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DESIGN PROBLEMS
1. The link shown, made of AISI C1045 steel, as rolled, is subjected to a tensile load
of 8000 lb. Let h = 1.5b . If the load is repeated but not reversed, determine the
dimensions of the section with the design based on (a) ultimate strength, (b) yield
strength. (c) If this link, which is 15 in. long., must not elongate more than 0.005
in., what should be the dimensions of the cross section?
Problems 1 3.
Solution:
For AISI C1045 steel, as rolled (Table AT 7)
su = 96 ksi
s y = 59 ksi
E = 30 10 6 psi
F
sd =
A
where
F = 8000 lb
A = bh
but
h = 1.5b
therefore A = 1.5b 2
N = factor of safety = 6 for repeated but not reversed load (Table 1.1)
s F
sd = u =
N A
96,000 8000
=
6 1.5b 2
5
b = 0.577 in say in .
8
Page 1 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
15
h = 1.5b = in
16
N = factor of safety = 3 for repeated but not reversed load (Table 1.1)
s F
sd = u =
N A
59,000 8000
=
3 1.5b 2
9
b = 0.521 in say in .
16
27
h = 1.5b = in
32
FL
(c) Elongation = =
AE
where,
= 0.005 in
F = 8000 lb
E = 30 10 6 psi
L = 15 in
A = 1.5b 2
then,
FL
=
AE
0.005 =
(8000)(15)
(1.5b )(30 10 )
2 6
3
b = 0.730 in say in .
4
1
h = 1.5b = 1 in
8
2. The same as 1 except that the material is malleable iron, ASTM A47-52, grade 35
018.
Solution:
For malleable iron, ASTM A47-52, grade 35 018(Table AT 6)
su = 55 ksi
s y = 36.5 ksi
E = 25 10 6 psi
Page 2 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
F
sd =
A
where
F = 8000 lb
A = bh
but
h = 1.5b
therefore A = 1.5b 2
N = factor of safety = 6 for repeated but not reversed load (Table 1.1)
s F
sd = u =
N A
55,000 8000
=
6 1.5b 2
7
b = 0.763 in say in .
8
5
h = 1.5b = 1 in
16
N = factor of safety = 3 for repeated but not reversed load (Table 1.1)
s F
sd = u =
N A
36,500 8000
=
3 1.5b 2
11
b = 0.622 in say in .
16
1
h = 1.5b = 1 in
32
FL
(c) Elongation = =
AE
where,
= 0.005 in
F = 8000 lb
E = 25 10 6 psi
L = 15 in
A = 1.5b 2
then,
Page 3 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
FL
=
AE
0.005 =
(8000)(15)
(1.5b )(25 10 )
2 6
7
b = 0.8 in say in .
8
5
h = 1.5b = 1 in
16
3. The same as 1 except that the material is gray iron, ASTM 30.
Solution:
For ASTM 30 (Table AT 6)
su = 30 ksi , no s y
E = 14.5 10 6 psi
Note: since there is no s y for brittle materials. Solve only for (a) and (c)
F
sd =
A
where
F = 8000 lb
A = bh
but
h = 1.5b
therefore A = 1.5b 2
Page 4 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
L = 15 in
A = 1.5b 2
then,
FL
=
AE
0.005 =
(8000)(15)
(1.5b )(14.5 10 )
2 6
1
b = 1.050 in say 1 in .
16
19
h = 1.5b = 1 in
32
4. A piston rod, made of AISI 3140 steel, OQT 1000 F (Fig. AF 2), is subjected to a
repeated, reversed load. The rod is for a 20-in. air compressor, where the
maximum pressure is 125 psig. Compute the diameter of the rod using a design
factor based on (a) ultimate strength, (b) yield strength.
Solution:
From Fig. AF 2 for AISI 3140, OQT 1000 F
su = 152.5 ksi
s y = 132.5 ksi
F = force = (20)2 (125) = 39,270 lb = 39.27 kips
4
From Table 1.1, page 20
Nu = 8
Ny = 4
Page 5 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
1
d = 1.23 in say 1 in
4
Solution:
su = 65 ksi
Nu = 8
F = 1500 kips
3Di2
A=
4
(D 2
o Di2 =) 4
(4 D i
2
)
Di2 =
4
3Di2 N u F (8)(1500 )
A= = =
4 su 65
7
Di = 8.85 in say 8 in
8
7 3
Do = 2 Di = 2 8 = 17 in
8 4
Solution:
From Table AT 7 for 4130, WQT 1100 F
su = 127 ksi
s y = 114 ksi
Page 6 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
5
Di = 0.61 in say in
8
5 1
Do = 2 Di = 2 = 1 in
8 4
(b) Based on ultimate strength
3Di2 N u F (4 )(50 )
A= = =
4 su 127
7
Di = 0.82 in say in
8
7 3
Do = 2 Di = 2 = 1 in
8 4
Solution:
FL FL
(a) = or A =
AE E
where,
F = 7000 lb
L = 55 in
= 0.030 in
E = 25 10 6 psi
A = d2 =
(7000)(55)
4 (
(0.030) 30 106 )
3
d = 0.74 in say in
4
(b) For gradually applied and repeated (not reversed) load
Ny = 3
sy =
NyF
=
(3)(7000) = 47,534 psi
A
(0.75)2
4
s y 48 ksi
say C1015 normalized condition ( s y = 48 ksi )
8. A centrifuge has a small bucket, weighing 0.332 lb. with contents, suspended on a
manganese bronze pin (B138-A, hard) at the end of a horizontal arm. If the pin
is in double shear under the action of the centrifugal force, determine the diameter
Page 7 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
needed for 10,000 rpm of the arm. The center of gravity of the bucket is 12 in.
from the axis of rotation.
Solution:
From Table AT 3, for B138-A, hard
sus = 48 ksi
W
F = 2r
g
where
W = 0.332 lb
g = 32.2 fps 2
2 n 2 (10,000 )
= = = 1047 rad sec
60 60
r = 12 in
W 0.332
F = 2r = (1047 )2 (1) = 11,300 lb = 11.3 kips
g 32.2
From Table 1.1, page 20
N = 3 ~ 4 , say 4
N F
A= u
su
(4 )(11.3)
2 d 2 = for double shear
4 48
25
d = 0.774 in say in
32
CHECK PROBLEMS
3
9. The link shown is made of AISIC1020 annealed steel, with b = in and
4
1
h = 1 in . (a) What force will cause breakage? (b) For a design factor of 4 based
2
on the ultimate strength, what is the maximum allowable load? (c) If N = 2.5
based on the yield strength, what is the allowable load?
Problem 9.
Page 8 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Solution:
For AISI C1020 annealed steel, from Table AT 7
su = 57 ksi
s y = 42 ksi
(a) F = su A
3 1
A = bh = 1 = 1.125 in 2
4 2
F = (57 )(1.125) = 64 kips
s A
(b) F = u
Nu
Nu = 4
3 1
A = bh = 1 = 1.125 in 2
4 2
F=
(57 )(1.125) = 16 kips
4
sy A
(c) F =
Ny
N y = 2 .5
3 1
A = bh = 1 = 1.125 in 2
4 2
F=
(42)(1.125) = 18.9 kips
2
10. A -in.bolt, made of cold-finished B1113, has an effective stress area of 0.334 sq.
in. and an effective grip length of 5 in. The bolt is to be loaded by tightening until
the tensile stress is 80 % of the yield strength, as determined by measuring the
total elongation. What should be the total elongation?
Solution:
sL
=
E
from Table AT 7 for cold-finished B1113
s y = 72 ksi
then, s = 0.80 s y = 0.8(72 ) = 57.6 ksi
E = 30 106 psi = 30,000 ksi
sL (57.6)(5)
= = = 0.0096 in
E 30,000
Page 9 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
11. A 4-lb. weight is attached by a 3/8-in. bolt to a rotating arm 14-in. from the center
of rotation. The axis of the bolts is normal to the plane in which the centrifugal
force acts and the bolt is in double shear. At what speed will the bolt shear in two
if it is made of AISI B1113, cold finish?
Solution:
From Table AT 7, sus = 62 ksi = 62,000 psi
2
1 3
A = 2 ( ) = 0.2209 in 2
4 8
W
F = 2 r = sus A
g
4
2 (14) = (62,000)(0.2209)
32.2
= 88.74 rad sec
2 n
= = 88.74
60
n = 847 rpm
12. How many -in. holes could be punched in one stroke in annealed steel plate of
AISI C1040, 3/16-in. thick, by a force of 60 tons?
Solution:
13. What is the length of a bearing for a 4-in. shaft if the load on the bearing is 6400
lb. and the allowable bearing pressure is 200 psi of the projected area?
Solution:
pDL = W
where
p = 200 psi
D = 4 in
W = 6400 lb
Page 10 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
(200)(4)L = 6400
L = 8 in
BENDING STRESSES
DESIGN PROBLEMS
14. A lever keyed to a shaft is L = 15 in long and has a rectangular cross section of
h = 3t . A 2000-lb load is gradually applied and reversed at the end as shown; the
material is AISI C1020, as rolled. Design for both ultimate and yield strengths. (a)
What should be the dimensions of a section at a = 13 in ? (b) at b = 4 in ? (c) What
should be the size where the load is applied?
Problem 14.
Solution:
For AISI C1020, as rolled, Table AT 7
su = 65 ksi
s y = 49 ksi
Design factors for gradually applied and reversed load
Nu = 8
Ny = 4
th 3
I= , moment of inertial
12
but h = 3t
h4
I=
36
Page 11 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Mc Fac
(a) s = =
I I
h
c=
2
F = 2000 lbs = 2 kips
(2)(13) h
s=
65
= 2
8 h 4
36
h = 3.86 in
h 3.86
t= = = 1.29 in
3 3
say
1
h = 4.5 in = 4 in
2
1
t = 1.5 in = 1 in
2
Mc Fbc
(b) s = =
I I
h
c=
2
F = 2000 lbs = 2 kips
(2)(4) h
s=
65
= 2
8 h 4
36
h = 2.61 in
h 2.61
t= = = 0.87 in
3 3
say
h = 3 in
t = 1 in
(c)
Page 12 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
3 h 4 .5 3
=
4 13 4
h = 2.33 in
1 t 1 .5 1
=
4 13 4
t = 0.78 in
say
5
h = 2.625 in or h = 2 in
8
15. A simple beam 54 in. long with a load of 4 kips at the center is made of cast steel,
SAE 080. The cross section is rectangular (let h 3b ). (a) Determine the
dimensions for N = 3 based on the yield strength. (b) Compute the maximum
deflection for these dimensions. (c) What size may be used if the maximum
deflection is not to exceed 0.03 in.?
Solution:
For cast steel, SAE 080 (Table AT 6)
s y = 40 ksi
E = 30106 psi
Page 13 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
From Table AT 2
FL (4 )(54 )
Max. M = = = 54 kips in
4 4
bh3
I=
12
but h = 3b
h4
I=
36
sy Mc
(a) s = =
Ny I
h
c=
2
(54) h
40
= 2
3 h4
36
h = 4.18 in
h 4.18
b= = = 1.39 in
3 3
1 h 4 .5 1
say h = 4 in , b = = = 1.5 in = 1 in
2 3 3 2
(b) =
FL3
=
(4000)(54)3 = 0.0384 in
48EI (1.5 )(4.5 )3
48(30 106 )
12
FL3
(c) =
h4
48E
36
0.03 =
(4000)(54)3 (36)
48(30 106 )(h 4 )
h = 4.79 in
h 4.79
b= = = 1.60 in
3 3
1 h 5.25 3
say h = 5.25 in = 5 in , b = = = 1.75 in = 1 in
4 3 3 4
Page 14 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
16. The same as 15, except that the beam is to have a circular cross section.
Solution:
s Mc
(a) s = y =
Ny I
d4
I=
64
d
c=
2
d
M
s= 4 =
2 32M
d d3
64
40 32(54 )
=
3 d3
d = 3.46 in
1
say d = 3 in
2
FL3
(b) =
48EI
d4
I=
64
64(4000 )(54 )
3
64 FL3
= = = 0.0594 in
48 E ( d 4 ) 48(30 10 6 )( )(3.5)4
64 FL3
(c) =
48E ( d 4 )
64(4000 )(54)
3
0.03 =
48(30 106 )( )d 4
d = 4.15 in
1
say d = 4 in
4
17. A simple beam, 48 in. long, with a static load of 6000 lb. at the center, is made of
C1020 structural steel. (a) Basing your calculations on the ultimate strength,
determine the dimensions of the rectangular cross section for h = 2b . (b)
Determine the dimensions based on yield strength. (c) Determine the dimensions
using the principle of limit design.
Page 15 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Solution:
FL (6 )(48)
M= = = 72 in kips
4 4
Mc
s=
I
h
c=
2
bh3
I=
12
h
but b =
2
4
h
I=
24
h
M
s = 4 = 3
2 12 M
h h
24
Page 16 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
h 3.76
b= = = 1.88 in
2 2
3 h 3.75 7
say h = 3.75 in = 3 in , b = = = 1.875 in = 1 in
4 2 2 8
bh 2
M = sy
4
h 2
h
72 = (48)
2
4
h = 2.29 in
h 2.29
b= = = 1.145 in
2 2
1 h 2 .5 1
say h = 2.5 in = 2 in , b = = = 1.25 in = 1 in
2 2 2 4
18. The bar shown is subjected to two vertical loads, F1 and F2 , of 3000 lb. each, that
are L = 10 in apart and 3 in. ( a , d ) from the ends of the bar. The design factor is 4
based on the ultimate strength; h = 3b . Determine the dimensions h and b if the
bar is made of (a) gray cast iron, SAE 111; (b) malleable cast iron, ASTM A47-
52, grade 35 018; (c) AISI C1040, as rolled (Fig. AF 1). Sketch the shear and
moment diagrams approximately to scale.
Page 17 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Problems18, 19.
Solution:
F1 = F2 = R1 = R2 = 3000 lb
Moment Diagram
Page 18 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
su = 55 ksi , Table AT 6
h
M
= 4 = 3
s Mc 2 18M
s= u =
N I h h
36
55 18(9 )
s= = 3
4 h
h = 2.28 in
h 2.28
b= = = 0.76 in
3 3
1 3
say h = 2 in , b = in
4 4
Solution:
[ M A =0 ] R1 = R2 = 1875 lb
Page 19 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Shear Diagram
Moment Diagram
su 18M
s= = 3
N h
30 18(5.625)
=
4 h3
h = 2.38 in
h 2.38
b= = = 0.79 in
3 3
1 3
say h = 2 in , b = in
4 4
(b) For malleable cast iron
su 18M
s= = 3
N h
55 18(5.625)
=
4 h3
h = 1.95 in
h 1.95
b= = = 0.65 in
3 3
7 5
say h = 1 in , b = in
8 8
Page 20 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
su 18M
s= = 3
N h
90 18(5.625)
=
4 h3
h = 1.65 in
h 1.65
b= = = 0.55 in
3 3
1 1
say h = 1 in , b = in
2 2
20. The bar shown, supported at A and B , is subjected to a static load F of 2500 lb.
at = 0 . Let d = 3 in , L = 10 in and h = 3b . Determine the dimensions of the
section if the bar is made of (a) gray iron, SAE 110; (b) malleable cast iron,
ASTM A47-52, grade 32 510; (c) AISI C1035 steel, as rolled. (d) For economic
reasons, the pins at A, B, and C are to be the same size. What should be their
diameter if the material is AISI C1035, as rolled, and the mounting is such that
each is in double shear? Use the basic dimensions from (c) as needed. (e) What
sectional dimensions would be used for the C1035 steel if the principle of limit
design governs in (c)?
Page 21 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
[ M A =0 ] 3RB = 13(2500)
RB = 10,833 lb
[ M B =0 ] 3RA = 10(2500 )
RA = 8333 lb
Shear Diagram
Moment Diagram
h = 3b
bh3
I=
12
h4
I=
36
h
c=
2
h
M
= 4 = 3
Mc 2 18M
s=
I h h
36
Page 22 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
h = 5.13 in
h
b = = 1.71 in
3
1 3
say h = 5 in , b = 1 in
4 4
(b) For malleable cast iron, ASTM A47-32 grade 32510
su = 52 ksi , s y = 34 ksi
N = 3 ~ 4 , say 4 for ductile, dead load
s 18M
s= u = 3
N h
52 18(25)
=
4 h3
h = 3.26 in
h
b = = 1.09 in
3
3 1
say h = 3 in , b = 1 in
4 4
(c) For AISI C1035, as rolled
su = 85 ksi , s y = 55 ksi
N = 4 , based on ultimate strength
s 18M
s= u = 3
N h
85 18(25)
=
4 h3
h = 2.77 in
h
b = = 0.92 in
3
say h = 3 in , b = 1 in
Page 23 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
11
say D = in
16
(e) Limit Design
bh 2
M = sy
4
For AISI C1035 steel, s y = 55 ksi
h
b=
3
h 2
h
M = 25 = (55)
3
4
h = 1.76 in
h
b = = 0.59 in
3
7 5
say h = 1.875 in = 1 in , b = in
8 8
21. The same as 20, except that = 30o . Pin B takes all the horizontal thrust.
Solution:
FV = F cos
[ M A =0 ] 3RB = 13FV
3RB = 13(2500) cos 30
RB = 9382 lb
[ M B =0 ] 3RA = 10 FV
3RA = 10(2500 ) cos 30
RA = 7217 lb
Shear Diagram
Page 24 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Moment Diagram
Page 25 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
su 18M
s= = 3
N h
85 18(21.65)
=
4 h3
h = 2.64 in
h
b = = 0.88 in
3
5 7
say h = 2 in , b = in
8 8
Page 26 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
22. A cast-iron beam, ASTM 50, as shown, is 30 in. long and supports two gradually
applied, repeated loads (in phase), one of 2000 lb. at e = 10 in from the free end,
and one of 1000 lb at the free end. (a) Determine the dimensions of the cross
section if b = c 3a . (b) The same as (a) except that the top of the tee is below.
Problem 22.
Solution:
M = F1d + F2 (d + e )
where:
F1 = 2000 lb
F2 = 1000 lb
d = 30 10 = 20 in
d + e = 30 in
M = (2000)(20) + (1000)(30) = 70,000 lb in = 70 kips in
Mc
s=
I
Solving for I , moment of inertia
Page 27 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
I=
(3a )(a )3 + (3a )(a )(a 2 ) + (a )(3a )3 + (3a )(a )(a 2 ) = 17 a 4
12 12 2
(a)
3a
ct =
2
5a
cc =
2
Based on tension
s Mct
st = u =
N I
(70) 3a
50
= 2
8 17a 4
2
a = 1.255 in
Based on compression
s Mcc
sc = uc =
N I
(70) 5a
164
= 2
8 17a 4
2
a = 1.001 in
Therefore a = 1.255 in
1
Or say a = 1 in
4
And b = c = 3a = 3(1.25) = 3.75 in
Page 28 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
3
Or b = c = 3 in
4
5a
ct =
2
3a
cc =
2
17a 4
I=
2
M = 70 kips in
Based on tension
s Mct
st = u =
N I
(70) 5a
50
= 2
8 17 a 4
2
a = 1.488 in
Based on compression
s Mcc
sc = uc =
N I
(70) 3a
164
= 2
8 17a 4
2
a = 0.845 in
Therefore a = 1.488 in
1
Or say a = 1 in
2
1
And b = c = 3a = 4 in
2
CHECK PROBLEMS
Page 29 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
23. An I-beam is made of structural steel, AISI C1020, as rolled. It has a depth of 3
in. and is subjected to two loads; F1 and F2 = 2F1 ; F1 is 5 in. from one end and
F2 is 5 in. from the other ends. The beam is 25 in. long; flange width is
b = 2.509 in ; I x = 2.9 in 4 . Determine (a) the approximate values of the load to
cause elastic failure, (b) the safe loads for a factor of safety of 3 based on the yield
strength, (c) the safe load allowing for flange buckling (i1.24), (f) the maximum
deflection caused by the safe loads.
Problems 23 25.
Solution:
Moment Diagram
Page 30 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Mc
(a) s y =
I
d 3
where c = = = 1.5 in
2 2
s y = 48 =
(9 F1 )(1.5)
2 .9
F1 = 10.31 kips
F2 = 2 F1 = 20.62 kips
sy Mc
(b) s = =
N I
48 (9 F1 )(1.5)
s= =
3 2 .9
F1 = 3.44 kips
F2 = 2 F1 = 6.88 kips
L 25
(c) = = 9.96 < 15 (page 34)
b 2.509
sc = 20 ksi ( page 34, i1.24)
Mc
sc =
I
20 =
(9 F1 )(1.5)
2 .9
F1 = 4.30 kips
F2 = 2 F1 = 8.60 kips
Page 31 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
ymax caused by F1
3
F a b(L + a1 ) 2
ymax1 = 1 1 1
3EIL 3 , b1 > a1
where E = 30,000 ksi
a1 = 5 in
b1 = 20 in
L = 25 in
I = 2.9 in 4
3
F1 (5) 20(25 + 5) 2
ymax1 = = 0.0022 F1
3(30,000)(2.9)(25) 3
ymax caused by F2
3
F b a (L + b2 ) 2
ymax 2 = 2 2 2
3EIL 3 , a2 > b2
where b2 = 5 in
a2 = 20 in
3
2 F1 (5) 20(25 + 5) 2
ymax 2 = = 0.0043F1
3(30,000)(2.9)(25) 3
Total deflection =
= ymax1 + ymax 2 = 0.022 F1 + 0.0043F1 = 0.0065F1
24. The same as 23, except that the material is aluminum alloy, 2024-T4, heat treated.
Solution:
Mc
(a) s y =
I
Page 32 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
s y = 47 =
(9 F1 )(1.5)
2 .9
F1 = 10.10 kips
F2 = 2 F1 = 20.20 kips
sy Mc
(b) s = =
N I
47 (9 F1 )(1.5)
s= =
3 2 .9
F1 = 3.36 kips
F2 = 2 F1 = 6.72 kips
L 25
(c) = = 9.96 < 15 (page 34)
b 2.509
sc = 20 ksi ( page 34, i1.24)
Mc
sc =
I
20 =
(9 F1 )(1.5)
2 .9
F1 = 4.30 kips
F2 = 2 F1 = 8.60 kips
25. A light I-beam is 80 in. long, simply supported, and carries a static load at the
midpoint. The cross section has a depth of d = 4 in , a flange width of b = 2.66 in ,
and I x = 6.0 in 4 (see figure). (a) What load will the beam support if it is made of
C1020, as-rolled steel, and flange buckling (i1.24) is considered? (b) Consider the
stress owing to the weight of the beam, which is 7.7 lb/ft, and decide whether or
not the safe load should be less.
Page 33 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Solution:
1 + 1800 1 +
b 1800
Mc
s=
I
d 4
c = = = 2 in
2 2
From Table AT 2
FL F (80 )
M= = = 20 F
4 4
Mc
s = sc =
I
15 =
(20 F )(2 )
6
F = 2.25 kips , safe load
wL2
addl M = (Table AT 2)
8
where w = 7.7 lb ft
Page 34 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
26. What is the stress in a band-saw blade due to being bent around a 13 -in. pulley?
The blade thickness is 0.0265 in. (Additional stresses arise from the initial tension
and forces of sawing.)
Solution:
t
c= = 0.0265 = 0.01325 in
2
r = 13.75 + 0.01325 = 13.76325 in
Using Eq. (1.4) page 11 (Text)
Ec
s=
r
where E = 30 106 psi
s=
(30 10 )(0.01325) = 28,881 psi
6
13.76325
27. A cantilever beam of rectangular cross section is tapered so that the depth varies
uniformly from 4 in. at the fixed end to 1 in. at the free end. The width is 2 in. and
the length 30 in. What safe load, acting repeated with minor shock, may be
applied to the free end? The material is AISI C1020, as rolled.
Solution:
For AISI C1020, as rolled
su = 65 ksi (Table AT 7)
Designing based on ultimate strength,
N = 6 , for repeated, minor shock load
Page 35 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
su 65
s= = = 10.8 ksi
N 6
Loading Diagram
4 1 h 1
=
30 x
h = 0.10 x + 1
wh 3
I=
12
h
c=
2
M = Fx
(Fx ) h
s=
Mc
= 2 = 6 Fx = 3Fx = 3Fx
I wh
3
2h 2
h 2
(0.10 x + 1)2
12
Differentiating with respect to x then equate to zero to solve for x giving maximum
stress.
ds (0.10 x + 1)2 (1) 2( x )(0.10 x + 1)(0.10 )
= 3F =0
dx (0.10 x + 1)4
0.10 x + 1 2(0.10 x ) = 0
x = 10 in
h = 0.10(10) + 1 = 2 in
s 3Fx
s= u = 2
N h
3F (10 )
10.8 =
(2)2
F = 1.44 kips
TORSIONAL STRESSES
DESIGN PROBLEMS
Page 36 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
28. A centrifugal pump is to be driven by a 15-hp electric motor at 1750 rpm. What
should be the diameter of the pump shaft if it is made of AISI C1045 as rolled?
Consider the load as gradually repeated.
Solution:
29. A shaft in torsion only is to transmit 2500 hp at 570 rpm with medium shocks. Its
material is AISI 1137 steel, annealed. (a) What should be the diameter of a solid
shaft? (b) If the shaft is hollow, Do = 2 Di , what size is required? (c) What is the
weight per foot of length of each of these shafts? Which is the lighter? By what
percentage? (d) Which shaft is the more rigid? Compute the torsional deflection
of each for a length of 10 ft.
Solution:
33,000hp 33,000(2500 )
T= = = 23,036 ft lb = 276 in kips
2 n 2 (570 )
For AISI 1137, annealed
s y = 50 ksi (Table AT 8)
s ys = 0.6 s y = 30 ksi
Page 37 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Design stress
s 30
s = ys = = 10 ksi
N 3
Tc
s=
J
D4
J=
32
D
c=
2
16T
s=
D3
16(276 )
10 =
D3
D = 5.20 in
1
say D = 5 in
4
(b) J = =
[
(Do4 Di4 ) (2 Di )4 Di4 ] = 15 D i
4
32 32 32
Do 2 Di
c= = = Di
2 2
TDi 32T
s= =
15 Di 15 Di3
4
32
32(276 )
10 =
15 Di3
Di = 2.66 in
Do = 2 Di = 5.32 in
say
5
Di = 2 in
8
1
Do = 5 in
4
Page 38 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
TL
=
JG
where
L = 10 ft = 120 in
G = 11.5 103 ksi
D4
For solid shaft, J =
32
(276)(120) 180
= 0.039 rad = (0.039 ) = 2 .2
o
=
(5.25) (11.5 10 )
4 3
32
(Do4 Di4 )
For hollow shaft, J =
32
(276)(120) 180
= 0.041 rad = (0.041) = 2 .4
o
=
[(5.25) (2.625) ](11.5 10 )
4 4 3
32
Therefore, solid shaft is more rigid, 2.2o < 2.4o
30. The same as 29, except that the material is AISI 4340, OQT 1200 F.
Solution:
33,000hp 33,000(2500 )
T= = = 23,036 ft lb = 276 in kips
2 n 2 (570 )
For AISI 4340, OQT 1200 F
s y = 130 ksi
s ys = 0.6 s y = 0.6(130 ) = 78 ksi
Page 39 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Design stress
s 78
s = ys = = 26 ksi
N 3
Tc
s=
J
D4
J=
32
D
c=
2
16T
s=
D3
16(276 )
26 =
D3
D = 3.78 in
3
say D = 3 in
4
(b) J = =
[
(Do4 Di4 ) (2 Di )4 Di4 ] = 15 D i
4
32 32 32
Do 2 Di
c= = = Di
2 2
TDi 32T
s= =
15 Di 15 Di3
4
32
32(276 )
26 =
15 Di3
Di = 1.93 in
Do = 2 Di = 3.86 in
say
Di = 2 in
Do = 4 in
Page 40 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
TL
=
JG
where
L = 10 ft = 120 in
G = 11.5 103 ksi
D4
For solid shaft, J =
32
(276)(120) 180
= 0.148 rad = (0.148) = 8.48
o
=
(3.75) (11.5 10 )
4 3
32
(Do4 Di4 )
For hollow shaft, J =
32
(276)(120 ) 180
= 0.122 rad = (0.122 ) = 6.99
o
=
4
[(4 ) (2 ) ](11.5 10 )
4 3
32
Therefore, hollow shaft is more rigid, 6.99o < 8.48o .
31. A steel shaft is transmitting 40 hp at 500 rpm with minor shock. (a) What should
be its diameter if the deflection is not to exceed 1o in 20 D ? (b) If deflection is
primary what kind of steel would be satisfactory?
Solution:
33,000hp 33,000(40 )
(a) T = = = 420 ft lb = 5.04 in kips
2 n 2 (500 )
G = 11.5 103 ksi
L = 20 D
Page 41 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
= 1o = rad
180
TL
=
JG
=
(5.04)(20 D )
180 D4
32
(
11.5 103 )
D = 1.72 in
3
say D = 1 in
4
16T 16(5.04 )
(b) s = = = 4.8 ksi
D 3 (1.75)3
32. A square shaft of cold-finish AISI 1118 transmits a torsional moment of 1200 in-
lb. For medium shock, what should be its size?
Solution:
Page 42 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
CHECK PROBLEMS
33. A punch press is designed to exert a force sufficient to shear a 15/16-in. hole in a
-in. steel plate, AISI C1020, as rolled. This force is exerted on the shaft at a
radius of -in. (a) Compute the torsional stress in the 3.5-in. shaft (bending
neglected). (b) What will be the corresponding design factor if the shaft is made
of cold-rolled AISI 1035 steel (Table AT 10)? Considering the shock loading that
is characteristics of this machine, do you thick the design is safe enough?
Solution:
For AISI C1020, as rolled
sus = 49 ksi
F = sus ( Dt )
15
where D = in
16
1
t = in
2
15 1
F = 49( ) = 72.2 kips
16 2
T = Fr
3
where r = in
4
3
T = (72.2 ) = 54.2 in kips
4
16T
(a) s =
d3
where d = 3.5 in
16(54.2 )
s= = 6.44 ksi
(3.5)3
sus 64
Design factor , N = = = 9.94 , the design is safe ( N 10 )
s 6.44
34. The same as 33, except that the shaft diameter is 2 in.
Solution:
Page 43 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
d = 2.75 in
16T
(a) s =
d3
16(54.2 )
s= = 13.3 ksi
(2.75)3
sus 64
Design factor , N = = = 4.8 , the design is not safe ( N < 10 )
s 13.3
35. A hollow annealed Monel propeller shaft has an external diameter of 13 in. and
an internal diameter of 6 in.; it transmits 10,000 hp at 200 rpm. (a) Compute the
torsional stress in the shaft (stress from bending and propeller thrust are not
considered). (b) Compute the factor of safety. Does it look risky?
Solution:
Tc
(a) s =
J
J=
( ) [
Do4 Di4 (13.5)4 (6.5)4
=
]
= 3086 in 4
32 32
Do 13.5
c= = = 6.75 in
2 2
33,000hp 33,000(10,000 )
T= = = 262,606 ft lb = 3152 in kips
2 n 2 (200 )
s=
(3152)(6.75) = 6.9 ksi
3086
(b) Factor of safety,
sus 98
N= = = 14.2 , not risky
s 6 .9
Page 44 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
STRESS ANALYSIS
DESIGN PROBLEMS
36. A hook is attached to a plate as shown and supports a static load of 12,000 lb. The
material is to be AISI C1020, as rolled. (a) Set up strength equations for
dimensions d , D , h , and t . Assume that the bending in the plate is negligible.
(b) Determine the minimum permissible value of these dimensions. In estimating
the strength of the nut, let D1 = 1.2d . (c) Choose standard fractional dimensions
which you think would be satisfactory.
Problems 36 38.
Solution:
s = axial stress
ss = shear stress
(a)
F 4F
s= = 2
1
d2 d
4
4F
Equation (1) d =
s
Page 45 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
F 4F 4F 4F
s= = = =
1
(
D 2 D12 ) ( 2
D D12
) [
D (1.2d )
2 2
] ( D 1.44d 2
2
)
4
4F
Equation (2) D = + 1.44d 2
s
F F
ss = =
D1h 1.2 dh
F
Equation (3) h =
1.2 dss
F
ss =
Dt
F
Equation (4) t =
Dss
F = 12,000 lb = 12 kips
Page 46 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
d = 1 in
1
D = 1 in
2
1
h = in
4
1
t = in
4
37. The same as 36, except that a shock load of 4000 lb. is repeatedly applied.
Solution:
F = 4000 lb = 4 kips
Page 47 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
1
d = 1 in
8
3
D = 1 in
4
3
h = in
8
1
t = in
4
38. The connection between the plate and hook, as shown, is to support a load F .
Determine the value of dimensions D , h , and t in terms of d if the connection
is to be as strong as the rod of diameter d . Assume that D1 = 1.2d , sus = 0.75su ,
and that bending in the plate is negligible.
Solution:
F
s=
1
d2
4
1
F = d 2s
4
1 s
(1) F = d 2 u
4 N
Page 48 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
F F
s= =
1 1
4
(
D 2 D12
4
) (
D 2 1.44d 2 )
1
(
F = D 2 1.44d 2 s
4
)
1 s
(
(2) F = D 2 1.44d 2 u )
4 N
F F
ss = =
D1h 1.2 dh
F = 1.2 dhss
s 0.75su
F = 1.2 dh us = 1.2 dh
N N
5s
(3) F = 0.9 dh u
N
F
ss =
Dt
F = Dtss
s 0.75su
F = Dt us = Dt
N N
s
(4) F = 0.75 Dt u
N
Page 49 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
39. (a) For the connection shown, set up strength equations representing the various
methods by which it might fail. Neglect bending effects. (b) Design this
connection for a load of 2500 lb. Both plates and rivets are of AISI C1020, as
rolled. The load is repeated and reversed with mild shock. Make the connection
equally strong on the basis of yield strengths in tension, shear, and compression.
Problems 39, 40
Solution:
F
(a) ss =
1
5 D 2
4
4F
Equation (1) D =
5 ss
F
s=
t (b 2 D )
F
Equation (2) b = + 2D
ts
F
s=
5 Dt
F
Equation (3) t =
5 Ds
N = 4 for repeated and reversed load (mild shock) based on yield strength
48
s= = 12 ksi
4
28
ss = = 7 ksi
4
From Equation (1)
Page 50 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
4F
D=
5 ss
where
F = 2500 lb = 2.5 kips
4F 4(2.5) 5
D= = = 0.30 in say in
5 ss 5 (7 ) 16
40. The same as 39, except that the material is 2024-T4, aluminum alloy.
Solution:
(a) Same as 39.
N = 4 for repeated and reversed load (mild shock) based on yield strength
47
s= = 12 ksi
4
25
ss = = 6 ksi
4
From Equation (1)
4F
D=
5 ss
where
F = 2500 lb = 2.5 kips
4F 4(2.5) 3
D= = = 0.33 in say in
5 ss 5 (6) 8
Page 51 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
F 2 .5 1
t= = = 0.11 in say in
5 Ds 3 8
5 (12 )
8
41. (a) For the connection shown, set up strength equations representing the various
methods by which it might fail. (b) Design this connection for a load of 8000 lb.
Use AISI C1015, as rolled, for the rivets, and AISI C1020, as rolled, for the
plates. Let the load be repeatedly applied with minor shock in one direction and
make the connection equally strong on the basis of ultimate strengths in tension,
shear, and compression.
Problem 41.
Solution:
(a)
3
F
F
sP = or sP = 4 Equation (1)
t (b D ) t (b 2 D )
F
ssR = Equation (2)
1
4 D 2 (2 )
4
Page 52 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
F
sR = Equation (3)
4 Dt
Page 53 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
3F 3(8) 7
b= + 2D = + 2 = 1.99 in say 2 in
1
4 (10.8)
4ts P 16
2
Therefore
b = 2 in
7
D = in
16
1
t = in
2
42. Give the strength equations for the connection shown, including that for the shear
of the plate by the cotter.
Problems 42 44.
Solution:
Axial Stresses
F 4F
s= = Equation (1)
1
D12 D12
4
F
s= Equation (2)
(L D2 )e
Page 54 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
F
s= Equation (3)
D2e
F 4F
s= = Equation (4)
1
(
a 2 D22 ) ( )
a 2 D22
4
F 4F
s= = 2
Equation (5)
1 D 4 D2e
D22 D2 e 2
4
Shear Stresses
F
ss = Equation (6)
2eb
F
ss = Equation (7)
2(L D2 + e )t
Page 55 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
F
ss = Equation (8)
at
F
ss = Equation (9)
D1m
F
ss = Equation (10)
2 D2 h
43. A steel rod, as-rolled AISI C1035, is fastened to a 7/8-in., as-rolled C1020 plate
by means of a cotter that is made of as-rolled C1020, in the manner shown. (a)
Determine all dimensions of this joint if it is to withstand a reversed shock load
F = 10 kips , basing the design on yield strengths. (b) If all fits are free-running
fits, decide upon tolerances and allowances.
Page 56 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
D2 = 1.80 in
3
say D2 = 1 in
4
and D2e = 1.273
3
1 e = 1.273
4
e = 0.73 in
3
say e = in
4
By further adjustment
5
Say D2 = 2 in , e = in
8
From Equation (8)
ssy F
ss = 2 =
N at
28 10
=
7 a (0.875)
a = 0.91 in
say a = 1 in
Page 57 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
48 4(10)
=
7 (a 2 2 2 )
a = 2.42 in
1
say a = 2 in
2
1
use a = 2 in
2
From Equation (7)
ssy F
ss = 2 =
N 2(L D2 + e )t
28 10
=
7 5
2 L 2 + (0.875)
8
L = 2.80 in
say L = 3 in
From Equation (6)
ssy F
ss = 2 =
N 2eb
28 10
=
7 5
2 b
8
b = 2 in
From Equation (10)
ssy F
ss = 2 =
N 2 D2 h
28 10
=
7 2(2)h
5
h = 0.625 in = in
8
Summary of Dimensions
L = 3 in
5
h = in
8
b = 2 in
7
t = in
8
Page 58 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
9
m= in
16
1
a = 2 in
2
1
D1 = 1 in
4
D2 = 2 in
5
e = in
8
t = 0.875 0.010 in
m = 0.5625 0.010 in
a = 2.500 0.010 in
D1 = 1.25 0.010 in
For Free Running Fits (RC 7) Table 3.1
Female Male
+ 0.0030 0.0040
b = 2.0 in b = 2.0 in
0.0000 0.0058
allowance = 0.0040 in
+ 0.0030 0.0040
D2 = 2.0 in D2 = 2.0 in
0.0000 0.0058
allowance = 0.0040 in
+ 0.0016 0.0020
e = 0.625 in e = 0.625 in
0.0000 0.0030
allowance = 0.0020 in
44. A 1-in. ( D1 ) steel rod (as-rolled AISI C1035) is to be anchored to a 1-in. steel
plate (as-rolled C1020) by means of a cotter (as rolled C1035) as shown. (a)
Determine all the dimensions for this connection so that all parts have the same
ultimate strength as the rod. The load F reverses direction. (b) Decide upon
tolerances and allowances for loose-running fits.
Page 59 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
su2 = 65 ksi
sus2 = 48 ksi
Ultimate strength
Use Equation (1)
1 1 2
Fu = su1 D12 = (85) (1) = 66.8 kips
4 4
Equation (9)
Fu = sus1 D1m
66.8 = (64)( )(1)m
m = 0.33 in
3
say m = in
8
From Equation (3)
Fu = su1 D2e
66.8 = (85)D2 e
D2e = 0.7859
From Equation (5)
1
Fu = su1 D22 D2 e
4
1
66.8 = (85) D22 0.7859
4
D2 = 1.42 in
3
say D2 = 1 in
8
3
D2e = 1 e = 0.7859
8
e = 0.57 in
9
say e = in
16
From Equation (4)
1
Fu = su2 (a 2 D22 )
4
1 3
2
66.8 = (65) a 2 1
4 8
a = 1.79 in
3
say a = 1 in
4
From Equation (8)
Page 60 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Fu = sus2 at
66.8 = (48)( )(a )(1)
a = 0.44 in
1
say a = in
2
3
use a = 1 in
4
From Equation (2)
Fu = su2 (L D2 )e
3 9
66.8 = (65) L 1
8 16
L = 3.20 in
1
say L = 3 in
4
From Equation (7)
Fu = 2 sus2 (L D2 e )t
3 9
66.8 = 2(48) L 1 (1)
8 16
L = 1.51 in
1
say L = 1 in
2
1
use L = 3 in
4
From Equation (6)
Fu = 2 sus1 eb
9
66.8 = 2(64 ) b
16
b = 0.93 in
say b = 1 in
From Equation (10)
Fu = 2 sus1 D2 h
3
66.8 = 2(64 ) 1 h
8
h = 0.38 in
3
say h = in
8
Dimensions
1
L = 3 in
4
Page 61 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
3
h= in
8
b = 1 in
t = 1 in
3
m = in
8
3
a = 1 in
4
D1 = 1 in
3
D2 = 1 in
8
9
e = in
16
45. Give all the simple strength equations for the connection shown. (b) Determine
the ratio of the dimensions a , b , c , d , m , and n to the dimension D so that the
connection will be equally strong in tension, shear, and compression. Base the
calculations on ultimate strengths and assume sus = 0.75su .
Page 62 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Problems 45 47.
Solution:
(a) Neglecting bending
1
Equation (1): F = s D 2
4
1
Equation (2): F = ss 2 c 2
4
Equation (3): F = s(2bc )
Equation (4): F = s(ac )
Equation (5): F = s[2(d c )b]
Equation (6): F = ss (4mb )
Equation (7): F = ss (2nb )
Equation (8): F = s(d c )a
su s
(b) s = and ss = us
N N
Therefore
ss = 0.75s
Equate (2) and (1)
1 1
F = ss 2 c 2 = s D 2
4 4
1 1
0.75s c 2 = s D 2
2 4
c = 0.8165 D
Equate (3) and (1)
1
F = s (2bc ) = s D 2
4
1
2b(0.8165 D ) = D 2
4
b = 0.4810 D
Page 63 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
Summary
a = 0.9620 D
b = 0.4810 D
c = 0.8165 D
d = 1.6329 D
m = 0.5443D
n = 1.0886 D
46. The same as 45, except that the calculations are to be based on yield strengths. Let
ssy = 0.6 s y .
Page 64 of 131
SECTION 1 DESIGN FOR SIMPLE STRESSES
1
Equation (1): F = s D 2
4
1
Equation (2): F = ss 2 c 2
4
Equation (3): F = s(2bc )
Equation (4): F = s(ac )
Equation (5): F = s[2(d c )b]
Equation (6): F = ss (4mb )
Equation (7): F = ss (2nb )
Equation (8): F = s(d c )a
sy s sy
(b) s = and ss =
N N
Therefore
ss = 0.6s
Equate (2) and (1)
1 1
F = ss 2 c 2 = s D 2
4 4
1 1
0 .6 s c 2 = s D 2
2 4
c = 0.9129 D
Equate (3) and (1)
1
F = s (2bc ) = s D 2
4
1
2b(0.9129 D ) = D 2
4
b = 0.4302 D
Page 65 of 131
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
DESIGN PROBLEMS
141. The maximum pressure of air in a 20-in. cylinder (double-acting air compressor)
is 125 psig. What should be the diameter of the piston rod if it is made of AISI
3140, OQT at 1000 F, and if there are no stress raisers and no column action? Let
N = 1.75 ; indefinite life desired. How does your answer compare with that
obtained for 4?
Solution:
For AISI 3140, OQT 1000 F
su = 153 ksi
s y = 134 ksi
4
Fmin = F = 39.27 kips
sm = 0
4 F 4(39.27 ) 50
sa = = = 2
d2 d2 d
50
2
= 0+
1 1 d
=
N 1.75 52
d = 1.2972 in
5
say d = 1 in
16
comparative to Problem 4.
142. A link as shown is to be made of AISI 2330, WQT 1000 F. The load F = 5 kips
is repeated and reversed. For the time being, ignore stress concentrations. (a) If
its surface is machined, what should be its diameter for N = 1.40 . (b) The same
as (a), except that the surface is mirror polished. What would be the percentage
saving in weight? (c) The same as (a), except that the surface is as forged.
Page 1 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Solution:
For AISI 2330, WQT 1000 F
su = 105 ksi
s y = 85 ksi
Page 2 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
D = 0.5 in
2 2
9 1
Savings in weight = 2 (100% ) = 21%
16 2
9
16
(c) As forged surface
Surface factor = 0.40 (Fig. AF 5)
sn = 0.5su = (0.80)(0.85)(0.40 )(52.5) ksi = 14.28 ksi
20 14.28
sa = =
D2 1 .4
D = 0.79 in
3
say D = in
4
143. The same as 142, except that, because of a corrosive environment, the link is
made from cold-drawn silicon bronze B and the number of reversals of the load
is expected to be less than 3 x 107.
Solution:
For cold-drawn silicon bronze, Type B.
sn = 30 ksi at 3 x 108
s y = 69 ksi
su = 93.75 ksi
0.085
3 108
sn at 3 x 10 = (30 )
7
7
= 36.5 ksi
3 10
sn = (0.80)(0.85)(36.5) = 24.82 ksi
20 24.82
sa = 2
=
D 1 .4
D = 0.60 in
5
say D = in
8
144. The same as 142, except that the link is made of aluminum alloy 2024-T4 with a
minimum life of 107 cycles.
Solution:
For AA 2024-T4
s y = 47 ksi
su = 68 ksi
sn = 20 ksi at 5 x108
Page 3 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
0.085
5 108
sn at 10 (20 )
7
7
= 27.9 ksi
10
sn = (0.80)(0.85)(27.9) = 19 ksi
20 19
sa = 2
=
D 1 .4
D = 0.685 in
11
say D = in
16
145. A shaft supported as a simple beam, 18 in. long, is made of carburized AISI 3120
steel (Table AT 10). With the shaft rotating, a steady load of 2000 lb. is appliled
midway between the bearings. The surfaces are ground. Indefinite life is desired
with N = 1.6 based on endurance strength. What should be its diameter if there
are no surface discontinuities?
Solution:
Page 4 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1 s
= 0+ a
N sn
s
sa = n
N
32(9 ) 67.32
=
D3 1 .6
D = 1.2964 in
1
say D = 1 in
4
146. (a) A lever as shown with a rectangular section is to be designed for indefinite
life and a reversed load of F = 900 lb . Find the dimensions of a section without
discontinuity where b = 2.8t and L = 14 in . for a design factor of N = 2 . The
material is AISI C1020, as rolled, with an as-forged surface. (b) compute the
dimensions at a section where e = 4 in .
(a) sm = 0
Mc
sa =
I
tb3 t (2.8t )
3
I= = = 1.8293t 4
12 12
b 2.8t
c= = = 1.4t
2 2
M = FL = (900)(14) = 12,600 in lb = 12.6 in kips
sa =
(12.6)(1.4t ) = 9.643
1.8293t 4 t3
sn = (0.85)(0.55)(32.5) = 15.20 ksi
Page 5 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Soderberg line
1 sm sa
= +
N s y sn
1 s
= 0+ a
N sn
s
sa = n
N
9.643 15.20
=
t3 2
t = 1.08 in
b = 2.8t = 2.8(1.08) = 3.0 in
1
say t = 1 in , b = 3.0 in
16
t = 0.713 in
b = 2.8t = 2.8(0.713) = 1.996 in
23
say t = in , b = 2 in
32
147. The same as 146, except that the reversal of the load are not expected to exceed
105 (Table AT 10).
Solution:
sn = 32.5 ksi
0.085
106
sn at 10 = (32.5) 5
5
= 39.5 ksi
10
sn = (0.85)(0.55)(39.5) = 18.5 ksi
sn
(a) sa =
N
9.643 18.5
=
t3 2
Page 6 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
t = 1.014 in
b = 2.8t = 2.8(1.014) = 2.839 in
13
say t = 1 in , b = 2 in
16
sn
(b) sa =
N
2.755 18.5
=
t3 2
t = 0.6678 in
b = 2.8t = 2.8(0.6678) = 1.870 in
11 7
say t = in , b = 1 in
16 8
Solution:
For AISI 3140 steel, OQT 1000 F
su = 152 ksi
s y = 134 ksi
sn = 0.5su = 76 ksi
For machined surface,
Surface factor = 0.78
Size factor = 0.85
sns = (0.6)(0.85)(0.78)(134) = 53.3 ksi
s ys = 0.6 s y = 0.6(134 ) = 80.4 ksi
1 sms sas
= +
N s ys sns
sms = 0
16T
sas =
D3
T = 15 in kips
16(15) 240
sas = =
D3 D3
1 s
= 0 + as
N sns
s
sas = ns
N
Page 7 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
240 53.3
=
D 3 1.75
D = 1.3587 in
3
say D = 1 in
8
149. The same as 148, except that the shaft is hollow with the outside diameter twice
the inside diameter.
Solution:
Do = 2 Di
16TDo 16(15)(2 Di ) 32
sas = = =
4 4
[
(Do Di ) (2 Di ) Di
4
]
4
Di3
s
sas = ns
N
32 53.3
=
Di3 1.75
Di = 0.694 in
11 3
say Di = in , Do = 1 in
16 8
150. The link shown is machined from AISI 1035 steel, as rolled, and subjected to a
repeated tensile load that varies from zero to 10 kips; h = 2b . (a) Determine these
dimensions for N = 1.40 (Soderberg) at a section without stress concentration.
(b) How much would these dimensions be decreased if the surfaces of the link
were mirror polished?
Page 8 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1
Fm = (10 + 0 ) = 5 kips
2
1
Fa = (10 0 ) = 5 kips
2
F 5 10
sm = m = 2
= 2
bh 1.5b 3b
F 5 10
sa = a = 2
= 2
bh 1.5b 3b
(a) Soderberg line
1 sm sa
= +
N s y sn
For machined surface,
Factor = 0.88
b = 0.5182 in
9
say b = in
16
27
h = 1.5b = in
32
b = 0.4963 in
1
say b = in
2
3
h = 1.5b = in
4
151. The same as 150, except that the link operates in brine solution. (Note: The
corroding effect of the solution takes precedence over surface finish.)
Page 9 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Solution:
Table AT 10, in brine, AISI 1035,
sn = 24.6 ksi
s y = 58 ksi
sn = (0.80)(0.85)(24.6) = 16.73 ksi
1 10 10
= 2 + 2
1.40 3b (55) 3b (16.73)
b = 0.60 in
5
say b = in
8
15
h = 1.5b = in
16
152. The simple beam shown, 30-in. long ( = a + L + d ), is made of AISI C1022 steel,
as rolled, left a forged. At a = 10 in , F1 = 3000 lb. is a dead load. At
d = 10 in , F2 = 2400 lb. is repeated, reversed load. For N = 1.5 , indefinite life,
and h = 3b , determine b and h . (Ignore stress concentration).
Solution:
For AISI C1022, as rolled
su = 72 ksi
s y = 52 ksi
sn = 0.5su = 36 ksi
For as forged surface
Figure AF 5, factor = 0.52
Size factor = 0.85
sn = (0.85)(0.52)(36) = 16 ksi
Loading:
Page 10 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
M A =0
10(3000) + 20(2400 ) = 30 R2
R2 = 2600 lb
F V =0
R1 + R2 = F1 + F2
R1 + 2600 = 3000 + 2400
R1 = 2800 lb
Shear Diagram
Then
Loading
M A =0
10(3000) + 30 R2 = 20(2400 )
R2 = 600 lb
F V =0
R1 + F2 = F1 + R2
R1 + 2400 = 3000 + 600
R1 = 1200 lb
Page 11 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Shear Diagram
Then using
M max = M C1 = 28 in kips
M min = M C2 = 12 in kips
1
Mm = (M max + M min ) = 1 (28 + 12) = 20 in kips
2 2
1 1
M a = (M max M min ) = (28 12 ) = 8 in kips
2 2
M c M c
sm = m , sa = a
I I
b(3b )
3 3
bh
I= = = 2.25b 4
12 12
h
c = = 1.5b
2
Mm Ma
sm = 3
, sa =
1.5b 1.5b3
1 sm sa
= +
N s y sn
20 8
1 1.5b3 1.5b3
= +
1.5 52 16
b = 0.96 in
say b = 1 in
h = 3b = 3 in
153. The same as 152, except that the cycles of F2 will not exceed 100,000 and all
surfaces are machined.
Solution:
Page 12 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
0.085
106
( )
sn at 10 cycles = 36 5
5
= 43.8 ksi
10
su = 72 ksi
Machined surface, factor = 0.90
sn = (0.85)(0.90)(43.8) = 33.5 ksi
20 8
1 1.5b3 1.5b3
= +
1.5 52 33.5
b = 0.8543 in
7
say b = in
8
5
h = 3b = 2 in
8
154. A round shaft, made of cold-finished AISI 1020 steel, is subjected to a variable
torque whose maximum value is 6283 in-lb. For N = 1.5 on the Soderberg
criterion, determine the diameter if (a) the torque is reversed, (b) the torque varies
from zero to a maximum, (c) the torque varies from 3141 in-lb to maximum.
