f por dr .

¥11¥
^

! :*
'

. .

:p .
roar

B
dlz
* *
"
I P=÷IfD2 . . . -
②

Page 188 of 253

1

Dt2

/
2 U
Pur ? dr
IT
T
-

dt2
Dt2

dj.tn?f-p/r2drd/2-=TjUgjP-CD3-d3#
T =

* *

.
. . . .

③ by ②
Dividing ,

÷ ¥pco
'
)
Ip 103
=
-
d ×

* *

rt=y÷¥ ④
- - - -
'

µjttttt
-

pm .

iis uniform

por =
wear

constant
Theory : -

µ,¥q¥%¥
t
.

B
p

xdz
Pma
por =
Pma ,

DIZ DIZ

dg.TN#/pr2.drd/z
/
P = 2K
por dr. T =

dlz Dk

dJjYPmaxxdzfr.drd1zd1zro_apma.iacr@7E.o
Dk T =

2x
pmax.dz/dr
=
.

""Ii::s*±÷⑥

Dividing ⑥ by ⑤ ,

T.ua/0max.d-CD2-d2)
=

28) sin x
x

Tl .
pmax'd CD
-
d

* *

T=÷÷nCD* . . -

Page 189 of 253

- -
⑦
1

Observations :

possible
-

smart as
ya
i> T a d- a lot sins lol .
TPP
sins

Torque capacity of clutch increase

→
cone as

the semitone angle decrease .

if > T = constant o
relatively small axial force can transmit a

semitone is decrease
given torque if the
angle .

P x sina

for
For
disengage
action 99
→ a ↳ to wedging Force PP

Clutch with semi

→ a small -
cone
angle required a
relatively small

force to
engage
the clutch but a
relatively large force to disengage
the clutch .

Relation beth Tpiate and Toone :

UI
Folate
Uq ( Dtd ) tone ( Dtd )
= =

Hsing

Tane L . .

.
9=12 .
-5 → taken
-
= -

1- plate Sina

Tcone=4.62Tpia →
Torque carrying capacity of cone clutch is

higher that of single plate clutch .

1/2
-

.
D-zd-sinx-z.ge
%
' * *

:/ b=o÷
'

a
t p
b

↳
p
t p
1- . - .
-1 . -

face width of friction

( b)
lining .

Page 190 of 253

1

Gus A clutch is used to connect electrical at

=
. cone an motor
running at
with is is
1440 rpm a machine which
stationary .
The machine

equivalent of 150 radius of gyration

to a rotor
kg mass and as

250mm .
The machine has to be
brought to the full speed of 1440 rpm

from stationary condition in 40 s .

The semi cone x is 12 -5
.
.
The

mean radius of the clutch is twice the face width .

The coefficient

of friction is 0.2 and the normal intensity of pressure between

contacting surface should not exceed o.in/mm2 .

Assuming uniform wear theory .

data 't Ni
.

=
O 9=12.5

NE 1440 rpm rm = 2b

m = 150
kg U = 0.2

K pmax O.IN/mm2 •z= 2.T.NL

= 250 mm =

60
t = HOS

=
2 XXX 1440
#

60
it inner and outer dice of cone clutch :

= 150.8
rad/s2
T I. a
T Tloltopmaxod ( D2 d2)
=
= -

8 sing = M .
K2 .
R
O

(Wyatt)
-

150×(70500-0)
=
*

36279.84 = Td ( D2 -

dy
8 sin 12 .
-5 = 9.375 X 150.8
-

40

: d ( D2 d2) 974001.21 35.34

'

-
=
=
Nom

35343.75N.mn#.:b=D-d2sinx
=

:/
→ D -
d = 2. b. sino -
① (Dtd ) sing = (D -

d) 4
D sin x t d sing = HD -

Hd
Rm 2. b
given ,
=

HD -
D sing =
Led t d sing

it:÷::÷ : : :S:
"

:÷÷÷÷÷÷
2
deride eq ② by ② ,
d ( ( i. rite d) -
d2) = 974001.21

Did =8b_
D -

d 2b sine
=
4-
sing ÷dD==Y}?}fmm
Page 191 of 253
1

2) Face width of the friction lining ,

b =
D -

d
-

2. sing

b =

177.36-159.212
X sin 12.5

b=40.96mmF
3 .
> Force Required to
engage the clutch

T = U ( Dtd )
4 sina

P = 4. T since .
4×35343.75 X Sini 2.5
=
-

U ( Dtd) 0.2×(177.36+159.21)

e
:
p=454.57
4. D Heat generation during each engagement
# wz
:
wavy
e
=

2
Heat generation = work done

Hg 15520.82=75.4 rads
→ = T @ → radian
.
=

H 35343.75
Wang time
=
X X
.g
40 ( s)
35243.75
Nym
75.4
rddfg
=
X X

106

=
106596.75 Nom or Joule

Hg
•
:
106.59
=
KJ

CRPQ P 20kW 57 T
M.jp ( Dtd )
= =

Q .
05 & 06 N = 2000 rpm 4 ,

Pg
2JlNTµ
. No .
73 A = 240 p =

= 0.2 GO

Pavg = 70×103
#

2
= 0.07 Mpa T =
20×103×60
#

2X TIX 1000
=
190.985 N m
-

4000)
Did P
rang 150 T µ r
.

= mm → : = .

avg
-

Lp Sina

P =

190.985×103×513,240.2×150
P = 2586.35 N

P = 2.586 kN
-

Page 192 of 253

1

6$ width
=

T = r x ( friction force)
PN 2. ST dr_ T r x u Pw
pang
=
= .
.
r . x

Sina
.

PN 2.
r

:
PN 190.985×103
Pang rang
b
=
=
IT .
. .
-

t -50 X O . 2

.
-

b = =
96 .
49 mm PN = 6366 . 17 N
2x Tl X 150 XO 07
100
-

a mm
#

*
centrifugal clutch
o
-

→ Required engage the load

after the
diving member

has attained a

particular speed ,
a

centrifugal crutch is

used .

permit to

to start
~

engine
worm up
~

~
accelerate to speed

→
generally used in I. C .

engines ,
which can 't

→
centrifugal force → works on principle of start under road .

centrifugal force .

the
→ Force
acting on shoe : -

fP utes .
-

Ps3

O
shoe

train: tps

rd =
radius of drum ( mm)

rg
=
radius of the center of gravity of the shoe in engaged position
of each shoe
m mass ( kg )
=

Rt =

centrifugal force ( N)
Ps force ( N )
=

Spring
Z =
number of shoes

Page 193 of 253

1

( radlsec)
Wz =

running Speed
we , =
Speed at which engagement start cradled

→
centrifugal force ,

MM
→ pm
( Rt) =
mating of mug ?rg
,
1000

( Pct) =
mwirg
,
1000

( Pct) , is balanced by an equal and opposite spring force at the

beginning
of the
engagement .

Ps =
( Pct) z =

#
Mwf rag or
#
ppg =
maeirg
#

1000 1000

centrifugal force is
slightly than the force
the
spring
→ when more
,
.

in
the shoe
begins to move a
radially outward direction .

Net force on drum = ( Pcf ) z -

Ps
=
(Pcf ) z -
( Pct) z

Netforceondrum-mrgyowg-w.at
*

→ Friction force =
Umrgluef-w
1000

→ Friction Torque = llom.rg.rd.fwz.hu#

1000

* *

Torque Carrying Capacity ,

p=←Euh±#r
Note
-

→
whenever road is required to
engage after driving member attains

a particular speed .

→ It allows motor or engine to start warm up and accelerate without

,

Load .

This clutch is preferred on motor with lucie

starting torque .

→ It is also called as an automatic clutch .

→
Engagement force is perpendicular to the shaft axis or it is radial .

Page 194 of 253

1

→ Application : -

Mopeds ,
battle tanks

The
engagement speed is 75% of the
working speed .

low in contact due

° At speeds ,
shoes are not with drum to
corresponding
low centrifugal force .

→ As speed increase , centrifugal force forces shoes towards drum

which will
bring shoes in contact with drum .
After contact
,
power
start transferred
getting .

② If needs to have zero road until I a specific amount of speed

force is
and
corresponding centrifugal reached .

② As the speed increases , centrifugal force will also increase .

Hence centrifugal clutch will take the road gradually with the

increase in speed .

③ If the load exceeds the

capacity ,
the
slipping will take

place .

→ It enables the prime mover to start up under no -

road conditions .

It picks up the road with the increase in speed

gradually
→ .

It is useful unit has tone torque

→
very when the power starting .

The effect of stiffness of centrifugal

increasing the
springs clutch

is the increase of engagement speed .

Qys A centrifugal clutch transmit Kw consists of

.
,
ing 20 at 750 rpm
four shoes .
The clutch is to be
engaged at 500 rpm .
The inner
radius of the drum is 165 mm .
The radius of the center of gravity
of the shoes is the clutch is The
240 mm
,
when
engaged .

coefficient of friction is 0.3

,
while the permissible pressure on

friction lining is o.IN/mm2 .

