SSM INSTITUTE OF ENGINEERING & TECHNOLOGY

Palani Road, Dindigul -624 002.

Department of Mechanical Engineering
ME 8593 - Design of Machine Elements
UNIT-I Class Work Problems
I. Curved Beams
1 The frame of a punch press is shown in Fig. Find the stresses at the inner and outer
5.9 surface at section X-X of the frame, if W = 5000 N.

2 The crane hook carries a load of 20 kN as shown in Fig. 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.

II. Principal Stresses:

3 A shaft, as shown in Fig. 5.17, is subjected to a bending load of 3 kN, pure torque of 1000
5.14 N-m and an axial pulling force of 15 kN. Calculate the stresses at A and B.

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4 An overhang crank with pin and shaft is shown in Fig. 5.18. A tangential load of 15 kN
5.15 acts on the crank pin. Determine the maximum principal stress and the maximum shear
stress at the centre of the crankshaft bearing.

III. Theories of Failure

5 The load on a bolt consists of an axial pull of 10 kN together with a transverse shear
5.16 force of 5 kN. Find the diameter of bolt required according to 1. Maximum principal
stress theory; 2. Maximum shear stress theory; 3. Maximum principal strain theory;
4. Maximum strain energy theory; and 5. Maximum distortion energy theory. Take
permissible tensile stress at elastic limit = 100 MPa and poisson’s ratio = 0.3.
6 A cylindrical shaft made of steel of yield strength 700 MPa is subjected to static
5.17 loads consisting of bending moment 10 kN-m and a torsional moment 30 kN-m.
Determine the diameter of the shaft using two different theories of failure, and
assuming a factor of safety of 2. Take E = 210 GPa and poisson's ratio = 0.25.
7 A mild steel shaft of 50 mm diameter is subjected to a bending moment of 2000N-m
5.18 and a torque T. If the yield point of the steel in tension is 200 MPa, find the maximum
value of this torque without causing yielding of the shaft according to
1. the maximum principal stress; 2. the maximum shear stress; and 3. the maximum
distortion strain energy theory of yielding.
IV Eccentric Loading
8 A hollow circular column of external diameter 250 mm and internal diameter 200 mm,
5.20 carries a projecting bracket on which a load of 20 kN rests, as shown in Fig. 5.22. The
centre of the load from the centre of the column is 500 mm. Find the stresses at the
sides of the column.

9 A mild steel link, as shown in Fig. 5.24 by full lines, transmits a pull of 80 kN.
5.22 Find the dimensions b and t if b = 3t.Assume the permissible tensile stress as 70 MPa.
If the original link is replaced by an unsymmetrical one, as shown by dotted lines in
Fig. 5.24, having the same thickness t, find the depth b1, using the same permissible
stress as before.

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10 A cast-iron link, as shown in Fig. 5.25, is to carry a load of 20 kN. If the tensile
5.23 and compressive stresses in the link are not to exceed 25 MPa and 80 MPa
respectively, obtain the dimensions of the cross-section of the link at the middle of its
length.

11 A mild steel bracket as shown in Fig. 5.28, is subjected to a pull of 6000 N acting at
5.25 45° to its horizontal axis. The bracket has a rectangular section whose depth is twice
the thickness. Find the cross-sectional dimensions of the bracket, if the permissible
stress in the material of the bracket is limited to 60 MPa.

V Variable Loading
12 A bar of circular cross-section is subjected to alternating tensile forces varying
6.4 from a minimum of 200 kN to a maximum of 500 kN. It is to be manufactured of a
material with an ultimate tensile strength of 900 MPa and an endurance limit of 700
MPa. Determine the diameter of bar using safety factors of 3.5 related to ultimate
tensile strength and 4 related to endurance limit and a stress concentration factor of
1.65 for fatigue load. Use Goodman straight line as basis for design
13 Determine the thickness of a 120 mm wide uniform plate for safe continuous
6.5 operation if the plate is to be subjected to a tensile load that has a maximum value of
250 kN and a minimum value of 100 kN. The properties of the plate material are as
follows: Endurance limit stress = 225 MPa, and Yield point stress = 300 MPa.
The factor of safety based on yield point may be taken as 1.5.
14 A circular bar of 500 mm length is supported freely at its two ends. It is acted upon by
6.8 a central concentrated cyclic load having a minimum value of 20 kN and a maximum
value of 50 kN. Determine the diameter of bar by taking a factor of safety of 1.5, size
effect of 0.85, surface finish factor of 0.9. The material properties of bar are given by :
ultimate strength of 650 MPa, yield strength of 500 MPa and endurance strength of
350 MPa.

