000 Unit I Introduction To Design For Static Strength 2016-17 As On 15082016 PDF

Design of Machine Elements I (Unit I)
UNIT I: Introduction to design for static strength
Introduction:
A machine is defined as an apparatus using mechanical power and having several parts
(Mechanisms), each with a definite function and together performing a particular task. It is can
also be defined as a tool containing one or more parts that uses energy to perform an intended
action. Machines are usually powered by mechanical, chemical, thermal, or electrical means, and
are often motorized. Historically, a power tool also required moving parts to classify as a
machine. However, the advent of electronics has led to the development of power tools without
moving parts that are considered machines.
According to Cambridge Dictionary, A Machine is a piece of equipment with several moving

parts that uses power to do a particular type of work.
A combination of a number of bodies (link) assembled in such a way that the motion of one
causes, constrained and predictable motion to the others is known as a mechanisms. Thus, the
function of a mechanism is to transmit and modify a motion.
A machine is a mechanism or a combination of mechanisms which, apart from imparting

motions to the parts, also transmits and modifies the available mechanical energy into some kind
of desired work. It is neither a source of energy nor a producer of work but helps in proper
utilization of the same.
Examples:
Industry Related:
Lathe, Shaper, Milling Machine, Drilling Machine, Gas Turbine, Steam Turbine, Wind Mill, IC
Engine, EC Engine, Water Pump, Wood Cutter, Screw Jack, Hydraulic Pump, Pneumatic Pump
etc.,
Transportation Related:
Bicycle, Motor bike, Scoter, Car, Van, Truck, Boat, Ships, Sub-marine, Locomotives, Aero
planes, Helicopter etc.,
Domestic Related:
Washing Machine, Wet Grinder, Mixture, Juice Maker etc.,
Machine element is a part of a machine represents a link, which is defined as a rigid body which
possesses at least two nodes which are points for attachment to other links
Machine design is defined as the use of scientific principles, technical information and
imagination in the description of a machine or a mechanical system to perform specific functions
with maximum economy and efficiency. This definition of machine design contains the
following important features:
1 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

1. A designer uses principles of basic and engineering sciences such a physics, mathematics,
statics and dynamics, strength of materials, thermodynamics and heat transfer, vibrations
and fluid mechanics. Some of the examples of these principles are
a. Newtons laws of motion
b. DAlemberts principle
c. Boyles and Charles laws of gases
d. Carnot cycles and
e. Bernoullis principles
2. The designer has technical information of the basic elements of a machine. These
elements include fastening devices, chain, belt and gear drives, bearing, oil seals and
gaskets, springs, shafts, keys, couplings and so on. A machine is a combination of these
basic elements. The designer knows the relative advantages and disadvantages of these
basic elements and their suitability in different applications
3. The designer uses his/her skill and imaginations to produce a configuration, which is a
combination of these basic elements. However, this combination is unique and different
in different situations. The intellectual part of constructing a proper configuration is
creative in nature.
4. The final outcome of the design process consists of the description of the machine. The
description is in the form of drawings of assembly and individual components
5. A design is created to satisfy a recognized need of customer. The need may be to perform
a specific function with maximum economy and efficiency.
Design Considerations
Sometimes the strength required of an element in a system is an important factor in the
determination of the geometry and the dimensions of the element. In such a situation it is said
that strength is an important design consideration. When it uses the expression design
consideration, it is referring to some characteristic that influences the design of the element or,
perhaps, the entire system. Usually quite a number of such characteristics must be considered
and prioritized in a given design situation. Many of the important ones are as follows (not
necessarily in order of importance):
1 Functionality 14 Noise
2 Strength/stress 15 Styling
3 Distortion/deflection/stiffness 16 Shape
4 Wear 17 Size
5 Corrosion 18 Control
6 Safety 19 Thermal properties
7 Reliability 20 Surface
8 Manufacturability 21 Lubrication
9 Utility 22 Marketability
10 Cost 23 Maintenance
11 Friction 24 Volume
12 Weight 25 Liability
13 Life 26 Remanufacturing/resource recovery
Some of these characteristics have to do directly with the dimensions, the material, the
processing, and the joining of the elements of the system. Several characteristics may be
interrelated, which affects the configuration of the total system.
Flow
Flow-charts - difference between
Design Process and a Basic Procedure for Design of Machine Element
Definition of a Code:
A code is a standard that has been adopted by one or more governmental bodies and is
enforceable by law. Any set of standards set forth and enforced by a local government agency for
the protection of public safety, health, industrial procedures for product
production,
ion, safety, quality
control etc., safety as in the structural safety of buildings (building code), health (health code),
3 | Department of Mechanical Engineering,

ngineering, PESIT, Bangalore, Dr. C V Chandrashekara
requirements for plumbing, ventilation etc., (sanitary code) and the specifications for fire escapes
or exits (fire code).
Definition of a standard:
A standard consists of technical definitions and guidelines that function as instructions for
designers/manufacturers and operators/users of equipment. Standards can run from a few pages
to a few hundred pages and are written by professionals who serve on ASME committees.
Standards are considered voluntary because they are guidelines and not enforceable by law.
ASME publishes standards, accredits users of standards to ensure that they are capable of
manufacturing products that meet those standards, and provides stamps that accredited
manufacturers may place on their products to indicate conformance to a standard.
Standardization is defined as obligatory norms, to which various characteristics of a product
should conform. The characteristics include materials, dimensions and shape of the component,
method of manufacturing, testing and method of marketing, packing and storing of the product.
The following standards are used in mechanical engineering design:
1. Standards for Materials, their chemical compositions, Mechanical Properties and heat
Treatment
Example: Indian standards IS 210 specifies seven grads of grey cast iron designated as
FG150, FG200, FG220, FG260, FG300, FG350 and FG400. The number indicates ultimate
tensile strength in N/mm2.
Review of strength of materials:
In engineering practice, the machine parts are subjected to various forces which may be due to
either one or more of the following:
1. Energy transmitted
2. Weight of machine
3. Frictional resistances
4. Inertia of reciprocating parts
5. Change of temperature, and
6. Lack of balance of moving parts
The different forces acting on a machine part produces various types of stresses.
Load: It is defined as any external force acting upon a machine part. The following four
types of the load are considered to be important.
1. Dead or steady load: A load is said to be a dead or steady load, when it does not change in
magnitude or direction.
2. Live or variable load: A load is said to be a live or variable load, when it changes continually.