Calculate :

data :
-
P = 75 Khl = 75×103 Walt
=

µ =
750 rpm
2

N, = 500 rpm

rd =
165mm

rg =
140 mm

µ I 0.3

Pmax =
O.tn/mm2
2=4

Page 195 of 253

1

if > Mass of each shoe

Cee , ⇐ 2TN = 2×9×5002 = 52.36 rad / see

60 60

Wz =
251 = 2×51×7502 = 78.54 rad ( see
60 60

P = 2T
60

;
o

T = 20×103×602 = 254 .
65 Nom

2 X TL X 750

T 254647.91
•
: = N mm
-

T =
Urm.rg.rd22(wz2-W
1000

0.3 X M X 140×165 X ( 78.542 52.362) XH

254647 91
-

. =

-1 0 0 0

:m=2o68k#
•

it >
Dimensionsoffrictionllining

← Fruiting
that of friction lining shoe

At!!!!!!
→ the arc or

fr
an
angle cos of 70 at the center of the

• .
1
l = contact
length of friction lining with drum
eh!
1¥ , - -
-

( mm)
b width of friction
=

lining ( mm)

: O = I 1=0 rd .

rd = 165 X 70 ×

180

;l=20l.5gmmY
→ Net force on drum =

1000
friction

pmaxt.b-m.rg.cwzz-w.rs#**b=w.indthg.ot 1000

→ 0.1 X 201.59 XD =
2. 68 X 140 X ( 78.542 - 52.362)
-

1000

°
: b =
64.28 mm = 65mm

Page 196 of 253

1

C. Rpg 2=4
2 IN
9. 09 & 10 P = 25,000 Walt at
2
=

60
→ Nz= 750 rpm

working we , = 0.75 of
Z
o
: we
z
=
-
2×1×750 = 78.54
rddfs.ec
60
di = 300 mm

Rg = 125mm

µ = 0.25 Pmax - 0.1 Mpa 0=600

→ p =
ZANT
-

T = U.m.rg.rd.tn ( Wf wid
-
-

60
1000
0.4375
25×103 = 2×17×750 X T
318.3g xp 03 =
0.25 X MX 125×150×44 * ( 78.545
- -

GO 1000

•
: T =

=
318.31

318.31 X
Nom

103 N .
mm
:M=6.2g
°

→ l= rd .
O → Pma , lb =
morgo(Wz2_w
= 150 X 60 X 2000
180
o.o x r 57.08 X b = 6.29 X 125 X 0.4375 x 78.542
-

•
: 1000

:b=r35.08m⑦
* clutch Position ?

Feng line - Gear Box - output shaft EMB Ta

Rang .

Speed High speed law Tx size of clutch

P= constant D= constant

Torque $ to
. Torque 99
°
: p=2T
60
Size of clutch lost size of clutch TB
MT constant
°
: x

N L
•
:
a
F

Page 197 of 253

1

CHAPTER 10:- BEARINGS

Page 198 of 253

1

CHAPTER 10:- BEARINGS

as:c :ion÷±÷÷÷:÷÷÷÷ E. ⑧ G- of cylinder

.

Tangential
%r rotten
Direction

*
Bearings ⇐

is
→
Bearings a mechanical element that permits relatives motion
between shaft
two parts ,
such as the and the
housing ,
with
minimum friction .

FunnotBe :
g
-

E .

Bearing ensures free rotation of the shaft or the axle with minimum
friction .

22 the shaft the axle and holds it

.

Bearing support or in correct

position .

B .
The
bearing takes up the forces that act on the shaft or the axle

and transmits them to the frame or the fundation .

Bearingdassfiedbagedondirectionoffor
W
I W

Thrust
Radial
Bearing Bearing

:÷÷÷÷E¥f÷¥iE④
Bearing
y.

:*
← Frame

to the shaft the axis of

→
perpendicular . act
along
rotation .

Page 199 of 253

1

Bearingdependsuponthetypefricti.co#
I
W W

sliding contact
Bearing Rowing contact
Bearing t
k antifriction
bearing I
1. Plain
bearings simply ball
bearings
2. Journal bearings
3. Sleeve
bearings
"
"
±
-
"
"

¥
Bearing
← shaft
ein:*
sna .
on .

[
-
-

I
¥ I
% I
Lubricating oil

surface
Ig
the
The of shaft sides Deep groove ball Bearing
the bush Cylindrical Roller
over surface of the .
.

Bearing
in friction and Angular Bearing
resulting wear .
3 . contact

4 Self aligning
.
-

Bearing
o Area Contact / Side contact 5 .
Taper roller
Bearing
G . Thrust Ball Bearing

o Point contact / Line contact

#] ¥
← Bearings
l¥nged Joint

snare :i ii:::
r I T

↳ Flywheel / Gear / Pulley

→ Support the shaft -

To take load of shaft
→ Arrow rotation of shaft with minimum friction .

↳ bearing not
given
tangential load .

Page 200 of 253

1

*
Rollingcontactbearng : -

Rolling contact
bearing subjected to

dynamiting
3. I
•

z Fatiguing
a

Yeh :#
""
to
shaft
fluctuating Loading
↳ we should referred
SM curve .

?
Is point A contact
always
Ans : No
#

also
rotating
"
bait "

①
I
B A

73

log , a

rog.is#ff
400 MPa →
Strength
tog ( sat)

it
ro

99 tote
← N Strength
-
tog polo .9Sut) - - - - - - - -
-

y P
upto 205
-

q
-

A 1400 MPa 104 cycle]

p
- - - - - - -

l l
- - - - - - -
t -

I -

q
B 1200 MPa
,
105 cycle]

l l
l l
l ! l l
J
O 3 66 tog ro
N

Disadvantage : -

Baa
s for long term ,
we can 't use

go with rolling contact

bearing .

0 Should not use for high

SN Curve load of high speed .

'

:&;÷n .sn#:::::::s:n:t
.
.
si

>
Nt

Page 201 of 253

1

Contact
*
Sliding-
: # Bearing
# #

Hydrostatic Bearing

÷:÷÷:
is atmospheric

÷÷÷
at pressure

÷÷÷÷÷÷÷÷
:÷÷÷:÷÷i÷:÷:: ::
.
"

÷ ÷ ÷I ÷i ÷
External pump used to wear PP

supply pressurised oil .

Stress concentration 41
.

→ It is also called as crack propagation

externally pressurised
it >
bearing .
Pressurised oil used .

No
starting and
stopping

÷÷÷÷÷::÷÷:c
shaft
. .in .

÷÷:÷: ÷÷÷:÷:÷*
rotating concentric .
with the bearing .
y
L
toad Pump
→
carrying capacity 1^4 pressure
is indepedent of the speed
of shaft .

Good stiffness radial load precision machine tool

→
against -

Application Terbo Turbine directly

:
generators → is mounted on

mills electric
centrifugal ball generator .

tydrdynamic Bearing
→ Pressure in oil is
generated due to rotation of shaft and
wedge
action .

hattatrest :

→ shaft will rest at bottom .

÷÷÷÷÷÷÷÷÷÷÷i
Prarfmssousrpenear:
-

→ Metal to metal contact .

→
Boundary lubrication .

Page 202 of 253

1

Nafta :

:÷i÷÷:÷t÷÷¥.ie?:::os:tei::::e::.:::::::wissn:i
s .

. to
→ Metal metal contact
-
wear take place

.fi#.E%D7I.!:gs.-emIIa7Ioimemet :hat:*:
tarted then mere win be

friction PP
*
wear 99
Pressure 94

ns.a.i.a.ma.m.is?:: : : : :I: n: aereaintreauent Automobile

Rolling
gearbox : contact
bearing
-

A
small created
gap
hydrodynamic
In!gn bearing torque required is
starting
→

µ
¥€ .ae
"
Mixed Lubricant
"

↳
[ Boundary t stable ]
oil
wedge

shaftathighpeed :

Thick film
" → stable

is :c::::m:c bearing
→

.. .

film
Pmax

→ As the shaft keeps rotating ,

the pressure gets developed and oil
firm support the shaft .

→ As the pressure gets developed within the sysm due to shape and rotation ,

it is also called as self -

Acting Bearing or self constrained

bearing .

Initially shaft is is
→ when the at rest and when shaft start
rotating ,
there a

metal to metal contact due to insuficient pressure in the oil firm .

Hence
sliding contact bearing should not be preferred where frequent starts

are required .

minimum fluid
→
Hydrodynamic bearing requires a speed to
generate a full film .

Below this speed mixed or

boundary lubrication .

Page 203 of 253

1

→ Hydrodynamic bearings need a

regular supply of oil . Intrypted oil

supply would result into ,

metal contact ,
overheating and sudden
bearing
failure .

Hence Hydrodynamic bearing is never used in critical application like

aerospace engines .

Hydrodynamic bearing is not suitable if

high load is present at the

beginning .

Hydrodynamic bearing requires high torque due to initial metal to metal friction .

→ If the direction of rotation is clockwise then the center of shaft will shift to left
ane vice-versa in thick film or Hydrodynamic lubrication .

If the direction of rotation in clockwise then the center of the shaft will shift
to right and vice versa in mixed lubrication .

→
Hydrodynamic bearing is suitable
only for radial toads .

→
sliding contact bearing are also called as plain bearing ,
Journal
bearing or

sleeve
bearing .

→ Journal means a shaft the part of the shaft or axle that rests

inside the
bearing .

→ Journal Diameter shaft Diameter

→ Length of the Journal →

Length of
bearing .

