Answer Keys

for Design
Works
 DESIGN WORK NO.1

Design Of Machine Members Under Pure Tensile Load

Problem 1.0

Given: F = 8,000 lb

h = 1.5b

L = 15 in

Find: Dimensions of the section based on:

a. Ultimate strength
b. Yield strength
c. δlimit = 0.005 in

Material Specifications: AISI C1045, as rolled

σu = 96 ksi Table AT 7, p. 14

σy = 59 ksi

Factor of Safety (repeated, but not reversed, ductile)

FSu = 6 Table 1.1, p. 2

FSy = 3

Solution:

Induced Stress:

F
σt = A ; F = 8,000 lb ; A = bh ; h = 1.5

A = b(1.5b) = 1.5b2

8,000 lb
σt = 1.5b2

a) based on ultimate strength

Design Stress:

1
 σ 96 ksi
σdu =FSu = = 16 ksi
u 6

for a good design,

σdu = σt

1 𝑘𝑖𝑝
8,000 lb ( )
16 ksi = 1000 𝑙𝑏
2
1.5b

b = 0.5773502692 in

5
b = 0.577 in. , say in.
8

h = 1.5b = 1.5(0.625 in) = 0.9375 in

h = 0.938 in. , say 1 in.

b) based on yield
Design Stress:
σy 59 ksi
σdy =FS = = 19.66666667 ksi
y 3

for a good design,

σdy = σt
1 𝑘𝑖𝑝
8,000 lb ( )
19.66666667 ksi = 1000 𝑙𝑏
2
1.5b

b = 0.5207556439 in
9
b = 0.521 in. , say in.
16

h = 1.5b = 1.5(0.5625 in) = 0.84375 in

7
h = 0.844 in. , say 8 in.

c) δlimit = 0.005 in,

for a good design,

2
 FL
δlimit = AE ;

F = 8,000 lb L = 15 in.

A = 1.5b2 E = 30 x 106 psi

(8,000 lb)(15 in.)

0.005 in = (1.5b2)(30 x 106 psi)

b = 0.7302967433 in.

3
b = 0.730 in. , say in.
4

h = 1.5b = 1.5(0.75 in) = 1.125 in

1
h = 1.125 in. , say 1 8
in.

3
Problem 2.0

Given: b = 19 mm

h = 38 mm

Find: Force (breakage), Maximum allowable load (ultimate)and the Maximum allowable
load (yield)

Material Specification: AISI C1020 Annealed

σu = 57 ksi Table AT 7, p. 14

σy = 42 ksi

Factor of Safety:

FSu = 4 (given)

FSy = 2.5 (given)

Solution:

a) Force (breakage)

Design Stress:

σ 57 ksi
σdu =FSu = = 14.25 ksi
u 4

σy 42 ksi
σdy =FS = = 16.8 ksi
y 2.5

Induced Stress:

F F
σd = A = bh

F
σ = A ; F = A(σ)

since material is ductile,

F = A(σy) = (bh)(σy)

4
 1 inch
F = (19 mm) (38 mm) (25.4 mm)2(42 ksi)

1000 lb 9.81 N
F = 47.002294 kips ( )(2.205 lb)
1 kip

F = 209112.2468 N

b) Based on ultimate strength

σdu = σt
F
σdu = ; F = A(σdu) = (bh)(σdu)
A
1 inch
F = (19 mm) (38 mm) ( (25.4 mm)2(14.25 ksi)
1000 lb 9.81 N
F = 15.94720689 kips ( )(2.205 lb)
1 kip

F = 70948. 79802 N

c) Based on yield strength

σdy = σt
F
σdy = ; F = A(σdy) = (bh)(σdy)
A
1 inch
F = (19 mm) (38 mm) ( (25.4 mm)2(16.8 ksi)
1000 lb 9.81 N
F = 18.8009176 kips ( )(2.205 lb)
1 kip

F =83644.89872 N

5
Problem 3.0

Given: D = 20 in.

Pmax = 125 psig

Find: Diameter of rod based on: a.) ultimate strength; b.) yield strength.

Material Specification: AISI 3140 steel, OQT 1000 F,

σu = 153 ksi Figure AF 2, p. 11

σy = 133 ksi

Factor of Safety (repeated, reversed, ductile)

FSu = 8 Table 1.1, p. 2

FSy = 4

Solution:

F πd2
P=A; F =PxA; A= 4

π(20 in.)2
F = (125 psi) ( )
4

1 kip
F = 39269.90817 lb (1000 lb) = 39.26990817 kips

Induced Stress:

F πd2
σt = A ; F = 39.26990817 kips ; A= 4

39.26990817 kips
σt = πd2
4

a) based on ultimate strength

Design Stress:

σ 153 ksi
σdu = FSu = = 19.125 ksi
u 8

for a good design,

6
 σdu = σt

39.26990817 kips
19.125 ksi = πd2
4

d = 1.616904167 in.

5
d = 1.617 in., say 1 8 in.

b) based on yield strength

Design Stress:

σy 133 ksi
σdy =FS = = 33.25 ksi
y 4

for a good design,

σdy = σt

39.26990817 kips
33.25 ksi = πd2
4

d = 1.226278679 in.

1
d = 1.226 in., say 1 in.
4

7
Problem 4.0

Given: F = 40 kips

L = 4 ft = 48 in.

E = 30 x 103 ksi

δ = 0.024 in.

Find: Dimension of the section, b or h since square bar.

Material Specifications: AISI C1045, annealed

σu = 90 ksi Figure AT 8, p. 16

σy = 55 ksi

Factor of Safety:

FSu = 5 (given)

Solution:

σu F
σd = =
FS A

90 40 kips
=
5 b2

b = 1.490711985 in.

FL
δ = 𝐸𝐴

(40 kips) (48 in.)

0.024 in. = (30 𝑥 103 𝑘𝑠𝑖) (b2)

b = 1.632993162 in.

3
∴ use b = 1 4 𝑖𝑛.

8
Problem 5.0

Given: D = 0.75 in.

A = 0.334 sq. in.

L = 5 in.

E = 30 x 103 ksi

σt = 0.8 (σy)

Find: Total elongation.

Material Specifications: Cold finished B1113

σu = 83 ksi Figure AT 7, p. 14

σy = 72 ksi

Solution:

FL F
δ = 𝐸𝐴 ; σt = 𝐴

σtL
δ= 𝐸

(0.8 x 72 ksi)(5 𝑖𝑛.)

δ= 30 𝑥 103 𝑘𝑠𝑖

δ = 0.010 in.

9
 DESIGN WORK NO.2

Design Of Machine Members Under Pure Compression

Problem 1.0

Given: 𝜎𝑢 = 65 𝑘𝑠𝑖

𝐹𝑐 = 1500 𝑘𝑖𝑝𝑠

FS = 8

D = 2d

Find: Outside and Inside Diameters

Material Specification: Cast Steel ASTM A27-58 Normalized

𝜎𝑢 = 65 𝑘𝑠𝑖 (𝑔𝑖𝑣𝑒𝑛)

𝜎𝑦 = 134 𝑘𝑠𝑖 (Table AT 6, page 8)

Factor of Safety

𝐹𝑆 =8 (given)

Solution:

Design Stress

𝜎 65 𝑘𝑠𝑖
𝜎𝑐 = 𝐹𝑆𝑢 = = 8.125 𝑘𝑠𝑖
8

For a good design:

Since there is no length given to compute for slenderness ratio, assume case 2.0.
Use JB Johnson formula.

𝜎𝑦 𝐿2
𝐹𝑐𝑟 = 𝜎𝑦 𝐴 [1 − 4𝜋2𝑛𝐸𝑘 2 ]

Since D = 2d,

L = 20D = 40d

10
 𝜋 𝜋 𝜋 𝜋
A = 4 (𝐷2 − 𝑑 2 ) = 4 (2𝑑 2 − 𝑑 2 ) = 4 (4𝑑 2 − 𝑑 2 ) = 4 (3𝑑 2 )

𝐷 2 +𝑑2 2𝑑2 +𝑑2 4𝑑2 +𝑑2 5𝑑2 √5𝑑

k=√ =√ =√ = √ 16 =
16 16 16 4

𝜎𝑦 𝐿2
𝐹𝑐𝑟 = 𝜎𝑦 𝐴 [1 − 4𝜋2𝑛𝐸𝑘 2 ]

𝜋 35ksi ×(40𝑑)2
1500 𝑘𝑖𝑝𝑠 = 35ksi × [ 4 (3𝑑 2 )] × [1 − 2 ]
√5𝑑
4𝜋 2 (1)(30×103 )( )
4

d = 13.0940967 in

Compute the B /𝒌𝟐 criterion:

𝜎𝑦 𝐿2 35𝑘𝑠𝑖(20×13.0940967 in)2
𝐵 = 𝜋2𝑛𝐸 = 𝜋 2 (1)(30×103 𝑘𝑠𝑖)

√5𝑑 √5(13.0940967 in) in

𝑘= =
4 4

B /𝑘 2 = 0.6052252036

Solving for slenderness ratio,

𝐿 40𝑑 40(13.0940967 in)

= √5𝑑
= √5(13.0940967 in)
𝐾
4 4

𝐿
= 71.55417528
𝐾

𝑳
Since B /𝒌𝟐 < 𝟐 and 120 > 𝑲 >30, Case 2.0 JB Johnson’s Formula governs the

design, dimension stays.

1
d = 13.0940967 in, say d = 13 2 in

1
D = 2d = 2(13 2 in) = 27 in
1
d = 13 2 in, D = 27 in

11
Problem 2.0

Given: D = 8 in

𝑃𝑚𝑎𝑥 = 200 𝑝𝑠𝑖 = 0.2 𝑘𝑠𝑖

L = 20 in

𝜎𝑢 = 70,000 𝑝𝑠𝑖

𝜎𝑦 = 38,000 𝑝𝑠𝑖

𝜎𝑑 = 8000 𝑝𝑠𝑖

Find: Size of the rod.

Material Specification: Cast Steel ASTM A27-58 Normalized

𝜎𝑢 = 70 𝑘𝑠𝑖 (𝑔𝑖𝑣𝑒𝑛)

𝜎𝑦 = 38 𝑘𝑠𝑖 (𝑔𝑖𝑣𝑒𝑛)

Factor of Safety:

𝜎 70 𝑘𝑠𝑖
𝐹𝑆𝑢 = 𝜎𝑢 = = 8.75
𝑑 8 𝑘𝑠𝑖

𝜎𝑦 38 𝑘𝑠𝑖
𝐹𝑆𝑦 = 𝜎 = = 4.75
𝑑 8 𝑘𝑠𝑖

Solution:

Design Stress:

𝜎𝑑 = 8 𝑘𝑠𝑖

For a good design:

Since there is no length given to compute for slenderness ratio, assume case 2.0.
Use JB Johnson formula.

𝐹𝑐𝑟
To solve for 𝐹𝑐𝑟 , use the formula 𝐹𝑆 = 𝑓

12
 𝜋(8𝑖𝑛)2
𝐹𝑐𝑟 = (𝐹𝑆) × 𝐹 where 𝐹 = 𝑃 × 𝐴 = 0.2 𝑘𝑠𝑖 × ( )=
4

10.05309649 𝑘𝑖𝑝𝑠

So, 𝐹𝑐𝑟 = (𝐹𝑆) × 𝐹 = 10.05309649 𝑘𝑖𝑝𝑠 × 8.75 = 87.9645943 𝑘𝑖𝑝𝑠

𝜎𝑦 𝐿2
𝐹𝑐𝑟 = 𝜎𝑦 𝐴 [1 − 4𝜋2𝑛𝐸𝑘 2 ]

𝜋(𝑑)2 38𝑘𝑠𝑖(20)2
87.9645943 𝑘𝑖𝑝𝑠 = 38 ksi × ( ) [1 − 2]
4 𝑑
4𝜋 2 (1)(30 × 103 𝑘𝑠𝑖) ( )
4

d = 1.74643653 in

Compute the B /𝒌𝟐 criterion:

𝜎𝑦 𝐿2 38𝑘𝑠𝑖(20 in)2
𝐵 = 𝜋2𝑛𝐸 = 𝜋2(1)(30×103𝑘𝑠𝑖)

𝑑 87.9645943 in
𝑘= =
4 4

B /𝑘 2 = 0.134650187

Solving for slenderness ratio,

𝐿 20𝑖𝑛 40(1.74643653 in)

= 𝑑 = 1.74643653 in
𝐾 ( )
4 4

𝐿
= 45.80756221
𝐾

𝑳
Since B /𝒌𝟐 < 𝟐 and 120 > 𝑲 >30, Case 2.0 JB Johnson’s Formula governs

the design, dimension stays.

3
d = 1.74643653 in, say d = 1 4 𝑖𝑛

13
Problem 3.0

Given: L = 20 in

n = 4 (both end fixed)

𝐹𝑐 = 30 kips

FS = 5

𝜎 = compression with buckling

Find: Size of the rod.

Materials Specification: SAE 1035 as rolled steel 𝐴𝑇 𝑇𝑎𝑏𝑙𝑒 𝐴𝑇 7, 𝑝. 14

𝜎𝑦 = 55 𝑘𝑠𝑖

𝜎𝑢 = 85 𝑘𝑠𝑖

Solution:

𝐹𝑐𝑟 = 𝐹𝑐 (FS) = (30 kips)(5) = 120 kips

Using the JB Johnson Formula,

1 − 𝜎𝑦 𝐿2
𝐹𝑐𝑟 = 𝜎𝑦 𝐴 ( )
𝜋𝑛𝐸4𝑘 2
𝜋
120 𝑘𝑖𝑝𝑠 = 55 𝑘𝑖𝑝𝑠/𝑖𝑛2 ( )(𝐷2 𝑟𝑜𝑑)
4

120 𝑘𝑖𝑝𝑠
𝑘𝑖𝑝𝑠
𝑘𝑖𝑝𝑠 𝜋 1 − (55 )(20 𝑖𝑛)2
= 55 2 ( ) (𝐷2 𝑟𝑜𝑑)( 𝑖𝑛2 )
𝑖𝑛 4 2 3 𝑘𝑖𝑝𝑠 𝐷2 𝑟𝑜𝑑 2
𝜋 (4)(30𝑥10) (4)( 4 )
𝑖𝑛2

5
𝐷2 𝑟𝑜𝑑 = 1.5642033867 𝑖𝑛 𝐷 = 1 8 𝑖𝑛

14
 𝑘𝑖𝑝𝑠 2
(55 2 )(20 𝑖𝑛)
( 𝑖𝑛 )
𝜎𝑦𝐿2 𝑘𝑖𝑝𝑠
𝐵 ( 𝜋𝑛𝐸 ) 𝜋 2 (4)(30𝑥10)3
= = 𝑖𝑛2
𝑘2 𝐷2 𝑟𝑜𝑑 2 1.5642033867 𝑖𝑛 2
( ( )
4 ) 4

𝐵
= 0.1349623747 𝑖𝑛 < 2
𝑘2

Thus, JB Johnson Formula governs the design.

15
Problem 4.0

Given: L = 1483 mm

F = 7300 lb

δ𝑙𝑖𝑚𝑖𝑡 = 0.800 mm

Find: Diameter and the suitable type of steel.

Solution:

Use the deformation limit formula:

4𝐹𝐿
δ𝑙𝑖𝑚𝑖𝑡 =
𝜋δ𝐸

4𝐹𝐿
𝑑 = √
𝜋δ𝐸

4(7300 𝑙𝑏)(1483 𝑚𝑚)

𝑑 = √ = 0.7578468399 𝑖𝑛
𝜋(0.800)((30𝑥10)6

13
𝑑 = 0.7578468399 𝑖𝑛 𝑑 = 𝑖𝑛
16

Equate the design stress to the induced stress:

𝜎𝑑 = 𝜎𝑡

4𝐹 𝜎y
2
=
𝜋𝑑 𝐹𝑆

Based on the yield strength, FS = 3

4𝐹(𝐹𝑆)
𝜎𝑦 =
𝜋𝑑 2

4(7300 𝑙𝑏)(3)
𝜎𝑦 =
13
𝜋 (16 𝑖𝑛)2

𝜎𝑦 = 43238.40345

16
Say C1015 normalized condition, 𝜎y = 44 𝑘𝑠𝑖

17
Problem 5.0

Given: W = 200 gm = 0.440925 lb

N = 8,000 rpm

r = 375 mm = 14.7638 in

Find: Diameter need for the rotation of the arm.