15 A 50 mm diameter shaft is made from carbon steel having ultimate tensile strength of
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6.9 630 MPa. It is subjected to a torque which fluctuates between 2000 N-m to – 800 N-m.
Using Soderberg method, calculate the factor of safety. Assume suitable values for any
other data needed.
16 A cantilever beam made of cold drawn carbon steel of circular cross-section as
6.10 shown in Fig. 6.18, is subjected to a load which varies from – F to 3 F. Determine the
maximum load that this member can withstand for an indefinite life using a factor
of safety as 2. The theoretical stress concentration factor is 1.42 and the notch
sensitivity is 0.9. Assume the following values :
Ultimate stress = 550 MPa , Yield stress = 470 MPa, Endurance limit = 275 MPa
Size factor = 0.85, Surface finish factor= 0.89

VI Combined Loading
17 A simply supported beam has a concentrated load at the centre which fluctuates
6.11 from a value of P to 4 P. The span of the beam is 500 mm and its cross-section is
circular with a diameter of 60 mm. Taking for the beam material an ultimate stress of
700 MPa, a yield stress of 500 MPa, endurance limit of 330 MPa for reversed bending,
and a factor of safety of 1.3, calculate the maximum value of P. Take a size factor of
0.85 and a surface finish factor of 0.9.
18 A steel cantilever is 200 mm long. It is subjected to an axial load which varies
6.12 from 150 N (compression) to 450 N (tension) and also a transverse load at its free end
which varies from 80 N up to 120 N down. The cantilever is of circular cross-section.
It is of diameter 2d for the first 50 mm and of diameter d for the remaining length.
Determine its diameter taking a factor of safety of 2.
Assume the following values :
Yield stress = 330 MPa, Endurance limit in reversed loading = 300 MPa
Correction factors = 0.7 in reversed axial loading
= 1.0 in reversed bending
Stress concentration factor = 1.44 for bending
= 1.64 for axial loading
Size effect factor = 0.85, Surface effect factor = 0.90, Notch sensitivity index = 0.90

Faculty Incharge HoD/Mech

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Interchangeability:
The term interchangeability is normally employed for the mass production of indentical items
within the prescribed limits of sizes. A little consideration will show that in order to maintain
the sizes of the part within a close degree of accuracy, a lot of time is required. But even then
there will be small variations. If the variations are within certain limits, all parts of equivalent
size will be equally fit for operating in machines and mechanisms. Therefore, certain
variations are recognised and allowed in the sizes of the mating parts to give the required
fitting. This facilitates to select at random from a large number of parts for an assembly and
results in a considerable saving in the cost of production. In order to control the size of
finished part, with due allowance for error, for interchangeable parts is called limit system.
It may be noted that when an assembly is made of two parts, the part which enters into
the other, is known as enveloped surface (or shaft for cylindrical part) and the other in which
one enters is called enveloping surface (or hole for cylindrical part).
Important Terms used in Limit System:
The following terms used in limit system (or interchangeable system) are important from
the subject point of view:
1. Nominal size. It is the size of a part specified in the drawing as a matter of convenience.
2. Basic size. It is the size of a part to which all limits of variation (i.e. tolerances) are applied
to arrive at final dimensioning of the mating parts. The nominal or basic size of a part is often
the same.
3. Actual size. It is the actual measured dimension of the part. The difference between the
basic size and the actual size should not exceed a certain limit, otherwise it will interfere with
the interchangeability of the mating parts.

4. Limits of sizes. There are two extreme permissible sizes for a dimension of the part as
shown in Fig. 3.1. The largest permissible size for a dimension of the part is called upper or
high or maximum limit, whereas the smallest size of the part is known as lower or minimum
limit.
5. Allowance. It is the difference between the basic dimensions of the mating parts. The
allowance may be positive or negative. When the shaft size is less than the hole size, then the
allowance is positive and when the shaft size is greater than the hole size, then the allowance
is negative.
6. Tolerance. It is the difference between the upper limit and lower limit of a dimension. In
other words, it is the maximum permissible variation in a dimension. The tolerance may be
unilateral or bilateral. When all the tolerance is allowed on one side of the nominal size, e.g.
then it is said to be unilateral system of tolerance. The unilateral system is mostly
used in industries as it permits changing the tolerance value while still retaining the same
allowance or type of fit.