Solution:
For AISI 1020, cold-finished
su = 78 ksi
s y = 66 ksi
sn = 0.5su = 39 ksi
size factor = 0.85
sns = (0.6)(0.85)(39) = 20 ksi
s ys = 0.6 s y = 0.6(66 ) = 40 ksi
1 sms sas
= +
N s ys sns
Page 13 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
32
3
= 0+
1 D
1.5 20
D = 1.34 in
3
say D = 1 in
8
16(3141) 16,000 16
sms = 3
= 3
psi = 3 ksi
D D D
16(3141) 16,000 16
sas = 3
= 3
psi = 3 ksi
D D D
16 16
1 D3 D 3
= +
1.5 40 20
D = 1.22 in
1
say D = 1 in
4
16(4712 ) 24,000 24
sms = 3
= 3
psi = 3 ksi
D D D
16(1571) 8,000 8
sas = 3
= 3
psi = 3 ksi
D D D
24 8
1 D3 D 3
= +
1.5 40 20
D = 1.145 in
5
say D = 1 in
32
Page 14 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
CHECK PROBLEMS
155. A simple beam 2 ft. long is made of AISI C1045 steel, as rolled. The dimensions
of the beam, which is set on edge, are 1 in. x 3 in. At the midpoint is a repeated,
reversed load of 4000 lb. What is the factor of safety?
Solution:
For AISI C1045, as rolled
su = 96 ksi
s y = 59 ksi
sn = 0.5su = 0.5(96) = 48 ksi
size factor = 0.85
sn = (0.85)(48) = 40.8 ksi
1 sm sa
= +
N s y sn
sm = 0
6M
sa = 2
bh
h = 3 in
b = 1 in
FL (4000 )(24 )
M= = = 24,000 in lb = 24 in kips
4 4
6(24 )
sa = = 16 ksi
(1)(3)2
1 16
= 0+
N 40.8
N = 2.55
156. The same as 155, except that the material is normalized and tempered cast steel,
SAE 080.
Solution:
Table AT 6
sn = 35 ksi
s y = 40 ksi
sn = (0.85)(35) = 29.75 ksi
1 16
= 0+
N 29.75
N = 1.86
157. A 1 -in. shaft is made of AISI 1045 steel, as rolled. For N = 2 , what repeated
and reversed torque can the shaft sustain indefinitely?
Page 15 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Solution:
For AISI 1045, as rolled
su = 96 ksi
s y = 59 ksi
sn = 0.5su = 0.5(96) = 48 ksi
DESIGN PROBLEMS
158. The load on the link shown (150) is a maximum of 10 kips, repeated and
reversed. The link is forged from AISI C020, as rolled, and it has a in-hole
drilled on the center line of the wide side. Let h = 2b and N = 1.5 . Determine b
and h at the hole (no column action) (a) for indefinite life, (b) for 50,000
repetitions (no reversal) of the maximum load, (c) for indefinite life but with a
ground and polished surface. In this case, compute the maximum stress.
Solution:
For AISI C1020, as rolled
su = 65 ksi
s y = 48 ksi
sn = 0.5su = 0.5(65) = 32.5 ksi
For as forged surface
Surface factor = 0.55
Size factor = 0.85
sn = (0.80)(0.85)(0.55)(32.5) = 12.2 ksi
1 sm K f sa
= +
N sy sn
Page 16 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Fig. AF 8, b h > 1
Assume K t = 3.5
d 1
Figure AF 7, r = = in = 0.125 in
2 8
a = 0.01 in
1 1
q= = = 0.926
a 0.01
1+ 1+
r 0.125
K f = q K t 1 + 1 = 0.926(3.5 1) + 1 = 3.3
( )
sm = 0
F 10
sa = =
b(h d ) b(2b 0.25)
1 K s
(a) = 0+ f a
N sn
1
= 0+
(3.3)(10)
1.5 b(2b 0.25)(12.2)
2
2b 0.25b = 4.06
b 2 0.125b 2.03 = 0
b = 1.489 in
1
say b = 1 in , h = 2b = 3 in
2
=
(5 104 ) = 2.0
log K
10 f 10log 3.3
1 K fl sa
=
N sn
1
=
(2.0)(10)
1.5 b(2b 0.25)(15.74)
2b 2 0.25b = 1.906
b 2 0.125b 0.953 = 0
b = 1.04 in
1 1
say b = 1 in , h = 2b = 2 in
16 8
Page 17 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
sn = (0.80)(0.85)(0.90)(32.5) = 20 ksi
1 K f sa
=
N sn
1
=
(3.3)(10)
1.5 b(2b 0.25)(20)
b 2 0.125b 1.2375 = 0
b = 1.18 in
3 3
say b = 1 in , h = 2b = 2 in
16 8
Kf F
Maximum stress =
b(h d )
b h > 1 , d h = 0.25 2.375 = 0.105
Figure AF 8
K t = 3.5
K f = q (K t 1) + 1 = 0.926(3.5 1) + 1 = 3.315
smax =
(3.315)(10) = 13.14 ksi
1.1875(2.375 0.25)
159. A connecting link as shown, except that there is a 1/8-in. radial hole drilled
through it at the center section. It is machined from AISI 2330, WQT 1000 F, and
it is subjected to a repeated, reversed axial load whose maximum value is 5 kips.
For N = 1.5 , determine the diameter of the link at the hole (a) for indefinite life;
(b) for a life of 105 repetitions (no column action). (c) In the link found in (a)
what is the maximum tensile stress?
Problem 159
Solution:
For AISI 2330, WQT 1000 F
su = 135 ksi
s y = 126 ksi
sn = 0.5su = 0.5(135) = 67.5 ksi
For machined surface, Fig. AF 7, surface factor = 0.80
Size factor = 0.85
sn = (0.80)(0.85)(0.80)(67.5) = 36.72 ksi
Page 18 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1 sm K f sa
= +
N sy sn
Fig. AF 8, b h > 1
Assume K t = 2.5
d 1
Figure AF 7, r = = in = 0.0625 in
2 16
a = 0.0025 in
1 1
q= = = 0.96
a 0.0025
1+ 1+
r 0.0625
K f = q(K t 1) + 1 = 0.96(2.5 1) + 1 = 2.44
(a) Indefinite life, K f = 2.44
sn = 36.72 ksi
sm = 0
F 4F 4(5) 20
sa = = = =
D 2 2
D 4 Dd 1 D 0.5 D
2
Dd D 2 4 D
4 8
1 K s
= 0+ f a
N sn
1
=
(2.44)(20)
1.5 36.72(D 2 0.5D )
D 2 0.5D = 2.00
D = 0.88 in
7
say D = in
8
K fl = log K f =
(105 ) = 1.81
10 10log 2.44
1 K fl sa
=
N sn
1
=
(1.81)(20)
1.5 44.66(D 2 0.5 D )
D 2 0.5D = 1.216
D = 0.71 in
Page 19 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
3
say D = in
4
4K f F
(c) smax =
D 2 0.5D
7 d 0.125
D = in , = = 0.14
8 D 0.875
Figure AF 8
K t = 2.6
K f = q(K t 1) + 1 = 0.96(2.6 1) + 1 = 2.54
4(2.54)(5)
smax = 2
= 25.82 ksi
7 7
0.5
8 8
160. A machine part of uniform thickness t = b 2.5 is shaped as shown and machined
all over from AISI C1020, as rolled. The design is for indefinite life for a load
repeated from 1750 lb to 3500 lb. Let d = b . (a) For a design factor of 1.8
(Soderberg), what should be the dimensions of the part? (b) What is the
maximum tensile stress in the part designed?
Page 20 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
r 1
= = 0.333
d 3
h 2b
= =2
d b
K t = 1.65
a = 0.01 in
1
q= 1.0
a
1+
r
K f K t = 1.65
Fm
sm =
bt
Fa
sa =
bt
b
t=
2 .5
1
Fm = (3500 + 1750 ) = 2625 lb
2
1
Fa = (3500 1750 ) = 875 lb
2
2625 6562.5
sm = =
b b2
b
2 .5
875 2187.5
sa = =
b b2
b
2 .5
1 6562.5 (1.65)(2187.5)
= +
1.8 48,000b 2 20,000b 2
b = 0.7556 in
or b = 0.75 in
b 0.75
t= = = 0.3 in
2 .5 2 .5
Page 21 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
2625 6562.5
sm = =
b b2
b
2 .5
875 2187.5
sa = =
b b2
b
2 .5
1 6562.5 (2.9)(2187.5)
= +
1.8 48,000b 2 20,000b 2
b = 0.904 in
15
or b = 0.9375 in = in
16
b 3
t= = in
2 .5 8
15
d = b = in
16
15 3 15
use b = in , t = in , d = in
16 8 16
(b) smax = sm + K f sa
d 15
r= = in
2 32
1
q= = 0.98
0.01
1+
15
32
K t = 2.9
K f = q(K t 1) + 1 = 0.98(2.9 1) + 1 = 2.86
Fm 6562.5 6562.5
sm = = = 2
= 7467 psi
bt b2 15
16
F 2187.5 2187.5
sa = a = = 2
= 2489 psi
bt b2 15
16
smax = sm + K f sa = 7467 + (2.86 )(2489 ) = 14,586 psi
162. The beam shown has a circular cross section and supports a load F that
varies from 1000 lb to 3000 lb; it is machined from AISI C1020 steel, as
rolled. Determine the diameter D if r = 0.2 D and N = 2 ; indefinite life.
Page 22 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Solution:
For AISI C1020, as rolled
su = 65 ksi
s y = 48 ksi
sn = 0.5su = 0.5(65) = 32.5 ksi
For machined surface
Surface factor = 0.90
Size factor = 0.85
sn = (0.85)(0.90 )(32.5) = 24.86 ksi
M A =0
12 F = 24 B
F = 2B
F
B=
2
F
A= B=
2
At discontinuity
6F
M= = 3F
2
M max = 3(3000) in lb = 9000 in lb = 9 in kips
M min = 3(1000) in lb = 3000 in lb = 3 in kips
1
M m = (9 + 3) = 6 in kips
2
1
M a = (9 3) = 3 in kips
2
32 M
s=
D3
Figure AF 12
D d =1.5d d =1.5
r d = 0.2d d = 0.2
K t = 1.42
assume K f K t = 1.42
Page 23 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1 sm K f sa
= +
N sy sn
1 (32 )(6 ) (1.42 )(32 )(3)
= +
2 48D 3 24.86D 3
D = 1.821 in
13
say D = 1 in
16
At maximum moment
12 F
M= = 6F
2
M max = 6(3000) in lb = 18000 in lb = 18 in kips
M min = 6(1000) in lb = 6000 in lb = 6 in kips
1
M m = (18 + 6 ) = 12 in kips
2
1
M a = (18 6 ) = 6 in kips
2
32 M
s=
D3
K f = 1.00
1 sm K f sa
= +
N sy sn
1 (32 )(12 ) (1.0 )(32 )(6 )
= +
2 48D 3 24.86D 3
D = 1.4368 in
13
Therefore use D = 1 in
16
164. The shaft shown is machined from C1040, OQT 1000 F (Fig. AF 1). It is
subjected to a torque that varies from zero to 10,000 in-lb. ( F = 0 ). Let r = 0.2 D
and N = 2 . Compute D . What is the maximum torsional stress in the shaft?
Solution:
Page 24 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
smax =
(16)(5) +
(1.2)(16)(5) = 14.686 ksi
3 3
9 9
1 1
16 16
165. An axle (nonrotating) is to be machined from AISI 1144, OQT 1000 F, to the
proportions shown, with a fillet radius r 0.25 D ; F varies from 400 lb to 1200
lb.; the supports are to the left of BB not shown. Let N = 2 (Soderberg line). (a)
At the fillet, compute D and the maximum tensile stress. (b) Compute D at
section BB. (c) Specify suitable dimensions keeping the given proportions, would
a smaller diameter be permissible if the fillet were shot-peened?
Page 25 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Solution:
For AISI 1144, OQT 1000 F
su = 118 ksi
s y = 83 ksi
sn = 0.5su = 59 ksi
For machined surface
Surface factor = 0.83
Size factor = 0.85
sn = (0.85)(0.83)(59) = 41.62 ksi
Page 26 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
32 M
s=
D3
K f = 1 .0
1 sm K f sa
= +
N sy sn
1
=
(32)(36) + (1.0)(32)(12)
2 83 (1.5 D )3 41.62 (1.5 D )3
D = 1.6335 in
11
say D = 1 in
16
Solution:
Tmax = 15 in kips
Tmin = 5 in kips
1
Tm = (15 + 5) = 10 in kips
2
1
Ta = (15 5) = 5 in kips
2
For AISI 1050, OQT 1100 F
su = 101 ksi
s y = 58.5 ksi
sn = 0.5su = 0.5(101) = 50.5 ksi
Page 27 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
(b) r = D 4
r D = 0.25
D d =1.5
Figure AF 12
K ts = 1.18
K fs K ts = 1.18 < 1.6
Therefore, smaller D is not reasonable.
170. The beam shown is made of AISI C1020 steel, as rolled; e = 8 in . The load F is
repeated from zero to a maximum of 1400 lb. Assume that the stress
concentration at the point of application of F is not decisive. Determine the
depth h and width t if h 4t ; N = 1.5 0.1 for Soderberg line. Iteration is
necessary because K f depends on the dimensions. Start by assuming a logical
K f for a logical h (Fig. AF 11), with a final check of K f . Considerable
estimation inevitable.
Page 28 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Problem 170
Solution:
1
A= B= F
2
At the hole
F
M = eB = (8) = 4 F
2
M max = 4 F
M min = 0
1
M m = (4 F ) = 2 F = 2(1.4 ) = 2.8 in kips
2
1
M a = (4 F ) = 2 F = 2(1.4 ) = 2.8 in kips
2
Mc
s=
I
I=
(h 2d )3 t
12
1
d = in = 0.5 in
2
1 11
c = 1 + = 1.75 in
2 22
For AISI C1020, as rolled
su = 65 ksi
s y = 48 ksi
sn = 0.5su = 0.5(65) = 32.5 ksi
Size factor = 0.85
sn = (0.85)(32.5) = 27.62 ksi
Fig. AF 7, c d = 1.75 0.5 = 3.5 > 0.5
Page 29 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Assume K t = 3.5
1 1
r = = 0.25 in
2 2
a = 0.010 in
1 1
q= = = 0.962
a 0.010
1+ 1+
r 0.25
K f = q (K t 1) + 1 = 0.962(3.5 1) + 1 = 3.4
1 sm K f sa
= +
N sy sn
1 12(2.8)(1.75) (3.4 )(12 )(2.8)(1.75)
= +
1.5 48(h 2d )3 t 27.62(h 2d ) t
3
(h 2d )3 t = 12.70
[h 2(0.50)]3 t = 12.70
(4t 1)3 t = 12.70
t = 0.8627 in
7
say t = in
8
h = 4t = 3.5 in
1 1 1
h > 1 + 1 + in
2 2 2
h > 3.5 in
Figure AF 11, h d > 10
h = 10d = 10(0.50) = 5 in
1
d
= 2 = 0 .5
b 5 1 1
2 2
Therefore K t = 3.5 , K f = 3.4
1
Use h = 5 in , t = 1 in
4
171. Design a crank similar to that shown with a design factor of 1.6 0.16 based on
the modified Goodman line. The crank is to be forged with certain surfaces
milled as shown and two -in. holes. It is estimated that the material must be of
the order of AISI 8630, WQT 1100 F. The length L = 17 in. , a = 5 in. , and the
load varies form + 15 kips to 9 kips. (a) Compute the dimensions at section AB
with h = 3b . Check the safety of the edges (forged surfaces). (Iteration involves;
one could first make calculations for forged surfaces and then check safety at
holes.) (b) Without redesigning but otherwise considering relevant factors ,
Page 30 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
quantitatively discuss actions that might be taken to reduce the size; holes must
remain as located.
Problems 171-174.
Solution:
At AB, machined
1 sm K f sa
= +
N su sn
Figure AF 11
1
b = in = 0.5 in
2
1
d = in = 0.25 in
4
d 0.25
= in = 0.5
b 0 .5
Assume K f = 3.50
q = 0.998
K f = q (K t 1) + 1 = 0.998(3.5 1) + 1 = 3.495
Mc
s=
I
I=
(h 2d ) b
3
12
Page 31 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
h 1 1 1 1 1 1 1
c= + = h 1 + = (4h 4 + 1) = (4h 3)
2 2 2 4 2 4 8 8
h = 3b
1
M (4h 3)
s=
8
3
1
h 2 4 b
12
3
M (12b 3)
s= 2
(3b 0.5)3 b
4.5M (4b 1)
s=
(3b 0.5)3 b
M = F (L a )
M max = (15)(17 5) = 180 in kips
M min = ( 9)(17 5) = 108 in kips
1
M m = (180 108) = 36 in kips
2
1
M a = (180 + 108) = 144 in kips
2
1 sm K f sa
= +
N su sn
1 4.5(36 )(4b 1) (3.495)(4.5)(144 )(4b 1)
= +
1.6 96(3b 0.5)3 b 34.68(3b 0.5) b
3
(4b 1) = 1
(3b 0.5)3 b 107.2
(3b 0.5)3 b = 107.2
(4b 1)
b = 2.6 in
5
say b = 2 in
8
7
h = 3b = 7 in
8
Checking at the edges (as forged)
M max = (15)(17 ) = 255 in kips
M min = ( 9)(17 ) = 153 in kips
1
M m = (255 153) = 51 in kips
2
Page 32 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1
M a = (255 + 153) = 204 in kips
2
6M 6M 2 M
s= 2 = 3 = 3
bh 9b 3b
K f 1 .0
1 sm K f sa
= +
N su sn
1 2(51) (1.0)(2)(204)
= 3 +
1.6 3b (96) 3b3 (17 )
b = 2.373 in
3
say b = 2 in
8
5 3
since b = 2 in > 2 in , safe.
8 8
CHECK PROBLEMS
Solution:
s n = 72 ksi
In section AB, machined
Page 33 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
M = F (L a )
M max = (+ 5)(15 3) = 60 in kips
M min = ( 3)(15 3) = 36 in kips
1
M m = (60 36 ) = 12 in kips
2
1
M a = (60 + 36 ) = 48 in kips
2
d = h = 4.5 in , b = 1.5 in
h
=3
b
4.5M (4b 1)
s=
(3b 0.5)3 b
4.5(12 )[4(1.5) 1]
sm = = 2.8125 ksi
[3(1.5) 0.5]3 (1.5)
4.5(48)[4(1.5) 1]
sa = = 11.25 ksi
[3(1.5) 0.5]3 (1.5)
1 sm K f sa
= +
N sy sn
K f = 3.495 from Problem 171.
1 2.8125 (3.495)(11.25)
= +
N 72 34.68
N = 0.85 < 1 , unsafe
To increase the margin of safety
1. reduce the number of repetitions of loads
2. shot-peening
3. good surface roughness
Recommendation:
No. 1, reducing the number of repetitions of loads.
175. The link shown is made of AISI C1020, as rolled, machined all over. It is loaded
3 9 5
in tension by pins in the D = in holes in the ends; a = in , t = in ,
8 16 16
1
h = 1 in . Considering sections at A, B, and C, determine the maximum safe
8
axial load for N = 2 and indefinite life (a) if it is repeated and reversed; (b) if it
is repeated varying from zero to maximum; (c) if it is repeatedly varies or
F = W to F = 3W . (d) Using the results from (a) and (b), determine the ratio of
the endurance strength for a repeated load to that for a reversed load (Soderberg
line).
Page 34 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Page 35 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1 1
q= = = 0.95
a 0.01
1+ 1+
r 3
16
k fA = q ktA 1 + 1 = 0.95(3.6 1) + 1 = 3.47
( )
F F 64 F
s= = =
(h d )t 1 1 3 5 15
8 8 16
1 64 Fm 3.47(64)Fa
= +
2 15(48) 15(20)
8
1= Fm + 1.48 Fa at A
45
At B Figure AF 9
9
d = a = in
16
1
h = 1 in
8
3
r = in
16
5
t = in
16
3
r 16
= = 0.33
d 9
16
1
1
h
= 8 =2
d 9
16
K tB = 1.63
a = 0.01 in
1 1
q= = = 0.95
a 0.01
1+ 1+
r 3
16
k fB = q (ktB 1) + 1 = 0.95(1.63 1) + 1 = 1.6
F F 256 F
s= = =
dt
9 5 45
16 16
Page 36 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1 256 Fm 1.6(256)Fa
= +
2 45(48) 45(20)
32
1= Fm + 0.455 Fa at B
135
b
at C, Figure AF 8, >1
h
1
D= in
8
9
h = a = in
16
1
d
= 8 = 0.22
h 9
16
K tC = 3.5
d 1
r = = in
2 16
a = 0.01 in
1 1
q= = = 0.862
a 0.01
1+ 1+
r 1
16
k fC = q (ktC 1) + 1 = 0.862(3.5 1) + 1 = 3.2
F F 256 F
s= = =
(h d )t 9 1 5 35
16 8 16
1 256 Fm 3.2(256)Fa
= +
2 35(48) 35(20)
32
1= Fm + 1.17 Fa at C
105
Equations
8
At A, 1 = Fm + 1.48 Fa
45
32
At B, 1 = Fm + 0.455 Fa
135
32
At C, 1 = Fm + 1.17 Fa
105
Page 37 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
Fm = 0
Fa = F
use at A
8
1= Fm + 1.48 Fa
45
8
1 = (0 ) + 1.48 Fa
45
F = 0.676 kip
(b) Fm = Fa = F
8
at A, 1 = F + 1.48 F
45
F = 0.603 kip
32
at B, 1 = F + 0.455 F
135
F = 1.480 kips
32
at C, 1 = F + 1.17 F
105
F = 0.678 kip
use F = 0.603 kip
Page 38 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
F (b ) 0.603
(d) Ratio = = = 0.892
F (a ) 0.676
179. A steel rod shown, AISI 2320, hot rolled, has been machined to the following
3 1
dimensions: D = 1 in. , c = in. , e = in. A semicircular groove at the
4 8
1 1
midsection has r = in. ; for radial hole, a = in. An axial load of 5 kips is
8 4
repeated and reversed ( M = 0 ). Compute the factor of safety (Soderberg) and
make a judgement on its suitability (consider statistical variations of endurance
strength i4.4). What steps may be taken to improve the design factor?
Problems 179-183
Solution:
AISI 2320 hot-rolled (Table AT 10)
su = 96 ksi
s y = 51 ksi
sn = 48 ksi
Size factor = 0.85
Surface factor = 0.85 (machined)
sn = (0.80)(0.85)(0.85)(48) = 27.74 ksi
1 sm K f sa
= +
N sy sn
sm = 0 , reversed
sa = s
1 K f sa
=
N sn
s
sa = n
NK f
at the fillet, Figure AF 12
1
r = e = in
8
Page 39 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
3
d =c= in
4
D = 1 in
1
r 8
= = 0.17
d 3
4
D 1
= = 1.3
d 3
4
K t = 1.55
a = 0.010 in
1 1
q= = = 0.926
a 0.010
1+ 1+
r 1
8
K f = q (K t 1) + 1 = 0.926(1.55 1) + 1 = 1.51
4(5)
sa = s = 2
= 11.32 ksi
3
4
sn 27.74
N= = = 1.62
sa K f (11.32)(1.51)
Page 40 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1 1
q= = = 0.926
a 0.010
1+ 1+
r 1
8
K f = q K t 1 + 1 = 0.926(1.75 1) + 1 = 1.7
( )
4F 4(5)
sa = s = 2
= 2
= 11.32 ksi
d 3
4
s 27.74
N= n = = 1.44
sa K f (11.32)(1.7 )
Steps to be taken:
1. Reduce number of cycle to failure
Page 41 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
186. A stock stud that supports a roller follower on a needle bearing for a cam is
5 7 3
made as shown, where a = in , b = in , c = in . The nature of the junction
8 16 4
of the diameters at B is not defined. Assume that the inside corner is sharp. The
material of the stud is AISI 2317, OQT 1000 F. Estimate the safe, repeated load
F for N = 2 . The radial capacity of the needle bearing is given as 1170 lb. at
2000 rpm for a 2500-hr life. See Fig. 20.9, p. 532, Text.
Problem 186
Solution:
AISI 2317, OQT 1000 F
su = 106 ksi
s y = 71 ksi
sn = 0.5su = 53 ksi
Size factor = 0.85
sn = (0.85)(53) = 45 ksi
Figure AF 12
5
d = a = in
8
3
D = c = in
4
r d 0 , sharp corner
3
D 4
= = 1.2
d 5
8
Assume K t = 2.7
K f K t = 2 .7
32 M
s=
a3
7
M = Fb = F = 0.4375 F
16
Page 42 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
5
a= in = 0.625 in
8
32(0.4375)F
s= = 18.25 F
(0.625)3
sm = sa = s = 18.25F
1 sm K f sa
= +
N sy sn
1 18.25 F (2.7 )(18.25 F )
= +
2 71 45
F = 0.370 kip = 370 lb < less than radial capacity of the needle bearing. Ok.
187. The link shown is made of AISI C1035 steel, as rolled, with the following
3 7 1 1
dimensions a = in. , b = in. , c = 1 in. , d = in. , L = 12 in. , r = in. The
8 8 2 16
axial load F varies from 3000 lb to 5000 lb and is applied by pins in the holes.
(a) What are the factors of safety at points A, B, and C if the link is machined all
over? What are the maximum stresses at these points?
Page 43 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
(a) at A, Figure AF 9
1
r = in
16
3
d = a = in
8
7
h = b = in
8
1
r 16
= = 0.17
d 3
8
7
h 8
= = 2.33
d 3
8
K t = 1.9
a = 0.010 in
1 1
q= = = 0.862
a 0.010
1+ 1+
r 1
16
K f = q(K t 1) + 1 = 0.862(1.9 1) + 1 = 1.78
F
s=
ac
4
sm = = 10.67 ksi
3
(1)
8
1
sa = = 2.67 ksi
3
(1)
8
1 10.67 (1.78)(2.67 )
= +
N 55 21.68
N = 2.42
At B, same as A, K f = 1.78
F
s=
(b a )c
4
sm = = 8 ksi
7 3
(1)
8 8
Page 44 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1
sa = = 2 ksi
7 3
(1)
8 8
1 8 (1.78)(2 )
= +
N 55 21.68
N = 3.23
At C, Figure AF 8
1
d = in
2
h = c = 1 in
b h >1
1
d 2
= = 0.5
h 1
K t = 2.2
a = 0.010 in
d 1
r = = in = 0.25 in
2 4
1 1
q= = = 0.962
a 0.010
1+ 1+
r 0.25
K f = q(K t 1) + 1 = 0.962(2.2 1) + 1 = 2.15
F
s=
(b a )(c d )
4
sm = = 16 ksi
7 3 1
1
8 8 2
1
sm = = 4 ksi
7 3 1
1
8 8 2
1 16 (2.15)(4 )
= +
N 55 21.68
N = 1.45
at A
s A = sm + K f sa = 10.67 + 1.78(2.67 ) = 15.42 ksi
at B
sB = sm + K f sa = 8 + 1.78(2 ) = 11.56 ksi
Page 45 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
at C
sC = sm + K f sa = 16 + 2.15(4 ) = 24.6 ksi
IMPACT PROBLEMS
189. A wrought-iron bar is 1in. in diameter and 5 ft. long. (a) What will be the stress
and elongation if the bar supports a static load of 5000 lb? Compute the stress
and elongation if a 5000 lb. weight falls freely 0.05 in. and strikes a stop at the
end of the bar. (b) The same as (a), except that the bar is aluminum alloy 3003-
H14.
Solution:
D = 1 in. , L = 5 ft
For wrought iron,
E = 28 106 psi
(a) elongation
F = 5000 lb
=
FL
=
(5000)(5)(12) = 0.01364 in
AE
4
(
(1)2 28 106 )
Stress and elongation
h = 0.05 in
W = 5000 lb
L = 5 ft = 60 in
1
W W 2hEA 2
s = + 1 +
A A LW
1
6 2
2
5000 5000
2(0.05 ) (
28 10 )
(1)
s= + 1 + 4 = 24,741 psi
2 2
(1) (1) (60)(5000)
4 4
sL (24,741)(60 )
= = = 0.053 in
E 28 106
=
FL
=
(5000)(5)(12) = 0.038 in
AE (1)2 10 106
( )
4
Stress and elongation
h = 0.05 in
Page 46 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
W = 5000 lb
L = 5 ft = 60 in
1
W W 2hEA 2
s = + 1 +
A A LW
1
6 2
2
5000 5000
2(0.05 ) 10 (
10 ) (1)
s= + 1 + 4 = 18,475 psi
2 2
(1) (1) (60)(5000)
4 4
sL (18,475)(60 )
= = = 0.111 in
E 10 106
190. What should be the diameter of a rod 5 ft. long, made of an aluminum alloy
2024-T4, if it is to resist the impact of a weight of W = 500 lb dropped through a
distance of 2 in.? The maximum computed stress is to be 20 ksi.
Solution:
For aluminum alloy, 2024-T4
E = 10.6 106 psi
W = 500 lb
h = 2 in
L = 5 ft = 60 in
s = 20 ksi = 20,000 psi
1
W W 2hEA 2
s = + 1 +
A A LW
1
20,000 = + 1+
(
5000 5000 2(2 ) 10.6 106 A 2 )
A A (60)(500)
1
40 A = 1 + (1 + 1413 A)2
D 2
A= = 0.9332
4
1
D = 1.09 in , say D = 1 in
16
191. A rock drill has the heads of the cylinder bolted on by 7/8-in. bolts somewhat as
shown. The grip of the bolt is 4 in. (a) If the shank of the bolt is turned down to
the minor diameter of the coarse-thread screw, 0.7387 in., what energy may each
bolt absorb if the stress is not to exceed 25 ksi? (b) Short bolts used as described
above sometimes fail under repeated shock loads. It was found in one instance
that if long bolts, running from head to head, were used, service failures were
eliminated. How much more energy will the bolt 21 in. long absorb for a stress of
Page 47 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
25 ksi. That the bolt 4 in. long? As before, let the bolt be turned down to the
minor diameter. The effect of the threads on the strength is to be neglected.
Problem 191
Solution:
s2 2
U= ( AL ) = s AL
2E 2E
2
D
(a) A =
4
L = 4 in
D = 0.7387 in
E = 30106 psi
s = 25 ksi = 25,000 psi
192. As seen in the figure, an 8.05-lb body A moving down with a constant
acceleration of 12 fps2, having started from rest at point C. If A is attached to a
steel wire, W & M gage 8 (0.162 in. diameter) and if for some reason the sheave
D is instantly stopped, what stress is induced in the wire?
Page 48 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
s 2 AL
= maL
2E
2maE 2WaE
s2 = =
A gA
W = 8.05 lb
a = 12 fps 2
g = 32 fps 2
b = 12 fps 2
E = 30106 psi
D 2
A=
4
8WaE 8(8.05)(12)(30 106 )
s2 = =
D 2 g (0.162)2 (32)
s = 93,741 psi
193. The hoist A shown, weighing 5000 lb. and moving at a constant v = 4 fps is
attached to a 2 in. wire rope that has a metal area of 1.6 sq. in. and a modulus
E = 12 106 psi . When h = 100 ft , the sheave D is instantly stopped by a brake
(since this is impossible, it represents the worst conceivable condition).
Assuming that the stretching is elastic, compute the maximum stress in the rope.
Solution:
s 2 AL
U=
2E
1 W 2
U = mv 2 = v
2 2g
s 2 AL W 2
= v
2E 2g
Wv 2 E
s2 =
gAL
W = 5000 lb
Page 49 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
v = 4 fps
E = 12 106 psi
A = 1.6 in 2
L = h = 100 ft
g = 32 fps 2
s2 =
(5000)(4)2 (12 106 )
(32)(1.6)(100)
s = 13,693 psi
194. A coarse-thread steel bolt, in. in diameter, with 2 in. of threaded and 3 in. of
unthreaded shank, receives an impact caused by a falling 500-lb weight. The area
at the root of the thread is 0.334 sq. in. and the effects of threads are to be
neglected. (a) What amount of energy in in-lb. could be absorbed if the maximum
calculated stress is 10 ksi? (b) From what distance h could the weight be
dropped for this maximum stress? (c) How much energy could be absorbed at the
same maximum stress if the unthreaded shank were turned down to the root
diameter.
Solution:
s 2 AL
U=
2E
(a) U = U1 + U 2
s12 A1L1
U1 =
2E
2
s AL
U2 = 2 2 2
2E
A1 = 0.334 in 2
A2 = (0.75) = 0.442 in 2
4
s1 = 10,000 psi
s A (10,000 )(0.334 )
s2 = 1 1 = = 7556 psi
A2 0.442
L1 = 2 in
L2 = 3 in
E = 30 10 6 psi
U1 =
(10,000)2 (0.334)(2) = 1.113 in lb
2(30 106 )
U2 =
(7556)2 (0.442)(3) = 1.262 in lb
2(30 106 )
Page 50 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1
W 2hEA 2
(b) s = 1 + 1 +
A LW
1
2
W 2hE
s = 1 + 1 +
A1 L L
W 1 + 2
A1 A2
1
W 2hEA1 A2 2
s = 1 + 1 +
A1 W ( A2 L1 + A1L2 )
W = 500 lb
A1 = 0.334 in 2
A2 = 0.442 in 2
L1 = 2 in
L2 = 3 in
E = 30106 psi
s = 10,000 psi
1
10,000 =
500
1 + 1 +
( )
2h 30 106 (0.334 )(0.442 ) 2
0.334 500[(0.442 )(2 ) + (0.334 )(3)]
h = 0.0033 in
s 2 AL
(c) U =
2E
A = 0.334 in 2
L = 5 in
E = 30106 psi
s = 10,000 psi
U=
(10,000) (0.334)(5)
2
= 2.783 in lb
2(30 106 )
196. A part of a machine that weighs 1000 lb. raised and lowered by 1 -in. steel rod
that has Acme threads on one end (see i8.18 Text, for minor diameter). The
length of the rod is 10 ft. and the upper 4 ft are threaded. As the part being
Page 51 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
lowered it sticks, then falls freely a distance of 1/8 in. (a) Compute the maximum
stress in the rod. (b) What would be the maximum stress in the rod if the lower
end had been turned down to the root diameter?
Solution:
1
W 2hEA 2
s= 1 + 1 +
A LW
1
2
W 2hE
s = 1 + 1 +
A1 L L
W 1 + 2
A1 A2
1
W 2hEA1 A2 2
s = 1 + 1 +
A1 W ( A2 L1 + A1L2 )
1
see i8.18 , D2 = 1 in , D1 = 1.25 in
2
(1.25) 2
A1 = = 1.227 in 2
4
(1.5)2
A2 = = 1.767 in 2
4
L1 = 4 in
L2 = 6 in
1
h = in = 0.125 in
8
W = 1000 lb
E = 30106 psi
1
s=
1000
1 + 1 +
( )
2(0.125) 30 106 (1.227 )(1.767 ) 2
= 28,186 psi
1.227 1000[(1.767 )(4 ) + (1.227 )(6 )]
1
W 2hEA 2
(b) s = 1 + 1 +
A LW
2
A = A1 = 1.227 in
L = L1 + L2 = 10 in
Page 52 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
s=
1000
1 + 1 +
( )
2(0.125) 30 106 (1.227 ) 2
= 25,552 psi
1.227 10(1000 )
Solution:
1
2
Wv E2
s=
g AL1 + We
o W
W
We = b
3
Wb = AL
= 0.284 lb in3
2
3 2
A= = 0.442 in
4 4
L = 6 ft = 72 in
Wb = (0.284)(0.442)(72) = 9.038 lb
9.038
We = = 3.013 lb
3
W = 50 lb
v = 2 fps
g o = 32 fps 2
E = 30106 psi
L = 6 ft
1
2
(50)(2) (30 10 ) = 8166 psi
2 6
s=
(32)(0.442)(6)1 + 3.013
50
For AISI 1010, cold drawn
s y = 55 ksi = 55,000 psi
s y 55,000
N= = = 6.74
s 8166
Page 53 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
199. A rigid weight of 100 lb is dropped a distance of 25 in. upon the center of a 12
in., 50-lb. I-beam ( I x = 301.6 in 4 ) that is simply supported on supports 10 ft
apart. Compute the maximum stress in the I-beam both with and without
allowing for the beams weight.
Solution:
yst =
WL3
=
(100)(120) 3
= 0.0004 in
48EI 48(30 106 )(301.6)
Mc
sst =
I
WL (100 )(120 )
M= = = 3000 in lb
4 4
h 12
c= = = 6 in
2 2
sst =
(3000)(6) = 59.68 psi
301.6
0.1415
s = (59.68) = 21,112 psi
0.0004
Page 54 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
201. A 3000 lb. automobile (here considered rigid) strikes the midpoint of a guard rail
that is an 8-in. 23-lb. I-beam, 40 ft. long; I = 64.2 in4 . Made of AISI C1020, as
rolled, the I-beam is simply supported on rigid posts at its ends. (a) What level
velocity of the automobile results in stressing the I-beam to the tensile yield
strength? Compare results observed by including and neglecting the beams
mass.
Solution:
For AISI C1020, as rolled
s y = 48 ksi = 48,000 psi
F Wv 2
=
2 2 go
F 48 EI
k= = 3
L
Mc FLc
s= =
I 4I
4 Is
F=
Lc
F F 2 L3 16 I 2 s 2 L3 s 2 IL
= = 2 2 =
2 96 EI L c (96 EI ) 6 Ec 2
Page 55 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
s = (48,000 ) =
2 2
=
( )
3Wv 2 Ec 2 3(3000 )v 2 30 106 (4 )
2
2 g o IL 32(64.2 )(40 )
v = 6.62 fps
Including mass of beam
2
2
3Wv Ec 1
s2 =
2 g o IL 1 + We
W
17Wb
We =
35
Wb = (23 lb ft )(40 ft ) = 920 lb
17(920 )
We = = 447 lb
35
s 2 = (48,000) =
2 3Wv 2
Ec 2
=
3(3000 )v 2
(30 10 6
)(4 )2
1
447
2 go IL 32(64.2)(40) 1 +
3000
v = 7.10 fps
202. A simple beam is struck midway between supports by a 32.2-lb. weight that has
fallen 20 in. The length of the beam is 12 ft. If the stress is not to exceed 20 ksi,
what size I-beam should be used?
Solution:
Page 56 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1
2h 2
y = yst + yst 1 +
yst
y
s = sst
yst
h = 20 in
s = 20,000 psi
WL3
yst =
48EI
1
y 96 EIh 2
= 1 + 1 +
yst WL3
with correction factor
1
2
y 96 EIh 1
= 1 + 1 +
yst WL 3
We
1+
W
Mc WLd
sst = =
I 8I
17 wL
We =
35
1
2
WLd 96 EIh 1
s= 1 + 1 +
8I WL3 1 + 17 wL
35W
W = 32.2 lb
h = 20 in
L = 12 ft = 144 in
E = 30106 psi
1
2
(32.2)(144)d 96 30 106 (I )(20)
( ) 1
1 + 1 +
(32.2)(144)3 1 + 17(w)(12)
s=
8I
35(32.2)
1
579.6d 1 2
s= 1 + 1 + 599 I
I 1 + 0.181w
From The Engineers Manual
By Ralph G. Hudson, S.B.
Page 57 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
204. A 10-in., 25.4-lb.., I-bean, AISI 1020, as rolled, is 10 ft. long and is simply
supported at the ends shown. There is a static load of F1 = 10 kips , 4 ft from the
left end, and a repeated reversed load of F2 = 10 kips , 3 ft from the right end. It is
desired to make two attachments to the beam through holes as shown. No
significant load is supported by these attachments, but the holes cause stress
concentration. Will it be safe to make these attachments as planned? Determine
the factor of safety at the point of maximum moment and at points of stress
concentration.
Problem 204
Solution:
Mass of beam negligible
For AISI C1020, as rolled
s y = 48 ksi
su = 65 ksi
( M A = 0)
4 F1 + (10 3)F2 = 10 B
1
B = (4 F1 + 7 F2 )
10
( M B = 0)
3F2 + (10 4)F1 = 10 A
1
A = (6 F1 + 3F2 )
10
F1 = 10 kips
F2 = 10 to 10 kips
1
Bmin = [4(10 ) + 7( 10 )] = 3 kips
10
Page 58 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
1
Bmax = [4(10) + 7(10)] = 11 kips
10
1
Amin = [6(10 ) + 3( 10 )] = 3 kips
10
1
Amax = [6(10 ) + 7(30 )] = 9 kips
10
Figure AF 11,
1
e = 1 in ,
2
1
d = in
4
1 1
c = 1 + 2 = 1.625 in
2 4
h = 10 in
h 10 1
b = e = 1 = 3.5 in
2 2 2
d 0.25
= = 0.07
b 3 .5
e 1.50
= = 6 > 0 .5
d 0.25
Use K t = 3.0
1
q= = 0.926
0.010
1+
1
8
K f = q (K t 1) + 1 = 0.926(3 1) + 1 = 2.85
sn = 0.5su = 0.5(65) = 32.5 ksi
size factor = 0.85
sn = 0.85(32.5) = 27.6 ksi
left hole, M = (2)A
M max = 2(9) = 18 ft kips
M min = 2(3) = 6 ft kips
Mc
s=
I
1
M m = (18 + 6 ) = 12 ft kips = 144 in kips
2
1
M a = (18 6 ) = 6 ft kips = 72 in kips
2
c = 1.625 in
I = 122.1 in 4 (Tables)
Page 59 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
sm =
(144)(1.625) = 1.92 ksi
122.1
sa =
(72 )(1.625) = 0.96 ksi
122.1
1 sm K f sa
= +
N sy sn
1 1.92 (2.85)(0.96 )
= +
N 48 27.6
N = 7 .2
at maximum moment, or at , F2
M max = 3(11) = 33 ft kips
M min = 3( 3) = 9 ft kips
Mc
s=
I
1
M m = (33 9 ) = 12 ft kips = 144 in kips
2
1
M a = (33 + 9 ) = 21 ft kips = 252 in kips
2
Page 60 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
10
c= = 5 in
2
I = 122.1 in 4 (Tables)
sm =
(144)(5) = 5.90 ksi
122.1
sa =
( 252 )(5)
= 10.32 ksi
122.1
K f = 1 .0
1 sm K f sa
= +
N sy sn
1 5.90 (1.0 )(10.32 )
= +
N 48 27.6
N =2
Since the design factor at the holes is much larger than at the point of maximum moment,
it is safe to make these attachment as planned.
205. The runway of a crane consists of L = 20 ft. lengths of 15-in., 42.9-lb. I-beams,
as shown, each section being supported at its ends; AISI C1020, as rolled. The
wheels of the crane are 9 ft apart, and the maximum load expected is
F = 10,000 lb on each wheel. Neglecting the weight of the beam, find the design
factor (a) based on variable stresses for 105 cycles, (b) based on the ultimate
strength. (Hint. Since the maximum moment will occur under the wheel, assume
the wheels at some distance x from the point of support, and determine the
dM
reaction, R1 as a function of x ; = 0 gives position for a maximum bending
dx
moment.)
Problem 205.
Solution:
( M R2 = 0 )
(L x )F + (L x a )F = LR1
R =
(2 L 2 x a )F
1
L
x
M = R1 x = (2 L 2 x a )F
L
Page 61 of 62
SECTION 2 VARYING LOADS AND STRESS CONCENTRATIONS
dM F
= [(2 L 2 x a ) + x( 2 )] = 0
dx L
2L 2x a 2x = 0
1 a
x = L
2 2
2
a a
L L F
M max = 2 2 L L a a F = 2
L 2 2L
L = 20 ft = 240 in
a = 9 ft = 108 in
F = 10,000 lb = 10 kips
2
108
240 (10 )
M max = 2
= 720.75 in kips
2(240 )
For 15-in., 42.9 lb, I-beam
I = 441.8 in4
15
c = = 7.5 in
2
Mc (720.75)(7.5)
smax = = = 12.24 ksi
I 441.8
For AISI C1029, as rolled
su = 65 ksi
sn = 0.5su = 32.5 ksi
size factor = 0.85
sn = 0.85(32.5) = 27.6 ksi
su 65
(b) N = = = 5.31
s 12.24
- end -
Page 62 of 62
SECTION 3 SCREW FASTENINGS
DESIGN PROBLEMS
221. A 5000-lb. gear box is provided with a steel (as rolled B1113) eyebolt for use
in moving it. What size bolt should be used: (a) if UNC threads are used? (b)
If UNF threads are used? (c) If the 8-thread series is used? Explain the basis
of your choice of design factor.
Solution:
B1113, as rolled
s y = 45 ksi (Table AT-7)
Fe = 5000 lb
sy 1 3
i5.6, sd = ( As ) 2 D < in
6 4
3
For D = in
4
As 0.35 sq.in.
sy 1
sd = (0.35) 2
6
sy
sd =
10
use design factor = 10
45,000 psi
sd =
10
sd = 4500 psi
Fe 5000
As = = = 1.111 sq.in.
sd 4500
3
Use D = 1 in , As = 1.155 sq.in.
8
Page 1 of 42
SECTION 3 SCREW FASTENINGS
3
Use D = 1 in , As = 1.155 sq.in.
8
3
Use D = 1 in , As = 1.233 sq.in.
8
222. A motor weighing 2 tons is lifted by a wrought-iron eye bolt which is screwed
into the frame. Decide upon a design factor and determine the size of the
eyebolt if (a) UNC threads are used, (b) UNF threads are used. Note: Fine
threads are not recommended for brittle materials.
Solution:
Table AT-7
Wrought iron, s y = 25 ksi
sy
sd =
10
25,000 psi
sd =
10
sd = 2500 psi
Fe 2(2000 )
As = = = 1.60 sq.in.
sd 2500
Table AT 17
3
Use D = 1 in , As = 1.90 sq.in.
4
1
Use D = 1 in , As = 1.581 sq.in.
2
Page 2 of 42
SECTION 3 SCREW FASTENINGS
224. A wall bracket, Fig. 8-13, Text, is loaded so that the two top bolts that fasten it
to the wall are each subjected to a tensile load of 710 lb. The bolts are to be
cold forged from AISI C1020 steel with UNC threads, Neglecting the effect of
shearing stresses, determine the diameter of these bolts if they are well
tightened.
Figure 8-13
Solution:
9
Use D = in , As = 0.1820 sq.in.
16
Page 3 of 42
SECTION 3 SCREW FASTENINGS
if si = 0.85s y (i5.8).
Figure 5.9
Solution:
Cold-finished AISI B1113
Table A-7, s y = 72 ksi
Fe = 1250 lb
sy 3
(a) Fe = ( As ) 2
6
72,000 3
1250 = ( As ) 2
6
3
As = 0.2214 sq.in. , D <
in
4
Table AT 14 , UNC Threads
5
Use D = in , As = 0.2260 sq.in.
8
Page 4 of 42
SECTION 3 SCREW FASTENINGS
5
T = 0.2 DFi = 0.2 (13,831) = 1729 in lb
8
Solution:
Table 5.2
SAE Grade 5
Assume s y = 88 ksi
200 (10)
2
(a) Fe = 4 = 1571 lb
10
s 3 3
Fe = y ( As ) 2 , D < in
6 4
88,000 3
1571 = ( As ) 2
6
3
As = 0.2255 sq.in. , D < in
4
Table AT 14 , UNC Threads
5
Use D = in , As = 0.2260 sq.in.
8
(b) T = CDFi
C = 0 .2
si = 0.9 s p
s p = 85 ksi , (Table 5.2)
si = 0.9(85,000 ) = 76,500 psi
Fi = si As = (76,500 )(0.2260 ) = 17,289 lb
Tightening torque
5
T = 0.2 DFi = 0.2 (17,289 ) = 2161 in lb
8
227. The American Steel Flange Standard specifies that 8 bolts are to be used on
flanges for 4-in. pipe where the steam or water pressure is 1500 psi. It is also
specified that, in calculating the bolt load, the outside diameter of the gasket,
which is 6 3/16 in., should be used. Determine (a) the diameter of the UNC bolts
if they are well-tightened and made of ASTM 354 BD (Table 5-2), (b) the
approximate torque to tighten the nuts if the initial stress is 90 % of the proof
Page 5 of 42
SECTION 3 SCREW FASTENINGS
stress. The Standard specifies that 1 1/4 in. bolts with 8 th./in. be used (these
bolts are also subjected to bending). How does your answer compare?
Solution:
sy 3 3
(a) Fe = ( As ) 2 , D< in
6 4
125,000 3
5638 = ( As ) 2
6
3
As = 0.4184 sq.in. , D <
in
4
Table AT 14 , UNC Threads
7
Use D = in , As = 0.4620 sq.in.
8
3
D> in
4
use
sd = (1 0.85)s y = 0.15(125,000 ) = 18,750 psi
Fe 5638
As = = = 0.3007 sq.in.
sd 18,750
Table AT 14 , UNC Threads
3
Use D = in , As = 0.334 sq.in.
8
(b) T = 0.2 DFi
si = 0.9 s p
si = 0.9(120,000 ) = 108,000 psi
Page 6 of 42
SECTION 3 SCREW FASTENINGS
1
D < 1 in as specified by the standard.
4
CHECK PROBLEMS
228. A cap screw, in.-10-UNC-2, with a hexagonal head that is 9/16 in. thick,
carries a tensile load of 3000 lb. If the material is AISI 1015, cold drawn, find
the factor of safety based on ultimate strengths of (a) the threaded shank, (b)
the head against being sheared off, and (c) the bearing surface under the head.
(d) Is there any need to consider the strength of standard cap-screw heads in
design?
Solution:
For in. UNC, Table AT 14,
As = 0.334 sq.in.
Head:
1
A = 1 in.
8
F 3000
(a) s == = 8982 psi
As 0.334
s 77,000
N= u = = 8.57
sd 8982
F
(b) ss =
Dt
9
t= in
16
3000
ss = = 2264 psi
3 9
4 16
s 58,000
N = us = = 25.6
ss 2264
Page 7 of 42
SECTION 3 SCREW FASTENINGS
360o
(c) = = 30 o
12
2
1
1
1 A A 1 8
Area = 6(2 ) tan = 6(2 ) tan 30 = 1.096 sq.in.
2 2 2 2 2
F 3000
sb = = 2
= 4586 psi
Area Ab 3
1.096
4 4
s 77,000
N= u = = 16.8
sb 4586
(d) No need to consider the strength of standard cap-screw heads since its factor of
safety is very much higher than for the threaded shank.
229. A bolt, 1 1/8 in.-7-UNC-2, is subjected to a tensile load of 10,000 lb. The head
has a thickness of in. and the nut a thickness of 1 in. If the material is SAE
grade 2 (Table 5.2), find the design factor as based on ultimate stresses (a) of
the threaded shank, (b) of the head against being sheared off, and (c) of the
bearing surface under the head. The bolt head is finished. (d) Is there any need
to consider the strength of standard bolt heads in design?
Solution:
1
For SAE grade 2 (Table 5.2), D = 1 in
8
su = 55 ksi , sus = 0.75su
For 1 1/8 in.-7-UNC-2 (Table AT 14)
As = 0.763 sq.in.
11
A =1 in
16
F = 10,000 lb.
Page 8 of 42
SECTION 3 SCREW FASTENINGS
F 10,000
(a) s == = 13,106 psi
As 0.763
s 55,000
N= u = = 4 .2
sd 13,106
F
(b) ss =
Dt
3
t= in
4
10,000
ss = = 3773 psi
1 3
1
8 4
s 0.75(55,000 )
N = us = = 11
ss 3773
360o
(c) = = 30 o
12
2
11
1
1 A A
1
Area = 6(2 ) tan = 6(2 ) 16 tan 30 = 2.4661 sq.in.
2 2 2 2 2
F 10,000
sb = = 2
= 6793 psi
Area Ab 1
2.4661 1
4 8
s 55,000
N= u = = 8 .1
sb 6793
(d) No need to consider the strength of standard bolt head in design since its factor of
safety is higher than for the threaded shank.
230. An axial force is applied to a regular nut which of course tends to shear the
threads on the screw. (a) What is the ratio of the force necessary to shear the
threads (all threads initially in intimate contact) to the force necessary to pull
the bolt in two? Use coarse threads, a 1 -in. bolt, and assume that
sus = 0.75su . The head thickness is 1 in. and the nut thickness is 1 5/16 in. (b)
Is failure of the thread by shear likely in this bolt?
Page 9 of 42
SECTION 3 SCREW FASTENINGS
Solution:
1 - in. UNC
As = 1.405 sq.in.
231. For bolted structural joints, specifications suggest that -in. bolts (high-
strength material) be tightened to an initial tension of Fi = 12,500 lb . What
should be the approximate tightening torque? How does your answer compare
with T = 90 ft lb ., which is the value in the specification?
Solution:
1
T = 0.2 DFi = 0.2 (12,500 ) = 1250 in lb
2
232. One method of estimating the initial tensile stress in a tightened bolt is to turn
the nut until it is snug, but with no significant stress in the bolt. Then the nut is
turned through a predetermined angle that induces a certain unit strain
corresponding to the desired stress. A - in. bolt of the type shown in Fig.
5.4, Text, is turned down until, for practical purposes, the diameter of the
entire shank is the minor diameter. The material is AISI 4140, OQT 1200 oF.
The grip is 5 in. and the effective strain length is estimated to be 5.3 in. If the
initial tensile stress at the root diameter is to be about 75 % of the yield
strength, through what angle should the nut be turned after it is just snug? The
threads are UNC and the parts being bolted are assumed to be rigid.