Material Specification: B124-3, 1/2 hard, rod (𝐴𝑇 𝑇𝑎𝑏𝑙𝑒 3, 𝑝. 5)

𝜎𝑢 = 43 𝑘𝑠𝑖

Solution:

F = (W/g)(𝑤 2 𝑟); w = 2𝜋𝑛/60

Since w is not yet given, solve it first;

𝑤 = 2𝜋(8,000 𝑟𝑝𝑚)/60

𝑤 = 837. 758041 rad/s

After finding the values, substitute to the formula

F = (W/g)(𝑤 2 𝑟);

F = (0.440925 lb/32.3 ft/𝑠 2 )(837.758041)2 (12𝑖𝑛 𝑥 1𝑓𝑡/12𝑖𝑛)

F = 9610. 501744 lb = 9.610501744 kips

From Table 1.1, p. 1

FS = 3 − 4 = 𝑠𝑎𝑦 4

Equate the design stress to the induced stress

𝜎𝑑 = 𝜎𝑡

4𝐹 𝜎𝑦
=
𝜋𝑑 2 𝐹𝑆

18
 4𝐹(𝐹𝑆) 4(9.610501744 𝑘𝑖𝑝𝑠(4)
𝑑 = √ = √
2𝜋𝜎u 2𝜋(48 𝑘𝑠𝑖)

3
𝑑 = 0.7140398817 𝑖𝑛 𝑑 = 𝑖𝑛
4

19
 DESIGN WORK NO. 3

Machine Member Under Pure Torsion

Problem 1.0

Given:

T = 1200 in - lb

Material Specifications:

AISI 1118, Cold-drawn

𝜎𝑦 = 75 𝑘𝑠𝑖
Table AT 7, page 14
𝜎𝑢 = 80 𝑘𝑠𝑖

Factor of Safety:

Since medium shock, one-direction, based on yield strength

FS = 3 (Table 1.1, page 2)

Design Stress:

𝝉𝒚 0.6(75 𝑘𝑠𝑖)
𝜏𝒅 = =
𝑭𝑺 3

𝜏𝒅 = 15 𝑘𝒔𝒊

For a good design,

𝜏𝑑 = 𝜏𝑠

𝑇
𝜏𝑑 = 𝐽

𝟐𝒃𝟐 𝒉
𝐽=𝑍= (Table AT 1, page 3) , since b=h
𝟗

𝟐𝒃𝟑
𝑍= 𝟗

20
 1𝑘𝑖𝑝
1200 𝑙𝑏 − 𝑖𝑛( )
15 𝑘𝑠𝑖 = 1000 𝑙𝑏
2𝑏 3
9

3
𝑏 = 0.7113786609 𝑖𝑛, 𝑆𝐴𝑌 𝑏 = 𝑖𝑛
4

𝟑
∴ use 𝒃 = 𝟒 𝒊𝒏

21
Problem 2.0

Given:

15
D = 16 in

d = 3.5 in

1
L = 2 in

3
r = in
4

Material Specifications:

AISI C1020, as rolled

𝜎𝑦 = 48 𝑘𝑠𝑖 Table AT 7, page 14

𝜎𝑢 = 65 𝑘𝑠𝑖

Factor of Safety:

Assume dead load, based on ultimate strength

FS = 4 (Table 1.1, page 2)

For Design Stress:

For a good design,

𝜏𝑑 = 𝜏𝑠

16𝑇
𝜏𝒅 =
𝜋𝑑3

Solve for Torque (T):

𝐹 = 𝜏𝑢 (𝜋)(𝐷)(𝐿) , since 𝜏𝒖 = 0.75(𝜎𝑢 )

15 1
𝐹 = 0.75(65 𝑘𝑠𝑖)(𝜋)( 𝑖𝑛)( 𝑖𝑛)
16 2

𝐹 = 71.79030087 𝑘𝑖𝑝𝑠

22
𝑇 = 𝐹𝑟

3
𝑇 = (71.79030087 𝑘𝑖𝑝𝑠)( 𝑖𝑛)
4

𝑇 = 53.84272565 𝑘𝑖𝑝 − 𝑖𝑛

16𝑇
𝜏𝒅 =
𝜋𝑑3

16( 53.84272565 𝑘𝑖𝑝 − 𝑖𝑛)

𝜏𝑑 =
𝜋(3.5 𝑖𝑛)3

𝜏𝑑 = 6.395772595 𝑘𝑠𝑖

∴ use 𝜏𝑑 = 6.3958 𝑘𝑠𝑖

23
Problem 3.0

Given:

P = 2,000 Hp

n = 600 rpm

D = 2d

Material Specifications:

AISI C1020, as rolled

𝜎𝑢 = 65 𝑘𝑠𝑖
Table AT 7, page 14
𝜎𝑦 = 48 𝑘𝑠𝑖

Factor of Safety:

Since mild shock, one direction, based on yield strength

FS = 3 (Table 1.1, page 2)

Design Stress:

(a)

𝜏𝑦 0.6(48 𝑘𝑠𝑖)
𝜏𝑑 = =
𝐹𝑆 3

𝜏𝑑 = 9.6 𝑘𝑠𝑖

For a good design,

𝜏𝒅 = 𝝉𝒔

16𝑇
𝜏𝑑 =
𝜋𝐷3

Solve for Torque (T):

𝑇𝑁
𝑃=
63025

24
 𝑃(63025)
𝑇=
𝑁

2,000 𝐻𝑝 (63025)
𝑇=
600 𝑟𝑝𝑚

1 𝑘𝑖𝑝
𝑇 = 210,083.3333 𝑙𝑏 − 𝑖𝑛 (1,000 𝑙𝑏)

𝑇 = 210.0833333 𝑘𝑖𝑝 − 𝑖𝑛

16𝑇
𝜏𝑑 =
𝜋𝐷3

16(210.0833333 𝑘𝑖𝑝 − 𝑖𝑛)

𝜏𝑑 =
𝜋𝐷3

𝐷 = 4.812419658 𝑖𝑛, 𝑆𝐴𝑌 5 𝑖𝑛

∴ use D = 5 in

(b)

𝑻𝒄
𝜏𝒅 =
𝑱

For Radial Distance (c):

𝐷 2𝑑
𝑐= = =𝑑
2 2

𝑻𝒄
𝜏𝒅 =
𝑱

For Polar Moment of Inertia (J):

𝜋(𝐷4 − 𝑑4 )
𝐽=
32

𝜋[(2𝑑)4 − 𝑑 4 ]
𝐽=
32

25
 𝑇𝑐
𝜏𝑑 =
𝐽

210.0833333 𝑘𝑖𝑝 − 𝑖𝑛 (𝑑)

96 𝑘𝑠𝑖 =
𝜋[(2𝑑)4 − 𝑑 4 ]
32

1
𝑑 = 2.458535051 𝑖𝑛, 𝑆𝐴𝑌 2 𝑖𝑛
2

𝐷 = 2𝑑

1
𝐷 = 2(2 𝑖𝑛)
2

𝐷 = 5 𝑖𝑛

1
∴ use D = 5 in and d = 2 2 𝑖𝑛

26
Problem 4.0

Given:

T = 3,400 N-m ≅ 3,400,000 N-mm

D = 1.25d

Material Specifications:

SAE 080, Cast Steel

𝜎𝑢 = 80 𝑘𝑠𝑖
Table AT. 6, page 8
𝜎𝑦 = 40 𝑘𝑠𝑖

101.325 𝑀𝑃𝑎
𝜎𝑢 = 80 𝑘𝑠𝑖 ( ) = 551.4285714 MPa
14.7 𝐾𝑠𝑖

101.325 𝑀𝑃𝑎
𝜎𝑦 = 40 𝑘𝑠𝑖 ( ) = 275.7142857 MPa
14.7 𝐾𝑠𝑖

Factor of Safety:

Assume dead load, based on ultimate strength

FS = 4 (Table 1.1, Page 2)

Design Stress:

𝜏 0.75 (551.4285714 𝑀𝑃𝑎)

𝜏𝑑 = 𝐹𝑆𝑢 = 4

𝜏𝑑 = 103.3928571 𝑀𝑃𝑎

For a good design,

𝜏𝑑 = 𝜏𝑠

16𝑇𝐷
𝜏𝑑 =
𝜋(𝐷 4 − 𝑑4 )

𝑁 16( 3,400,000 𝑁 − 𝑚𝑚)

103.3928571 =
𝑚𝑚2 𝜋[(1.25𝑑)4 − 𝑑 4 ]

27
𝑑 = 52.56468112 𝑚𝑚, 𝑆𝐴𝑌 𝑑 = 53 𝑚𝑚

∴ use d = 53 mm

28
Problem 5.0

Given:

𝜋 𝑟𝑎𝑑
𝜃𝐿𝑖𝑚𝑖𝑡 = 2∘ ( ) = 0.03480658504 𝑟𝑎𝑑
180∘

L = 2.5 m

1000 𝐾𝑃𝑎
𝜏𝑠 = 95 𝑀𝑃𝑎 ( ) = 95,000 𝐾𝑃𝑎
1 𝑀𝑃𝑎

𝐺 = 77𝑥106 𝐾𝑃𝑎

Material Specifications: N/A

Factor of Safety: N/A

Design Stress:

𝜏𝑑 = 𝜏𝑠 = 95,000 𝐾𝑃𝑎

𝜏𝑑 = 95,000 𝐾𝑃𝑎

For a good design,

16𝑇 𝑇𝐿 𝜋𝑑4
𝜏𝑑 = , 𝜃 = 𝐽𝐺 , 𝐽 =
𝜋𝐷 3 32

𝜏𝑑 𝜋𝐷 3
𝑇=
16

95,000 𝐾𝑃𝑎 𝜋𝑑3 1000𝑚𝑚

( ) (2.5𝑚) (
16 1𝑚 )
𝜃=
𝜋𝑑4
( ) (77𝑥106 𝐾𝑃𝑎)
32

𝑑 = 176.7239953, 𝑆𝐴𝑌 177 𝑚𝑚

∴ use d = 177 mm

29
 DESIGN WORK NO. 4

Pure Bending

Problem 1.0

Given:

L = 52 in

F = 8000 lb

h = 2b

Material Specifications:

C1020 as rolled

𝜎𝑢 = 65 ksi

𝜎𝑦 = 48 ksi

*Taken from Table AT 7 pg. 14

Factor of Safety:

For ultimate strength

FS = 4

For yield strength

FS = 2

*Taken from Table 1.1 pg. 2

Schematic Diagram:

30
Design Stress:

For ultimate strength

𝜎𝑢
𝜎𝑑 =
𝐹𝑆

65 𝑘𝑠𝑖
𝜎𝑑 =
2

𝜎𝑑 = 16.25 𝑘𝑠𝑖

For yield strength

𝜎𝑦
𝜎𝑑 =
𝐹𝑆

48 𝑘𝑠𝑖
𝜎𝑑 =
2

𝜎𝑑 = 24 𝑘𝑠𝑖

Induced Stress:

𝑀𝑐
𝜎𝑓 =
𝐼

where:

𝐹𝐿
𝑀 = 𝑀𝑚𝑎𝑥 = (Table AT 2, page 4)
4

31
 8 𝑘𝑖𝑝𝑠(52 𝑖𝑛)
𝑀=
4

𝑀 = 104 𝑘𝑖𝑝𝑠 − 𝑖𝑛

ℎ
𝑐=
2

𝑏ℎ3
𝐼=
12

For a good design,

𝜎𝑑 = 𝜎𝑓

𝑀𝑐
𝜎𝑑 =
𝐼

A.) Based on ultimate strength

ℎ
104 𝑘𝑖𝑝𝑠 − 𝑖𝑛 (2)
16.25 𝑘𝑠𝑖 =
𝑏ℎ3
( )
12

2𝑏
104 𝑘𝑖𝑝𝑠 − 𝑖𝑛 ( 2 )
16.25 𝑘𝑠𝑖 =
𝑏(2𝑏)3
( )
12

1
𝑏 = 2.125317138 𝑖𝑛, 𝑠𝑎𝑦 𝑏 = 2 𝑖𝑛
4

1 1
ℎ = 2𝑏 = 2 (2 𝑖𝑛) = 4 𝑖𝑛
4 2

∴ use b = 2 1/4 in and h = 4 1/2

in
B.) Based on yield strength

ℎ
104 𝑘𝑖𝑝𝑠 − 𝑖𝑛 (2)
24 𝑘𝑠𝑖 =
𝑏ℎ3
( )
12

32
 2𝑏
104 𝑘𝑖𝑝𝑠 − 𝑖𝑛 ( 2 )
24 𝑘𝑠𝑖 =
𝑏(2𝑏)3
( )
12

7
𝑏 = 1.866255578 𝑖𝑛, 𝑠𝑎𝑦 𝑏 = 1 𝑖𝑛
8

7 3
ℎ = 2𝑏 = 2 (1 𝑖𝑛) = 3 𝑖𝑛
8 4

∴ use b = 1 7/8 in and h = 3 3/4

in

33
Problem 2.0

Given:

L = 1400 mm

F = 130000 N

h = 3b

Material Specifications:

Cast Steel SAE 0105

𝜎𝑢 = 105 ksi

𝜎𝑦 = 85 ksi

*Taken from Table AT 6, page 8

Factor of Safety:

FS = 3 (given)

Schematic Diagram:

Design Stress:

𝜎𝑦
𝜎𝑑 =
𝐹𝑆

85 𝑘𝑠𝑖
𝜎𝑑 =
3

34
 𝜎𝑑 = 28.33333333 ksi

Induced Stress:

𝑀𝑐
𝜎𝑓 =
𝐼

where:

𝐹𝐿
𝑀 = 𝑀𝑚𝑎𝑥 = (Table AT 2, page 4)
4

ℎ
𝑐=
2

𝑏ℎ3
𝐼=
12

For a good design,

𝜎𝑑 = 𝜎𝑓

𝑀𝑐
𝜎𝑑 =
𝐼

Substituting,

1000 𝑝𝑠𝑖 0.101325 𝑀𝑃𝑎

28.33333333 𝑘𝑠𝑖 ( ) ( )
1 𝑘𝑠𝑖 14.7 𝑝𝑠𝑖
(130000 𝑁)(1400 𝑚𝑚) 3𝑏
( )( )
4 2
=
𝑏 (3𝑏 3 )
12

A.) Dimensions

b = 111.8120387 mm, say 112 mm

h = 3b = 3(112 mm) = 336 mm

∴ use b = 112 mm and h = 336 mm

35
B.) Maximum Deflection

𝐹𝐿3
𝛿 = − 48𝐸𝐼 (Table AT 2, page 4)

Where:

𝐸 = 207 𝐺𝑃𝑎

Substituting,

(130000 𝑁)(1400 𝑚𝑚)3

𝛿𝑚𝑎𝑥 = −
1000 𝑀𝑃𝑎 (112 𝑚𝑚)(336 𝑚𝑚)3
48(207 𝐺𝑃𝑎) ( 1 𝐺𝑃𝑎 ) ( )
12

𝛿𝑚𝑎𝑥 = -0.1014054432 mm

∴ 𝛿𝑚𝑎𝑥 = 0.101 mm Downward

C.) Dimensions when 𝛿𝑙𝑖𝑚 = 0.150 mm

𝐹𝐿3
𝛿𝑙𝑖𝑚 =
48𝐸𝐼

(130000 𝑁)(1400 𝑚𝑚)3

0.150 𝑚𝑚 =
1000 𝑀𝑃𝑎 (𝑏)(3𝑏)3
48(207 𝐺𝑃𝑎) ( 1 𝐺𝑃𝑎 ) ( 12 )

b = 101.5571546 mm, say 102 mm

h = 3b = 3(102 mm) = 306 mm

∴ use b = 102 mm and h = 306 mm

36
Problem 3.0

Given:
F₁ = F₂ = 3500 lbf

L = 15 in

a = d = 3 in

h = 3b; b = h/3S

Find:
b&h
Factor of Safety:
FS = 5 (Given)
Solution:
Obtaining ΣM

ΣM = Fa = (3500 lbf)(3 in)

ΣM = 10500 lbf – in (1 kip / 1000 lbf)

ΣM = 10.5 kips – in

𝑏ℎ3
I= ; b = h/3
12

ℎ4
I = 36

a.) Gray cast iron, SAE 111

Material Specifications:

σu = 30 ksi (From Table AT. 6 pg. 8)

For a Good Design:

𝜎𝑢 𝑀𝑐
𝐹𝑆
= 𝐼

37
 ℎ
30 𝑘𝑠𝑖 (10.5𝑘𝑖𝑝𝑠−𝑖𝑛)( )
= ℎ4
2
5
36

h = 3.158179799 in

h = 80.2177668946 mm = 81 mm

b = h/3 = 81 mm/3 = 27 mm

∴ use b = 27 mm and h = 81 mm

(b) Malleable cast iron, ASTM A47-52, grade 35 018

Material Specifications:

σu = 55 ksi (From Table AT. 6 pg. 8)

For a Good Design:

𝜎𝑢 𝑀𝑐
=
𝐹𝑆 𝐼

ℎ
55 𝑘𝑠𝑖 (10.5𝑘𝑖𝑝𝑠−𝑖𝑛)( )
= ℎ4
2
5
36

h = 2.580415883 in

h = 65.5425634282 mm = 66 mm

b = h/3 = 66 mm/3 = 22 mm

∴ use b = 22 mm and h = 66 mm

(c) AISI C1040 steel, as rolled

Material Specifications:

σu = 90 ksi (From Figure AF.1 pg.10)

For a Good Design:

𝜎𝑢 𝑀𝑐
𝐹𝑆
= 𝐼

38
 ℎ
90 𝑘𝑠𝑖 (10.5𝑘𝑖𝑝𝑠−𝑖𝑛)( )
= ℎ4
2
5
36

h = 2.18975957 in

h = 55.619893078 mm = 56 mm

b = h/3 = 56 mm/3 = 18.6666666667 mm = 19 mm

∴ use b = 19 mm and h = 56 mm

39
Problem 4.0

Given:

L = 8 ft

F = 12,000 lb

b = 3 in

h = 4 in

Material Specifications:

B1113 Cold Finished

𝜎𝑢 = 83 ksi

𝜎𝑦 = 72 ksi

*Taken from TABLE AT 7 pg.14

Schematic Diagram:

12000 lb

3 in

4 in

Induced Stress:
𝑀𝑐
𝜎𝑓 =
𝐼

Where:

𝐹𝐿
𝑀 = 𝑀𝑚𝑎𝑥 = 8

40
 *Taken from TABLE AT 2 pg. 4

12 𝑖𝑛
(12 𝐾𝑖𝑝𝑠) (8 𝑓𝑡 × )
1 𝑓𝑡
𝑀 =
8
𝑀 = 144 𝐾𝑖𝑝𝑠 − 𝑖𝑛

For a good design,

𝜎𝑑 = 𝜎𝑓

𝑀𝑐
𝜎𝑑 =
𝐼

Where:

ℎ
𝑐=
2

𝑏ℎ3
𝐼=
12

A.) Based on yield strength

𝜎𝑦 𝑀𝑐
=
𝐹𝑠 𝐼

4 𝑖𝑛
72 𝐾𝑠𝑖 (144 𝐾𝑖𝑝 − 𝑖𝑛) ( 2 )
=
𝐹𝑠 (3 𝑖𝑛)(4 𝑖𝑛)3
( )
12

𝐹𝑠 = 4
B.) Based on ultimate strength

𝜎𝑢 𝑀𝑐
=
𝐹𝑠 𝐼

𝑖𝑛
83 𝐾𝑠𝑖 (144 𝐾𝑖𝑝 − 𝑖𝑛) (4 2 )
=
𝐹𝑠 (3𝑖𝑛)(4𝑖𝑛)3
( )
12

𝐹𝑠 = 4.611111111

41
𝐹𝑠 = 4.611

42
Problem 5.0
Given:
½-in structural steel plates
I-section at G = H
L = 54in
F = 4kips at center
FS = 5
ymax ≤ 0.03in
Find:
(a) G = H = ? ; at FS = 5 ; based on yield strength
(b) ymax based on calculated G = H at (a)
(c) G = H = ? ; at ymax ≤ 0.03in
Material Specifications:
AISI 1020, as rolled
by Table AT 7 page 14
𝜎𝑢 = 65 𝑘𝑠𝑖
𝜎𝑦 = 48 𝑘𝑠𝑖
𝐸 = 30 × 106 𝑝𝑠𝑖 = 30 × 103 𝑘𝑠𝑖
Factor of Safety:
FS = 5 (Given)
Design Stress:
Based on yield strength
𝜎𝑦
𝜎𝑑 =
𝐹𝑆
48𝑘𝑠𝑖
𝜎𝑑 =
5
𝜎𝑑 = 9.6𝑘𝑠𝑖
Induced Stress:
𝑀𝑐
𝜎𝑓 =
𝐼
by TABLE AT 2 page 4
𝐹𝐿
𝑀𝑚𝑎𝑥 = =𝑀
4
43
 by TABLE AT 1 page 3
1
𝐼 = 12 (𝐺𝐻 3 − 𝑔ℎ3 )
𝐻
𝑐=
2
For a Good Design:
𝜎𝑑 = 𝜎𝑓
𝐹𝐿 𝐻
( 4 )( 2 )
9.6𝑘𝑠𝑖 =
1
(𝐺𝐻 3 − 𝑔ℎ3 )
12
But 𝐺 = 𝐻
1
𝑔 = (𝐺 − 2)
1 1
ℎ = [𝐻 − 2 ( )] = [𝐺 − 2 ( )] = [𝐺 − 1]
2 2
(4𝑘𝑖𝑝𝑠)(54𝑖𝑛) 𝐺
[ ] (2)
4
9.6𝑘𝑠𝑖 =
1 3 1 3
12 (𝐺(𝐺) − (𝐺 − 2)(𝐺 − 1) )
324𝐺
9.6 =
1
(𝐺 4 − (𝐺 − 2)(𝐺 − 1)3 )
324𝐺
9.6 =
1
(𝐺 4 − (𝐺 − 2)(𝐺 3 − 3𝐺 2 + 3𝐺 − 1))
324𝐺
9.6 =
7𝐺 3 9𝐺 2 5𝐺 1
(𝐺 4 − (𝐺 4 −
2 + 2 − 2 + 2))
324𝐺
9.6 =
7𝐺 3 9𝐺 2 5𝐺 1
( − )
2 2 + 2 −2
7𝐺 3 9𝐺 2 5𝐺 1
9.6 ( − + − ) = 324𝐺
2 2 2 2
7𝐺 3 9𝐺 2 5𝐺 1
9.6 ( − + − ) = 324𝐺
2 2 2 2
33.6𝐺 3 − 43.2𝐺 2 + 24𝐺 − 4.8 = 324𝐺
33.6𝐺 3 − 43.2𝐺 2 − 300𝐺 − 4.8 = 0

44
 𝐺1 = 3.705599123𝑖𝑛
𝐺2 = −0.01603749898𝑖𝑛
𝐺3 = −2.403847338𝑖𝑛
Use G1 since dimensions cannot be negative, therefore G = H = 3.706 in
(a) SAY, G = H = 3 ¾ in
By TABLE AT 2 page 4
𝐹𝐿3
𝑦𝑚𝑎𝑥 = −
48𝐸𝐼
By TABLE AT 1 page 3
1
𝐼= (𝐺𝐻 3 − 𝑔ℎ3 )
12
3
But 𝐺 = 𝐻 = 3 4 𝑖𝑛
1 3 1 1
𝑔 = (𝐺 − ) = 3 𝑖𝑛 − 𝑖𝑛 = 3 𝑖𝑛
2 4 2 4
1 3 3
ℎ = [𝐻 − 2 ( )] = 𝐻 − 1 = 3 𝑖𝑛 − 1𝑖𝑛 = 2 𝑖𝑛
2 4 4
(−4𝑘𝑖𝑝𝑠)(54𝑖𝑛)3
∴ 𝑦𝑚𝑎𝑥 =−
1 3 3 1 3
48(30 × 103 𝑘𝑠𝑖)[12 (3 4 𝑖𝑛)(3 4 𝑖𝑛)3 − (3 4 𝑖𝑛)(2 4 𝑖𝑛)3 )]

𝑦𝑚𝑎𝑥 = 0.04032449433𝑖𝑛
(b) The maximum downwards deflection, ymax = 0.040in

If ymax ≤ 0.03in
By TABLE AT 2 page 4
𝐹𝐿3
𝑦𝑚𝑎𝑥 =−
48𝐸𝐼
By TABLE AT 1 page 3
1
𝐼= (𝐺𝐻 3 − 𝑔ℎ3 )
12
But 𝐺 = 𝐻
1
𝑔 = (𝐺 − 2)
1 1
ℎ = [𝐻 − 2 (2)] = [𝐺 − 2 (2)] = [𝐺 − 1]

45
 (−4𝑘𝑖𝑝𝑠)(54𝑖𝑛)3
− ≤ 0.03𝑖𝑛
1 1
48(30 × 103 𝑘𝑠𝑖) [12 (𝐺(𝐺)3 − (𝐺 − 2)(𝐺 − 1)3 )]
1 1
174.96 ≤ [ (𝐺(𝐺)3 − (𝐺 − )(𝐺 − 1)3 )]
12 2
7𝐺 3 9𝐺 2 5𝐺 1
174.96 ≤ ( − + − )
2 2 2 2
0 ≤ (3.5𝐺 3 − 4.5𝐺 2 + 2.5𝐺 − 175.46)
𝐺1 ≥ 4.097405021 𝑖𝑛
𝐺2 ≥ −1.405845368 + 3.202892482𝑖 𝑖𝑛
𝐺3 ≥ −1.405845368 − 3.202892482𝑖 𝑖𝑛
Use G1 since dimensions should be real and positive, therefore G = H = 4.097 in
(c) SAY, G = H = 4 ¼ in

46
 DESIGN WORK NO. 5
Design of Pressure Vessels

Problem 1.0

Given:

𝑃 = 600 𝑝𝑠𝑖

𝐷𝑖 = 12 𝑖𝑛

𝜎𝐷 = 3600 𝑝𝑠𝑖

Find:

Required thickness (t)?

Solution:

Assume thin-walled

For a good design,

𝜎𝐷 = 𝜎𝑡

𝑃𝑖 𝐷𝑖
3600 𝑝𝑠𝑖 =
2𝑡

(600 𝑝𝑠𝑖)(12 𝑖𝑛)

3600 𝑝𝑠𝑖 =
2𝑡

(600 𝑝𝑠𝑖)(12 𝑖𝑛)

𝑡=
2 (3600 𝑝𝑠𝑖)

𝑡 = 1 𝑖𝑛

Using limiting criteria to check the assumption,

𝑡
𝐿𝑖𝑚𝑖𝑡𝑖𝑛𝑔 𝐶𝑟𝑖𝑡𝑒𝑟𝑖𝑎: ≤ 0.1 (𝑡𝑜 𝑏𝑒 𝑐𝑜𝑛𝑠𝑖𝑑𝑒𝑟𝑒𝑑 𝑎𝑠 𝑡ℎ𝑖𝑛 − 𝑤𝑎𝑙𝑙𝑒𝑑)
𝑑

𝑡 1 𝑖𝑛
= = 0.0833
𝑑 12𝑖𝑛

47
 𝑡
𝑆𝑖𝑛𝑐𝑒 = 0.0833 ≤ 0.1, 𝑡ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒, 𝑡ℎ𝑒 𝑎𝑠𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑖𝑠 𝑐𝑜𝑟𝑟𝑒𝑐𝑡
𝑑

Thus, the required thickness would be,

𝑡 = 1 𝑖𝑛

48
Problem 2.0

Given:

𝑃𝑖 = 230 𝑝𝑠𝑖

𝐷𝑖 = 250 𝑚𝑚

𝑡 = 2.75 𝑚𝑚

Find:

𝑇𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑆𝑡𝑟𝑒𝑠𝑠 (𝜎𝑐 ) = ?

𝐿𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙 𝑆𝑡𝑟𝑒𝑠𝑠 (𝜎𝐿 ) = ?

Solution:

Limiting Criteria

𝑡
≤ 0.1 𝑓𝑜𝑟 𝑡ℎ𝑖𝑛 𝑤𝑎𝑙𝑙𝑒𝑑
𝑑

𝑡 2.75𝑚𝑚
= = 0.011 ≤ 0.1
𝑑 250 𝑚𝑚

𝑇ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒, 𝑡ℎ𝑖𝑛 − 𝑤𝑎𝑙𝑙𝑒𝑑.

For Tangential Stress

𝑃𝐷𝑖
𝜎𝑐 =
2𝑡

(230𝑝𝑠𝑖)(250𝑚𝑚)
𝜎𝑐 =
2(2.75𝑚𝑚)

𝜎𝑐 = 10454.545454 𝑝𝑠𝑖

𝜎𝑐 = 10454.545 𝑝𝑠𝑖

For Longitudinal Stress

𝑃𝐷𝑖
𝜎𝐿 =
4𝑡

49
 (230 𝑝𝑠𝑖)(250𝑚𝑚)
𝜎𝐿 =
4(2.75𝑚𝑚)

𝜎𝐿 = 5227.272727 𝑝𝑠𝑖

𝜎𝐿 = 5227.273 𝑝𝑠𝑖

50
Problem 3.0

Given:

𝐷𝑖 = 3𝑓𝑡 = 36 𝑖𝑛

𝑃𝑖 = 1000 𝑝𝑠𝑖

𝐽. 𝐸. = 90%

Find:

𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑡) = ?

Material Specification:

AISI C1020, as rolled.

From Table AT 10, p.18

𝜎𝑢 = 65 𝑘𝑠𝑖

𝜎𝑦 = 48 𝑘𝑠𝑖

𝜎𝑛 = 33 𝑘𝑠𝑖

Factor of Safety (FS):

𝐹𝑆 = 3 (𝑔𝑖𝑣𝑒𝑛)

Solution:

Assume thin-walled, ductile material.

For a good design,

𝜎𝐷′ = 𝜎𝑡

𝜎𝐷 ( 𝐽𝐸) = 𝜎𝑡

𝜎𝑦 𝑃𝐷𝑖
(𝐽𝐸) =
𝐹𝑆 2𝑡

51
(48000 𝑝𝑠𝑖) (1000 𝑝𝑠𝑖)(36𝑖𝑛)
(0.90) =
3 2𝑡

𝑡 = 1.25 𝑖𝑛

Limiting Criterion,
𝑡
≤ 0.1 𝑓𝑜𝑟 𝑡ℎ𝑖𝑛 𝑤𝑎𝑙𝑙𝑒𝑑
𝑑

𝑡 1.25 𝑖𝑛
= = 0.035 ≤ 0.1
𝑑 36 𝑖𝑛

𝑇ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒, 𝑡ℎ𝑖𝑛 − 𝑤𝑎𝑙𝑙𝑒𝑑.

Thus, the thickness would be,

𝑡 = 1.25 𝑖𝑛

52
Problem 4.0

Given:

𝑡 = 2𝑖𝑛

𝐷𝑖 = 16 𝑖𝑛; 𝑟𝑖 = 8 𝑖𝑛

𝜎𝑡𝑖 = 120 𝑘𝑠𝑖

Find:

𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 (𝑃𝑖 ) = ?

Solution:

Working equation:

𝑃𝑖 (𝑟𝑜2 + 𝑟𝑖2 ) − 2𝑃𝑜 𝑟𝑜2

𝜎𝑡𝑖 =
𝑟𝑜2 − 𝑟𝑖2

Limiting Criteria

𝑡
𝐿𝑖𝑚𝑖𝑡𝑖𝑛𝑔 𝐶𝑟𝑖𝑡𝑒𝑟𝑖𝑎: ≤ 0.1 (𝑡𝑜 𝑏𝑒 𝑐𝑜𝑛𝑠𝑖𝑑𝑒𝑟𝑒𝑑 𝑎𝑠 𝑡ℎ𝑖𝑛 − 𝑤𝑎𝑙𝑙𝑒𝑑)
𝑑

𝑡 2 𝑖𝑛
= = 0.125
𝑑 16 𝑖𝑛
𝑡
𝑆𝑖𝑛𝑐𝑒 ≥ 0.1, 𝑡ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒, 𝑖𝑡 𝑖𝑠 𝑡ℎ𝑖𝑐𝑘 − 𝑤𝑎𝑙𝑙𝑒𝑑
𝑑

To solve for ro,

𝑟𝑜 = 𝑟𝑖 + 𝑡

𝑟𝑜 = 8 𝑖𝑛 + 2𝑖𝑛 = 10𝑖𝑛

By rearranging the working equation,

(𝜎𝑡𝑖 )(𝑟𝑜2 − 𝑟𝑖2 ) + 2𝑃𝑜 𝑟𝑜2

𝑃𝑖 =
(𝑟𝑜2 + 𝑟𝑖2 )

Substituting the values, (assume Po = 1 atm = 14.7 psi)

53
 ((120000 𝑝𝑠𝑖)((10 𝑖𝑛)2 − (8 𝑖𝑛)2 ) + 2(14.7 𝑝𝑠𝑖)(10 𝑖𝑛)2 )
𝑃𝑖 =
(10 𝑖𝑛)2 + (8𝑖𝑛)2

𝑃𝑖 = 26359.3902439 𝑝𝑠𝑖

𝑃𝑖 = 26359.390 𝑝𝑠𝑖

54
Problem 5.0

Given:

𝐷𝑖 = 16 𝑖𝑛

𝐷𝑜 = 24 𝑖𝑛

𝑃𝑖 = 760 𝑘𝑠𝑖

𝑃𝑜 = 200 𝑘𝑠𝑖

Find:

Longitudinal Stress (𝜎𝐿 ) = ?

Hoop Stress on Inner Fiber (𝜎𝑡𝑖 ) = ?

Hoop Stress on Outer Fiber (𝜎𝑡𝑜 ) = ?