3. Suddenly applied or shock loads: A load is said to be a suddenly applied or shock load, when
it is suddenly applied or removed.
4. Impact load: A load is said to be an impact load, when it is applied with some initial velocity.
[Note: A machine part resists a dead load more easily than a live load and a live load more easily
than a shock load.]
Stress:
It is defined as the internal resistance offered by the machine component for any deformation

under the action of external force or load. Mathematically,
, = /

,
=
=
Some conversions for units of stress are as follows:
1 Pa (Pascal) 1 N/m2 1 x 10-6 N/ mm2

1 MPa (Mega Pascal) 1 x 106 N/ m2 1 N/mm2
1 GPa (Giga Pascal) 1 x 109 N/ m2 1 kN/mm2
Strain:
It is defined as the deformation per unit length under the action of external force or load.

Mathematically,
, =

,
=
= !
Tensile stress and tensile strain:
When a component is subjected to two equal and opposite axial pulling force (tensile load) as
shown in Figure 1, then the stress induced at any section of the component is known as tensile
stress. The ratio of increase in length to the original length is known as tensile strain.
P P P t P
t
Fig. 1 Tensile stress and strain

Compressive stress and tensile strain:
When a component is subjected to two equal and opposite axial pushing force (compressive
load) as shown in Figure 2, then the stress induced at any section of the component is known as
compressive stress. The ratio of decrease in length to the original length is known as compressive
strain.
P P P c P
c
Fig. 2 Compressive stress and strain
Youngs modulus:
The ratio of stress to strain within the elastic limit of a material is known as Youngs modulus or
Modulus of Elasticity. Mathematically,

"= = /

[For details of Mechanical properties of various engineering materials, refer Tabl1 I.1 to I.18
from page No. 458 to 475, Design Data Hand Book (DDHB)]
Shear stress and shear strain:
When a body is subjected to two equal and opposite forces acting tangentially across the
resisting section, as a result of which the body tends to shear off the section as shown in
Figure 3, then the stress induced is called shear stress. The corresponding stain is known as
shear strain and it is measure in terms of angular deformation.
p d p
p p
Fig. 3 Shear stress and shear strain
Mathematically,
%
# , $ = = ; /
&

Rigidity modulus:
The ratio of shear stress to shear strain within the elastic limit of a material is known as Youngs
modulus or Modulus of Elasticity. Mathematically,
$
(= /

Stress-strain Diagram:
In designing various parts/elements of a machine, it is necessary to know how the material will
function/behave in service condition. For this purpose certain characteristics or properties of the
material should be known well in advance the machine design process. The mechanical
properties mostly used in mechanical engineering practice are commonly determined from a
standard tensile test. This test consists of gradually loading a standard specimen of a material and
noting the corresponding values of load and elongation until the specimen fractures. The load is
applied and measured by a testing machine. The stress is determined by dividing the load values
by the original cross-sectional area of the specimen. The elongation is measured by determining
the amounts that two reference points on the specimen are moved apart by the action of the
machine. The original distance between the two reference points is known as gauge length. The
strain is determined by dividing the elongation values by the gauge length.
The values of the stress and corresponding strain are plotted taking stress in y-axis and strain
x-axis. Such plot/diagram is known as stress-strain diagram of the material tested, as shown in
Figure 4
Fig. 4 Stress and Strain Diagram

Working stress or allowable stress or permissible stress or design stress:
When designing machine parts/elements, it is desirable to keep the stress lower than the yield
stress or ultimate stress. This stress is known as the working stress or design stress or safe stress
or permissible stress or allowable stress.
Note: By failure it is not meant actual breaking of the material. Some machine parts are said to
fail when they have elastic deformation, and they no more perform their function satisfactory.
Factor of safety:
It is defined as the ratio of the maximum stress to the working stress. Mathematically,
Factor of safety = Maximum stress/Working or design stress
In case of ductile materials e.g. mild steel, where the yield point is clearly defined, the factor of
safety is based upon the yield point stress. In such cases,
Factor of safety = Yield point stress /Working or design stress = e/i
In case of brittle materials e.g. cast iron, the yield point is not well defined as for ductile
materials. Therefore, the factor of safety for brittle materials is based on ultimate stress.
Factor of safety = Ultimate stress / Working or design stress = u/i
This relation may also be used for ductile materials.
Selection of Factor of Safety (FOS):
The selection of factor of safety for designing a machine component depends on a number of
considerations, such as the material, mode of manufacture, type of stress, general service
conditions and shape of the parts. Before selecting a factor of safety, a design engineer should
consider the following points:
1. The reliability of the properties of the material and change of these properties during service
2. The reliability of test results & accuracy of application of these results to actual machine parts
3. The reliability of applied load
4. The certainty as to exact mode of failure
5. The extent of simplifying assumptions
6. The extent of localized stresses
7. The extent of initial stresses set up during manufacture
8. The extent of loss of life if failure occurs and
9. The extent of loss of property if failure occurs

Each of the above factors must be carefully considered and evaluated. The values of factor of
safety based on ultimate strength for different materials and type of load are given in the
following Table 1:
Table 1 Factor of safety for various engineering material under different load conditions
Material Steady load Live load Shock load
Cast iron 5 to 6 8 to 12 16 to 20
Wrought iron 4 7 10 to 15
Steel 4 8 12 to 16
Soft materials and alloys 6 9 15
Leather 9 12 15
Timber 7 10 to 15 20
Linear strain and Lateral strain:
Consider a circular bar of diameter d and length l, subjected to a tensile force P as shown in
Figure 5(a).
l l+l
P d P P d-d P
(b)
(a)
Fig. 5 Linear strain and Lateral strain
It is noticed that due to tensile force, the length of the bar increases by an amount l and the
diameter decreases by an amount d, as shown in Figure 5(b). Similarly, if the bar is subjected to
a compressive force, the length of bar will decrease which will be followed by increase in
diameter.
Every direct stress is accompanied by a strain in its own direction which is known as linear
strain and an opposite kind of strain in lateral direction, (at right angles to it), is known as lateral
strain.