Solution:
Page 10 of 42
SECTION 3 SCREW FASTENINGS
sL
=
E
L = 5.3 in
1
pitch, p = in = 0.10 in
10
=
p
(360o )
sL
=
pE
(360o )
=
(86,250)(5.3) (360o ) = 55o
(0.10)(30 106 )
233. When both ends of a bolt are accessible for micrometer measurements, the
total elongation caused by tightening can be determined by measuring
lengths before and after tightening. In order to reduce this total elongation to
unit elongation, thence to stress, the effective strain length for the bolt must be
known. For a 1 -in steel bolt, threaded for its full length, 8-thread series, the
effective strain length has been found by experiment to be
Le = 0.97G + 1.1 in. , where G is the grip (by W.A. McDonald, North
Carolina State College). Let the bolt material be AISI 8742, OQT 1000 oF. (a)
It is desired that the initial tensile stress be about 0.7 s y . What total elongation
should be obtained for a grip length of 4.8 in.? (b) Investigate the approximate
tightening torque for the specified condition. How could this torque be
obtained?
Solution:
1 in., 8-thread series
Table 5.1
Page 11 of 42
SECTION 3 SCREW FASTENINGS
Dr = 1.0966 in
As = 1.000 sq.in.
Th in. = 8
AISI 8742, OQT 1000 oF
s y = 147 ksi
(a) si = 0.70 s y
si = 0.70(147 ) = 102.9 ksi = 102,900 psi
si Le
=
E
Le = 0.97G + 1.1 in.
G = 4.8 in
Le = 0.97(4.8) + 1.1 in. = 5.756 in
si Le (102,900 )(5.756 )
= = = 0.01975 in
E 30 10 6
64TL
(b) = =
p Dr4G
G = 11.5 106 psi
1
p = in = 0.125 in
8
0.01975 64T (5.756 )
= =
0.125 (1.0966 )4 (11.5 106 )
T = 22,408 in lb
ELASTIC CONSIDERATIONS
Page 12 of 42
SECTION 3 SCREW FASTENINGS
Page 13 of 42
SECTION 3 SCREW FASTENINGS
1 2 1
De = 1 + = 2 in.
2 2 2
Ac = De2 D2
4 4
Ac =
4
[(2.5) (1) ] = 4.1234 sq.in.
2
2
c =
Fi L
=
(15,000)(2) = 0.000686 in.
Ac Ec (4.1234 ) 10.6 10 6( )
(b) Fe = 5000 lb
kb b
= 5000
0.000686
Fb = Fe = Fe
kb + k c b + c 0.000686 + 0.00127
Fb = 1754 lb
Bolt:
Ft = Fi + Fb = 15,000 + 1754 = 16,754 lb
F 16,754
sb = t = = 29,132 psi
As 0.606
Member B and C
kc
Fc = Fi Fe
kb + kc
c
Fc = Fi Fe
b + c
0.00127
Fc = 15,000 5000 = 11,754 lb
0.00127 + 0.000686
F 11,754
sc = c = = 2851 psi
Ac 4.1234
(c) Fo = opening load
+ c
= 15,000
0.00127 + 0.000686
Fo = Fi i = 23,102 lb
i 0.00127
Fig. 5.6
Page 14 of 42
SECTION 3 SCREW FASTENINGS
237. A 1-in. steel bolt is used to clamp two aluminum (2014-T6, HT aged) plates
together as shown by Fig. 5.9, Text. The aluminum plates have a total
thickness of 2 in. and an equivalent diameter of 2 in. The bolt is heated to a
temperature of 200 oF, the inserted in the aluminum plates, which are at 80 oF,
and tightened so as to have a tensile tightening stress of 30 ksi in the
unthreaded shank while steel at 200 oF. What is the tensile stress in the bolt
after assembly has cooled to 80 oF? The deformations are elastic.
Figure 5.9
Solution:
For aluminum 2014-T6
E = 10.6 106 psi
sb = 30,000 psi
2
Fi = sb Ab = (30,000 ) (1) = 23,562 lb
4
Fi L
c = .
Ac E c
Ac = De2 D 2
4 4
4
[ 2 2
]
Ac = (2 ) (1) = 2.3562 sq.in.
Page 15 of 42
SECTION 3 SCREW FASTENINGS
E c = 10.6 10 6 psi
c = i =
FL (23,562)(2) = 0.001887 in
( )
Ac Ec (2.3562 ) 10.6 10 6
L = L c = 2 0.001887 = 1.998113 in.
L = Lt
= 0.000007 in. (in. F ) for steel
L = (0.000007 )(1.998113)(80 200) = 0.001678 in.
i = i + L = 0.002 0.001678 = 0.000322 in.
s L
i = b
Eb
s (2 )
0.000322 = b 6
30 10
sb = 4830 psi
238. A 1 1/8-in. steel bolt A passes through a yellow brass (B36-8) tube B as
shown. The length of the tube is 30 in. (virtually the unthreaded bolt length),
the threads on the bolt are UNC, and the tubes cross-sectional area is 2 sq. in.
After the nut is snug it is tightened turn. (a) What normal stresses will be
produced in the bolt and in the tube? Assume that washers, nut, and head are
rigid. (b) What are the stresses if an axial load of 5 kips is now applied to the
bolts end? Compute the bolt load that just results in a zero stress in the tube.
Prob. 238
Solution:
For Yellow brass, B36-8,
E = 15 106 psi
Steel bolt
E = 30 106 psi
Table AT 14, 1 1/8 in., UNC
Dr = 0.9497 in.
As = 0.763 sq.in.
Th in = 7
Page 16 of 42
SECTION 3 SCREW FASTENINGS
L = 30 in.
i
=
p
1
p = in.
7
1
= turn
4
1 1 1
i = = in.
4 7 28
FL
i = i
Ab Eb
1 Fi (30 )
=
28 1 2
1 (30 10 )
6
4 8
Fi = 35,500 lb
Fi 35,500
(a) Bolt: sb = = = 46,527 psi
As 0.763
Fi
Tube: sc =
Ac
Ac = 2 sq.in.
F 35,500
sc = i = = 17,750 psi
Ac 2
(b) Fe = 5000 lb
Ac Ec (2)(15 106 )
kc = = = 1,000,000 lb in
L 30
2
1
1 (30 10 )
6
kb = b b =
AE 4 8
= 994,000 lb in
L 30
Bolts:
kb
Ft = Fi + Fe
kb + k c
994,000
Ft = 35,500 + (5000 ) = 38,000 lb
994,000 + 1,000,000
F 38,000
st = t = = 49,800 psi
As 0.763
Page 17 of 42
SECTION 3 SCREW FASTENINGS
Tube:
kc
Fc = Fi Fe
k +
b c k
1,000,000
Fc = 35,500 (5000) = 33,000 lb
994,000 + 1,000,000
F 33,000
sc = c = = 16,500 psi
Ac 2
For zero stress in the tube
k +k 994,000 + 1,000,000
Fo = b c Fi = (35,500) = 70,787 lb
kc 1,000,000
ENDURANCE STRENGTH
DESIGN PROBLEMS
Problem 239
Solution:
For AISI C1118, as rolled
s y = 46 ksi
su = 75 ksi
si = 0.5s y
Page 18 of 42
SECTION 3 SCREW FASTENINGS
Fi = si As = 23 As kip = 23,000 As lb
kb
Fb = Fe
kb + k c
AE
kb = b b
Lb
Eb = 30 10 6 psi (steel)
Lb = t
Ac Ec
kc =
Lc
For cast-iron class 20
Ec = 9.6 10 6 psi
Lc = t
Ac = De2 D 2
4 4
Ab = D 2
4
De = 2 D
3 2
Ac = (2 D ) D 2 =
2
D = 3 Ab
4 4 4
AE
kb = b b
Lb
Ab (30106 )
kb =
t
3 A (9.6 106 )
kc = b
t
kb 30 106 300
= =
kb + kc 30 10 + 3(9.6 10 ) 588
6 6
Fb1 = 0
kb
Fe =
300 1500
Fb 2 = = 383 lb
kb + k c 588 2
1 1
Fm = Fi + (Fb 2 + Fb1 ) = 23,000 As + (383 + 0 ) = 23,000 As + 192 lb
2 2
1 1
Fa = (Fb 2 Fb1 ) = (383 0 ) = 192 lb
2 2
Page 19 of 42
SECTION 3 SCREW FASTENINGS
N = 1.75
1 sm K f sa
= +
N sy sn
192 192
23,000 + (1.8)
1 As As
= +
1.75 46,000 25,500
As = 0.2482 sq.in.
1 sm K f sa
= +
N su sn
192 192
23,000 + (1.8)
1 As As
= +
1.75 75,000 25,500
As = 0.0609 sq.in.
Table AT 14, UNC
3
Use D = in. , As = 0.0775 sq.in.
8
Page 20 of 42
SECTION 3 SCREW FASTENINGS
3
(c) Recommended, D = in. UNC
4
240. A connection similar to Fig. 5.9, Text, is subjected to an external load that
varied from 0 to 1250 lb. The bolt is cold forged from AISI B1113 steel; UNC
threads.The aluminum parts C (3003 H14) have a total thickness of 1 in.
and an external diameter of 2 D . It is desired that the connection not open for
an external load of 1.5Fe . Determine (a) the initial tensile load on the bolt, (b)
the bolt diameter for N = 2 based on the Soderberg line.
Fig. 5.9
Solution:
kc
(a) Fi = QFe lb
k +
b ck
Q = 1 .5
AE
kb = b b
Lb
Ab = D 2
4
Eb = 30 10 6 psi
1
Lb = 1 in.
2
AE
kc = c c
Lc
Ac = De2 D 2
4 4
De = 2 D
3 2
Ac = (2 D ) D 2 =
2
D = 3 Ab
4 4 4
Ec = 10 10 6 psi (3003-H14 aluminum)
Page 21 of 42
SECTION 3 SCREW FASTENINGS
1
Lc = 1 in.
2
kb = b
(
A 30 106 )
1
1
2
kc = b
(
3 A 10 106 )
1
1
2
kc
=
(
3 10 106 )
= 0.5
(
kb + kc 30 106 + 3 10 106 )
Fe = 1250 lb
kc
Fi = QFe lb
kb + kc
Fi = (1.5)(1250)(0.5) = 937.5 lb
su = 83 ksi
s y = 72 ksi
kb
Fb = Fe
kb + k c
Fb1 = 0
kb 30 106
Fb 2 = Fe = 6
(1250) = 625 lb
kb + k c
6
( )
30 10 + 3 10 10
1
Fm = Fi + (Fb 2 + Fb1 ) = 937.5 + 1 (625 + 0) = 1250 lb
2 2
1 1
Fa = (Fb 2 Fb1 ) = (625 0 ) = 312.5 lb
2 2
F 1250
sm = m =
As As
Page 22 of 42
SECTION 3 SCREW FASTENINGS
Fa 312.5
sa = =
As As
243. This problem concerns the Freon compressor of 226: size, 10 x 18 in.; 10
studs, UNC; made of C1118, as rolled; 200 psi gas pressure. The initial
tension in the bolts, assumed to be equally loaded, is such that a cylinder
pressure of 300 psi is required for the joint to be on the opening. The bolted
parts are cast steel and for the first calculations, it will be satisfactorily to
assume the equivalent diameter of the compressed parts to be twice the bolt
size. (a) For N = 2 on the Soderberg criterion, what bolt size is required? (b)
Compute the torque required for the specified initial tension.
Solution:
(10)
2
Fo = 300 = 2356 lb.
4 10
kc
Fi = Fo
k +
b c k
AE
kb = b b
Lb
Ab = D 2
4
Eb = 30 10 6 psi
Lb = L
AE
kc = c c
Lc
Ac = De2 D 2
4 4
De = 2 D
Page 23 of 42
SECTION 3 SCREW FASTENINGS
Ac = (2 D )2 3 2
D2 =
D = 3 Ab
4 4 4
Cast Steel, Ec = 30 10 6 psi
Lc = L
kb =
(
Ab 30106 )
L
3 A (30 106 )
kc = b = 3kb
L
kc 3kb
Fi = Fo = (2356 ) = 1767 lb
k +
b c k k
b + 3k b
kb
(a) Fb = Fe
k +
b ck
Fb1 = 0
kb kb (10)2 (200)
Fb 2 = Fe = = 393 lb
k +
b ck k
b + 3k b 4 10
1
Fm = Fi + (Fb 2 + Fb1 ) = 1767 + 1 (393 + 0) = 1964 lb
2 2
1 1
Fa = (Fb 2 Fb1 ) = (393 0 ) = 196 lb
2 2
Fm 1964
sm = =
As As
F 196
sa = a =
As As
For C1118, as rolled
su = 75 ksi
s y = 46 ksi
sn = 0.5su = 0.5(75) = 37.5 ksi = 37,500 psi
Page 24 of 42
SECTION 3 SCREW FASTENINGS
245. A cast-iron (class 35) Diesel-engine cylinder head is held on 8 stud bolts with
UNC threads. These bolts are made of AISI 3140 steel, OQT 1000 oF (Fig.
AF2). Assume that the compressed material has an equivalent diameter twice
the bolt size. The maximum cylinder pressure is 750 psi and the bore of the
engine is 8 in. Let the initial bolt load be such that a cylinder pressure of 1500
psi brings the joint to the point of opening. For a design factor of 2, determine
the bolt diameter (a) using the Soderberg equation, (b) using the Goodman
equation. (c) What approximate torque will be required to induce the desired
initial stress? (d) Determine the ratio of the initial stress to the yield strength.
Considering the lessons of experience (i5.8), what initial stress would you
recommend? Using this value, what factor of safety is computed from the
Soderberg equation?
Solution:
(8)
2
Fo = 1500 = 9425 lb.
4 8
kc
Fi = Fo
k
b c+ k
Ab Eb
kb =
Lb
Ab = D 2
4
Eb = 30 10 6 psi
Lb = L
AE
kc = c c
Lc
Ac = De2 D 2
4 4
De = 2 D
3 2
Ac = (2 D ) D 2 =
2
D = 3 Ab
4 4 4
Page 25 of 42
SECTION 3 SCREW FASTENINGS
kb
Fb = Fe
kb + k c
Fb1 = 0
kb 30 106 (8)2 (750 )
Fb 2 = Fe = = 1923 lb
kb + k c
6
(
30 10 + 3 14.5 10
6
)
4 8
1
Fm = Fi + (Fb 2 + Fb1 ) = 5578 + 1 (1923 + 0) = 6540 lb
2 2
1 1
Fa = (Fb 2 Fb1 ) = (1923 0 ) = 962 lb
2 2
Fm 6540
sm = =
As As
F 962
sa = a =
As As
(a) For AISI 3140 steel, OQT 1000 oF
su = 153 ksi
s y = 134 ksi
sn = 0.5su = 0.5(153) = 76.5 ksi = 76,500 psi
Page 26 of 42
SECTION 3 SCREW FASTENINGS
1 sm K f sa
= +
N su sn
1
=
6540
+
(3.3)(962)
2 153,000 As 52,000 As
As = 0.2076 sq.in.
Fi 5578
(d) si = = = 24,681 psi
As 0.226
s 24,681
Ratio = i = = 0.184
s y 134,000
Page 27 of 42
SECTION 3 SCREW FASTENINGS
1 sm K f sa
= +
N sy sn
1 118,159 (3.3)(4257 )
= +
N 134,000 52,000
N = 0.87
Solution:
Fe min = 0
Fe max = 30,000 lb
kc
Fi = QFe
k +
b ck
Q = 1.25
AE
kb = b b
Lb
Ab = D2
4
Eb = 30 10 6 psi
Lb = L
Page 28 of 42
SECTION 3 SCREW FASTENINGS
Ac Ec
kc =
Lc
Ac = De2 D2
4 4
De = 2 D
Ac = (2 D )2 3 2
D2 =
D = 3 Ab
4 4 4
Ec = 10.6 10 6 psi , (Aluminum 2014-T6)
Lc = L
Ab Eb Ab (30 106 )
kb = =
Lb L
Ac Ec 3 Ab (10.6 106 )
kc = =
Lc L
kc
Fi = QFe
kb + kc
3(10.6 106 )
Fi = (1.25)(30,000) 6
= 19,296 lb
30 10 + 3(10.6 10 )
6
kb
Fb = Fe
kb + k c
Fb1 = 0
kb 30 106
Fb 2 = Fe = 6
(30,000) = 14,563 lb
30 10 + 3(10.6 10 )
6
kb + k c
1
Fm = Fi + (Fb 2 + Fb1 ) = 19,296 + 1 (14,563 + 0) = 26,578 lb
2 2
1 1
Fa = (Fb 2 Fb1 ) = (14,563 0 ) = 7282 lb
2 2
Fm
sm =
nAs
F
sa = a
nAs
For -in.-UNF (Table AT 14)
As = 0.1419 sq.in.
F 26,578 187,300
sm = m = =
nAs 0.1419n n
Page 29 of 42
SECTION 3 SCREW FASTENINGS
Fa 7282 51,318
sa = = =
nAs 0.1419n n
Soderberg Equation, N = 2
1 sm K f sa
= +
N sy sn
1 187,300 (3.3)(51,318)
= +
2 125,000n 46,580n
n = 10.3
248. The maximum external load on the cap bolts of an automotive connecting rod
end, imposed by inertia forces at top dead center, is taken to be 4000 lb.; the
minimum load is zero at bottom dead center. The material is AISI 4140, OQT
1100oF (qualifying for SAE grade 5); assume that sn = 0.45su . The grip for
through bolts is 1.5 in. For design purposed, let each bolt take half the load,
3
and use an equivalent De = 1 in. for the connected parts. The threads extend
8
a negligible amount into the grip. For the initial computation, use an opening
load Fo = 1.75 Fe . Considering the manner in which the bolt is loaded, we
decide that a design factor of 1.4 (Soderberg) should be quite adequate. (a)
Does a 5/16-24 UNF satisfy this situation? If not, what size do you
recommend? (b) Experience suggests that, in situations such as this, an initial
stress of the order suggested in i5.8, Text, is good insurance against fatigue
Page 30 of 42
SECTION 3 SCREW FASTENINGS
Solution:
Fo = 1.75Fe = 1.75(4000) = 7000 lb
kc
Fi = Fe
kb + k c
AE
kb = b b
Lb
Ab = D2
4
Eb = 30 10 6 psi
Lb = 1.5 in.
AE
kc = c c
Lc
Ac = De2 D2
4 4
2
3 2 2
Ac = 1 D = 1.485 D = 1.485 Ab
4 8 4 4
6
Ec = 10.6 10 psi , (Aluminum 2014-T6)
Lc = 1.5 in.
As Ab
Ab Eb Ab (30 106 )
kb = =
Lb 1.5
Ac Ec (1.485 As )(30 106 )
kc = =
Lc 1.5
1.485 As
Fi = 7000 = 7000 4714 As
1.485
kb
Fb = Fe
kb + k c
Fb1 = 0
kb
Fe = s (4,000) = 2694 As
A
Fb 2 =
kb + k c 1.485
1
Fm = Fi + (Fb 2 + Fb1 ) = 7000 4714 As + 1 (2694 As + 0 ) = 7000 3367 As
2 2
1 1
Fa = (Fb 2 Fb1 ) = (2694 As 0 ) = 1347 As
2 2
Page 31 of 42
SECTION 3 SCREW FASTENINGS
Table 5.2
su = 120 ksi
s y = 88 ksi
7
(a) 5/16-24 UNF will not satisfy the situation. Instead use D= in ,
16
As = 0.1187 sq.in.
Page 32 of 42
SECTION 3 SCREW FASTENINGS
8879
+ 1347
1 0.1187
= + (3.3)(1347 )
N 88,000 54,000
N = 1.06 , it decreases
N > 1 , therefore, safe.
Considering variation of si , si tends to exceeds the limiting stress therefore reduces the
factor of safety. While stress relaxation tends to reduce the limiting stress approaching
the si and causing lower design factor.
at Fi = 8879 lb
7
T = 0.2 DFi = 0.2 (8879 ) = 777 in lb
16
CHECK PROBLEMS
249. A 1-in. steel bolt A (normalized AISI 1137, cold-rolled threads) passes
through a yellow brass tube B (B36-8, hard) as shown. The tube length is
30 in., its cross-sectional area is 2 sq. in. and the UNC bolt threads extend a
negligible amount below the nut. The steel washers are in. thick and are
assumed not to bend (clearances are exaggerated). The nut is turned turn.
(a) If an external tensile axial load, varying from 0 to 5 kips, is repeatedly
applied to the bolt, what is the factor of safety of the bolt by the Soderberg
criterion? (b) What is the external load on the bolt at the instant that the load
on the tube becomes zero.
Solution:
Page 33 of 42
SECTION 3 SCREW FASTENINGS
Dr = 0.8466 in.
Th in. = 8
1 1
p= = in.
Th in 8
1
=
p 4
1 1 1
= = in.
4 8 32
1
Lb = 30 + 2 = 30.5 in.
4
Eb = 30 10 6 psi
1 Fi (30.5)
= =
32 (1)2 30 106
( )
4
Fi = 24,141 lb
kb
Fb = Fe
k +
b ck
AE
(1)2 (30 106 )
kb = b b = 4 = 772,525
Lb 30.5
AE
kc = c c
Lc
Ac = 2 sq.in.
Lc = 30 in.
Ec = 15 10 6 psi (Yellow Brass)
2(15 106 )
kc = = 1,000,000
30
(a) Fb1 = 0
772,525
Fb 2 = (5000) = 2179 lb
772,525 + 1,000,000
1 1
Fm = Fi + (Fb 2 + Fb1 ) = 24,141 + (2179 + 0 ) = 25,230 lb
2 2
1 1
Fa = (Fb 2 Fb1 ) = (2179 0 ) = 1090 lb
2 2
Fm 25,230
sm = = = 38,227 psi
As 0.606
Page 34 of 42
SECTION 3 SCREW FASTENINGS
Fa 1090
sa = = = 1799 psi
As 0.606
For normalized AISI 1137, cold-rolled thread
su = 98 ksi
s y = 58 ksi
kc
(b) Fi = Fo
kb + k c
1,000,000
24,141 = Fo
772,525 + 1,000,000
Fo = 42,790 lb
250. A -in. fine-thread bolt, made of AISI 1117, cold drawn, with rolled threads,
passes through a yellow brass tube and two steel washers, as shown. The tube
is 4 in. long, 7/8 in. internal diameter, 1 -in. external diameter. The washers
are each -in. thick. The unthreaded part of the bolt is 3 in. long. Assume that
there is no stretching of the bolt inside the nut in finding its k . The
unlubricated bolt is tightened by a torque of 1800 in-lb. The external load,
varying from 0 to 4 kips, is axially applied to the washers an indefinite
number of times. (a) Compute the factor of safety of the bolt by the Soderberg
criterion. Is there any danger of failure of the bolt? (b) What pull must be
exerted by the washers to remove all load from the brass tube?
Solution:
T = 0.2 DFi
3
1800 = 0.2 Fi
4
Fi = 12,000 lb
Page 35 of 42
SECTION 3 SCREW FASTENINGS
kb
Fb = Fe
kb + kc
1 1 1
= +
kb kb1 kb 2
AE
kb1 = b b
Lb1
Lb1 = 3 in.
2
3
Ab = = 0.4418 sq.in.
4 4
Eb = 30 10 6 psi
kb1 =
(0.4418)(30 106 ) = 4,418,000
3
As Eb
kb 2 =
Lb 2
For -in. UNF (Table AT 14)
As = 0.373 sq.in.
1
Lb 2 = 4 + 2 3 = 1.5 in.
2
kb 2 =
( )
(0.373) 30 106 = 7,460,000
1.5
1 1 1
= +
kb kb1 kb 2
1 1 1
= +
kb 4,418,000 7,460,000
kb = 2,774,733
AE
kc = c c
Lc
1 7
2 2
Ac = 1 = 0.6259 sq.in.
4 4 8
Ec = 15 10 6 psi
Lc = 4 in.
kc =
(0.6259)(15 106 ) = 2,347,125
4
Fb1 = 0
2,774,733
Fb 2 = (4000) = 2167 lb
2,774,733 + 2,347,125
Page 36 of 42
SECTION 3 SCREW FASTENINGS
1
Fm = Fi + (Fb 2 + Fb1 ) = 12,000 + 1 (2167 + 0) = 13,084 lb
2 2
1 1
Fa = (Fb 2 Fb1 ) = (2167 0 ) = 1084 lb
2 2
F 13,084
sm = m = = 35,078 psi
As 0.373
F 1084
sa = a = = 2906 psi
As 0.373
For AISI 111, cold drawn, rolled threads
sn = 40 ksi
s y = 68 ksi
K f = 1 .4
sn = 0.8(40) = 32 ksi = 32,000 psi , axial loading
1 sm K f sa
(a) = +
N sy sn
1 35,078 (1.4)(2906)
= +
N 68,000 32,000
N = 1.56
kc
(b) Fi = Fo
kb + k c
2,347,125
12,000 = Fo
2,774,733 + 2,347,125
Fo = 26,186 lb
251. A coupling bolt (i5.13, Text) is used to connect two parts made of cast-iron,
class 35. The diameter of the coarse-thread bolt is -in.; its grip is 2 in., which
is also nearly the unthreaded length. The bolt tightened to have an initial
tension of 4000 lb. The parts support an external load Fe that tends to separate
them and it varies from zero to 5000 lb. What is the factor of safety,
(Soderberg)?
Solution:
Fi = 4000 lb
kb
Fb = Fe
kb + kc
Page 37 of 42
SECTION 3 SCREW FASTENINGS
Ab Eb
kb =
Lb
2
1
Ab = = 0.19635 sq.in. (unthreaded length)
4 2
Eb = 30 10 6 psi
Lb = 2 in.
kb =
(0.19635)(30 106 ) = 2,945,250
2
Table AT 14, UNC
1
D = in.
2
As = 0.1419 sq.in.
3
A = in.
4
h
De = A +
2
h = 2 in.
3 2 3
De = + = 1 in.
4 2 4
AE
kc = c c
Lc
3 1
2 2
Ac = De2 D2 =1 = 2.209 sq.in.
4 4 4 4 2
Ec = 14.5 10 6 psi , (Cast iron, class 35)
Lc = 2 in.
kc =
(2.209)(14.5 106 ) = 16,015,250
2
Fb1 = 0
2,945,250
Fb 2 = (5000) = 777 lb
2,945,250 + 16,015,250
1 1
Fm = Fi + (Fb 2 + Fb1 ) = 4000 + (777 + 0 ) = 4389 lb
2 2
1 1
Fa = (Fb 2 Fb1 ) = (777 0 ) = 389 lb
2 2
Fm 4389
sm = = = 30,930 psi
As 0.1419
F 389
sa = a = = 2741 psi
As 0.1419
Page 38 of 42
SECTION 3 SCREW FASTENINGS
1
For ASTM 354 BC (Table 5.2), D = in.
2
su = 125 ksi
s y = 109 ksi
sn = 0.5su
For axial loading
sn = (0.8)(0.5)(125) = 50 ksi = 50,000 psi
K f = 1 .8
Soderberg Line
1 sm K f sa
= +
N sy sn
1 30,930 (1.8)(2741)
= +
N 109,000 50,000
N = 2 .6
252. The cap on the end of a connecting rod (automotive engine) is held on by two
5/16-in. bolts that are forged integrally with the main connecting rod. These
bolts have UNF threads with a 5/8-in. on an unthreaded length of virtually 5/8
in. The nuts are to be tightened with a torque of 20 ft-lb. and the maximum
external load on one bolt is expected to be 2330 lb. Let the equivalent
diameter of the connected parts be in. (a) Estimate the maximum force on
the bolt. (b) Compute the opening load. Is this satisfactory? (c) If the bolt
material is AISI 4140, OQT 1000 oF, what is the factor of safety based on the
Soderberg criterion?
Solution:
T = 20 ft lb = 240 in lb
T = 0.2 DFi
5
240 = 0.2 Fi
16
Fi = 3840 lb
kb
Fb = Fe
k +
b ck
Ab Eb
kb =
Lb
2
5
Ab = = 0.0767 sq.in. (unthreaded length)
4 16
Eb = 30 10 6 psi
5
Lb = in.
8
Page 39 of 42
SECTION 3 SCREW FASTENINGS
kb =
(0.0767 )(30 106 ) = 3,681,600
5
8
Ac Ec
kc =
Lc
3 5
2 2
2 2
Ac = D
e D = = 0.3651 sq.in.
4 4 4 4 16
Ec = 30 10 6 psi , (Cast iron, class 35)
5
Lc = in.
8
kc =
( )
(0.3651) 30 106 = 17,524,800
5
8
3,681,600
Fb = (2330) = 405 lb
3,681,600 + 17,524,800
Fb 405
(c) Fm = Fi + = 3840 + = 4042 lb
2 2
F 405
Fa = b = = 202 lb
2 2
For AISI 4140, OQT 1000 oF
su = 170 ksi
s y = 155 ksi
Table AT 12, K f = 2.6
sn = 0.5su
For axial loading
sn = (0.8)(0.5)(170) = 68 ksi = 68,000 psi
Soderberg Line
1 sm K f sa
= +
N sy sn
Page 40 of 42
SECTION 3 SCREW FASTENINGS
SET SCREWS
254. A 6-in. pulley is fastened to a 1 in. shaft by a set screw. If a net tangential
force of 75 lb, is applied to the surface of the pulley, what size screw should
be used when the load is steady?
Solution:
6
Tangential force = (75 lb ) = 365 lb
1.25
Assume tangential force = holding force
Table 5.3, use Screw size 8, Holding force = 385 lb.
Solution:
1.25
Tangential force = (1000 lb ) = 833 lb
32
Holding force = (6)(833) = 5000 lb
Table 5.3, use Screw size in.
Solution:
Torque = (16)(40) = 640 in lb
2(640 )
Tangential force = = 640 lb
2
Page 41 of 42
SECTION 3 SCREW FASTENINGS
257. A 12-in. gear is mounted on a 2-in. shaft and is held in place by a 7/16 in.
setscrew. For a design factor of 3, what would be the tangential load that
could be applied to the teeth and what horsepower could be transmitted by the
screw.
Solution:
Table 5.3, 7/16 in.
Holding force = 2500 lb
2500
Tangential force = = 833 lb
3
2
Tangential load on gear = 833 = 139 lb
12
Assume vm = 4500 fpm
Hp transmitted =
(139)(4500) = 19 hp
33,000
- end -
Page 42 of 42
SECTION 4 - SPRINGS
Solution:
For oil tempered wire, Table AT 17
146
su = 0.19 ksi , [0.032 < Dw < 0.5]
Dw
solid stress = 0.6 s u
design stress, (average service)
ssd = 0.324 su
0.324(146 ) 47.304
ssd = = ksi
Dw0.19 Dw0.19
Dw + Dm 7
F = 2850 lb = 2.85 kips
8FDm 47.304
ss = K =
3
Dw Dw0.19
say K = 1.3
8(2.85)(7 Dw ) 47.304
ss = 1.3 =
Dw3 Dw0.19
Dw = 1.062 in > 0.5 in
47.304
use ssd = ksi = 54 ksi
(0.5)0.19
8(2.85)(7 Dw )
ss = 1.3 = 54
Dw3
Dw = 1.015 in
say Dw = 1.0 in
8(2.85)Dm
ss = 1.3 = 54
(1)
3
Dm = 5.72 in
Page 1 of 70
SECTION 4 - SPRINGS
say Dm = 5.0 in
OD = Dm + Dw = 5.0 + 1.0 = 6 in < 7 in.
D 5 .0
C= m = =5
Dw 1.0
= Free length Compressed length = 18 in 15 in = 3 in.
8FC 3 N c
=
GDw
3
G = 10,500 ksi , Dw > in
8
8(2.85)(5) N c
3
=3=
(10,500)(1)
N c = 11.05
say N c = 11.5
8(2.85)(5) (11.5)
3
= = 3.12 in
(10,500)(1)
Free length = 15 + 3.12 = 18.12 in
At 2.85 kips
8FDm
ss = K
3
Dw
C =5
4C 1 0.615 4(5) 1 0.615
K= + = + = 1.3105
4C 4 C 4(5) 4 5
8(2.85)(5)
ss = 1.3105 = 47.55 ksi
(1)
3
Page 2 of 70
SECTION 4 - SPRINGS
1
use P = 1 in
2
Pitch angle,
P 1.5
= tan 1 = tan 1 o o
= 5.5 < 12 , o.k.
D (5 )
Summary of answer:
Dw = wire diameter = 1 in.
Dm = coil diameter = 5 in.
N c = no. of active coils = 11 1/2
P = pitch = 1 in.
= pitch angle = 5.5o
sso = solid stress = 87.63 ksi
272. A coil spring is to be used for the front spring of a automobile. The spring is
to have a rate of 400 lb./in., an inside diameter of 4 3/64 in., and a free length
of 14 1/8 in., with squared-and-ground ends. The material is to be oil-
tempered chrome vanadium steel. Decide upon the diameter of the wire and
the number of free coils for a design load of F = 1500 lb . Be sure solid
stress is all right. How much is the pitch angle?
Solution:
Table AT 17 Cr-V steel
168
su = 0.166 ksi , [0.032 < Dw 0.437]
Dw
average service
ssd = 0.324su
0.324(168) 54.432
ssd = = 0.166 ksi
Dw0.166 Dw
Max solid stress = 0.6su
Page 3 of 70
SECTION 4 - SPRINGS
3
ID = Dm Dw = 4 in = 4.046875 in
64
Dm = Dw + 4.046875 in
8FDm
ss = K = ssd
3
Dw
Assume K = 1.3
F = 1500 lb = 1.5 kips
54.432 8(1.5)(Dw + 4.046875)
ssd = 0.166
= 1.3
Dw Dw3
Dw = 0.747 in > 0.437 in
use
54.432
ssd = ksi = 62.45 ksi
(0.437 )0.19
8(1.5)(Dw + 4.046875)
ssd = 1.3 = 62.45
Dw3
Dw = 0.724 in
3
use Dw = in
4
3 3 51
Dm = + 4 = 4 in
4 64 64
8FDm
ss = K
3
Dw
4C 1 0.615
K= +
4C 4 C
51
4
Dm 64
C= = 6.4
Dw 3
4
4(6.4) 1 0.615
K= + = 1.235
4(6.4) 4 6.4
51
8(1.5) 4
ss = 1.235 64 = 53.64 ksi < 62.45 ksi , (o.k.)
3
3
4
8FC 3 N c
=
GDw
Page 4 of 70
SECTION 4 - SPRINGS
3
G = 10,500 ksi , D w > in
8
F 1500
= = = 3.75 in
k 400
8(1.5)(6.4 ) N c
3
= 3.75 =
(10,500) 3
4
N c = 9.4
Table AT 16, Total coils = N c + 2 = 9.4 + 2 = 11.4 for square and grounded end.
Summary of answer:
Dw = wire diameter = in.
No. of free coils = 11.4
0.6(168)
Permissible solid stress = = 115.65 ksi
(0.437 )0.166
Free length = PN c + 2 Dw
3
Solid height = Dw ( N c + 2 ) = (11.4 ) = 8.55 in
4
1
14 8.55
Solid stress = (53.64 ) 8 = 78.74 ksi < 115.65 ksi (safe)
3.75
Pitch:
1
PN c + 2 Dw = 14 in
8
3 1
P(9.4 ) + 2 = 14
4 8
11
P = 1.343 in = 1 in
32
Pitch angle,
11
1
1 P
= tan = tan 32 = 5.1o < 12o , o.k.
1
D 4 51
64
Page 5 of 70
SECTION 4 - SPRINGS
273. A coiled compression spring is to fit inside a cylinder 5/8 in. in diameter. For
one position of the piston, the spring is to exert a pressure on the piston
equivalent to 5 psi of piston area, and in this position, the overall length of the
spring must not exceed (but may be less than) 2 in. A pressure of 46 psi on the
piston is to compress the spring in. from the position described above.
Design a spring for medium service. Specify the cheapest suitable material,
number of total and active coils for square-and-ground ends, and investigate
the pitch angle, and solid stress.
Solution:
8FDm
ss = K
3
Dw
5 D
OD = Dm + Dw = in w
8 2
5
Dm + 1.5 Dw = in
8
2
5
F1 = (5) = 1.534 lb
4 8
2
5
F2 = (46 + 5) = 15.647 lb
4 8
Page 6 of 70
SECTION 4 - SPRINGS
4C 1 0.615
K= +
4C 4 C
1.81
4C 1 0.615 0.625
+ (39.845)C = 38,556
4C 4 C C + 1 .5
4C 1 0.615
(C + 1.5) C = 413.3
1.81
+
4C 4 C
C = 7.035
0.625 0.625
Dw = = = 0.0732 in
C + 1.5 7.035 + 1.5
Table AT 15, Dw = 0.0720 in , W & M 15
Dm = 7.035(0.0720) = 0.5065 in
For N c
8(F2 F1 )C 3 N c
2 1 =
GDw
G = 11.5 106 psi
3 8(15.647 1.534)(7.035) N c
3
2 1 = =
4 (
11.5 106 (0.0720) )
N c = 15.8
Table AT 16,
Total coils = N c + 2 = 15.8 + 2 = 17.8
Solid height = ( N c + 2)Dw = (15.8 + 2)(0.0720) = 1.28 in
Free length = PN c + 2 Dw
Free length = 2 + 1
8(F1 )C 3 N c
1 =
GDw
8(1.534 )(7.035) (15.8)
3
1 = = 0.082 in.
( )
11.5 106 (0.0720)
Free length = 2 + 0.082 = 2.082 in
8(F2 )C 3 N c
2 =
GDw
8(15.647 )(7.035) (15.8)
3
2 = = 0.832 in.
(
11.5 106 (0.0720) )
Solid Height Free Length - 2
Solid Height 2.082 0.832 in
Solid Height 1.25 in
But Solid Height > 1.25 in.
Page 7 of 70
SECTION 4 - SPRINGS
Table AT 17
146
su = 0.19 ksi , 0.028 < Dw < 0.5
Dw
87.5
Max solid stress = ksi
D w0.19
146 47.304
ssd = 0.324 =
Dw0.19 Dw0.19
8FC 47.304 47,304
ss = K 2
= 0.19
ksi = 0.19
psi
wD Dw D w
K
( )
8 15.647 C
= 47,304 Dw1.81
K (39.845)C = 47,304 Dw1.81
0.625
Dw =
C + 1 .5
4C 1 0.615
K= +
4C 4 C
1.81
4C 1 0.615 0.625
+ (39.845)C = 47,304
4C 4 C C + 1 .5
4C 1 0.615
(C + 1.5) C = 507.1
1.81
+
4C 4 C
C = 7.684
0.625 0.625
Dw = = = 0.0680 in
C + 1.5 7.684 + 1.5
Table AT 15, Dw = 0.0625 in , W & M 16
Dm = 7.684(0.0625) = 0.48025 in
15
say Dm = = 0.46875 in
32
D 0.46875
C= m = = 7 .5
Dw 0.0625
8FC
ss = K
2
Dw
4C 1 0.615 4(7.5) 1 0.615
K= + = + = 1.1974
4C 4 C 4(7.5) 4 7.5
8(15.647 )(7.5)
ss = 1.1974 2
= 91,600 psi = 91.6 ksi
(0.0625)
For N c
Page 8 of 70
SECTION 4 - SPRINGS
8(F2 F1 )C 3 N c
2 1 =
GDw
G = 11.5 106 psi
3 8(15.647 1.534)(7.5) N c
3
2 1 = =
4 ( )
11.5 106 (0.0625)
N c = 11.32
Table AT 16, squared and ground ends
Total coils = N c + 2 = 11.32 + 2 = 13.32
Solid height = ( N c + 2)Dw = (11.32 + 2)(0.0625) = 0.8325 in
Free length = PN c + 2 Dw
Free length = 2 + 1
8(F1 )C 3 N c
1 =
GDw
8(1.534 )(7.5) (11.32)
3
1 = = 0.082 in.
( )
11.5 106 (0.0625)
Free length = 2 + 0.082 = 2.082 in = P(11.32) + 2(0.0625)
11
P = 0.1729 in in
64
Pitch angle,
P 0.1729
= tan 1 = tan 1 o o
= 6.7 < 12 , o.k.
D (0.46875 )
Solid stress
2 0.8325
sso = (91.6 ) = 142.6 ksi
0.75
87.5
Permissible solid stress = = 148.8 ksi > 137.5 ksi , safe.
(0.0625)0.19
Summary of answer:
Suitable material = Oil-Tempered Spring Wire
Total Coils = 13.32
Active Coils, N c = 11.32
274. A helical spring is to fit about a 11/16-in. rod with a free length of 2 in. or
less. A maximum load of 8 lb. is to produce a deflection of 1 in. The spring
is expected to be compressed less than 5000 times during its life, but is
subjected to relatively high temperatures and corrosive atmosphere. Select a
material and determine the necessary wire size, mean coil diameter, and
number of coils. Meet all conditions advised by Text.
Page 9 of 70
SECTION 4 - SPRINGS
Solution:
For 5000 cycles < 104 cycles, use light service
Use stainless steel, type 302 (Cr-Ni), ASTM A313 for relative high temperature and
corrosive atmosphere, Table AT 17.
ssd = 0.32su (i)
170
su = ksi , [0.01 < Dw < 0.13]
Dw0.14
97
su = 0.41 ksi , [0.13 < Dw < 0.375]
Dw
Maximum solid so = 0.47 su
8FDm
ss = K 3
D w
F = 8 lb
11 D
Dm Dw = + w
16 2
Dm 1.5Dw = 0.6875 in
CDw 1.5 Dw = 0.6875
0.6875
Dw =
C 1 .5
4C 1 0.615
K= +
4C 4 C
170
assume su = 0.14 ksi
Dw
0.32(170 ) 54.4 54,400
ssd = 0.14
= 0.14 ksi = psi
Dw Dw Dw0.14
4C 1 0.615 8(8)C
+ = 54,400 D1w.86
4C 4 C
1.86
4C 1 0.615 64C 0.6875
+ = 54,400
4C 4 C C 1 .5
4C 1 0.615
(C 1.5) C = 1330
1.86
+
4C 4 C
C = 12.919
0.6875
Dw = = 0.0602 in
12.919 1.5
Use Table AT 15, Dw = 0.0625 in , 16 W & M
Dm = 12.919(0.0602) = 0.8074 in
25
say Dm = in = 0.78125 in
32
Page 10 of 70
SECTION 4 - SPRINGS
11
Dm Dw >
16
0.78125 0.0625 > 0.6875
0.71875 > 0.6875
Dw
0.71875 0.6875 = 0.03125 = , o.k.
2
Dm 0.71875
C= = = 12.5
Dw 0.0625
[0.0625 < 0.13], therefore, su =
170
ksi is o.k.
Dw0.14
8FC
ss = K
2
D
w
4(12.5) 1 0.615
K= + = 1.1144
4(12.5) 4 12.5
8(8)(12.5)
ss = 1.1144 2
= 72,648 psi
(0.0625)
8(F )C 3 N c
=
GDw
G = 10.6 106 psi
8(8)(12.5) N c
3
3
=1 =
( )
4 10.6 106 (0.0625)
N c = 9.3
To check for solid stress and pitch
Minimum solid height = Dw N c = (0.0625)(9.3) = 0.58125 in
(72,648) 2 3 0.58125
Solid stress = 4 = 90,000 psi = 90 ksi
3
1
4
Permissible solid stress =
(0.47 )(170) = 117.8 ksi > 90 ksi , o.k.
(0.0625)0.14
Free length = PN c , minimum
3
P (9.3) = 2
4
P = 0.2957 in
Pitch angle,
P 0.2957
= tan 1 = tan 1 = 7.5o < 12o , o.k.
D (0.71825)
Summary of answer
Material, Stainless Steel, Cr-Ni. ASTM A313
Page 11 of 70
SECTION 4 - SPRINGS
Dw = 0.0625 in , 16 W & M
25
Dm = in
32
N c = 9.3
275. In order to isolate vibrations, helical compression springs are used to support a
machine. The static load on each spring is 3500 lb., under which the deflection
should be about 0.5 in. The solid deflection should be about 1 in. and the
outside coil diameter should not exceed 6 in. Recommend a spring for this
application; include scale, wire size, static stress, material, number of coils,
solid stress, and pitch of coils.
Solution:
Use Music wire (The best material)
Table AT 17
190
su = 0.154 ksi , [0.004 < Dw < 0.192]
Dw
Maximum solid sso = 0.5su
Light service, ssd = 0.405su
0.405(190 ) 76.95 76,950
ssd = 0.154
= 0.154 ksi = 0.154 psi
Dw Dw Dw
8FC
ss = K
2
Dw
F = 3500 lb
OD = Dm + Dw = 6 in
(C + 1)Dw = 6
6
Dw =
C +1
4C 1 0.615 8(3500 )C
76,950
ss = + =
4C 4 C 6 6 0.154
C + 1 C + 1
4C 1 0.615
4C 4
+
C
[
C (C + 1) ]
1.846
= 235.9
C = 5.635
6
Dw = = 0.9043 in > 0.192 in
5.635 + 1
76.950
use ss = = 99,216 psi
(0.192)0.154
Page 12 of 70
SECTION 4 - SPRINGS
4C 1 0.615 8(3500 )C
ss = + = 99,216
4C 4 C 6
C + 1
4C 1 0.615
C (C + 1) = 400.8
2
+
4C 4 C
C = 6.205
6
Dw = = 0.8328 in
6.205 + 1
13
Say Dw = in = 0.8125 in
16
Dm = (6.205)(0.8125) = 5.042 in
Say Dm = 5 in
D 5
C= m = = 6.154
Dw 0.8125
4(6.154) 1 0.615
K= + = 1.2455
4(6.154) 4 6.154
8FC
ss = K 2
Dw
8(3500)(6.154)
ss = 1.2455 = 103,481 psi > 99,216 psi , not o.k.
(0.8125)
2
Use Dm = 4.5 in
D 4 .5
C= m = = 5.5385
Dw 0.8125
4(5.5385) 1 0.615
K= + = 1.2763
45.5385 4 5.5385
8(3500)(5.5385)
ss = 1.2763 = 95,435 psi > 99,216 psi , o.k.
(0.8125)
2
Page 13 of 70
SECTION 4 - SPRINGS
4C 1 0.615 8(3500 )C
ss = + = 61,244
4C 4 C 6
C + 1
4C 1 0.615
C (C + 1) = 247.4
2
+
4C 4 C
C = 5 .1
6
Dw = = 0.9836 in
5 .1 + 1
Say Dw = 1.0 in
Dm = (5.1)(1.0) = 5.1 in
Say Dm = 5 in
D 5
C = m = =5
Dw 1
8FC
ss = K
2
Dw
4(5) 1 0.615
K= + = 1.3105
4(5) 4 5
8(3500)(5)
ss = 1.3105 2
= 58,400 psi > 61,244 psi o.k.
(1.0 )
Use Dw = 1.0 in , Dm = 5 in
1
Solid stress = (58,400 ) = 116,800 psi < 122,488 psi , o.k.
0 .5
8(F )C 3 N c
=
GDw
(Table AT 17)
G = 12 106 psi
8(3500 )(5) N c
3
= 0.5 =
( )
12 106 (1.0)
N c = 1.7143
say N c = 1.75
Free length Solid length = Solid Deflection
PN c Dw N c = 1 in
P(1.75) (1)(1.75) = 1
9
P = 1.5714 in 1 in
16
Pitch angle,
Page 14 of 70
SECTION 4 - SPRINGS
9
P 1
= tan 1 = tan 1 16 = 5.68o < 12o , o.k.
D (5)
Summary of answer.
F 3500
Scale, k = = = 7000 lb in
0 .5
Wire size, Dw = 1.0 in
Material = Music Wire
Solid sress = 116,800 psi
9
Pitch of stress = P = 1 in
16
276. The front spring of an automobile has a total of 9 coils, 7 3/8 active coils
(square-and-ground ends), an inside diameter of 4 3/64 in., and a free length
of 14 in. It is made of SAE 9255 steel wire, OQT 1000oF, with a diameter
of 43/64 in. Compute (a) the rate (scale) of the spring; (b) the solid stress
and compare with a permissible value (is a stop needed to prevent solid
compression?). (c) Can 95 % of the solid stress be repeated 105 times without
danger of failure? Would you advise shot peening of the spring?
Solution:
8FC 3 N c
(a) =
GDw
43 3
Dw = in > in
64 8
6
G = 10.5 10 psi
D
C= m
Dw
Dm Dw = ID
43 3
Dm = 4 in
64 64
23
Dm = 4 in
32
23
4
C = 32 = 7.0233
43
64
Page 15 of 70
SECTION 4 - SPRINGS
3
Nc = 7
8
(10.5 10 ) 64
6 43
F
GD
k = rate = = 3 w = = 345 lb in
8C N c 3 3
8(7.0233) 7
8
277. An oil-tempered steel helical compression spring has a wire size of No. 3 W
& M, a spring index of 4.13, 30 active coils, a pitch of 0.317 in., ground-and-
squared ends; medium service. (a) What maximum load is permitted if the
recommended stress is not exceeded (static approach)? Compute (b) the
Page 16 of 70
SECTION 4 - SPRINGS
corresponding deflection, (c) solid stress,. (d) pitch angle, (e) scale, (f) the
energy absorbed by the spring from a deflection of 0.25 in. to that of the
working load. (g) Is there any danger of this spring buckling? (h) What
maximum load could be used if the spring were shot peened?
Solution:
Table AT 17, oil-tempered
146
su = 0.19 ksi , [0.032 < Dw < 0.5]
Dw
87.5
Maximum solid sso = 0.19 ksi
Dw
ssd = 0.324su (medium service)
8F C
(a) ss = K s 2
Dw
4C 1 0.615
K= +
4C 4 C
4(4.13) 1 0.615
K= + = 1.3885
4(4.13) 4 4.13
0.324(146 )
ss = ssd = = 61.858 ksi = 61,858 psi
(0.2437 )0.19
8(F )(4.13)
ss = 61,858 = 1.3885 2
(0.2437 )
F = 252 lb
8FC 3 N c
=
GDw
G = 11.5 106 psi
N c = 30
8(252)(4.13) (30)
3
= = 1.52 in
( )
11.5 106 (0.2437 )
Page 17 of 70
SECTION 4 - SPRINGS
87.5 87.5
Maximum solid sso = ksi = ksi = 114.4 ksi > 89.491 ksi , o.k. safe
0.19
Dw (0.2437 )0.19
P 0.317
(d) = tan 1 = tan 1 = 5.76o < 12o , o.k.
D (1)
F 252
(e) scale = k = = = 166 lb in
1.52
1
(f) U s = k ( 22 12 )
2
k = 166 lb in
1 = 0.25 in
2 = 1.52 in
1
[ ]
U s = (166 ) (1.52 ) (0.25) = 186.6 in lb
2
2 2
280. It is desired to isolate a furnace, weighing 47,300 lb., from the surroundings
by mounting it on helical springs. Under the weight, the springs should deflect
approximately 1 in., and at least 2 in. before becoming solid. It has been
decided to use springs having a wire diameter of 1 in., an outside diameter of
5 3/8 in., 4.3 free coils. Determine (a) the number of springs to be used, (b)
the stress caused by the weight, (c) the solid stress. (d) What steel should be
used?
Solution:
Page 18 of 70
SECTION 4 - SPRINGS
Dw = 1 in
3
Dm + Dw = 5 in
8
3
Dm = 4 in
8
3
4
D
C = m = 8 = 4.375
Dw 1
8FC 3 N c
(a) =
GDw
Assume N c = 4.3
3
G = 10.5 106 psi , Dw > in
8
8F (4.375) (4.3)
3
= 1.0 =
(
10.5 106 (1))
F = 3645 lb
W 47,300
No. of springs = = = 13
F 3645
W 47,300
(b) F = = = 3638 lb
13 13
8F C
ss = K s 2
Dw
4C 1 0.615
K= +
4C 4 C
4(4.375) 1 0.615
K= + = 1.3628
4(4.375) 4 4.375
8(3638)(4.375)
ss = 1.3628 = 55,235 psi
(1.0)2
2
(c) Solid Stress = ss = 55,235 = 110,470 psi
1
(d) s ys 110,470 psi
s ys
110,470
sy = = = 184,117 psi = 184.117 ksi
0.6 0.6
From Table AT 7,
Use AISI 8760, OQT 800 oF, s y = 200 ksi
Page 19 of 70
SECTION 4 - SPRINGS
DESIGN PROBLEMS
282. A spring, subjected to a load varying from 100 lb. to 250 lb., is to be made of oil-
tempered, cold-wound wire. Determine the diameter of the wire and the mean
diameter of the coil for a design factor of 1.25 based on Wahls line. The spring
index is to be at least 5. Conform to good practice, showing checks for all
significant parameters. Let the free length be between 6 and 8.
Solution:
Fmax = 250 lb
Fmin = 100 lb
1 1
Fm = (Fmax + Fmin ) = (250 + 100 ) = 175 lb = 0.175 kip
2 2
1 1
Fa = (Fmax Fmin ) = (250 100 ) = 75 lb = 0.075 kip
2 2
Wahls line
1 sms sas 2sas
= +
N s ys sno
8 KFa Dm 8 KFa C
sas = =
Dw3 Dw2
8 KFm Dm 8 KFmC
sms = =
K cDw3 K cDw2
C =5
4C 1 0.615
K= +
4C 4 C
4(5) 1 0.615
K= + = 1.31
4(5) 4 5
Fig. AF 15, C = 5
K c = 1.19
For oil-tempered wire,
87.5
s ys = 0.19
Dw , [0.032 < Dw < 0.5]
47
sno =
Dw0.1 , [0.041 < Dw < 0.15]
30
sno = 0.34
Dw , [0.15 < Dw < 0.625]
N = 1.25
Page 20 of 70
SECTION 4 - SPRINGS
8(1.31)(0.075)(5) 1.251
sas = =
Dw2 Dw2
8(1.31)(0.175)(5) 2.453
sms = =
(1.19)Dw2 Dw2
30
say sno = 0.34 ksi
Dw
1 sms sas 2sas
= +
N s ys sno
2.453 1.251 1.251
2
2 2
Dw + Dw
=
1
1.25 87.5 30
0.19 0.34
Dw Dw
1 1 1
= 1.81
+
1.25 72.8 Dw 11.99 Dw1.66
Dw = 0.2857 in > 0.15 in
Table AT 15, use No. 1, W & M
Dw = 0.2830 in
Summary of answer
Dw = 0.2830 in
1
Dm = 1 in
2
283. A carbon-steel spring is to be subjected to a load that varies from 500 to 1200 lb.
The outside diameter should be between 3.5 and 4 in., the spring index between 5
to 10; approximate scale of 500 lb./in. Choose a steel and for a design factor of
1.4 by the Wahl line, find the wire diameter. Also determine the number of active
Page 21 of 70
SECTION 4 - SPRINGS
coils and the free length for squared-and-ground ends. Conform to the general
conditions specified in the Text.
