AssignmentSolution1,Engi4438WA

Q1:
Critical locations include, from left to right, gear keyway (x = 9), right bearing shoulder (x =
11 0.453 = 10.547), and coupling keyway (where d = 1.500)
Gear keyway is subject to a bending memoent and a torque. The torsional shear and bending
stresses are, tm =

( 16 )( 2500 )
= 1932psi , and sa
3
p ( 1.875 )

( 32 )( 2178 )
3
p ( 1.875 )

= 3366psi ,

respectively.

From Table A-20, 1030 HR has, Sy = 37.5 ksi and Sut = 68 ksi. Therefore Se = (0.5)Sut =
(0.5)(68) = 34 ksi.
-0.265

The modifying factors are, ka = a ( Sut ) = 2.70 ( 68 )

-0.107

kb = 0.879d -0.107 = 0.879 ( 1.875 )

= 0.883

= 0.822 kc = 1 kd = 1 , ke = 1

The corrected endurance limit is then Se = kakbkckdkeSe' = (0.883)(0.822)(1)(1)(1)(34) = 24.7ksi

Stress concentration factors are, for standard keyway, Kt = 2.2, Kts = 3.0. With r = 0.02 and Sut =
68 ksi, Figures 6-20 and 21 give q = 0.6, qs = 0.63. Fatigue stress concentration factors are then
Kf = 1 + 0.6 * (2.2 1) = 1.72, Kfs = 1 + 0.63 * (3.0 1) = 2.26.
von Mises stresses for mean and alternating stress are
sa' = K f sa = 1.72 * 3366 = 5790psi , sm' = 3K fs tm = 3 * 2.26 * 1932 = 7363psi
Now applying the mod-Goodman criterion,
s'
s'
1
5790
7363
= a + m =
+
= 0.34 ,
24700 68000
n
Se
Sut

or n = 2.9 > 1.7

For localized yielding (yielding at first load cycle),

Sy
n

'
= sa' + sm

37500
= 5756 + 7362 = 13118 ,
n

or n = 2.9 > 1
Coupling keyway is subject to a torque only, with tm =
The mod-Goodman criterion becomes

s '
s '
1
= a + m =
n
Se
Sut

The mod-Goodman criterion can also be written as

( 16 )( 2500 )
= 3773psi .
3
p ( 1.5 )
3 * 3773
= 0.0961 ,
68000

or n = 10.4 >> 1.7

t
t
1
3773
= a + m =
= 0.0828 ,
n
Se
Ssu
0.67 * 68000

12.1 >> 1.7.

Page 1 of 4

or n =

AssignmentSolution1,Engi4438WA
Guarding agaist yielding at first load cycle:

0.577Sy
n

= ta + tm

0.577 * 37500
= 3773 ,
n

or n = 5.7

> 1.7
Right bearing shoulder is subject to a bending moment and a torque. The bending moment is
proportioned from known values in bending moment diagram. That is, M = 2178 * (0.453/2) =
493.3 lb.in. The torque remains T = 2500 lb.in. Hence
sa =

( 32 )( 493.3 )
= 1289psi and
3
p ( 1.574 )

tm =

( 16 )( 2500 )
= 3265psi
3
p ( 1.574 )

For corrected endurance limit, only kb is different, compared with the gear keyway.
-0.107
kb = 0.879d -0.107 = 0.879 ( 1.574 )
= 0.837 Therefore:
.
Se = kakbkckd keSe' = (0.883)(0.837)(1)(1)(1)(34) = 25.1ksi

Bearing seat radius is r = 0.03. d = 1.574, but D is not given. Assume D = 1.875 for worse
case. From Figures A-15-8 and -9, Kts = 2.0 and Kt = 2.5. Using r = 0.03 and Sut = 68 ksi,
Figures 6-20 and 21 result in q = 0.65, qs = 0.7. Fatigue stress concentration factors are then Kf =
1 + 0.65 * (2.5 1) = 1.98, Kfs = 1 + 0.7 * (2.0 1) = 1.7.
von Mises stresses for mean and alternating stress are
sa' = K f sa = 1.98 * 1289 = 2552psi , sm' = 3K fs tm = 3 * 1.7 * 3265 = 9614psi
The mod-Goodman criterion:

s'
s'
1
2552
9614
= a + m =
+
= 0.24 ,
n
Se
Sut
25100 68000

Guarding against yielding at first load cycle:

Sy
n

= sa' + sm'

or n = 4.2 > 1.7

37500
= 2552 + 9614 = 12166 ,
n

or n

= 3.1 > 1.7

Therefore the gear keyway is most critical in terms of fatigue as well as yielding at first load
cycle. The minimum safety factor against fatigue is 2.9 at the gear keyway.
Q2:
From Table A-20, Sy = 61.5 ksi and Sut = 112 ksi for AISI 1080 steel HR.
For torsion, Ssu = 0.67Sut = 75.0 ksi, and Ssy = 0.577Sy = 35.5 ksi. Therefore Se = (0.5)Ssu =
(0.5)(75.0) = 37.5 ksi.
b

-0.265

The modifying factors are, ka = a ( Ssu ) = 2.70 ( 75.0 )

-0.107

kb = 0.879d -0.107 = 0.879 ( 1 )

= 0.860

= 0.879 kc = 0.59 kd = 1 ke = 0.868

,
,
,

Page 2 of 4

AssignmentSolution1,Engi4438WA
The corrected endurance limit is Se = kakbkckdkeSe' = (0.860)(0.879)(0.59)(1)(0.868)(37.5) = 14.5ksi
Notch sensitivity is, from Eq. (6-35), a = 0.04099, using Sut+20 (ksi) = 132.0 ksi for Sut. And
1

from Eq. (6-34), qshear =

1+

1+

1
= 0.885 .
0.04099
0.1

Theoretical stress concentration factor Kts is from Figure A-15-8, using D/d = 2 and r/d = 0.1,
yielding a Kts = 1.45.
Fatigue stress concentration factor is then K fs = 1 + ( Kts - 1 )qshear = 1 + ( 1.45 - 1)( 0.885 ) = 1.40
Now apply Kfs to the applied stresses of 10 ksi, 20 ksi, 25 ksi and 35 ksi such that
ta 1 = K fs t1,nom = 1.40 ( 10 ) = 14.0ksi
ta 3 = K fs t3,nom = 1.40 ( 25 ) = 35.0ksi

ta 2 = K fs t2,nom = 1.40 ( 20 ) = 28.0ksi

ta 4 = K fs t4,nom = 1.40 ( 35 ) = 49.0ksi

Stress a1 (= 14.0 ksi) does not exceed Se, therefore N1 = . Other shear stresses will cause finite
lives. From Eqs. (6-14) through (6-16),
2

a =

( fSsu )
Se

( 0.9 75.0ksi )
14.5ksi

28ksi

Therefore, N 2 =
314.2ksi
49ksi
N 4 =

314.2ksi

1
(-0.2226)

fS
1
1
0.9 75.0ksi
= 314.2ksi, b = - log su = - log
= -0.2226
3
Se
3
14.5ksi

1
(-0.2226)

35ksi
= 52,143cycles , N 3 =

314.2ksi

1
(-0.2226)

= 19,136cycles ,

= 4,220cycles

From the stress-time plot, the numbers of stress cycles within a 30 second interval are n1 = 13, n2
= 4, n3 = 2, n4 = 1. Therefore, if X is the number of 30-second blocks to failure, Miners rule
yields,
Xn1
13
Xn2
Xn 3
Xn 4
4
2
1

= X +
+
+
+
+
+
= ( 4.1819 10-4 ) X = 1

N 1
52,143 19,136 4, 220
N2
N3
N4

or X = 2,391 blocks.
If measured stress is considered measured at the fillet, then N1 = because stress a1 (= 10 ksi)
does not exceed Se. Other shear stresses will cause the following finite lives:
20ksi
N 2 =

314.2ksi

35ksi
N 4 =

314.2ksi

(-0.2226)

(-0.2226)

25ksi
= 236, 406cycles , N 3 =

314.2ksi
= 19,136cycles

Page 3 of 4

(-0.2226)

= 86, 757cycles ,

AssignmentSolution1,Engi4438WA
Miners rule then gives,
Xn1
N1

Xn2
N2

Xn 3
N3

Xn 4
N4

13
4
2
1
= X +
+
+
= 0.0009223 ) X = 1
236, 406 86, 757 19,136 (

Or X = 10,842 blocks.
Q3.
nodes
CD
FG
IJ
BE
AH
HK

maximum
30
30
20
35
40
40

minimum
20
0
-10
10
-50
-50

mean
25
15
5
22.5
-5
-5

alternating
5
15
15
12.5
45
45

The number of cycles in the block is 5.

Page 4 of 4

# of cycle
1
1
1
1
1/2
1/2