Poissons Ratio:
It has been found experimentally that when a body is stressed within elastic limit, the lateral
strain bears a constant ratio to the linear strain. Mathematically,
1 -
&, =,= =
-
Following Table 2 gives the values of Poisson's ratio for some of the materials commonly used
in engineering practice.
Table 2 Values of Poissons ratio for commonly used materials
Material Poissons Ratio () Material Poissons Ratio ()
Steel 0.25 to 0.33 Aluminium 0.32 to 0.36
Cast iron 0.23 to 0.27 Concrete 0.08 to 0.18
Copper 0.31 to 0.34 Rubber 0.45 to 0.50
Brass 0.32 to 0.42

Problems involving uni-axial load
1. Find the diameter of a rod made of C14 material subjected to the load as shown in Figure 6.
Assume the factor safety as 3.
F = 2 kN
Figure 6
Solution:
Data Given:
Tensile load, = 2 / = 2 102

Material: C14
Factor of Safety, !# = 3

Nature of Load: Tensile
Diameter of the rod, d =?

Notice that one end of the rod is fixed and other end is subjected to a pull of 2 kN, i.e., the rod is
subjected to a tensile load.
From Design Data Hand Book (DDHB) Page No. 463, Table I.8 for C14 material we have,
4 = 216 /
Yield strength,
6
4 216
788 = = = 72 /
!# 3
4
We know that,
788 = =
;
4 2 102
72 =
;
< , = 5.94
@AB C = D EE
Round it off to the next nearest inter number

F = 2 kN
F = 2 kN
Fig. 7
Solution:
Data Given:

Material: C14

Nature of Load: Shear

Notice that the rod is inserted through two plates, which are pulling the rod on either side
creating a shear load across the cross section of the rod with a magnitude of 2 kN.
4 = 216 /
Yield strength,
6
4 216
788 = = = 72 /
!# 3
Knowing the allowable yield stress, one can estimate the allowable shear stress of the material
6 , $788 = 0.5 788 = 0.5 72 = 36 /

using the following relation:
4
We know that,
$788 = =
;
4 2 102
36 =
;
< , = 8.41
@AB C = G EE
Round it off to the next nearest inter number

F = 2 kN
30 mm
Fig. 8
Solution:
Data Given:

Material: C14

Nature of Load: Bending
Length of the rod, - = 30

Notice that the rod is subjected to a bending load of 2 kN acting at the free end. The cross section
near to the fixed is the critical cross-section.
4 = 216 /
Yield strength,
6
4 216
788 = = = 72 /
!# 3
Bending moment, H = - = 2 102 30 = 6 10I
H 32H
From DDHB, Page No. 2, Equation, 1.1 (b), we have
J = =
K ; 2
; 2
Where, Z is section modulus and given by DDHB, Page No. 13, Table 1.3 (a), g row
K=
32
[Note that this induced bending stress should be less than or equal to allowable stress of the
32H
material]
J = 788 =
; 2
32 6 10I
72 =
; 2
< , = 20.39
C = LM EE

4. Determine the required thickness of the steel bracket at section A-A when loaded as
shown in Figure 9. The material of the element is C35. Assume the factor of safety as 3.
5000 N
50 b
50
A A
50
Fig. 9 Steel Bracket
5. A mild steel bracket shown in Figure 10 is subjected to a pull of 10 kN. The bracket has a
rectangular cross-section whose depth is twice the width. If the allowable stress for the
material is 80 N/mm2, determine c/s of the bracket.
150
600
10kN
200
X t
A
2t
X
Fig. 10 Steel Bracket

Principal Stresses:
There are many situations when mechanical components are subjected to several types of loads
simultaneously. A transmission shaft shown in Figure 10 is a good example and is subjected to
bending as well as torsional moment at the same time, leads to bending stress and shear stress
respectively.
Mounting Element (Gear)

Transmission Shaft
Bearing A Bearing B
Fig. 10 Transmission shaft
In such cases, it is essential to determine the state of stresses to follow the safe design procedure.
State of stresses are estimated depending upon the nature of combined stresses acting on the
mechanical element.
A case, where two axial (Bi-axial) stresses and one shear stress acting on a component is
considered here for analysis purpose as shown in Figure 11.
Y
y yx
xy
x x
X
xy
yx y
Fig. 11 Bi-axial stresses with shear stress

The normal stresses are acting perpendicular to the area under considerations and are denoted by
x and y in the X and Y directions respectively, while the shear stresses acts over the area and is
denoted by xy and yx.
xy indicates the shear stress acting on the area which is perpendicular to X-direction and is
acting in the Y-direction.
For normal stresses, tensile stresses are considered to be positive and the compressive stresses
are negative. The shear stresses are positive if they act in the positive directions of the reference
axis. It can be proved that, xy = yx
With this, principal stresses are calculated using the following relations:
Maximum Principal Stress,
P + 4 P 4
N = O R + ST U + $P4
<<VW, . 5, "X. 1.8()
2 2
Minimum Principal Stress,
P + 4 P 4
= O R ST U + $P4
<<VW, . 5, "X. 1.8( )
2 2
Maximum Shear Stress,
P 4
$[7P = ST U + $P4
= N <<VW, . 5, "X. 1.8()
2 2

Problems on principal stresses:
6. The stresses on two mutually perpendicular planes through a point in a body are 30 MPa
and 15 MPa, both tensile along with a shear stress of 25 MPa. Find the Principal Stresses.
Solution:
P = 30 H = 30 / (%)

Given:
4 = 15 H = 15 / (%)

$ = 25 H = 25 /

P + 4 P 4
N = O R + ST U + $P4
<<VW, . 5, "X. 1.8()
2 2
30 + 15 30 15
N = O R + SO R + 25 = 22.5 + 26.1
2 2
]M = ^_. D `/EEL (abcdefb)

P + 4 P 4
= O R ST U + $P4
<<VW, . 5, "X. 1.8( )
2 2
30 + 15 30 15
= O S
R O R + 25 = 22.5 26.1
2 2
]L = g. D `/EEL (hiEjkbddelb)

P 4
$[7P = ST U + $P4
<<VW, . 5, "X. 1.8()
2
30 15
$[7P = S O R + 25
2
mEAn = LD. M `/EEL

and 30 MPa both tensile along with a shear stress of 60 MPa. Determine the Principal
Stresses.
Solution:
P = 120 H = 120 / (%)

Given:
4 = 30 H = 30 / (%)

$ = 60 H = 60 /

P + 4 P 4
N = O R + ST U + $P4
<<VW, . 5, "X. 1.8()
2 2
120 + 30 120 30
N = O R + SO R + 60 = 75 + 75
2 2
]M = Mop `/EEL (abcdefb)

P + 4 P 4
= O R ST U + $P4
<<VW, . 5, "X. 1.8( )
2 2
120 + 30 120 30
= O S
R O R + 60 = 75 75
2 2
]L = p

P 4
$[7P = S T U + $P4
<<VW, . 5, "X. 1.8()
2
120 30
$[7P = S O R + 60
2
mEAn = qo `/EEL

and 50 MPa both tensile. Determine the maximum value of the shear stress which can be
applied so that the maximum value of the permissible Principal Stress is limited to 120
[ : $ = 52.9 H $ = 55 H]

MPa.