Solution:
For carbon steel, Table AT 17
91
s ys = 0.1 ksi , [0.093 < Dw < 0.25]
Dw
49
sno = 0.15 ksi , [0.093 < Dw < 0.25]
Dw
Fmax = 1200 lb
Fmin = 500 lb
1 1
Fm = (Fmax + Fmin ) = (1200 + 500 ) = 850 lb = 0.85 kip
2 2
1 1
Fa = (Fmax Fmin ) = (1200 500 ) = 350 lb = 0.35 kip
2 2
OD = 3.5 ~ 4.0 in
C = 5 ~ 10
Wahls line
1 sms sas 2sas
= +
N s ys sno
Figure AF 15, C = 5 ~ 10
Assume K = 1.2 , K c = 1.125
8 KFa Dm
sas =
Dw3
8 KFm Dm
sms =
K cDw3
OD 3.75 in
Dm = 3.75 Dw
8(1.2 )(0.35)(3.75 Dw ) 1.0695(3.75 Dw )
sas = =
Dw3 Dw3
8(1.2 )(0.85)(3.75 Dw ) 2.3088(3.75 Dw )
sms = =
(1.125)Dw3 Dw3
3.75 Dw
(2.3088 1.0695) 3.75 3 Dw 2(1.0695)
1 Dw + Dw3
=
1.4 91 49
0.1 0.15
Dw Dw
1 3.75 Dw 3.75 Dw
= 2.9
+
1.4 73.4285 Dw 22.9079 Dw2.85
Dw = 0.6171 in > 0.25 in
Use
Page 22 of 70
SECTION 4 - SPRINGS
91
s ys = = 104.53 ksi
(0.25)0.1
49
sno = = 60.33 ksi
(0.25)0.15
3.75 Dw
(2.3088 1.0695) 3.75 3 Dw 2(1.0695)
1 Dw + Dw3
=
1 .4 104.53 60.33
1 3.75 Dw 3.75 Dw
= +
1.4 84.346 Dw3 28.205 Dw3
1 3.75 Dw
=
1.4 21.137 Dw3
Dw = 0.5935 in
use
19
Dw = in
32
3
Dm + Dw 3 in
4
19 3
Dm + = 3 in
32 4
5
Dm = 3 in
32
5
3
Dm 32
C= = = 5.316
Dw 19
32 . o.k.
19
Wire Diameter Dw = in , Carbon Steel
32
Number of coils:
8FC 3 N c
=
GDw
3
G = 10.5 106 psi = 10,500 ksi , Dw > in
8
F GDw
=k = 3
8C N c
(10.5 10 ) 19
6
500 = 32
8(5.316 ) N c
3
N c = 10.4
Table AT 16, square-and-ground ends
Page 23 of 70
SECTION 4 - SPRINGS
Free length = PN c + 2 Dw
Solid height = Dw N c + 2 Dw
Total Coils = N c + 2
19
Solid height = Dw N c + 2 Dw = (10.4 + 2 ) = 7.3625 in
32
F 1200
= = = 2.4 in
k 500
Min. Free length = 2.4 + 7.3625 in = 9.7625 in
Use Free length = 10 in
Solid stress:
T = solid deflection = 10 7.3625 = 2.6375 in
F = k T = (500)(2.6375) = 1319 lb
4C 1 0.615
K= +
4C 4 C
4(5.316) 1 0.615
K= + = 1.29
4(5.316) 4 5.316
5
8(1.29)(1319) 3
ss =
8 KFDm
= 32 = 23,033 psi = 23.033 ksi < s (= 104.53 ksi )
3 3 ys
Dw 19
32
Solution:
Page 24 of 70
SECTION 4 - SPRINGS
Table AT 16,
For carbon steel,
182
su = 0.1 ksi , [0.093 < Dw < 0.25]
Dw
91
s ys = 0.1 ksi
91 Dw
Max. solid s ys = 0.1 ksi
Dw
49
sno = 0.15 ksi , [0.093 < Dw < 0.25]
Dw
Dm = 2 in.
Fmax = 300 lb
Fmin = 100 lb
8F C
ss = K s 2
Dw
4C 1 0.615
K= +
4C 4 C
Dm
C=
Dw
D 2
Dw = m =
C C
4C 1 0.615 8(0.3)(2 ) 47.866
ss = + =
4C 4 C 2 3 2 0.1
C C
4C 1 0.615 2.9
4C 4 + C C = 233.84
C = 6.075
2
Dw = = 0.3292 in > 0.25 in
6.075
47.866
Therefore use ssd = = 54.984 ksi
(0.25)0.1
Page 25 of 70
SECTION 4 - SPRINGS
4C 1 0.615 8(0.3)(2 )
ss = + = 54.984
4C 4 C 2 3
C
4C 1 0.615 3
4C 4 + C C = 287.9
C = 6.136
2
Dw = = 0.3259 in
6.136
21
say Dw = in
64
91
(b) s ys = = 104.53 ksi
(0.25)0.1
49
sno = = 60.33 ksi
(0.25)0.15
1 1
Fm = (Fmax + Fmin ) = (300 + 100 ) = 200 lb = 0.2 kip
2 2
1 1
Fa = (Fmax Fmin ) = (300 100 ) = 100 lb = 0.1 kip
2 2
Dm 2
C= = = 6.095
Dw 21
64
Figure AF 15
K c = 1.15
K = 1.25
K 8Fm Dm
sms =
K c Dw3
1.25 8(0.2 )(2)
sms = = 31.34 ksi
1.15 21 3
64
8 KFa Dm
sas =
Dw3
Page 26 of 70
SECTION 4 - SPRINGS
8(0.1)(2)
sas = 1.25 = 18.02 ksi
21 3
64
Wahls line
1 sms sas 2sas
= +
N s ys sno
1 31.34 18.02 2(18.02 )
= +
N 104.53 60.33
N = 1.38
285. A helical spring of hard-drawn wire with a mean diameter of 1 in. and square-
and-ground ends is to be subjected to a maximum load of 325 lb. (a) Compute the
wire diameter for average service. (b) How many total coils are required if the
scale is 800 lb./in.? (c) For a minimum load of 100 lb., what is the factor of safety
according to Wahl line? Would it be safe for an indefinite life?
Solution:
Table AT 17,
Hard-drawn wire,
140
su = 0.19 ksi , [0.028 < Dw < 0.625]
Dw
70
Maximum solid ss = s ys = 0.19 ksi
Dw
sno =
(0.9)(47 ) ksi , [0.041 < D < 0.15]
w
Dw0.1
sno =
(0.9)(30) ksi , [0.15 < D < 0.625]
w
Dw0.34
Average service
0.2754(140 ) 38.556
(a) ssd = 0.85(0.324 )su = 0.2754 su = = ksi
Dw0.19 Dw0.19
F = 325 lb = 0.325 kip
1
Dm = 1 in
2
8 FDm
ss = K 3
Dw
Page 27 of 70
SECTION 4 - SPRINGS
4C 1 0.615
K= +
4C 4 C
1 .5
Dw =
C
4C 1 0.615 8(0.325)(1.5) 38.556
ss = + =
4C 4 C 1.5 1.5
3 0.19
C C
4C 1 0.615 2.81
+ C = 97.05
4C 4 C
C = 4.586
1 .5 1 .5
Dw = = = 0.3271 in < 0.625 in
C 4.586
21
Dw = in
64
Dm 1 .5
(b) C = = = 4.57
Dw 21
64
4(4.57 ) 1 0.615
K= + = 1.345
4(4.57 ) 4 4.57
8FC 3 N c
=
GDw
F GD
=k = 3 w
8C N c
k = 800 lb in = 0.8 kip in
(11,500) 21
0.8 = 64
3
84.57 N c
N c = 6.2
70
(c) s ys = 0.19
= 86.5 ksi
21
64
sno =
(0.9)(30)
= 39.44 ksi , Dw > 0.15 in
0.19
21
64
1
Fm = (325 + 100 ) = 212.5 lb = 0.2125 kip
2
Page 28 of 70
SECTION 4 - SPRINGS
1
Fa = (325 100) = 112.5 lb = 0.1125 kip
2
K c = 1.212 , Fig. AF 15
K = 1.345
K 8Fm Dm 1.345 8(0.2125)(1.5)
sms = = = 25.5 ksi
K c Dw3 1.212 21
3
64
8Fm Dm
8(0.1125)(1.5)
sas = K 3
= 1.345 = 16.36 ksi
Dw 21
3
64
1 sms sas 2sas 25.5 16.36 2(16.36)
= + = +
N s ys sno 86.5 39.44
N = 1.07 < 1.15[N min ]
Not safe for indefinite life.
286. A helical spring is to be subjected to a maximum load of 200 lb. (a) Determine
the wire size suitable for medium service if the material is carbon steel ASTM
A230; C = 6 . Determine the factor of safety of this spring according to the Wahl
line (b) If the minimum force is 150 lb., (c) if the minimum force is 100 lb., (d) if
the minimum force is 25 lb.
Solution:
Page 29 of 70
SECTION 4 - SPRINGS
8 FDm
ss = K 3
Dw
4C 1 0.615
K= +
4C 4 C
4(6) 1 0.615
K= + = 1.2525
4(6) 4 6
F = 200 lb
8(200)(6) 58,968
ss = 1.2525 2 =
Dw Dw0.1
Dw = 0.2371 in
Factor of safety.
91 91
s ys = 0.1 ksi = ksi = 104.8 ksi
Dw (0.2437 )0.1
49 49
sno = 0.15 ksi = ksi = 60.56 ksi
Dw (0.2437 )
1
(a) Fm = (200 + 150) = 175 lb = 0.175 kip
2
1
Fa = (200 150) = 25 lb = 0.025 kip
2
Figure AF 15, K c = 1.156
K 8FmC 1.2525 8(0.175)(6 )
sms = = = 48.8 ksi
K c Dw2 1.156 (0.2437 )2
8F C 8(0.025)(6 )
sas = K a 2 = 1.2525 2
= 8.1 ksi
Dw (0.2437 )
1 sms sas 2sas
= +
N s ys sno
1 48.8 8.1 2(8.1)
= +
N 104.8 60.56
N = 1.525
1
(b) Fm = (200 + 100) = 150 lb = 0.15 kip
2
1
Fa = (200 100) = 50 lb = 0.05 kip
2
Page 30 of 70
SECTION 4 - SPRINGS
1
(c) Fm = (200 + 25) = 112.5 lb = 0.1125 kip
2
1
Fa = (200 25) = 87.5 lb = 0.0875 kip
2
Figure AF 15, K c = 1.156
K 8FmC 1.2525 8(0.1125)(6)
sms = = = 31.36 ksi
K c Dw2 1.156 (0.2437 )2
8F C 8(0.0875)(6)
sas = K a 2 = 1.2525 2
= 28.2 ksi
w D (0.2437 )
1 sms sas 2sas
= +
N s ys sno
1 31.36 28.20 2(28.20 )
= +
N 104.8 60.56
N = 1.04
CHECK PROBLEMS
A Diesel valve spring is made of 3/8-in. chrome-vanadium steel wire, shot-peened; inside
diameter is 3 in., 7 active coils, free length is 7 3/8 in., solid length is 4 1/8 in., length
with valve closed, 6 in., length when open, 5 1/8 in. (a) Compute the spring constant
and the factor of safety as defined by the Wahl criterion (see 6.13, Text). (b) Is there
any danger of damage to the spring if it is compressed solid? (c) What is the natural
frequency? If this spring is used on a 4-stroke Diesel engine at 450 rpm, is there any
danger of surge? Compute the change of stored energy between working lengths.
Solution:
Page 31 of 70
SECTION 4 - SPRINGS
s ys =
(1.25)(100 ) ksi , [0.032 < D < 0.437]
w
Dw0.166
sno =
(1.25)(49) ksi , [0.028 < D < 0.5]
w
Dw0.15
3
Dw = in = 0.375 in
8
s ys =
(1.25)(100) ksi = 147.1 ksi
(0.375)0.166
sno =
(1.25)(49) ksi = 70.96 ksi
(0.375)0.15
8FC 3 N c
(a) =
GDw
F GD
=k = 3 w
8C N c
G = 11.5 106 psi
Nc = 7
Dw = 0.375 in
Dm Dw = ID = 3 in
Dm = 3.375 in
D 3.375
C= m = =9
Dw 0.375
k = spring constant
k= 3 =
GDw (
11.5 106 )(0.375)
= 105.64 lb in
8(9 ) (7 )
3
8C N c
3 1
1 = 7 4 = 3.25 in
8 8
F1 = k1 = (105.64)(3.25) = 343.33 lb
3 1
2 = 7 6 = 1.125 in
8 4
F2 = k 2 = (105.64)(1.125) = 118.85 lb
1
Fm = (343.33 + 118.85) = 231.09 lb = 0.231 kip
2
1
Fa = (343.33 118.85) = 112.24 lb = 0.11224 kip
2
K 8FmC
sms =
K c Dw2
Page 32 of 70
SECTION 4 - SPRINGS
4C 1 0.615
K= +
4C 4 C
4(9) 1 0.615
K= + = 1.162
4(9 ) 4 9
Figure AF 15, K c = 1.10
K 8FmC 1.162 8(0.231)(9)
sms = 2
= 2
= 39.8 ksi
Kc Dw 1.10 (0.375)
8F C 8(0.11224 )(9)
sas = K a 2 = 1.162 = 21.3 ksi
(0.375)
2
Dw
1 sms sas 2sas
= +
N s ys sno
1 39.8 21.3 2(21.3)
= +
N 147.1 70.96
N = 1.377
For steel
14,050 Dw
= cps
N c Dm2
14,050
= cps
N c C 2 Dw
14,050
= cps = 66 cps
(7 )(9)2 (0.375)
2
For 450 rpm, = 450 = 47 cps
60
66
= 1.4 < 12 , there is danger of surging.
47
Page 33 of 70
SECTION 4 - SPRINGS
(d) U s =
1
2
( ) 1
[ ]
k 12 22 = (105.64 ) (3.25) (1.125) = 491 in lb
2
2 2
289. A helical spring is hot wound from 5/8-in. carbon-steel wire with an outside
diameter of 3 in. A force of 3060 lb. is required to compress the spring 1
in to the solid heigh. In service the spring is compressed so that its
deformation varies form in. to1 1/8 in. (a) What is the factor of safety by
the Wahl criterion? (b) Is the solid stress safe? Compute (c) the pitch angle,
(d) the change of stored energy between the working lengths, (e) the factor of
safety if the spring is peened?
Solution:
Page 34 of 70
SECTION 4 - SPRINGS
5
Dw = in = 0.625 in
8
1
Dm + Dw = 3 in
4
Dm = 2.625 in
D 2.625
C= m = = 4 .2
Dw 0.625
4C 1 0.615
K= +
4C 4 C
4(4.2) 1 0.615
K= + = 1.3808
4(4.2) 4 4.2
K c = 1.234
K 8FmC 1.3808 8(1.4207 )(4.2)
sms = = = 43.5 ksi
K c Dw2 1.234 (0.625)2
8F C 8(0.5464)(4.2)
sas = K a 2 = 1.3808 = 20.7 ksi
(0.625)
2
Dw
1 sms sas 2sas
= +
N s ys sno
1 43.5 20.7 2(20.7 )
= +
N 104.5 60.33
N = 1.106
F = 3.060 kip
8 FC 8(3.060)(4.2)
Solid stress, ss = K 2 = 1.3808 2
= 115.7 ksi < 135.4 ksi , safe
Dw (0.625)
3
(c) Solid deflection = 1 in
4
(P Dw )N c = 1.75 in
8FC 3 N c
=
GDw
G = 10.5 106 psi , hot-wound
F GD
k= = 3w
8C N c
Page 35 of 70
SECTION 4 - SPRINGS
1748.6 =
(10.5 10 )(0.625)
6
8(4.2 ) N c
3
N c = 6.332
(P 0.625)(6.332) = 1.75
P = 0.9014 in
Pitch angle
P P
tan = =
Dm CDw
P 0.9014
= tan 1 = tan 1 = 6.24o
CDw (4.2)(0.625)
(d) U s =
1
2
( 1
) [ ]
k 12 22 = (1748.6 )(1.125) (0.5) = 888 in lb
2
2 2
ENERGY STORAGE
293. A 10-lb. body falls 10 in. and then strikes a helical spring. Design a hard-
drawn carbon steel spring that will absorb this shock occasionally without
permanent damage. Determine appropriate values of wire diameter, coil
diameter, pitch, free length, closed length, and the maximum stress under the
specified conditions, and scale. Let C = 7 .
Solution:
Page 36 of 70
SECTION 4 - SPRINGS
4C 1 0.615
K= +
4C 4 C
4(7 ) 1 0.615
K= + = 1.213
4(7 ) 4 7
D 2
V w (Dm )N c
4
2 Dw2 Dm N c
V=
4
Dm = CDw
2CDw3 N c
V=
4
8FC 3 N c
=
GDw
U s = W (h + )
8 FC
ss = K 2
Dw
s D 2
F= s w
8KC
s D 2 8C 3 N c
= s w
8KC GDw
s sDwC 2 N c
=
KG
2 2 3
ssDwC 2 N c s s CD w N c
U s = W h + =
KG 16 K 2G
Wh
Nc = 2 2 2
ss CDw s sDwC 2W
16 K 2G KG
36.855
when ss = ksi
Dw0.1
Wh
Nc =
(36.855) CDw 36.855D w0.9C 2W
2 2 2.8
16 K 2G KG
Nc =
( 0.010)(10)
(36.855)2 2 (7)Dw2.8 36.855D w0.9 (7 )2 (0.010)
16(1.213) (11,500)
2
(1.213)(11,500)
0.10
Nc =
0.3466 Dw 0.004067 D w0.9
2.8
Page 37 of 70
SECTION 4 - SPRINGS
combination of Dw and N c
Gage No. W & M Dw Nc Dw N c
12 0.1055 991.2 105
11 0.1205 312.1 37.6
10 0.1350 166.1 22.4
9 0.1483 108.0 16.0
8 0.1620 75.2 12.2
7 0.1770 53.7 9.5
6 0.1920 40.2 7.7
5 0.2070 31 6.4
4 0.2253 23.4 5.3
3 0.2437 18.1 4.4
0.9 2
s sDwC 2 N c 36.855D w C N c 36.855 (0.2437 ) (7 ) (18.1)
0.9 2
= = = = 2.066 in
KG KG (1.213)(11,500)
36.855
ss = = 42.44 ksi
(0.2437 )0.1
91 91
sso = 0.1 = = 104.8 ksi
Dw (0.2437 )0.1
Solid deflection
104.8
= (2.066 ) = 5.1 in
42.44
(P Dw )N c = 5.1
(P 0.2437)(18.1) = 5.1
P = 0.5255 in
17
say P = = 0.53125 in
32
Minimum Solid Height = Dw N c = (0.2437 )(18.1) = 4.41 in
Assume squared and ground end
Solid height = Dw N c + 2 Dw = (0.2437 )(18.1) + 2(0.2437 ) = 5.0 in
Solid deflection = (0.53125 0.2437 )(18.1) = 5.2 in
Free length = 5.0 in + 5.2 in = 10.2in
Summary of answer:
Dw = 0.2437 in , No. 3 W & M
Page 38 of 70
SECTION 4 - SPRINGS
45
Dm = 1 in
64
17
P= in
32
Free length = 10.2 in
Closed length = 5 in
Maximum stress = 42.44 ksi
Solution:
0.9837 = Dw2.62 N c
Table AT-15
W&M Dw Nc Dw N c
Page 39 of 70
SECTION 4 - SPRINGS
Page 40 of 70
SECTION 4 - SPRINGS
45
P
= tan 1 = tan 1 64 = 5o < 12o
Dm 2 9
16
Volume
Dw2 (0.4305)2 9
V (Dm )N c = 2 (9 ) = 10.55 in
3
4 4 16
Summary of answer:
Dw = 0.4305 in , No. 5-0 W & M
9
Dm = 2 in
16
Nc = 9
21
Free length = 6 in
64
Pitch Angle = = 5o
Solid Stress = 80.65 ksi
Volume of metal = 10.55 in3
297. Two concentric helical springs are to be subjected to a load that varies from a
maximum of 235 lb. to a maximum of 50 lb. They are to fit inside a 1 5/8 in.
cylinder. The maximum deflection is to be in., and the deflection when
compressed solid is to be approximately 1 in. Using the static approach for
severe service (maximum load), determine the wire diameter, mean coil
diameter, number of coils, solid length, and free length of both springs. (Start
with oil-tempered wire and assume a diametral clearance between the outer
D
spring and the cylinder of w , assume a similar clearance between springs.
2
Search for a suitable spring index and wire size.)
Solution:
Page 41 of 70
SECTION 4 - SPRINGS
146
su = ksi , [0.032 < Dw < 0.5]
Dw0.19
87.5
Max. solid ss = 0.19 ksi , [0.032 < Dw < 0.5]
Dw
Severe service
0.263(146 ) 38.398
ssd = 0.263su = = ksi
Dw0.19 Dw0.19
F = 235 lb = 0.235 kip
o = i
8FoCo3 N co 8Fi Ci3 N i
=
GDwo GDwi
Assume, Co = Ci
3GDwo
Fo =
32C 3 N co
3GDwi
Fi =
32C 3 N ci
8F C
sso = K o2
Dwo
8F C
ssi = K i 2
Dwi
D D
C = mo = mi
Dwo Dwi
4C 1 0.615
K= +
4C 4 C
D
Dmo Dwo wi = Dmi + Dwi
2
Dmo Dmi = Dwo + 1.5Dwi
D
1.625 wo = Dmo + Dwo
2
Dmo + 1.5Dwo = 1.625
CDwo + 1.5Dwo = 1.625
1.625
Dwo =
C + 1 .5
1.625C
Dmo =
C + 1 .5
CDwo CDwi = Dwo + 1.5Dwi
(C 1)Dwo = (C + 1.5)Dwi
Page 42 of 70
SECTION 4 - SPRINGS
1.625(C 1)
Dwi =
(C + 1.5)2
1.625C (C 1)
Dmi =
(C + 1.5)2
8F C 38.398
sso = K o2 = 0.19 ksi
Dwo Dwo
1.81
15.08Dwo
Fo =
KC
8F C 38.398
ssi = K i 2 = 0.19 ksi
Dwi Dwi
1.81
15.08Dwi
Fi =
KC
Fo + Fi = F = 0.235 kip
1.81 1.81
15.08Dwo 15.08Dwi
+ = 0.235
KC KC
1.81 1.81
15.08 Dwo + 15.08 Dwi = 0.235 KC
1.81 1.81
1.625 1.625(C 1)
15.08 + 15.08 = 0.235 KC
C + 1 .5 C + 1.5
1 (C 1)
1.81
4C 1 0.615
154.52 + 3.62
= 0.235 + C
(C + 1.5) (C + 1.5)
1.81
4C 4 C
C = 5.328
1.625(5.328 1)
Dwi = = 0.1509 in
(5.328 + 1.5)2
1.625
Dwo = = 0.2380 in
5.328 + 1.5
Table AT 15, use Dwi = 0.1620 in , No. 8 W & M and Dwo = 0.2625 in , No. 2 W & M
13
Dmo = CDwo = (5.328)(0.2625) = 1.3986 in 1 in
32
7
Dmi = CDwi = (5.328)(0.1620 ) = 0.8631 in in
8
7
= = 5.401
Dmi 8
Ci =
Dwi 0.1620
13
1
=
Dmo 32
Co = = 5.357
Dwo 0.2625
Page 43 of 70
SECTION 4 - SPRINGS
1.81
15.08Dwo
Fo =
K o Co
4(5.357 ) 1 0.615
Ko = + = 1.287
4(5.357 ) 1 5.357
15.08(0.2625)
1.81
Fo = = 0.194 kip
(1.287 )(5.357 )
1.81
15.08Dwi
Fi =
K i Ci
4(5.401) 1 0.615
Ki = + = 1.2843
4(5.401) 1 5.401
15.08(0.1620)
Fi = = 0.081 kip
(1.2843)(5.401)
Fo + Fi = 0.194 + 0.071 = 0.275 kip > 0.235 kip , ok
3GDwo
Fo =
32C 3 N co
3(11,500)(0.2625)
0.194 =
32(5.357 ) N co
3
N co = 9.5
3GDwi
Fi =
32C 3 N ci
3(11,500)(0.1620)
0.071 =
32(5.401) N ci
3
N ci = 15.6
87.5
Max. solid stress, sss = 0.19 ksi ,
Dw
87.5
ssso = = 112.82 ksi
(0.2625)0.19
87.5
sssi = = 123.65 ksi
(0.1620)0.19
Stress
38.398
ssi = = 54.26 ksi
(0.1620)0.19
38.398
sso = = 49.51 ksi
(0.2625)0.19
Solid stress
1
sso = 49.51 = 66.01 ksi < 112.82 ksi
0.75
Page 44 of 70
SECTION 4 - SPRINGS
1
ssi = 54.26 = 72.35 ksi < 123.65 ksi
0.75
Solid length
Dwo N co = (0.2625)(9.5) = 2.5 in
Dwi N ci = (0.1620 )(15.6) = 2.53 in
Free Length = 3 in + 1 in = 4 in
Summary of answer:
Outside wire.
Dwo = 0.2625 in , No. 2 W & M
13
Dmo = 1 in
32
N to = 11.43
Solid length = 3 in
Free length = 4 in
Inside wire.
Dwi = 0.1620 in , No. 8 W & M
7
Dmi = in
8
N ti = 18.52
Solid length = 3 in
Free length = 4 in
298. Two concentric, helical compression springs are used on a freight car. The
larger spring has an outside diameter of 7 in., a free length of 7 1/8 in., and is
made of a 1 in. steel bar. The smaller has an outside diameter of 4 1/8 in., a
free length of 6 13/16 in. , and is made of 7/8 in. steel bar. The solid height of
each spring is 5 in. and the forces required to compress them solid are
15,530 lb. and 7,000 lb., respectively. The working load on the two springs is
11,350 lb. Determine (a) the number of free coils in each spring, (b) the stress
in each spring when compressed solid, (c) the stresses induced by the working
Page 45 of 70
SECTION 4 - SPRINGS
load. Notice that the outer spring deflects 5/16 in. before the inner one takes a
load. (d) What energy is absorbed while changing deflection from that at the
working load to that when the springs are compressed solid?
Solution:
ODo = 7 in
3
Dwo = 1 in
8
1
FLo = 7 in
8
1
ODi = 4 in
8
7
Dwi = in
8
13
FLi = 6 in
16
1
(a) Solid height = Dw N T = 5 in
4
5.25
N To = = 3.82
1.375
5.25
N Ti = =6
0.875
(b) Fo = 15,530 lb
Fi = 7000 lb
8 FC
ss = K 2
Dw
3
Dmo = 7 1 = 5.625 in
8
Dmo 5.625
Co = = = 4.091
Dwo 1.375
4(4.091) 1 0.615
Ko = + = 1.393
4(4.091) 4 4.091
1 7
Dmi = 4 = 3.25 in
8 8
D 3.25
Ci = mi = = 3.714
Dwi 0.875
4(3.714) 1 0.615
Ki = + = 1.442
4(3.714) 4 3.714
Page 46 of 70
SECTION 4 - SPRINGS
Solid stress
8(15,530)(4.091)
sso = 1.393 = 119,203 psi
(1.375 ) 2
8(7000 )(3.714 )
ssi = 1.442 = 124,689 psi
(0.875)
2
Fi + Fo = 11,350 lb
15,530
ko = = 8283 lb in
1 1
7 5
8 4
7000
ko = = 4480 lb in
13 1
6 5
16 4
5
o i = = 0.3125 in
16
Fi = ki i = 4480 i
Fo = ko o = 8283(0.3125 + i )
Fi + Fo = ko o = 4480 i + 8283(0.3125 + i ) = 11,350 lb
i = 0.6865 in
o = 0.3125 + 0.6865 = 0.9990 in
Fi = (4480)(0.6865) = 3076 lb
Fo = (8283)(0.9990) = 8275 lb
Stresses
8(8275)(4.091)
sso = 1.393 = 63,516 psi
(1.375)
2
8(3076)(3.714)
ssi = 1.442 = 54,792 psi
(0.875)
2
(d) Energy
1
U so = ko ( o22 o21 )
2
1 1
o 2 = 7 5 = 1.875 in
8 4
o1 = 0.9990 in
1
[ ]
U so = (8283)(1.875) (0.999 ) = 10,427 in lb
2
2 2
Page 47 of 70
SECTION 4 - SPRINGS
1
U si =
2
( )
ki i22 i21
13 1
i 2 = 6 5 = 1.5625 in
16 4
o1 = 0.6865 in
1
[ ]
U si = (4480 )(1.5625) (0.6865) = 4,413 in lb
2
2 2
TORSION-BAR SPRINGS
299. A torsion-bar similar to that shown is to be used for the front spring of an
automobile. Its rate should be 400 lb./in. of deflection of the end of the arm
which is e = 10 in. long. It is made of AISI 9261,OQT 900 oF, and the
maximum repeated load is 1500 lb. perpendicular to the centerline of the arm.
The support is such that bending of the bar is negligible. (a) Determine its
diameter and length so that no permanent set occurs due to a 30 % overload
(limited by a stop). Use s ys = 0.6 s y , but check with equation (c) 6.3, Text, if
appropriate. (b) Determine the factor of safety according to the Soderberg
criterion if the load varies from 1200 lb. to 1500 lb.; minimum r d = 0.1 ,
D d = 3 . (c) The same as (b) except that the bar is shot-peened all over. What
other steps may be taken to improve the fatigue strength?
Solution:
e = 10 in
For AISI 9261, OQT 900 oF
s y = 192 ksi
su = 215 ksi
s ys = 0.6 s y = 115.2 ksi = 115,200 psi
Page 48 of 70
SECTION 4 - SPRINGS
16T
(a) ss =
d3
T = Fe = (1.3)(1500)(10) = 19,500 in lb
16(19,500 )
115,200 =
d3
d = 0.95 in
use d = 1 in
117 117
6.3 ss = 0.3 = 0.3 = 117 ksi s ys
Dw (1)
(b) Soderberg Criterion
1 sms K f sas
= +
N s ys sns
sns = (0.6)(0.5)(215) = 64.5 ksi
Figure AF 12, r d = 0.1 , D d = 3
K t = 1.45
K f K t = 1.45
1
Fm = (1500 + 1200) = 1350 lb
2
Tm = (1350)(10) = 13,500 in lb = 13.5 in kips
16(13.5)
sms = = 68.8 ksi
(1)3
1
Fa = (1500 1200) = 150 lb
2
Ta = (150)(10) = 1500 in lb = 1.5 in kips
16(1.5)
sas = = 7.64 ksi
(1)3
1 68.8 (1.45)(7.64 )
= +
N 115.2 64.5
N = 1.30
(c) Shot-peened
s ys = 1.25(115.2 ) = 144 ksi
sns = 1.25(64.5) = 80.6 ksi
1 68.8 (1.45)(7.64 )
= +
N 144 80.6
N = 1.625
Page 49 of 70
SECTION 4 - SPRINGS
300. A solid steel torsion bar is loaded through a 10 in. arm as shown. The load F
perpendicular to the center-line of the arm varies from 500 to 1000 lb.,
7
200,000 cycles. The bar is d = in. in diameter and 30 in. long; let D d = 3 ;
8
r d = 0.1 ; (a) Determine the maximum stress in the bar, the angular
deflection, and the scale (lb./in.) where F is applied. The support is such that
bending of the bar is negligible. (b) Select a material and heat treatment for
this bar for a minimum N = 1.2 , Soderberg criterion.
Page 50 of 70
SECTION 4 - SPRINGS
TL 64TL
= =
JG d 4G
64(500 )(10 )(30 )
min = 4
= 0.4533 rad
7
(
11.5 10 6
)
8
64(1000 )(10 )(30 )
max = 4
= 0.9066 rad
7
(
11.5 10 6
)
8
F 1000
scale = = = 110.3 lb in
e (0.9066)(10)
1 sms K f sas
(c) = +
N s ys sns
0.085
10 6
sns = (0.6 )(0.5)su = 0.344 su
200,000
s ys = 0.6 s y
1
=
57
+
(1.33)(19)
1.2 0.6s y 0.344su
Use AISI 8760, OQT 800 oF
s y = 200 ksi
su = 220 ksi
N = 1.24
Solution:
Page 51 of 70
SECTION 4 - SPRINGS
Free length = PN c + 2b
F = 0.325 lb
2.4 FDm 2.4(0.325)(1.5)
ss = Kq = 1.275 = 48.65 ksi
(0.313)
3 3
b
0.6(146 )
solid stress = = = 109.2 ksi
(0.313)0.19
109.2 13
solid deflection = = = 0.91 in
48.65 32
(P b )N c = 0.91
(P 0.313)(7.34) = 0.91
P = 0.437 in
Page 52 of 70
SECTION 4 - SPRINGS
7
use P = in
16
7 27
Free length = PN c + 2b = (7.34 ) + 2(0.313) = 3.837 in 3 in
16 32
7
=
P 16
tan =
Dm (1.5)
= 5.3o < 10o
1 2 1 1 13
(d) U s = k = F = (0.325) = 0.066 in kip = 66 in lb
2 2 2 32
66
Us = = 0.085 Btu
778
302. A coil spring, of hard-drawn carbon steel, is to deflect 1 in. under a load of
100 lb. The outside coil diameter is to be 1 in. Compute the number of active
coils, (a) if the wire is round, 5/32 in. in diameter, (b) if the wire is square,
5/32 in. on the side, (c) if the wire is rectangular 1/8 x 3/16 in., long
dimension parallel to the axis, (d) If the wire is rectangular 3/16 x 1/8 in.,
short dimension parallel to the axis. (e) What is the maximum stress in each of
the above springs under the 100-lb load? (f) What is the ratio of the
approximate volumes, square- or rectangular-wire to round wire spring?
Solution:
Dm + Dw = 1 in
5
(a) Dw = in
32
5 27
Dm = 1 = in
32 32
27
Dm 32
C= = = 5.4
Dw 5
32
8FC 3 N c
=
GDw
8(100 )(5.4 ) N c
3
1=
5
(
11.5 10 6 )
32
N c = 14.3
Page 53 of 70
SECTION 4 - SPRINGS
5
(b) Square, b = in
32
5 27
Dm = 1 = in
32 32
2.45 FD m3 N c
=
0.44Gb 4
3
27
2.45(100) N c
1= 32
4
6 5
( )
0.44 11.5 10
32
N c = 20.5
3 1
(c) b = in , t = in
16 8
1 7
Dm = 1 t = 1 = in
8 8
3
2.45FD m N c
= 3
Gt (b 0.56t )
3
7
2.45(100 ) N c
1= 8
3
1 3 1
( )
11.5 10 6 0.56
8 16 8
N c = 16.1
1 3
(d) b = in , t = in
8 16
3 13
Dm = 1 t = 1 = in
16 16
3
2.45FD m N c
= 3
Gt (b 0.56t )
3
13
2.45(100 ) N c
1= 16
3
3 1 3
( )
11.5 10 6 0.56
16 8 16
N c = 11.5
Page 54 of 70
SECTION 4 - SPRINGS
8 FC
For (a) ss = K
Dw3
4(5.4) 1 0.615
K= + = 1.284
4(5.4) 4 5.4
8(100)(5.4)
ss = 1.284 = 72,320 psi
5 3
32
Page 55 of 70
SECTION 4 - SPRINGS
K q = 1 .2
13
(100)
ss = 1.2 16 3 1 + 1.8 3 = 63,232 psi
1 3 2 8
2
16
2
8 16
Ratio of volume
Square to round wire
V 1.327
= b = = 1.825
Va 0.727
Rectangular to round wire (long dimension parallel to the axis)
V 1.037
= c = = 1.426
Va 0.727
Rectangular to round wire (short dimension parallel to the axis)
V 0.688
= d = = 0.946
Va 0.727
Page 56 of 70
SECTION 4 - SPRINGS
TENSION SPRINGS
305. Design two tension springs for a spring balance with a capacity of 200 lb.
Each spring supports a maximum load of 100 lb. The outside diameter must
not exceed 1 in. and the total length including end loops must not exceed 9
in. Select a material and determine the dimension, including wire diameter,
number of coils, and free length.
Solution:
Table AT 17, assume oil tempered wire
146
su = 0.19 ksi
Dw
87.5
s ys = 0.19 ksi
Dw
0.8(87.5) 70
ssd = 0.19
= 0.19 ksi , [0.032 < Dw < 0.5]
Dw Dw
F = Fi + k
8 K cFDm
ss =
Dw3
2r D
C= m = m
Dw Dw
8FaC 3 N c
=
G Dw
GD
k = 3w
8C N
G D 8F C N c
3
k = 3 w a = Fa
8C N GDw
Fa = 100 lb = 0.10 kip
Figure AF 15, assume K c = 1.2
8 K cFi Dm 8 K cFa Dm
ss = +
Dw3 Dw3
8 K cFaC
s s = K c si +
Dw2
OD = Dm + Dw = 1.25 in
1.25
Dw =
C +1
6.21, assume si = 18 ksi
ssd = ss
Page 57 of 70
SECTION 4 - SPRINGS
70 8(1.2 )(0.1)C
0.19
= (1.2 )(18) +
Dw Dw2
70(C + 1) 8(1.2 )(0.1)C (C + 1)
0.19 2
= 21.6 +
(1.25)0.19 (1.25)2
67.1(C + 1) = 21.6 + 0.1956C (C + 1)
0.19 2
C = 6 .7
1.25 1.25
Dw = = = 0.1623 in
C + 1 6 .7 + 1
Table AT 15, use Dw = 0.1620 in , 8 W & M
Dm = CDw = (6.7 )(0.1620 ) = 1.085 in
say Dm = 1.0 in
D 1 .0
C= m = = 6.17
Dw 0.1620
si = 17.7 ksi
To check, Fig. AF 15, K c = 1.15
8(1.15)(0.10 )(6.17 )
ss = 1.15(17.7 ) + = 89.20 ksi
(0.1620)2
70
ssd = = 98.92 ksi > 89.20 ksi , o.k.
(0.1620)0.19
Total length = Dw N c + 2(Dm + Dw )
9.5 = (0.162)N c + 2(1.0 + 0.162)
N c = 44.3 coils
Summary of answer:
Material, oil-tempered wire
Dw = 0.1620 in , 8 W & M
N c = 44.3 coils
Free length = 7.18 in.
306. Two helical tension springs are to be used in scales for weighing milk. The
capacity of the scales is 30 lb., each spring carries 15 lb. with a deflection of 3
9/16 in. The springs are made of No. 14, W & M steel wire, outside diameter,
29/32 in. (a) how many coils should each spring have? (b) What is the
maximum stress in the wire? What material should be used?
Page 58 of 70
SECTION 4 - SPRINGS
Solution:
k = 15 lb
9
= 3 in
16
(a) Table AT 15, No. 14 W &M
Dw = 0.0800 in
29
Dm = OD Dw = 0.0800 = 0.82625 in
32
D 0.82625
C= m = = 10.328
Dw 0.0800
8(k )C 3 N c
=
GDw
9 8(15)(10.328) N c
3
3 =
(
16 11.5 106 (0.080) )
N c = 24.8
(b) F = Fi + k
si Dw3
Fi =
8Dm
6.21, C = 10.328
si = 11,272 psi
(11,272)(0.08)3
Fi = = 2.743 lb
8(0.82625)
F = 2.743 + 15 = 17.743 lb
Figure AF 15, K c = 1.09
8 K c FDm 8(1.09 )(17.743)(0.82625)
ss = = = 79,476 psi
Dw3 (0.080)3
s 79,476
s ys s = = 99,345 psi = 99.345 ksi
0 .8 0 .8
Table AT 17, use Hard drawn wire
70 70
s ys = 0.19 = = 113 ksi > 99.345 ksi
Dw (0.080)0.19
307. A tension spring for a gas-control lever is made of Dw = 0.078 in steel wire;
inside diameter, 0.609 in.; number of coils, 55; free length including end
loops, 5 9/16 in. When the spring is extended to a length of 6 5/16 in., it must
exert a force 5 lb.; it must extend to (a) the initial tension, (b) the stress in
the spring caused by the initial tension (compare with the recommended
Page 59 of 70
SECTION 4 - SPRINGS
maximum values), (c) the stress caused by the 5 -lb load, (d) the maximum
stress. What material should be used? (e) What energy is absorbed from the
point where the load is the initial tension until the springs length is 6 5/16 in.?
(Data courtesy Worthington Corporation.)
Solution:
Dw = 0.078 in
Dm Dw = 0.609 in
Dm = 0.609 + 0.078 = 0.687 in
D 0.687
C= m = = 8 .8
Dw 0.078
N c = 55
8FC 3 N c
=
GDw
1
F = 5 lb
2
5 9
= 6 5 = 0.75 in
16 16
8(k )(8.8) (5)
3
= 0.75 =
( )
11.5 106 (0.078)
k = 2.244 lb
(c) F = 5.5 lb
8 K c FC
ss =
Dw2
C = 8 .8
Figure AF 15
K c = 1.1
8(1.1)(5.5)(8.8)
ss = = 22,284 psi
(0.078)2
Page 60 of 70
SECTION 4 - SPRINGS
F = k
5 9
= 9 5 = 3.75 in
16 16
F = Fi + k = 3.256 + (2.992)(3.75) = 14.476 lb
8 K c FC 8(1.1)(14.476 )(8.8)
ss = = = 58,651 psi
Dw2 (0.078)2
Table AT 16
s 58,651
s ys s = = 73,300 psi = 73.3 ksi
0 .8 0 .8
Table AT 17, use Hard drawn wire
70 70
s ys = 0.19 = = 113.658 ksi > 73.3 ksi
Dw (0.078)0.19
1 2 1
k = (2.992 )(0.75) = 0.8415 in lb
2
(e) U s =
2 2
TORSION SPRINGS
Solution:
T = M = Fa
F = 55 lb
a = 2 in
T = M = (55)(2) = 110 in lb
Dm = 2.5 in
182
Table AT 17, su = 0.1 ksi , [0.093 < Dw < 0.25]
Dw
Average service
182 117.936 117,936
sd = (1.6 )(0.405)su = 0.648 0.1 = 0.1
ksi = psi
Dw Dw Dw0.1
KMc
(a) ss =
I
For round wire, assume K c = K ci = 1.08 , Table AT 18
D
c= w
2
Page 61 of 70
SECTION 4 - SPRINGS
I Dw3
=
c 32
ss =
(1.08)(110)(32) = 117,936
Dw3 Dw0.1
Dw = 0.2060 in < 0.25 in
Table AT 15, use Dw = 0.2070 in , No. 5 W & M
r D 2
To check: = m = = 9.66 > 9 , ok
c Dw 0.2070
Table AT 18, K = 1.08
ss =
(1.08)(110)(32) = 136,430 psi
(0.2070 )3
117,936
ssd = = 138,054 psi > 136,430 psi
(0.2070)0.1
Therefore, use No. 5 W & M, Dw = 0.2070 in
MDm N c
(b) =
EI
6
E = 30 10 psi
Dw4
I=
64
= 180o =
64 MDm N c
=
EDw4
64(110 )(2 )N c
=
(30 106 )(0.2070)4
N c = 12.29
1 1
(c) U s = T = (110 )( ) = 172.8 in lb
2 2
312. A pivoted roller follower is held in contact with the cam by a torsion spring.
The moment exerted by the spring varies from 20 lb-in to 50 lb-in. as the
follower oscillates through 30o. The spring is made of AISI 6152 steel, OQT
1000 oF. What should be the value of Dw , Dm , and N c if the factor of safety
is 1.75 based on the Soderberg line? Would this be a conservative or risky
approach?
Solution:
AISI 6152, OQT 1000 oF
su = 184 ksi
Page 62 of 70
SECTION 4 - SPRINGS
s y = 173 ksi
sn = 0.5su = 92 ksi
1
M m = (50 + 20 ) = 35 lb in
2
1
M a = (50 20 ) = 15 lb in
2
assume K = 1.08
32 KM m 32(1.08)(35) 385
sm = = = 3 psi
Dw3 Dw3 Dw
32 KM a 32(1.08)(15) 165
sa = = = 3 psi
Dw3 Dw3 Dw
1 s m sa
= +
N s y sn
1 385 165
= +
1.75 173,000 Dw 92,000 Dw3
3
Dw = 0.1916 in
Table AT 15, use Dw = 0.1920 in , No. 6 W & M
To solve for K
32(35)K
sm = = 50,369 K psi
(0.1920)3
32(15)K
sa = = 21,587 K psi
(0.1920)3
1 50,369 K 20,587 K
= +
1.75 173,000 92,000
K = 1.0868
Table AT 18 K ci = K = 1.0868
r Dm
= = 9.32 > 9 , ok
c Dw
Dm = 9.32(0.1920) = 1.7894 in
7
use Dm = 1 in = 1.875 in
8
MDm N c 64MDm N c
= =
EI EDw4
30 64(50 20 )(1.875)N c
=
180 (30 106 )(0.1920)4
N c = 5.93
Summary of answer:
Dw = 0.1920 in , No. 6 W & M
Page 63 of 70
SECTION 4 - SPRINGS
7
Dm = 1 in
8
N c = 5.93 , N > 1.4 , therefore conservative.
315. A cantilever flat spring of uniform strength, Fig. 6.20, Text, is to absorb an
energy impact of 500 ft-lb. Let the thickness of the steel, AISI 1095, OQT 900
o
F, be in. and let the maximum stress be half of the yield strength. (a) Find
the width b of the spring at the widest point in terms of the length L .
Determine values of b for lengths of 36 in., 48 in., 60 in., and 72 in. (b)
Determine the deflection of the spring for each set of values found in (a).
Solution.
Fig. 6/20
6 FL
sB =
bh 2
6 FL3
=
Ebh3
AISI 1095, OQT 900 oF, s y = 104 ksi , Table AT 9
s B = 0.5s y = 0.5(104 ) = 52 ksi = 52,000 psi
1
Us = F
2
s bh 2
F= B
6L
s bh 2 L3 s B L2
= 6 B 3
=
6 L Ebh Eh
1 s bh 2 s B L2 1 s B2 bhL
U s = B =
2 6 L Eh 12 E
U s = 500 ft lb = 6000 in lb
Page 64 of 70
SECTION 4 - SPRINGS
(52,000)2 b 1 L
6000 =
1 2
12 30 106
bL = 1598 in 2
1598 in 2
b=
L
1598 in 2
L = 36 in , b = = 44.4 in
36 in
1598 in 2
L = 48 in , b = = 33.3 in
48 in
1598 in 2
L = 60 in , b = = 26.6 in
60 in
1598 in 2
L = 72 in , b = = 22.2 in
72 in
s B L2
(b) =
Eh
L = 36 in , =
(52,000 )(36 )
2
= 4.4928 in
1
(
30 10 6
)
2
L = 48 in , =
(52,000 )(48)
2
= 7.9872 in
6 1
(
30 10 )
2
L = 60 in , =
(52,000 )(60 )
2
= 12.48 in
6 1
(
30 10 )
2
L = 72 in , =
( 52,000)(72 )
2
= 17.9712 in
6 1
(
30 10 )
2
317. One of the carbon contacts on a circuit breaker is mounted on the free end of
a phosphor-bronze beam ( = 0.35 ). This beam has the shape of the beam
9 1 1
shown in Fig. 6.24, Text, with b = 1 in. , b = in. , L = 4 in. , and h = in.
16 2 16
When the contacts are closed, the beam deflects in. Compute (a) the force
on the contacts, (b) the maximum stress.
Solution:
Page 65 of 70
SECTION 4 - SPRINGS
Figure 6.24
6 FL 3WL
s= 2 =
bh bh 2
= 1
(
K FL3 1 2 ) (
K WL3 1 2
= 1
)
3EI 6 EI
9
b 16
= = 0.5625
b 1
Figure 6.25, K1 = 1.14
=
3
[
3 4(1.14 )F (4.5) 1 (0.35)
2
]
3
4
(16 106 )(1) 161
F = 8 lb
6 FL 6(8)(4.5)
(b) s = = 2
= 55,296 psi
bh 2 1
(1)
16
318. A cantilever leaf spring 26 in. long is to support a load of 175 lb. The
construction is similar to that shown in Fig. 6.22 (a), Text. The leaves are to
be 2 in. wide, 3/16 in. thick; SAE 9255 steel, OQT 1000 oF; 107 cycles (
6.26). (a) How many leaves should be used if the surfaces are left as rolled?
(b) The same as (a) except that the leaves are machined and the surfaces are
not decarburized. (c) The same as (b), except that the surface is peened all
over. (d) Which of these springs absorbs the most energy? Compute for each:
(e) What are the load and deflection of the spring in (b) when the maximum
stress is the standard-test yields strength?
Solution:
Figure 6.22 (a)
6 FL
sA = 2
bh
Page 66 of 70
SECTION 4 - SPRINGS
6 FL3
A =
Ebh3
b = N1b
F = 175 lb
b = 2 in
3
h = in
16
L = 26 in
6.26, SAE 9255, OQT 1000 oF
su = 180 ksi
s y = 160 ksi
3
t= in = 0.1875 in
16
sd = 83.75 ksi
Page 67 of 70
SECTION 4 - SPRINGS
1
(d) U s = F
2
F = 175 lb
6 FL3
=
EN1bh 3
For (a) N1 = 17
6(175)(26 )
3
= 3
= 2.745 in
3
( )
30 10 (17 )(2 )
6
16
1
U s = (175)(2.745) = 240 in lb
2
For (b) N1 = 7
6(175)(26 )
3
= 3
= 6.666 in
3
( )
30 10 6 (7 )(2 )
16
1
U s = (175)(6.666 ) = 583 in lb
2
For (c) N1 = 5
6(175)(26 )
3
= 3
= 9.332 in
3
( )
30 10 (5)(2 )
6
16
1
U s = (175)(9.332 ) = 817 in lb
2
Page 68 of 70
SECTION 4 - SPRINGS
6 FL 6 FL
sd = 2
=
bh N1bh 2
6 F (26 )
160,000 = 2
(7 )(2) 3
16
load F = 505 lb
6(505)(26 )
3
= 3
= 19.24 in
3
( )
30 10 (7 )(2 )
6
16
319. The rear spring of an automobile has 9 leaves, each with an average thickness
of 0.242 in. and a width of 2 in.; material is SAE 9261, OQT 1000 oF. The
length of the spring is 56 in. and the total weight on the spring is 1300 lb.
Assume the spring to have the form shown in Fig. 6.22 (b), Text. Determine
(a) the rate of the spring, (b) the maximum stress caused by the dead weight.
(c) What approximate repeated maximum force (0 to Fmax ) would cause
impending fatigue in 105 cycles, the number of applications of the maximum
load expected during the ordinary life of a car? (If the leaves are cold rolled
to induce a residual compressive stress on the surfaces, the endurance limit as
su 2 should be conservative.)
Solution:
Figure 6.22 (b)
3FL
sA =
2bh 2
3FL3
A =
8Ebh 3
F = 1300 lb
h = 0.242 in
N1 = 9
b = 2 in
L = 56 in
F 8Ebh3
(a) Rate , k = =
A 3L3
k= =
( )
8 EN1bh 3 8 30 10 6 (9 )(2 )(0.242 )
3
= 116.21lb in
3(56 )
3
3L3
Page 69 of 70
SECTION 4 - SPRINGS
F = 1200 lb
321. The front spring of an automobile is made similar to Fig. 6.23, Text. The
average thickness for each of the 6 leaves, 0.213 in.; material is SAE 9255,
OQT 1000 oF. The load caused by the weight of the car is 775 lb. (a) What
stress is caused by a force of twice the dead weight? (b) What load would
stress the spring to the yield strength?
Solution:
Figure 6.23
6 FL 3WL 3WL
s= 2 = 2
=
bh bh N1bh 2
W = 775 lb , N1 = 6 , b = 2 in , h = 0.213 in
36 in
L= = 18 in
2
(a) W = 2(775) = 1550 lb
3(1550 )(18)
s= = 153,740 psi
(6)(2)(0.213)2
(b) SAE 9255, OQT 1000 oF
s y = 160 ksi
6 FL 3WL 3WL
s= 2
= 2
=
bh bh N1bh 2
3W (18)
160,000 =
(6)(2)(0.213)2
W = 1613 lb
- end -
Page 70 of 70
SECTION 5 COLUMNS
DESIGN PROBLEMS
334. A round steel rod made of structural steel, AISI C1020, as rolled, is to be used as
a column, centrally loaded with 10 kips; N = 3 . Determine the diameter for (a)
L = 25 in. , (b) L = 50 in. (c) The same as (a) and (b) except that the material is
AISI 8640, OQT 1000 F. Is there any advantage in using this material rather than
structural steel?