→
Applications : IC engine crankshaft ,
connecting rod
,
steam and gas
turbine ,

centrifugal pumps , Large size electric motors , concrete mixtures .

Main of
→
advantage sliding bearing over rolling contact
bearing is superior
toad carrying capacity at higher speed .

→
hydrodynamic bearing ,
high load carrying capacity at high speed .

⇐g A
.
Stoke
engine
1-
power stroke 2 cycles

IN 4000
engine
=
Dpmm
I see =
40002 rotation
60

power stroke per second = 40002 = 33.33

4.
2X 60

toad
High speed , High

Ate : Non
rotating member

No torsion stress

Bending can happened

Page 204 of 253
1

.E-
E#i:!ionis.i .ntaa-
Load

Carrying -

Hydrostatic bearings
capacity
Hydrodynamic Bearings

bearing
speed

1. B low speed and high load →

Roiling contact
bearing
2 > .

High speed and high speed →

Hydrodynamic bearing
* Frictionradius k Rt ) :
-

l CoA) = radius of shaft / Journal =

Rj

÷¥i÷÷÷i
r
Rf Rj sing
= x for small of ,

"

* sma . :* .

* * : U = coefficient of friction

py=µ×p

Nomenclature
-
: .

;÷÷÷÷÷÷÷÷÷÷÷÷i÷:
"

clearance radial
•

: c =

:
cc R2
•

⇐ -
A

Cd =
diametrical clearance
÷
Cd ⇐
22 . CC

¥¥
Nr =
Speed of shaft / Journal in RPM

Ms =
speed of shaft / Journal in Rpg

÷
M=60XN€
W Radial load on
bearing ( Hydrodynamic can take
only radial toad )
=

µ =

bearing pressure **

µ=z? Page 205 of 253

1

÷÷÷÷÷÷÷÷÷÷÷
No = minimum thickness
,
of oil
.sn .

film

: R too
•

=
et r t

* * R -

r = e tho
¢
**

eccentricity , e=c-&
if ,
For maximum eccentricity too =
0 ( No oil film)
* *

÷ema×=c=p_€
* *

Eccentric Ratio
,

§=÷ty
Fa #
: e
•

⇐ =

→ c = e thro
•

E=Ez⇐L-hi t**
I =

ez +
h¥

:¥=e_h
.

Petroffisequation.io -

Page 206 of 253

1

frictional force , F=f.N=f#T

frictional torque ,
T - F * A

=
f- * Nox r =
f- x Wx M

t-f.p.2.hr# ②
• .

. -

Velocity of surface of
journal ,

UA
°

: = r x we

= r x 2TN = r x 2x Ms .

60 Is RPS

Newton 's lane of viscosity ,

c- =
ie de
dy

C- 2 TLA Nts
= u x

e.
:

T=ex2TL£t
Torque T =
shear force * radius
,

= shear stress x Area x radius

T=u*2TcrNs*2arL*i ②
°

from ② and ② ,

f- µ 1/1
2 L r2
.
. . .
E 41 Tch . .
µ . r3% his .LT
-

f-2.TL?f-r.NsJ.:t=zaz.CEy.u;pnosI*I7: cgan
•

'
: aa

→ concentric shaft
↳ petrol equation
→ No
leakage

friction torque ,
# =
f- * Ww * A

of power
Loss P
atom * f- w x R
=
x
,

Page 207 of 253

1

¥1 = clearance ratio xx > I

U .
Ns = dimensionless number
-

•
:

Bearingcharacteristicnumber-U.IS#*-*
Mckee
: - 's
Equation
#

ft-k-0.326.r.z.tl#Ns
→
•

.
.

Applicable for all condition

→ k =
leakage factor = 0.02

* Characteristics

¥±i
A
f- l
Boundary condition
¥a
efficient l Lubricant
co -

Mixed
of friction loaf
l
l l
l l

f www.an ,
l l l
Hydrodynamic ,

l l l
z
BEN = U -

Ns
Tp
bearingmodulluske
Ik =

It is BCN for which the coefficient of friction is

minimum .

BCN e k → Left side Area

,

film
"
thin oil unstable lubrication
"

BCN D K Right side area

" "
thick film stable Lubrication

i >
.
point B
,
BCN = k coefficient of friction minimum
less toss of power

Page 208 of 253

1

ii. > point D

Bente
,

toad 99 coefficient of friction 99

Pressure 99 loss of power Bt

lost
BCN Meat generation PP

Temperature of heat Bt

Viscosity of oil lost

-
• BCN lob

After more coefficient of friction 99

takes place boundary condition

↳ No desirable
Not safe points
working .

iii. § Point E BCNe

,

toad 9$ coefficient of friction lost

Pressure BB loss of heat lol .

Bcnbts Temperature of heat lots

↳ Transfer to Viscosity of oil 99

Left hand side .

BCNT.is
↳ stable condition of E is

restored safe
,
working .

if work near
bearing modulus ?

→ if increase of toad it
more
, goes on

left side .

condition
working ,

A >
loading
static BCM Z 3K
B >
Dynamic loading BCN Erste

sommerfeidNumbers-CEJZ.MN# •

: S = clearance ratio
Z
* Beni

Q 4.6 BCN U.NL U.Ns.2.tn# : BCN xf

-

=
.
. =

GATE 1996 B w

→ w Pts BCN ble coefficient of friction lot

01A :
-

decrease with increase in toad .

Page 209 of 253

1

9. 4.7 .
BCN = U . Ns Load PA

GATE 1997 TO Pressure pp

BCN lot

Restore higher magnitude of toad

→ stable
operating condition
,

Load 99

viscosity of oil lap

Q feed
bearing
4.13 Natural
.
.

journal
GATE 2007 d = 50 MM

2x U.NL
(
L = 50mm :
°

S =

Ns =
20 RPS D

2o.gg/2x20X00-3x20X#5OU=20mPa.s=20xro-3Pa.5
=(
ht = 2 kno

2×103×103×103
C = 50 um = 50×10-3 mm
1.5=0.1257
Sommerfeld Number = ?

9.4.14 .
D= 40mm → T =
f- x Wx Pr

GATE 2008 L =
40mm

Is f-
UNSC
#
be 20 rad 0.002 0.326
= =
f- .
.

µ =
20 m .
Pass
IP

C =
0.020mm :
.

W are not there .

Loss of torque = ?
T f. w
°

: = .
A

UNIE
= 2%2 x
Ic x

we
x # r

⇐
2×2 x
20
×
20×10-3 X 20×40×40 × -
20
-
-

0.020 2 " X ( too 2 1000

Q .
4.15 Dp =
50.05 mm clearance = 50.05-502 = 0.025 mm

GATE Z
2010 Dz = 50 mm

L = 20mm → T =
fxwx R

N = 1200 rpm

LIZ
U =
0.03 Pa .
s f = x
rz x U.ws#D
W
Power Loss =
? ( Watt)

f- = 2×2 × -
25
×
0.03 X 1200×20×50

GO Xwxciooo)2
°
: T =
f- X W X R O 025
-

It 84 255 = It 84
xwx
- .
=
-
- -

W 1000 W

=
0.296 N M -

Loss of power P 2TNL×T 2×51×12002×0.296

,
= = =
37.2inch
GO 60

Page 210 of 253

1

9.4.19 . W s 2000N Sommerfeld Number

,

GATE 2014 N = 2000 Arps

D

C
=L

=
20
=
40mm

UM
S =

( I )2 Mins
P

0<03×2000×40×-40
( 20-12
U =
0.03 Pa .s = ×

20×00-3 60*2000 X Cr 00032

= 0.8
I

D= 5%692
p=W_ Lj
c.
Rpg 40mm : =
= i. 44
L 'D 40
9. OL W =3 KN

Pg - No .
58 p = I. 3 Mpa L =
3000
L 40×1.3
= ?
-

d L =
57.69 mm

2. 2 kN

CRPQ ! I = i. 5

B D

Fg?No
A

58 200mm IT 300mm → : L
°
→
.
= i. 5 D

41<-500 -
IT
-

mm

RA RB

WRBX
EMA =O
p =

500
L DD-

=
2200×200
a

: RB = 880 N p = 13202 = 1.408 rqpa

( 2532
-

RA 1. 5
(maximum)
X
→ = 1320N

CRPQ D= 75 mm

9.3 .

Nµ= 300 rpm Nz = 400 rpm

Pg .
No .
58 U =
0.06
Pa -

C =
0.2 mm

p, = i. 4 MPa Pz =
?

BCN = lt Ns.
States
factory condition
,
BCN > k

To
°

:
CBCN) , =
CBCN)z

¥
.tn#.. 30.g=4q.

:Pz=l.87M

Page 211 of 253

1

CRPQ E =
0.8 o
: E = I -
ho
-

9. 4 .
h =
?
C

€
Pg No 58
hog L 0.8 =
0.2€
-

=
.
.