Theories of Failure under Static Load:

The strength of machine members is based upon the mechanical properties of the materials used.
Since these properties are usually determined from simple tension or compression tests,
therefore, predicting failure in members subjected to uni-axial stress is both simple and straight-
forward. But the problem of predicting the failure stresses for members subjected to bi-axial or
tri-axial stresses is much more complicated. Unfortunately, design data for such cases not readily
available for design purpose. However, designer has to decide about the limit; thereafter the
elastic failure of elements can be declared. To address these issues several numbers of different
theories have been formulated. The principal theories of elastic failure for a member subjected
to bi-axial stress are as follows:
1. Maximum principal (or normal) stress theory (also known as Rankines theory)
2. Maximum shear stress theory (also known as Guests or Trescas or Coulombs theory)
3. Maximum principal (or normal) strain theory (also known as Saint Venant theory)
4. Maximum total strain energy theory (also known as Haighs theory)
5. Maximum distortion energy theory (also known as Henckys and Huber Von Mises theory)
Since ductile materials usually fail by yielding i.e. when permanent deformations occur in the
material and brittle materials fail by fracture, therefore the limiting strength for these two classes
of materials is normally measured by different mechanical properties. For ductile materials, the
limiting strength is the stress at yield point as determined from simple tension test and it is,
assumed to be equal in tension or compression. For brittle materials, the limiting strength is the
ultimate stress in tension or compression.
Maximum Principal or Normal Stress Theory (Rankines Theory)
[Ref: DDHB, Eq. No. 2.8(a), Page No. 21]
P + 4 P 4
u = v w + Sx y + $P4

2 2
u = N
According to this theory, the failure or yielding occurs at a point in a member when the
maximum principal or normal stress in a bi-axial stress system reaches the limiting strength of
the material in a simple tension test.

Maximum Strain Energy Theory or Saint-Vanants Theory

[Ref: DDHB, Eq. No. 2.8(b), Page No. 22]
maximum strain energy in a bi-axial stress system reaches a value equal to the shear stress at
yield point in a simple tension test.
u = N ,
Maximum Shear Stress Theory (Guests or Trescas Theory)
[Ref: DDHB, Eq. No. 2.8(c), Page No. 22]
u = N
N
mEAn = x y ; z N
2
N
mEAn = - x , y ; z N
2 2
[Note: mEAn =
{|
L}~@
]
maximum shear stress in a bi-axial stress system reaches a value equal to the shear stress at yield
point in a simple tension test.
Shear Energy Theory or Maximum Distortion Energy Theory (Hencky and Von Mises
Theory) [Ref: DDHB, Eq. No. 2.8(d), Page No. 22]
u = N + N
According to this theory, the failure or yielding occurs at a point in a member when the distortion
strain energy (also called shear strain energy) per unit volume in a bi-axial stress system reaches
the limiting distortion energy (i.e. distortion energy at yield point) per unit volume as determined
from a simple tension test.
Maximum Total Strain Energy Theory (Haighs Theory)
[Ref: DDHB, Eq. No. 2.8(e), Page No. 22]
u = N + 2,N
According to this theory, the failure or yielding occurs at a point in a member when the strain
energy per unit volume in a bi-axial stress system reaches the limiting strain energy (i.e. strain
energy at the yield point) per unit volume as determined from simple tension test.
Selection and use of Failure Theories:
While selecting the theories of failure, the following general points should be used:
1. For ductile materials maximum shear stress theory and distortion energy theory is used,
where, the criterion of failure is yielding. It is assumed that the yield strength in tension is
equal to the yield strength in compression.
2. Distortion energy theory predicts yielding with precise accuracy, but involves slightly
complicated design calculations. This theory is used when the factor of safety is to be
held in close limits and the cause of failure of the component is being investigated. This
theory predicts the failure most accurately.
3. Maximum shear stress theory is used of ductile materials, if dimensions need not be held
too close and a generous factor of safety is used. The calculations involved in this theory
are easy.
4. The maximum principal stress theory is the proper choice for brittle materials.

Problems on Theories of Failure:
9. A plate of C45 steel is subjected to the following stresses:

P = 150 H , 4 = 100H $P4 = 50 H
Find the factor of safety using,
a. Maximum Principal Stress Theory
b. Maximum Shear Stress Theory and
[N = 180.9 H (%), = 69.1 H (%);

c. Maximum Distortion Energy Theory (Hencky - Mises Theory)
(). !# = 1.96; (6). !# = 1.9517 (). !# = 2.233]
Solution:
Given
P = 150 H , 4 = 100H $P4 = 50 H
From DDHB, Page No. for C45 steel, we have
u = 150 H
P + 4 P 4
N = O R + ST U + $P4
<<VW, . 5, "X. 1.8()
2 2
150 + 100 150 100

N = O S
R+ O R + 50 = 125 + 55.90
2 2
]M = M_p. Gp `/EEL (abcdefb)

P + 4 P 4
= O S
R T U + $P4
<<VW, . 5, "X. 1.8( )
2 2
150 + 100 150 100

= O S
R O R + 50 = 125 55.90
2 2
]L = DG. Mp `/EEL (abcdefb)

P 4
$[7P = ST U + $P4
<<VW, . 5, "X. 1.8()
2
150 100
$[7P = SO R + 50
2
mEAn = oo. Gp `/EEL