Solution:
For AISI C1020,as rolled
s y = 48 ksi
F = 10 kips
N =3
(a) Le = L = 25 in.
Consider first J.B. Johnson
Le
2
sy
Fc = NF = s y A1 2
k
4 E
2
D
A=
4
D
k=
4
E = 30 103 ksi
2
(48) 25
D
2
(3)(10) = (48) D 1 2 4 3
(
4 4 30 10 )
4
30 = 12D 2 1 2 2
D
48
30 = 12D 2
D = 1.096 in
1
say D = 1 in = 1.0625 in
16
Page 1 of 18
SECTION 5 COLUMNS
Le 25
= = 94 < 120 o.k.
k 1.0625
4
(b) Le = L = 50 in.
Consider Eulers Equation
2 EA
Fc = NF = 2
Le
k
D 2
(
2 30 103 ) 4
(3)(10 ) =
2
50
D
4
3 4
30 = 0.1875 D
D = 1.507 in
1
say D = 1 in = 1.5 in
2
Le 50
= = 133 > 120 o.k.
k 1 .5
4
Le 2 2 E 2
=
k s y
1
(
Le 2 2 30 103 2
=
)
k 150 = 62.83
For (a) Le = L = 25 in.
Consider first J.B. Johnson
Le
2
sy
Fc = NF = s y A1 2
k
4 E
Page 2 of 18
SECTION 5 COLUMNS
2
(150) 25
D
2
(3)(10) = (150) D 1 2 4 3
(
4 4 30 10 )
12.5
30 = 37.5D 2 1 2 2
D
468.75
30 = 37.5D 2
D = 1.23 in
say D = 1.25 in
Le 25
= = 80 > 62.83 use Eulers equation
k 1.25
4
2 EA
Fc = NF = 2
Le
k
D 2
(
2 30 103 ) 4
(3)(10) =
2
25
D
4
3 4
30 = 0.75 D
D = 1.0657 in
1
say D = 1 in = 1.0625 in
16
Le 25
= = 94 > 62.83 ok
k 1.0625
4
For (b) Le = L = 50 in.
Consider Eulers Equation
2 EA
Fc = NF = 2
Le
k
Page 3 of 18
SECTION 5 COLUMNS
D 2
2 (30 103 )
(3)(10) = 4
2
50
D
4
3 4
30 = 0.1875 D
D = 1.507 in
1
say D = 1 in = 1.5 in
2
Le 50
= = 133 > 62.83 o.k.
k 1 .5
4
There is no advantage.
335. A hollow circular column, made of AISI C1020, structural steel, as rolled, is to
support a load of 10,000 lb. Let L = 40 in , Di = 0.75Do , and N = 3 . Determine
Do by (a) using either Eulers or the parabolic equation; (b) using the straight-
line equation. (c) What factor of safety is given by the secant formula for the
dimensions found in (a)?
Solution:
For AISI C1020, as rolled
s y = 48 ksi
Le = L = 40 in
F = 10,000 lb = 10 kips
N =3
Di = 0.75Do
I
k=
A
(Do4 Di4 )
I=
64
[ 4
]
= Do4 (0.75Do ) = 0.033556 Do4
A= =
[
(Do2 Di2 ) Do2 (0.75Do )2 ]
= 0.343612 Do2
4 4
0.033556 Do4
k= = 0.3125Do
0.343612 Do2
Page 4 of 18
SECTION 5 COLUMNS
sy
Fc = NF = s y A1 2
k
4 E
2
25
(48)
0.3125Do
(3)(10) = (48)(0.343612)Do2 1 2 4 3
(
4 30 10 )
30 = 16.493376 Do2 10.9519
Do = 1.576 in
9
say Do = 1 in = 1.5625 in
16
Le 40
= = 82 < 120 o.k.
k 0.3125(1.5625)
Page 5 of 18
SECTION 5 COLUMNS
ec
= 0.25 , (i7.8)
k2
N (10) 40 10 N
1 + 0.25 sec
48 =
0.8389 2(0.4883) (30 103 )(0.8389)
[ (
48 = 11.92 N 1 + 0.25 sec 0.81645 N )]
N = 2.289
336. A column is to be built up of -in., AISI C1020, rolled-steel plates, into a square
box-section. It is 6 ft long and centrally loaded to 80,000 lb. (a) Determine the
size of section for N = 2.74 . (b) Compute N from the secant formula for the
size found and compare with 2.74.
Solution:
For AISI C1020, rolled-steel plate
s y = 48 ksi
b 4 (b 1) b 4 (b 1)
4 4
I= =
12 12 12
A = b (b 1)
2 2
b 4 (b 1)
4
I
k= =
A [
12 b 2 (b 1)
2
]
Le = L = 6 ft = 72 in
F = 80,000 lb = 80 kips
(a) N = 2.74
Consider J.B. Johnson
Le
2
sy
NF = s y A1 2
k
4 E
72
2
(48)
(2.74)(80) = (48)A 1 2 k 3
4 (30 10 )
10.085 A
219.2 = 48 A
k2
Page 6 of 18
SECTION 5 COLUMNS
try b = 3.23 in
k=
(3.23) (3.23 1)
4 4
2 = 1.1331 in
12[(3.23) (3.23 1) ]
2
10.085(5.46 )
219.2 = 48(5.46 ) = 219.2 ok
(1.1331)2
Therefore use b = 3.23 in
Le 72
= = 63.54 < 120 o.k.
k 1.1331
1
b = 3.23 in or b = 3 in
4
NF ec Le NF
(b) s y = 1 + sec
A k 2 2k EA
ec
= 0.25 , (i7.8)
k2
N (80) 72 80 N
1 + 0.25 sec
48 =
5.46 2(1.1331) (30 103 )(5.46)
[ (
48 = 14.652 N 1 + 0.25 sec 0.70214 N )]
N = 2.2 < 2.74
337. A column is to be made of -in structural steel plates (AISI 1020, as rolled),
welded into an I-section as shown in Table AT 1 with G = H . The column, 15 ft
long, is to support a load of 125 kips. (a) Determine the cross-sectional
dimensions from the straight-line equation. (Using either Johnsons or Eulers
equation, compute the equivalent stress and the factor of safety. (c) Compute N
from the secant formula.
Solution:
For AISI C1020, as rolled
s y = 48 ksi
Le = L = 15 ft = 180 in
F = 125 kips
Page 7 of 18
SECTION 5 COLUMNS
Table AT 1.
G=H
( )
A = GH gh = H 2 (H 0.5)(H 1) = H 2 H 2 1.5H + 0.5 = 1.5H 0.5 = 0.5(3H 1)
1 GH 3 gh3 1 H 4 (H 0.5)(H 1) H 4 (H 0.5)(H 1)
3 3
k= = =
12 GH gh 12 0.5(3H 1) 6(3H 1)
k=
(7.37 )4 (7.37 0.5)(7.37 1)3 = 3.04527 in
6(3(7.37 ) 1)
A = 0.5[3(7.37 ) 1] = 10.555 in
0.792
7.8125 10.5551 = 7.81
3.04527
Therefore use H = 7.37 in
3
Or H = 7 in = 7.375 in
8
L 180
(b) Consider J.B. Johnson, e = = 59 < 120
k 3.04527
s
se = y
N
F 125
se = = = 13.8 ksi
Le
2
180
2
sy (48)
A 1 k
10.555 1 3.04527
4 2 E (
4 2 30 103 )
Page 8 of 18
SECTION 5 COLUMNS
sy 48
N= = = 3.48
se 13.8
[ (
48 = 11.843 N 1 + 0.25 sec 0.5872 N )]
N = 2 .8
338. The link shown is to be designed for N = 2.5 to support an axial compressive
load that varies from 0 to 15 kips; L = 20 in ; Material AISI 1030, as rolled. (a)
Determine the diameter considering buckling only. (b) Determine the diameter
considering varying stresses and using the Soderberg line (perhaps too
conservative). Estimate an appropriate strength-reduction factor (see Fig. AF 6).
(c) Keeping in mind that the stress is always compressive, do you think that the
answer from (a) will do? Discuss.
Problem 338.
Solution:
For AISI C1030, as rolled
s y = 51 ksi
su = 80 ksi
1 1
( )
Le 2 2 E 2 2 2 30 103 2
= =
k s y 51 = 108
L = 20 in
N = 2 .5
(a) F = 15 kips
Consider J.B. Johnson
Page 9 of 18
SECTION 5 COLUMNS
Le
2
s y
NF = s y A1 2
k
4 E
D
k=
4
D 2
A=
4
Le = L = 20 in
20
2
(51) D
2
(2.5)(15) = (51) D 1 2 4 3
4 4 (30 10 )
2.72
37.5 = 12.75 D 2 1 2 2
D
34.68
37.5 = 12.75 D 2
D = 1.101 in
3
say D = 1 in = 1.1875 in
16
Le 20
= = 68 < 108 o.k.
k 1.1875
4
Page 10 of 18
SECTION 5 COLUMNS
Le
2
sem
Fm = sem A1 2
k
4 E
20
2
(51) D
2
D
7.5 = (3.923) 1 2 4 3
4 4 (30 10 )
2.72
7.5 = 0.98 D 2 1 2 2
D
2.67
7.5 = 0.98 D 2
D = 1.65 in
5
say D = 1 in = 1.625 in
8
Le 20
= = 49 < 108 o.k.
k 1.625
4
(c) The answer in (a) will not do because it is lower than (b)
339. The connecting link for a machine (see figure) is subjected to a load that varies
fro + 450 (tension) to 250 lb. The cross section is to have the proportions
G = 0.4 H , t = 0.1H , fillet radius r 0.05 H ; L = 10 in ; material, AISI C1020,
as rolled. (a) Considering buckling only, determine the dimensions for a design
factor of 2.5. (b) For the dimension found compute the factor of safety from the
Soderberg criterion.
Page 11 of 18
SECTION 5 COLUMNS
Table AT 1
G = 0 .4 H
t = 0.1H
r 0.05 H
A = GH gh
g = G t = 0.4 H 0.1H = 0.3H
h = H 2(0.1H ) = 0.8 H
A = (0.4 H )(H ) (0.3H )(0.8H ) = 0.16 H 2
1 GH 3 gh3 1 (0.4 H )(H ) (0.3H )(0.8 H )
3 3
k= = = 0.35824 H
12 GH gh 12 (
0.16 H 2 )
s y
NF = s y A1 2
k
4 E
F = 350 lb = 0.35 kip
Le = 10 in
10
2
48
2
( 2
(2.5)(0.35) = (48) 0.16 H 1 2
) (0.35824 H )
(
4 30 10 3
)
0.875 = 7.68 H 2 0.2425
H = 0.3815 in
Le 10
= = 73 < 120 ok
k (0.35824)(0.3815)
15
say H = in = 0.46875 in
32
3
G = 0.4 H = 0.1875 in = in
16
3
t = 0.1H = 0.046875 in = in
64
Page 12 of 18
SECTION 5 COLUMNS
k = 0.35824(0.46875) = 0.1679 in
Fmin 350
smin = s e = A = 0.0352 = 11,600 psi = 11.6 ksi
Le
2
10
2
s y 48
1 k 1 0.1679
(
4 2 E 4 2 30 103 )
F + 450
smax = max = = +12,800 psi = +12.8 psi
A 0.0352
1
sm = (12.8 11.6 ) = 0.6 ksi
2
1
sa = (12.8 + 11.6 ) = 12.1 ksi
2
su = 0.5sn = 0.5(65) = 32.5 ksi
Size factor = 0.85
su = 0.85(32.5) ksi = 27.62 ksi
Figure AF 9, r = 0.05H = 0.05(0.46875) = 0.023
h = 1.5H = 15.(0.46875) = 0.7031 in
d = H = 0.4688 in
r 0.05 H
= = 0.05
d H
h 1 .5 H
= = 1 .5
d H
K t = 2.65
1 1
q= = = 0.70
0.01 0.01
1+ 1+
r 0.023
K f = 0.70(2.65 1) + 1 = 2.2
1 sm K f sq
= +
N sy sn
1 0.6 (2.2 )(12.1)
= +
N 48 27.62
N = 1.024
CHECK PROBLEMS
341. The link shown is subjected to an axial compressive load of 15 kips. Made of
AISI C1030, as rolled, it has sectional length of 20 in. Assume a loose fit with the
Page 13 of 18
SECTION 5 COLUMNS
pins. What is (a) the critical load for this column, (b) the design factor, (c) the
equivalent stress under a load of 15 kips? What material does the secant formula
indicate as satisfactory for the foregoing load, when (e) ec k 2 = 0.25 , (f)
L
e= e .
400
b = 0.75 in
h = 1.75 in
A = bh = (0.75)(1.75) = 1.3125 in 2
For loose fit
bh3
I=
12
I bh 3 h 1.75
k= = = = = 0.5052 in
A 12bh 12 12
Le 20
= = 39.6 < 108 for AISI C1030, as rolled
k 0.5052
use J.B. Johnson equation
Le
2
20
2
sy 51
(a) Fc = s y A 1 k
= (51)(1.3125) 1 0.5052
= 62.42 kips
4 2 E 4 2 (30,000)
(b) Fc = NF
F 62.42
N= c = = 4.16
F 15
s 51
(c) se = y = = 12.26 ksi
N 4.16
F 15
(d) Actual s = = = 11.43 ksi
A 1.3125
Page 14 of 18
SECTION 5 COLUMNS
Secant Formula
NF ec Le NF
sy = 1 + sec
A k 2 2k EA
ec
(e) 2 = 0.25
k
62.42 20 62.42
sy = 1 + 0.25 sec = 64.4 ksi
1.3125 ( )
2(0.5052) 30 10 (1.3125)
3
Le 20
(f) e = = = 0.05 in
400 400
h 1.75
c= = = 0.875 in
2 2
ec (0.05)(0.875)
= = 0.1714
k2 (0.5052)2
62.42 20 62.42
sy = 1 + 0.1714 sec = 59.12 ksi
1.3125 2(0.5052 ) ( )
30 10 (1.3125)
3
343. A schedule-40, 4-in. pipe is used as a column. Some of its properties are:
Do = 4.5 in , Di = 4.026 in , I = 3.174 sq.in. , L = 15 ft ; material equivalent to
AISI C1015, as rolled. The total load to be carried is 200 kips. (a) What
minimum number of these columns should be used if a design factor of 2.5 is
desired and the load evenly distributed among them? For the approximately fixed
ends, use Le = 0.65L as recommended by AISC. (b) What is the equivalent stress
in the column?
Solution:
For AISI C1015, as rolled
s y = 45.5 ksi
1 1
( )
Le 2 2 E 2 2 2 30 103 2
= =
k s y 45.5 = 114
L = 15 ft = 180 in
Le = 0.65L = 0.65(180) = 117 in
Le 117
= = 77.5 < 114
k 1.509
Page 15 of 18
SECTION 5 COLUMNS
sy
s y A k (45.5)(3.174) 45.5(77.5)
2
(a) F = 1 = 1 2 = 44.4 kips
N 4 2 E 2.5 4 (30,000)
No. of columns
200
= = 4.5 say 5 columns
44.4
F
(b) se = A
Le
2
s y
1 k
4 2 E
200
F= = 40 kips
5
40
se = 3.174 = 16.4 ksi
77.5
2
45.5
1 k
4 2 (30,000)
Page 16 of 18
SECTION 5 COLUMNS
Solution:
For AISI C1022, as rolled
s y = 52 ksi
1 1
Le 2 2 E 2 2 2 (30 103 ) 2
= = = 107
k s y 52
(a) k = 2.54 in
I = 93.0 in 4
Le = 0.8(30)(12) = 288 in
Le 288
= = 113.4 > 107
k 2.54
Use Eulers Equation
2 EA 2 (30,000)(14.4)
Fc = = = 332 kips
Le
2
(113.4)2
k
F
{ [
52 = c 1 + 0.25 sec 0.0863
14.4
Fc ]}
Fc = 273 kips
348. A 4 x 3 x -in. angle is used as a flat-ended column, 5 ft. long, with the resultant
load passing through the centroid G (see figure); k x = 1.25 in , k y = 0.86 in ,
ku = 1.37 in , kv = 0.64 in , A = 3.25 sq.in. Find the safe load if N = 2.8 and the
material is (a) structural steel, (b) magnesium alloy AZ 91C (i7.12.\, Text), (c)
magnesium alloy AZ 80A, (d) magnesium alloy AZ 80A as before, but use the
Johnson formula and compare.
Page 17 of 18
SECTION 5 COLUMNS
Solution:
L (5)(12 )
Le = = = 30 in
2 2
k = k min = 0.64 in
Le 30
= = 46.875
k 0.64
(a) Structural steel, s y = 48 ksi
Le
= 46.875 < 120
k
use J.B. Johnson
Le
2
sy
s y A k (48)(3.25) 48(46.875)
2
F= 1 = 1 2 = 50.75 kips
N 4 2 E 2.8 4 (30,000 )
(b) magnesium alloy AZ 91C
NF C
= 2
A Le
C
1+ 6
k
64.4 10
C = 57,000
(2.8)(F ) = 57,000
psi
57,000(46.875)
2
3.25
1+
64.4 106
F = 22,467 lb = 22.467 kips
(c) magnesium alloy AZ 80A
C = 82,900
(2.8)(F ) = 82,900
psi
82,900(46.875)
2
3.25
1+
64.4 106
F = 25,134 lb = 25.134 kips
y
s y A
s
F= 1 2 =
k (36)(3.25) 1 36(46.875)2 = 39 kips > 25.134 kips
N 4 E 2.8 4 (30,000)
2
- end -
Page 18 of 18
SECTION 7 SHAFT DESIGN
471. A short stub shaft, made of SAE 1035, as rolled, receivers 30 hp at 300 rpm via a
12-in. spur gear, the power being delivered to another shaft through a flexible
coupling. The gear is keyed (profile keyway) midway between the bearings. The
pressure angle of the gear teeth = 20 o ; N = 1.5 based on the octahedral shear
stress theory with varying stresses. (a) Neglecting the radial component R of the
tooth load W , determine the shaft diameter. (b) Considering both the tangential
and the radial components, compute the shaft diameters. (c) Is the difference in
the results of the parts (a) and (b) enough to change your choice of the shaft size?
Problem 471.
Solution:
For SAE 1035, as rolled
s y = 55 ksi
su = 85 ksi
sn = 0.5su = 0.5(85) = 42.5 ksi
A = W cos
63,000hp 63,000(30 )
T= = = 6300 in lb
n 300
AD
T=
2
A(12 )
6300 =
2
A = 1050 lb
A = W cos
1050 = W cos 20
W = 1118 lb
Shear stress
16T 16(6300 )
ss = =
d3 d3
100,800
ss = sms =
d3
sas = 0
Page 1 of 76
SECTION 7 SHAFT DESIGN
bending stress
From Table AT 2
FL
M=
4
(a) Negligible R :
AL (1050 )(16 )
M= = = 4200 in lb
4 4
32 M 32(4200 ) 134,400
s= = =
d3 d3 d3
sm = 0
134,400
sa = s =
d3
s K f sa
se = n s m +
sy SF
For profile keyway
K f = 2 .0
K fs = 1.6
SF = 0.85
K s
se = f a =
(2.0)(134,400) = 100,661
SF ( )
(0.85) d 3 d3
s K fs sas
ses = ns sms +
s ys SF
sns sn 42.5 1
= = =
s ys s y 55 1.294
sns 1 100,800 24,796
ses = sms = 3
=
s ys 1.294 d d3
Octahedral-shear theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 100,661 2
2 2
24,796
= +
3
(
1.5 42,500d 0.577 42,500d 3 )
d = 1.569 in
Page 2 of 76
SECTION 7 SHAFT DESIGN
11
use d = 1 in
16
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 107,180 2
2 2
24,796
= +
3
(
1.5 42,500d 0.577 42,500d 3 )
d = 1.597 in
11
use d = 1 in
16
(c) The difference in the results of the parts (a) and (b) is not enough to change the choice
of the shaft size.
472. A cold-finished shaft, AISI 1141, is to transmit power that varies from 200 to 100
and back to 200 hp in each revolution at a speed of 600 rpm. The power is
received by a 20-in. spur gear A and delivered by a 10-in. spur gear C. The
tangential forces have each been converted into a force ( A and C shown) and a
couple (not shown). The radial component R of the tooth load is to be ignored in
the initial design. Let 2 and, considering varying stresses with the maximum
shear theory, compute the shaft diameter.
Page 3 of 76
SECTION 7 SHAFT DESIGN
Solution:
For AISI 1141, cold-finished
s y = 90 ksi
sn = 50 ksi
sn 1
=
s y 1.8
SF = 0.85
63,000hp
T=
n
63,000(200 )
Tmax = = 21,000 in lb
600
63,000(100 )
Tmin = = 10,500 in lb
600
1 1
Tm = (Tmax + Tmin ) = (21,000 + 10,500 ) = 15,750 in lb
2 2
1 1
Ta = (Tmax Tmin ) = (21,000 10,500 ) = 5,250 in lb
2 2
16T
ss =
d3
16(15,750 ) 252,000
sms = =
d3 d3
16(5250 ) 24,000
sas = =
d3 d3
s K fs sas
ses = ns sms +
s ys SF
For profile keyway
K f = 2 .0
K fs = 1.6
sns sn 1
= =
s ys s y 1.8
1 252,000 (1.6)(84,000) 94,894
ses = 3
+ =
1.8 d 0.85 d 3 d3
Bending stress, negligible radial load
T = 21,000 in lb at 200 hp
For A:
20
A = T
2
A(10 ) = 21,000
Page 4 of 76
SECTION 7 SHAFT DESIGN
A = 2100 lb at 200 hp
For C:
10
C = T
2
C (5) = 21,000
C = 4200 lb at 200 hp
[ M ]
= 0 A(10 ) + D(25) = C (15)
B
at 200 hp
(2100)(10) + D(25) = (4200)(15)
D = 1680 lb
[ F V =0 ]
A+C = B + D
at 200 hp
2100 + 4200 = B + 1680
B = 4620 lb
At 200 hp: A = 2100 lb , B = 4620 lb , C = 4200 lb , D = 1680 lb
Shear Diagram
Maximum moment at B
M = (2100)(10 ) = 21,000 in lb
32 M 32(21,000 ) 672,000
s= = =
d3 d3 d3
sm = 0
672,000
sa = s =
d3
s
se = n s m +
K f sa
= 0+
(2.0)(672,000) = 503,304
sy SF 0.85 d 3 d3
Page 5 of 76
SECTION 7 SHAFT DESIGN
94,894
ses =
d3
Maximum Shear Theory
1
1 se ses
2 2 2
= +
N sn 0.5sn
1
1 503,304 2
2 2
94,894
= +
3
(
2 50,000d 0.5 50,000d 3 )
d = 2.78 in
3
use d = 2 in
4
475. A shaft S, of cold-drawn AISI 1137, is to transmit power received from shaft W,
which turns at 2000 rpm, through the 5-in. gear E and 15-in. gear A. The power
is delivered by the 10-in. gear C to gear G, and it varies from 10 hp to 100 hp and
back to 10 hp during each revolution of S. The design is to account for the
varying stresses, with calculations based on the octahedral shear stress theory.
Let N = 1.8 and compute the shaft diameter, using only the tangential driving
loads for the first design.
Solution.
For AISI 1137, cold drawn
s y = 93 ksi
su = 103 ksi
sn = 0.5su = 0.5(103) = 51.5 ksi
sn sns 51.5 1
= = =
s y s ys 93 1.806
63,000hp
T=
n
5 in. E
n= (2000 rpm) = 667 rpm
15 in. A
Page 6 of 76
SECTION 7 SHAFT DESIGN
63,000(100 )
Tmax = = 9450 in lb
667
63,000(10 )
Tmin = = 945 in lb
667
1 1
Tm = (Tmax + Tmin ) = (9450 + 945) = 5197.5 in lb
2 2
1 1
Ta = (Tmax Tmin ) = (9450 945) = 4252.5 in lb
2 2
16T
ss =
d3
16(5197.5) 83,160
sms = =
d3 d3
16(4252.5) 68,040
sas = =
d3 d3
s K fs sas
ses = ns sms +
s ys SF
For profile keyway
K f = 2 .0
K fs = 1.6
SF = 0.85
1 83,160 (1.6)(68,040) 55,425
ses = +
3
=
1.806 d 0.85 d 3 d3
Bending stress, using only tangential loads
Page 7 of 76
SECTION 7 SHAFT DESIGN
C (5) = 9450
C = 1890 lb
[ M B ]
= 0 6 A + 20 D = 14C
6(1260) + 20 D = 14(1890)
D = 945 lb
[ F =0
V ]
A+C = B + D
1260 + 1890 = B + 945
B = 2205 lb
Shear diagram
Maximum moment at B
M = (1260)(6) = 7560 in lb
32 M 32(7560 ) 241,920
s= = =
d3 d3 d3
sm = 0
241,920
sa = s =
d3
s K f sa (2.0 )(241,920 ) 181,189
se = n s m + = =
sy SF 0.85 d 3 d3
55,425
ses =
d3
Octahedral Shear Theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 181,189 2
2 2
55,425
= +
2 51,500d 0.577 51,500d 3
3
( )
d = 1.997 in
use d = 2 in
Page 8 of 76
SECTION 7 SHAFT DESIGN
478. A shaft made of AISI 1137, cold rolled, for a forage harvester is shown.
Power is supplied to the shaft by a vertical flat belt on the pulley A. At B, the
roller chain to the cutter exerts a force vertically upwards, and the V-belt to
the blower at C exerts a force vertically upwards. At maximum operating
conditions, the flat belt supplies 35 hp at 425 rpm, of which 25 hp is delivered
to the cutter and 10 hp to the blower. The two sections of the shaft are joined
by a flexible coupling at D and the various wheels are keyed (sled-runner
keyway) to the shafts. Allowing for the varying stresses on the basis of the
von Mises-Hencky theory of failure, decide upon the diameters of the shafts.
Choose a design factor that would include an allowance for rough loading.
Problem 478.
Solution:
For AISI 1137, cold rolled
s y = 93 ksi
su = 103 ksi
sn = 0.5su = 0.5(103) = 51.5 ksi
sn sns 51.5 1
= = =
s y s ys 93 1.806
Pulley,
63,000hp 63,000(35)
TA = = = 5188 in lb
n 425
For flat-belt
2T 4(5188)
FA = F1 + F2 = 2(F2 F1 ) = 2 A = = 692 lb
DA 30
Sprocket,
63,000hp 63,000(25)
TB = = = 3706 in lb
n 425
For chain,
2T 2(3706 )
FB = B = = 741 lb
DB 10
Sheave,
63,000hp 63,000(10 )
TC = = = 1482 in lb
n 425
Page 9 of 76
SECTION 7 SHAFT DESIGN
For V-belt,
2T 3(1482 )
FC = F1 + F2 = 1.5(F2 F1 ) = 1.5 C = = 445 lb
DC 10
Consider shaft ABD.
35 hp
Shaft ABD
[ M D' =0 ]
(6 + 8 + 4)FA = (8 + 4)A'+4FB
18(692) = 12 A'+4(741)
A' = 791 lb
[ F V =0 ]
FA + D = FB + A
692 + D = 741 + 791
D = 840 lb
Shear Diagram
Maximum M at A.
M = (6)(692) = 4152 in lb.
32 M 32(4152 ) 132,864
s= = =
d3 d3 d3
sm = 0
132,864
sa = s =
d3
Page 10 of 76
SECTION 7 SHAFT DESIGN
sn K f sa
se = sm +
sy SF
For sled-runner keyway (Table AT 13)
K f = 1 .6
K fs = 1.6
SF = 0.85
s
se = n s m +
K f sa
= 0+
(1.60)(132,864) = 79,610
sy SF 0.85 d 3 d3
at A T = TA = 5188 in lb
16T 16(5188) 83,008
ss = = =
d3 d3 d3
sms = ss
sas = 0
s K fs sas
ses = ns sms +
s ys SF
1 83,000 14,630
ses = =
3
1.806 d d3
Choose a design factor of 2.0
N = 2 .0
von Mises-Hencky theory of failure (Octahedral shear theory)
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 79,610 2
2 2
14,630
= +
3
(
2 51,500d 0.577 51,500d 3 )
d = 1.48 in
1
use d = 1 in
2
Page 11 of 76
SECTION 7 SHAFT DESIGN
[ M C' =0 ]
8 D = 3FC
8 D = 3(445)
D = 167 lb
[ F V =0 ]
C = D + FC
C = 167 + 445
C = 612 lb
Shear Diagram
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 25,616 2
2 2
4180
= +
3
(
2 51,500d 0.577 51,500d 3 )
Page 12 of 76
SECTION 7 SHAFT DESIGN
d = 1.011 in
use d = 1 in
479. A shaft for a punch press is supported by bearings D and E (with L = 24 in.)
and receives 25 hp while rotating at 250 rpm, from a flat-belt drive on a 44-
in. pulley at B, the belt being at 45o with the vertical. An 8-in. gear at A
delivers the power horizontally to the right for punching operation. A 1500-lb
flywheel at C has a radius of gyration of 18 in. During punching, the shaft
slows and energy for punching comes from the loss of kinetic energy of the
flywheel in addition to the 25 hp constantly received via the belt. A
reasonable assumption for design purposes would be that the power to A
doubles during punching, 25 hp from the belt, 25 hp from the flywheel. The
phase relations are such that a particular point in the section where the
maximum moment occurs is subjected to alternating tension and
compression. Sled-runner keyways are used for A, B, and C; material is cold-
drawn AISI 1137, use a design factor of N = 2.5 with the octahedral shear
theory and account for the varying stresses. Determine the shaft diameters.
Problems 479-480
Solution:
Flat-Belt Drive (B)
63,000hp 63,000(25)
TB = = = 6300 in lb
n 250
2T 4(6300)
FB = F1 + F2 = 2(F1 F2 ) = 2 B = = 573 lb
DB 44
Gear A, Doubled hp
63,000hp 63,000(25 + 25)
TA = = = 12,600 in lb
n 250
2T 2(12,600 )
FA = A = = 3150 lb
DA 8
Loading:
Page 13 of 76
SECTION 7 SHAFT DESIGN
Vertical:
Page 14 of 76
SECTION 7 SHAFT DESIGN
M DV = (6 )(1500 ) = 9000 in lb
M BV = (16 )(510 ) = 8160 in lb
M AV = (5)(510 ) = 2550 in lb
Horizontal:
Shear Diagram
Page 15 of 76
SECTION 7 SHAFT DESIGN
M Dh = 0 in lb
M Bh = (8)(386 ) = 3088 in lb
M Ah = (5)(2359 ) = 11,795 in lb
MA = (M ) + (M )
Ah
2
AV
2
= (11,795)2 + (2550)2 = 12,068 in lb
MB = (M ) + (M )
Bh
2
BV
2
= (3088)2 + (8160)2 = 8725 in lb
M D = 9000 in lb
Therefore
M max = 12,068 in lb
32 M 32(12,068) 386,176
s= = =
d3 d3 d3
sn K f sa
se = sm +
sy SF
For AISI 1137, cold-drawn,
s y = 93 ksi
su = 103 ksi
sn = 0.5su = 0.5(103) = 51.5 ksi
For sled-runner keyway (Table AT 13)
K f = 1 .6
K fs = 1.6
SF = 0.85
se = 0 +
(1.60)(386,176 ) = 231,386
0.85 d 3 d3
Page 16 of 76
SECTION 7 SHAFT DESIGN
50 hp
63,000hp 63,000(25 + 25)
TA = = = 12,600 in lb
n 250
2T 2(12,600 )
FA = A = = 3150 lb
DA 8
16T 16(12,600 ) 201,600
ss max = = =
d3 d3 d3
25 hp
63,000hp 63,000(25)
TA = = = 6,300 in lb
n 250
2T 2(6,300 )
FA = A = = 1575 lb
DA 8
16T 16(6,300 ) 100,800
ss min = = =
d3 d3 d3
,800 151,200
sms =
1
(ss max + ss min ) = 1 201,600 + 100
3
=
2 2 d d3
,800 50,400
sas =
1
(ss max ss min ) = 1 201,600 100
3
=
2 2 d d3
sns K fs sas
ses = sms +
s ys SF
1 151,200 (1.6)(50,400) 56,848
ses = 3
+ =
1.806 d 0.85 d 3 d3
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 231,386 2
2 2
56,848
= +
3
(
2 51,500d 0.577 51,500d 3 )
d = 2.14 in
3
say d = 2 in
16
THRUST LOADS
Page 17 of 76
SECTION 7 SHAFT DESIGN
481. A cold-drawn monel propeller shaft for a launch is to transmit 400 hp at 1500
rpm without being subjected to a significant bending moment; and Le k < 40 .
The efficiency of the propeller is 70 % at 30 knots (1.152 mph/knot). Consider
that the number of repetitions of the maximum power at the given speed is 2x
105. Let N = 2 based on the maximum shear theory with varying stress.
Compute the shaft diameter.
Solution:
For cold-drawn monel shaft, Table AT 10
s y = 75 ksi
sn = 42 ksi at 108
at 2 x 105
0.085
108
sn 42
5
= 71.23 ksi
2 10
sn sns 71.23 1
= = =
s y s ys 75 1.053
63,000hp 63,000(400 )
T= = = 16,800 in lb
n 1500
16T 16(16,800 ) 268,800
ss = = =
D3 D3 D3
s ms = ss
s as = 0
sns K fs sas
ses = sms +
s ys SF
SF = 0.85
assume K f = K fs = 1.0
1 268,800 81,255
ses = 3
+ 0 =
1.053 D D3
Fvm
= hp
33,000
vm = (30 knots )(1.152 mph knot )(5280 ft mi )(1 hr 60 min ) = 3041 fpm
F (3041)
= (0.70)(400)
33,000
F = 3040 lb
4F 4(3040 ) 12,160
s= 2
= =
D D2 D2
sm= s
sa = 0
Page 18 of 76
SECTION 7 SHAFT DESIGN
sn K f sa
se = sm +
sy SF
1 12,160 3676
se = +0 = 2
2
1.053 D D
1 se ses
2 2 2
= +
N sn 0.5sn
1
1 3676 2
2 2
81,255
= +
2
(
2 71,230 D 0.5 71,230 D 3 )
1
1 2.2815 2
2 2
1
= +
2 19.377 D 2 D 3
By trial and error
11
D = 1.66 in = 1 in
16
482. A shaft receives 300 hp while rotating at 600 rpm, through a pair of bevel gears,
and it delivers this power via a flexible coupling at the other end. The shaft is
designed with the average forces ( at the midpoint of the bevel-gear face); the
tangential driving force is F , G = 580 lb , Q = 926 lb ; which are the rectangular
components of the total reaction between the teeth; Dm = 24 in , L = 36 in ,
a = 10 in . Let the material be AISI C1045, cold drawn; N = 2 . Considering
varying stresses and using the octahedral shear theory, determine the shaft
diameter.
Solution:
Page 19 of 76
SECTION 7 SHAFT DESIGN
Vertical:
D 24
Q m = 926 = 11,112 in lb
2 2
G = 580 lb
[ M B =0 ]
QDm
Av (36 ) + G (10 ) = 0
2
QDm
= G (10 ) + Av (36 )
2
11,112 = 580(10) + Av (36)
Av = 148 lb
Page 20 of 76
SECTION 7 SHAFT DESIGN
[ F =0]
v
Av + Bv = 580 lb
148 + Bv = 580 lb
Bv = 432 lb
Shear Diagram
Moment Diagram
M Cv = 11,112 in lb
M Bv = 5328 in lb
Horizontal:
[ M B =0 ]
Ah (36) = (2625)(10)
Ah = 729 lb
[ F h =0 ]
Bh = Ah + F
Bh = 725 + 2625
Page 21 of 76
SECTION 7 SHAFT DESIGN
Bh = 3354 lb
Shear Diagram
M Ch = 0
M Bh = (36 )(729 ) = 26,244 in lb
Maximum M
M = MB = (M ) + (M )
Bh
2
BV
2
(26,244)2 + (5328)2 = 26,780 in lb
=
32 M 4Q 32(26,780 ) 4(926 ) 856,960 3,704
smax = + = + = +
D D2
3
D3 D2 D3 D2
4Q 32 M 3704 856,960
smin = =
D 2 D3 D 2 D3
1
sm = (smax + smin )
2
1 856,960 3704 3704 856,960 3704
sm = + + =
2 D3 D2 D2 D 3 D 2
1
sa = (smax smin )
2
856,960
sa =
D3
s K f sa
se = n s m +
sy SF
assume K f = 1.0 at B
1 3704 1.0 856,960 964 320,916
se = +
2 3
= 2 +
1.7 D 0.85 D D D3
Octahedral Shear Theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
Page 22 of 76
SECTION 7 SHAFT DESIGN
1
694 320,916 2
2
1
1 2
+ 3 94,370
2
1
2
6.42 3.27
2 2
= D D + =
3
+ 3 + 3
0.577(50,000)D
2
2 50,000 72 D D D
By trial and error, use
1
D = 2 in
2
483. The worm shown is to deliver 65.5 hp steadily at 1750 rpm. It will be integral
with the shaft if the shaft size needed permits, and its pitch diameter 3 in. The 12-
in. pulley receives the power from a horizontal belt in which the tight tension
F1 = 2.5F2 . The forces (in kips) on the worm are as shown, with the axial force
taken by bearing B. The strength reduction factor for the thread roots may be
taken as K f = 1.5 , shear or bending. The shaft is machined from AISI 1045, as
rolled. (a) For N = 2.2 (Soderberg criterion) by the octahedral-shear theory,
compute the required minimum diameter at the root of the worm thread (a first
approximation). (b) What should be the diameter of the shaft 2.5 in. to the left of
the centerline of the worm? (c) Select a shaft size D and check it at the pulley A.
Problem 483.
Solution:
For AISI 1045, as rolled
s y = 59 ksi
su = 96 ksi
sn = 0.5su = 48 ksi
sn sns 48 1
= = =
s y s ys 59 1.229
63,000hp 63,000(65.5)
T= = = 2358 in lb
1750 1750
(F1 F2 ) 12 = T
2
(2.5F2 F2 )(6) = 2358
F2 = 262 lb
F1 = 2.5F2 = 655 lb
Page 23 of 76
SECTION 7 SHAFT DESIGN
Horizontal
[ M B =0 ]
(917 )(6) + (1570)(6.5) = 13Eh
Eh = 1208 lb
[ F h =0 ]
917 + Eh = Bh + 1570
917 + 1208 = Bh + 1570
Bh = 555 lb
Shear Diagram
M Ah = 0
M Bh = (917 )(6 ) = 5502 in lb
M Ch = (1208)(6.5) = 7852 in lb
Vertical:
3
M = (2540 ) = 3810 in lb
2
[
M E =0 ]
M + (1170)(6.5) = 13Bv
3810 + (1170)(6.5) = 13Bv
Bv = 878 lb
Page 24 of 76
SECTION 7 SHAFT DESIGN
[ F =0]
v
Ev + Bv = 1170
Ev + 878 = 1170
Ev = 292 lb
Shear Diagram
Moment Diagram
M Av = 0
M Bv = 0
M Cv = 5707 in lb
M= (M h )2 + (M v )2
MA = (0)2 + (0)2 = 0
MB = (5502)2 + (0)2 = 5502 in lb
MC = (7852)2 + (5707)2 = 9707 in lb
(a) Minimum diameter at the root of the warm thread.
K f = K fs = 1.5
M = M C = 9707 in lb
F = 2540 lb
Page 25 of 76
SECTION 7 SHAFT DESIGN
310,624 10,160
smin = +
Dr3 Dr2
1
sm = (smax + smin )
2
10,160
sm =
Dr2
1
sa = (smax smin )
2
310,624
sa =
Dr3
s K f sa
se = n s m +
sy SF
1 10,160 1.5 310,624 2632 174,485
se = 2
+ 3 = D2 + D3
1.229 Dr 0.85 Dr r r
1 se ses
2 2 2
= +
N sn 0.577 sn
1
2632 174,485 2 2 1
2 + 3.635 1
2 2 2 2
1 Dr Dr
3
9764 1
= + = + +
2.2 48,000 0.577(48,000)Dr3 2
18.24 Dr Dr3 2.84 Dr3
Page 26 of 76
SECTION 7 SHAFT DESIGN
3
r= in
16
Figure AF 12
3
r 16
= 0.1
d 3
2.023 2 2
16
D 2.023
= = 1 .2
d 3
2.023 2 2
16
K f = K t = 1.65
K fs = K ts = 1.34
at 2.5 in to the shaft
M h = (917 )(6) + (362)(6.5 2.5) = 6950 in lb
M v = (878)(6.5 2.5) = 3512 in lb
M= (6950)2 + (3512)2 = 7787 in lb
10,160
sm =
D2
32 M 32(7787 ) 249,184
sa = = =
D3 D3 D3
s K f sa
se = n s m +
sy SF
1 10,160 1.65 249,184 2632 153,970
se = +
2 3
= +
1.229 D 0.85 D D2 D3
9764
ses =
D3
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
2632 153,970 2 2 1
1 2
+ 3 9764
2
1
2
3.21 1
2 2
= D D + =
3
+ 3 +
0.577(48,000)D
2
2.2 48,000
18.24 D D 2.84 D 3
Page 27 of 76
SECTION 7 SHAFT DESIGN
15
(c) Selecting D = 1 in = 1.9375 in
16
At the pulley A, or 3 in. right of centerline
M h = (917 )(3) = 2751 in lb
Mv = 0
M = 2751 in lb
For sled runner keyway
K f = 1 .6
K fs = 1.6
sm = 0
32 M 32(2751)
sa = = = 3853 psi
D 3
(1.9375)3
s K f sa
se = n s m +
sy SF
1 .6
se = 0 + (3853) = 7253 psi
0.85
9764
ses = = 1343 psi
(1.9375)3
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 7253
2 2 2
1343
= +
N 48,000 0.577(48,000)
N = 6.30 > 2.2 , therefore o.k.
484. A propeller shaft as shown is to receive 300 hp at 315 rpm from the right through
a flexible coupling. A 16-in. pulley is used to drive an auxiliary, taking 25 hp.
The belt pull FB is vertically upward. The remainder of the power is delivered to
a propeller that is expected to convert 60% of it into work driving the boat, at
which time the boat speed is 1500 fpm. The thrust is to be taken by the right-hand
bearing. Let N = 2 ; material cold-worked stainless 410. Use the octahedral shear
theory with varying stresses. (a) Determine the shaft size needed assuming no
buckling. (b) Compute the equivalent column stress. Is this different enough to
call for another shaft size? Compute N by the maximum shear stress theory,
from both equations (8.4) and (8.11).
Page 28 of 76
SECTION 7 SHAFT DESIGN
Problem 484.
Solution:
For stainless 410, cold-worked
s y = 85 ksi
sn = 53 ksi
SF = 0.85
Belt drive
63,000hp 63,000(25)
TB = = = 5000 in lb
n 315
2T 4(5000)
FB = F1 + F2 = 2(F1 F2 ) = 2 B = = 1250 lb
DB 16
Propeller
63,000hp 63,000(300 25)
TP = = = 55,000 in lb
n 315
Thrust
Fvm = hp(33,000)
F (1500) = (0.60)(300 25)(33,000)
F = 3630 lb
Vertical loading
[ M E =0 ]
(20)(1250) = 60C
C = 417 lb
[ F =0]
v
A + C = FB
A + 417 = 1250
Page 29 of 76
SECTION 7 SHAFT DESIGN
A = 833 lb
Shear Diagram
M B = (20)(833) = 16,660 in lb
Maximum T at B
T = TB + TP = 60,000 in lb
Page 30 of 76
SECTION 7 SHAFT DESIGN
1 se ses
2 2 2
= +
N sn sns
N = 2 , Octahedral Shear Theory, sns = 0.577 sn
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
2882 319,430 2
2
1
1 2
+ 3 190,510
2
1
2
6.027 6.230
2 2
= D D + =
3
+ +
0.577(53,000 )D
2
2 53,000
18.39 D D 3 D 3
By trial and error
D = 2.6 in
5
say D = 2 in = 2.625 in
8
190,510
ses = = 10,533 psi
(2.625)3
Equation (8.4)
Page 31 of 76
SECTION 7 SHAFT DESIGN
1 1
2 s 2 2 18,078 2
2
= ss + = (10,533) +
2
= 13,880 psi
2 2
0.5sn 0.5(53,000)
N= = = 1.91
13,880
Equation (8.11) sns = 0.5sn
1 1
1 s ss 18,078 2 10,533 2 2
2 2 2
= + = +
N sn sns
53,000 0.5(53,000 )
N = 1.91
CHECK PROBLEMS
485. A 3-in. rotating shaft somewhat as shown (482) carries a bevel gear whose mean
diameter is Dm = 10 in and which is keyed (profile) to the left end. Acting on the
gear are a radial force G = 1570.8 lb , a driving force Q = 3141.6 lb . The thrust
force is taken by the right-hand bearing. Let a = 5 in and L = 15 in ; material,
AISI C1040, annealed. Base calculations on the maximum shearing stress theory
with variable stress. Compute the indicated design factor N . With the use of a
sketch, indicate the exact point of which maximum normal stress occurs.
Solution:
For AISI C1040, annealed, Figure AF 1
s y = 48 ksi
su = 80 ksi
sn = 0.5su = 40 ksi
sn sns 40 1
= = =
s y s ys 48 1.2
FDm (6283.2 )(10 )
T= = = 31,416 in lb
2 2
16T 16(31,416 )
ss = = = 5926 psi
D3 (3)3
sms = ss
sas = 0
s K fs sas
ses = ns sms +
s ys SF
1
ses = (5926 ) + 0 = 4940 psi
1 .2
Vertical
Page 32 of 76
SECTION 7 SHAFT DESIGN
AV + BV = G
523.6 + BV = 1570.8
BV = 1047.2 lb
Shear Diagram
Moment Diagram
M CV = 15,708 in lb
M BV = 7854 in lb
Page 33 of 76
SECTION 7 SHAFT DESIGN
Horizontal
[ M B =0 ]
15 Ah = 5(6283.2)
Ah = 2094.4 lb
[ F h =0 ]
Bh = Ah + F
Bh = 2094.4 + 6283.2
Bh = 8377.6 lb
Shear Diagram
M Ch = 0
M Bh = (15)(2094.4 ) = 31,416 in lb
Maximum Moment
M = M B2h + M Bv
2
= (31,416)2 + (7854)2 = 32,383 in lb
Since thrust force is taken by the right-hand bearing
sms = 0
32 M 32(32,383)
sas = = = 12,217 psi
D3 (3)3
s K f sa
se = n s m +
sy SF
Assume K f = 1.0 at the bearing B
1 .0
se = 0 + (12,217 ) = 14,373 psi
0.85
Page 34 of 76
SECTION 7 SHAFT DESIGN
1 se ses
2 2 2
= +
N sn 0.5sn
1
1 14,373 4940
2 2 2
= +
N 40,000 0.5(40,000)
N = 2 .3
Solution:
For AISI 1117, as rolled
s y = 44.3 ksi
Page 35 of 76
SECTION 7 SHAFT DESIGN
su = 70.6 ksi
sn = 0.5su = 35.3 ksi
sn sns 35.3 1
= = =
s y s ys 44.3 1.255
SF = 0.85
63,000(52 )
T= = 10,400 in lb
315
Pulley C
2T 4(10,400)
FC = F1 + F2 = 2(F2 F1 ) = 2 = = 2311 lb
D
C 18
Pulley D
2T 4(10,400)
FD = F1 + F2 = 2(F2 F1 ) = 2 = = 1664 lb
D
D 25
Horizontal
[ M A =0 ]
15(2311) = 59 Bh
Bh = 588 lb
[ F h =0 ]
Ah + Bh = 2311
Ah + 588 = 2311
Ah = 1723 lb
Shear Diagram
M Ch = (1723)(15) = 25,845 in lb
Page 36 of 76
SECTION 7 SHAFT DESIGN
Vertical
[ M B =0 ]
18(1664) = 59 Av
Av = 508 lb
[ F =0]
v
Av + Bv = 1664
508 + Bv = 1664
Bv = 1156 lb
Shear Diagram
M Cv = (508)(15) = 7620 in lb
M Dv = (1156 )(18) = 20,808 in lb
Page 37 of 76
SECTION 7 SHAFT DESIGN
32(26,945)
sa = = 18,952 psi
(2.4375)3
assume K f = K fs = 1.0
sn K f sa
se = sm +
sy SF
1 (1.0)(18,952) = 22,300 psi
se = (0 ) +
1.255 0.85
16T 16(10,400 )
ss = = = 3658 psi
D 3 (2.4375)3
sms = s s = 3658 psi
sas = 0
sns K fs sas
ses = sms +
s ys SF
1
ses = (3658) + 0 = 2915 psi
1.255
Octahedral shear theory sns = 0.577 sn
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 22,300
2 2 2
2915
= +
N 35,300 0.577(35,300)
N = 1.544
489. A shaft for a general-purpose gear-reduction unit supports two gears as shown.
The 5.75-in. gear B receives 7 hp at 250 rpm. The 2.25-in. gear A delivers the
power, with the forces on the shaft acting as shown; the gear teeth have a
o
1 A B
pressure angle of = 14 ( tan = h = h ). Both gears are keyed (profile) to
2 Av Bv
the shaft of AISI 1141, cold rolled. (a) If the fillet radius is 1/8 in. at bearing D,
where the diameter is 1 3/8 in., compute N based on the octahedral-shear-stress
theory (Soderberg line). The shaft diameter at A is 1 11/16 in. What is N here?
Page 38 of 76
SECTION 7 SHAFT DESIGN
Gear B:
5.75
Bv = T = 1764 in lb
2
Bv = 614 lb
Bh = Bv tan = 614 tan 14.5 = 159 lb
Gear A:
2.25
Av = T = 1764 in lb
2
Av = 1568 lb
Ah = Av tan = 1568 tan 14.5 = 406 lb
Vertical
Page 39 of 76
SECTION 7 SHAFT DESIGN
[ M D =0 ]
8Cv = 4(1568) 3(614)
Cv = 554 lb
[ F =0]
v
Cv + Dv = Av + Bv
554 + Dv = 1568 + 614
Dv = 1628 lb
Shear Diagram
Horizontal
[ M C =0 ]
4(406) + 8Dh = 11(159)
Dh = 16 lb
[ F h =0 ]
Ch + Bh = Ah + Dh
Ch + 159 = 406 + 16
Ch = 263 lb
Shear Diagram
Page 40 of 76
SECTION 7 SHAFT DESIGN
M Ah = (263)(4 ) = 1052 in lb
M Dh = (159 )(3) = 477 in lb
(a) At bearing D
1
r = in
8
3
d = 1 in
8
r 0.125
= 0.10
d 1.375
D 1.375 + 0.25
= 1 .2
d 1.375
K t K f = 1 .6
K ts K fs = 1.34
M = MD
sm = 0
32 M 32(1903)
sa = = = 7456 psi
d 3 (1.375)3
s K f sa
se = n s m +
sy SF
se = 0 +
(1.6)(7456) = 14,035 psi
0.85
16T 16(1764 )
sms = = = 3456 psi
D (1.375)3
3
sas = 0
sns K fs sas
ses = sms +
s ys SF
1
ses = (3456 ) + 0 = 1920 psi
1 .8
Octahedral shear theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
Page 41 of 76
SECTION 7 SHAFT DESIGN
1 14,035
2 2 2
3456
= +
N 50,000 0.577(50,000)
N = 3.28
(b) At A
For profile keyway
K f = 2.0 , K fs = 1.6
11
d =1 in = 1.6875 in
16
M = M A = 2453 in lb
sm = 0
32 M 32(2453)
sa = = = 5200 psi
d 3
(1.6875)3
s K f sa
se = n s m +
sy SF
se = 0 +
(2.0)(5200) = 12,235 psi
0.85
16T 16(1764 )
sms = = = 1870 psi
D (1.6875)3
3
sas = 0
sns K fs sas
ses = sms +
s ys SF
1
ses = (1870 ) + 0 = 1040 psi
1 .8
Octahedral shear theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 12,235
2 2 2
1040
= +
N 50,000 0.577(50,000)
N = 4.043
THRUST LOADS
491. The high-speed shaft of a worm-gear speed reducer, made of carburized AISI
8620, SOQT 450 F, is subjected to a torque of 21,400 in-lb. Applied to the right
Page 42 of 76
SECTION 7 SHAFT DESIGN
end with no bending. The force on the worm has three components: a horizontal
force opposing rotation of W = 6180 lb , a vertical radial force S = 1940 lb , and a
rightward thrust of F = 6580 lb . The shaft has the following dimensions: a = 6 ,
7 9 3 9
b = 4 , c = 10 , d = 4 , e = 2 , f = 13 , g = 11.646 , h = 10.370 ,
8 16 4 16
13
D1 = 3.740 , D2 = 4 , D3 = 4 , D4 = 3.3469 , D5 = 3.253 , r1 = 0.098 ,
16
3 1
r2 = r3 = , r4 = 0.098 , r5 = , all in inches. The pitch diameter of the worm,
4 16
6.923 in., is the effective diameter for the point of application of the forces. The
root diameter, 5.701 in. is used for stress calculations. The left-hand bearing
takes the thrust load. Calculate N based on the octahedral-shear-stress theory
with varying stresses. (Data courtesy of Cleveland Worm and Gear Company.)