CRPQ D= 150 mm
g- = 2AM
f. iv. r

Q . 5 .
L =
225 mm
To
W
Pg . No .
58 =
9000 N

f-
UNSC Ig
N = 1000 rpm
°

: = O -
002 f- 0.326

= 0.075mm to

④ =
go KL = 90×103
-
J
-
= 0.002 t 0.326×75-1
,
-
UX 1000*150×225
min 60 S
0.075 9000×000032

Leakage factor =
0.002 %
.
f- =
0.002 t 2.224 U

90×103
-
=
2X TIX 1000
-
× 9000 ×
-
75 X ( 0.002 t 1.224 U ]
60 60 1000

U = 0.0157 parsec

CRPQ D= 50 mm

L
go
75mm
9. 06
-
=
= 257N
-
xfxwxr = h .

Apg
.
DF
60
Pg . No . 58 D= 2 Mpa

N =
500 rpm
.
: 21×5002×0.0015 X 2x
iocxfhpx 25
1000
N = 11.6 W/m2oc GO

A- 8 X A- 11.6×8 X Atp x ( Fs 28 )
housing
=

projected
=
-

To = 28°C → TTS = 70.32°C

f = 0.0015

Ts =
?

CRPQ D= 100 mm

9. 07908 L = 150mm 77 Sommerfield NO ,

Pg . No .
58 w = 4.5 KN
2x UI
N 600
rpm s=
(f)
=

's
µ = 18.5 x ro kg/m -
s
p
18.5×10-3×6002
(50-12
Cd = 0.1 to =
×
Pa -

Sec
0.05 GOX 4500
E 0.4
.

=
un -

0.1×0.15

:
Cd 2C
15=0.617-7
-
=

: C = 0.1 = 0.05
-

2 8D ho =
?
E = I -

hoc o

:
tho =
0.03mm

0.4 =p -
he
0.05
Page 212 of 253
1

CRPQ P 2AM
150 kN
Cf f WX R
=
= x
X

To
Q . 9 D= 300 MM RPM
→

plays
€

Page No 59
f- Mont
f-
. .
N =
1800 rpm ÷ = 0.002 t 0.326
k
p = 1.6 N/mm2
µ 20 Cp 20×10-3 0.002 +

{0.326×151×20×40.361,108,002}
= = =

0.125
Ccd = 0.25 mm

K = 0.002 = 00.0108

' -

Cd ( KJ) 2111800) x 0.0108 150×1031

Cf
. =
2C = X
-

min
0221=0.125
C =
x 150

9- ( Kalinin)
KITmin
=
2748

CRPQ di = 12mm Thrust → Axial compression .

Q .
10 do =
75mm

Pg . No .IO P = 0.6 MPa p = D-

toad = ?
( do
'
-
did)

W =

0.6×41×(752-122) =

= 2.58
2582 N

kN
=

CRPQ Foot step bearing

. -

9. H

Pg . No 59 .
Shaft DA =
astr dr .

PN astr drx
Foot step µ
= .

bearing

# aar.dr.p.fr
r

xpxfx Rs
2¥
. .

. T =

'

p=a%N=2sx2 xpxfx
:
R

2×57×600 120×103×0.05
P
2g x
=
: X
o

g- '

4¥
:*
bearing for
bearing is is
bearing
161
us . The modulus a 9628 .
What the

for
bearing design
ESE ?
-
characteristic number considered
A) 1628 B) 3256 C) 4884 D) 6512

? . K =
1628

static
loading ,
BCN =3 K

E 3×1628 =
4884
#

Page 213 of 253

1

Resistance ( concept)
*
Rotting
9. 3. L Wheel
€ EMA = O
→

Yp! !!?9:O, ?
P = 10×300 = WX 0.3

:P=5%f
i

mm
W A
d = 600mm
Necessary to roil
F-
for the
¥
=

:P 0.5N wheel
along
.

w ⇐ 500M =

µ = 0.3
-

Rolling resistance
the rain .

"

Contact Antifriction
"

*
Rotting Bearing Bearing
: - →

IRON Motion
ing

#
T
( friction lot

wear lol
.

immense
shaft

Irma Eatouisnteaon
I shaft
9-
.

outer race touter ring

cage

→ For
starting conditions and at moderate speeds ,
the frictional losses in

bearing minimum because of friction the

Roiling contact
rotting so
are

wear is also less .

friction
Hence , they carted as anti -

bearing .

→ The baits fail due to fatigue .

Roiling is limited fatigue failure

contact
bearing life by .

→ The design perimeters are toad .no#Les and reliability .

*
Eager

→
cage also called as retainer or separator .

→
cage doesn't allow the ball to cluster together and maintain proper relative

angular position .
Without cage ,
balls will rub against each other .

without the element will in contact with each other and

→
cage , rolling comes

friction
will
undergo rigorous sliding .

Page 214 of 253

1

The primary turn of is to keep the distance between

→ a
cage proper rolling
element and secure the proper load distribution and balance within the

bearing .

cage also helps to control the

rolling element from falling out while
handling
them .

→
Cages do not support the load .

Cco)
*
staticoadcarryigcapacity : -

→ It is defined as the static load which is corresponds to a total

permanent deformation of balls and races

,
at the most heavily stressed point
4
-

of contact equal to IO of the ball diameter .

deformation
• The permanent is known as
brinelng ( Brin elling means

permanent indentation)

→ Friction torque =
elxhtxr
~ xuedeeify
>

Power loss in friction = UXWXV

Strebeck Equation :-

K Xd 2x z
co ball
bearing
= - →
-

kxdxhxz
bearing
Co = -
Rooter
-

5-

of element
Where , 2 =
no .

rolling
of element
d =
dice .

roiling
L of
Length roller
=

K = constant

*
Readily of Bearings :
-

is of
→
Rating life the life that 90% of a
group identical
bearing will

complete or exceed before fatigue failure .

R =
-
No .
of bearing which have successfully
-
completed L million revolutions

Total number of
bearing under test

→
reliability of bearing selected from the manufacturer 's catalogue is
0.9 or 90% .

Expected reliability is > 90%

Page 215 of 253

1

a Reliability
Relationship between life and
→
bearing
100 •

reliability is
given by a wie bull

Lso distribution
go • .

" *
O bearing
( No of cycles)
b
.

For R= e
-

( Ya)
,

where
,
R =
releabitity ( in fraction)
L =

corresponding Life

÷b
9=-6.48
°
:
÷=el4a)b loge =

#
b
-

if is Life
→ Loo the
corresponding to a
reliability of 90% or Rao ,

→ R =
90% =
0.9 → Failure = 10%

1h10
rife Tx Failure

'

iogef ,÷) frat) ②

-
-
-

dividing eg .
② by ② ,

* *

"
Tine: in: :c: :c:iii. tin:O:c::*
"

90% .

i
Lso is the median life life which
f. of → or

NY ,

{5÷ =

( tog
t°8el%
e ( Yo ) .g
) 50%

exceed
of the

before
bearing
fatigue
win

failure
complete

.
or

450 = 5-
.

: Lso = 5L
go

%
Page 216 of 253
1

If there sysm
Case : are N
bearings in the each
having the same
-

,
=

reliability R , then the reliability of the complete sysm is given by ,

Rs=(R
bearing failing during
Where ,
Rs indicates the probability of one out of N

its life time .

* Dynamicoadcarryngcapacity Cc ) : -

Fa
→

µ Angular contact
bearing
←

v → It can take axial and radial load .

F
R

Expected reliability → 907 .

of 106 ( L million)
No cycle =

is defined ( or axial
→ It as the radial load in radial
bearing load in thrust

for minimum life of million revolution

bearing ) that can be carried a one

with at least 90% reliability .

basic toad
↳ it is also called as load
rating or rated .

↳ The rated life is one million cycles .

P=CsfXVFRtYF#
where
,
Cs → service factor / Load factor
FR & Fa → Radial and axial force respectively
x and Y → Radial and axial factor
no → Race rotation factor .

if ,
inner race
rotating ,
0=1

outer race
rotating ,
V= 1.2

•
Tmax
→
design
* *

cs⇐¥m
Tag → specific . " ,

Page 217 of 253

1

if Lh Number of hours
working
=

N ⇐
Speed in rotation

:
NO.co/-cycles--6G0XLhxNcycl#
* Load
-
life relationship :
-

if ,
C = 10000 N → 13=0.9 → L = 106 cycles
Pr = 104 N → 1=106 cycles
'
Pz = to N → L > 106 cycles
13 =p 05 N → Ls 106 cycles

life is
bearing
↳
given by ,
** *

Lpo=§Jkcy of
in
→
only case 90%
reliability applicable .

life (
where
,
hero =
rated
bearing in million revolution )
C =
dynamic toad capacity

÷÷:÷.im
s.%9a.ii.ebre.iinekr.mg ,
*

NK
•

: CC =p ( Lpo)
given ,
so
by default
its 90% .

"3
for ball
bearing ,
C =P ( Lro)

0.3
for roller
bearing ,
C =p ( Lio)

→ The relationship between life in million revolutions and life in

hours
working are
given ,

Lio=60joNjLro②
where heron
,
= rated
bearing life ( hours)
n -
speed of rotation

Designation ,
bearing number :
63.01 ,

1--708*5 =
40 mm
mm

bore dice of
bearing shaft
↳ or .

→ As the third last digit increase toad

, capaciti also
increasing .

G 93-O 8
view
toad capacity PP
Page 218 of 253
1

B
Bearing Number : A C D

→ CD x 5 bore or inside or shaft diameter

B I → Extra light series

2 →
Light series

3 → Medium series
4 →
heavy series

A-
Type of bearing
G → Deep ball groove
7- →
Angular contact
o → set
Aligning bait
bearing .