Note that N , N >


N =
!#
353
180.9 =
!#
!# = 1.96
Since N ,

b. Maximum Shear Stress Theory
N 180.90 69.10
$[7P = - x , y ; $[7P = - v , w
2 2 2 2
$[7P = - (90.45,34.55)
$[7P = 90.45 /
353
W, $[7P = ; 90.45 =
2!# 2!#
!# = 1.9513
c. Maximum Distortion Energy Theory (Hencky - Mises Theory)
u
= N + N
!#
353
= 180.9 + 69.1 180.9 69.1
!#
!# = 2.2325
10. A material has maximum yield strength in tension and compression as 100 MPa.
Compute factor of safety for the following theories of failure
a. Maximum Normal Stress Theory
c. Maximum Distortion Energy Theory
Considering the following stresses:
i. N = 70 H , = 70 H 2 = 0
ii. N = 70 H , = 30 H 2 = 0
iii. N = 0 , = 30 H 2 = 70 H
[(a). (i). FOS = 1.43; (ii). FOS = 1.43; (iii). FOS = 1.43
(b). (i). FOS = 1.43; (ii). FOS = 1.43; (iii). FOS = 1.43 and
(c). (i). FOS = 1.43; (ii). FOS = 1.644; (iii). FOS = 1.644]
11. A mild steel shaft of 60 mm diameter is subjected to a bending moment of 25 x 105 N-

mm and Torque T. If the yield point of steel in tension is 230 N/ mm2, find the maximum
value of Torque without causing yield of the shaft according to:
c. Maximum Distortion Energy Theory

Assume the FOS = 1.5
[(a). T = 3.126 x 106 N-mm; (b). T = 2.078 x 106 N-mm and (c). T = 2.4 x 106 N-mm]
12. A round rod of diameter 50 mm is to sustain an axial compression load of 20 kN and a

twisting moment of 1.5 kNm. The rod is made of carbon steel C40. Determine the factor
of safety as per the following theories of failure:
a. Maximum Principal Strain Theory
b. Distortion Energy Theory and
c. Maximum Elastic Strain Energy Theory
[(a). FOS = ; (b). FOS = ; (c). FOS = ]
13. A rod of circular cross section is to sustain a torsional moment of 300 kNm and bending
moment 200 kNm. Selecting C45 steel and assuming factor of safety 6, determine the
diameter of the rod as per the following theories of failure: [Assume = 0.3]
b. Maximum Shear Stress Theory
c. Maximum Distortion Energy Theory and
d. Total Energy Theory
[(a). 290 mm; (b). 315 mm; (c). 305 mm and (d). 301 mm Consider the highest value]
14. Determine the maximum normal stress and maximum shear stress at section A-A for the
crank shown in Figure 12, when a load of 10 kN is assumed to be concentrated at the
centre of crank pin.
50 Crank Pin
25
10 kN
75
Crank Shaft 125
A
A Crank Web
100 40 25
Fig. 12 Crank

15. A circular rod of diameter 50 mm is subjected to loads as shown in Figure 13. Determine
the nature and magnitude of stresses at the critical points.
1 kNm 3 kN
A
50
15 kN
B 250
Fig. 13
16. Determine the maximum normal stress and maximum shear stress at section A-A for the
crank shown in Figure 14, when a load of 10 kN is assumed to be concentrated ,is
applied at the centre of crank pin. Neglect the effect of transverse shear.
50 Crank Pin
25
10 kN
0
30
75
Crank Shaft 125
A
A Crank Web
75 38 25
Fig. 14 Crank
17. A 50 mm diameter steel rod supports a 9 kN load and in addition is subjected to a
torsional moment of 100 N-m as shown in Figure 15. Determine the maximum tensile
and the maximum shear stress.
A
50
100 Nm
28
9 kN
Fig. 15
18. A bar of 50 mm diameter fixed at one end is subjected to a torsional load of 1 kN-m in
addition to an axial pull of 15 kN as shown in Figure 16. Determine the principal stresses
if the length of the shaft is 250 mm.
A 1 kNm
50
15 kN
B 250
Fig. 16

Design for Impact loads:

Derivation of instantaneous Stress due to axial loading:
Consider a bar carrying a load W at a height h and falling on the collar provided at the lower
end of the bar as shown in Figure 17.
Fig. 17 Impact load (Ref. page No. 27 and 28 DDHB)

Let,
A = Cross-sectional area of the bar in mm2
E = Youngs modulus of the material of the bar in N/mm2
L= Length of the bar in mm
W = Falling load in N
h = Height through which the load falls in mm
= Instantaneous deformation of the bar in mm
= Impact Stress or instantaneous stress induced in the bar due to the impact load in N/mm2
F = Force at which the deflection is produced in N
= Instantaneous load at the time of hit
The potential energy lost by the weight = the strain energy absorbed by the system
Strain energy absorbed by the system,
1
= (1)
2
Potential energy last by the weight,
= ( + ) (2)

Equating equation (1) and (2), we get,

1
= ( + )
2
2( + )
= (3)

-

/. , = (4)
"
Substituting eqn. (3) in eqn. (4) we get,
2( + ) -
=

"
-
W, =
"
2( + )
=

On simplification, we get
2 2 = 0

It is in the form of a quadratic equation in and on solving we get,

The general equation for the deformation under impact action,
2
= 1 + S1 +

(Refer DDHB; page No. 27 Eqn. 2.26(b))

On multiplying both the side by , The general equation for the impact stress,
2
= 1 + S1 +

On making substitution = =

2"
= 1 + S1 +
-
(Refer DDHB; page No. 27 Eqn. 2.26(a))
Where, 1 + 1 + is known as Impact factor


Derivation of instantaneous Bending Stress due to Central Point Load:

Consider a simply supported beam subjected to a load W at a height h and falling at the
midpoint of the beam as shown in Figure 18.
y
L
Fig. 18 Impact load (Ref. page No. 27 and 28 DDHB)

Let,
E = Youngs modulus of the material of the beam in N/mm2
I = Moment of inertia of the beam cross-section in mm4
L= Length of the beam in mm
W = Falling load in N
h = Height through which the load falls in mm
y= deformation of the bar in mm
b = Impact Stress or Instantaneous stress induced in the beam due to the impact lad in N/mm2
F = Force at which the deflection y is produced in N
= Equivalent load producing the same deflection
The potential energy lost by the weight = the strain energy absorbed by the system
Strain energy absorbed by the system,
1
= (1)
2
Potential energy last by the weight,
= ( + ) (2)
Equating equation (1) and (2), we get,
1
= ( + )
2

2( + )
= (3)

-2
/. , = (4)
48"z
Substituting eqn. (3) in eqn. (4) we get,
2( + ) -2
=
48"z
-2
W, =
48"z
2( + )
=

On simplification, we get
2 2 = 0

It is in the form of a quadratic equation in and on solving we get,

The general equation for the deformation under impact action,
2
= 1 + S1 +

(Refer DDHB; page No. 27 Eqn. 2.26(d))

N

On multiplying both the side by , the general equation for the impact stress,
-2 12" -2 12" 2
= 1 + S1 +
48"z - 48"z -
- - 2
= 1 + S1 +
4z 4z
On making substitution = =