Problem 491
Solution:
Table AT 11n For AISI 8620, SOQT 450 F
s y = 120 ksi
su = 167 ksi
sn = 0.5su = 83.5 ksi
sn sns 83.5 1
= = =
s y s ys 120 1.437
SF = 0.85
T = 21,400 in lb
Vertical
Page 43 of 76
SECTION 7 SHAFT DESIGN
6.923 6.923
M = F = 6580 = 22,777 in lb
2 2
[
M A =0 ]
22,777 + (11.646)(1940) = (11.646 + 10.370)Gv
Gv = 2061 lb
[ F =0]
v
S + Av = Gv
1940 + Av = 2061
Av = 121 lb
Shear Diagram
Moment Diagram
M Av = 0
M Bv = (121)(1.2035) = 146 in lb
M Cv = (121)(1.2035 + 4.875) = 736 in lb
M Dv = (121)(1.2035 + 4.875 + 5.5675) = 1409 in lb at left side
M Dv = 1409 + M = 1409 + 22,777 = 21,368 in lb at right side
M Ev = 21,368 (2061)(4.4325) = 12,233 in lb
M Fv = 12,233 (2061)(4.5625) = 2830 in lb
M Gv = 2830 (2061)(1.375) = 0
Horizontal
Page 44 of 76
SECTION 7 SHAFT DESIGN
[ M A =0 ]
(11.646)(6180) = (11.646 + 10.370)Gh
Gh = 3269 lb
[ F h =0 ]
Ah + Gv = W
Ah + 3269 = 6180
Ah = 2911 lb
Shear Diagram
Moment Diagram
M Ah = 0
M Bh = (2911)(1.2035) = 3500 in lb
M Ch = (2911)(1.2035 + 4.875) = 17,695 in lb
M Dh = 33,900 in lb
M Eh = 33,900 (3269 )(4.4325) = 19,410 in lb
M Fh = 19,410 (3269 )(4.5625) = 4495 in lb
M Fh = 4495 (3269 )(1.375) = 0
Combined
M = M h2 + M v2
MA = (0)2 + (0)2 = 0 in lb
MB = (3500)2 + (146)2 = 3503 in lb
MC = (17,695)2 + (736)2 = 17,710 in lb
MD = (33,900)2 + (1409)2 = 33,930 in lb (left)
MD = (33,900)2 + (21,368)2 = 40,073 in lb (right)
ME = (19,410)2 + (12,233)2 = 22,944 in lb
Page 45 of 76
SECTION 7 SHAFT DESIGN
Shear Stresses:
16T 16(21,400 )
ssA = ssB = = = 2083 psi
D13 (3.740)3
16T 16(21,400 )
ssC = = = 978 psi
D23 (4.8125)3
16T 16(21,400 )
ssD = = = 588 psi
Dr3 (5.701)3
16T 16(21,400 )
ssE = = = 1703 psi
D33 (4)3
16T 16(21,400 )
ssF = ssG = = = 2907 psi
D43 (3.3469)3
4F 4(6580 )
sC = = = 362 psi
D2 (4.8125)2
2
4F 4(6580 )
sD = = = 258 psi
Dr (5.701)2
2
4F 4(6580 )
sE = = = 524 psi
D3 2
(4 )2
Page 46 of 76
SECTION 7 SHAFT DESIGN
4F 4(6580 )
sE = sF = = = 748 psi
D4 (3.3469 )2
2
r1 0.098
At B: = = 0.03
D1 3.740
D2 4.8125
= = 1 .3
D1 3.740
Figure AF 12
K f K t = 2 .3
K fs K ts = 1.7
sn K f sa
se = sm +
sy SF
sm = sB = 599 psi
sa = s B = 682 psi
1 (2.3)(682 ) = 2262 psi
se = (599 ) +
1.437 0.85
s K fs sas
ses = ns sms +
s ys SF
sms = ssB = 2083 psi
sas = 0
1
ses = (2083) + 0 = 1450 psi
1.437
Octahedral shear theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 2262
2 2 2
1450
= +
N 83,500 0.577(83,500)
N = 24.7
r2 0.75
At C: = = 0.16
D2 4.8125
Dr 5.701
= = 1 .2
D2 4.8125
Figure AF 12
K f K t = 1 .5
K fs K ts = 1.2
Page 47 of 76
SECTION 7 SHAFT DESIGN
sn K f sa
se = sm +
sy SF
sm = 362 psi
sa = 1618 psi
1 (1.5)(1618) = 3107 psi
se = (362 ) +
1.437 0.85
s K fs sas
ses = ns sms +
s ys SF
sms = ssC = 978 psi
sas = 0
1
ses = (978) + 0 = 681 psi
1.437
Octahedral shear theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 3107
2 2 2
681
= +
N 83,500 0.577(83,500)
N = 25.1
At D:
Page 48 of 76
SECTION 7 SHAFT DESIGN
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 4067
2 2 2
409
= +
N 83,500 0.577(83,500)
N = 20.2
r3 0.75
At E: = = 0.19
D3 4
Dr 5.701
= = 1.43
D3 4
Figure AF 12
K f K t = 1.45
K fs K ts = 1.25
sn K f sa
se = sm +
sy SF
sm = sE = 524 psi
sa = s E = 3652 psi
1 (1.45)(3652) = 6595 psi
se = (524 ) +
1.437 0.85
s K fs sas
ses = ns sms +
s ys SF
sms = s sE = 1703 psi
sas = 0
1
ses = (1703) + 0 = 1185 psi
1.437
Octahedral shear theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 6595
2 2 2
1185
= +
N 83,500 0.577(83,500)
N = 12
r4 0.098
At F: = = 0.03
D4 3.3469
Page 49 of 76
SECTION 7 SHAFT DESIGN
D3 4
= = 1 .2
D4 3.3469
Figure AF 12
K f K t = 2 .3
K fs K ts = 1.7
sn K f sa
se = sm +
sy SF
sm = sF = 748 psi
sa = s F = 1443 psi
1 (2.3)(1443) = 4425 psi
se = (748) +
1.437 0.85
s K fs sas
ses = ns sms +
s ys SF
sms = s sF = 2907 psi
sas = 0
1
ses = (2907 ) + 0 = 2023 psi
1.437
Octahedral shear theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 4425
2 2 2
2023
= +
N 83,500 0.577(83,500)
N = 14.8
3
Then N = 12 at r3 = in (E)
4
492. The slow-speed shaft of a speed reducer shown, made of AISI 4140, OQT 1200
F, transmits 100 hp at a speed of 388 rpm. It receives power through a 13.6 in.
gear B. The force on this gear has three components: a horizontal tangential
driving force Ft = 2390 lb , a vertical radial force S = 870 lb , and a thrust force
Q = 598 lb taken by the right-hand bearing. The power is delivered to a belt at
F that exerts a downward vertical force of 1620 lb.; sled runner keyways. Use
the octahedral shear theory with the Soderberg line and compute N at sections C
and D. (Data courtesy of Twin Disc Clutch Company.)
Page 50 of 76
SECTION 7 SHAFT DESIGN
Vertical
13.6 13.6
M = Q = (598) = 4066.4 in lb
2 2
[
M A =0 ]
Page 51 of 76
SECTION 7 SHAFT DESIGN
3 5 3 5 3 7 11 13 3
1 + 1 (870 ) + 1 + 1 + 3 + 1 + 1 + + 2 (1620 ) + 4066.4
16 8 16 8 8 32 32 16 4
3 5 3 7
= 1 + 1 + 3 + 1 Gv
16 8 8 32
Gv = 3573 lb
[ F =0]
v
Av + S + F = Gv
Av + 870 + 1620 = 3573
Av = 1083 lb
Shear Diagram
Moment Diagram
M Av = 0
3
M Pv = (1083)1 = 1286 in lb
16
5
M Bv = 1286 + ( 1083)1 = 3046 in lb at the left
8
M Bv = 3046 + 4066.4 = 1021 in lb at the right
3
M Cv = 1021 (1953) 3 = 5570 in lb
8
7
M Gv = 5570 (1953)1 = 7950 in lb
32
Page 52 of 76
SECTION 7 SHAFT DESIGN
11
M Dv = 7950 + (1620 )1 = 5773 in lb
32
13
M Ev = 5773 + (1620 ) = 4457 in lb
16
3
M Fv = 4457 + (1620 ) 2 = 0 in lb
4
Horizontal
[ M A =0 ]
13 13 19
2 (2390 ) + 2 + 4 Gh
16 16 32
Gh = 908 lb
[ F h =0 ]
Ah + Gh = Ft
Ah + 908 = 2390
Ah = 1482 lb
Shear Diagram
M Ah = 0
3
M Ph = (1482 )1 = 1760 in lb
16
5
M Bh = 1760 + (1482 )1 = 4168 in lb
8
Page 53 of 76
SECTION 7 SHAFT DESIGN
3
M Ch = 4168 (908) 3 = 1104 in lb
8
7
M Ch = 1104 (908)1 = 0 in lb
32
M Dh = 0 in lb
M Eh = 0 in lb
M Fh = 0 in lb
Combined
M = M h2 + M v2
M A = 0 in lb
MP = (1760)2 + (1286)2 = 2180 in lb
MB = (4168)2 + (3046)2 = 5163 in lb
MC = (1104)2 + (5570)2 = 5678 in lb
MD = (0)2 + (5773)2 = 5773 in lb
ME = (0)2 + (4457 )2 = 4457 in lb
MF = (0)2 + (0)2 = 0 in lb
1
at C: r = in = 0.125 in
8
d = 2.750 in
D = 2.953 in
r 0.125
= = 0.05
d 2.750
D 2.953
= = 1.10
d 2.750
Figure AF 12
K f 1 K t = 1 .9
K fs1 K ts = 1.3
For sled runner keyway
K f 2 = 1 .6
K fs 2 = 1.6
Page 54 of 76
SECTION 7 SHAFT DESIGN
sn K f sa
se = sm +
sy SF
4Q 4(598)
sm = = = 101 psi
d 2
(2.750)2
32 M C 32(5678)
sa = = = 2781 psi
d3 (2.750)3
1 (2.4)(2781) = 7920 psi
se = (101) +
1.482 0.85
s K fs sas
ses = ns sms +
s ys SF
16T 16(16,237 )
sms = = = 3976 psi
d 3 (2.750)3
sas = 0
1
ses = (3976 ) + 0 = 2683 psi
1.482
Octahedral shear theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 7920
2 2 2
2683
= +
N 56,000 0.577(56,000)
N =6
1
at D: r = in = 0.0625 in
16
d = 2.953 in
3
D = 3 in = 3.375 in
8
r 0.0625
= = 0.02
d 2.953
D 3.375
= = 1.14
d 2.953
Figure AF 12
K f K t = 2 .4
K fs K ts = 1.6
sn K f sa
se = sm +
sy SF
Page 55 of 76
SECTION 7 SHAFT DESIGN
4Q 4(598)
sm = = = 87.3 psi
d 2
(2.953)2
32 M C 32(5773)
sa = = = 2284 psi
d3 (2.953)3
1 (2.4)(2284) = 6508 psi
se = (87.3) +
1.482 0.85
s K fs sas
ses = ns sms +
s ys SF
16T 16(16,237 )
sms = = = 3211 psi
d 3 (2.953)3
sas = 0
1
ses = (3211) + 0 = 2167 psi
1.482
Octahedral shear theory
1
1 se ses
2 2 2
= +
N sn 0.577 sn
1
1 6508
2 2 2
2167
= +
N 56,000 0.577(56,000)
N = 7 .5
TRANSVERSE DEFLECTIONS
494. The forces on the 2-in. steel shaft shown are A = 2 kips , C = 4 kips . Determine
the maximum deflection and the shafts slope at D.
Problems 494-496
Solution:
Page 56 of 76
SECTION 7 SHAFT DESIGN
[M B = 0]
2(10) + 25D = 4(15)
D = 1.6 kips
[Fv = 0]
A+C = B + D
2 + 4 = B + 1 .6
B = 4.4 kips
Shear Diagram
Moment Diagram
M 64 M
=
EI E D 4
A B C D
M (in kip ) 0 -20 16 0
M 4 4
D 10 0 -135.8 108.6 0
EI
Page 57 of 76
SECTION 7 SHAFT DESIGN
Scale ss = 10 in in
M 200 104
, Scale sM = per in
EI EI D4
Deflection:
0.625
At A: y A = in
D4
Page 58 of 76
SECTION 7 SHAFT DESIGN
0.375
At C: yC = in
D4
Slope:
0.075
At A: = rad
D4
0.0125
At B: = rad
D4
0.05625
At D: = rad
D4
Maximum deflection:
0.625
y = yA = = 0.04 in
(2 )4
Shafts slope at D
0.05625
= = 0.0035 rad
(2)4
495. The forces on the steel shaft shown are A = 2 kips , C = 4 kips . Determine the
constant shaft diameter that corresponds to a maximum deflection of 0.006 in. at
section C.
Solution:
(see Problem 494)
0.375
yC = = 0.006
D4
D = 2.812 in
7
say D = 2 in
8
496. The forces on the steel shaft shown are A = 2 kips , C = 4 kips . Determine a
constant shaft diameter that would limit the maximum deflection at section A to
0.003 in.
Solution:
(see Problem 494)
0.625
yA = = 0.003
D4
D = 3.80 in
7
say D = 3 in
8
Page 59 of 76
SECTION 7 SHAFT DESIGN
Problem 497
Solution:
[ M R1 = 0 ]
(3000 ) 7 + 1 1 (2100) 7 + 2 1 + 1 = 7 + 2 1 + 2 + 7 R2
8 8 8 4 8 4 8
R2 = 444 lb
[ F = 0]
R1 + R2 + 2100 = 3000
R1 444 + 2100 = 3000
R1 = 1344 lb
Loading
Shear Diagram
Moment Diagram
Page 60 of 76
SECTION 7 SHAFT DESIGN
M A = 0 in lb
7
M B = (1344 ) = 1176 in lb
8
7 1
M C = (1134 ) + 1 = 2688 in lb
8 8
1
M D = 2688 (1656 )1 = 825 in lb
8
M E = 825 (1656)(1) = 831 in lb
M F = 831 + (444)(1) = 387 in lb
7
M G = 387 + (444 ) = 0 in lb
8
A B1 B2 C D1 D2 E F1 F2 G
M (in kips ) 0 1.18 1.18 2.69 0.83 0.83 -0.83 -0.39 -0.39 0
D(in ) 1 1 2 2 2 1 1 1 1 1
(M
EI
)( )
10 4 0 1.58 0.50 1.14 0.35 0.60 -0.60 -0.28 -0.52 0
Scale ss = 2 in in
Page 61 of 76
SECTION 7 SHAFT DESIGN
M 2 104
, Scale sM = per in
EI EI D4
y deflection, Scale s y = 8 10 4 D 4 in in
( )
at R1 , A = 0.375 4 10 4 = 1.5 10 4 rad
at R2 , G = 0 rad
at C, yC = 0.1875(8 10 4 ) = 1.5 10 4 in
Page 62 of 76
SECTION 7 SHAFT DESIGN
498. (a) Determine the diameter of the steel shaft shown if the maximum deflection is
to be 0.01 in.; C = 1.5 kips , A = 1.58 kips , L = 24 in . (b) What is the slope of the
shaft at bearing D? See 479.
[ M D =0 ]
6(1.5) + 8(0.424) = 24 Ev
Ev = 0.516 kip
[ F v =0 ]
Dv + 0.424 = 1.5 + Ev
Dv + 0.424 = 1.5 + 0.516
Dv = 1.592 kip
Shear Diagram
M C = 0 ; M D = 6(1.5) = 9 in kips
M B = 9 + 8(0.092) = 8.264 in kips
Page 63 of 76
SECTION 7 SHAFT DESIGN
C D B A E
M (in kips ) 0 -9 -8.264 -2.588 0
(
M
EI
)
D 4 10 4 0 -61.1 -56.1 -17.6 0
Scale ss = 8 in in
M 120 10 4
, Scale sM = per in
EI EI D4
Page 64 of 76
SECTION 7 SHAFT DESIGN
Deflections.
0.384
yCv = in
D4
0.288
y Bv = in
D4
0.168
y Av = in
D4
Slope
0.057
Dv = rad
D4
Horizontal
[ M D =0 ]
8(0.424 ) + 24 Eh = 19(1.58)
Eh = 1.1095 kip
[ F h =0 ]
Dh + Eh + 0.424 = 1.58
Dh + 1.1095 + 0.424 = 1.58
Page 65 of 76
SECTION 7 SHAFT DESIGN
Dh = 0.0465 kip
Shear Diagram
Moments
MC = 0
MD = 0
M B = 8( 0.0465) = 0.372 in kip
M A = 0.372 + 11( 0.4705) = 5.5475 in kips
M E = 5.5475 + 5(1.1095) = 0
C D B A E
M (in kips ) 0 0 -0.372 -5.5475 0
(
M
EI
)
D 4 10 4 0 0 -2.53 -37.7 0
Scale ss = 8 in in
M 4 104
, Scale sM = per in
EI EI D4
Page 66 of 76
SECTION 7 SHAFT DESIGN
Deflections.
0.064
yC h = in
D4
0.072
y Bh = in
D4
0.096
y Ah = in
D4
Slope
0.012
Dh = rad
D4
Resultant deflection:
1
(
y = yh2 + yv2 )
2
yC =
[(0.064) + (0.384) ]
2 2 2
=
0.390
4
D D4
1
yB =
[(0.072) + (0.288) ]
2 2 2
=
0.297
4
D D4
1
yA =
[(0.096) + (0.168) ]
2 2 2
=
0.194
4
D D4
Slope:
Page 67 of 76
SECTION 7 SHAFT DESIGN
1
= ( +
2
h v )
2 2
D =
[(0.012) + (0.057) ]
2 2 2
=
0.05823
rad
4
D D4
(a) Diameter D.
0.390
Maximum deflection = yC = = 0.01 in
D4
D = 2.50 in
CRITICAL SPEED
499. A small, high-speed turbine has a single disk, weighing 0.85 lb., mounted at the
midpoint of a 0.178-in. shaft, whose length between bearings is 6 in. What is
the critical speed if the shaft is considered as simply supported?
Solution:
Table AT 2
y=
WL3
=
(0.85)(6.5)
3
= 0.052634 in
6 (0.178 )
4
3EI
(
3 30 10
64
)
1 1 1
30 g o ( Wy ) 2 30 g o 2 30 386 2
nc = = = = 818 rpm
Wy 2 y 0.052634
500. The bearings on a 1 -in. shaft are 30 in. apart. On the shaft are three 300-lb
disks, symmetrically placed 7.5 in. apart. What is the critical speed of the shaft?
Solution:
Page 68 of 76
SECTION 7 SHAFT DESIGN
Table AT 2
Deflection of B.
y B = y B1 + y B2 + y B3
y B1 =
(300)(22.5)(7.5)([ 30)2 (22.5)2 (7.5)2 ] = 0.01273 in
6 (1.5 )
4
6(30 10 )
(30)
64
y B2 =
[ ]
(300)(15)(7.5)(30)2 (15)2 (7.5)2 = 0.01556 in
(1.5)4
(
6 30 106 ) (30)
64
y B3 =
( [
300)(7.5)(7.5)(30) (7.5) (7.5)
2 2 2
]
= 0.00990 in
6 (1.5 )
4
(
6 30 10 )
64
(30)
y B = 0.01273 + 0.00990 + 0.01556 = 0.03819 in
Deflection of C.
yC = yC1 + yC2 + yC3
yC1 =
( [
300)(7.5)(30 15)( 30) (7.5) (30 15) ]
2 2 2
= 0.01556 in
6 (1.5 )
4
6(30 10 ) (30)
64
yC2 =
[ ]
(300)(15)(30 15)(30)2 (15)2 (30 15)2 = 0.02264 in
6 (1.5 )
4
(
6 30 10 ) (30)
64
yC3 =
[ ]
(300)(7.5)(15)(30)2 (7.5)2 (15)2 = 0.01556 in
(1.5)4
(
6 30 106 ) (30)
64
yC = 0.01556 + 0.02264 + 0.01556 = 0.05376 in
Deflection of D.
y D = y D1 + y D2 + y D3
Page 69 of 76
SECTION 7 SHAFT DESIGN
y D1 =
(300)(7.5)(30 22.5)([ 30)2 (7.5)2 (30 22.5)2 ] = 0.00990 in
6 (1.5 )
4
6(30 10 )
(30)
64
y D2 =
[ ]
(300)(15)(30 22.5)(30)2 (15)2 (30 22.5)2 = 0.01556 in
6 (1.5 )
4
(
6 30 10 )
(30)
64
y D3 =
[ ]
(300)(7.5)(22.5)(30)2 (7.5)2 (22.5)2 = 0.01273 in
(1.5)4
(
6 30 106 ) (30 )
64
y D = 0.00990 + 0.01556 + 0.01273 = 0.03819 in
1 1
30 g o ( Wy ) 30 g o ( y B + yC + y D ) 2
2
nc = =
Wy 2 y B2 + yC2 + y D2
1
30 386(0.03819 + 0.05376 + 0.03819) 2
nc = = 888 rpm
(0.03819)2 + (0.05376)2 + (0.03819)2
501. A fan for an air-conditioning unit has two 50-lb. rotors mounted on a 3-in. steel
shaft, each being 22 in. from an end of the shaft which is 80 in. long and simply
supported at the ends. Determine (a) the deflection curve of the shaft considering
its weight as well as the weight of the rotors, (b) its critical speed.
Solution:
W1 = 50 lb
W3 = 50 lb
2
W2 = (0.284 ) (3) (80 ) = 160 lb weight of shaft
4
160
w2 = = 2 lb in
80
Deflection of B.
y B = y B1 + y B2 + y B3
Page 70 of 76
SECTION 7 SHAFT DESIGN
y B1 =
(50)(50)(22)([ 80)2 (58)2 (22)2 ] = 0.002844 in
6 (35 )
4
6(30 10 )
(80)
64
y B3 =
[ ]
(50)(22)(22)(80)2 (22)2 (22)2 = 0.002296 in
6 (3)
4
(
6 30 10 ) (80)
64
y B2 =
[ ]
(2)(22)(80)3 2(80)(22)2 (22)3 = 0.006843 in
(3)4
(
6 30 106 )
64
y B = 0.002844 + 0.006843 + 0.002296 = 0.011983 in
Deflection of C.
yC = yC1 + yC2 + yC3
yC1 =
( [
50)(22)(80 40)( 80) (22) (80 40) ]
2 2 2
= 0.003317 in
6 (35)
4
6(30 10 ) (80)
64
yC3 =
( [
50)(22 )(40)(80) (22) (40)
2 2 2
]
= 0.003317 in
6 (3)
4
(
6 30 10 ) (80)
64
yC2 =
[ ]
(2)(40)(80)3 2(80)(40)2 (40)3 = 0.008942 in
6 (3)
4
(
6 30 10 )
64
yC = 0.003317 + 0.008942 + 0.003317 = 0.015576 in
By symmetry
y D = y B = 0.011983 in
Page 71 of 76
SECTION 7 SHAFT DESIGN
30 g o ( Wy ) 2
nc =
Wy 2
Wy = (50)(0.011983) + (160)(0.015576) + (50)(0.011983) = 3.69046
Wy = (50)(0.011983) + (160)(0.015576) + (50)(0.011983) = 0.053177
2 2 2 2
1
30 386(3.69046) 2
nc = = 1563 rpm
0.053177
ASME CODE
Solution:
For AISI C1050, annealed
s y = 53 ksi
su = 92 ksi
0.3s y = 15.9 ksi
0.18su = 16.56 ksi
use d = 0.3s y = 15.9 ksi
M = 43 in kips
T = 27 in kips
1
16 FD 1 + B 2
( ) 2 2
(K sT ) + K m M +
3 2
D =
(
d 1 B 4 )
8
Reduce to
1
)[ ]
16
3
D = (K sT ) + ( K m M )
2 2 2
(
d 1 B 4
For mild shock load, rotating shafts
K m = 1.75
K s = 1.25
B=0
1
16
3
D =
(15,900)
{
[(1.25)(27,000)] + [(1.75)(43,000)]
2
}
2 2
D = 2.98 in
say D = 3 in
Page 72 of 76
SECTION 7 SHAFT DESIGN
503. A machinery shaft is to transmit 82 hp at a speed of 1150 rpm with mild shock.
The shaft is subjected to a maximum bending moment of 7500 in-lb. and an axial
thrust load of 15,000 lb. The material is AISI 3150, OQT 1000 F. (a) What
should be the diameter when designed according to the Code? (b) Determine the
corresponding conventional factor of safety (static-approach and maximum-shear
theory).
Solution:
16 (
FD 1 + B 2 ) 2
2
(K sT ) + K m M +
3 2
(a) D =
( )
d 1 B 4
8
16 (1)(15,000)D 2
2
[(1.25)(4492)] + (1.75)(7500) +
3 2
D =
(27180) 8
1
{
D 3 = 0.1874 31.53 + [13.125 + 1.875D ] }
2 2
D = 1.4668 in
say D = 1.5 in
32 M 4F 32(7500 ) 4(15,000 )
(b) s = + = + = 31,124 psi = 31.124 ksi
3
D D 2
(1.5)3 (1.5)2
Page 73 of 76
SECTION 7 SHAFT DESIGN
16T 16(4492 )
ss = = = 6778.5 psi = 6.7785 ksi
D 3 (1.5)3
1 s ss
2 2
= +
N s y s ys
Maximum shear theory
s ys = 0.5s y
1 31.124 6.7785
2 2
= +
N 130 0.5(130)
N = 3.83
504. short stub shaft, made of SAE 1035, as rolled, receives 30 hp at 300 rpm via a
12-in. spur gear, the power being delivered to another shaft through a flexible
coupling. The gear is keyed midway between the bearings and its pressure angle
= 20o . See the figure for 471. (a) Neglecting the radial component of the tooth
load, determine the shaft diameter for a mild shock load. (b) Considering both
tangential and radial components, compute the shaft diameter. (c) Is the
difference in the foregoing results enough to change your choice of the shaft
size?
Solution:
Page 74 of 76
SECTION 7 SHAFT DESIGN
16 (
FD 1 + B 2 ) 2
2
D3 = ( K T )2
+ K
m M +
(
d 1 B 4
) s
8
Reduce to
1
)[ ]
16
D3 = ( K T )2
+ ( K M )2 2
(
d 1 B 4
s m
D = 1.5461 in
9
say D = 1 in
16
505. Two bearings D and E, a distance D = 24 in . Apart, support a shaft for a punch
press on which are an 8-in. gear A, a 44-in. pulley B, and a flywheel C, as
indicated (498). Weight of flywheel is 1500 lb.; pulley B receives the power at an
angle of 45o to the right of the vertical; gear A delivers it horizontally to the right.
The maximum power is 25 hp at 250 rpm is delivered, with heavy shock. For
cold-finish AISI 1137, find the diameter by the ASME Code.
Solution:
Page 75 of 76
SECTION 7 SHAFT DESIGN
Data and figure is the same as in Problem 479. Also figure is the same as in Problem 498.
For AISI 1137, cold-finished
s y = 93 ksi
su = 103 ksi
0.3s y = 27.9 ksi
0.18su = 18.54 ksi
use d = 0.18s u = 18.54 ksi
From Problem 479
M = M B = 14,343 in lb = 14.343 in kips
T = TA = 12,600 in lb = 12.6 in kips
For heavy shock load
K m = 2.5
K s = 1.75
B=0
1
16 (
FD 1 + B 2
)
2 2
(K sT ) + K m M +
2
D3 =
( 4
d 1 B
) 8
1
)[ ]
16
D3 = ( K T )2
+ ( K M )2 2
(
d 1 B 4
s m
1
16
D3 =
(18.54)
{
[(1.75)(12.6)]2 + [(2.5)(14.343)]2 }2
D = 2.2613 in
5
say D = 2 in
16
- end -
Page 76 of 76
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
551. (a) A 3 x 3 in. full bearing supports a load of 900 lb., c d D = 0.0015 ,
n = 400 rpm . The temperature of the SAE 40 oil is maintained at 140 oF.
Considering the bearing lightly loaded (Petroff), compute the frictional torque,
fhp, and the coefficient of friction. (b) The same as (a) except that the oil is
SAE 10W.
Solution.
DLvips D
(a) T f =
(cd 2) 2
L = 3 in
D = 3 in
Dn (3)(400)
vips = = = 20 ips
60 60
c d D = 0.0015
SAE 40 oil, 140 oF, Figure A16.
= 7.25 reyns
F= =
( )
DLvips 7.25 10 6 ( )(3)(3)(20 )
= 17.173 lb
(cd 2) (0.0015 2)
D 3
T f = F = (17.173) = 25.76 in lb
2 2
Fvm
fhp =
33,000
Dn (3)(400 )
vm = = = 314.16 fpm
12 12
fhp =
Fvm
=
(17.173)(314.16) = 0.1635 hp
33,000 33,000
F 17.173
f = = = 0.0191
W 900
F= =
( )
DLvips 2.2 10 6 ( )(3)(3)(20 )
= 5.211 lb
(cd 2) (0.0015 2)
D 3
T f = F = (5.211) = 7.817 in lb
2 2
Fvm
fhp =
33,000
Page 1 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
Dn (3)(400 )
vm = = = 314.16 fpm
12 12
fhp =
Fvm
=
(5.211)(314.16) = 0.0496 hp
33,000 33,000
F 5.211
f = = = 0.00579
W 900
553. The average pressure on a 6-in. full bearing is 50 psi, cd = 0.003 in. , L D = 1 .
While the average oil temperature is maintained at 160 oF with n = 300 rpm ,
the frictional force is found to be 13 lb. Compute the coefficient of friction
and the average viscosity of the oil. To what grade of oil does this
correspond?
Solution:
W
p=
LD
D = 6 in.
L D =1
L = 6 in.
W = pLD = (50)(6)(6 ) = 1800 lb
F = 13 lb
Coefficient of Friction
F 13
f = = = 0.0072
W 1800
DLvips
F=
(cd 2)
Dn (6)(300)
vips = = = 30 ips
60 60
DLvips ( )(6)(6)(30 )
F= = = 13 lb
(cd 2) (0.003 2)
= 1.8 10 6 reyn = 1.8 reyns
Figure AF 16, 160 oF use SAE 10W or SAE 20W
FULL BEARINGS
Page 2 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
(e) the temperature rise as the oil passes through the bearing, (f) the maximum
pressure.
Solution:
(a) D = 4 in
L D =1
L = 4 in
cd = 0.0011D = 0.0011(4) = 0.0044 in
ho = 0.00088 in
2h 2(0.00088)
= 1 o = 1 = 0 .6
cd 0.0044
Table AT 20
= 0.6 , L D = 1
Sommerfield Number
2
ns D
S=
p cd
320
ns = = 5.333 rps
60
W 2000
p= = = 125 psi
LD (4)(4)
cd D = 0.0011
2
(5.333) 1
0.121 =
125 0.0011
= 3.4 10 6 reyn = 3.4 reyns
Figure AF-16, 150 oF, use SAE 30 or SAE 20 W
Select SAE 30, the nearest
= 3.9 106 reyn
Page 3 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
Dn (4)(320)
vm = = = 335.1 fpm
12 12
Frictional loss = Fvm = (7.084 )(335.1)2374 ft lb min
(c) Table AT 20, L D = 1 , = 0.6
q
= 4.33
rcr ns L
D
r = = 2.0 in
2
c 0.0044
cr = d = = 0.0022 in
2 2
ns = 5.333 rps
L = 4 in
q = 4.33rcr ns L = 4.33(2.0 )(0.0022 )(5.333)(4 ) = 0.4064 in 3 sec
555. A 4-in., 360o bearing, with L D = 1.1 (use table and chart values for 1), is to
support 5 kips with a minimum film thickness 0.0008 in.; cd = 0.004 in. ,
n = 600 rpm . Determine (a) the needed absolute viscosity of the oil .(b)
Suitable oil if the average film temperature is 160 F, (c) the frictional loss in
hp. (d) Adjusting only ho to the optimum value for minimum friction,
determine the fhp and compare. (e) This load varies. What could be the
magnitude of the maximum impulsive load if the eccentricity ration
becomes 0.8? Ignore squeeze effect.
Page 4 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
Solution:
D = 4 in
L = 1.1D = 1.1(4) = 4.4 in
W 5000
p= = = 284 psi
LD (4.4)(4)
ho = 0.0008 in
cd = 0.004 in.
2h 2(0.0008)
= 1 o = 1 = 0 .6
cd 0.004
600
= = 10 rps
60
S = 0.121
2 2
r ns n s D
S = =
cr p p cd
2
(10)
4
0.121 =
284 0.004
= 3.4 106 reyn
r
f = 3.22
cr
D
f = 3.22
cd
4
f = 3.22
0.004
f = 0.00322
F = f W = (0.00322)(5000 lb ) = 16.1 lb
Dn (4)(600)
vm = = = 628.3 fpm
12 12
Page 5 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
fhp =
Fvm
=
(16.1)(628.3) = 0.3065 hp
33,000 33,000
Table AT 20, L D = 1
ho cr = 0.30 optimum value for minimum friction
r
f = 2.46
cr
D
f = 2.46
cd
4
f = 2.46
0.004
f = 0.00246
F = f W = (0.00246)(5000 lb ) = 12.3 lb
Dn (4)(600)
vm = = = 628.3 fpm
12 12
fhp =
Fvm
=
(12.3)(628.3) = 0.234 hp < fhp (c )
33,000 33,000
S = 0.0446
2 2
r ns n s D
S = =
cr p p cd
0.0446 =
(3.2 10 )(10)
6
4
2
p 0.004
p = 717.5 psi
W = pDL = (717.5)(4)(4.4) = 12,628 lb
556. For an 8 x 4 in. full bearing, cr = 0.0075 in. , n = 2700 rpm , average
= 4 10 6 reyn . (a) What load may this bearing safely carry if the minimum
film thickness is not to be less than that given by Norton, i11.14, Text? (b)
Compute the corresponding frictional loss (fhp). (c) Complete calculations for
the other quantities in Table AT 20, , q , qs , to , pmax . Compute the
maximum load for an optimum (load) bearing (d) if cr remains the same, (e)
if ho remains the same.
Page 6 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
Solution:
D L = 8 4
L D =1 2
cr = 0.0075 in
r = D 2 = 4 in
= 4 10 6 reyn
ho
(b) Table AT 20, L D = 1 2 , = 0.27
cr
= 38.5o
r
f = 4.954
cr
D
f = 4.954
cd
4
f = 4.954
0.004
f = 0.0093
F = f W = (0.0093)(9536 lb ) = 88.7 lb
Dn (8)(2700)
vm = = = 5655 fpm
12 12
fhp =
Fvm
=
(88.7 )(5655) = 15.2 hp
33,000 33,000
Page 7 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
ho
(c) Table AT 20, L D = 1 2 , = 0.27
cr
= 38.5o
q
= 5.214
rcr ns L
q = 5.214rcr ns L = 5.214(4 )(0.0075)(45)(4 ) = 28.2 in 3 sec
qs
= 0.824
q
qs = 0.824(28.2 ) = 23.2 in 3 sec
ct
= 20.26
p
20.26(298)
t = = 54 o F
112
p
= 0.3013
pmax
298
pmax = = 989 psi
0.3013
h
To solve for maximum load, Table AT 20, L D = 1 2 , o = 0.43
cr
2
r ns
S = = 0.388
cr p
(d) cr = 0.0075 in
2
(
4 4 10 (45)
S = 0.388 =
6
)
0.0075 p
p = 132 psi
W = pDL = (132)(8)(4) = 4224 lb
(e) ho = 0.002 in
ho
= 0.43
cr
0.002
cr = = 0.00465 in
0.43
S = 0.388 =
4
2 6
(
4 10 (45) )
0.00465 p
p = 343.3 psi
W = pDL = (343.3)(8)(4) = 10,986 lb
Page 8 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
557. A 6 x 6 in full bearing has a frictional loss of fhp = 11 when the load is
68,500 lb. and n = 1600 rpm ; cr r = 0.001 . (a) Compute the minimum film
thickness. Is this in the vicinity of that for an optimum bearing? (b) What is
the viscosity of the oil and a proper grade for an operating temperature of 160
F? (c) For the same ho , but for the maximum-load optimum, determine the
permissible load and the fhp.
Solution:
L = 6 in
D = 6 in
L D =1
r = D 2 = 3 in
cr r = 0.001
n = 1600 rpm
Dn (3)(1600)
vm = = = 2513 fpm
12 12
Fvm
fhp =
33,000
33,000(11)
F= = 144.45 lb
2513
F 144.45
f = = = 0.00211
W 68,500
r 1
(a) f = (0.00211) = 2.11
cr 0.001
r
Table AT 20, L D = 1 , f = 2.11
cr
Near the vicinity of optimum bearing
cr = 0.001r = 0.001(3) = 0.003 in
ho = 0.254cr = 0.254(0.003) = 0.0008 in
r
(b) Table AT 20, L D = 1 , f = 2.11
cr
S = 0.0652
2
r ns
S = = 0.388
cr p
1600
ns = = 26.67 rps
60
W 68,500
p= = = 1902.8 psi
LD (6)(6)
Page 9 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
2
1 ( )(26.67 )
S = 0.0652 =
0.001 1902.8
= 4.7 10 6 reyn
Figure AF 16, 160 F, use SAE 40.
fhp =
Fvm
=
(206.65)(2513) = 15.74 hp
33,000 33,000
558. The maximum load on a 2.25 x 1.6875 in. main bearing of an automobile is
3140 lb. with wide-open throttle at 1000 rpm. If the oil is SAE 20W at 210 F,
compute the minimum film thickness for a bearing clearance of (a) 0.0008 in.
and (b) 0.0005 in. Which clearance results in the safer operating conditions?
Note: Since a load of this order exists for only 20-25o of rotation, the actual
ho does not reach this computed minimum (squeeze effect).
Solution:
D L = 2.25 1.6875 in
L 1.6875
= = 0.75
D 2.25
Page 10 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
SAE 20 W at 210 oF
= 0.96 10 6 reyn
W = 3140 lb
n = 1000 rpm
W 3140
p= = = 827 psi
DL (2.25)(1.6875)
1000
ns = = 16.67 rps
60
D
r = = 1.125 in
2
2
ns r
S=
p cr
(a) cr = 0.0008 in
S=
(0.96 10 )(16.67 ) 1.125
6
= 0.038
2
827 0.0008
Table AT 20, L D = 3 4 , S = 0.038
L D ho cr S
1 0.2 0.0446
0.2 0.0923
0.2 0.0685
L D ho cr S
1 0.1 0.0188
0.1 0.0313
0.1 0.0251
At L D = 3 4
ho 0.038 0.0251
= (0.2 0.1) + 0.1 = 0.13
cr 0.0685 0.0251
ho = 0.13cr = 0.13(0.0008) = 0.0001 in
(b) cr = 0.0005 in
S=
(0.96 10 )(16.67 ) 1.125
6 2
= 0.098
827 0.0005
Page 11 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
L D ho cr S
1 0.2 0.0446
0.2 0.0923
0.2 0.0685
L D ho cr S
1 0.4 0.121
0.4 0.319
0.4 0.220
At L D = 3 4
ho 0.098 0.0685
= (0.4 0.2) + 0.2 = 0.239
cr 0.220 0.0685
ho = 0.239cr = 0.239(0.0005) = 0.00012 in
561. A 360o bearing supports a load of 2500 lb.; D = 5 in. , L = 2.5 in. ,
cr = 0.003 in. , n = 1800 rpm ; SAE 20 W oil entering at 100 F. (a) Compute
the average temperature t av of the oil through the bearing. (An iteration
procedure. Assume ; compute S and the corresponding to ; then the
average oil temperature t av = ti + to 2 . If this t av and the assumed do not
locate a point in Fig. AF 16 on the line for SAE 20 W oil, try again.) Calculate
(b) the minimum film thickness, (c) the fhp, (d) the amount of oil to be
supplied and the end leakage.
Solution:
D = 5 in
L = 2.5 in
L 2 .5
= = 0 .5
D 5
cr = 0.003 in
(a) Table AT 20
cto
Parameter, , c = 112
p
2
r ns
S =
cr p
Page 12 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
W 2500
p= = = 200 psi
DL (5)(2.5)
1800
ns = = 30 rps
60
D
r = = 2.5 in
2
cr = 0.003 in
Fig. AF 16, SAE 20 W, Table AT 20, L D = 0.5 , ti = 100 o F
cto
Trial ( t o F ), reyns S to o F t av = ti + to 2 o F
p
3.5 x 10-6 (130 F) 0.365 36.56 65 132.5
-6
3.2 x 10 (134 F) 0.333 34.08 61 130.5
-6
3.4 x 10 (132 F) 0.354 35.71 64 132.0
Page 13 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
PARTIAL BEARINGS
Solution:
D = L = 2 in
L D =1
cr = 0.001 in
r = D 2 = 1 in
n = 2400 rpm
ns = 40 rps
= 3 106 reyn
ho = 0.004 in.
ho 0.0004
= = 0. 4
cr 0.001
Dn (2)(2400)
vm = = = 1257 fpm
12 12
Page 14 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
2
r ns
S =
cr p
0.121 =
2
(
1 3 10 (40 )
6
)
0.001 p
p = 992 psi
W = pDL = (992)(2)(2) = 3968 lb
fhp:
F = fW
rf
= 3.22
cr
1
f = 3.22
0.001
f = 0.00322
F = f W = (0.00322)(3968) = 12.78 lb
fhp =
Fvm
=
(12.78)(1257 ) = 0.4868 hp
33,000 33,000
Oil flow, q
q
= 4.33
rcr ns L
q
= 4.33
(0.1)(0.001)(40)(2)
q = 0.3464 in3 sec
End leakage
qs
= 0.680
q
qs = 0.68(0.3464 ) = 0.2356 in3 sec
Temperature rise, to
cto
= 14.2
p
(112)to = 14.2
992
to = 126 o F
Page 15 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
rf
= 2.28
cr
q
= 3.25
rcr ns L
qs
= 0.572
q
cto
= 12.4
p
Load W
2
r ns
S =
cr p
0.128 =
2
(
1 3 10 (40 )
6
)
0.001 p
p = 937.5 psi
W = pDL = (937.5)(2)(2) = 3750 lb
fhp:
F = fW
rf
= 2.28
cr
1
f = 2.28
0.001
f = 0.00228
F = f W = (0.00228)(3750) = 8.55 lb
fhp =
Fvm
=
(8.55)(1257) = 0.3257 hp
33,000 33,000
Oil flow, q
q
= 3.25
rcr ns L
q
= 3.25
(0.1)(0.001)(40)(2)
q = 0.26 in3 sec
End leakage
qs
= 0.572
q
qs = 0.572(0.26 ) = 0.1487 in3 sec
Temperature rise, to
Page 16 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
cto
= 12.4
p
(112)to = 12.4
937.5
to = 104 o F
Load W
2
r ns
S =
cr p
0.162 =
2
(
1 3 10 (40 )
6
)
0.001 p
p = 741 psi
W = pDL = (741)(2 )(2) = 2964 lb
fhp:
F = fW
rf
= 2.16
cr
1
f = 2.16
0.001
f = 0.00216
F = f W = (0.00216)(2964) = 6.4 lb
fhp =
Fvm
=
(6.4)(1257 ) = 0.2438 hp
33,000 33,000
Oil flow, q
Page 17 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
q
= 2.24
rcr ns L
q
= 2.24
(0.1)(0.001)(40)(2)
q = 0.1792 in3 sec
End leakage
qs
= 0.384
q
q s = 0.384(0.1792 ) = 0.0688 in 3 sec
Temperature rise, to
cto
= 15
p
(112)to = 15
741
to = 99 o F
L D = 1 , ho cr = 0.4
S = 0.450
rf
= 3.29
cr
q
= 1.56
rcr ns L
qs
= 0.127
q
cto
= 28.2
p
Load W
2
r ns
S =
cr p
2
(
1 3 10 (40 )
0.450 =
6
)
0.001 p
p = 267 psi
W = pDL = (267 )(2)(2) = 1068 lb
fhp:
F = fW
Page 18 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
rf
= 3.29
cr
1
f = 3.29
0.001
f = 0.00329
F = f W = (0.00329)(1068) = 3.514 lb
fhp =
Fvm
=
(3.514)(1257) = 0.1339 hp
33,000 33,000
Oil flow, q
q
= 1.56
rcr ns L
q
= 1.56
(0.1)(0.001)(40)(2)
q = 0.1248 in3 sec
End leakage
qs
= 0.127
q
qs = 0.127(0.1248) = 0.0158 in3 sec
Temperature rise, to
cto
= 28.2
p
(112)to = 28.2
267
to = 67 o F
Solution:
L = 2 in
D = 2 in
W = 5000 lb
cr = 0.001 in.
n = 2400 rpm
ns = 40 rps
= 3 106 reyn
r = D 2 = 1 in
Page 19 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
W 5000
p= = = 1250 psi
LD (2)(2)
2 2
( )
r ns 1 3 10 6 (40 )
S = = = 0.10
cr p 0.001 1250
Dn (2)(2400)
vm = = = 1257 fpm
12 12
Using Fig. AF 17 and AF 18
ho
= 0.346
cr
r
f = 2 .8
cr
ho = 0.346(0.001) = 0.000346 in
1
f = 2 .8
0.001
f = 0.0028
F = f W = (0.0028)(5000) = 14 lb
Fvm = (14)(1257 ) = 17,600 ft lb min
ho
= 0.344
cr
r
f = 2 .0
cr
ho = 0.344(0.001) = 0.000344 in
1
f = 2 .0
0.001
f = 0.0020
F = f W = (0.0020)(5000) = 10 lb
Fvm = (10)(1257 ) = 12,570 ft lb min
ho
= 0.302
cr
Page 20 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
r
f = 1 .7
cr
ho = 0.302(0.001) = 0.000302 in
1
f = 1 .7
0.001
f = 0.0017
F = f W = (0.0017 )(5000) = 8.5 lb
Fvm = (8.5)(1257 ) = 10,685 ft lb min
ho
= 0.20
cr
r
f = 1 .4
cr
ho = 0.20(0.001) = 0.0002 in
1
f = 1 .4
0.001
f = 0.0014
F = f W = (0.0014)(5000) = 7 lb
Fvm = (7 )(1257 ) = 8,800 ft lb min
564. A 120o partial bearing is to support 4500 lb. with ho = 0.002 in. ; L D = 1 ;
D = 4 in. ; cd = 0.010 in. ; n = 3600 rpm . Determine (a) the oils viscosity,(b)
the frictional loss (ft-lb/min), (c) the eccentricity angle, (d) the needed oil
flow, (e) the end leakage, (f) the temperature rise of the oil as it passes
through, (g) the maximum pressure. (h) If the clearance given is the average,
what approximate class of fit (Table 3.1) is it? (i) What maximum impulsive
load would be on the bearing if the eccentricity ratio suddenly went to 0.8?
Ignore squeeze effect.
Solution:
W = 4500 lb
ho = 0.002 in
L D =1
D = 4 in
L = 4 in
r = D 2 = 2 in
cd = 0.010 in.
n = 3600 rpm
Page 21 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
3600
ns = = 60 rps
60
Dn (2)(3600)
vm = = = 3770 fpm
12 12
W 4500
p= = = 281.25 psi
LD (4 )(4)
ho 2ho 2(0.002 )
= = = 0 .4
cr cr 0.010
Table AT 22, L D = 1 , ho cr = 0.4
S = 0.162
= 35.65o
r
f = 2.16
cr
q
= 2.24
rcr ns L
qs
= 0.384
q
cto
= 15.0
p
p
= 0.356
pmax
2
r ns
(a) S =
cr p
2
D ns
S =
cd p
2
4 (60 )
0.162 =
0.010 281.25
= 4.75 106 reyn
r
(b) f = 2.16
cr
D
f = 2.16
cd
4
f = 2.16
0.010
f = 0.0054
F = f W = 0.0054(4500) = 24.30 lb
Page 22 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
(c) = 35.65o
q 4q
(d) = = 2.24
rcr ns L Dcd ns L
4q
= 2.24
(4)(0.010)(60)(4)
q = 5.4 in3 sec
qs
(e) = 0.384
q
qs = 0.384(5.4 ) = 2.07 in3 sec
cto
(f) = 15.0
p
(112)to = 15.0
281.25
to = 38 o F
p
(g) = 0.356
pmax
281.25
pmax = = 790 psi
0.356
(h) cd = 0.010 in , D = 4 in
Table 3.1
RC 8, Hole, average = + 0.0025
Shaft, average = - 0.00875
cd = 0.0025 + 0.00875 = 0.01125 0.010 in
Class of fit = RC 9
(i) = 0.80
Table AT 22, , L D = 1
S = 0.162
2
D ns
S =
cd p
2
(
4 3 10 (60 )
0.0531 =
6
)
0.010 p
p = 542 psi
Page 23 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
565. A 120o partial bearing is to support 4500 lb., D = 3 in. , cd = 0.003 in. ;
n = 3600 rpm ; SAE 20W entering at 110 F. Calculate (a) the average
temperature of the oil as it passes through,(b) the minimum film thickness, (c)
the fhp, (d) the quantity of oil to be supplied. HINT: In (a) assume and
determine the corresponding values of S and to ; then tav = ti + to 2 . If
assumed and tav do not locate a point in Fig. AF 16 that falls on line for
SAE 20W, iterate.
Solution:
W = 4500 lb
D = 3 in
L = 3 in
L D =1
cd = 0.003 in.
2
D ns
S =
cd p
3600
ns = = 60 rps
60
W 4500
p= = = 500 psi
DL (3)(3)
cto
, (SAE 20W)
p
cto
Trial t , oF S to tav = ti + to 2
p
3.5 x 10-6 130 0.42 19.8 88 154
2.0 x 10-6 160 0.24 15.4 68 144
2.6 x 10-6 145 0.312 17.7 79 149.5
2.35 x 10-6 150 0.282 17.2 76 148
2.4 x 10-6 149 0.288 17.3 78 149
Page 24 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
ho
= 0.513
cr
2ho
= 0.513
cd
2ho = 0.513(0.003)
ho = 0.00077 in
q
= 2.528
rcr ns L
4q
= 2.528
Dcd ns L
4q
= 2.528
(3)(0.003)(60)(3)
q = 1.024 in3 sec
Solution:
W = 6000 lb
Page 25 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
D = 8 in
L = 4 in
n = 1000 rpm
1000
ns = = 16.67 rps
60
L D =1 2
ho = 0.002 in
S = 0.126
2
r ns
S =
cr p
W 6000
p= = = 187.5 psi
DL (4)(8)
D
r = = 4 in
2
2
4 (16.67 )
S = 0.126 =
0.0087 187.5
= 6.70 106 reyn
r
f = 2.97
cr
4
f = 2.97
0.0087
f = 0.00646
F = f W = (0.00646 )(6000) = 38.76 lb
Dn (8)(1000)
vm = = = 2094 fpm
12 12
Page 26 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
fhp =
Fvm
=
(38.76)(2094) = 2.46 hp
33,000 33,000
cd 2cr 2(0.0087 )
For (a) = = = 0.0022
D D 8
cd
> 0.0022
D
cd
= 0.0030
D
cd = 0.0030(8) = 0.0240 in
cr = 0.0120 in
ho 0.002
= = 0.1667
cr 0.012
Table AT 21, L D = 1 2
r
f = 1.67
cr
4
f = 1.67
0.0016
f = 0.00668
F = f W = (0.00668)(6000 ) = 40.08 lb
Dn (8)(1000)
vm = = = 2094 fpm
12 12
fhp =
Fvm
=
(40.08)(2094) = 2.54 hp > 2.46 hp
33,000 33,000
cd
< 0.0022
D
cd
= 0.0020
D
cd = 0.0020(8) = 0.0160 in
cr = 0.0080 in
ho 0.002
= = 0.25
cr 0.008
Table AT 21, L D = 1 2
r
f = 3.26
cr
4
f = 3.26
0.0016
f = 0.00652
Page 27 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
567. A 120o partial bearing supports 3500 lb. when n = 250 rpm ; D = 5 in. ,
L = 5 in. ; = 3 106 reyn . What are the clearance and minimum film
thickness for an optimum bearing (a) for maximum load, (b) for minimum
friction? (c) On the basis of the average clearance in Table 3.1, about what
class fit is involved? Would this fit be on the expensive or inexpensive side?
(d) Find the fhp for each optimum bearing.
Solution:
D = 5 in.
L = 5 in.
L
=1
D
n = 250 rpm
250
ns = = 4.17 rps
60
= 3 106 reyn
W = 3500 lb
W 3500
p= = = 140 psi
DL (5)(5)
L h
(a) Table AT 22, = 1 , max. load o = 0.46
D cr
S = 0.229
2
r ns
S =
cr p
D
r = = 2.5 in
2
2
( )
2.5 3.0 106 (4.17 )
S = 0.229 =
cr 140
cr = 0.00156 in
ho = 0.46cr = 0.46(0.00156) = 0.00072 in
Page 28 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
L h
(b) Table AT 22, = 1 , min. friction o = 0.40
D cr
S = 0.162
2
r ns
S =
cr p
D
r = = 2.5 in
2
2
( )
2.5 3.0 106 (4.17 )
S = 0.162 =
cr 140
cr = 0.00186 in
ho = 0.46cr = 0.40(0.00186) = 0.00074 in
L h
(d) Table AT 22, = 1 , max. load o = 0.46
D cr
r
f = 2.592
cr
2 .5
f = 2.592
0.00156
f = 0.00162
F = f W = (0.00162 )(3500 ) = 5.67 lb
Dn (5)(250)
vm = = = 327.25 fpm
12 12
fhp =
Fvm
=
(5.67)(327.25) = 0.0562 hp
33,000 33,000
ho
For minimum friction, = 0.40
cr
r
f = 2.16
cr
2 .5
f = 2.16
0.00186
f = 0.00161
F = f W = (0.00161)(3500) = 5.635 lb
Page 29 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
Dn (5)(250)
vm = = = 327.25 fpm
12 12
fhp =
Fvm
=
(5.635)(327.25) = 0.0559 hp
33,000 33,000
570. A 180o partial bearing is to support 17,000 lb. with p = 200 psi ,
n = 1500 rpm , ho = 0.003 in , L D = 1 . (a) Determine the clearance for an
optimum bearing with minimum friction. (b) Taking this clearance as the
average, choose a fit (Table 3.1) that is approximately suitable. (c) Select an
oil for an average temperature of 150 F. (d) Compute fhp.