Ques . If the
designation of a deep groove ball
bearing is 6014 ,

then bore diameter is mm .

-

soon .

-bore 70
diameter 14×5 = =

-
mm

QIU . If the dynamic capacity of 6205 number

bearing is 00.8 kN ,

the same for 6305 number

bearing must be
-
.

a) 5 kN b) 8 kN c) LO KN VED) 16.2 kN

Sorn .

C C last TP
6205 > 62-05 3 digid
C. 6305 > 10.8 loud
carrying capacity PP

Qys 4. L
.
.

Pp =
9800N Pz = 4900N ball
bearing ,

GATE 1987 Np =
1000 rpm Nz =
4900 ht K =3

LH = 3000 hours

k
Lio =

( PE) For same

bearing ,

: C =p ( Loo ]% C, Cz
•

.
=

"
( i 80 ] "3 b
9800 X = 4900 x ( Lio]
(hero) , = 60×N×L# ( Lro) =
1440
2
106

=
#
60×1000×3000 ( bro)z =

#
60 X N X Iroh
106 pot

( Lion)z
( hero) ,
= 180 =

1440×10660×2000
= 12000 hr → Ans
-
ur

Page 219 of 253

1

9us.4.se : Lio
( Ep)3 ②
.
=
-

GATE 1988
43
c. =
P ( hero ]
.

11 11

For same
bearing ,
P ( Lion ]3 =

1%140,213 i > if dia . at shaft

4 is reduced to half ,
3.
: Lior =
-
P = a torque capacity
Pk will also reduce
8 times .

La=g⑦
÷
÷
= 8

Pus The Life of ball load life

.
a
bearing at a of Lo kN is 8000 hours ,
Its

in hours if the load increased to condition

,
is 20 kN
, keeping all other are

same is .
-

[ GATE 2000 ]
Pp to kN P2 20 kN
SI
=
=
.

Nr = 8000 hr Nz =
-
hr

Lpo =
GOX MX Lion
to
same
bearing co Ca Lz 0.125 Lp
=
=

pp ( L , )% =
Paltz) "3
× Lz ,
in =
0.125×607 8000
"3

(F)
"

Eo 0.5
=
=

2
hz=1000h€

9.4.12 Pp = F Pz =
2E

GATE ( 2007) Lr ,h= 8000 hr Lz ,h= ?

"3
'
↳
Same
bearing ,
Pr ( Lr ) = P2 ( b) o
: L2 ,h = 0.125 his ,h
L2 h ,
= 0.125×8000

Y÷=ff÷)3 0.125 10001

=
=

Life ball of is hrs

Ques . of
bearing at load LO kN 24000 ,
If the road is

increased to 20kW
,
what is life ?

Pr = to kN 13=20 kN :

fh % to
.

Li h L2 , h 20
,
=
24000 =
?

Pr ( L, ]% =
Pz ( Lz]'
13
-
L2 =
to Xi 0×10

24000 20×20×20
°
:
Lol Lo ]% ( Lz]% Lz
300€ hrs
2408002
= 20 = =

Page 220 of 253

1

)
9.4.88 C = 26 kN

GATE 20dg p = 2kW

3×106=83×106
Lpf ( F) 3×106 =/ = 512×106
run
revolution

9.4.16 .
Two identical
bearing ,
Pr = 30kW °

: I = ?
GATE 2011 Pz =
45 kN L2

p → L Cr =
Cz
"3 "3
Q → 2 Pp ( Lr ) =P, ( Lz]

q→3
"3=
:( tf ) .
435¥ tf =¥3= at
,
L
m
-

Q .
4.22 C = 35 k5

GATE 2018 P =
45 KN

L =

( Ep) 3=1345313--0.47 below 0.5

"3
9.4.20
)
FL = K
"3
GATE 2015 o
: C = F L

"
↳
°

: 2x ( 540 ) %
= Fx ( r )

°
: F = 16.286 kN

9. 4.8 .
C = 22 kN
given : 6306

GATE 1997 N =
600 revlmin To deep ball
grove
Loh =
2000 hrs .

L =
GOXNX Lh =
60×600×2000 = 72
- f

106
I

106

"3

Icp)3 @ 2) 22
L= =

ps
.

:p=5.29kN②
CRPQ ( Pg . No .
64,65 ]

( g)
3
9. L
L =
o

:P=kN_
6210
↳
deep bearing ( ball)
C -

- 22.5 kN 27=122,5-13
1=27
Page 221 of 253
1

9.29 Life Rso

C =
48.545 kN Average →

'

: 150 = 5 Lso =
-
GOXNX Lh =
60×500×6000
-

Loo to 106

Lro = =
3=6 Lso =
180

#
→ Lso =

( 36 )
"3
=

48,5452 p=i4.7l

9. 3
=
&
41 FR = 2.5 kN

Fa = 1.5 kN

Cs = d. 5

N = 1000 rpm
× =
0.56

Y = i. 4

37 →
Total no .

of hr ⇐ 40×52×5 =
10400 hr

"
m
Lpo GOX NX 10400 60×1000×00400
:
624
•
= =
=
- -

=
106 106

4 > . → F =
Csf XVFR t Y Fa]
=
1.5/(0.56×2.5) t ( t.MX 1.5 ) )
=
5.25 kN

% C = Px 243
(6243% 6644.86kg
"

= 5.25 X =

Cf .
07 to
10J 1- 3 kN

⇐
ADF.mn#a::immD-.B.-r
|
RAY v

W =L kN
/
RB ,V
.

1000
#
B
N
saw

t 5 KN
-

7.7 Resultant radial toad ?

RR =
2/12-14.52 = 4.609
kNI4.6

Page 222 of 253

1

8 > . Maximum radial toad ?

EMB =O

RR X 300 = RAX 500

RA =
4.61×3002
500
=2.76⑦

toad ?
9 > Equivalent
.

bending
P =
Cut XVFR t Y Fa )

=
1/(0.56×2.766) t ( 2.5×2)) =4.55
to ) .
dynamic load ?

3
Lio
(F)
-

( ÷ )3

c-2 .39kN@tXDesignforcyoadsandspe dsEg.ba

60×40,006×50002
:
o

"
bearing operation under the
following conditions :

i > Radial load 2500 N at 700 rpm for 25% of the time

it > Radial load 5000N at 900 rpm for 50% of the time

iii > Radial load 1000N at 750 rpm for the

remaining 25% of the time .

→
Necessary to consider the complete work cycle while
finding out the dynamic
toad capacity of the
bearing .

Suppose that the work cycle is divided into x elements .

Let Pr ,
Pz ,
Ps .
. . . .
Bc be the toads
hi ,
ha ,
Ms .
. - - - Pn be the toads

Li
1¥13
'

: =
minion revolution

3×006
(
L, =
revolution

Page 223 of 253

1

→ in one revolution
,
the life consumed is 14L ]
,

:
÷ Hoo
.

= '
'

NxP
Yo'gP÷ztNo2gg Ca ) Life consumed
by the
SII
→
t +
- - - -

. . . .

106 complete work cycle .

life consumed
by the work
cycle =
N×l - - - -
(b)
3
106 [

: N Not Nz t Nz t t Nsc
-

=
. . . .

⑤
equating egn ,
⑨ and
,

's
N , P,
3
* Nz 133 t Nz Ps3 f- . . . .
t Na BP =
Nope

:
Pe
,3B3tNNs
-

Nlp t Nz t
Nzt . .
.

**

P → used for calculating the dynamic toad .

CRPQ
Q .
05 & 06

% of element Load speed Revolution in elements

time (kN ) ( RPM) time

30% 5 900 0.3×900 =

270

40% F 1440 0.4×1440=576

30 To 3 720 0.3 × 720 =

286

16.6 kN
given C =

57 equivalent radial load ?

Pe =

×576¥33T 270 -1576 f- 216

Pe = 6.067 kN

( Epe ) =/ !?%z]3=
3
6.7 hero = 20.48 million revolutions

Page 224 of 253

1

*
Bearing Applications :-

② for
Bail
bearing → Used light radial toad .

② cylindrical Rotter
bearing → Can not takes the axial toad .

③ Needle suitable for

oscillatory motions
bearing →
Ideally ,

IC Engines piston pin bearings Rocker ,

arms
,

Universal joint .

⑥ Tapper FR > Fa
roller
bearing →

It can take heavy radial and axial load .

Page 225 of 253

1

CHAPTER 11:- GEARS

Page 226 of 253
1

CHAPTER 11:- GEARS

SPUR GEARS
o

#
*
Terminology :

.¥µ÷!÷÷
-

"'
' ' and
missin !
4-
:*
men:c peace
Pitch surface ~
←
Gear
#
"" "
""
"

on:* :
land
clearance
Pdendum
circle
* velocity Ratio ( V. R )
. = Anguocit¥dng9a =
Speed ratio
of the driven
Angular velocity gears

→ size of gear Specified by pitch circle diameter (d) .

it is traced line
→ Involute → a curve
by a point on a as the
line rolls without circle
slipping on a .

Base circle →
imaginary circle from which the involute curve of the

tooth profile is
generated .