I I
we get
2
J = J 1 + S1 +

(Refer DDHB; page No. 27 Eqn. 2.26(c))

Students are advised to derive an equation for

1. The impact stress due to torsion
$ = $ 1 + 1 + [Ref: DDHB, eqn. 2.26(e)]

2. The angular deformation due to torsional impact action
= 1 + 1 + [Ref: DDHB, eqn. 2.26(f)]

[Where r is the moment arm of the load W]

Problems on Design for Impact Load:

19. Derive the equation for impact stress due to torsion with usual notations
20. Derive the equation for angular deformation due to torsional impact action with usual
notations
21. A bar made of C60 material is 40 mm diameter and 1.2 m long, has a collar securely
fitted to one end. It is suspended vertically with the collar at the lower end and a mass of
2,000 kg is placed on the collar producing an extension in the bar of 0.25 mm. Find the
height from which the same load could be dropped on to the collar without causing
yielding. Also find the impact factor. Assume a factor of safety as 4.
Solution:
Given:
= 40
FOS = 4
- = 1.2 = 1.2 102

= 2,000 / = 2,000 9.81
= 0.25
From DDHB, Table I.8, Page No. 464, we have
u = 412 /
For Material: C 60;
u 412
788 = = = 103 / = z
!# 4
4 4 2,000 9.81
# #, = = = = 15.6 /
; ; 40
From DDHB, Equation 2.26 (a),
2
= 1 + S1 +

2
103 = 15.6 1 + S1 +
0.25
= 3.798 = 3.8
2 2 3.8
z , z = 1 + S1 + = 1 + S1 +
0.25 0.25
z = 6.6

22. An unknown weight falls through 20 mm on a collar rigidly attached to the lower end of
a vertical bar 2 m long and 500 sq. mm section. If the maximum instantaneous extension
known to be 2 mm, find the corresponding stress, value of unknown weight and the
impact factor. [Take E = 200 GPa]
Solution:
= 20 - = 2 = 2 102
Given:
= 500 = 2
" = 200 ( = 200 10 / 2
=?
=? z =?
-
We know that,
"= = =

"
200 10 2
2
= = = 200 /
- 2 102
But, From DDHB, Equation 2.26 (a),
2 2"
= 1 + S1 + = 1 + S1 +
-
2 20 200 102 500

200 = 1 + S1 +
500 2 102
2 10
10 10I = 1 + S1 +

10 10I 2 10
1 = S1 +

10 10I 2 10

1 1 =

10 10I 2 10 10I 2 10

+1 1=

10 10 2 10 = 2 10

10 10 = 22 10
10 10
=
22 10
= 4545.45
2 10 2 10
z , z = 1 + S1 + = 1 + S1 + = 22
4545.45

23. A simply supported beam of width 50 mm, depth 150 mm is 1.5 m long. It is struck by a
weight of 1000 N that falls from a height of 10 mm at its mid-point. Determine: [Take E
= 20.6 x 104 N/mm2]
a. Impact factor
b. Instantaneous maximum deflection
c. Instantaneous maximum stress and
d. Instantaneous maximum load
Solution:
Given:

24. A cantilever beam of width 50 mm, depth 150 mm is 1.5 m long. It is struck by a weight
of 1000 N that falls from a height of 10 mm at its free end. [Take E = 20.6 x 104
N/mm2].Determine:
a. Impact factor
b. Instantaneous maximum deflection
c. Instantaneous maximum stress and
d. Instantaneous maximum load
6 = 50 = 150
Given:
- = 1.5 = 1.5 10 = 1,000

2
= 10 " = 20.6 10I /

z =? =?
J =?

=?
H. W , H[7P = - = 1,000 1.5 102 = 1.5 10

From DDHB, Table 1.4, Page No. 15,
-2 -2 12
H. <, = =
3 " z 3 " 6 2
1,000 (1.5 102 )2 12

= = 0.388 ( )
3 20.6 10I 50 1502
H 6H 6 1.5 10
J = = = = 8 /
K 6 50 150
2 2 10
z , z = 1 + S1 + = 1 + S1 + = 8.25
0.388
H. z , = z = 0.388 8.25 = 3.2
H. z , J = J z = 8 8.25 = 66 /
H. z / , = z = 1,000 8.25 = 8,250

25. A steel rod is 1.5 m long. It has to resist longitudinally an impact of 2.5 kN falling under
gravity at a velocity of 0.99 m/s. Maximum computed stress is limited to 150 MPa. [Take
E = 20.6 x 104 N/mm2].Determine
a. Diameter of the rod required and
b. Impact factor
[Answer: d = 45 mm and IF = 92.89]
26. A steel rope runs at a speed of 2.5 m/s between the rails of a narrow gauge. The weight of
a loaded car which must be connected with the steel rope of pulling force 8 kN. Area of
cross-section of the rope is 100 mm2, the length of the rope between the driving pulley
and the point where the car is hooked is 300 m. Determine the stress induced in the rope
by the impact of hooking in the car. [Take E = 20.6 x 104 N/mm2]
[Answer: = 184.33 N/mm2]
27. A cantilever beam of span 800 mm long has a rectangular cross-section of depth 200 mm.
The free end of the beam is subjected to a transverse load of 1 kN that drops on to it from
a height of 40 mm. Selecting C40 steel and a factor of safety 3, determine the rectangular
cross-section
[Answer: 80 mm]
28. A simply supported beam of span 800 mm long has a rectangular cross-section of depth
200 mm. The mid-point of the beam is subjected to a transverse load of 1 kN that drops
on to it from a height of 40 mm. Selecting C40 steel and a factor of safety 3, determine
the rectangular cross-section
[Answer: 80 mm]
29. A weight of 1 kN is dropped from a height of 50 mm at the free end of cantilever beam of
effective length 300 mm. Determine the cross-section of the cantilever beam of square
cross-section. If the allowable stress in the material is limited to 80 MPa
[Answer: 312 x 312 mm]
30. A beam of I cross-section with 300 mm depth is resting on two end supports 5 m apart.
It is loaded by a weight of 5,000 N falling through a height h and striking the beam at
its mid-point. Moment of inertia of the section is 9.6 x 107 mm4. Modulus of elasticity is
given as 21 x 104 N/mm2. Determine the permissible value of h if the material of the
beam is taken as C40 with a factor of safety 3.
Solution:
Given:
depth, d = 300 mm
Length of beam, L = 5 m = 5, 000 mm
Load, W = 5, 000N
Moment of inertia, I = 9.6 x 107 mm4