Material Specifications:

AISI 3150 OQT 1000 (from Table AT 7, p.14)

𝜎𝑢 = 151 𝑘𝑠𝑖

𝜎𝑢 = 130 𝑘𝑠𝑖

Factor of Safety:

F.S. = 5 (given)

Solution:

𝐷𝑖 16 𝑖𝑛
𝑟𝑖 = = = 8 𝑖𝑛
2 2

𝐷𝑜 24 𝑖𝑛
𝑟𝑜 = = = 12 𝑖𝑛
2 2

𝑟𝑜 = 𝑟𝑖 + 𝑡 ⇒ 𝑡 = 𝑟𝑜 − 𝑟𝑖

𝑡 = 12 𝑖𝑛 − 8 𝑖𝑛 = 4𝑖𝑛

Solving for Longitudinal Stress on a fiber

55
 𝑃𝑖 𝑟𝑖 2
𝜎𝑙 = ; 𝑡 = 𝑟𝑜 − 𝑟𝑖
(𝑟𝑜 − 𝑟𝑖 )(𝑡)

𝑃𝑖 𝑟𝑖 2
𝜎𝑙 =
𝑡2

760 𝑘𝑠𝑖 (8 𝑖𝑛)2

𝜎𝑙 = = 3040 𝑘𝑠𝑖
(4 𝑖𝑛)2

𝜎𝑙 = 3040 𝑘𝑠𝑖

Solving for Hoop Stress on the inner fiber

𝑷𝒊 (𝒓𝒊 𝟐 + 𝒓𝒐 𝟐 ) − 𝟐𝑷𝒐 𝒓𝒐 𝟐
𝜎𝑡𝑖 =
𝒓𝒐 𝟐 − 𝒓𝒊 𝟐

760 𝑘𝑠𝑖 [(8 𝑖𝑛)2 + (12 𝑖𝑛)2 ] − 2 (200 𝑘𝑠𝑖)(12 𝑖𝑛)2

𝜎𝒕𝒊 = = 1256 𝑘𝑠𝑖
(12 𝑖𝑛)2 − (8 𝑖𝑛)2

𝜎𝑡𝑖 = 1256 𝑘𝑠𝑖

Solving for Hoop Stress on the outer fiber

2𝑃𝑖 𝑟𝑖 2 − 𝑃𝑜 (𝑟𝑜 2 + 𝑟𝑖 2 )
𝜎𝑡𝑜 =
𝑟𝑜 2 − 𝑟𝑖 2

2 (760 𝑘𝑠𝑖)(8 𝑖𝑛)2 − 200 𝑘𝑠𝑖[(12 𝑖𝑛)2 + (8 𝑖𝑛)2 ]

𝜎𝑡𝑜 = = 696 𝑘𝑠𝑖
(12 𝑖𝑛)2 − (8 𝑖𝑛)2

𝜎𝑡𝑜 = 696 𝑘𝑠𝑖

56
 DESIGN WORK NO. 6
Variable Stress Without Concentration

Problem 1.0

Given:

T = 4238 lb-in = 4.238 kips-in

Material Specifications:

AISI 1045 steel, as rolled

𝜎𝑢 = 96 ksi

𝜎𝑦 = 59 ksi

BHN = 215

*Taken from Table AT 7, page 14

Factor of Safety:

FS = 2 (Given)

Use Soderberg Equation, (Ductile and Torsion)

1 𝜏𝑚 𝜏
= + 𝜏𝑎
𝐹𝑆 𝜏𝑦 𝑛

𝜏𝑦 = 0.6 𝜎𝑦

𝜏𝑦 = 0.6 (59 ksi)

𝜏𝑦 = 35.4 ksi

For 𝜏𝑛 (indefinite life), since torsion

𝜏𝑛 = 0.6 𝜎′𝑛 (surface factor) (size)

size = 0.85 [range 0.5 in to 2 in]

Surface factor

57
 Assume Machined

Surface factor = 85% - Figure AF 5, page 21

𝜎′𝑛 = 0.5 (𝜎𝑢 )

𝜎′𝑛 = 0.5 (96 ksi)

𝜎′𝑛 = 48 ksi

𝜏𝑛 = 0.6 𝜎′𝑛 (surface factor) (size)

𝜏𝑛 = 0.6 (48 ksi) (0.85) (0.85)

𝜏𝑛 = 20.808 ksi

a. Torque is reversed

𝜏𝑚 = 0

𝜏𝑎 = 𝜏𝑚𝑎𝑥

16𝑇 16 (4.238 𝑘𝑖𝑝𝑠−𝑖𝑛)

𝜏𝑎 = 𝜋𝐷3 = 𝜋𝐷 3

21.58395676 𝑘𝑖𝑝𝑠−𝑖𝑛
𝜏𝑎 = 𝐷3

Substituting to the Soderberg Equation:

1 𝜏𝑚 𝜏𝑎
= +
𝐹𝑆 𝜏𝑦 𝜏𝑛

21.58395676 𝑘𝑖𝑝𝑠 − 𝑖𝑛
1 0 𝐷3
= +
2 35.4 𝑘𝑠𝑖 20.808 𝑘𝑠𝑖

D = 1.275391661 in

3
D = 1.275 in, say 1 8 in

Range: 0.5 in to 2 in

3
∴ 𝑈𝑠𝑒 D = 1 in
8

58
b. Torque is repeated
Soderberg Equation:
1 𝜏𝑚 𝜏𝑎
= +
𝐹𝑆 𝜏𝑦 𝜏𝑛
𝜎𝑚𝑎𝑥
𝜎𝑚 = 2
𝜎𝑚𝑎𝑥
𝜎𝑎 = 2
𝜏𝑚𝑎𝑥
𝜏𝑎 =
2

16𝑇
𝜏𝑚𝑎𝑥 =
𝜋𝐷3
16(4.238 𝑘𝑖𝑝𝑠 − 𝑖𝑛)
𝜏𝑚𝑎𝑥 =
𝜋𝐷3

21.58395676 𝑘𝑖𝑝𝑠 − 𝑖𝑛
𝜏𝑚𝑎𝑥 =
𝐷3

21.58395676 𝑘𝑖𝑝𝑠 − 𝑖𝑛 21.58395676 𝑘𝑖𝑝𝑠 − 𝑖𝑛

1 2𝐷3 2𝐷3
= +
2 35.4 𝑘𝑠𝑖 20.808 𝑘𝑠𝑖

D = 1.180950963 in

1
D = 1.810 in, say 1 8 in

Range: 0.5 in to 2 in

1
∴ 𝑈𝑠𝑒 D = 1 in
8

59
Problem 2.0

Given:

𝑃𝑚𝑎𝑥 = 125 psi

d = 20 in

Material Specifications:

AISI 3140, OQT at 1000 °F

𝜎𝑢 = 153 ksi

𝜎𝑦 = 134 ksi

BHN = 311

*Taken from Table AF 2, page 11

Factor of Safety:

FS = 2 (Given)

Design Stress:

Use Soderberg Equation: (Ductile, Compression, Repeated and reversed)

1 𝜎𝑚 𝜎𝑎
= +
𝐹𝑆 𝜎𝑦 𝜎𝑛⬚

For 𝜎𝑛 (Indefinite Life):

𝜎𝑛 = 0.8 𝜎𝑛′ (Surface Factor)

Surface Factor:

Assumed Machined

Surface Factor = 78% - Figure AF 5, page 21

𝜎𝑛′ = 0.5 𝜎𝑢

𝜎𝑛′ = 0.5 (153 ksi)

60
 𝜎𝑛′ = 76.5 ksi

𝜎𝑛 = 0.8 (76.5 ksi) (0.78)

𝜎𝑛 = 47. 736 ksi

For Double Acting:

𝜎𝑚 = 0 and 𝜎𝑎 = 𝜎𝑚𝑎𝑥

𝐹𝑚𝑎𝑥 = 𝐹 = 𝑃𝐴

𝜋𝑑2 𝜋(20 𝑖𝑛)2

𝐹 = 𝑃( ) = 125 𝑝𝑠𝑖 ( )
4 4

𝐹 = 39269.90817 psi = 39.26990817 kips

𝐹𝑚𝑎𝑥 39.26990817 𝑘𝑖𝑝𝑠 50

𝜎𝑎 = 𝜎𝑚𝑎𝑥 = = = 2
𝐴 𝜋𝑑 2 𝑑
( )
4

Soderberg Equation:

1 𝜎𝑚 𝜎𝑎
= +
𝐹𝑆 𝜎𝑦 𝜎𝑛

50
1 0 ( 2)
= + 𝑑
2 134 𝑘𝑠𝑖 47.736 𝑘𝑠𝑖
1
d = 1.447361405 in, say 1 2 𝑖𝑛

1
∴ Use d = 1 2 𝑖𝑛

61
Problem 3.0

Given:

1
𝐷 = 1 𝑖𝑛
2

Material Specifications:

AISI C1045, As Rolled

𝜎𝑢 = 96 𝑘𝑠𝑖

𝜎𝑦 = 59 𝑘𝑠𝑖

Taken from Table AT 7, page 14

For 𝜏𝑦 ,

𝜏𝑦 = 0.6 (59 𝑘𝑠𝑖)

𝜏𝑦 = 35.4 𝑘𝑠𝑖

Factor of Safety:

FS = 2 (Given)

For Good Design,

Use Soderberg Equation,

1 𝜏𝑚 𝜏𝑎
= +
𝐹𝑆 𝜏𝑦 𝜏𝑛

For 𝜏𝑛 ,

𝜏𝑛 = 0.6(𝜎𝑛′ )(𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝐹𝑎𝑐𝑡𝑜𝑟)(𝑆𝑖𝑧𝑒)

𝜎𝑛′ = 0.5(𝜎𝑢 )

𝜎𝑛′ = 0.5(96 𝑘𝑠𝑖)

𝜎𝑛′ = 48 𝑘𝑠𝑖

62
Assume Size = 0.85

𝜏𝑛 = 0.6(48 𝑘𝑠𝑖)(0.85)

𝜏𝑛 = 24.48 𝑘𝑠𝑖

For 𝜏𝑚 ,

Since Reverse

�
Substituting to Soderberg Equation,
�
1 0 𝑘𝑠𝑖 𝜏𝑎
�= +
2 35.4 𝑘𝑠𝑖 24.48 𝑘𝑠𝑖
�
𝜏𝜏𝑎 =0
= 12.24
𝑘𝑠𝑖 𝑘𝑠𝑖
𝑚

For Torque,

16𝑇
𝜏𝑎 =
𝜋(𝐷)3

16𝑇
12.24 𝑘𝑠𝑖 = 3
1
𝜋 (1 2 𝑖𝑛)

𝑇 = 8.111199532 𝑘𝑖𝑝 ∙ 𝑖𝑛

T = 8.111 kip-in

63
Problem 4.0

Given:

Tmax = 17500 lb-in = 17.5 kips-in, reversed

Material Specifications:

AISI 4130 steel, WQT 1100 °F

𝜎𝑢 = 127 ksi

𝜎𝑦 = 114 ksi

BHN = 260

*Taken from Table AT 7, page 14

For 𝜏𝑦 :

𝜏𝑦 = 0.6 𝜎𝑦

𝜏𝑦 = 0.6 (114 ksi)

𝜏𝑦 = 68.4 ksi

For 𝜏𝑛 (indefinite life):

𝜏𝑛 = 0.6 𝜎𝑛′ (surface factor) (size)

For 𝜎𝑛′ : (BHN < 400)

𝜎𝑛′ = 0.5 𝜎𝑢

𝜎𝑛′ = 0.5 (127 ksi)

𝜎𝑛′ = 63.5 ksi

For surface factor:

Surface Factor = machined (given)

64
 Surface Factor = 82% = 0.82 (Figure AF 5, page 21)

For Size:

Size = assume 0.85

Substituting,

𝜏𝑛 = 0.6 𝜎𝑛′ (surface factor) (size)

𝜏𝑛 = 0.6 (63.5 ksi) (0.82) (0.85)

𝜏𝑛 = 26.5557 ksi

For 𝜏𝑚 and 𝜏𝑎 :

Since Torque is reversed;

𝜏𝑚 = 0

𝜏𝑎 = 𝜏𝑚𝑎𝑥

16𝑇𝑚𝑎𝑥
𝜏𝑎 =
𝜋𝐷3

16(17.5 𝑘𝑖𝑝 − 𝑖𝑛)

𝜏𝑎 =
𝜋𝐷3

89.12676813 𝑘𝑖𝑝 − 𝑖𝑛
𝜏𝑎 =
𝐷3

Substituting to the Soderberg Equation:

1 𝜏𝑚 𝜏𝑎
= +
𝐹𝑆 𝜏𝑦 𝜏𝑛

89.12676813 𝑘𝑖𝑝 − 𝑖𝑛
1 0 𝐷3
= +
1.75 68.4 𝑘𝑠𝑖 26.5557 𝑘𝑠𝑖

D = 1.804247662 in

65
 7
D = 1.804 in, say 1 in
8

7
∴ use D = 1 in
8

66
Problem 5.0

Given:

L = 16 in

F = 1500 lb

Material Specifications:

AISI C1137 steel, annealed

𝜎𝑢 = 85 𝑘𝑠𝑖

𝜎𝑦 = 50 𝑘𝑠𝑖

𝐵𝐻𝑁 = 174

*Taken from Table AT8, page 16

Factor of Safety:

FS = 2 (Given)

Use Soderberg’s Equation

1 𝜎𝑚 𝜎𝑎
= +
𝐹𝑆 𝜎𝑦 𝜎𝑛

Assume repeated and reverse, hence reversed will prevail.

67
For 𝜎𝑚 :

𝜎𝑚 = 0

For 𝜎𝑎 :

32𝑀
𝜎𝑎 = 𝜎max ⬚ =
𝜋𝐷3

Solve for M,

𝐹𝐿
𝑀 =
4

*Taken from Table AT 2, page 4

(1500 𝑙𝑏)(16 𝑖𝑛)

𝑀 =
4

𝑀 = 6000 𝑙𝑏 − 𝑖𝑛

𝑀 = 6 𝑘𝑖𝑝𝑠 − 𝑖𝑛

Substituting,

32(6 𝑘𝑖𝑝𝑠 − 𝑖𝑛)

𝜎𝑎 =
𝜋𝐷3

61.11549815 𝑘𝑖𝑝𝑠
𝜎𝑎 =
𝐷3

For 𝜎𝑛 : (indefinite life)

𝜎𝑛 = 0.8(𝜎𝑛′ )(𝑠𝑢𝑟𝑓)(𝑠𝑖𝑧𝑒)

Since BHN < 400,

𝜎𝑛′ = 0.5(𝜎𝑢 )

𝜎𝑛′ = 0.5(85 𝑘𝑠𝑖)

𝜎𝑛′ = 42.5 𝑘𝑠𝑖

Assume machined,

68
 𝑠𝑢𝑟𝑓 = 0.92 ; Taken from Figure AF 5, page 21

Assume,

𝑠𝑖𝑧𝑒 = 0.85

Substituting,

𝜎𝑛 = 0.8(42.5 𝑘𝑠𝑖)(0.92)(0.85)

𝜎𝑛 = 26.588 𝑘𝑠𝑖

Substitute to Soderberg’s Equation,

1 𝜎𝑚 𝜎𝑎
= +
𝐹𝑆 𝜎𝑦 𝜎𝑛

61.11549815 𝑘𝑖𝑝𝑠
1 0 𝐷3
= +
2 50 𝑘𝑠𝑖 26.588 𝑘𝑠𝑖

𝐷 = 1.662768903 𝑖𝑛

3
∴ 𝐷 = 1.663 𝑖𝑛, 𝑠𝑎𝑦 1 𝑖𝑛
4

69
 DESIGN WORK NO. 7
Variable Stress With Concentration

Problem 1.0

Given:

F=10 kips

1
d= in
4

h=2b

Find:

Base (𝑏)

Height (ℎ)

Material Specification:

AISI C1020 as rolled, repeated and reversed, forged

From Table AT 10, p. 18

σu =65 ksi

σu =48 ksi

σn =33 ksi

For as forged surface (Figure AF 5, p. 21)

Surface factor = 0.55

Size factor = 0.85

Factor of Safety:

FS = 1.5 (Given)

70
Solution:

(a) for indefinite life

σn =0.8σn1 (surface factor)(size)

σn =0.8(33 ksi)(0.55)(0.85)

σn =12.342 ksi

Since ductile, use Soderberg Equation,

1 σm σa
= +kf
FS σy σn

From Figure AF 8, p. 22

b
>1
h

Assume k t = 3.5

From Figure AF 7, p. 22

1
d 4 1
r= = = in
2 2 8

r = 0.125 in

a = 0.01 in

1 1
q= a=
1+ r 1+ 0.01
0.125

q = 0.9259259259

kf =q(kt -1)+1=0.926(3.5-1)+1

kf = 3.314814815

𝜎𝑚 = 0 (since repeated and reversed)

71
 F 10
σa = =
(h-d)b (2b-0.25)b

Substituting values in Soderberg Equation,

10
1 (2b-0.25)b
=(3.315) [ ]
1.5 12.342

b = 1.483153556 in

1
b = 1.483 in, say 1 in
2

1
h =2b= 2(1 in) = 3 in
2

1
b=1.483 in, say 1 in
2

h=3 in

(b) For indefinite life, ground and polished surface: (Surface factor = 0.90)

σn =0.8σn1 (surface factor)(size)

σn =0.8(33 ksi)(0.90)(0.85)

σn =20.196 ksi

Substituting values in Soderberg Equation,

10
1 (2b-0.25)b
=(3.315) [ ]
1.5 20.196

b = 1.173759684 in

3
b = 1.174 in, say 1 in
16

72
 3 3
h = 2b = 2(1 in) = 2 in
16 8

3
b = 1.174 in, say 1 in
16

3
h=2 in
8

73
Problem 2.0

Given:

Fmax =5 kips

N=1.5

1
d= in
8

Find:

a) Diameter for indefinite life, (𝐷)

b) Diameter for a life of 105 repetitions (no column action), (𝐷)
c) Maximum tensile stress in the link found in (a), (𝜎𝑚𝑎𝑥 )
Material Specification:

AISI 2330, WQT 1000 F

From Table AT 9, p. 17

σu =105 ksi

σu =85 ksi

σn' =52.5 ksi

For machined surface (Figure AF 5, p. 21)

Surface factor = 0.80

Size factor = 0.85

Factor of Safety:

FS = 1.5 (Given)

Solution:

(a) for indefinite life

σn =0.8σn1 (surface factor)(size)

74
σn =0.8(52.5ksi)(0.80)(0.85)

σn =28.56 ksi

Since ductile, use Soderberg Equation,

1 σm σa
= +kf
FS σy σn

From Figure AF 8, p. 22

b
>1
h

Assume kt =2.5

From Figure AF 7, p. 22

1
d 8 1
r= = = in
2 2 16

a = 0.0025 in

q = 0.9615384615

kf =q(kt -1)+1=0.9615384615(3.5-1)+1

1 1
q= a = 0.0025
1+ r 1+
0.0625

kf = 2.442307692

𝜎𝑚 = 0 (since repeated and reversed)

F 4F 4 (5) 20
σa = = = =
ΠD2 1 1 2
-dD ΠD2 -4D (8) ΠD2 -4D (8) ΠD -0.5D
4

Substituting values in Soderberg Equation,

1 2.442307692 (20)
=
1.5 28.56 (ΠD2 -0.5D)

75
 D=0.986738116 in, say D=1 in

(b) For a life of 105 repetitions or cycles

0.09
106
σn =(28.56) [ ]
105

σn = 35.13647609 ksi

log 2.44
(105 )( 3
)
kfl =
10log 2.44

kfl = 1.813566917

Substituting values in Soderberg Equation,

1 1.813566917 (20)
=
1.5 35.13647609 ksi (ΠD2 -0.5D)