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When the tolerance is allowed on both sides of the nominal size, e.g. , then it is said to
be bilateral system of tolerance. In this case + 0.002 is the upper limit and – 0.002 is the
lower limit. The method of assigning unilateral and bilateral tolerance is shown in Fig. 3.2
(a) and (b) respectively.
7. Tolerance zone. It is the zone between the maximum and minimum limit size, as shown in Fig. 3.3.

8. Zero line. It is a straight line corresponding to the basic size. The deviations are measured
from this line. The positive and negative deviations are shown above and below the zero line
respectively.
9. Upper deviation. It is the algebraic difference between the maximum size and the basic
size. The upper deviation of a hole is represented by a symbol ES (Ecart Superior) and of a
shaft, it is represented by es.
10. Lower deviation. It is the algebraic difference between the minimum size and the basic
size. The lower deviation of a hole is represented by a symbol EI (Ecart Inferior) and of a
shaft, it is represented by ei.
11. Actual deviation. It is the algebraic difference between an actual size and the
corresponding basic size.
12. Mean deviation. It is the arithmetical mean between the upper and lower deviations.
13. Fundamental deviation. It is one of the two deviations which is conventionally chosen to
define the position of the tolerance zone in relation to zero line, as shown in Fig. 3.4.

Fits
The degree of tightness or looseness between the two mating parts is known as a fit of the
parts. The nature of fit is characterised by the presence and size of clearance and interference.
The clearance is the amount by which the actual size of the shaft is less than the actual size
of the mating hole in an assembly as shown in Fig. 3.5 (a). In other words, the clearance is

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the difference between the sizes of the hole and the shaft before assembly. The difference
must be positive.

The interference is the amount by which the actual size of a shaft is larger than the actual
finished size of the mating hole in an assembly as shown in Fig. 3.5 (b). In other words, the
interference is the arithmetical difference between the sizes of the hole and the shaft, before
assembly. The difference must be negative.
Types of Fits
According to Indian standards, the fits are classified into the following three groups :
1. Clearance fit. In this type of fit, the size limits for mating parts are so selected that
clearance between them always occur, as shown in Fig. 3.5 (a). It may be noted that in a
clearance fit, the tolerance zone of the hole is entirely above the tolerance zone of the shaft.
In a clearance fit, the difference between the minimum size of the hole and the maximum size
of the shaft is known as minimum clearance whereas the difference between the maximum
size of the hole and minimum size of the shaft is called maximum clearance as shown in Fig.
3.5 (a). The clearance fits may be slide fit, easy sliding fit, running fit, slack running fit and
loose
running fit.
2. Interference fit. In this type of fit, the size limits for the mating parts are so selected that
interference between them always occur, as shown in Fig. 3.5 (b). It may be noted that in an
interference fit, the tolerance zone of the hole is entirely below the tolerance zone of the
shaft.
In an interference fit, the difference between the maximum size of the hole and the minimum
size of the shaft is known as minimum interference, whereas the difference between the
minimum size of the hole and the maximum size of the shaft is called maximum
interference, as shown in Fig. 3.5 (b).
The interference fits may be shrink fit, heavy drive fit and light drive fit.
3. Transition fit. In this type of fit, the size limits for the mating parts are so selected that
either a clearance or interference may occur depending upon the actual size of the mating
parts, as shown in Fig. 3.5 (c). It may be noted that in a transition fit, the tolerance zones of
hole and shaft overlap. The transition fits may be force fit, tight fit and push fit.
Basis of Limit System:
The following are two bases of limit system:
1. Hole basis system. When the hole is kept as a constant member (i.e. when the lower
deviation of the hole is zero) and different fits are obtained by varying the shaft size, as
shown in Fig. 3.6 (a), then the limit system is said to be on a hole basis.
2. Shaft basis system. When the shaft is kept as a constant member (i.e. when the upper
deviation of the shaft is zero) and different fits are obtained by varying the hole size, as
shown in Fig. 3.6 (b), then the limit system is said to be on a shaft basis.
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The hole basis and shaft basis system may also be shown as in Fig. 3.7, with respect to the
zero line.

It may be noted that from the manufacturing point of view, a hole basis system is always
preferred. This is because the holes are usually produced and finished by standard tooling like
drill, reamers, etc., whose size is not adjustable easily. On the other hand, the size of the shaft
(which is to go into the hole) can be easily adjusted and is obtained by turning or grinding
operations.