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Design and Manufacturing Homework

Assignment #1

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Problem 1
If any machine element undergoes force application, element must be designed based on the
engineering principles. A perfect design gives the idea how long or how much efficient each
machine elements works. When a load acting on an object the object tries to resist the load.
Some material may deform under the application of load or some may resist without changing
the shape. The ability of a material to withstand the load/stress can be inherent or can be
achieved by artificial operations. Yield stress is the property of each material indicates how
much load /stress a material can withstand. If the stress is more than yield stress material will
deform. During the design, it must be noted that the stress developed in the material must not
cross the yield stress value. If the load acting on the element is not varying, static analysis is
used. In the static analysis the yield stress is considered as the maximum stress factor for ductile
material. If the lad is fluctuating in nature fatigue analysis has to be applied in the design. The
stress limit applied to fatigue is an endurance limit. Endurance limit is defined as the stress
limit below which the machine element will work for million life cycles.

Problem description
In this problem, a mechanical element in with rectangular cross-section is to be replaced with
identical element made of material AISI1020 plain carbon steel. Load requirement is given as
58KN on the cross-section of 30cm2. The length of the element must be 60cm long. The
properties of the material are shown below.

Tensile strength = 420MPa

Yield strength = 350MPa

Elastic modulus = 205GPa

Poisson’s ratio = 0.29

Density = 7870 Kg/m3

Solution
The maximum tensile strength of the material is 420MPa. But the yield strength is 350MPa so
that the material will start to deform if the stress developed in the material crosses 350MPa. To
find the material capability to withstand 58KN load, stress needs to be calculated.

Considering the material weight = density* volume *gravity

= 7870 * (60*30*10-6) * 9.81

1
 = 138.9 = 140N

Total load requirement = 58000+140 = 58140N

Stress developed in the material will be

𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝐿𝑜𝑎𝑑
Stress = 𝐶𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎

58140
= 30∗10−4 = 19.38MPa

To find the maximum stress developed in the design the principal stress has to be determined.

𝜎𝑥 = 19.38MPa ( Tensile stress)

𝜎𝑦 = 0MPa ( No stress in lateral direction)

𝜎𝑥𝑦 = 0MPa ( No tangential stress or torque)

𝜎𝑥 +𝜎𝑦 𝜎𝑥 +𝜎𝑦 2 2
Principal stress, P= ± √( ) + (𝜎𝑥𝑦 )
2 2

19.38+0 19.38+0 2
P= ± √( ) + (0)2
2 2

P = 19.38MPa

Since the maximum allowable stress is 350MPa the developed stress is much less than the
yield. To find the life cycle of the design fatigue analysis has to be checked.

𝜎𝑎 𝜎𝑚 1
+ =
𝜎𝑒 𝜎𝑢 𝐹𝑆

𝜎𝑒 = endurance limit = 0.5*𝜎𝑢 * Ka*Kb*Kc*Kd

Assuming Ka = Kb = Kc = Kd = 1

𝜎𝑒 = 0.5*𝜎𝑢 = 0.5 * 420 = 210MPa

𝜎𝑎 = 19.38MPa

𝜎𝑚 = 19.38/2 = 9.69MPa

19.38 9.69 1
+ =
210 420 𝐹𝑆

2
The factor of safety = 8.66

Conclusion
The selected material and the size of the design is capable of performing the required task and
has more than one million life cycle.

Problem 2
Bearing is a machine element which helps to reduce friction effectively between two rotating
joints. There are two different types of bearings. One is ball bearing and another is roller
bearings. Ball bearings are common and can support both radial and axial loads. Ball bearings
generally used for low load applications. The balls installed in the bearing is responsible for
smooth rotation between two concentric surfaces. Since the ball has point contact with the
nearby joins the force will be acting as concentrated load. If more load is applied the balls may
get deformed. So it is important for a ball bearing to be designed based on the maximum
dynamics load capacity.

Problem description
In this problem, a suitable bearing has to be selected for a shaft diameter of 45mm rotating at
6500RPM. The radial load acting on the bearing is 4.2KN and expected service life is 5000
hours.

Solution
Bearing life in million years can be calculated as

60∗𝑛∗𝐿ℎ
L= 106

60∗6500∗5000
L= 106

L = 1950 million rev

The dynamics load capacity of the bearing is

C = P 𝐿0.3

C = 4200 * 19500.3

C = 40.763KN

From the deep groove ball bearing catalog for dynamics load of 4KN and shaft diameter of
45mm open type bearing 6309 is used

3
Conclusion
The selected bearing is

Width of bearing, B = 25mm, Outside diameter of bearing surface, D = 100mm, shaft diameter,
d = 45mm,

References
 Bansal, R. (2015). A textbook of the strength of materials. New Delhi: Laxmi
Publications.
 S. Ramamrutham (2009) Strength of material, Published by Dhanpat Rai Publishing
company.
 R.S.Lehri & A.S.Lehri (2008) Strength of materials, Seventh edition,
published by S.K.Kataria.