13
D=0.7861317109 in, say D= in
16

(c) Solving for maximum tensile stress

4kf F
σmax =
ΠD2 -0.5D
13 d 0.125
D= 16 in, = 13
D
16

D=0.1538461538 in

From Figure AF 8, p. 22

kt =2.6

76
Using the equation from Figure AF 7, p.22,

kf =q(kf -1)+1=0.9615384615(2.6-1)+1

kf =2.538461538

Substituting values in the formula for tensile stress,

4(5)(2.538461538)
σmax =
7 2 7
Π (8) -0.5 (8)

σmax =25.80023294 ksi

σmax = 25.800 ksi

77
Problem 3.0

Given:

d=50 mm

σu =630 MPa=630 N/mm2

Tmax =2000N-m

Tmin =-800N-m

Find:

Factor of Safety (FS)

Solution:

Mean or average torque,

Tmax + Tmin
Tm =
2

(2000 N-m) + (-800N-m)

Tm =
2

Tm = 600 N − m

Tm = 600000 N − mm

Mean or average shear stress,

16Tm
τm =
πd3

16 (600000N-mm)
τm =
π×(50mm)3

τm =24.44619926 MPa

Variable torque

Tmax - Tmin
Ta =
2

78
 (2000N-m) - (-800N-m)
Ta =
2

Ta =1400 N-m

Ta =1400000 N-mm

Variable shear stress,

16Tv
τa =
πd3

16(1400000N-mm)
τa =
π×(50mm)3

τa =57.0411316 MPa

Since the endurance limit in reversed bending (𝜎n) is taken as one-half the ultimate
tensile strength and the endurance limit in shear (τn) is taken as 0.6σn , therefore

τn =0.6σn =0.6×(0.5σu )=0.3σu

τn =0.3×630 MPa

τn =189 MPa

Assume the yield stress (σy) for carbon steel in reversed bending as 510𝑁 − 𝑚𝑚2,
surface finish factor as 0.87, size factor as 0.85 and fatigue stress concentration
factor (kfs) as 1. Since the yield stress in shear (τy) for shear loading is taken as one-
half the yield stress in reversed bending (σy), therefore

τy =0.5σy (510MPa)=255MPa

Using Soderberg Equation,

1 τm τa
= +kfs
FS τy τn

1 24.446 57.041
= +(1) ( )
FS 255 189(0.87)(0.85)

FS=1.984175393

79
 FS=1.984

80
Problem 4.0

Given:

Fmin =1000 lb

Fmax =3000 lb

r=0.2D

Find:

Diameter (𝐷)

Material Specification:

AISI C1020 steel as rolled,

σu =65 ksi

σy =48 ksi

For machine surface,

Surface factor = 0.90

Size factor = 0.85

Solution:

Solving for the endurance limit,

σn' =0.5(65 ksi)=32.5 ksi

Substituting to the formula of the endurance strength,

σn =(32.5)(0.90)(0.85)

σn =24.8625 ksi

Solving for the moment at point A,

ΣMA =0

81
12F=24B

F=2B

F
B=
2

F
A=B=
2

At discontinuity,

6F
M= =3F
2

Mmax =(3in)(3000 lb)

Mmax =9 kip-in

Mmin =(3in)(1000 lb)

Mmin =3 kip-in

1
Mm = (9+3)
2

Mm =6 kip-in

1
Ma = (9-3)
2

Ma =3 kip-in

From Figure AF 12, p. 24,

D 1.5d
=
d d

D
=1.5
d

r 0.2d
=
d d

82
r
=0.2
d

kt =1.42

Assume 𝑘𝑓 = 𝑘𝑡 ,

1 σm σa
= +kf
FS σy σn

1 (32)(6) (32)(3)
= +(1.42) [ ]
2 45πD3 24.8625πD3

D= 1.820851899 in

13
D= 1.821 in, say D=1 in
16

At maximum moment,

12F
M=
2

M=6F

Mmax =(6in)(3000 lb)

Mmax =18 kip-in

Mmin =(6in)(1000 lb)

Mmin =6 kip-in

1
Mm = (18+6)
2

Mm =12 kip-in

1
Ma = (18-6)
2

Ma =6 kip-in

83
kf =1.00

Substituting to Soderberg’s Equation,

1 σm σa
= +kf
FS σy σn

1 (32)(12) (32)(6)(1.0)
= +
2 48πD3 24.8625πD3

D=1.4368 in

Note: Choose bigger dimension therefore use 13

D=1 in
16

84
Problem 5.0

Given:

b=60 mm

t=10 mm

d=12 mm

F=12 kN=12000 N

Find:

σmax

Solution:

Using equations from Figure AF 8, p. 22

F
σ=
(h-d)t

12000N
σ=
(60mm-12mm)10mm

σ=25MPa

Ratio of diameter of hole to width of plate,

d 12
= =0.2
b 60

From Figure AF 8, p. 22

kt =2.5

σmax = kt σ

σmax =2.5(25MPa)

σmax =62.5 MPa

85
(b)

Given:

D=50 mm

d=25 mm

r=5 mm

F=12 kN=12000 N

Find:

σmax

Solution:

Using equations from Figure AF 12, p. 24

4F
σ=
πd2

4(12000N)
σ=
π×25mm2

σ=24.44619926 MPa

Ratio of maximum diameter to minimum diameter

D 50
= =2
d 25

Ratio of radius of fillet to minimum diameter

r 5
= =0.2
d 25

From Figure AF 12, p. 24

kt =1.64

σmax = kt σ

86
σmax =1.64 (24.44619926 MPa)

σmax =40.09176678 MPa

σmax =40.092 MPa

87
 DESIGN WORK NO. 8
Shaft Design

Problem 1.0
Given:

P = 300 Hp

d = 0.6D

n = 500 rpm

Material Specifications:

AISI C1020 as rolled

σu = 65 ksi,

σy = 48 ksi,

Taken from Table AT 7, p. 14

Factor of Safety:

FS = 2 (Given)

Design Stress:

𝜏𝑦 = 0.6(σ𝑦 ) = 0.6(48 𝑘𝑠𝑖) = 28.8 𝑘𝑠𝑖

𝜏𝑦 28.8 𝑘𝑠𝑖
𝜏𝑑 = =
𝐹𝑆 2
𝜏𝑑 = 14.4 𝑘𝑠𝑖

For a good design:

𝜏𝑑 = 𝜏ℎ

Induced Stress

16𝑇 1
𝜏ℎ = [ ]
𝜋𝐷3 1 − 𝑘 4

88
 𝑑 0.6𝐷
𝑘= ;= ; 𝑘 = 0.6
𝐷 𝐷

For Torque

63025ℎ𝑝 63025(300)
𝑇= =
𝑛 500

𝑇 = 37,815 𝑖𝑛 − 𝑙𝑏 = 37.815 𝑖𝑛 − 𝑘𝑖𝑝𝑠

16𝑇 1
𝜏𝑑 = [ ]
𝜋𝐷 1 − 𝑘 4
3

16(37.815 𝑘𝑠𝑖) 1
14.4 𝑘𝑠𝑖 = 3
[ ]
𝜋𝐷 1 − (0.6)4
𝐷 = 2.486094389 𝑖𝑛

For d,
𝑑 = 0.6𝐷 = 0.6(2.486094389 𝑖𝑛)
𝑑 = 1.491656634 𝑖𝑛

𝟏
∴ 𝑫 = 𝟐. 𝟒𝟖𝟔 𝒊𝒏, 𝒔𝒂𝒚 𝟐 𝒊𝒏
𝟐
𝟏
𝐝 = 𝟏. 𝟒𝟗𝟐 𝒊𝒏, 𝒔𝒂𝒚 𝟏 𝟐 𝒊𝒏

89
Problem 2.0
Given:

k = 0.9

P = 60 Kw

n = 1350 rpm

L = 36 in

dg = 12 in

Material Specifications:

AISI C1045 as rolled

σu = 96 ksi, Table AT 7, p. 14

σy = 59 ksi, Table AT 7, p. 14

Taken from Table AT 7, p. 14

Factor of Safety

Assume Dead Load and based on Yield Strength

FS = 2

Taken from Table 1.1, p. 2

Design Stress:

σy 59 𝑘𝑠𝑖
σd = =
FS 2

σd = 29.5 ksi

For Torque:

1 𝐻𝑝
60 𝑘𝑤 𝑥 = 80.42895442 𝐻𝑝
.746 𝑘𝑤

90
 63025ℎ𝑝 63025(80.42895442 𝐻𝑝)
𝑇= =
𝑛 1350 𝑟𝑝𝑚

𝑇 = 3,754.840632 𝑖𝑛 − 𝑙𝑏 = 3.754840632 𝑖𝑛 − 𝑘𝑖𝑝𝑠

For Forces:

𝑇 = 𝐹𝑟

𝑇 3.754840632 𝑖𝑛 − 𝑘𝑖𝑝𝑠
𝐹𝑏 = =
𝑟 12
2 𝑖𝑛

𝐹𝑏 = 0.6258067719 𝑘𝑖𝑝𝑠

For Moment:

𝐹𝐿 0.6258067719 𝑘𝑖𝑝𝑠 𝑥 36 𝑖𝑛
𝑀= =
4 4

𝑀 = 5.632260947 𝑖𝑛 − 𝑘𝑖𝑝𝑠

For a good design, 𝜎𝑑 = 𝜎𝑓ℎ

𝜎𝑦 32𝑀 1
= [ ]
𝐹𝑆 𝜋𝐷 1 − 𝑘 4
3

59 32(5.632260947 𝑖𝑛 − 𝑘𝑖𝑝𝑠) 1
= [ ]
2 𝜋𝐷3 1 − (0.9)4
7
𝐷 = 1.78159736 𝑖𝑛 = 1 𝑖𝑛
8
𝑑 7
𝑘 = ; 𝑑 = 𝑘 𝑥 𝐷 = 0.9 𝑥 1 𝑖𝑛
𝐷 8
3
𝑑 = 1.6875 in = 1 𝑖𝑛
4

91
 7
∴ 𝑈𝑠𝑒 𝐷 = 1.782 𝑖𝑛, 𝑠𝑎𝑦 1 𝑖𝑛
8
3
𝑑 = 1.688 𝑖𝑛, 𝑠𝑎𝑦 1 4 𝑖𝑛

92
Problem 3.0

Given:

rpulley = 500 mm

L = 750 mm

F = 5kN

T = 3kN-m

Material Specification:
SAE/AISI C1020 as rolled

σu = 64ksi

σy = 48ksi

Taken from TABLE AT 7, p.14

Factor of Safety:
F.S. = 2 (Given)

Ductile, based on yield stress, ∴ Maximum Shear Stress Theory

Use Shear

τy (0.6)σy (0.6)48 ksi

τd = F.S. = =
F.S. 2

τd = 14.4 ksi

Solution:

Convert:

101.235 kPa 1000 psi

14.4 ksi ( )( ) = 99257.14286 kPa
14.7 psi 1ksi

For Force:

93
 T 3kN − m
F1 = F2 = = = 6kN
r 500mm ( 1m )
1000mm

For V&M Diagram

Schematic Diagram:

Reaction Forces

ΣMA = 0 ↺+

−6kN(250 mm) − (6kN + 5kN)(500mm) + R D (750mm) = 0

6kN(250 mm) + (6kN + 5kN)(500mm)

RD =
750mm

R D = 9.3333333333 kN

ΣFy = 0 ↑+

R A − 6kN − (6kN + 5kN) + 9.3333333333kN = 0

R A = 7.6666666667 kN

For Shear

94
RA = 7.6666666667 kN

RA-B = 7.6666666667 kN

RB-C = (7.6666666667 − 6) kN = 1.6666666667 kN

RC-D = (1.6666666667 − 11) kN = −9.3333333333 kN

RD = (−9.3333333333 + 9.333333333) kN = 0

For Moment

MA = 0

MB = (7.6666667kN)(0.25m) = 1.9166666667 kN − m

MC = 1.91666667kN − m + (1.666667 kN)(0.25m) = 2.3333333 kN − m

MD = 2.33333333kN − m + (−9.3333333kN)(0.25m) = 0

95
V& M Diagram

Maximum moment attain in C

∴MC = MMax = 2.333333333 kN-m

For a good design:

τd = τMax

16TE 16
τd = 3
= (√MMax 2 +TMax 2 )
πD πD3

96
 16
99257.14286 kPa = (√(2.333333333 kN − m)2 +(3kN − m)2 )
πD3

3 16
D= √ (√(2.333333333 kN − m)2 +(3kN − m)2 )
π(99257.14286 kPa)

D = 0.0579899748m = 57.9899748 mm, say 58 mm

D = 58 mm

97
Problem 4.0
Given:

PMax = 300 Hp

PMin = 100 Hp

N = 700 rpm

dgA = 20 in

dGc = 10 in

Material Specification:
AISI 2330 WQT 1300°F

σu = 107ksi

σy = 91ksi

BHN = 217

Taken from TABLE AT 9, p. 17

Factor of Safety:
Ductile, Bases on Yield, Dead Load

F.S.= 2

Taken From Table 1.1, p. 2

Keyway
Assume Hardened

kf = 2

Ks =1.6

Taken from Table AT 13, p. 21

Design Stress
Solution:

98
FOR 300 Hp

For Torque:

TMax N
PMax =
63025

TMax (700rpm)
300 Hp =
63025

300Hp(63025)
TMax = = 27010.71429lb − in
700rpm

TMax = 27.01071429kips − in

For Forces

TMax 27.01071429kips − in
FA = = = 2.701071429 kips
rA 10 in

TMax 27.01071429kips − in
FC = = = 5.402142857 kips
rC 5 in

For V&M Diagram

Schematic Diagram

Reaction Forces

99
ΣMB = 0 ↺ +

2.701071429 kips(10in) − 5.402142857 kips(25in) + R D (35in) = 0

5.402142857 kips(25in) − 2.701071429 kips(10in)

RD =
35in

R D = 3.086938776 kips

ΣFy = 0 ↑+

−2.701071429 kips + R B − 5.402142857 kips + 3.086938776 kips = 0

R B = 5.01627551 kips

For Shear

RA = −2.701071429 kips

RA-B = −2.701071429 kips

RB-C = (−2.701071429 + 5.01627551 ) kips = 2.3150204082 kips

RC-D = (2.3150204082 − 5.402142857)kips = −3.086938776 kips

RD = (−3.086938776 + 3.086938776) kips = 0

For Moment

MA = 0

MB = (−2.701071429 kips)(10in) = −27.01071429 kips − in

MC = −27.01071429kips − in + (2.3150204082 kip)(25in) =

30.86938776 kips − in

MD = 30.86938776 kips − in + (−3.086938776 kips)(10in) = 0

100
V&M Diagram

Maximum moment attain in C

∴ MC = MMax = 30.86938776 kips − in

101
FOR 100 Hp

For Torque:

TMin N
PMin =
63025

TMin (700rpm)
100 Hp =
63025

100Hp(63025)
TMin = = 9003.571429 lb − in
700rpm

TMin = 9.003571429 kips − in

For Forces

TMin 9.003571429 kips − in

FA = = = 0.9003571429 kip
rA 10 in

TMin 9.003571429 kips − in

FC = = = 1.800714286 kips
rC 5 in

For V&M Diagram

Schematic Diagram

102
 Reaction Forces

ΣMB = 0 ↺ +

0.9003571429kip(10in) − 1.800714286 kips(25in) + R D (35in) = 0

1.800714286 kips(25in) − 0.9003571429 kip(10in)

RD =
35in

R D = 1.028979592 kips

ΣFy = 0 ↑+

−0.9003571429kip + R B − 1.800714286 kips + 1.028979592 kips = 0

R B = 1.6720918337 kips

For Shear

RA = −0.9003571429 kip

RA-B = −0.9003571429 kip

RB-C = (−0.9003571429 + 1.6720918337) kip = 0.7717346939 kip

RC-D = (0.7717346939 − 1.800714286)kips = −1.028979592 kips

RD = (−1.028979592 + 1.028979592) kips = 0

For Moment

MA = 0

MB = (−0.9003571429kip)(10in) = −9.003571429 kips − in

MC = −9.003571429 kips − in + (0.7717346939 kip)(25in) =

10.28979592 kips − in

MD = 10.28979592 kips − in + (−1.028979592 kips)(10in) = 0

103
 V&M Diagram

Maximum moment attain in C

∴MC = MMin = 10.28979592 kips − in

For a good design:

104
 1 σe 2 τe 2 σn τn
= √( ) + ( ) ; σe = (σm ) + k f σa & τe = (τm ) + k f τa
F. S. σn τn σy τy

For σn:

σn = 0.8(σ′ n )(Surface Factor)(Size)

Wherein:

σ′ n = 0.5(σu ), Since BHN < 400

Surface Factor = 0.85 >Assume Machined, Taken from Figure AF 5, p. 2

Size = 0.85 >Assume the diameter is 0.5 - 2

σn = 0.8(σ′ n )(Surface Factor)(Size)

σn = 0.8(0.5(σu ))(Surface Factor)(Size)

σn = 0.8(0.5(107 ksi))(0.85)(0.85)

σn = 30.923 ksi

For σm and σa:

σMax + σMin σMax − σMin

σm = & σa =
2 2

For σMax and σMin:

32M
σ=
πD3

105
 32(30.86938776 kips − in) 314.4330017 kips − in
σMax = =
πD3 D3

32(10.28979592 kips − in) 104.8110006 kips − in

σMin = =
πD3 D3

314.4330017 kips−in 104.811006 kips−in

+ 209.6220011 kips−in
D3 D3
σm = =
2 D3

157.2165009 kips−in 52.40550028 kips−in

− 104.8110006 kips−in
D3 D3
σa = =
2 D3

σn
σe = (σ ) + k f σa
σy m

30.923 ksi 209.6220011 kips − in 104.8110006 kips − in

σe = ( 3
) + 2( )
91 ksi D D3

280.8543214 kips − in
σe =
D3

For τn:

τn = 0.6(σ′ n )(Surface Factor)(Size)

Wherein:

σ′ n = 0.5(σu ), Since BHN < 400

Surface Factor = 0.85 , Assume Machined, Taken from Figure AF 5, p. 2

Size = 0.85 , Assume the diameter is 0.5 - 2

τn = 0.6(σ′ n )(Surface Factor)(Size)

τn = 0.6(0.5(σu ))(Surface Factor)(Size)

106
 τn = 0.6(0.5(107 ksi))(0.85)(0.85)

τn = 23.19225 ksi

For τm and τa:

τMax + τMin τMax − τMin

τm = & τa =
2 2

For τMax and τMin:

16T
τ=
πD3

16(27.01071429kips − in) 137.5644383 kips − in

τMax = =
πD3 D3

16(9.003571429 kips − in) 45.85481275 kips − in

τMin = =
πD3 D3

137.5644383 kips−in 45.85481275 kips−in

+ 91.70962551 kips−in
D3 D3
τm = =
2 D3

137.5644383 kips−in 45.85481275 kips−in

− 45.85481276 kips−in
D3 D3
τa = =
2 D3

τn
τe = (τ ) + k fs τa
τy m

23.19225 ksi 91.70962551 kips − in 45.85481276 kips − in

τe = ( ) + 1.6 ( )
0.6(91 ksi) D3 D3

112.3228755 kips − in
τe =
D3

107
 1 σe 2 τe 2
= √( ) + ( )
F. S. σn τn

280.8543214 kips − in 2 112.3228755 kips − in 2

1 D3 D3
= √( ) +( )
2 30.923 ksi 23.19225 ksi

3
D = 2.740671622 in, say 2 in
4

NOT IN RANGE OF 0.5 - 2, RECOMPUTE USING Size = 1

For σn:

σn = 0.8(σ′ n )(Surface Factor)(Size)

σn = 0.8(0.5(σu ))(Surface Factor)(Size)

σn = 0.8(0.5(107 ksi))(0.85)(1)

σn = 36.38 ksi

σn
σe = (σ ) + k f σa
σy m

36.38 ksi 209.6220011 kips − in 104.8110006 kips − in

σe = ( 3
) + 2( )
91 ksi D D3

293.4247308 kips − in
σe =
D3

For τn:

τn = 0.6(σ′ n )(Surface Factor)(Size)

τn = 0.6(0.5(σu ))(Surface Factor)(Size)

108
 τn = 0.6(0.5(107 ksi))(0.85)(1)

τn = 27.285 ksi

τn
τe = (τ ) + k fs τa
τy m

27.285 ksi 91.70962551 kips − in 45.85481276 kips − in

τe = ( ) + 1.6 ( )
0.6(91 ksi) D3 D3

119.1973182 kips − in
τe =
D3

1 σe 2 τe 2
= √( ) + ( )
F. S. σn τn

293.4247308 kips − in 2 119.1973182 kips − in 2

1 D3 D3
= √( ) +( )
2 36.38 ksi 27.285 ksi

3
D = 2.637395042 in, say 2 in
4
3
D = 2 8 in

109
Problem 5.0
Given:

P = 200kW

N = 400 rpm

F = 5kN

L = 1.5m

Material Specification:

AISI 1117 SWQT 350

σu = 96ksi

σy = 59ksi

Taken from TABLE AT 11, p. 20

Factor of Safety

F.S. = 2.5 (Given)

Design Stress

Ductile, based on yield stress, ∴Maximum Shear Stress Theory

Use Shear

τy (0.6)σy (0.6)59 ksi

τd = F.S. = =
F.S. 2.5

τd = 14.16 ksi

Solution:

Convert

101.235 kPa 1000 psi

14.16 ksi ( )( ) = 97602.85714kPa
14.7 psi 1ksi

110
 For Maximum Bending Moment

Fab
MMax = ,Taken form Table AT 2, p. 4
L

5kN(1m)(0.5m)
MMax = = 1.666666667 kN − m
1.5m

For Maximum Torque

2πTN
P= 60

2πT(400 rpm)
200kW = 60

200kW(60)
T = TMax = 2π(400 rpm) = 4.774648293 kN − m

For a good design

τd = τMax

16Te 16
𝜏𝑑 = = (√(MMax )2 + (TMax )2 )
πD3 πD3

97602.85714kPa
16
= (√(1.666666667 kN − m)2 + (4.774648293 kN − m)2 )
πD3

D = 0.0641414231m = 64.1414231mm say 65mm

D = 65 mm

111
 DESIGN WORK NO. 9
Shaft Design Using Code

Problem 1.0
Given: T = 35 kip.in

M = 50 kip.in

Find: Diameter according to mild shock load.

Material Specification: Normalized AISI C1045 (Table AT 8, p.17)

𝜎𝑢 = 99 𝑘𝑠𝑖

𝜎𝑦 = 61 𝑘𝑠𝑖

Factor of Safety (Assume gradually applied, 𝑇𝑎𝑏𝑙𝑒 9.1, 𝑝. 1 )

𝑘𝑚 = 1.5 − 2.0 = 1.75

𝑘𝑠 = 1.0 − 1.5 = 1.25

Solution:

Design Stress:
For shafts with definite specifications, use;
τd = 0.18𝜎𝑢 = 0.18(99 𝑘𝑠𝑖) = 17.82 𝑘𝑠𝑖

τd = 0.3𝜎𝑢 = 0.3(61 𝑘𝑠𝑖) = 18. 3 𝑘𝑠𝑖

ASME CODE:

Use smaller value and assume w/out keyway, use 17.82 𝑘𝑠𝑖.

Te = √(𝑘𝑚 𝑀)2 + √(𝑘𝑠 𝑇)2

Then, substitute the value to the equation:

Te = √((1.75)( 50 𝑘𝑖𝑝. 𝑖𝑛 ))2 + √((1.25)(35))2 =
87. 74964387 𝑘𝑖𝑝 − 𝑖𝑛.
Equate the design stresses,

112
 τd = τmax

where;

16 𝑇𝑒
τd = τmax =
𝜋𝐷3

16 (87. 74964387 𝑘𝑖𝑝 − 𝑖𝑛)

17. 83 =
𝜋𝐷3

D = 2.926541653 in 𝐷 = 3 𝑖𝑛𝑐ℎ𝑒𝑠

113
Problem 2.0
Given: L = 18 in.

P = 300 Hp

N = 1000 rpm

Rotating shaft

Find: Shafts Diameter

Material Specification: AISI 3120 steel (𝑇𝑎𝑏𝑙𝑒 𝐴𝑇 10, 𝑝. 19)

𝜎𝑦 = 100 𝑘𝑠𝑖

𝜎𝑛 = 90 𝑘𝑠𝑖

90
𝜎𝑢 = 0.64 𝑘𝑠𝑖 = 140.625 𝑘𝑠𝑖

Factor Safety:

FS = 2

Design Stress:
For shafts with definite specifications, use;
τd = 0.18𝜎𝑢 = 0.18( 140.625 𝑘𝑠𝑖) = 25. 3125 𝑘𝑠𝑖

τd = 0.3𝜎𝑢 = 0.3(100 𝑘𝑠𝑖) = 30 𝑘𝑠𝑖

Use smaller value and assume w/out keyway, use 25. 3125 𝑘𝑠𝑖.

Solution:

𝑇𝑁
𝑃 =
63025

63025𝑃
𝑇 =
𝑁

63025(300 𝐻𝑝)
𝑇 =
1800 𝑟𝑝𝑚

𝑇 = 10. 50416667 𝑘𝑖𝑝 − 𝑖𝑛

114
For a good design, equate the design stress to the induced stress;

16 𝑇 (𝑘𝑠)
τd =
𝜋𝐷3

16 (10.50416667 𝑘𝑖𝑝 − 𝑖𝑛 (1.0)

25. 3125 =
𝜋𝐷3

3
D = 1.286368335 in. 𝐷 = 1 𝑖𝑛
8

115
Problem 3.0
Given: L = 18 in.

P = 300 Hp

N = 1000 rpm

Rotating shaft

Find: Shafts Diameter

Material Specification: AISI 3120 steel (𝑇𝑎𝑏𝑙𝑒 𝐴𝑇 10, 𝑝. 19)

𝜎𝑦 = 100 𝑘𝑠𝑖

𝜎𝑛 = 90 𝑘𝑠𝑖

90
𝜎𝑢 = 0.64 𝑘𝑠𝑖 = 140.625 𝑘𝑠𝑖

Factor Safety:

FS = 2

Design Stress:
For shafts with definite specifications, use;
τd = 0.18𝜎𝑢 = 0.18( 140.625 𝑘𝑠𝑖) = 25. 3125 𝑘𝑠𝑖

τd = 0.3𝜎𝑢 = 0.3(100 𝑘𝑠𝑖) = 30 𝑘𝑠𝑖

Use smaller value and assume w/out keyway, use 25. 3125 𝑘𝑠𝑖.

Solution:

𝑇𝑁
𝑃 =
63025

63025𝑃
𝑇 =
𝑁

63025(300 𝐻𝑝)
𝑇 =
1800 𝑟𝑝𝑚

𝑇 = 10. 50416667 𝑘𝑖𝑝 − 𝑖𝑛

116
For a good design, equate the design stress to the induced stress;

16 𝑇 (𝑘𝑠)
τd =
𝜋𝐷3

16 (10.50416667 𝑘𝑖𝑝 − 𝑖𝑛 (1.0)

25. 3125 =
𝜋𝐷3

3
D = 1.286368335 in. 𝐷 = 1 𝑖𝑛
8

117
Problem 4.0
Given: 𝑇𝑚𝑎𝑥 = 15000 lb-in

D = 2d

Find: Inner and Outer Diameter

Material Specification: AISI 3140 steel OQT 800℉ (𝐹𝑖𝑔𝑢𝑟𝑒 𝐴𝐹 2, 𝑃. 12)

𝜎𝑦 = 193 𝑘𝑠𝑖

𝜎𝑦 = 180 𝑘𝑠𝑖

Factor of Safety (Assume gradually applied) (𝑇𝑎𝑏𝑙𝑒 9.1, 𝑝. 2)

𝑘𝑠 = 1.75

Solution:

𝑑 𝑑
𝑘= = = 0.5
𝐷 2𝐷

ASME CODE:

τd = (0.18 𝜎𝑢 ) = 0.18 (193 𝑘𝑠𝑖) = 34.73 𝑘𝑠𝑖

τd = 0.3 𝜎𝑦 = 0.3(180 𝑘𝑠𝑖) = 54 𝑘𝑠𝑖

Use the smaller value, 34.73 ksi

Since it is a hollow shaft, use the equation;

16 𝐾𝑠 𝑇 1
τd = 3
𝑥
𝜋𝐷 1 − 𝑘4

16 (1.75)(15000 𝑙𝑏 − 𝑖𝑛) 1
34.74 ksi = 3
𝑥
𝜋𝐷 1 − 0.54

D = 1.601152787 𝑖𝑛

D = 2𝑑

118
 𝐷
d=
2

7
D = 0.8005763935 𝑖𝑛 𝐷 = 8 𝑖𝑛

119
Problem 5.0
Given: N = 500 rpm
P = 200 hp
𝑑𝑔𝑎 = 8 in

Rotating shafts
Find: Diameter
Material Specifications: AISI 3140 steel OQT 800℉ (𝐹𝑖𝑔𝑢𝑟𝑒 𝐴𝐹 2, 𝑃. 12)
𝜎𝑦 = 193 𝑘𝑠𝑖

𝜎𝑦 = 180 𝑘𝑠𝑖

Factor of Safety (Assume gradually applied) (𝑇𝑎𝑏𝑙𝑒 9.1, 𝑝. 2)

𝑘𝑚 = 1.5

𝑘𝑠 = 1.0

Solution:

63025 𝑃
T =
𝑁
63025 (200 ℎ𝑝)
T = = 25210 𝑙𝑏 − 𝑖𝑛
500 𝑟𝑝𝑚
𝑇 25210 𝑙𝑏 − 𝑖𝑛
𝐹𝐴 = =
𝑟𝑔𝑎 8
2 𝑖𝑛
𝐹𝐴 = 6302.5 𝑙𝑏

120
Using the Shear and Moment Diagram, we can get the value of Bending Moment
+↑ ∑ 𝑅𝐵 = 0 ;
-3𝑅𝑐 + 𝐹𝐴 = 0; 𝑅𝑐 = 2100.8333 𝑙𝑏
∑ 𝐹𝑦 = 0 ; 𝑅𝐵 = 𝐹𝐴 − 𝑅𝑐

𝑅𝐵 = 6302.5 − 2100.833333 = 4201.667 𝑙𝑏

Values from the Shear Diagram
𝑉𝐴1 = 0
𝑉𝐴2 = −6302.5
𝑉𝐵1 = −6302.5
𝑉𝐵2 = −2100.8333
𝑉𝐶1 = 2100.8333
𝑀𝐴 = 0
𝑀𝐵 = −6302.5
𝑀𝐶 = 12605
Using ASME Code:
τd = 0.18𝜎𝑢 = 0.18( 193 𝑘𝑠𝑖) = 34.74 𝑘𝑠𝑖

τd = 0.3𝜎𝑢 = 0.3(180 𝑘𝑠𝑖) = 54 𝑘𝑠𝑖

Use smaller value, use 34.74 ksi

121
To find the equivalent torque, we must use the formula;

𝑇𝑒 = √(𝑘𝑚 𝑀)2 + √(𝑘𝑠 𝑇)2

12
𝑇𝑒 = √(1.5)(6302.5 𝑙𝑏 − 𝑖𝑛)2 ( ) + √(1)(25210 𝑙𝑏 − 𝑖𝑛)2
1

𝑇𝑒 = 116. 2123579 𝑘𝑖𝑝 − 𝑖𝑛

Equate the design stresss to the induced stress

16 𝑇𝑒
τd =
𝜋𝐷3
16 (116. 2123579 𝑘𝑖𝑝 − 𝑖𝑛)
34.74 𝑘𝑠𝑖 =
𝜋𝐷3
5
𝐷 =2.573144662 in 2 8 𝑖𝑛

122
 DESIGN WORK NO. 10

Design of Keys

Problem 1.0

Given:

D = 3 ¼ in = 3.25 in

hp = 85 hp

n = 100 rpm

FS = 2.25

Material Specifications:

For sprocket (annealed nodular iron, 60-45-10)

σy = 55 ksi, Table AT 6, p. 8

For shaft (9AISI 1040 cold-rolled [10% work])

σy = 85 ksi, Table AT 10, p. 18

For key, (cold-finished B1113)

σy = 72 ksi, Table AT 7, p. 14

Factor of Safety:

F.S. = 2.25 (Given)

Design Stress:

3 1 1
Use 𝑏 = 4 𝑖𝑛, 𝑡 = 2 𝑖𝑛 for 𝐷 = 3 4 𝑖𝑛, from Table AT 19, p. 38

Square key,
3
𝑏=𝑡= 𝑖𝑛
4

123
 For Torque:

63025ℎ𝑝 63025(85)
𝑇= =
𝑛 100

𝑇 = 53,571.25 𝑖𝑛 − 𝑙𝑏 = 53.57125 𝑖𝑛 − 𝑘𝑖𝑝𝑠

By shear,
𝜏𝑦 = 0.6(𝜎𝑦 ) = 0.6(72 𝑘𝑠𝑖)
𝜏𝑦 = 43.2 𝑘𝑠𝑖
𝜏𝑦 43.2 𝑘𝑠𝑖
𝜏𝑑 = =
𝐹𝑆 2.25
𝜏𝑑 = 19.2 𝑘𝑠𝑖

By compression,

Use σy of sprocket because it is the weakest material

𝜎𝑦 55 𝑘𝑠𝑖
𝜎𝑑 = =
𝐹𝑆 2.25
𝜎𝑑 = 24.44444444 𝑘𝑠𝑖
Induced Stress
4𝑇
𝜎𝑘 =
𝐷𝑡𝐿

For a good design:

Induced Stress for shear

2𝑇
𝜏𝑘 =
𝐷𝑏𝐿

𝜏𝑘 = 𝜏𝑑
2𝑇
𝜏𝑑 =
𝐷𝑏𝐿
2𝑇 2 (53.57125 𝑖𝑛 − 𝑘𝑖𝑝𝑠)
𝐿= =
𝜏𝑑 𝑏𝐷 19.2 𝑘𝑠𝑖 (3 𝑖𝑛) (3.25 𝑖𝑛)
4
𝐿 = 2.289369658 𝑖𝑛

124
𝜎𝑘 = 𝜎𝑑
4𝑇
𝜎𝑑 =
𝐷𝑡𝐿
4𝑇 4(53.57125 𝑖𝑛 − 𝑘𝑖𝑝𝑠)
𝐿= =
𝜎𝑑 𝑡𝐷 24.44444444 𝑘𝑠𝑖 (3 𝑖𝑛) (3.25 𝑖𝑛)
4
𝐿 = 3.596391609 𝑖𝑛

3
∴ 𝑈𝑠𝑒 𝐿 = 3.596 𝑖𝑛, 𝑠𝑎𝑦 3 𝑖𝑛
4

125
Problem 2.0
Given:

D = 3 in

hp = 75 hp

n = 210 rpm

FS = 4

Material Specifications:

For cast-steel gear (SAE 0030)

σy = 35 ksi, Table AT 6, p. 8

For shaft (AISI 1045, as rolled)

σy = 59 ksi, Table AT 7, p. 14

For key (AISI C1020, cold-drawn)

σy = 66 ksi, Table AT 7, p. 14

Factor of Safety:

F.S. = 4 (Given)

Design Stress:

3 1
Use 𝑏 = 4 𝑖𝑛, 𝑡 = 2 𝑖𝑛 for 𝐷 = 3 𝑖𝑛, from Table AT19, p. 38

For Torque:

63025ℎ𝑝 63025(75)
𝑇= =
𝑛 210

𝑇 = 22,508.92857 𝑖𝑛 − 𝑙𝑏 = 22.50892857 𝑖𝑛 − 𝑘𝑖𝑝𝑠

Flat Key

By shear,

126
 𝜏𝑦 = 0.6(𝜎𝑦 ) = 0.6(66 𝑘𝑠𝑖)
𝜏𝑦 = 39.6 𝑘𝑠𝑖
𝜏𝑦 36.6 𝑘𝑠𝑖
𝜏𝑑 = =
𝐹𝑆 4
𝜏𝑑 = 9.9 𝑘𝑠𝑖

By compression,

Use σy of cast-steel gear because it is the weakest material

𝜎𝑦 35 𝑘𝑠𝑖
𝜎𝑑 = =
𝐹𝑆 4
𝜎𝑑 = 8.75 𝑘𝑠𝑖

For a good design:

Induced Stress for Shear

2𝑇
𝜏𝑘 =
𝐷𝑏𝐿

𝜏𝑘 = 𝜏𝑑

2𝑇
𝜏𝑑 =
𝐷𝑏𝐿
2𝑇 2 (22.50892857 𝑖𝑛 − 𝑘𝑖𝑝𝑠)
𝐿= =
𝜏𝑑 𝑏𝐷 3
9.9 𝑘𝑠𝑖 (4 𝑖𝑛) (3 𝑖𝑛)

𝐿 = 2.021003688𝑖𝑛

Induced Stress for compression

4𝑇
𝜎𝑘 =
𝐷𝑡𝐿

𝜎𝑘 = 𝜎𝑑

4𝑇
𝜎𝑑 =
𝐷𝑡𝐿
4𝑇 4 (22.50892857 𝑖𝑛 − 𝑘𝑖𝑝𝑠)
𝐿= =
𝜎𝑑 𝑡𝐷 1
8.75 𝑘𝑠𝑖 (2 𝑖𝑛) (3𝑖𝑛)

127
𝐿 = 6.859863846 𝑖𝑛

∴ Use L = 6.860 in, say 7 in

128
Problem 3.0
Given:

D = 2in

Material Specification:

For Key (AISI 2317, QOT 1000 F.)

σu = 106 ksi
Table AT 7, p.14
σy = 71 ksi

For Shaft, (AISI 1137, cold drawn)

σu = 103 ksi
Table AT 8, p.16
σy = 93 ksi

For Key (AISI C1020, cold drawn)

σu = 78 ksi
Table AT 7, p.14
σy = 66 ksi

Solution:

Design Stress:

𝜏𝑦 = (0.6)(𝜎𝑦 )

𝜏𝑦 = (0.6)(93)

𝜏𝑦 = 55.8 𝑘𝑠𝑖

To solve for Torque (Τ):

𝜎𝑦 𝜋𝐷3
𝑇=
16

(55.8)(𝜋)(2)3
𝑇=
16

T = 87.65043504 kip ∙ in

129
A. Key material, cold-drawn, C1020, Table AT 7

Where:

𝜎𝑦 = 66 𝑘𝑠𝑖

𝜏𝑦 = (0.6)(𝜎𝑦 )

τy = (0.6)(66 ksi)

τy = 39.6 ksi

1 3
Table AT19, use b = in, t = 8 in for D =2in,
2

1
For square key, b = t = 2 in

By shear;

2𝑇
𝐿=
𝜏𝑑 (𝑏)(𝐷)

2(87.65043504 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿=
1
(39.6) (2) (2)

2
L = 4.4268 in say 4 in
5

By compression;

4𝑇
𝐿=
𝜎𝑐 (𝑡)(𝐷)

4(87.65043504 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿=
1
(66) (2) (3)

2
L = 5.3121 in say 5 in
6

1 3
For Flat key, b = in, t = 8 in
2

130
 By shear;

2𝑇
𝐿=
𝜏𝑑 (𝑏)(𝐷)

2(87.65043504 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿=
1
(39.6) (2) (2)

2
L = 4.4268 in say 4
5

By compression;

4𝑇
𝐿=
𝜎𝑐 (𝑡)(𝐷)

4(87.65043504 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿=
3
(66) (8) (3)

L = 7.0829 in say 7

B. Key material, AISI 2317, QOT 1000, Table AT 7

Where:

𝜎𝑦 = 71 𝑘𝑠𝑖

𝜏𝑦 = (0.6)(𝜎𝑦 )

𝜏𝑦 = (0.6)(71 𝑘𝑠𝑖)

τy = 42.6 ksi

1 3
Table AT19, use b = in, t = 8 in for D =2in,
2

1
For square key, b = t = 2 in

By shear;

2𝑇
𝐿=
𝜏𝑑 (𝑏)(𝐷)

131
 2(87.65043504 𝑘𝑖𝑝 ∙ 𝑖𝑛)
𝐿=
1
(42.6) (2) (2)

L = 4.1150 in

By compression;

4𝑇
𝐿=
𝜎𝑐 (𝑡)(𝐷)

4(87.65043504 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿=
1
(71) (2) (3)

8
L= 4.9381 in say 4 in
9

1 3
For Flat key, b = in, t = 8 in
2

By shear;

2𝑇
𝐿=
𝜏𝑑 (𝑏)(𝐷)

2(87.65043504 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿=
1
(42.6) (2) (2)

L=4.1150 in

By compression;

4𝑇
𝐿=
𝜎𝑐 (𝑡)(𝐷)

4(87.65043504 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿=
3
(71) (8) (3)

3
L= 6.5841 in say 6 in
5

132
Problem 4.0
Given:

D = 2in

L = 3in

P = 40 hp

N = 200 rpm

Material Specification:

For Pulley, Cast steel, SAE 080, N&T

σu = 80 ksi
Table AT 6, p.8
σy = 40 ksi

For Shaft, (C1144, OQT 1000 F, cold drawn)

σu = 118 ksi
Table AT 7, p.14
σy = 83 ksi

For Key (AISI 1015, cold drawn)

σu = 77 ksi
Table AT 7, p.14
σy = 63 ksi

Solution:

To solve for Torque (Τ):

𝑇𝑁
𝑃=
63025

𝑇(200 𝑟𝑝𝑚)
40 ℎ𝑝 =
63025

𝑇 = 12605 𝑙𝑏 ∙ 𝑖𝑛

133
 T = 12.605 kip ∙ in

1 3
Table AT19, use b = in, t = 8 in for D =2in
2

𝟏
A. Square Key, b = t = 𝟐

By shear;

2𝑇
𝜏𝑑 =
𝐿 (𝑏)(𝐷)

2(12.605 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝜏𝑑 =
1
(3) (2) (2)

3
𝜏𝑑 = 8.4033 𝑖𝑛 𝑠𝑎𝑦 8 𝑖𝑛
7

σy(0.6)
𝐹𝑆 =
𝜏𝑑

0.6(63 𝑘𝑠𝑖)
𝐹𝑆 =
8.403333333𝑖𝑛

𝐹𝑆 = 4.4982 < 6.21

By compression;

4𝑇
𝜎𝑐 =
𝐿 (𝑡)(𝐷)

4(12.605 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿=
1
(3) (2) (2)

7
𝐿 = 16.8067 𝑖𝑛 𝑠𝑎𝑦 16 𝑖𝑛
8

σy(𝑃𝑢𝑙𝑙𝑒𝑦)
𝐹𝑆 =
σc

134
 40
𝐹𝑆 =
16.80666667in
2
𝐹𝑆 = 2.3800 𝑖𝑛 𝑠𝑎𝑦 2 5 in

1 3
B. Flat key, b = in, t = 8 in
2

By shear;

2𝑇
𝜏𝑑 =
𝐿 (𝑏)(𝐷)

2(12.605 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝜏𝑑 =
1
(3) (2) (2)

3
𝜏𝑑 = 8.4033 𝑖𝑛 𝑠𝑎𝑦 8 𝑖𝑛
7

σy(0.6)
𝐹𝑆 =
𝜏𝑑

0.6(63 𝑘𝑠𝑖)
𝐹𝑆 =
8.403333333𝑖𝑛

𝐹𝑆 = 4.4982 < 6.21

By compression;

4𝑇
𝜎𝑐 =
𝐿 (𝑡)(𝐷)

4(12.605 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿=
3
(3) (8) (2)

3
𝐿 = 22.4089 𝑖𝑛 𝑠𝑎𝑦 22 𝑖𝑛
7

135
 σy(𝑃𝑢𝑙𝑙𝑒𝑦)
𝐹𝑆 =
σc

40
𝐹𝑆 =
22.4089
5
𝐹𝑆 = 1.7850𝑖𝑛 𝑠𝑎𝑦 15 6 in

Final Answer;

2 5
∴ use Square key N = 2.3800 𝑖𝑛 𝑠𝑎𝑦 2 5 𝑖𝑛, , and Flat key N = 1.7850, say 16 in

136
Problem 5.0
Given:

D = 1 ¾ in

Hp = 65.5 hp

N = 1750 rpm

Material Specification:

For Shaft, (1045, as rolled)

σu = 96 ksi
Table AT 7, p.14
σy = 59 ksi

For Key (1020, cold drawn)

σu = 78 ksi
Table AT 7, p.14
σy = 66 ksi

Factor of Safety:

F.S. = 1.5 (Given)

Solution:

To solve for Torque (Τ):

63025 ℎ𝑝
𝑇=
𝑛

63025 (65.5)
𝑇=
1750

𝑇 = 2358.9357142 𝑙𝑏 ∙ 𝑖𝑛

𝑇 = 2.3589357142 𝑘𝑖𝑝 ∙ 𝑖𝑛

3 1 3
Use 𝑏 = 8 𝑖𝑛, 𝑡 = 4 𝑖𝑛 for 𝐷 = 1 4 𝑖𝑛, from Table AT 19, p. 38

137
 Flat Key,

Design Stress

By shear,

𝜏𝑦 = 0.6(𝜎𝑦 ) = 0.6(66 𝑘𝑠𝑖)

𝜏𝑦 = 39.6 𝑘𝑠𝑖

𝜏𝑦 39.6 𝑘𝑠𝑖
𝜏𝑑 = =
𝐹𝑆 1.5

𝜏𝑑 = 26.4 𝑘𝑠𝑖

By compression,

Use σy of cast-steel gear because it is the weakest material

𝜎𝑦 59 𝑘𝑠𝑖
𝜎𝑑 = =
𝐹𝑆 1.5

𝜎𝑑 = 39.3 𝑘𝑠𝑖

For a good design

𝜏𝑘 = 𝜏𝑑

Induced Stress for shear

2𝑇
𝜏𝑘 =
𝐷𝑏𝐿

2𝑇
𝜏𝑑 =
𝐷𝑏𝐿

2𝑇 2 (2.3589357142 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿= =
𝜏𝑑 𝑏𝐷 3 3
26.4 𝑘𝑠𝑖 (8 𝑖𝑛) (1 4 𝑖𝑛)

138
𝐿 = 0.2723158 𝑖𝑛

Induced Stress for compression

4𝑇
𝜎𝑘 =
𝐷𝑡𝐿

4𝑇
𝜎𝑑 =
𝐷𝑡𝐿

4𝑇 4 (2.3589357142 𝑘𝑖𝑝 ∙ 𝑖𝑛)

𝐿= =
𝜎𝑑 𝑡𝐷 1 3
39.3 𝑘𝑠𝑖 (4 𝑖𝑛) (1 4 𝑖𝑛)

𝐿 = 0.5487891 𝑖𝑛

9
∴ 𝑈𝑠𝑒 𝐿 = 0.549 𝑖𝑛, 𝑠𝑎𝑦 𝑖𝑛
16

139
 DESIGN WORK NO. 11

Design of Couplings

Problem 1.0

Given:

𝑀𝑁
𝜏𝑠𝑡 = 60
𝑚2

𝐷𝑐 = 200 mm

Solid shaft

𝐷𝑠 = 90 mm

Hollow Shaft

𝐷0 = 100 mm

𝐷𝑖 = 90 mm

Required:

Number of bolts

Solution:

Solving torque of the shafts:

For hollow shaft:

16 𝑇𝐷0
𝜏𝑠𝑡 =
𝜋(𝐷0 4 − 𝐷𝑖 4 )

𝜏𝑠𝑡 𝜋(𝐷0
4 − 𝐷 4)
𝑇= 𝑖
16 𝐷0

140
 𝑀𝑁 𝑘𝑁
(60 2 )(1000 )(𝜋)((0.1)4 − (0.09)2 )
𝑀𝑁
𝑇= 𝑚
16(0.1)

𝑇 = 4.051476426 kN - m

For solid shaft:

16 𝑇
𝜏𝑠𝑡 =
𝜋𝐷𝑠 3

𝜏𝑠𝑡 𝜋𝐷𝑠
3
𝑇=
16 𝐷0

𝑀𝑁 𝑘𝑁
(60 2 )(1000𝑀𝑁)(𝜋) (0.093 )
𝑇= 𝑚
16

𝑇 = 8.588328917 kN - m

Use lower value of torque 𝑇 = 4.051476426 kN - m

Solving for number of bolts:

𝝅 𝟐 𝑫𝒄
𝑻 = 𝒅 𝝉 𝒏
𝟒 𝟐

𝑻
𝒏 =
𝝅 𝟐 𝑫𝒄
𝒅 𝝉
𝟒 𝟐

141
 𝟏𝟎𝟎𝟎 𝒎𝒎
4.051476426 𝑘𝑁 − 𝑚 ( )
𝒏 = 𝟏𝒎
𝝅 𝑀𝑁 𝑘𝑁 𝟏𝒎 𝟐𝟎𝟎 𝒎𝒎
(𝟏𝟎𝟐 )(60 2 )(1000 )( )2 ( )
𝟒 𝑚 𝑀𝑁 𝟏𝟎𝟎𝟎 𝒎𝒎 𝟐

𝒏 = 8.5975 bolts

𝑛 = 9 bolts

Therefore, 9 bolts are needed for the coupling to be as strong as the weaker shaft

142
Problem 2.0

Given:

𝜎𝑠 = 60 ksi

𝜏𝑠 = 40 ksi

𝜎𝑑 = 67 ksi

𝜏𝑑 = 43 ksi

P = 230 hp

N = 1200 rpm

𝑁𝐵 = 8

Design Stress:

𝑃 (63025)
● Finding torque from the power formula: 𝑇 = 𝑁
230 ℎ𝑝 (63025)
𝑇= = T = 12079.79167 lbs-in → 12.0798 kips-in
1200 𝑟𝑝𝑚

For a good design, equate:

2𝑇 3 16 𝑇
● 𝜏𝑑 = 𝜏𝑘 ; 𝜏𝑑 = 𝐷𝑏𝐿 ; 𝐷 = √( 𝜋 𝜏 )
𝑠

3 16 (12.079167 𝑘𝑖𝑝𝑠−𝑖𝑛) 3
𝐷 = √( ) = D = 1.154311939 in. say 1 16 in.
𝜋 (40 𝑘𝑠𝑖)

2𝑇 2 (12.079167 𝑘𝑖𝑝𝑠−𝑖𝑛) 15
𝐿 = 𝐷𝑏𝜏 = 𝐿 = 3 1 = L = 1.89254998 in. say 1 16in.
𝑑 (1 𝑖𝑛)( 𝑖𝑛) (43 𝑘𝑠𝑖)
16 4

143
 ● From Table AT 19 Key Dimensions :
The key fails in shear loads with reference to the initial shaft diameter
1 3
dimension: 𝑏 = 4 in. , 𝑡 = 16 in.

4𝑇
● 𝜎𝑑 = 𝜎𝑘 ; 𝜎𝑑 = 𝐷𝑡𝐿
4𝑇
𝐿=
𝐷𝑡𝜎𝑑

4 (12.079167 𝑘𝑖𝑝𝑠−𝑖𝑛) 1
𝐿= 3 3 = 𝐿 = 3.23899101 in. say 3 4 in.
(1 𝑖𝑛) ( 𝑖𝑛) (67 𝑘𝑠𝑖)
16 16

1
Therefore, we use L = 3 4 𝑖𝑛. coupling between points A and B.

144
Problem 3.0
Given:

D = 4.8 in. F = 8.37 in. B = 7.415 in. T = 7.4 kip-ft

H = 6.52 in. f = 2 in. 𝑁𝐵 = 7

L = 3.7 in. b = t = 0.5 in. d = 0.5 in.