Modulus of elasticity, E = 21 x 104 N/mm2
factor of safety, FOS = 3
From DDHB, Table I.8 for C40, we have

e = 324 N/mm2
From DDHB, Table 1.4 for simply supported beam,
- 5,000 300
Maximum bending moment,
H[7P = = = = 6.25 10
4 4 4
-2 2 5,000 5002

Maximum deflection,
[7P = = = = 0.646
48"z 4"z 48 21 10I 9.6 10
Static bending stress,
300
H H 2 6.25 10 2

J = = = = 9.7656 /
z z 9.6 x 10
But, we know that,

2 2
J = J 1 + S1 + = 9.7656 1 + S1 +
0.646
For safe design, this induced impact bending stress must be less than or equal to
allowable stress, i.e.,
J
u
!#
2 324
9.7656 1 + S1 + =
0.646 3
= gL. gD EE

Curved Beam:
[Ref: DDHB K Mahadevan 4th Edition, chapter 10, Page No. 159 onwards]
A curved beam is defined as a beam in which the neutral axis in unloaded condition is curved
instead of straight.
The following assumptions are made in the stress analysis of curved beam.
1. The material is homogeneous and obeys Hooks Law
2. Plane sections perpendicular to the axis of the beam remain plane after bending
3. The moduli of elasticity in tension and compression are equal
Following are the two factors which distinguish the analysis of straight and curved beams are:
Straight Beam Curved Beam
The neutral and centroidal axes of the The neutral axis if shifted towards the
straight beam are coincident centre of curvature
The bending stresses in a straight beam The stress distribution is hyperbolic

vary linearly with distance from the
neutral axis.
Analysis of stresses in curved beam: [Ref: Fig 10.1 DDHB]
c2 co
c1 ci
co
ci
Fig. 19 Curved beam

The eccentricity e between the centroidal and neutral axes is given by,
= & &

The general equation for the stress at any fiber at a distance y from the neutral axis is given by,
H
= O R (<<VW, "X. 10.1 ())
& +
The maximum stress occurs either at the inner fiber or at the outer fiver and is given by,
Maximum tensile stress due to bending,
H
= + (<<VW, "X. 10.1 (6))
&
Maximum compressive stress due to bending,
H
= + (<<VW, "X. 10.1 (6))
&
, = + = N +
Note:
* For symmetrical cross-sections, such as Circular or Rectangular, the maximum bending stress
always occurs at the inner fiber.
* For unsymmetrical cross-sections, it is necessary to calculate the stresses at the inner as well
as outer fiber to determine the maximum stress.

Problems on Curved Beams:
31. A crane hook having an approximate trapezoidal cross-section is shown in Figure 20. It is
made of plain carbon steel 45C8 and the factor of safety is 3.5. Determine the load
carrying capacity of the hook.
Fig. 20 Crane hook

Solution:
From DDHB, Page No. 461, Table 1.6, for 48C8 plain carbon steel, we have
e = 320 N/mm2
Factor of safety, FOS = 3.5
From DDHB, Table 10.1, Page No. 163 for trapezoidal section, we have
b = 30 mm
b1 = 90 mm
h = 120 mm
P =?
Step I: Draw the cross-section given along with the notations, as follows:
b = 30
c0 c2
h =120
C e A
N c c1 A
i
b1 = 90 Ri Rn R Ro
Fig. 21 Cross-section of a crane hook

Step II: Calculate the eccentricity using relation given in the Table 10.1, Page No. 163
, = & &

, & =
6N (& + ) 6(& N ) (& + )
O u R (6N 6)
(& N )
(6N + 26) 120(90 + 2 30)
N = = = 50
3(6N + 6) 3(90 + 30)
& = & + N = 50 + 50 = 100
= N = 120 50 = 70
(6 + 6N ) (30 + 90)
= = 120 = 7200
2 2
7200
& =
90(100 + 70) 30(100 50) (100 + 70)
O
120 R (90 30)
u (100 50)
& = 89.1819
= 100 89.1819
b = Mp. _M_^ EE (& 4 )
Step III: Determine the bending stresses at the inner fibre and outer fibre as follows:
From DDHB, Equation No. 10.1(b), page No. 159, we have
H H
= =
& &
, W , H = & = (100)
= N = 50 10.8184 = 39.1816
= + = 70 + 10.8184 = 80.8184
& = & + = 50 + 120 = 170
H (100)39.1816 7.2435
= = =v w /
& 7200 10.8184 50 7200
H (100)80.8184 4.3943
= = =v w /
& 7200 10.8184 170 7200
Step III: Calculate the direct tensile stress at section XX:

= = /
qLpp

Step IV: Calculate the load carrying capacity of crane hook:

Superimposing the two stresses with direct stress and equating the resultant to
4
permissible stress separately, we get
= +

320 7.2435
= +
3.5 7200 7200
= qG, _oo`
4
And
= +

320 4.3943
= +
3.5 7200 7200
= M, LL, pgL`
Therefore the load carrying capacity of the crane-hook is P =79, 855 N (Choose the lowest
value)
32. A ring of steel bar has a diameter of 20 mm and carries a pull of 4 kN as shown in Figure
22. Determine the stresses at points A, B, C and D of the rim. The mean radius of the rim
is 100mm.
Fig. 22 Ring of a steel bar

Solutions:
= 4 102
Given:
& = 100 (H )

< = 20

Step I: Draw the cross-section given along with the notations, as follows:
c0 ci
R
e Rn
Ri
R0
Fig. 23 Cross-Section steel ring

Step II: Calculate the eccentricity using relation given in the Table 10.1, Page No. 162
= </2 = 10
For solid circular section, we have,
= & &
1 1
2 2 10
, & = = = 99.7494
& & 100 100 10
= & & = 100 99.7494 = 0.2506
Step III: Determine the bending stresses at the inner fibre and outer fibre as follows:
At section AB:
Section AB is subjected to only bending stresses and is calculated as follows:
Maximum tensile stress due to bending at the outer fibre (Point A) is given by,
H
=
&
Maximum compressive stress due to bending at the inner fibre (Point B)is given by,
H
=
&
H = 0.318& = 0.318 4 102 100

Bending moment at point A & B at a point of application of load, is given by Eqn. 10.5 as
H = 1.272 10
= + = 10 + 0.2506 = 10.2506
& = & + = 100 + 10 = 110
= = = 314.159 mm