→ Base circle of two matting gears are

tangent to pressure
line .

Pressure ( x) is angle which the line of action makes with

angle → It

circle
the common
tangent to the pitch .

→ Also carved as
angle of obliquity .

11 . circular pitch ,
-

② 2= number
of teeth

P=d⑦ ②
2 . Diametral Pitch
,
-

From eqn ② and ② ,

P*p=T -

3 Module
m=÷= or
d=m ④
-

.
,

Page 227 of 253

1

4 Center distance between two

.

gears :

Wr¥ .

dp-d# map mzg

+
a = =
-
a = center to center distance
2
Lp = number of teeth on pinion
number of teeth
* *
2g = on
gear

q=M(2pzt2 ⑤ of ( )
:
pinion
•

Np =
speed RPM

Speed of gear ( RPM)

Ng
=

5
Gearratio

:i=EE
.

* Gears manufacture
by casting ,
blanking and
Machining

power transmission made

by steel
gear .

→
raining
→ Rack
generation
→
Mobbing Fae

→ Ferrone
gear shaper method

* : Analysis.
Force -

According to fundamental law of gearing

% ¥¥¥÷
,

o_O the resultant force Pm always acts

along the
pinion
driver line
pressure .

To
#
/¥¥P#
→

Pp
#

Fem of
Be

④
At pitch point
force By →
→
Resulting Mr .

← \ .

Tangential Radial

coins : int ami

:÷t
Use fun for the
separating
- →

determine the magnitude force .

of Always directed
the torque ,
power .

towards the center of gear .

Page 228 of 253

1

Power p = 2KN T= Torque transmitted by gear (

N mm)
-

GO
p Power transmitted by gears ( KKD
=

'
N =
Speed of rotation ( RPM)

T-ego.fm#,xio6N.mm ⑦
:
o

pitch circle radius

→
Tangential component acts at .

Pt x I = TT
2

Pt=2 ⑧
°

pr-ept.to#T-- ⑨

Resultant force PN ,

Pn=cPot⑤ -
④

Assumption :
-

I. 3 As the point of contact moves ,

the magnitude of resultant force
force PN changes .
This effect is
neglected in the above
analysis .

2. D
only one
pair of teeth takes the entire road .

3 > . Valid under static

loading .

→ decide direction of two component :-

÷¥÷→
Afsisnuimoedi 's driving element . CA.c.ws)

gear is driven element .

( cm)
,

#
Q . 5.40 .
P = 20 KW P =
2TlNT_ =
we x-p

GATE 201g we =
200 rad Is 60

Pg .
No .
210 D= 100mm
°

: T =
20×1032 = 100 N . mm

9 = 200 200 I 100×103 N mm-

→
Pit =
= 2×20/0×1032 =
22000 No

dog 1007

→ Pr = Pt .
tan X =
20000 X tan 20 =
727.94 N =
0.73kg
Page 229 of 253
1

9. 5. Tt D= 50 mm → P= Tx we
P
GATE 2014 we = 200 radlsec T = 3×102 = 15 N - M

P =
3 kW
200
z r -5×003 N .
mm

4 = 200

F- =
? Pp = 2. F
=
2×15×103 = 600 N
- -

dp

50--3 Normal force ,

PN =
-
Pt =
-
600 = 638.551N
Tf
- -

( 0520 COS 20

CRPQ Zp =
25

G. 1 Np =
1200 rpm

Pg .
No 89 .
Ng = 200
rpm G. R .
=
Lg
-
=
-
Np
mmodulus of teeth 4mm Ip NG
gear
=

.
.

2g 1200
=

m(Z9
-
-

center
of distance = 25 20

2
2g = 150

=
41251-150)
=
=
350 MM
+

( Rpg Lp =
19
a =
m(2pt2g)
T
9.2 2g =3 -7

Pg No .
89 A =
140 mm 140 = Me ( 19 t )
37

÷m=5m⑦

60×10×1069.4
CRPQ p= g KW p =

. N =
1440 rpm 2xIxN

60×9×106
Pg .
No -
89
dg =
100mm
-

2×1×1440

=
59683.10 N - mm

2. T
Pt =

Tg
= -
2×59683.10 = 1193.66 N I I. 2 kept
100

CRPQ P =
to KW

9. 05 V = 600 mlmin P = Tx at

Pg . 89 D= 100mm p = TX I
R

T =
10×103×50 50000 N mm-

600/60 = 50 Nom
Nrm

2 XT
Pf =
-
=
2×50000
-
= 1000 Nd = t kN -

-
D too

Page 230 of 253

1

Beamstrengthofg-eartooth.ir
*

Lewis eqn is considered the basic

✓
I → as

T equation in the
design of
gears

µt
.

At
l
lb
i → cantilever beam
if i

in:& :n÷ia:O:::*:*.am:S :*
" .

I 1- I
of tooth
:
.

1-
f- I - . . -
- -

t
. -

i
# h →

Assumption :-
i > Effect of the radial component ( Pr ) which induces
-
,

is
compressive stress
neglected .

ii > ( Pt) is
It is assumed that the
tangential component
uniformly distributed over the face width of the gear .

This is possible when the

gears are rigid and

accurately machined .

till The affect of stress concentration is

neglected .

in It is assumed that at time of

any only one pair
teeth is in contact and takes the total toad .

Pp

I.
/ → Tooth profile is
pageboy
t
in
bending .

*±±
Pf E of parabola
if i
,
'
Advantage outline is
it i

.
beam of uniform strength .

↳ weakest
i portion ,
where parabola tangent to the
i
' i. N
! e tooth profile .

t
:
ON At section XX
,
Mlb =
Ptxh

: I
batz y=tz
°

:
.
=

Bb
MEI Ptxhxtzx ¥5
=
=

: Pt = 2/6 b. b. FEZ .

:
Pf =
-
6b . b. t2
-

h.tf.LI 6. A
6

Page 231 of 253

1

→ Pt = m . b. bb .
th
6hm
-

Y → Lewis form factor

Y-Lewisformfactor-c.tn
°

:
pt-m.b.bb.IT Give relationship between tangential force
°

and the
corresponding stress .

Pt PP lob PP

when stress reaches to

permissible stress ,

the force beam

corresponding carted as

strength .

maximum value of tangential force

→ the
bending strength is the that

the tooth can iitransit without

bending failure .

sbe-m.6b.b.IT
where Sb beam of tooth CN)
strength gear
=

Gb permissible strength ( NIMMD

bending
=

* *

it¥::÷s%±:÷%÷i
*
strength factor :
-

K =
( Pt) pinion =
{ mxbxbbx Y ) p
-
-

( Pt) Gear ( mxbxbbx Y } a-

bp=bG⇐÷
→
Mp =
Mg &
* *

if k > I
,
Pinion is
stronger →
Design should be for gear
KSL ,
Gear is stronger →
Design should be for pinion

6b×Y=strengthfactor

Page 232 of 253

1

**

*p=o.rsy_o.9z
For ,
200 full depth sysm ,

2. = No .

of teeth 2 PP
0.942-11 .
YPP

:
•

2g >
Zp
:
Yg >
Yp

%bf54.FI#.ygxxoYIp-sadee:.rgnissnsoIi:ngerfor
* If pinion and both are made of same material
gear ,

*
Velocity :

effect of
→
Cu is used to consider dynamic loading .

pt-m.bobb.PE
Static design ,

=
permissible tangential toad

dynamic road
→ In
loading ,
the permissible tangential will be

smarter than that of eq . of static .

i > Co > I ii > Cu EI

Pt Cv
Pt=m.b.6boYT
load pinion
→ tangential on

945 .
M = i. 25 mm 6 = Ku WT
#
-

Gate Fm Y
2020 Lp 20
-

9=200
6.F.m.TN/p=
Pt =

ku 1200 rpm

2g =
60
=
400×50×1.25×0.3222
b = f- = 50 mm 1.26

Y = 0.322 Pt =
6388.8g Nt

Ku = t .
26

Gb = 400 Mpa

Page 233 of 253

1

Power =
Pt XV =
Pt x Rx we
°

: m = I
T

=
6388.89 X
25
×
2X Text 200 d = m .
I
- -

2×103 60
Up =
1.25×20

=
10035.64 Watt = 25mm

=
10.04 kW = ro KW
I #

PUS . 5.9 and 5.10 4=200 g y f- = 60×10×1062

GATE 2009 m = Mmm 2K Np

Zp = 21
= 60×05×0062
P =p -5kW 2X SIX 960

N =
960 RPM
f- = 149207.76 Namm

b = 25mm

Pt = 2 -
T =
2. T
- -

dp mx2p

Pt = 2×149207.76 = 3552 ht
-4×20
-

to >
geometrical factor / Lewis factor (4) =
0.32

Cu = i. 5

Pt =
m.b.bb.it Cu > L

Cu

-
3552 X 1.5
= bb
4×25×0.32

→ Lb = 166.5 N/mm2

945 . 5.8 . M =3 MM °
: Pt =
m.6b.b.pt
GATE 2008
Lg = 16 Cu

b = 36 mm

4--200 °

: P =
Tx LANs
P =
3kW f- =
-
3000 = 23.87 Nm = 23.87×103
Nom
NN§== 20 REVIS 2X SIX 20

Cu = 1.5

Y = 0.3
°

: 2. T 3 X Gb X 36×0.3
-
=

dg i. 5

r
: fb = 21123.879103kt =
46.05 Mpa
3×1693×36×0.3
=

Page 234 of 253

1

Cf .
5.5
,
5.6 and 5.7 Lp =
20 teeth 5.7 center distance ,

GAT20F 2g = Leo teeth

Zp )
Np
9=21 ( 2g
= 30 RPS f-

p = 20kW

X = 200 =

5-2 [401-20]
m = 5 mm

Length of arc = 19mm a=r50m⑦

6. D contact ratio =
Length of arc
-

circular pitch

19 19 19 = I. 2b
- -
= #
=
- =

Tex M 1×5
Ted
2

Pt Pt 2T T= 20×106
7. § PN =
f
=
-
#

COS 20
dg 2×57×30

2122.06 2×106103.29 T = 106103.29 N mm -

= -

= -

cos 20 5×20

=
2258226N -
= 2122.06 N

CRPQ Pt =
mxbxbbxy art the opt Y > 0.3

Cf .
3 7.56×103 =
8×90 X 35
XY
SO TL not there .