Material specifications for AISI B1113 Cold-finished metal:

𝜎𝑢 = 83 𝑘𝑠𝑖<Table AT 7>

𝜎𝑦 = 72 𝑘𝑠𝑖

Solution:

Shear stress based on yield strength

𝜏𝑦 = (0.6)𝜎𝑦 → 0.6 (72 ksi) = 43.2 ksi

Torque in terms of kip-in

12 𝑖𝑛𝑐ℎ
7.4 kip-ft = 88.8 kip-in
1 𝑓𝑜𝑜𝑡

Failure analysis of each part for every load

● Key fails in Shear

2𝑇 2 (88.8 𝑘𝑖𝑝 − 𝑖𝑛)
𝜏𝑘 = = = 20 𝑘𝑠𝑖
𝐷𝑏𝐿 (4.8 𝑖𝑛) (0.5 𝑖𝑛) (3.7 𝑖𝑛)

● Key fails in Compression

4𝑇 4 (88.8 𝑘𝑖𝑝 − 𝑖𝑛)
𝜎ₖ = = = 40 𝑘𝑠𝑖
𝐷𝑡𝐿 (4.8 𝑖𝑛) (0.5 𝑖𝑛) (3.7 𝑖𝑛)

● Bolt fails in Shear

145
 8𝑇 8 (88.8 𝑘𝑖𝑝 − 𝑖𝑛)
𝜏𝐵 = = = 17.426 𝑘𝑠𝑖
𝐵 𝑁𝐵 𝜋𝑑² (7.415 𝑖𝑛) (7) 𝜋 (0.5 𝑖𝑛)²

● Bolt fails in Compression

2𝑇 2 (88.8 𝑘𝑖𝑝 − 𝑖𝑛)
𝜎𝐵 = = = 2.281 𝑘𝑠𝑖
𝐵 𝑁𝐵 𝑑𝑓 (7.415 𝑖𝑛) (7) (0.5 𝑖𝑛) (3 𝑖𝑛)

● Hub failure in Shear

2𝑇 2 (88.8 𝑘𝑖𝑝 − 𝑖𝑛)
𝜏𝐻 = = = 0.443 𝑘𝑠𝑖
𝜋𝐻²𝑓 𝜋 (6.52 𝑖𝑛. )² (3 𝑖𝑛)

● Shaft failure in Shear

16𝑇 16 (88.8 𝑘𝑖𝑝−𝑖𝑛)
𝜏𝑑 = = = 4.089 ksi
𝜋𝐷³ 𝜋 (4.8 𝑖𝑛)³

Finding the suitable factor of safety of each part from every load

● Key fails in Shear

𝜏𝑦𝑘 43.2 𝑘𝑠𝑖
𝐹𝑆 = = = 2.16
𝜏𝑑𝑘 20 𝑘𝑠𝑖

● Key fails in Compression

𝜎𝑦𝑘 72 𝑘𝑠𝑖
𝐹𝑆 = = = 1.8
𝜎𝑑𝑘 40 𝑘𝑠𝑖

● Bolts fail in Shear

𝜏𝑦𝐵 43.2 𝑘𝑠𝑖
𝐹𝑆 = = = 2.479
𝜏𝑑𝐵 17.426 𝑘𝑠𝑖

● Bolts fail in Compression

𝜎𝑦𝐵 72 𝑘𝑠𝑖
𝐹𝑆 = = = 31.564
𝜎𝑑𝐵 2.281 𝑘𝑠𝑖

● Hub failure in Shear

𝜏𝑦𝐻 43.2 𝑘𝑠𝑖
𝐹𝑆 = = = 97.456
𝜏𝑑𝐻 0.443 𝑘𝑠𝑖

● Shaft failure in Shear

146
 𝜏𝑦𝑑 43.2 𝑘𝑠𝑖
𝐹𝑆 = = = 10.564
𝜏𝑑𝑑 4.089 𝑘𝑠𝑖

Therefore use FS = 97.456 to satisfy the factor of safety for all parts.

147
Problem 4.0
Given:

1
D = 5 in. 𝜏𝐵 = 4.25 ksi H= 66

1
𝜏𝐻 = 12.5 ksi 𝑁𝐵 = 6 f = 1 24

1
𝜏𝑆 = 7 ksi L = 4 8in d = 7.1 in

1
𝜏𝑘 = 8.75 ksi B = 9 in
2

Design Stress:

From table AT 19, p.38

1 7
b = 14 in ; t = 8 in

Key fails in shear:

2𝑇
𝜏𝑘 =
𝐷𝑏𝐿

1 1
𝜏𝑘 𝐷𝑏𝐿 8.75 𝑘𝑠𝑖 𝑥 5 𝑖𝑛 𝑥 1 𝑖𝑛 𝑥 4 𝑖𝑛
T= = 4 8
= 112.7929688 kip - in
2 2

Bolt fails in shear:

8𝑇
𝜏𝐵 =
𝐵𝑁𝐵 𝜋𝑑2

1
𝜏𝐵 𝐵𝑁𝐵 𝜋𝑑2 4.25 𝑘𝑠𝑖 𝑥 9 𝑥5 𝑖𝑛 𝑥 𝜋 𝑥 (7.1 𝑖𝑛 )2
T= = 2
= 4795.5714821 kip - in
8 8

Hub fails in shear:

148
 2𝑇
𝜏𝐻 =
𝜋𝐻 2 𝑓

1 1
𝜏𝐻 𝜋𝐻 2 𝑓 12.5 𝑘𝑠𝑖 𝑥 𝜋 𝑥 (6 𝑖𝑛 )2 𝑥 (1 𝑖𝑛)
T= = 6 24
= 777.7856736 kip - in
1 2

Shaft fails in shear:

16𝑇
𝜏𝑆 =
𝜋𝐷 3

𝜏𝑆 𝜋𝐷 3 7 𝑘𝑠𝑖 𝑥 𝜋 𝑥 (5 𝑖𝑛 )3
𝑇= = = 171.8058482 kip - in
16 16

Therefore T = 112.7929688 kip - in is the maximum safe torque that the mechanism can
resist.

149
Problem 5.0
Given:

F = 400 mm B = 120 mm

D = 60 mm f = 35 mm

𝑁𝐵 = 4 𝜏𝑠 = 30 MPa

d = 20 mm

Design stress:

Shaft fails in shear,

16𝑇
𝜏𝑆 =
𝜋𝐷 3

𝜏𝑆 𝜋𝐷 3
𝑇= 16

1000 𝑘𝑃𝑎 1𝑚
30 𝑀𝑃𝑎 𝑥 ( )𝑥 𝜋 𝑥 (60 𝑚𝑚 𝑥 )3
𝑇= 1 𝑀𝑃𝐴 1000 𝑚𝑚
16

𝑇 = 1.272345025 kN - m

Bolt fails in shear

8𝑇
𝜏𝐵 =
𝐵𝑁𝐵 𝜋𝑑2

8 (1.272345025 𝑘𝑁 − 𝑚)
𝜏𝐵 = 1𝑚 1𝑚
120 𝑚𝑚 𝑥 ( ) 𝑥 𝜋 𝑥 (20 𝑚𝑚 𝑥 )2
1000 𝑚𝑚 1000 𝑚𝑚

1 𝑀𝑃𝐴
𝜏𝐵 = 67500.00002 kPa x
1000 𝑘𝑃𝑎

𝜏𝐵 = 6.750000002 MPa

𝜏𝐵 = 6.750 MPa

150
 DESIGN WORK NO. 12

Belt Design

Problem 1.0

Given:

1 𝐻𝑝
𝑇𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝐻𝑝 = 20 𝑘𝑊 (0.746 𝑘𝑊) = 26.80965147

𝑁1 = 1750 𝑟𝑝𝑚

𝑁2 = 360 𝑟𝑝𝑚

𝐷1 = 6 𝑖𝑛

C120 Belt Design

Solution:

𝑁1 𝐷2
=
𝑁2 𝐷1

𝑁1
𝐷2 = (𝐷1 )
𝑁2

1750 𝑟𝑝𝑚
𝐷2 = (6 𝑖𝑛) = 29.167 𝑖𝑛
360 𝑟𝑝𝑚

From Table 17.3, C120

𝐿𝑠𝑡 = 122.9 𝑖𝑛

Design Considerations:

a.) For actual center distance

For 𝐶𝑎𝑐𝑡

B + √𝐵 2 − 32 (𝐷2 − 𝐷1 )2
𝐶𝑎𝑐𝑡 =
16

B = 4L – 6.28 (𝐷2 − 𝐷1 )

151
 B = 4(122.9 in) – 6.28 (29.167 𝑖𝑛 − 6 𝑖𝑛)

B = 346.113 in

Substituting

346.113 in + √(346.113 𝑖𝑛)2 − 32 (29.167 𝑖𝑛 − 6 𝑖𝑛)2

𝐶𝑎𝑐𝑡 =
16

𝐶𝑎𝑐𝑡 = 41.65357738 𝑖𝑛

∴ 𝐶𝑎𝑐𝑡 = 41.654 𝑚𝑚

b.) For 𝐶𝑚𝑖𝑛 , assume open belt

For open length

𝜋 (𝐷2 − 𝐷1 )2
𝐿 = 2𝐶𝑚𝑖𝑛 + [𝐷2 + 𝐷1 ] + [ ]
2 4𝐶𝑚𝑖𝑛

𝜋 (29.167 𝑖𝑛 − 6 𝑖𝑛)2
122.9 𝑖𝑛 = 2(𝐶𝑚𝑖𝑛 ) + [29.167 𝑖𝑛 + 6 𝑖𝑛] + [ ]
2 4(𝐶𝑚𝑖𝑛 )

𝐿 = 2.115311909 𝑖𝑛

∴ 𝐶𝑎𝑐𝑡 = 2.115 𝑖𝑛

152
Problem 2.0

Given:

𝐶𝑚𝑖𝑛 = 300 𝑚𝑚

𝐷1 = 20 𝑚𝑚

𝐷2 = 100 𝑚𝑚

Design Considerations:

For actual length

For open length

𝜋 (𝐷2 − 𝐷1 )2
𝐿 = 2𝐶𝑚𝑖𝑛 + [𝐷2 + 𝐷1 ] + [ ]
2 4𝐶𝑚𝑖𝑛

𝜋 (100 𝑚𝑚 − 20 𝑚𝑚)2
𝐿 = 2(300 𝑚𝑚) + [100 𝑚𝑚 + 20 𝑚𝑚] + [ ]
2 4(300 𝑚𝑚)

𝐿 = 788.8288925 𝑚𝑚

∴ 𝐿 = 788.829 𝑚𝑚

153
Problem 3.0

Given:

Hp = 7Hp

𝑁1 = 500 𝑟𝑝𝑚

𝑁2 = 300 𝑟𝑝𝑚

𝐶𝑚𝑖𝑛 = 30 𝑖𝑛

𝐷1 = 20 𝑖𝑛

𝐷2 = 30 𝑖𝑛

Solution:

𝐷𝑒𝑠𝑖𝑔𝑛 𝐻𝑝 = 𝑁𝑠𝑓 (𝑇𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 ℎ𝑝)

𝑁𝑠𝑓 = 1.4 ( 𝑇𝑎𝑏𝑙𝑒 17.7)

𝐷𝑒𝑠𝑖𝑔𝑛 𝐻𝑝 = 1.4 (7𝐻𝑝)

𝐷𝑒𝑠𝑖𝑔𝑛 𝐻𝑝 = 9.8 𝐻𝑝

Solve for Actual Length:

𝜋 (𝐷2 − 𝐷1 )2
𝐿 = 2𝐶𝑚𝑖𝑛 + [𝐷2 + 𝐷1 ] + [ ]
2 4𝐶𝑚𝑖𝑛

𝜋 (30 𝑖𝑛 − 20 𝑖𝑛)2
𝐿 = 2(30 𝑖𝑛) + [30 𝑖𝑛 + 20 𝑖𝑛] + [ ]
2 4(30𝑖𝑛)

𝐿 = 139.3731497 𝑖𝑛

At 500rpm and 9.8 Hp:

154
 C-section (Figure 17.4)

At Table 17.3, C-section:

𝐿 = 139.3731497 𝑖𝑛

Therefore, use C144

𝐿𝑠𝑡𝑑 = 146.9 𝑖𝑛

a = 8.792

c = 38.819

e = 0.0416

Solving For Rated Hp/belt:

0.09
103 𝑐 𝑒𝑉𝑚 2 𝑉𝑚
Rated Hp/belt = [𝑎 ( ) − − ]( )
𝑉𝑚 𝑘𝑑 𝐷1 106 103

𝐷2 30 𝑖𝑛
= 20 𝑖𝑛 = 1.5 in
𝐷1

𝑘𝑑 = 1.11 ( 𝑇𝑎𝑏𝑙𝑒 17.4)

0.09
103 38.819
Rated Hp/belt = [8.792 (1350fpm) − (1.11)(20𝑖𝑛) −

(0.0416)(1350𝑓𝑝𝑚)2 1350𝑓𝑝𝑚
]( )
106 103

Rated Hp/belt = 9.089944031 Hp/belt

Solving for Adjusted Rated hp/belt

RHP/belt
Adj. Rated hp/belt = (𝑘𝜃 ) (𝑘𝐿 )

155
Solve for 𝐶𝑎𝑐𝑡

B + √𝐵 2 − 32 (𝐷2 − 𝐷1 )2
𝐶𝑎𝑐𝑡 =
16

Where:

B = 4L – 6.28 (𝐷2 − 𝐷1 )

B = 4(146.9 in) – 6.28 (30 𝑖𝑛 − 20 𝑖𝑛)

B = 524.8 in

Substituting:

524.8 in + √(524.8 in)2 − 32 (30 𝑖𝑛 − 20 𝑖𝑛)2

𝐶𝑎𝑐𝑡 =
16

𝐶𝑎𝑐𝑡 = 65.40889449 in

For 𝑘𝜃 , Table 17.5

𝐷2 −𝐷1 25 𝑖𝑛 −12.5 𝑖𝑛
= = 0.1528844063
𝐶𝑎𝑐𝑡 55.284 𝑖𝑛

Interpolation:

0.1 0.99
0.1528844063 𝑘𝜃
0.2 0.97
𝑘𝜃 = 0.9794231187 (Table 17.5)

For 𝑘𝐿 , Table 17.6: C144

𝑘𝐿 = 1.00 (Table 17.6)

156
 Substitution

RHP/belt
Adj. Rated hp/belt = (𝑘𝜃 ) (𝑘𝐿 )

RHP/belt
Adj. Rated hp/belt = 0.9794231187) (1.00)

Adj. Rated hp/belt = 9.280916345 Hp/belt

Solving For No. of belts

9.8 ℎ𝑝
No. of belts = 𝐴𝑑𝑗. 𝑟𝑎𝑡𝑒𝑑 ℎ𝑝/𝑏𝑒𝑙𝑡

9.8 ℎ𝑝
No. of belts = 9.280916345 Hp/belt

No. of belts = 1.055930216 belts

No. of belts ≈ 2 𝑏𝑒𝑙𝑡𝑠

∴ 𝑢𝑠𝑒 2 𝑏𝑒𝑙𝑡𝑠, 𝐶144𝑉 − 146.9 𝑖𝑛

157
Problem 4.0

Given:

1000 𝑚𝑚
𝐶𝑚𝑖𝑛 = 3𝑚 ( ) = 3000 𝑚𝑚
1𝑚

𝐷1 = 150 𝑚𝑚

𝐷2 = 250 𝑚𝑚

Design Considerations:

For actual length

For open length

𝜋 (𝐷2 − 𝐷1 )2
𝐿 = 2𝐶𝑚𝑖𝑛 + [𝐷2 + 𝐷1 ] + [ ]
2 4𝐶𝑚𝑖𝑛

𝜋 (250 𝑚𝑚 − 150 𝑚𝑚)2

𝐿 = 2(3000 𝑚𝑚) + [250 𝑚𝑚 + 150 𝑚𝑚] + [ ]
2 4(3000 𝑚𝑚)

𝐿 = 6157.912966 𝑚𝑚

∴ 𝐿 = 6157.913 𝑚𝑚

158
Problem 5.0

Given:

Hp = 50 Hp

𝐷1 = 8 𝑖𝑛

𝑁1 = 1150 𝑟𝑝𝑚

𝑁2 = 400 𝑟𝑝𝑚

𝑁𝑠𝑓 = 1.5

Solution:

𝐷2 𝑁1
=
𝐷1 𝑁2

1150𝑟𝑝𝑚
𝐷2 = (8in)
400𝑟𝑝𝑚

𝐷2 = 23 𝑖𝑛

𝐷1 + 𝐷2
𝐶𝑚𝑖𝑛 = + 𝐷1
2

23𝑖𝑛 + 8𝑖𝑛
𝐶𝑚𝑖𝑛 = + 8𝑖𝑛
2

𝐶𝑚𝑖𝑛 = 23.5𝑖𝑛

𝐶𝑚𝑖𝑛 = 𝐷2 = 23 𝑖𝑛

Therefore, use
𝐶𝑚𝑖𝑛 = 23.5 𝑖𝑛

159
 𝜋 (𝐷2 − 𝐷1 )2
𝐿 = 2𝐶𝑚𝑖𝑛 + [𝐷2 + 𝐷1 ] + [ ]
2 4𝐶𝑚𝑖𝑛

𝜋 (23𝑖𝑛 − 8𝑖𝑛)2
𝐿 = 2(23.5 𝑖𝑛) + [23𝑖𝑛 + 23.5𝑖𝑛] + [ ]
2 4(23.5𝑖𝑛)

𝐿 = 98.08830315 𝑖𝑛

𝐷𝑒𝑠𝑖𝑔𝑛 𝐻𝑝 = 𝑁𝑠𝑓 (𝑇𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 ℎ𝑝)

= 1.5 ( 50𝐻 𝑝)

𝐷𝑒𝑠𝑖𝑔𝑛 𝐻𝑝 = 75𝐻𝑝

At 1150 rpm and 75 Hp

C-section (Figure 17.14)

Since L= 98.0880315 in

At C-section, L standard = 98.9 in (Table 17.3)

𝐿𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 = 98.9 𝑖𝑛

160