Solution:
W = 17,000 lb
p = 200 psi
n = 1500 rpm
1500
ns = = 25 rps
60
L D =1
L=D
W
p=
DL
17,000
200 =
D2
D = L = 9.22 in
D 9.22
r= = = 4.61 in
2 2
(a) For optimum bearing with minimum friction
Page 30 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
2
r ns
S =
cr p
2
4.61 (25)
0.158 =
0.00682 200
= 2.8 106 reyn
Fig. AF 16, at 150 F
Use Either SAE 20W or SAE 30.
571. The reaction on a 120o partial bearing is 2000 lb. The 3-in journal turns at
1140 rpm; cd = 0.003 in. ; the oil is SAE 20W at an average operating
temperature of 150 F. Plot curves for the minimum film thickness and the
frictional loss in the bearing against the ratio L D , using L D = 0.25, 0.5, 1,
and 2. (Note: This problem may be worked as a class problem with each
student being responsible for a particular L D ratio.)
Solution:
W = 2000 lb
D = 3 in.
n = 1140 rpm
1140
ns = = 19 rps
60
cd = 0.003 in
cr = 0.0015 in
For SAE 20W, 150 F
= 2.75 106 reyn
L
(a) = 0.25
D
Page 31 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
Page 32 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
1 .5
f = 2.35
0.0015
f = 0.00235
F = f W = (0.00235)(2000) = 4.7 lb
Dn (3)(1140)
vm = = = 895 fpm
12 12
fhp =
Fvm
=
(4.7 )(895) = 0.1275 hp
33,000 33,000
L
(c) =1
D
L = D = 3 in
W 2000
p= = = 222 psi
DL (3)(3)
L
Table AT 22, =1
D
D
r = = 1.5 in
2
2 2
(
r ns 1.5 2.75 106 (19 )
S = =
)
= 0.2354
cr p 0.0015 222
ho
= 0.4658
cr
ho = 0.4658(0.0015) = 0.000699 in
r
f = 2.634
cr
1 .5
f = 2.634
0.0015
f = 0.002634
F = f W = (0.002634)(2000 ) = 5.268 lb
Dn (3)(1140)
vm = = = 895 fpm
12 12
fhp =
Fvm
=
(5.268)(895) = 0.1429 hp
33,000 33,000
L
(d) =2
D
L = 2 D = 2(3) = 6 in
W 2000
p= = = 111 psi
DL (3)(6)
L
Table AT 22, =2
D
Page 33 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
D
r= = 1.5 in
2
2 2
( )
r ns 1.5 2.75 106 (19 )
S = = = 0.47
cr p 0.0015 111
ho
= 0.718
cr
ho = 0.718(0.0015) = 0.00108 in
r
f = 3.8118
cr
1 .5
f = 3.8118
0.0015
f = 0.003812
F = f W = (0.003812)(2000) = 7.624 lb
Dn (3)(1140)
vm = = = 895 fpm
12 12
fhp =
Fvm
=
(7.624)(895) = 0.2068 hp
33,000 33,000
L
ho , in fhp
D
0.25 0.000125 0.119
0.5 0.000324 0.128
1.0 0.000699 0.143
2.0 0.001080 0.207
Page 34 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
STEADY-STATE TEMPERATURE
Solution:
D = 8 in.
L = 8 in.
L D =1
W = 12,000 lb
D
r = = 4 in
2
cr = 0.0015r = 0.0015(4) = 0.0060 in
ho 0.0024
= = 0. 4
cr 0.0060
n = 500 rpm
500
ns = = 8.33 rps
60
Table AT 21, ho cr = 0.4 , L D = 1
S = 0.128
r
f = 2.28
cr
cto
= 12.4
p
W 12,000
p= = = 187.5 psi
DL (8)(8)
ho
(a) = 1 = 1 0 .4 = 0 .6
cr
2
r ns
(b) S =
cr p
2
4 (8.33)
S = 0.128 =
0.0060 187.5
= 6.5 106 reyn
Page 35 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
r
(c) f = 2.28
cr
4
f = 2.28
0.0060
f = 0.00342
F = f W = (0.00342 )(12,000) = 41.04 lb
Dn (8)(500)
vm = = = 1047 fpm
12 12
fhp =
Fvm
=
(41.04)(1047) = 1.302 hp
33,000 33,000
Frictional loss = 43,000 ft-lb/min
hc = 0.017
(1000 )
0.6
= 0.467 ft lb min sq.in. F
(8)0.4
hcr = 0.467 + 0.108 = 0.575 ft lb min sq.in. F
Ab = 20 DL = 20(8)(8) = 1280 sq.in.
Q = hcr Ab tb
43,000 = (0.575)(1280)(tb )
tb = 58.42 F
Oil-bath, 1000 fpm
toa (1.2)(1.3)(tb )
toa = (1.2)(1.3)(58.42) = 91.1 F
assume 100 F ambient temperature
tb = 100 + 58.42 F = 158.42 F
tb = 100 + 91.1 F = 191.1 F
cto
(c) = 12.4
p
(112)to = 12.4
187.5
to = 20.8 F
Solve for to 2
Page 36 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
573. A 2 x 2-in. full bearing (ring-oiled) has a clearance ratio cd D = 0.001 . The
journal speed is 500 rpm, = 3.4 106 reyn , and ho = 0.0005 in. The ambient
temperature is 100 F; Ab = 25DL , and the transmittance is taken as
hcr = 2 Btu hr sq. ft. F . Calculate (a) the total load for this condition; (b)
the frictional loss, (c) the average temperature of the oil for steady-state
operation. Is this temperature satisfactory? (d) For the temperature found,
what oil do you recommend? For this oil will ho be less or greater than the
specified value? (e) Compute the temperature rise of the oil as it passes
through the bearing. Is this compatible with other temperatures found? (f)
What minimum quantity of oil should the ring deliver to the bearing?
Solution:
L = 2 in.
D = 2 in.
cd D = 0.001
cd = (0.001)(2) = 0.0020 in
= 3.4 106 reyn
ho = 0.0005 in.
cr = 0.0010 in
(a) S = 0.1925
Page 37 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
2
r ns
S =
cr p
D
r = = 1 in
2
500
ns = = 8.33 rps
60
2
(
1 3.4 10 (8.330 )
S = 0.1925 =
6
)
0.0010 p
p = 147 psi
W = pDL = (147 )(2)(2) = 588 lb
r
(b) f = 4.505
cr
1
f = 4.505
0.001
f = 0.004505
F = f W = (0.004505)(588) = 2.649 lb
Dn (2)(500)
vm = = = 261.8 fpm
12 12
U f = Fvm = (2.649 )(261.8) = 693.5 ft lb min
(c) Q = hcr Ab tb
hcr = 2 Btu hr sq. ft. F = 0.18 ft lb min sq.in. F
Ab = 25DL = 25(2)(2) = 100 sq.in.
Q =Uf
(0.18)(100)(tb ) = 693.5
tb = 38.53 F
toa = 2tb = 2(38.53) = 77 F
to = 77 + 100 = 177 F , near 160 F
satisfactory.
Page 38 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
S =
2
(
1 3.3 10 (8.33)
6
) = 0.187
0.0010 147
Table AT 20, L D = 1 , S = 0.187
ho cr = 0.4923
ho = 0.4923(0.0010) = 0.00049 in < ho (= 0.0005 in )
cto
(e) = 19.25
p
(112)to = 19.25
147
to = 25.3 F
to1 + to 2 = 2(177 ) = 354 F
t o 2 t o1 = 25.3 F
2to 2 = 354 + 25.3
to 2 = 190 F < 200 F
compatible.
q
(f) = 4.16
rcr ns L
q
= 4.16
(1)(0.001)(8.33)(2)
q = 0.0693 in3 sec
574. An 8 x 9-in. full bearing (consider L D = 1 for table and chart use only)
supports 15 kips with n = 1200 rpm ; cr r = 0.0012 ; construction is medium
heavy with a radiating-and-convecting area of about 18 DL ; air flow about the
bearing of 80 fpm may be counted on (nearby) pulley; ambient temperature is
90 F. Decide upon a suitable minimum film thickness. (a) Compute the
frictional loss and the steady state temperature. Is additional cooling needed
for a reasonable temperature? Determine (b) the temperature rise of the oil as
it passes through the load-carrying area and the grade of oil to be used if it
enters the bearing at 130 F, (c) the quantity of oil needed.
Solution:
D = 8 in.
L = 9 in.
W = 15,000 lb.
n = 1200 rpm.
1200
ns = = 20 rps
60
cr r = 0.0012
Page 39 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
r = D 2 = 4 in
cr = 0.0012(4) = 0.0048 in
By Norton: ho = 0.00025 D = 0.00025(8) = 0.002 in
ho 0.002
= = 0 .4
cr 0.0048
Table AT 20, L D = 1 , ho cr = 0.4
S = 0.121
r
f = 3.22
cr
q
= 4.33
rcr ns L
cto
= 14.2
p
r
(a) f = 3.22
cr
4
f = 3.22
0.0048
f = 0.003864
F = f W = (0.003864)(15,000) = 57.96 lb
Dn (8)(1200)
vm = = = 2513 fpm
12 12
U f = Fvm = (57.96 )(2513) = 145,654 ft lb min
Q = hcr Ab tb
hr = 0.108 ft lb min sq.in. F
va0.6
hc = 0.017 ft lb min sq.in. F
D 0.4
hc = 0.017
(80)0.6 = 0.103 ft lb min sq.in. F
(8)0.4
hcr = hc + hr = 0.103 + 0.108 = 0.211 ft lb min sq.in. F
Ab = 18DL = 18(8)(9 ) = 1296 sq.in.
Uf =Q
145,654 = (0.211)(1296)tb
tb = 533 F , very high, additional cooling is necessary.
cto
(b) = 14.2
p
Page 40 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
W 15,000
p= = = 208 psi
DL (8)(9)
(112)to = 14.2
208
to = 26 F
ti = 130 F
to = 156 F
tave = 12 (130 + 156) = 143 F
2
r ns
S =
cr p
2
4 (20 )
S = 0.121 =
0.0048 208
= 1.8 106 reyn
Figure AF 16, = 1.8 reyns , 143 F
Use SAE 10W
q
(c) = 4.33
rcr ns L
q
= 4.33
(4)(0.0048)(20)(9)
q = 14.96 in3 sec
575. A 3.5 x 3.5-in., 360o bearing has cr r = 0.0012 ; n = 300 rpm ; desired
minimum ho 0.0007 in . It is desired that the bearing be self-contained (oil-
ring); air-circulation of 80 fpm is expected; heavy construction, so that
Ab 25DL . For the first look at the bearing, assume = 2.8 106 reyn and
compute (a) the frictional loss (ft-lb/min), (b) the average temperature of the
bearing and oil as obtained for steady-state operation, (c) to as the oil passes
through the load-carrying area (noting whether comparative values are
reasonable). (d) Select an oil for the steady-state temperature and decide
whether there will be any overheating troubles.
Solution:
D = 3.5 in.
L = 3.5 in.
cr r = 0.0012
r = D 2 = 1.75 in.
cr = (0.0012)(1.75) = 0.0021 in
ho 0.0007 in
Page 41 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
2
r ns
(a) S =
cr p
300
ns = = 5 rps
60
= 2.8 106 reyn
2
(
1.75 2.8 10 (5)
S = 0.0954 =
6
)
0.0021 p
p = 102 psi
W = pDL = (102)(3.5)(3.5) = 1250 lb
r
f = 2.71
cr
1.75
f = 2.71
0.0021
f = 0.00325
F = f W = (0.00325)(1250) = 4.0625 lb
Dn (3.5)(300 )
vm = = = 275 fpm
12 12
U f = Fvm = (4.0625)(275) = 1117 ft lb min
(b) Q = hcr Ab tb
hr = 0.108 ft lb min sq.in. F
va0.6
hc = 0.017 ft lb min sq.in. F
D 0.4
hc = 0.017
(80 )
0.6
= 0.143 ft lb min sq.in. F
(3.5)0.4
hcr = hc + hr = 0.143 + 0.108 = 0.251 ft lb min sq.in. F
Ab = 25DL = 25(3.5)(3.5) = 306.25 sq.in.
Uf =Q
1117 = (0.251)(306.25)tb
Page 42 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
tb = 14.5 F
toa = 2tb = 2(14.5) = 29 F
assume ambient temperature of 100 F
tb = 114.5 F
to = 129 F
cto
(c) = 12.12
p
(112)to = 12.12
102
to = 11 F
to1 + to 2 = 2(129) = 258 F
to 2 to1 = 11 F
2to 2 = 269 F
to 2 = 135 F < 140 F
reasonable
576. A 10-in. full journal for a steam-turbine rotor that turns 3600 rpm supports a
20-kip load with p = 200 psi ; cr r = 0.00133 . The oil is to have
= 2.06 106 reyn at an average oil temperature of 130 F. Compute (a) the
minimum film thickness (comment on its adequacy), (b) the fhp, (c) the
altitude angle, the maximum pressure, and the quantity of oil that passes
through the load-carrying area (gpm).(d) At what temperature must the oil be
introduced in order to have 130 F average? (e) Estimate the amount of heat
lost by natural means from the bearing (considered oil bath) with air speed of
300 fpm. If the amount of oil flow computed above is cooled back to the
entering temperature, how much heat is removed? Is this total amount of heat
enough to care for frictional loss? If not, what can be done (i11.21)?
Page 43 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
Solution:
D = 10 in.
n = 3600 rpm
3600
ns = = 60 rps
60
W = 20,000 lb
p = 200 psi
W
p=
DL
20,000
200 =
10 L
L = 10 in
L D =1
D
r = = 5 in
2
cr r = 0.00133
cr = 0.00133(5) = 0.00665 in
= 2.06 106 reyn
tave = 130 F
2
r ns
S =
cr p
S =
5
2
( )
2.06 10 (60 )
6
= 0.35
0.00665 200
Table AT 20, L D = 1 , S = 0.35
ho cr = 0.647
= 65.66o
r
f = 7.433
cr
q
= 3.90
rcr ns L
p
= 0.495
pmax
cto
= 30.8
p
qs
= 0.446
q
Page 44 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
r
(b) f = 7.433
cr
5
f = 7.433
0 . 00665
f = 0.0099
F = f W = (0.0099)(20,000) = 198 lb
Dn (10)(3600)
vm = = = 9425 fpm
12 12
fhp =
Fvm
=
(198)(9425) = 56.55 hp
33,000 33,000
(c) = 65.66o
p 200
pmax = = = 404 psi
0.495 0.495
q = 3.90rcr ns L
q = 3.90(5)(0.00665)(60)(10) = 77.805 in3 sec
q = (77.805 in3 sec )(1 gpm 231 in3 )(60 sec min ) = 0.21 gpm
cto
(d) = 30.8
p
(112)to = 30.8
200
to = 55 F
t
tave = ti + o
2
55
130 = ti +
2
ti = 102.5 F
(e) Q = hcr Ab tb
hr = 0.108 ft lb min sq.in. F
va0.6
hc = 0.017 ft lb min sq.in. F
D 0.4
hc = 0.017
( 300 )
0.6
= 0.207 ft lb min sq.in. F
(3.5)0.4
hcr = hc + hr = 0.207 + 0.108 = 0.315 ft lb min sq.in. F
Assume
Page 45 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
not enough to care for frictional loss, use pressure feed (i11.21).
DESIGN PROBLEMS
578. A 3.5-in. full bearing on an air compressor is to be designed for a load of 1500
lb.; n = 300 rpm ; let L D = 1 . Probably a medium running for would be
satisfactory. Design for an average clearance that is decided by considering both
Table 3.1 and 11.1. Choose a reasonable ho , say one that gives ho cr 0.5 .
Compute all parameters that are available via the Text after you have decided on
details. It is desired that the bearing operate at a reasonable steady-state
temperature (perhaps ring-oiled medium construction), without special cooling.
Specify the oil to be used and show all calculations to support your conclusions.
What could be the magnitude of the maximum impulsive load if the eccentricity
ration becomes 0.8, squeeze effect ignored?
Solution:
L D =1
D = 3.5 in
L = 3.5 in
W = 1500 lb
n = 300 rpm
300
ns = = 5 rps
60
W 1500
p= = = 122.45 psi
DL (3.5)(3.5)
Table 3.1, medium running fit,
D = 3.5 in
RC 5 or RC 6
Use RC 6
Average cd = 0.0052 in
Page 46 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
Page 47 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
tb = 30 F
toa = 2tb = 2(30) = 60 F
assume ambient temperature = 90 F
t o = 150 F
2
r ns
S =
cr p
2
1.75 (5)
S = 0.1925 =
0.00275 122.45
= 11.6 106 reyn
Figure AF 16, 150 F, 11.6 106 reyn
Use SAE 70 oil
580. A 2500-kva generator, driven by a water wheel, operates at 900 rpm. The weight
of the rotor and shaft is 15,100 lb. The left-hand, 5 in, full bearing supports the
larger load, R = 8920 lb . The bearing should be above medium-heavy
construction (for estimating Ab ). (a) Decide upon an average clearance
considering both Table 3.1 and 11.1, and upon a minimum film thickness
( ho cr 0.5 is on the safer side). (b) Investigate first the possibility of the
bearing being a self-contained unit without need of special cooling. Not much air
movement about the bearing is expected. Then make final decisions concerning
oil-clearance, and film thickness and compute all the parameters given in the text,
being sure that everything is reasonable.
Solution:
n = 900 rpm
900
ns = = 15 rps
60
D = 5 in
W = R = 8920 lb
Page 48 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
(b) Use L D = 1
L = 5 in
D
r = = 2.5 in
2
W 8920
p= = = 356.8 psi
DL (5)(5)
Table AT 20, L D = 1 , ho cr = 0.5
S = 0.1925
r
f = 4.505
cr
q
= 4.16
rcr ns L
cto
= 19.25
p
2
r ns
S =
cr p
2
2.5 (15)
S = 0.1925 =
0.00255 356.8
= 4.8 106 reyn
r
f = 4.505
cr
2 .5
f = 4.505
0.00255
f = 0.00460
F = f W = (0.00460 )(8920) = 41.032 lb
Dn (5)(900)
vm = = = 1178 fpm
12 12
U f = Fvm = (41.032 )(1178) = 48,336 ft lb min
Q = hcr Ab tb
Medium-Heavy
Ab = 20.25DL = 20.25(5)(5) = 506.25 sq.in.
Assume hcr = 0.516 ft lb min sq.in. F
Q =Uf
Page 49 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
(0.516)(506.25)(tb ) = 48,336
tb = 185 F , very high
Therefore, special cooling is needed.
cto
= 19.25
p
(112)to = 19.25
356.8
to = 61 F
Assume ti = 100 F
61
tave = 100 + 130 F
2
Figure AF 16, = 4.8 reyns , 130 F
Select SAE 30 oil. = 6.0 reyns
2
r ns
S =
cr p
S =
2
(
2.5 6.0 10 (15)
6
)
= 0.242
0.00255 356.8
Table AT 20, L D = 1 , S = 0.242
SAE 30 oil at 130 F
ho
= 0.569
cr
= 61.17o
r
f = 5.395
cr
q
= 4.04
rcr ns L
cto
= 22.75
p
p
= 0.4734
pmax
Oil, SAE 30
cr = 0.00255 in
ho = 0.569(0.00255) = 0.00145 in
PRESSURE FEED
581. An 8 x 8-in. full bearing supports 5 kips at 600 rpm of the journal; cr = 0.006 in. ;
let the average = 2.5 106 reyn . (a) Compute the frictional loss U f . (b) The
Page 50 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
oil is supplied under a 40-psi gage pressure with a longitudinal groove at the
point of entry. Assuming that other factors, including U f , remain the same and
that the heat loss to the surrounding is negligible, determine the average
temperature rise of the circulating oil.
Solution:
L = 5 in
D = 5 in
W = 5000 lb
n = 600 rpm
600
ns = = 10 rps
60
cr = 0.006 in
= 2.5 106 reyn
L D =1
W 5000
p= = = 78.125 psi
DL (8)(8)
2
r ns
S =
cr p
S =
2
4 2.5 10 (10 )
6
(= 0.1422
)
0.006 78.125
pi = 40 psi
q = 2.5
(0.006) (40) 1 2 (4)
3
tan [1 + 1.5(0.57)2 ]in3 sec
3(2.5 106 ) 8
Page 51 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
583. A 4-in. 360o bearing, with L D = 1 , supports 2.5 kips with a minimum film of
ho = 0.0008 in. , cd = 0.01 in. , n = 600 rpm. The average temperature rise of the oil
is to be about 25 F. Compute the pressure at which oil should be pumped into the
bearing if (a) all bearing surfaces are smooth, (b) there is a longitudinal groove at
the oil-hole inlet. (c) same as (a) except that there is a 360o circumferential
groove dividing the bearing into 2-in. lengths.
Solution:
D = 4 in
L = 4 in
r = 2 in
W = 2500 lb
cd = 0.010 in
cr = 0.005 in
n = 600 rpm
600
ns = = 10 rps
60
to = 25 F
W 2500
p= = = 156.25 psi
DL (4)(4)
ho = 0.00080 in
ho 0.0008
= = 0.16
cr 0.005
Table AT 20, L D = 1 , ho cr = 0.16
r
f = 1.44 , = 0.84
cr
2
f = 1.44
0.005
f = 0.0036
F = f W = (0.0036)(2500) = 9 lb
Dn (4)(600)
vm = = = 628 fpm
12 12
U f = Fvm = (9 )(628) = 5652 ft lb min = 1130 in lb sec
S = 0.0343
Page 52 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
2
r ns
S =
cr p
2
2 (10 )
S = 0.0343 =
0.005 156.25
= 3.35 106 reyn
U f = cqto
1130 = (112)(q )(25)
q = 0.404 in3 sec
(a) Smooth
cr3 pi 1 2 r
q=
3
tan
L
( 2 3
1 + 1.5 in sec )
0.404 =
(0.005)3 ( pi ) tan 1 2 (2) [1 + 1.5(0.84)2 ] in3 sec
3(3.35 106 ) 4
pi = 12.5 psi
(b) Longitudinal groove
2.5cr3 pi 1 2 r
q=
3
tan
L
(
2 3
1 + 1.5 in sec )
2.5(0.005) ( pi ) 1 2 (2)
3
0.404 =
(
3 3.35 10 6
tan
) 4 [
1 + 1.5(0.84) in3 sec
2
]
pi = 5 psi
(c) Circumferential groove
2 rcr3 pi
q=
3L
(
1 + 1.5 2 in3 sec )
2 (2)(0.005) ( pi )
3
) [
1 + 1.5(0.84) in3 sec ]
2
0.404 =
(
3 3.35 10 (4 )
6
pi = 5 psi
BEARING CAPS
584. An 8-in. journal, supported on a 150o partial bearing, is turning at 500 rpm;
bearing length = 10.5 in., c d = 0.0035 in ., ho = 0.00106 in . The average
temperature of the SAE 20 oil is 170 F. Estimate the frictional loss in a 160o cap
for this bearing.
Solution:
Page 53 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
ho = 0.00106 in
c d = 0.0035 in
c r = 0.00175 in
ho
2
hav = cr 1 + 0.741 in
cr
0.00106
2
F=
( )
1.7 106 (117.3)(209.5)
= 21.424 lb
0.00195
Dn (8)(500)
vm = = = 1047 fpm
12 12
U f = Fvm = (21.424 )(1047 ) = 22,430 ft lb min = 1130 in lb sec
Solution:
c d = 0.002 in
c r = 0.001 in
ho = 0.0007 in
ho 0.0007
= = 0 .7
cr 0.001
Page 54 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
ho
= 1 = 1 0 .7 = 0 .3
cr
( ) [ ]
hav = cr 1 + 0.74 2 = (0.001) 1 + 0.74(0.3) = 0.001067 in
2
Avips
F=
hav
Dn (2)(500)
vm = = = 261.8 fpm
12 12
12
vips = (261.8) = 52.36 ips
60
1 160 1 160
A= DL = ( )(2 )(2 ) = 5.585 sq.in.
2 180 2 180
F=
(2.5 106 )(5.585)(52.36) = 0.685 lb
0.001067
U f = Fvm = (0.685)(261.8) = 179.3 ft lb min
Solution:
2
r ns
S =
cr p
400
ns = = 6.67 rps
60
W 10,000
p= = = 156.25 psi
DL (8)(8)
S =
2
(
1 3.4 10 (6.67 )
6
)= 0.145
0.001 156.25
(a) Table AT 22, L D = 1 , S = 0.145
r
f = 2.021
cr
= 0.6367
r
f = 2.021
cr
1
f = 2.021
0.001
f = 0.002021
Page 55 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
F = f W = (0.002021)(10,000) = 20.21 lb
Dn (8)(400)
vm = = = 838 fpm
12 12
U f 1 = Fvm = (20.21)(838) = 16,936 ft lb min
CAP:
hav = cr (1 + 0.74 2 )
cr = 0.001r
D
r = = 4 in
2
cr = 0.001(4) = 0.004 in
( ) [ ]
hav = cr 1 + 0.74 2 = (0.004) 1 + 0.74(0.6367 ) = 0.0052 in
2
Avips
F=
hav
12
vips = (838) = 167.6 ips
60
1 150 1 150
A= DL = ( )(8)(8) = 83.78 sq.in.
2 180 2 180
F=
( )
3.4 106 (83.78)(167.6)
= 9.18 lb
0.0052
U f 2 = Fvm = (9.18)(838) = 7693 ft lb min
Total Frictional Loss
= U f 1 + U f 2 = 16,936 + 7693 = 24,629 ft lb min
(b) 360o Bearing, L D = 1 , S = 0.145
r
f = 3.65
cr
= 0.5664
BEARING:
1
f = 3.65
0.001
f = 0.00365
F = f W = (0.00365)(10,000) = 36.5 lb
Dn (8)(400)
vm = = = 838 fpm
12 12
U f 1 = Fvm = (36.5)(838) = 30,587 ft lb min
CAP:
hav = cr (1 + 0.74 2 )
[ ]
hav = cr (1 + 0.74 2 ) = (0.004) 1 + 0.74(0.5664) = 0.00495 in
2
Page 56 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
Avips
F=
hav
F=
(3.4 10 )(83.78)(167.6) = 9.645 lb
6
0.00495
U f 2 = Fvm = (9.645)(838) = 8083 ft lb min
Total Frictional Loss
= U f 1 + U f 2 = 30,587 + 8083 = 38,670 ft lb min
(e) the temperature rise of the oil in the bearing both by equation (o), i11.13,
Text, and by Table AT 22. (f) What is the heat loss from the bearing if the oil
temperature is 180 F? Is the natural heat loss enough to cool the bearing? (g) It is
desired to pump oil through the bearing with a temperature rise of 12 F. How
much oil is required? (h) For the oil temperature in (f), what is a suitable oil to
use?
Solution:
2
r ns
S =
cr p
1200
ns = = 20 rps
60
W 10,000
p= = = 156.25 psi
DL (8)(8)
1 (2.5 10 )(20 )
2 6
S = = 0.32
0.001 156.25
(a) Table AT 22, L D = 1 , S = 0.32
= 0.5417
ho
= 0.4583
cr
r
f = 3.18
cr
q
= 2.60
rcr ns L
Page 57 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
qs
= 0.305
q
cto
= 17.834
p
p
= 0.38434
pmax
ho = 0.4583cr = 0.4583(0.001)(4) = 0.00183 in
BEARING:
r
f = 3.18
cr
1
f = 3.18
0.001
f = 0.00318
F = f W = (0.00318)(10,000) = 31.8 lb
Dn (8)(1200)
vm = = = 2513 fpm
12 12
U f 1 = Fvm = (31.8)(2513) = 79,913 ft lb min , 2.42 hp
CAP:
hav = cr (1 + 0.74 2 )
cr = 0.001r
D
r = = 4 in
2
cr = 0.001(4) = 0.004 in
[ ]
hav = cr (1 + 0.74 2 ) = (0.004) 1 + 0.74(0.5417 ) = 0.00487 in
2
Avips
F=
hav
12
vips = (2513) = 503 ips
60
1 160 1 160
A= DL = ( )(8)(8) = 89.36 sq.in.
2 180 2 180
F=
( )
2.5 106 (89.36)(5036)
= 23.1 lb
0.00487
U f 2 = Fvm = (23.1)(2513) = 58,050 ft lb min , 1.76 hp
Total Frictional Loss
= U f 1 + U f 2 = 79,913 + 58,050 = 137,963 ft lb min
Uf 137,963
fhp = = = 4.18 hp
33,000 33,000
(b) Full Bearing, L D = 1 , S = 0.32
Page 58 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
Table AT 20
ho
= 0.6305
cr
r
f = 6.86
cr
= 0.3695
ho = 0.6305(0.004 ) = 0.002522 in
BEARING:
r
f = 6.86
cr
1
f = 6.86
0.001
f = 0.00686
F = f W = (0.00686)(10,000) = 68.6 lb
U f 1 = Fvm = (68.6 )(2513) = 172,392 ft lb min , 5.224 hp
CAP:
hav = cr (1 + 0.74 2 )
[ ]
hav = cr (1 + 0.74 2 ) = (0.004) 1 + 0.74(0.3695) = 0.00440 in
2
Avips
F=
hav
F=
(2.5 10 )(89.36)(503) = 25.54 lb
6
0.00440
U f 2 = Fvm = (25.54 )(2513) = 64,182 ft lb min , 1.946 hp
Total Frictional Loss
= U f 1 + U f 2 = 172,392 + 64,182 = 236,574 ft lb min
Uf 236,574
fhp = = = 7.17 hp
33,000 33,000
Page 59 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
qs = 2.03 in 3 sec
(e) Equation(o)
U f 1 = cqto
12
U f 1 = 79,913 ft lb min = 79,913 in lb sec = 15,983 in lb sec
60
U f 1 = 15,983 = (112 )(6.656 )to
to = 21.4 F
Table 22.
cto
= 17.834
p
112to
= 17.834
156.25
to = 24.9 F
(f) Q = hcr Ab tb
assume hcr = 0.516 ft lb min sq.in. F
Ab = 25DL = 25(8)(8) = 1600 sq.in.
t
tb = oa
2
assume ambient = 100 F
180 100
tb = = 40 F
2
Q = (0.516 )(1600 )(40 ) = 33,024 ft lb min < U f 1
Therefore not enough to cool the bearing.
(g) Qr + Q = U f 1 + U f 2
Qr + 33,024 = 137,963
Qr = 104,939 ft lb min
Qr = 20,988 in lb sec
Qr = cqto
20,988 = (112)q(12)
q = 15.62 in3 sec
Page 60 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
IMPERFECT LUBRICATION:
588. A 0.5 x 0.75-in. journal turns at 1140 rpm. What maximum load may be
supported and what is the frictional loss if the bearing is (a) SAE Type I, bronze
base, sintered bearing, (b) nylon (Zytel) water lubricated, (c) Teflon, with
intermittent use, (d) one with carbon graphite inserts.
Solution:
(a) f = 0.12
Dn (0.5)(1140)
vm = = = 149.23 fpm
12 12
pvm = 50,000
p(149.23) = 50,000
p = 335 psi
W = pDL = (335)(0.5)(0.75) = 126 lb
F = f W = (0.12)(126) = 15.12 lb
U f = Fvm = (15.12 )(149.23) = 2256 ft lb min
Page 61 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
F = f W = (0.20)(37.69) = 7.54 lb
U f = Fvm = (7.54 )(149.23) = 1125 ft lb min
590. A bearing to support a load of 150 lb at 800 rpm is needed; D = 1 in. ; semi-
lubricated. Decide upon a material and length of bearing, considering sintered
metals, Zytel, Teflon, and graphite inserts.
Solution:
Dn (1)(800)
vm = = = 209.44 fpm
12 12
assume, L = D = 1 in
W 150
p= = = 150 psi
DL (1)(1)
pvm = (150)(209.44) = 31,416
Use sintered metal, limit pvm = 50,000
THRUST BEARINGS
592. A 4-in. shaft has on it an axial load of 8000 lb., taken by a collar thrust
bearing made up of five collars, each with an outside diameter of 6 in. The
shaft turns 150 rpm. Compute (a) the average bearing pressure, (b) the
approximate work of friction.
Solution:
4W 4(8000 )
(a) p = = = 283 psi
Do2 (6)2
593. A 4-in. shaft, turning at 175 rpm, is supported on a step bearing. The bearing
area is annular, with a 4-in. outside diameter and a 3/4 in. inside diameter.
Take the allowable average bearing pressure as 180 psi. (a) What axial load
may be supported? (b) What is the approximate work of friction?
Solution:
Dn
vm =
12
Page 62 of 63
SECTION 9 JOURNAL AND PLANE-SURFACE BEARINGS
1
D= (4 + 0.75) = 2.375 in
2
Dn (2.375)(175)
vm = = = 108.81 fpm
12 12
assume f = 0.065 , average
4W
(a) p =
(
Do2 Di2 )
2 3
2
- end -
Page 63 of 63
SECTION 10 - BALL AND ROLLER BEARINGS
601. The radial reaction on a bearing is 1500 lb.; it also carries a thrust of 1000 lb.;
shaft rotates 1500 rpm; outer ring stationary; smooth load, 8-hr./day service, say
15,000 hr. (a) Select a deep-groove ball bearing. (b) What is the rated 90 % life
of the selected bearing? (c) For b = 1.34 , compute the probability of the selected
bearing surviving 15,000 hr.
Solution:
Fx = 1500 lb
Fy = 1000 lb
( )
B10 = (15,000 )(60 )(1500 ) 106 = 1350 mr
F e= 0.56Cr Fx + Ct Fz
Cr = 1 , outer ring stationary
assume Ct = 1.8
F e= 0.56(1)(1500) + (1.8)(1000) = 2640 lb
1
B 3 1
Fr = 10 Fe = (1350)3 (2640) = 29,178 lb
Br
(a) Table 12.3
use 320, Fr = 29,900 lb
Fs = 29,900 lb
To check:
Fz 1000
= = 0.0340
Fs 29,400
Table 12.2, Ct = 1.93 , Q = 0.2286
Fz 1000
= = 0.667 > Q
Cr Fx (1.0 )(1500 )
F e= 0.56Cr Fx + Ct Fz
F e= 0.56(1)(1500) + (1.93)(1000) = 2770 lb
1
B 3 1
Fr = 10 Fe = (1350)3 (2770) = 30,614 lb
Br
2.4 % higher than 29,900 lb. Safe.
Therefore use Bearing 320, Deep-Groove Ball Bearing.
(b) Fr = 29,900 lb
F e= 2770 lb
1
B 3
29,900 = 10 (2770 ) = 30,614 lb
1 mr
B10 = 1258 mr
Page 1 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
( )
B10 = (HR )(60 )(1500 ) 106 = 1258
HR 14,000 hr
1
1 b
ln
B P
(c) =
B10 1
ln
P10
1 1
ln = ln
P10 0.9
B10 = 1258 mr
B = 1350 mr
1
1 1.34
ln
1350 P
=
1258 1
0.9
ln
P = 0.891
602. A certain bearing is to carry a radial load of 500 lb. and a thrust of 300 lb. The
load imposes light shock; the desired 90 % life is 10 hr./day for 5 years at
n = 3000 rpm . (a) Select a deep-groove ball bearing. What is its bore? Consider
all bearings that may serve. (b) What is the computed rated 90 % life of the
selected bearing? (c) What is the computed probability of the bearing surviving
the specified life? (d) If the loads were changed to 400 and 240 lb., respectively,
determine the probability of the bearing surviving the specified life, and the 90 %
life under the new load.
Solution:
Fx = 500 lb
Fz = 300 lb
Assume Cr = 1
Fz 300
= = 0 .6
Cr Fx (1.0 )(500 )
Fz
Table 12.2, >Q
Cr Fx
(a) F e= 0.56Cr Fx + Ct Fz
Cr = 1
Assume Ct = 1.8
F e= 0.56(1)(500) + (1.93)(300 ) = 820 lb
Page 2 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
1
1 b
ln
B P
(c) =
B10 1
ln
P10
Page 3 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
use b = 1.125
B10 = 3119 mr
B = 3285 mr
1
1 1.125
ln
3285 P
=
3119 1
0.9
ln
P = 0.8943
(d) Fx = 400 lb
Fz = 240 lb
Cr = 1
Fz 240
= = 0 .6
Cr Fx (1.0 )(400 )
Table 12.2
Ct = 2.15
Q = 0.21 < 0.6
F e= 0.56Cr Fx + Ct Fz
F e= 0.56(1)(400) + (2.15)(240) = 740 lb
F e= (1.1)(740) = 814 lb
1
B 3
Fr = 10 Fe
Br
1
B 3
14,100 = 10 (814)
1
B10 = 5197 mr
1
1 b
ln
=
B P
B10 1
ln
P10
1
1 1.125
ln
3285 P
=
5197 1
0.9
ln
P = 0.939
Life:
B10 = (YR)(365)(10 )(60 )(3000 )(10 6 ) = 5197
Page 4 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
YR = 8 years
603. The smooth loading on a bearing is 500-lb radial, 100 lb. thrust; n = 300 rpm . An
electric motor drives through gears; 8 hr./day, fully utilized. (a) Considering
deep-groove ball bearings that may serve, choose one end specify its bore. For
the bearing chosen, determine (b) the rated 90 % life and (c) the probability of
survival for the design lufe.
Solution:
Fx = 500 lb
Fz = 100 lb
Table 12.1, 8 hr./day fully utilized, assume 25,000 hr
B10 = (25,000 )(60 )(300 )(106 ) = 450 mr
(a) assume Cr = 1
Fz 100
= = 0 .2
Cr Fx (1.0 )(500 )
F
consider Q > z
Cr Fx
Fe = Cr Fx = (1.0)(500) = 500 lb
1
B 3 1
Fr = 10 Fe = (450)3 (500) = 3832 lb
Br
Table 12.3
Bearing No. Fr , lb Fs , lb
207 4440 3070
306 4850 3340
305 3660 2390
Select 305, Fr = 3660 lb , Fs = 2390 lb
Bore (Table 12.4) = 25 mm
Fz 100
(a) = = 0.0418
Fs 2390
Table 12.2, 0.22 < Q0.26
F
Q> z
Cr Fx
Fe = Cr Fx = (1.0)(500) = 500 lb
1
B 3
3660 = 10 (500)
1
B10 = 392 mr
Rated Life:
Page 5 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
( )
B10 = (HR )(60 )(300 ) 106 = 392
HR 22,000 hr
1
1 b
ln
=
B P
(c)
B10 1
ln
P10
b = 1.125
1
1 1.125
ln
450 P
=
392 1
0.9
ln
P = 0.884
605. A No. 311, single-row, deep-groove ball bearing is used to carry a radial load of
1500 lb. at a speed of 500 rpm. (a) What is the 90 % life of the bearing in hours?
What is the approximate median life? What is the probability of survival if the
actual life is desired to be (b) 105 hr., (c) 104 hr.?
Solution:
Table 12.3, No. 311
Fs = 9400 lb
Fr = 12400 lb
Fx = 1500 lb
assume Cr = 1
Fe = Cr Fx = (1)(1500 ) = 1500 lb
1
B 3
(a) Fr = 10 Fe
Br
1
B 3
12400 = 10 (1500)
1
B10 = 565 mr
( )
B10 = (HR )(60 )(500 ) 106 = 565
HR 18,800 hr
Page 6 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
( ) ( )
(b) B = 105 (60)(500) 106 = 3000 mr
1
1 b
ln
=
B P
B10 1
ln
P10
b = 1.125
1
1 1.125
ln
3000 P
=
565 1
0.9
ln
P = 0.502
(c) 104 hr
( ) ( )
B = 104 (60)(500) 106 = 300 mr
1
1 b
ln
=
B P
B10 1
ln
P10
b = 1.125
1
1 1.125
ln
300 P
=
565 1
0.9
ln
P = 0.950
606. The load on an electric-motor bearing is 350 lb., radial; 24 hr. service,
n = 1200 rpm ; compressor drive; outer race stationary. (a) Decide upon a deep-
groove ball bearing, giving its significant dimensions. Then compute the selected
bearings 90 % life, and the probable percentage of failures that would occur
during the design life. What is the approximate median life of this bearing? (b)
The same as (a), except that a 200 series roller bearing is to be selected.
Solution:
Fx = 350 lb
Fe = Cr Fx
outer race stationary, Cr = 1
Fe = (1)(350) = 350 lb
Page 7 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
Table 12.1
90 % Life, hrs = 50,000 hrs
( )
B = (50,000)(60)(1200) 106 = 3600 mr
1
B 3 1
(a) Fr = 10 Fe = (3600)3 (350 ) = 5364 lb
Br
Table AT 12.3
earing No. Fr , lb Fs , lb
208 5040 3520
209 5660 4010
306 4850 3340
307 5750 4020
Use No. 209 Fr = 5660 lb
Table 12.4, Dimension
Bore = 45 mm
O.D. = 85 mm
Width of Races = 19 mm
Max. Fillet r = 0.039 mm
90 % Life:
1
B 3
Fr = 10 Fe
Br
1
B 3
5660 = 10 (350)
1
B10 = 4229 mr
( )
B10 = (HR )(60 )(1200 ) 106 = 4229
HR 58,740 hr
Probability.
1
1 b
ln
=
B P
B10 1
ln
P10
b = 1.125
1
1 1.125
ln
3600 P
=
4229 1
0.9
ln
P = 0.916
% failures = 1 0.916 = 0.084 = 8.4 %
Page 8 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
90 % life:
1
B 3
Fr = 10 Fe
Br
1
B 3
5900 = 10 (350)
1
B10 = 4790 mr
( )
B10 = (HR )(60 )(1200 ) 106 = 4790
HR 66,530 hr
Probability.
1
1 b
ln
=
B P
B10 1
ln
P10
b = 1.125
1
1 1.125
ln
3600 P
=
4790 1
0.9
ln
P = 0.926
% failures = 1 0.926 = 0.074 = 7.4 %
Median Life = 5(66,530) = 332,650 hrs
608. A deep-groove ball bearing on a missile, supporting a radial load of 200 lb., is to
have a design life of 20 hr.; with only a 0.5 % probability of failure while
n = 4000 rpm . Using a service factor of 1.2 , choose a bearing. ( A 5- or 6- place
log table is desirable.)
Page 9 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
Fe = Cr Fx = (1.0)(200) = 200 lb
Fe = (1.2)(200) = 240 lb
( )
B10 = (20 )(60 )(4000 ) 106 = 4.8 mr
P = 1 0.005 = 0.995
1
1 b
ln
=
B P
B10 1
ln
P10
b = 1.125
1
1 1.125
ln
4.8 0.995
=
B10 1
0.9
ln
B10 = 72 mr
1
B 3 1
Fr = 10 Fe = (72)3 (240) = 998.4 lb
Br
Table 12.3
Select No. 201, Fr = 1180 lb
VARIABLE LOADS
610. A certain bearing is to carry a radial load of 10 kip at a speed of 10 rpm for 20 %
of the time, a load of 8 kips at a speed of 50 rpm for 50 % of the time, and a load
of 5 kips at 100 rpm during 30 % of the time, with a desired life of 3000 hr.; no
thrust. (a) What is the cubic mean load? (b) What ball bearings may be used?
What roller bearings?
Solution:
1
F 3n + F23n2 + F33n3 + L 3
(a) Fm = 1 1
n
n = n1 + n2 + n3
For 1 min.
n1= (0.2)(10) = 2 rev
n 2 = (0.5)(50) = 25 rev
n3 = (0.3)(100) = 30 rev
n = 2 + 25 + 30 = 57 rev
F1 = 10 kips
Page 10 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
F2 = 8 kips
F3 = 5 kips
1
(10 )3 (2 ) + (8)3 (25) + (5)3 (30 ) 3
Fm = = 6.88 kips
57
612. A deep-groove ball bearing No. 215 is to operate 30 % of the time at 500 rpm
with Fx = 1200 lb and Fz = 600 lb , 55 % of the time at 800 rpm with
Fx = 1000 lb and Fz = 500 lb , and 15 % of the time at 1200 rpm with
Fx = 800 lb and Fz = 400 lb . Determine (a) the cubic mean load; (b) the 90 % life
of this bearing in hours, (c) the average life in hours.
Solution:
Bearing No. 215, Fr = 11,400 lb , Fs = 9,250 lb
Table 12.2, Fz Fs
At 30 % of the time, 500 rpm
Fz 600
= = 0.065
Fs 9250
Ct = 1.66
Q = 0.266
Fz 600
= = 0 .5 > Q
Cr Fx (1)(1200 )
Fe1 = 0.56Cr Fc + Ct Fz = 0.56(1)(1200) + (1.66)(600) = 1668 lb
At 55 % of the time, 800 rpm
Fz 500
= = 0.054
Fs 9250
Page 11 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
Ct = 1.73
Q = 0.257
Fz 500
= = 0 .5 > Q
Cr Fx (1)(1000 )
Fe 2 = 0.56Cr Fc + Ct Fz = 0.56(1)(1000) + (1.73)(500) = 1425 lb
At 15 % of the time, 1200 rpm
Fz 400
= = 0.043
Fs 9250
Ct = 1.84
Q = 0.242
Fz 400
= = 0 .5 > Q
Cr Fx (1)(800 )
Fe1 = 0.56Cr Fc + Ct Fz = 0.56(1)(800) + (1.84)(400) = 1184 lb
1
F 3n + F23n2 + F33n3 + L 3
(a) Fm = 1 1
n
n = n1 + n2 + n3
F1 = 1668 lb
F2 = 1425 lb
F3 = 1184 lb
For 1 min.
n1= (0.3)(500 ) = 150 rev
n 2 = (0.55)(800) = 440 rev
n3 = (0.15)(1200 ) = 180 rev
n = 150 + 440 + 180 = 770 rev
1
(1668) (150 ) + (1425) (440 ) + (1184 ) (180 )
3 3 3 3
Fm = = 1434 kips
770
(b) Fe = Fm = 1434 lb
1
B 3
Fr = 10 Fe
Br
1
B 3
11,400 = 10 (1434 )
1
B10 = 503 mr
For 1 min = 770 rev
Page 12 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
614. A shaft for the general-purpose gear-reduction unit described in 489 has radial
bearing reactions of RC = 613 lb and RD = 1629 lb ; n = 250 rpm . Assume that
the unit will be fully utilized for at least 8 hr./day, with the likelihood of the same
uses involving minor shock. (a) Select ball bearings for this shaft. (b) Select
roller bearings. (c) What is the probability of both bearings C and D surviving for
the design life?
Solution:
3
Problem 489, D = 1 in = 1.375 in
8
Ref: Design of Machine Members, Doughtie and Vallance
Fc = (K a K l )K o K p K s K t Fr
at C. Fr = RC = 613 lb
K t = 1.0
K p = 1 .0
K o = 1.0
Kr Na
Ks = 3
Nc
N a = 250 rpm
N c = 500 rpm
K r = 1.5
Ks = 3
(1.5)(250) = 0.90856
500
K a = 1.0
Ha
Kl = 3
H c K rel
Table 12.1, 8 hr/day, fully utilized, Text
H a = 25,000 hr
H c = 10,000 hr
assume K rel = 1.0 for 90 % reliability
25,000
Kl = 3 = 1.3572
10,000
Page 13 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
Fc = (K a K l )K o K p K s K t Fr
Fc = (1.0)(1.3572)(1.0)(1.0 )(0.90856)(1.0)(613) = 756 lb
Table 9-7, Doughtie and Vallance,
Two-row spherical Type, No. 207
Bore = 1.3780 in, Fc = 880 lb
At D. Fr = RD = 1629 lb
Fc = (K a K l )K o K p K s K t Fr
Fc = (1.0)(1.3572)(1.0)(1.0 )(0.90856)(1.0)(1629) = 2009 lb
Table 9-7, Doughtie and Vallance,
Two-row spherical Type, No. 407
Bore = 1.3780 in, Fc = 2290 lb
(b) at C, Fc = 756 lb
Table 9.8, Doughtie and Vallance
Use No. 207, Bore = 1.3780 in, Fc = 1540 lb
at C, Fc = 2009 lb
Table 9.8, Doughtie and Vallance
Use No. 307, Bore = 1.3780 in, Fc = 2660 lb
Page 14 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
25,000
1.547 = 3
10,000 K rel
K rel = 0.675
Table 9-3, Reference
Probability = 93.3 %
615. A shaft similar to that in 478 has the following radial loads on the bearings, left
to right: 803 lb, 988 lb, 84 lb, and 307 lb; no thrust. The minimum shaft diameter
at the bearings are 1.250 in, 1.125 in, 1.000 in, and 1.0625 in. Assume that the
service will not be particularly gentle; intermittently used, with n = 425 rpm . (a)
Select ball bearing for this shaft. (b) Select roller bearings.
Solution:
Page 15 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
Ha
Kl = 3
H c K rel
H c = 10,000 hr
Table 12.1, Text, H a = 10,000 hr (intermittent)
90 % reliability, K rel = 1.0
10,000
Kl = 3 = 1 .0
10,000
K o = 1.0
K p = 1 .0
K r = 1.5 assumed
Kr Na
Ks = 3
Nc
N a = 425 rpm
N c = 500 rpm
Ks = 3
(1.5)(425) = 1.0844
500
K t = 1.0
Fc = (1.0)(1.0)(1.0)(1.0)(1.0844)(1.0)(803) = 870 lb
Table 9-7, Ref.
Two-row spherical type, 207
Fc = 880 lb
Bore = 1.3780 in
Fc = (1.0)(1.0)(1.0)(1.0)(1.0844)(1.0)(84) = 91 lb
Page 16 of 17
SECTION 10 - BALL AND ROLLER BEARINGS
Fc = (1.0)(1.0)(1.0)(1.0)(1.0844)(1.0)(307 ) = 333 lb
Table 9-7, Ref.
Deep-groove type, 106
Fc = 544 lb
Bore = 1.1811 in
- end -
Page 17 of 17
SECTION 12 HELICAL GEARS
DESIGN PROBLEMS
701. For continuous duty in a speed reducer, two helical gears are to be rated at 7.4 hp
at a pinion speed of 1750 rpm; m w 2.75 ; the helix angle 15o ; 20o F.D. teeth in
the normal plane; let N p = 21 teeth, and keep b < 2 D p . Determine the pitch, face,
N g , and the material and heat treatment. Use through-hardened teeth with a
maximum of 250 BHM (teeth may be cut after heat treatment).
Solution:
= 15o
n = 20o
D p n p
vm =
12
N p 21
Dp = =
Pd Pd
n p = 1750 rpm
21
(1750)
Pd 9621
vm = =
12 Pd
33,000hp (33,000 )(7.4 )
Ft = = = 25.38 Pd
vm 9621
P
d
b 2 Dp
21 42
b = 2 =
Pd Pd
0.05vm (Ft + Cb cos 2 )cos
Fd = Ft + 1
lb
0.05vm + (Ft + Cb cos )
2 2
Table AT 25
Assume C = 1660
= 15o
9621 42
0.05 25.38Pd + 1660 cos 2 15 cos15
Pd Pd
Fd = 25.38Pd + 1
lb
9621 42 2
0.05 + 25.38Pd + 1660 cos 2 15
Pd Pd
Page 1 of 14
SECTION 12 HELICAL GEARS
465 65050
25.38 Pd +
Pd Pd
Fd = 25.38 Pd + 1
lb
481 65050 2
+ 25.38 Pd +
Pd Pd
For continuous service: Fw Fd
bD pQK g
Fw =
cos 2
2mg 2(2.75)
Q= = = 1.467
mg + 1 2.75 + 1
Table At 26, Bhn = 250
Sum of BHN = 500, n = 20o
K g = 131
42 21 (1.467 )(131) 181,670
Fw = 2
=
Pd Pd cos 15 Pd2
Fw Fd
By trial and error method
Pd Fd Fw
7 3967 3708
6 4758 5046
use Pd = 6
21 21
Dp = = = 3.5 in
Pd 6
42 42
b= = = 7 in
Pd 6
9621 9621
vm = = = 1604 fpm
Pd 6
Fig. AF 19, permissible error = 0.0018 in
Fig. AF 20
Use carefully cut gears, Pd = 6
Error = 0.001 in is o.k.
For material
Strength
sbY cos
Fs =
K f Pd
Page 2 of 14
SECTION 12 HELICAL GEARS
Np 21
N ep = = = 23
cos cos3 15
3
Ans.
Pd = 6
b = 7 in
N g = mw N p = (2.75)(21) = 58
Material. C1050, OQT 1100 F
Solution:
(4.75)(1750)
vm = = 2176 fpm
12
33,000hp (33,000 )(50 )
Ft = = = 758 lb
vm (2176)
Dynamic load:
Fd = Ft +
( )
0.05vm Ft + Cb cos 2 cos
lb
1
( 2
0.05vm + Ft + Cb cos 2 )
Fig. AF 19, vm = 2176 fpm
Permissible error = 0.0014 in
Page 3 of 14
SECTION 12 HELICAL GEARS
Table AT 25,
Steel and steel, 20o FD
C = 1660
Fd = 758 +
( )
0.05(2176) 758 + 1660b cos 2 15 cos15
lb
1
(
0.05(2176) + 758 + 1660b cos 152
)
2
105.1(758 + 1548.8b )
Fd = 758 + 1 lb
108.8 + (758 + 1548.8b )2
Wear load:
bD pQK g
Fw =
cos 2
2mg 2(4.25)
Q= = = 1.619
mg + 1 4.25 + 1
Table At 26, 20o FD,
Sum of BHN =2(350)=700
K g = 270
b(4.75)(1.619 )(270 )
Fw = = 2225b
cos 2 15
2
Fw Fd , bmin = 2 Pa = = 4.69 in.