Pg No 89
Y
-

0.3
-

.
.
-
=

CRPQ p = 2kt Y for

60
9.6
Pg . No .

8g =
2tNxPtx R
GO

257N M * I

go-xmb.by Yax
=
.
-

2×03

°
: 20 X r 03 =
#
2×57×300
x m × the XM X 80 × 0.094 X X X
MX 18
#

60
2×103

m=5.98=Gmmf
CRPQ .

Tstarting =L -
5
Thinning
9. 07408
Pg 90 60×11×103
Thinning
No 60 P 72.94 Nom
-

=
. .

= =
-
-

LAN 2x XX 1440

Tstarting = 1.5 X 72.996 =

109.42 Nom

77 Pt =
Ltstarting =
2×009-42×1032 = 1458.93 ht

m x -2 6×25 = 1.5 kN
-

Page 235 of 253

1

87 Pt = m . b. Gb .
Y .
JL .
Cu 4=0 . A

1458.93 = GX b X 200 X 0.8 X SIX 0.28 Cv =

0.29

: b = 17.57mm = 18 mm
I

CRPQ Strength factor = Bb Y -

9. 12

Pg . No .
90 bb Y strength factor =6boY
Pinion 120hPa 0.093 11.26 Mpa → pinion is

Gear 100 MPa 0.13 13 MPa weak .

CR Pg j = Lo = Ig
9. 9 to 11 Tp
Page No 90 .

Lg = 10
Lp

Mz ( 2g -1210)
C. D .
=

( )
821
660 =
Lp -1102 p

Zp = 15

: Bp m2p 8×15 120

°

mm
= = =

9 > .

Pt =
2T 60 XP
- = -

Dp RpX2XIXN

=
2×60 X 500×103×103 = 44209.71 N
-

120 X 2X TL X 1800 = 44.2 kN

-10 . > Pr =
Pt tana
-

44.2 tan 22.5 18.32 radial toad

kN
Neoteny ( Not )
a =

↳
=
a- . .

Radial load on tooth

Radial toad on
bearing ?

Rv
bearing RH both
•
: on
,

are radial force

1
.

pD.com#-h p
o

Tota 'I÷¥I bearing

on

"

Ey
' .

t
I o
: PN = Pt = -
44.2 kN

RA ,v = Pr v j cos 22.5 COS 22.5

Pr
pN=47.84k÷

Page 236 of 253

1

* wear
⑧
strength of gear tooth :
-

→ Earle buckingham
The wear strength is the maximum value of the tangential force that the

tooth transmit failure

can without
pitting .

Pw
=Sw=boQ.dp o
: Sue X
{ Ept fig }
Where Sw : Sue BHN
.

wear
strength X
=
,

Q =
ratio factor
K =
Load stress factor

Load factor CQ ) ,

Q={jf9z External
gear
( by default)
.

: 9 =
2(o
G. R .
+ I

?§
Q=z2go}a
Internal gears

Load stress factor K

,

Se = endurance strength

se2.,?ignx. [ ¥p LEG? Young 's

°
:
K =
E = modulus
+
X =
pressure angle

{ 13,11%12
: K
°
=
o.io x For

CRPQ r
:
g =
-
2×28 =
2×29/2 p
-

9. 13 Zg t Ip 2g g- L
-

/2p
No 90
Pg .

2 ( G. RD
§
2×2
Q =

-
= =
=
1.33

G. R . T L q

: Sw = b. Q .
dp .
K

= too x t - 33 X 400 X t . 5 =
80000 N

= 80 kN
=

Page 237 of 253

1

CHAPTER 12:- SPRINGS

Page 238 of 253
1

CHAPTER 12:- SPRINGS

* seriesandparaeconnectons : -

Seriesconnections
P

force
→ The
acting on each spring is same and equal to external

H force .

§
The total deflection of
spring combination
"

i s equal to the sum

Of the deflection of individual springs .

x - - . .
-
×

* *
B
:s=si- deflection of
.

g
spring
§gII×
→

× -

: stifness *
Ig
.
⇐
,

"t¥ Peg PEI

: s, Sz
o

=
and =

¥=P÷tP¥t . . . . . . .

* *

but pp=Pz=Ps=€T

¥ # Fut
so
, =
t . . . . .

* *

"

keg=÷¥
Paralretconnection
force the combination is
p The
acting on
spring
f- equal to the sum of force acting on individual
I / springs .

} §
The deflection of individual spring is same and
*i K2 equal to the deflection of the combination .

* *

¥ P
p=p
we know K = I
,

* *
8

but : P=k s .

°
: KS = Krs t Kast . . .

teg-kr-kztks.tn#
Page 239 of 253
1

CRPQ

Fg?no . .. ¥InE"im.DE#Emiijn-fEParaner connection

keg =
kit K2
⇐
3kt 5k ⇐
88 µ

: 8=1 =
B-
Keg 8K

*
Terminologically :
-

D= wire diameter Cmm )

of
Spring
<④/# -
Di = inside diameter of
spring
coil ( mm )

/
= .

+ outside ( mm)
# Do diameter of
spring coil
=

D= mean coil diameter ( mm)

:o=oit
.

"
""

staring namexeaniscoidoetdini::* : one

¥¥⇐f
a
wire diameter .

a
e -
Do -

index indicates relative

spring sharpness
→

coil
of curvature of .

C e 3 → Actual stresses in the wire

are excessive due to curvature

effect .

variation dice
C D i -5 →
large in coir .

c =
he to 12 For all practical application .

Stiffness of the
Spring ,

k=P where ,
K
P
=

=
stiffness
axial
spring
of
spring
force
(Nlmm)
( N)
s = axial deflection of

spring corresponding to

force P Cmm)

Page 240 of 253

1

tressanddeffectiprngo.TW
*

o egn →
L . Load stress eqn
2 .
Load deflection egn

pp
p
¥4 .

-
-
-

§
.

#
E
my
#

I 0 i -
-

X
.

-
t
F- # Dt2

tp F
'

P is
→
acting at end
of bracket induced torsional shear stress .

T=P
e.
=%a Ea
'
-

a=% -
⑦

→ The equivalent bar is bent in the form of helical coil ,

there are

additional stresses on account are

following :

i > direct transverse shear stress

or in the
spring .

it > when the bar is bent in the form of coil ,

the length of the

inside fiber is less than the

length of outside fiber . This results

in stress concentration at the inside fiber of the coils .

eg ② does not take into consideration the effect of direct shear stress

and stress concentration due to curvature effect .

Assume ,
Ks =
factor to account for direct shear stress

Kc =
factor to account for stress concentration due to
curvature effect

Page 241 of 253

1

: combined effect ,
k=ks

it Torsional shear stress

it ) Direct shear stress

iii) combined
roading

a÷gz 7¥
Direct shear stress Ez = =

Tz=8Izf0I -

Resultant shear stress

,
C- =
To t Tz

.to#-c=8%34r-o.ejdQ--
:# ÷
'
=
+

Ks
( 0.31)
Lt
°

: =

* *

Ks=fzxq
-

A.M . Wahl 's derived the eqn for resultant stress

,

T=k.8y K =
stress factor or Wahl factor

Page 242 of 253

1

Wahi factor ,

k=%+Q{B# C =

Spring index

↳ simple method to find out resultant shear stress

in the springs .

Resultant shear stress maximum at the inside radius

of the coil .

Angle of Twist ,
O =

ILL
d. G

where ,
O =
Angle of twist ( radians)

T =
Torsional moment

L
Length of the bar
=

d- =
poker moment of inertia of bar
G modulus of
rigidity
=

X Je D N

o=b%Dj zoo .gs !

°

:
o = m -
.
active

' '

off
Axial deflection 8

) ( ) spring the ,

8 =
O x ( Length of brackets )

.
,
÷ . "

* *

:s=spa%
s

Ivp
( K) ↳
of
spring Pz ein
rate K = Load deflection .

p
* *

k=g¥
- - - - - -
A

strain
energy ,
Ut °
strain energy
°

Page 243 of 253

1

it
WEY N, Nz =

Totaizturns
=
. -

I 2

×
ki =
Kz = 2K

is
mmmmm-m.tt#e--tE.-Ea--F-Ie=LTekr=2kkz-
-

2K

: ke K
ro

X
2K

ii. D -

Tmnt x
2K
→ keg =
2kt 2K = 4k

CRPQ k x I
g. e Nr

Pg .
No 95 . K N -
= constant

( kN ) ( kN )
original
=
cut

spring spring
'
: kN K I
o
= .