I I
= = 10 0.2506 = 9.7494
& = & = 100 10 = 90
H 1.272 10 10.2506
= = = Mop. oD `/EEL (abcdefb) and
& 314.159 0.2506 110
H 1.272 10 9.7494
= = = Mqo. pL `/EEL (hiEjkbddeic)
& 314.159 0.2506 90
[Note: The sign attached to A and B is based on the observations made]
At section CD:
Section CD is subjected to bending stresses as well as direct stresses and is calculated as follows:
H
Maximum compressive stress due to bending at the outer fibre (Point C) is given by,
=
&
H
Maximum tensile stress due to bending at the inner fibre (Point D) is given by,
=
&
Bending moment at point C & D at a point 900 away from the application of load, is given by
H = 0.182& = 0.182 4 102 100

Eqn. 10.6 as
H = 0.728 10
H 0.728 10 10.2506
= = = _D. Mq `/EEL (hiEjkbddelb)
& 314.159 0.2506 110
H 0.728 10 9.7494
= = = Mpp. Mq `/EEL (abcdefb)
& 314.159 0.2506 90
Direct tensile stresses at points C and D is given by,

= = 2NI.N = 12.73/ (%)
I N
= + = 12.73 86.17
Therefore, effective stresses acting at points C and D is given by,
]h = qg. ^^ `/EEL (hiEjkbddelb)

= + = 12.73 + 100.17
] = MML. Gp `/EEL (abcdefb)
33. A machine member is made from a circular section rod and is loaded as shown in Figure
24. If the maximum stress at any section or point is not to exceed 18 N/mm2, determine
the diameter of the rod.
Fig. 24

34. A trough as shown in Figure 25 is 25 mm thick by 200mm width is subjected to a

concentrated load of 1800 N. Determine the magnitude and location of maximum tension
and compressive stresses at sections AA, BB and CC.
Fig. 25 Trough
35. A portable hydraulic riveter has maximum riveting force of 70 KN. The U-frame is made
of cast steel shown in Figure 26 with an ultimate tensile strength of 480 MN/m2 and a
yield point in tension of 240 MN/m2. Compute the maximum tensile and compressive
stresses in the section AB by
(a). Applying straight beam formula
(b). Applying curved beam formula
(c). By what theory would you design this section?
(d). If the radius of curvature is increased to 200 mm, will the stress as indicated by the
curved beam formula be marginally changed?
(e). Draw any conclusion regarding the radius of curvature of beam
Fig. 26

36. The crane-hook carries a load of 20 kN as shown in Figure 27. The section at X-X is
rectangular whose horizontal side is 100 mm. Find the stresses in the inner and outer
fibres at the given section.
Fig. 27 Crane hook
37. A C-clamp is subjected to a maximum load of W, as shown in Figure 28. If the maximum
tensile stress in the clamp is limited to 140 MPa, find the value of loads W.
Fig. 28 C-clamp

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Design of Machine Elements I (Unit I)

UNIT I: Introduction to design for static strength

According to Cambridge Dictionary, A Machine is a piece of equipment with several moving

A machine is a mechanism or a combination of mechanisms which, apart from imparting

1 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

3 | Department of Mechanical Engineering,

4 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

1 Pa (Pascal) 1 N/m2 1 x 10-6 N/ mm2

 =        

 = !      

Tensile stress and tensile strain:

Fig. 1 Tensile stress and strain

5 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Compressive stress and tensile strain:

Shear stress and shear strain:

Fig. 3 Shear stress and shear strain

6 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Fig. 4 Stress and Strain Diagram

7 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Working stress or allowable stress or permissible stress or design stress:

8 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Linear strain and Lateral strain:

Fig. 5 Linear strain and Lateral strain

9 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

10 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Problems involving uni-axial load

Tensile load,  = 2 / = 2 102 

Factor of Safety, !# = 3

Diameter of the rod, d =?

11 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Tensile load,  = 2 / = 2 102 

Factor of Safety, !# = 3

Diameter of the rod, d =?

6  , $788 = 0.5 788 = 0.5 72 = 36 /

12 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Tensile load,  = 2 / = 2 102 

Factor of Safety, !# = 3

Length of the rod, - = 30 

13 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Fig. 9 Steel Bracket

14 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Mounting Element (Gear)

Fig. 10 Transmission shaft

Fig. 11 Bi-axial stresses with shear stress

15 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Maximum Principal Stress,

Minimum Principal Stress,

Maximum Shear Stress,

16 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

Problems on principal stresses:

P = 30 H = 30 / (%)

4 = 15 H = 15 / (%)

Maximum Principal Stress,

Minimum Principal Stress,

Maximum Shear Stress,

17 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

P = 120 H = 120 / (%)

4 = 30 H = 30 / (%)

Maximum Principal Stress,

Minimum Principal Stress,

Maximum Shear Stress,

18 | Department of Mechanical Engineering, PESIT, Bangalore, Dr. C V Chandrashekara

[ : $ = 52.9 H  $ = 55 H]

=

= !

Tensile load, = 2 / = 2 102

Factor of Safety, !# = 3

Tensile load, = 2 / = 2 102

Factor of Safety, !# = 3

6 , $788 = 0.5 788 = 0.5 72 = 36 /

Tensile load, = 2 / = 2 102

Factor of Safety, !# = 3

Length of the rod, - = 30

P = 30 H = 30 / (%)

4 = 15 H = 15 / (%)

P = 120 H = 120 / (%)

4 = 30 H = 30 / (%)

[ : $ = 52.9 H $ = 55 H]

u = N + 2,N

[N = 180.9 H (%), = 69.1 H (%);

(). !# = 1.96; (6). !# = 1.9517 (). !# = 2.233]

150 + 100 150 100

150 + 100 150 100

Note that N , N >

Since N ,

It is in the form of a quadratic equation in and on solving we get,

Where, 1 + 1 + is known as Impact factor

$ = $ 1 + 1 + [Ref: DDHB, eqn. 2.26(e)]

= 1 + 1 + [Ref: DDHB, eqn. 2.26(f)]

- = 1.2 = 1.2 102

- = 1.5 = 1.5 10 = 1,000

= 10 " = 20.6 10I /

H. W , H[7P = - = 1,000 1.5 102 = 1.5 10

H. z , J = J z = 8 8.25 = 66 /

H. z / , = z = 1,000 8.25 = 8,250

-2 2 5,000 5002