Kt==3

Iq's d2
CRPQ F =
3600 N A wire = = 365L

0.2 .
A wire = 36 I MMZ

Pg .
No . 95 C =
do d ⇐ 922 MM

c-
8PDeµ ) : C I
=
It
Tld
's
d

( ]
= it D= Cxd = 10×12=120 mm

⇐
668.45 Npm m2

CRPQ
9. A
-mga =
¥ N/mm3
,
Imax =
to × 8
The
G = 80×103 Mpa 22

#D3
8,417€
TLDN I
,
L = 800 TL =
= ×

: DN = 800 mm N / Gd 't

d =
8 mm I TOO * Dfat
ad

2.
(F) N =

foe x a. d

(80012 =
80×103×8
-

LO
N

Page 244 of 253

N=L0m⑦
1

Gates A helical
spring has
spring constant K .
If the wire diameter ,

diameter the of coils all doubled then

spring and number are

of
the
spring constant the new
spring becomes
=
.

Sol . A> Kk
I

I § K ⇐
GDI FB > K
8ND3 C > 8k

g.Y.IS?Y-..p-=ajd!.=E
' ' K' ⇐
d > role

¥
9. 11.1 AD
GATE 1987
¥ =
IT t
tf t
¥2
( Pg
{
No 173] ,
K,
. .

I
=

# +
¥ ,

{ ki =

Kika

I o
: K =
Kika

{ Kz
Kr take

¥ .

BD TP keg ② = Kit Kr = 2K ,

1-

Hu Ki Ki
÷, :# ¥ .

I l L
=
2
-
kit Kz

T
-

keg 2kr.kz

{ Kz ÷
keg = 2ki.kz
2kt # K2

¥
ex t ← DD t
l l l l l
ke9②=2kz
"
{ } { Kr Kz
m m
{ Kafka
=a¥t¥
L

l l l l l .

|
T
-

{ :
Keq②=2Kr
s

K
,

2kz kit
#

¥ ,

Keg = 2k . + ka

Page 245 of 253

1

P.gg
9. 11.2 k Nlmm
toooo
N = 20 ⇐ =
= 100
→

GATE 1995 p =
1000 N H
s -
romm
×{×
it cut into 2 piece ,
I
K -

IT
Fwm
P 1000
-

MEWF
at =
-
=

} {
→ -

8 8
2K me
8 =
1000 1000 = 2.5mm
=

#
-
-
-

: K' = 2K 4×100 400

9. 11.3 K = I 8=10 -

Lf
GATE 2005 88

i> K =
I
2g ii > k =
22g
#

Lo -
200
Lo -

200

:
2g = Kho -

200k 22g = Kobo -

LOOK

22g = E. Lo -
LOOK → (2×9.81) = 1960 Lo -

40.2×0960)
2g = k Lo -
200k : Lo = 200mm

-
-
+
-

20g = LOOK

k 20×9-81
=

-
=
199660 Nlm
100/203

9. 11.4 D= 2mm

GATE 2008 IT = 800 MPa

G = 80×103 Mpa

D =
20mm Dz= 10mm
,

Lfree = 40mm K =
?

N =
10
Always ,

=Dlot KPP

i> K =
644 K, =
Gd4
-

-8133N
8 (2033 N -

ki = Gd 't
-

8000×8 N

Gd'll Gd4
ii > Kz =
-
=
-

8X Cio)3xN 1000×8 N

:
Kz 8000
-

-
I -
= 8
Ki 2000

:kz=
Page 246 of 253
1

Q . 11.6 Imax =
24 MPa

GATE 2017

c
; Imax =
8PD_ = 24
IT .
43

Ez =
Emax =
8 P ( 213) = 8 PD
- -

3
Tl .

( 2 d) 4×43

:
Tz = Tr =
-
24 = 6 MPa
-

4 4

9. 11.7
.

Change in
Spring stiffness = ? ( %)
GATE 2018

i k =
G. d9
p
-

's
Tl D Np

Kz = G(i.02d)4 =
I. 08243 ki
's
Je D N

change in stifness = K2 x 100%

Kr

0.08243
= X HOO =
8.242%
u r

Page 247 of 253

1

CHAPTER 13:- DESIGN OF SHAFTS

Page 248 of 253
1

CHAPTER 13:- DESIGN OF SHAFTS

* shaftd
strength :
-

Transmission to axial tensile force

shafts are
subjected ,
bending moment

or torsional moment or their combination .

Transmission shaft are

subjected to
→
bending moment
Twisting moment

Axial tensile force , ft = I =

di I. d2

dk
Pure
bending moment
,
Gb =

MEI =

32M¥44
=

Ted 's
64

Tjr
T.cl/2--gz.q4=tGT
Pure torsional moment
,
I -_
=

A- Add -3

if of force
,
combination axial
,
bending moment
, Twisting moment

6×=6t
if ,
combination of
bending and torsional moment without
any axial force

6x=⑦
(E) tf
§
a
°
: -

-
Fundamental eqn for design a shaft .

)#
2 2
@

Imax ⑦
•

• = +

I> Maximum principal stress theory :-

Gb =
32Mt I =

3 's
Tld Ted

t.IE#EasTa=IfasLm-ofE-
÷: a -
-

I
Page 249 of 253
1

I -5 Meg Equivalent
6, =
-

3
where ,
Meg =

bending moment

Tld

→ when
acting alone ,
will produce the same

by =

bending stresses in the shaft as under the

Fos
combined
loading .

6r=÷,eg
.

:Meg=M-fM2tT#
27 Maximum shear stress
theory

Imax =

.VE#tEasF
=

Imax
,÷ 1¥72
:
°

Where , Teg =
equivalent torsional moment

Imax =L6#
Tlds

Imax =
Ssy =
Syt
-
-

FOS FOS

:tmax=I÷=÷a5
* shaft design on Torsional rigidity basis :
-

( Lateral Rigidity )

→ If it is does not twist too much under the action of external torque ,
is called shaft on torsional rigidity basis .

→ If it is does not deflect too much under the action of external forces
of lateral
and
bending moment ,
it is said to be rigid on the basis
rigidity .

Such application like machine tool spindle it is to design

,
necessary
on basis of torsional rigidity .

Page 250 of 253

1

: O = O →
radians .

G. F
"
-

: d- = Id
32
O =
-
180 × T L
.

Tl
G. F

II
'

tax
'
=
× x

O=58g4.dT
O =
angle of twist ( deg ) .

of shaft subjected ( mm)

L =
Length to
twisting moment

T = Torsional moment ( N - mm )
of N/mmD
G =
Modulus
rigidity (

d =
Shaft diameter .
Cmm)

→ As per ASME code for shaft design ,

)
Imax = 0.30 Syt ( whichever is minimum )
Imax =
0.18 Sat

For the key slot is to be reduced by 25% .

Imax = 0.225
Syt
Imax = O .
135 Sat

3¥ ,(k2tkT)
)
→ Imax =

Fhiiiiati loading .

Go
,%fMkbµc¥, z )
→ =

* Design of Hollow shaft on

strength basis :
-

let ,
di = c

do

di = inner dice of hollow shaft

do =
outer dice of hollow shaft
C =
ratio of inner dice to outer diameter .

Page 251 of 253

1

Axial Tensile force lot = GP 4P

=
, -

CI
-

Jl ( doz -
d ;D Idf ( r -

bending Moment ,
Gb =
M ÷ 6b=32
L
Tldo3( r c4) -

: I
( do't di 't )
e

= -

64

= I do 't ft - ch ]
64

•
: De
y
=

Torsional shear stress ,

C- =

F : C- = 16T

:
-

d- = do
't
(t -
ch) T¥c4J

r= de
2

i> Maximum principal stress theory

↳ =

.cat#aF/Mtt* )
by =
16 Meg
Ttd)

a=:÷=::%÷
ii > Maximum shear stress
theory

emax=s÷=I÷s=%%
* Design of hollow shaft on torsional rigidity basis :

o=:::÷

Page 252 of 253

1

Gus
qEd2
1.2 W L
.

Tma ,
= = .

f.
Gate Iggy Tlds

Pg . No .
252

T =
C-max.tt
TG

tmaxjt.cl#
I
*¥
o
: =
x =

W , 4. g. L

T
o
: - xd
w

9. i. 5 .
dB =
2dA Imax =
1Gt
TA Jed 's
GATE 1994 = ?
-

TB f- =
Imax .
I .d3
To

dat yds
I÷ T
:
•
. .

.
=

's
( dB)

:¥.=
s

Q . 4.17 T= 50 Nm

GATE 2012 Farrow = 140 MPa →

Ssg
Pg No . 269 FOS =
2

Ssy =
-
16T
-

FOS Tlds

; d
's
=
16×50×003-1122 D= 15.37mm

IT X 140 I 16 mm

Page 253 of 253