Pd tan
By trial and error method
b Fd Fw
5 5203 11125
6 5811 13350
use b = 5 in
Material:
Strength:
sbY sbY cos
Fs = =
K f Pdn K f Pd
Np
N ep =
cos3
N p = Pd D p = (5)(4.375) = 22
22
N ep = = 25
cos3 15
Table AT 24, Load near middle
Page 4 of 14
SECTION 12 HELICAL GEARS
N ep = 25 , n = 20o FD
Y = 0.580
assume K f = 1.7
s (5)(0.580) cos15
Fs = = 0.32955s
(1.7 )(5)
Fs = N sf Fd
for 24 hr/day service, heavy shock loading
N sf = 1.75
0.32955s = (1.75)(5203)
s = 27,629 psi
s
use sn = u
3
su = 3(27,629) = 82,887 psi
Table AT 9
Use 4150, OQT 1200 F,
su = 159ksi , BHN = 331 < 350
Ans.
Pd = 5
b = 5 in
Material. 4150, OQT 1200 F
705. Design the teeth for two herringbone gears for a single-reduction speed reducer
with mw = 3.80 . The capacity is 36 hp at 3000 rpm of the pinion; = 30o ; F.D.
teeth with n = 20o . Since space is at a premium, the initial design is for N p = 15
teeth and carburized teeth of AISI 8620; preferably b < 2 D p .
Solution:
N 15
Dp = p =
Pd Pd
b 2Dp
30
b = 2 Dp =
Pd
D p n p
vm =
12
15
(3000)
P
vm = d
11,781
=
12 Pd
Page 5 of 14
SECTION 12 HELICAL GEARS
Page 6 of 14
SECTION 12 HELICAL GEARS
11,781
Pd vm =
Pd
5 2356.2
4 1963.5
6 1683
8 1473
9 1309 fpm
use Pd = 9
Fd = 3008 lb
Fw = 5794 lb > Fd
30 30
b= = = 3.3 in
Pd 9
use b = 3.0 in
Designed Data:
Pd = 9
b = 3.0 in
N p = 15
N g = mw N p = (3.8)(15) = 57
Page 7 of 14
SECTION 12 HELICAL GEARS
N p 15
Dp = = = 1.67 in
Pd 9
N 57
Dg = g = = 6.33 in
Pd 9
CHECK PROBLEMS
707. The data for a pair of carefully cut gears are: Pdn = 5 , n = 20o , = 12o ,
b = 3.5 in. , N p = 18 , N g = 108 teeth; pinion turns 1750 rpm. Materials: pinion,
SAE 4150, OQT to BHN = 350; gear, SAE 3150, OQT to BHN = 300. Operation
is with moderate shock for 8 to 10 hr./day. What horsepower may be transmitted
continuously?
Solution:
N
Dp = p
Pd
Pd = Pdn cos = (5)cos15 = 4.89
18
Dp = = 3.681 in
4.89
Wear load
bD pQK g
Fw =
cos 2
b = 3.5 in.
2Ng 2(108)
Q= = = 1.7143
N p + N g 18 + 108
Table AT 26, n = 20o
Sum of BHN = 350 + 300 = 650
K g = 233
Fw =
(3.5)(3.681)(1.7143)(233) = 5379 lb
cos 2 12
Strength of gear
sbY
Fs = lb
K f Pdn
For gear: SAE 3150, OQT to BHN = 300
su = 151 ksi
sn = 0.5su = 0.5(151) = 75.5 ksi
Ng 108
N eg = = = 116
cos cos3 12
3
Page 8 of 14
SECTION 12 HELICAL GEARS
Fs =
(87,500)(3.5)(0.534) = 19,240 lb
(1.7 )(5)
For moderate shock, 8 to 10 hr./day
Use N sf = 1.5
Fs N sf Fd
19,240 = 1.5Fd
Fd 12,827 lb
Therefore use Fd = Fw = 5379 lb
0.05vm (Ft + Cb cos 2 )cos
Fd = Ft + 1
lb
0.05vm + (Ft + Cb cos 2 )2
Fig. AF 20, carefully cut gears, Pdn = 5 , e = 0.001 in
Table AT 25, steel and steel, 20o FD
C = 1660
D p n p (3.681)(1750)
vm = = = 1686 fpm
12 12
Fd = Ft +
[ ]
0.05(1686) Ft + 1660(3.5) cos 2 12 cos12
lb
1
[ ]
0.05(1686) + Ft + 1660(3.5) cos 12 2
2
82.46[Ft + 5559]
Fd = Ft + 1
= 5379 lb
84.3 + [Ft + 5559]2
Trial and error
Ft = 1800 lb
Fv
hp = t m =
(1800)(1686) = 92 hp
33,000 33,000
Page 9 of 14
SECTION 12 HELICAL GEARS
708. Two helical gears are used in a single reduction speed reducer rated at 27.4 hp at
a motor speed of 1750 rpm; continuous duty. The rating allows an occasional 100
% momentary overload. The pinion has 33 teeth. Pdn = 10 , b = 2 in. , n = 20o ,
= 20o , mw = 2.82 . For both gears, the teeth are carefully cut from SAE 1045
with BHN = 180. Compute (a) the dynamic load, (b) the endurance strength;
estimate K f = 1.7 . Also decide whether or not the 100 % overload is damaging.
(c) Are these teeth suitable for continuous service? If they are not suitable
suggest a cure. (The gears are already cut.)
Solution:
N
Dp = p
Pd
Pd = Pdn cos = (10) cos15 = 9.66
33
Dp = = 3.42 in
9.66
D p n p (3.42)(1750)
vm = = = 1567 fpm
12 12
33,000hp 33,000(27.4 )
Ft = = = 577 lb
vm 1567
(a) Dynamic load
0.05vm (Ft + Cb cos 2 )cos
Fd = Ft + 1
lb
0.05vm + (Ft + Cb cos 2 )2
Fig. AF 20, carefully cut gears, Pdn = 10 , e = 0.001 in
Table AT 25, steel and steel, 20o FD
C = 1660
b = 2 in
Fd = 577 +
[ ]
0.05(1567 ) 577 + 1660(2)cos 2 15 cos15
= 2578 lb
1
[
0.05(1567 ) + 577 + 1660(2)cos 15
2
]2
Page 10 of 14
SECTION 12 HELICAL GEARS
Y = 0.645
K f = 1 .7
Fs =
sbY
=
(45,000)(2)(0.645) = 3415 lb
K f Pdn (1.7 )(10)
For 100 % overload
Ft = 2(577 ) = 1154 lb
0.05vm (Ft + Cb cos 2 )cos
Fd = Ft + 1
lb
0.05vm + (Ft + Cb cos )
2 2
Fd = 1154 +
[ ]
0.05(1567 ) 1154 + 1660(2)cos 2 15 cos15
= 3475 lb
1
[
0.05(1567 ) + 1154 + 1660(2) cos 15 2
]
2
bD pQK g
(c) Fw =
cos 2
b = 2 in.
2mw 2(2.82 )
Q= = = 1.476
mw + 1 2.82 + 1
Table AT 26, n = 20o
Sum of BHN = 2(180) = 360
K g = 62.5
Fw =
(2)(3.42)(1.476)(62.5) = 676 lb < F (= 2578 lb )
d
cos 2 15
Therefore not suitable for continuous service.
Cure: Through hardened teeth
For Bhn
2578
Kg = (62.5) = 238
676
min Bhn = 0.5(650) = 325
709. Two helical gears are used in a speed reducer whose input is 100 hp at 1200 rpm,
from an internal combustion engine. Both gears are made of SAE 4140, with the
pinion heat treated to a BHN 363 415, and the gear to 321 363; let the teeth
be F.D.; 20o pressure angle in the normal plane; carefully cut; helix angle
= 15o ; N p = 22 , N g = 68 teeth; Pd = 5 , b = 4 in . Calculate the dynamic load,
the endurance strength load, and the limiting wear load for the teeth. Should these
gears have long life if they operate continuously? (Data courtesy of the Twin
Disc Clutch Co.)
Solution:
Page 11 of 14
SECTION 12 HELICAL GEARS
N p 22
Dp = = = 4.4 in
Pd 5
D p n p (4.4)(1200)
vm = = = 1382 fpm
12 12
33,000hp 33,000(100 )
Ft = = = 2388 lb
vm 1382
Dynamic load
0.05vm (Ft + Cb cos 2 )cos
Fd = Ft + 1
lb
0.05vm + (Ft + Cb cos )2
2
Fd = 2388 +
[ ]
0.05(1382) 2388 + 1660(4) cos 2 15 cos15
= 5930 lb
1
[
0.05(1382 ) + 2388 + 1660(4)cos 152
]
2
Page 12 of 14
SECTION 12 HELICAL GEARS
Fw =
(4)(4.4)(1.511)(270) = 7696 lb
cos 2 15
Since Fw (= 7696 lb ) > Fd (= 5930 lb ) these gears have long life if they operate
continuously.
CROSSED HELICAL
710. Helical gears are to connect two shafts that are at right angles
( N1 = 20 , N 2 = 40 , Pdn = 10 , 1 = 2 = 45o ). Determine the center distance.
Solution:
D cos 1
N1 = 1 = Pdn D1 cos 1
Pcn
20 = (10)(D1 )cos 45
D1 = 2.83 in
N 2 = Pdn D2 cos 2
40 = (10)(D2 )cos 45
D2 = 5.66 in
C = 12 (D1 + D2 ) = 12 (2.83 + 5.66) = 4.25 in
712. Two shafts that are at right angles are to be connected by helical gears. A
tentative design is to use N1 = 20 , N 2 = 60 , Pdn = 10 , and a center distance of 6
in. What must be the helix angles?
Solution:
= 1 + 2 = 90o
N1
D1 =
Pdn cos 1
N2
D2 =
Pdn cos 2
C = 2 (D1 + D2 )
1
Page 13 of 14
SECTION 12 HELICAL GEARS
N1 N2
2C = +
Pdn cos 1 Pdn cos 2
20 60
2(6 ) = +
10 cos 1 10 cos 2
2 6
12 = +
cos 1 cos 2
1 3
6= +
cos 1 cos 2
By trial and error method
1 3
6= +
cos 1 sin 1
1 = 39.5o
2 = 50.5o
- end -
Page 14 of 14
SECTION 13 BEVEL GEARS
DESIGN PROBLEMS
751. Decide upon the pitch, face, N g , material, and heat treatment of a pair of straight
bevel gears to transmit continuously and indefinitely a uniform loading of 5 hp at
900 rpm of the pinion, reasonable operating temperature, high reliability;
mg 1.75 ; D p 3.333 in . Pinion overhangs, gear is straddle mounted.
Solution:
1
(
L = rp2 + rg2 )2
1 1
tan p = =
mg 1.75
p = 29.75o
L sin p = rp
3.333
L sin 29.75 =
2
L = 3.358 in
33,000hp
Ft = lb
vm
D p n p (3.333)(900)
vm = = = 785.4 fpm
12 12
33,000(5)
Ft = = 210 lb
785.4
Fd = (VF )N sf K m Ft
50 + vm2 50 + (785.4 ) 2
1 1
VF = = = 1.56
50 50
One gear straddle, one not
K m = 1.2
Table 15.2, uniform
N sf = 1.0
Fd = (1.56)(1.0)(1.2 )(210) = 393 lb
Wear load
2
s2 C
Fw = D pbI cd2 l
C e K t Cr
D p = 3.333 in
b = 0.3L = 0.3(3.358) = 1.0 in
Temperature factor
K t = 1.0 , reasonable operating temperature
Life factor for wear
Page 1 of 17
SECTION 13 BEVEL GEARS
b = 1.0 in
sd = design flexural stress
Min. BHN = 300
sd = 19 ksi
Fs = F d
(19,000)(1.0)(0.240) 1
(0.71)(1)(1.5) = 393
Pd
Pd = 11
say Pd = 10
10 10
so that b = = = 1.0 in
Pd 10
Dg = D p mg = (3.333)(1.75) = 5.833 in
Page 2 of 17
SECTION 13 BEVEL GEARS
752. A pair of steel Zerol bevel gears to transmit 25 hp at 600 rpm of the pinion;
mg = 3 ; let N p 20 teeth; highest reliability; the pinion is overhung, the gear
straddle mounted. An electric motor drives a multi-cylinder pump. (a) Decide
upon the pitch, face width, diameters, and steel (with treatment) for intermittent
service. (b) The same as (a) except that indefinite life is desired.
Solution:
N 20
Dp = p =
Pd Pd
20
(600)
D p n p Pd 1000
vm = = = fpm
12 12 Pd
10
Let b =
Pd
Dynamic load
Fd = (VF )N sf K m Ft
33,000hp
Ft = lb
vm
33,000(25)
Ft = = 262.6 Pd
1000
Pd
1
1000
2
50 +
Pd
1
50 + vm 2
1.121 1.121
VF = = = 1 + 12 = 1 +
50 50 Pd Pd
Table 15.2, electric motor drives a multi-cylinder pump
Service factor, N sf = 1.25
One gear straddle, one not, K m = 1.2
1.121
Fd = 1 + (1.25)(1.2 )(262.6 )Pd = 394 Pd 1 + 1.121
Pd Pd
(a) Strength of Bevel Gears
s bJ K l
Fs = d
Pd K s K t K r
Size factor, assume K s = 0.71
Page 3 of 17
SECTION 13 BEVEL GEARS
66,408 1.121
= 394 P
d 1 +
Pd2 P
d
Pd = 4.814
say Pd = 5
10 10
b= = = 2.0 in
Pd 5
Page 4 of 17
SECTION 13 BEVEL GEARS
N p = 20 , N g = 60
I = 0.083
Elastic coefficient, steel on steel (Table 15.4)
Ce = 2800
Pd = 5
Fw = Fd
2
(2800) (1.0)(1.25) 5
scd = 155,730 psi
Table 15.3
Use steel, min. BHN = 360, scd = 160 ksi
Pd = 5
b = 2 in
D p = 4 in
Dg = mg D p = (3)(4 ) = 12 in
steel, min. BHN = 360
Strength:
s bJ K l
Fs = d
Pd K s K t K r
Fs = Fd
(15,000) 10 (0.205)(1.0) 1.121
Pd = 394 Pd 1 +
Pd (0.71)(1.0)(3) P
d
14,437 1.121
= 394 Pd 1 +
Pd 2 P
d
Pd = 2.799
say Pd = 3
10 10
b= = = 3.33 in
Pd 3
Wear load
Page 5 of 17
SECTION 13 BEVEL GEARS
2
scd2 Cl
Fw = D pbI 2
C e K t Cr
N p 20
Dp = = = 6.67 in
Pd 3
Fw = Fd
2
(2800) (1.0)(1.25) 3
scd = 113,744 psi
Table 15.3
Use steel, min. BHN = 240, scd = 115 ksi
Pd = 3
b = 3.33 in
D p = 6.67 in
Dg = mg D p = (3)(6.67 ) = 20 in
steel, min. BHN = 240
753. Decide upon the pitch, face, and number of teeth for two spiral-bevel gears for a
speed reducer. The input to the pinion is 20 hp at 1750 rpm; mg 1.9 ; pinion
overhung, gear-straddle mounted. It is hoped not to exceed a maximum D p of 4
3/8-in.; steel gears with minimum 245 BHN on pinion and 210 BHN on gear.
The gear is motor-driven, subject to miscellaneous drives involving moderate
shock; indefinite life against breakage and wear with high reliability. If the gears
designed for the foregoing data are to be subjected to intermittent service only,
how much power could they be expected to transmit?
Solution:
D p n p (4.375)(1750)
(a) vm = = = 2000 fpm
12 12
33,000hp 33,000(20 )
Ft = = = 330 lb
vm 2000
Dynamic load
Fd = (VF )N sf K m Ft
One gear straddle, one not
K m = 1.2
Table 15.2
Motor-driven, moderate shock
Page 6 of 17
SECTION 13 BEVEL GEARS
N sf = 1.25
1
70 + vm2 2
1
VF = , spiral
70
1
70 + (2000) 2
1 2
VF = = 1.254
70
Fd = (1.254)(1.25)(1.2)(330) = 621 lb
Wear load
2
s2 C
Fw = D pbI cd2 l
C e K t Cr
D p = 4.375 in
Temperature Factor, K t = 1.0
Design contact stresses,
BHN = 245 , pinion
scd = 116 ksi
Life factor for wear
Cl = 1.0 , indefinite life
Reliability factor for wear
Cr = 1.25 , high reliability
Geometry factor for wear, Fig. 15.8
Assume I = 0.12
Elastic coefficient, steel on steel (Table 15.4)
Ce = 2800
2
Fw = (4.375)(b )(0.12)
(116,000)2 1.0 = 721b
(2800)2 (1.0)(1.25)
Fw = Fd
721b = 621
b = 0.8613 in
7
say b = in = 0.875 in
8
Strength of gear
s bJ K l
Fs = d
Pd K s K t K r
sd = design flexural stress
min. BHN = 210
sd = 15.4 ksi
Size factor, assume K s = 0.71
Page 7 of 17
SECTION 13 BEVEL GEARS
Fs = Fd
3543
= 621
Pd
Pd = 5.7
say Pd = 6
7
Then, Pd = 6 , b = in , N p = D p Pd = (4.375)(6 ) = 26
8
N g = mw N p = (1.9 )(26 ) = 50
Fs =
(15,400)(0.875)(0.292) 4.6 = 3142 lb
(0.71)(1)(1.5)
6
Wear load
2
s2 C
Fw = D pbI cd2 l
C e K t Cr
D p = 4.375 in
K t = 1.0
scd = 116 ksi
Ce = 2800
Page 8 of 17
SECTION 13 BEVEL GEARS
Fw = (4.375)(0.875)(0.116 )
(116,000)2 1.5 = 1098 lb
(2800)2 (1.0)(1.25)
use Fw = Fd
Fd = (VF )N sf K m Ft
1098 = (1.254)(125)(1.2)Ft
Ft = 584 lb
Fv
hp = t m =
(584)(2000) = 35 hp
33,000 33,000
CHECK PROBLEMS
755. A pair of straight-bevel gears are to transmit a smooth load of 45 hp at 500 rpm
3
of the pinion; mg = 3 . A proposed design is Dg = 15 in. , b = 2 in. , Pd = 4 .
8
Teeth are carburized AISI 8620, SOQT 450 F. The pinion overhangs, the gear is
straddle-mounted. Would these gears be expected to perform with high reliability
in continuous service? If not would you expect more than 1 failure in 100?
Solution:
D 15
D p = g = = 5 in
mg 3
D p n p (5)(500)
vm = = = 655 fpm
12 12
33,000hp 33,000(45)
Ft = = = 2267 lb
vm 655
Dynamic load
Fd = (VF )N sf K m Ft
50 + vm2 50 + (655) 2
1 1
VF = = = 1.512
50 50
One gear straddle, one not
K m = 1.2
Smooth load, N sf = 1.0
Fd = (1.512)(1.0)(1.2 )(2267 ) = 4113 lb
Page 9 of 17
SECTION 13 BEVEL GEARS
Fs =
(30,000)(2.375)(0.205) 1 5143
4 (0.71)(1)(K ) = K
r r
Fs = Fd
5143
= 4113
Kr
K r = 1.25 < 1.5 will not perform high reliability.
Wear load
2
s2 C
Fw = D pbI cd2 l
C e K t Cr
D p = 5 in
b = 2.375 in
Table 15.3, scd = 225 ksi
Table 15.4, Ce = 2800
Geometry factor for wear, Figure 15.7
N p = 20 , N g = 60
I = 0.083
Kt = 1
life factor for wear Cl = 1
2
Fw = (5)(2.375)(0.083)
(225,000)2 1 =
6364
(2800)2 (1)(Cr ) Cr2
Fw = Fd
Page 10 of 17
SECTION 13 BEVEL GEARS
6364
= 4113
Cr2
Cr = 1.244 1.25 , high reliability
Since K r < 1.5 ,this will not perform high reliability but 1 in 100, K r 1.12 < 1.25
756. A gear catalog rates a pair of cast-iron, straight-bevel gears at 15.26 hp at 800
rpm of the 16-tooth pinion; mg = 3.5 , b = 3 in. , Pd = 3 ; pinion overhangs,
straddle-mounted gear. Assume the cast iron to be class 30. If the load is smooth
is this rating satisfactory, judging by the design approach of the Text for good
reliability (a) when strength alone is considered, (b) when long continuous
service is desired?
Solution:
N 16
Dp = p = = 5.333 in
Pd 3
D p n p (5.333)(800)
vm = = = 1117 fpm
12 12
33,000hp 33,000(15.26 )
Ft = = = 451 lb
vm 1117
Dynamic load
Fd = (VF )N sf K m Ft
50 + vm2 50 + (1117 ) 2
1 1
VF = = = 1.668
50 50
One gear straddle, one not
K m = 1.2
Smooth load, N sf = 1.0
Fd = (1.668)(1.0)(1.2)(451) = 903 lb
(a) Strength
s bJ K l
Fs = d
Pd K s K t K r
Pd = 3 ,
K s = 0.76
Kl = 1
Kt = 1
K r = 1.5
sd = 4.6 ksi , cast-iron class 30
N p = 16
Page 11 of 17
SECTION 13 BEVEL GEARS
N g = mw N p = (3.5)(16 ) = 56
J = 0.184
(4,600)(3)(0.184) 1
Fs = = 742 lb < 903 lb(= Fd )
3 (0.76)(1)(1.5)
with
K l = 1.4 for 106 cycles
Fs = (1.4)(742) = 1040 lb > 903 lb(= Fd )
Therefore satisfactory for 106 cycles.
Fw = (5.333)(3)(0.077 )
(50,000)2 1 = 389 lb < Fd (= 903 lb )
(2250)2 (1)(1.25)
Therefore, not satisfactory for long continuous service.
757. An 870-rpm motor drives a belt conveyor through bevel gears having 18 and 72
3
teeth; Pd = 6 , b = 1 in . Both gears are straddle-mounted. What horsepower may
4
these gears transmit for an indefinite life with high reliability if both gears are (a)
cast-iron, class 40; (b) AISI 5140, OQT 1000 F; (c) AISI 5140, OQT 1000 F,
flame hardened (d) AISI 8620, SOQT 450 F?
Solution:
N 18
D p = p = = 3 in
Pd 6
D p n p (3)(870)
vm = = = 683 fpm
12 12
Dynamic load
Page 12 of 17
SECTION 13 BEVEL GEARS
Fd = (VF )N sf K m Ft
Both gears straddle mounted
K m = 1.0
Table 15.2, N sf = 1.0
50 + vm2 50 + (683) 2
1 1
VF = = = 1.523
50 50
Fd = (1.523)(1.0)(1.0)Ft = 1.523Ft
Fs =
(7000)(1.75)(0.204) 1
= 434 lb
6 (0.64)(1)(1.5)
Wear:
2
s2 C
Fw = D pbI cd2 l
C e K t Cr
D p = 3 in
3
b = 1 in
4
Table 15.3, scd = 65 ksi , cast-iron class 40
Table 15.4, cast-iron and cast-iron Ce = 2250
Cl = 1 , indefinite life
Kt = 1
Cr = 1.25 , high reliability
Geometry factor for wear, Figure 15.7
N p = 18 , N g = 72
I = 0.082
Page 13 of 17
SECTION 13 BEVEL GEARS
Fw = (3)(1.75)(0.082 )
(65,000) 1
2
= 230 lb
(2250)2 (1)(1.25)
Fd = Fw
1.523Ft = 230
Ft = 151 lb
Fv
hp = t m =
(151)(683) = 3 hp
33,000 33,000
Fs =
(19,000)(1.75)(0.204) 1
(0.64)(1)(1.5) = 1178 lb
6
Wear:
2
s2 C
Fw = D pbI cd2 l
C e K t Cr
Table 15.3, scd = 135 ksi
Table 15.4, steel and steel, Ce = 2800
2
Fw = (3)(1.75)(0.082)
(135,000) 1
2
= 640 lb
(2800)2 (1)(1.25)
Fd = Fw
1.523Ft = 640
Ft = 420 lb
Fv
hp = t m =
(420)(683) = 8.7 hp
33,000 33,000
Fs =
(13,500)(1.75)(0.204) 1
(0.64 )(1)(1.5) = 837 lb
6
Wear:
2
s2 C
Fw = D pbI cd2 l
C e K t Cr
Table 15.3, scd = 190 ksi
Table 15.4, steel and steel, Ce = 2800
Page 14 of 17
SECTION 13 BEVEL GEARS
Fw = (3)(1.75)(0.082)
(190,000) 1
2
= 1269 lb
(2800)2 (1)(1.25)
Fd = Fs
1.523Ft = 837
Ft = 550 lb
Fv
hp = t m =
(550)(683) = 11.4 hp
33,000 33,000
Fs =
(30,000)(1.75)(0.204) 1
(0.64)(1)(1.5) = 1859 lb
6
Wear:
2
s2 C
Fw = D pbI cd2 l
C e K t Cr
Table 15.3, scd = 225 ksi
Table 15.4, steel and steel, Ce = 2800
2
Fw = (3)(1.75)(0.082)
(225,000) 1
2
= 1779 lb
(2800)2 (1)(1.25)
Fd = Fw
1.523Ft = 1779
Ft = 1168 lb
Fv
hp = t m =
(1168)(683) = 24.2 hp
33,000 33,000
Solution:
N 20
Dp = p = = 4 in
Pd 5
D p n p (4)(800)
vm = = = 838 fpm
12 12
Page 15 of 17
SECTION 13 BEVEL GEARS
33,000hp 33,000(15)
Ft = = = 591 lb
vm 838
Fd = (VF )N sf K m Ft
50 + vm2 50 + (838) 2
1 1
VF = = = 1.579
50 50
assume K m = 1.0
Fd = (1.579 )(N sf )(1.0 )(591) = 933 N sf
Strength of bevel gear
s bJ K l
Fs = d
Pd K s K t K r
For AISI 4140, OQT 800 F, BHN = 429
sd = 24 ksi
assume K l = 1
Kt = 1
Pd = 5
K s = 0.675
Figure 15.5, N p = 20 , N g = 60
J = 0.205
Fs =
(24,000)(2)(0.205) 1 2916
= K
5 (0.675)(1)(K r ) r
Fs = Fd
2916
= 933 N sf
Kr
3.1254
Kr =
N sf
Wear load:
2
s2 C
Fw = D pbI cd2 l
C e K t Cr
BHN = 429
Table 15.3, scd = 190 ksi
Table 15.4, steel and steel, Ce = 2800
D p = 4 in
b = 2 in
Assume Cl = 1.0 , K t = 1.0
Fig. 15.7, N p = 20 , N g = 60
I = 0.083
Page 16 of 17
SECTION 13 BEVEL GEARS
2
(190,000 ) 1
2
3058
( )( )(
Fw = 4 2 0.083 ) =
(2800 )2 (1)(Cr ) Cr2
Fd = Fw
3058
933 N sf =
Cr2
1.810
Cr =
N sf
(a) Table 15.2, smooth load
N sf = 1.0
3.1254 3.1254
For strength, K r = = = 3.1254
N sf 1
1.810 1.810
For wear, Cr = = = 1.810
N sf 1
N sf = 2.0
3.1254 3.1254
For strength, K r = = = 1.5627
N sf 2
1.810 1.810
For wear, Cr = = = 1.2799
N sf 2
- end -
Page 17 of 17
SECTION 14 WORM GEARS
DESIGN PROBLEMS
791. (a) Determine a standard circular pitch and face width for a worm gear drive with
an input of 2 hp at 1200 rpm of the triple-threaded worm; the 1.58-in. ( Dw ) is
steel with a minimum BHN = 250; gear is manganese bronze (Table AT 3);
mw = 12 . Consider wear and strength only. Use a n to match the lead angle .
1200 + vmg
a) Fd = Ft lb
1200
33,000hp
Ft =
vmg
Dg ng
vmg =
12
n 1200
ng = w = = 100 rpm
mw 12
Dg = mw Dw tan
N t Pc
tan =
Dw
N P N m P (3)(12)Pc
Dg = mw Dw t c = t w c = = 11.46 Pc
Dw
(11.45Pc )(100)
vmg = = 300 Pc
12
33,000(2 ) 220
Ft = =
300 Pc Pc
1200 + 300 Pc 220 55(4 + Pc )
Fd = = lb
1200 Pc Pc
Wear load
Fw = Dg bK w
say b = 2 Pc ,
Dg = 11.46 Pc
Fw = Fd
Page 1 of 19
SECTION 14 WORM GEARS
Dg 11.46 Pc
tan = = = 0.60443Pc
mw Dw (12)(1.58)
5
Use n = 20o , = 20.7o , Pc = in
8
Fw = Fd
n = 20o
Y = 0.392
= 20.7o
5
Pc = in
8
5
b = 1 in
32
(30,000)(0.392)1 5 5
cos 20.7
Fs = 32 8 = 2530 lb > Fd
5
use Pc = in
8
5
b =1 in
32
Page 2 of 19
SECTION 14 WORM GEARS
cos n f tan
(b) e = tan
cos n tan + f
n = 20o
= 20.7o
Dwnw (1.58)(1200 )
vr = = = 531 fpm > 70 fpm
12 cos 12 cos 20.7
0.32 0.32
f = = = 0.0334
0.36
vr (531)0.36
cos 20 0.0334 tan 20.7
e = tan 20.7 = 0.902 = 90.2%
cos 20 tan 20.7 + 0.0334
decide upon a pitch and face width that satisfies these requirements (i16.11,
Text); specifying the pressure angle, diameters, and center distance. How does
Dw used compare with that from equation (m), i16.11, Text? What addendum
and dedendum are recommended by Dudley? Compute a face length for the
worm. (b) Compute the efficiency. What do you recommend as the next trial for
a better reducer?
Solution:
33,000hp
Ft =
vmg
Dg ng
vmg =
12
n 1750
ng = w = = 159.1 rpm
mw 11
PN Pm N P (11)(4 )
Dg = c g = c w t = c = 14 Pc
(14 Pc )(159.1)
vmg = = 583Pc
12
33,000(20 ) 1132
Ft = =
583Pc Pc
Page 3 of 19
SECTION 14 WORM GEARS
1200 + vmg
Fd = Ft lb
1200
1200 + 583Pc 1132 1132(1 + 0.4858 Pc )
Fd = = lb
1200 Pc Pc
(a) Wear
Fw = Dg bK w
b = 2 Pc ,
Dg = 14 Pc
Fw = Fd
Page 4 of 19
SECTION 14 WORM GEARS
Fs =
(31,000)(0.470 )(2.0)(1.0)cos 34.18 = 7674 lb > F , ok
d
use Pc = 1.0 in
b = 2.0 in
n = 25o
7
Dw = 1 in
8
7
Dg = mw Dw tan = (11)1 tan 34.18 = 14.0 in
8
1 1 7
C = (Dw + Dg ) = 1 + 14 = 7.9375 in
2 2 8
Equation (m)
Dw =
C 0.875
in =
(7.9375)0.875 = 2.785 in > 1.875 in , ok
2 .2 2 .2
Addendum and dedendum (by Dudley)
N
Face length = Pc 4.5 + g
50
N g = mw N p = (11)(4 ) = 44
44
Face length = 1.0 4.5 + = 5.38 in
50
Or
[
Face length = 2 2a(Dg 2a ) ]
1
2
Dg = 14 in
a = 0.2633 in
1
Face length = 2{2(0.2633)[14 2(0.2633)]} 2 = 5.33 in
Use Face length = 5.38 in
cos n f tan
(b) e = tan
cos n tan + f
Dwnw (1.875)(1750 )
vr = = = 1038 fpm > 70 fpm
12 cos 12 cos 34.18
Page 5 of 19
SECTION 14 WORM GEARS
0.32 0.32
f = = = 0.0263 ( 70 < vr < 3000 fpm )
0.36
vr (1038)0.36
n = 25o , = 34.18o ,
cos 25 0.0263 tan 34.18
e = tan 34.18 = 0.94 = 94%
cos 25 tan 34.18 + 0.0263
recommendation for next trial
n = 30o
max = 45o
793. The input to a worm-gear set is to be 25 hp at 600 rpm of the worm with
m w = 20 . The hardened-steel worm is to be the shell type with a diameter
approximately as given in i16.11, Text, and a minimum of 4 threads; the gear is
to be chilled phosphor bronze (Table AT 3). (a) Considering wear and strength
only determine suitable values of the pitch and face width. Let n be appropriate
to the value of . (b) Compute the efficiency. (c) Estimate the radiating area of
the case and compute the temperature rise of lubricant. Is special cooling needed?
Solution:
33,000hp
Ft =
vmg
Dg ng
vmg =
12
n 600
ng = w = = 30 rpm
mw 20
PN Pm N P (20 )(4 ) 80 Pc
Dg = c g = c w t = c =
80 Pc
(30)
vmg =
= 200 Pc
12
33,000(25) 4125
Ft = =
200 Pc Pc
1200 + vmg
Fd = Ft lb
1200
1200 + 200 Pc 4125 687.5(6 + Pc )
Fd = = lb
1200 Pc Pc
shell type: Dw = 2.4 Pc + 1.1 in
NP
tan = t c =
(4)Pc =
4 Pc
Dw ( )(2.4 Pc + 1.1) (2.4 Pc + 1.1)
Page 6 of 19
SECTION 14 WORM GEARS
Fw = Fd
80 Pc 687.5(6 + Pc )
(2 Pc )(K w ) =
Pc
687.5(6 + Pc )
50.93Pc2 K w =
Pc
Table AT 27, Hardened steel and chilled bronze
By trial and error method
Page 7 of 19
SECTION 14 WORM GEARS
1
C=
2
(Dw + Dg )
Dw = 3.5 in
80 Pc 80(1)
Dg = = = 25.5 in
1
C = (3.5 + 25.5) = 14.5 in
2
Amin = 43.2(14.5) = 4072 sq.in.
1.7
Temperature rise = t
Qc = hcr At ft lb min
794. A 50-hp motor turning at 1750 rpm is to deliver its power to a worm-gear
reducer, whose velocity ratio is to be 20. The shell-type worm is to be made of
high-test cast iron; since a reasonably good efficiency is desired, use at least 4
threads; manganese bronze gear (Table AT 3). (a) Decide upon Dw and n , and
determine suitable values of the pitch and face width. Compute (b) the efficiency,
(c) the temperature rise of the lubricant. Estimate the radiating area of the case. Is
special cooling needed?
Solution:
33,000hp
Ft =
vmg
Dg ng
vmg =
12
n 1750
ng = w = = 87.5 rpm
mw 20
PN Pm N P (20 )(4 ) 80 Pc
Dg = c g = c w t = c =
Page 8 of 19
SECTION 14 WORM GEARS
80 Pc
(87.5)
vmg =
= 583Pc
12
33,000(50 ) 2830
Ft = =
583Pc Pc
1200 + vmg
(a) Fd = Ft lb
1200
1200 + 583Pc 2830 1375(2.06 + Pc )
Fd = = lb
1200 Pc Pc
Wear load
Fw = Dg bK w
b = 2 Pc ,
80 Pc
Dg =
Fw = Fd
80 Pc 1375(2.06 + Pc )
(2 Pc )(K w ) =
Pc
1375(2.06 + Pc )
50.93Pc2 K w =
Pc
NP
tan = t c
Dw
Shell-type
Dw = 2.4 Pc + 1.1 in
4 Pc
tan =
(2.4 Pc + 1.1)
Table AT 27, high-test cast-iron and manganese bronze
By trial and error and using Table AT 27 ( n )
Kw Pc Pc (std) max i16.11 n
80 1.012 1.0 20 16 14
115 0.885 7/8 19.2 25 20
7
Use = 19.2o , n = 20o , Pc = in
8
7
Dw = 2.4 Pc + 1.1 = 2.4 + 1.1 = 3.2 in
8
Fw = Fd
Page 9 of 19
SECTION 14 WORM GEARS
7
1375 2.06 +
80 7 8
(b )(115) =
8 7
8
b = 1.80 in
7
say b = 1 in
8
cos n f tan
(b) e = tan
cos n tan + f
= 19.2o
n = 20o
Dwnw
vr =
12 cos
nw = 1750 rpm
Dw = 3.2 in
Dwnw (3.2 )(1750 )
vr = = = 1552 fpm
12 cos 12 cos19.2
0.32 0.32
f = 0.36 = = 0.0227 ( 70 < vr < 3000 fpm )
vr (1552)0.36
cos 20 0.0227 tan 19.2
e = tan 19.2 = 0.9273 = 92.73%
cos 20 tan 19.2 + 0.0227
Figure AF 1
3272
A= = 22.7 ft 2
144
hcr = 0.43 ft lb min sq.in. F
Page 10 of 19
SECTION 14 WORM GEARS
Q = Qc
119,955 = (0.43)(3272)(t )
t = 85 F
with t1 = 100 F
t2 = 185 F > 150 F
Therefore, special cooling is needed.
CHECK PROBLEMS
Solution:
33,000hp
Ft =
vmg
Dg ng
vmg =
12
nw 580
ng = = = 48.3 rpm
mw 20
PN P m N (1.15278)(12 )(3)
Dg = c g = c w t = = 13.21 in
(13.21)(48.3)
vmg = = 167 fpm
12
1200 + vmg
(a) Fd = Ft
1200
1200 + 167
Fd = Ft
1200
33,000(16 )
Ft = = 3162 lb
167
1200 + 167
Fd = (3162 ) = 3602 lb
1200
Page 11 of 19
SECTION 14 WORM GEARS
(30,000)(0.470) 2 1 (1.15278)cos19.34
Fs = 4 = 10,984 lb
Service factor
F 10,984
N sf = s = = 3.05
Fd 3602
(c) Fw = Dg bK w
Dg = 13.21 in
b = 2.25 in
Table AT 27, hardened-steel worn and manganese bronze gear
n = 25o
K w = 100
Fw = (13.21)(2.25)(100) = 2972 lb < Fd (= 3602 lb )
Therefore, not good for indefinitely continuous service
cos n f tan
(d) e = tan
cos n tan + f
Dwnw (1.15278)(580 )
vr = = = 185.5 fpm
12 cos 12 cos19.34
0.32 0.32
f = 0.36 = = 0.0488 ( 70 < vr < 3000 fpm )
vr (185.5)0.36
cos 25 0.0488 tan 19.34
e = tan 19.34 = 0.85 = 85%
cos 25 tan 19.34 + 0.0488
hp 16 hp
hpi = o = = 18.82 hp
e 0.85
Page 12 of 19
SECTION 14 WORM GEARS
1
C=
2
(Dw + Dg )
1
C = (1.15278 + 13.21) = 7.18 in
2
A = 43.2(7.18) = 1233 sq.in.
1.7
Figure AF 1
1233
A= = 8.6 ft 2
144
hcr = 0.47 ft lb min sq.in. F
Q = Qc
93,159 = (0.47 )(1233)(t )
t = 161 F
on the gear
Ft = 3162 lb
radial components
Ft sin n 3162 sin 25
S= = = 1593 lb
cos n cos f sin cos 25 cos19.34 0.0488 sin 19.34
Solution:
Page 13 of 19
SECTION 14 WORM GEARS
cos n f tan
(a) e = tan
cos n tan + f
= 28o57' = 28.95o
n = 25o
Dwnw
vr =
12 cos
nw = 1750 rpm
N P
Dg = g c
N g = mw N t = (8)(5) = 40
Dg =
(40)(1.2812) = 16.31 in
NP
tan = t c
Dw
tan 28.95 =
(5)(1.2812)
Dw
Dw = 3.686 in
(3.686 )(150 )
vr = = 1923 fpm
12 cos 28o57'
0.32 0.32
f = 0.36 = = 0.0210 ( 70 < vr < 3000 fpm )
vr (1923)0.36
cos 25 0.0210 tan 28.95
e = tan 28.95 = 0.9475 = 94.75%
cos 25 tan 28.95 + 0.0210
(b) Fw = Dg bK w
Dg = 16.31 in
b = 2.5 in
Table AT 27, hardened-steel worn and phosphor bronze gear
n = 25o
K w = 100
Fw = (16.31)(2.5)(100) = 4078 lb
Fs =
(31,000)(0.470 )(2.5)(1.2812 )cos 28.95 = 13,000 lb
Page 14 of 19
SECTION 14 WORM GEARS
(e) t = 90 F
hpi t
=
hpi t
hpi 90
=
68.5 124
hpi = 50.8 hp
Since 36.5 hp < 50.8 hp, therefore on the safe side.
Page 15 of 19
SECTION 14 WORM GEARS
HEATING
799. The input to a worm-gear reducer is 50.5 hp at 580 rpm of the 4-threaded worm.
The gear case is 22 x 31 x 45 in. in size; n = 25o , Pc = 1.5 in , Dw = 4.432 in ,
f = 0.035 , room temperature = 80 F. Compute the steady-state temperature for
average cooling.
Solution:
NP 4(1.5)
tan = t c =
Dw (4.432 )
= 23.3o
cos n f tan
e = tan
cos n tan + f
cos 25 0.035 tan 23.3
e = tan 23.3 = 0.9025
cos 25 tan 23.3 + 0.035
Q = (1 e )(hpi ) = (1 0.9025)(50.5)(33,000) = 162,484 ft lb min
Qc = hcr At ft lb min
A = 2[(22)(31) + (31)(45)] = 4154 sq.in.
Figure AF 1
4154
A= = 28.85 ft 2
144
hcr = 0.42 ft lb min sq.in. F
Q = Qc
162,484 = (0.42)(4154 )(t )
t = 93 F
t1 = 80 F
t2 = 173 F
Solution:
NP 4(1.0 )
tan = t c =
Dw (1.875)
= 34.2o
0.32 0.32
f = = = 0.0263 ( 70 < vr < 3000 fpm )
0.36
vr (1037 )0.36
Page 16 of 19
SECTION 14 WORM GEARS
cos n f tan
e = tan
cos n tan + f
cos 25 0.0263 tan 34.2
e = tan 34.2 = 0.94
cos 25 tan 34.2 + 0.0263
Q = (1 e )(hpi ) = (1 0.94)(20)(33,000) = 39,600 ft lb min
Qc = hcr At ft lb min
A = 1500 sq.in.
Figure AF 1
1500
A= = 10.4 ft 2
144
hcr = 0.46 ft lb min sq.in. F
Q = Qc
39,600 = (0.46 )(1500)(t )
t = 57 F
t1 = 80 F
t2 = 137 F
Solution:
Qc = hcr At ft lb min
Figure AF 1
1800
A= = 12.5 ft 2
144
hcr = 0.46 ft lb min sq.in. F
A = 1800 sq.in.
t = 180 100 = 80 F
Qc = hcr At = (0.46)(1800)(80) = 66,240 ft lb min
Q = (1 e )(hpi )(33,000) ft lb min
Q = Qc
(1 e)(hpi )(33,000) = 66,240
e = 0.9035
cos n f tan
e = tan
cos n tan + f
Page 17 of 19
SECTION 14 WORM GEARS
N t Pc 4(1.0 )
tan = =
Dw (2 )
= 32.5o
cos 25 f tan 32.5
0.9035 = tan 32.5
cos 25 tan 32.5 + f
0.5217 + 0.9035 f = 0.5774 0.4059 f
f = 0.0425
FORCE ANALYSIS
1
804. The input to a 4-threaded worm is 21 hp at 1750 rpm; e = 90% , Dw = 2 in ,
4
o
Dg = 14 in , N g = 44 , n = 25 . (a) From the horsepowers in and out, compute
the tangential forces on the worm Wt and the gear Ft . (b) Using this value of Ft ,
compute Wt from equation (k), i16.8, Text. (Check?) (c) Compute the separating
force. (d) What is the end thrust on the worm shaft? On the gear shaft?
Solution:
hpi = 21 hp
hpo = (hpi )(e ) = (21)(0.90) = 18.9 hp
N Dg
mw = g =
N t Dw tan
44 14
=
4 1
2 tan
4
= 29.5o
cos n f tan
e = tan
cos n tan + f
cos 25 f tan 29.5
0.90 = tan 29.5
cos 25 tan 29.5 + f
0.4615 + 0.90 f = 0.5128 0.32 f
f = 0.0420
Dg ng
vmg =
12
ng N t
=
nw N g
Page 18 of 19
SECTION 14 WORM GEARS
ng 4
=
1750 44
ng = 159 rpm
(14)(159)
vmg = = 583 fpm
12
33,000hpo 33,000(18.9)
(a) Ft = = = 1070 lb
vmg 583
33,000hpi
Wt =
vw
D n (2.25)(1750)
vw = w w = = 1031 fpm
12 12
33,000(21)
Wt = = 672 lb
1031
- end -
Page 19 of 19
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
LEATHER BELTS
DESIGN PROBLEMS
Solution:
hp = 1
(F F2 )vm
33,000
60 = 1
(F F2 )(4948)
33,000
F1 F2 = 400 lb
F1 = 3F2
3F2 F2 = 400 lb
F2 = 200 lb
F1 = 3F2 = 3(200) = 600 lb
F1 = sbt
sd = 300
For cemented joint, = 1.0
sd = 300 psi
20
F1 = 600 = (300 )(b )
64
b = 6.4 in
say b = 6.5 in
Page 1 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
F1 600
(c) s = = = 128 psi
bt 20
(1)(15)
64
1 1 1 1 1
(d) 2 Fo2 = F12 + F22 = (600)2 + (200)2
Fo = 373.2 lb
F1 = 525 lb
1 1 1
2(373.2) = (525) + F
2 2
2
2
F2 = 247 lb
F1 525
= = 2.1255
F2 247
842. A 20-hp, 1750 rpm, slip-ring motor is to drive a ventilating fan at 330 rpm. The
horizontal center distance must be about 8 to 9 ft. for clearance, and operation is
continuous, 24 hr./day. (a) What driving-pulley size is needed for a speed
recommended as about optimum in the Text? (b) Decide upon a pulley size (iron
or steel) and belt thickness, and determine the belt width by the ALBA tables. (c)
Compute the stress from the general belt equation assuming that the applicable
coefficient of friction is that suggested by the Text. (d) Suppose the belt is
installed with an initial tension Fo = 70 lb in . (17.10), compute F1 F2 and the
stress on the tight side if the approximate relationship of the operating tensions
1 1 1
and the initial tensions is F1 + F = 2 F .
2
2
2
o
2
Page 2 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
Solution:
vm = 4000 to 4500 fpm
assume vm = 4250 fpm
D n
vm = 1 1
12
D (1750 )
4250 = 1
12
D1 = 9.26 in
say D1 = 10 in
23
(b) Using Heavy Double Ply Belt, t = in
64
Minimum pulley diameter for vm 4250 fpm , D1 = 10 in
Use D1 = 10 in
D n (10 )(1750)
vm = 1 1 = = 4581 fpm
12 12
ALBA Tables
(
hp = (hp in., Table 17.1)(bCmC p ) C f1 C f 2 L )
hp in = 13.8
Slip ring motor, Cm = 0.4
Pulley Size, D1 = 10 in
C p = 0 .7
Table 17.7, 24 hr/day, continuous
N sf = 1.8
Assume C f = 0.74
hp = (1.8)(20) = (13.8)(b )(0.4)(0.7 )(0.74 )
b = 12.59 in
use b = 13 in
Page 3 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
33,000(1.8)(20 )
F1 F2 = = 260 lb
4581
f = 0.3 on iron or steel
D D1
2
C
C = 8 ~ 9 ft use 8.5 ft
1750
D2 = (10 ) = 53 in
330
53 10
= = 2.72 rad
8.5(12 )
f = (0.3)(2.72) = 0.816
e f 1 e 0.816 1
= 0.816 = 0.5578
e f e
23 12(0.035)(76.35)
2
F1 F2 = 260 = (13) s (0.5578)
64 32.2
s = 176 psi
1 1 1
(d) F1 2 + F22 = 2 Fo2
Fo = (70 lb in )(13 in ) = 910 lb
F1 F2 = 260 lb
F2 = F1 260 lb
1 1 1
F1 + (F1 260)2 = 2(910)2 = 60.33
2
F1 = 1045 lb
F2 = 1045 260 = 785 lb
F11045
s= = = 224 psi
bt 23
(13)
64
F1 1045
= = 1.331
F2 785
Page 4 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
1 1 1
initial tension Fo is F1 + F = 2 F . For the condition in (c), compute Fo . Is it
2
2
2
o
2
Solution:
(a) Table 17.1
D n (16)(1140 )
vm = 1 1 = = 4775 fpm
12 12
Use heavy double-ply belt
23
t= in
64
hp in = 14.1
(
hp = (hp in., Table 17.1)(bCmC p ) C f1 C f 2 L)
line starting electric motor , Cm = 0.5
Table 17.7, squirrel-cage, electric motor, line starting, reciprocating compressor
N sf = 1.4
D1 = 16 in , C p = 0.8
assume, C f = 0.74
hp = (1.4)(100) = 140 hp
hp = 140 = (14.1)(b )(0.5)(0.8)(0.74)
b = 33.5 in
use b = 34 in
Page 5 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
e f 1
= 0.2496
e f
f = 0.28715
D D1
2
C
C = 8 ft
53 16
= = 2.7562 rad
8(12)
f (2.7562) = 0.28715
f = 0.1042 < 0.3
Therefore satisfactory.
(c) F1 F2 = 968 lb
F1 = 2F2
2 F2 F2 = 968 lb
F1 = 2 F2 = 2(968) = 1936 lb
F 1936
s= 1 = = 159 psi
bt 23
(34)
64
Fo = 1411 lb
1411
Fo = = 41.5 lb in of width is less than Taylors recommendation and is reasonable.
34
Page 6 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
Solution:
D1n1 (13)(865)
(a) vm = = = 2944 fpm
12 12
Table 17.1, use Heavy Double Ply,
Dmin = 9 in for vm = 2944 fpm
belts less than 8 in wide
23
t= in
64
( )
hp = (hp in., Table 17.1)(bCmC p ) C f1 C f 2 L
hp in = 9.86
Table 17.2
Cm = 0.67
C p = 0 .8
C f = (0.74 )(0.80 ) = 0.592
Table 17.7, electric motor, compensator-started (squirrel cage) and reciprocating
compressor
N sf = 1.4
hp = (1.4)(50) = 70 hp
hp = 70 = (9.86)(b )(0.67 )(0.8)(0.592 )
b = 22.4 in
use b = 25 in
Page 7 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
e f 1 e 0.705 1
= 0.705 = 0.5059
e f e
33,000(1.4 )(50 )
F1 F2 = = 785 lb
2944
23 12(0.035)(49.1)
2
F1 F2 = 785 = (25) s (0.5059 )
64 32.2
s = 204 psi
Cemented joint, = 1.0
s = 204 psi
23
(c) F1 = sbt = (204 )(25) = 1833 lb
64
F2 = 1833 785 = 1048 lb
F1 1833
= = 1.749
F2 1048
1 1 1
(d) 2 Fo2 = F12 + F22
1 1 1
2 F = (1833)2 + (1048)2
o
2
Fo = 1413 lb
1413
Fo = = 56.5 lb in
25
Approximately less than Taylors recommendation ( = 70 lb/in.)
(e) L 2C + 1.57(D2 + D1 ) +
(D2 D1 )2
4C
Page 8 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
CHECK PROBLEMS
846. An exhaust fan in a wood shop is driven by a belt from a squirrel-cage motor that
runs at 880 rpm, compensator started. A medium double leather belt, 10 in. wide
is used; C = 54 in .; D1 = 14 in . (motor), D2 = 54 in ., both iron. (a) What
horsepower, by ALBA tables, may this belt transmit? (b) For this power,
compute the stress from the general belt equation. (c) For this stress, what is
F1 F2 ? (d) If the belt has stretched until s = 200 psi on the tight side, what is
F1 F2 ? (e) Compute the belt length.
Solution:
12 vs2 e f 1
(b) F1 F2 = bt s
32.2 e f
b = 10 in
20
t= in
64
= 0.035 lb cu. in.
3225
vs = = 53.75 fps
60
D D1
= 2
C
54 14
= = 2.4 rad
54
Leather on iron f = 0.3
f = (0.3)(2.4) = 0.72
Page 9 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
e f 1 e 0.72 1
= 0.72 = 0.51325
e f e
33,000(26.43)
F1 F2 = = 270 lb
3225
20 12(0.035)(53.75)
2
F1 F2 = 270 = (10 ) s (0.51325)
64 32.2
s = 206 psi
20
(c) F1 = sbt = (206 )(10 ) = 644 lb
64
F2 = 644 270 = 374 lb
F1 644
= = 1.72
F2 374
(e) L 2C + 1.57(D2 + D1 ) +
( D2 D1 )
2
4C
Solution:
D1n1 (8)(1750)
(a) vm = = = 3665 fpm
12 12
b = 6 in
F1 F2 = (40)(6) = 240 lb
Page 10 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
hp =
(F1 F2 )vm = (240)(3665) = 26.65 hp
33,000 33,000
(b) F1 = 3F2
3F2 F2 = 240 lb
F2 = 120 lb
F1 = 360 lb
F
s= 1
bt
For heavy single-ply leather belt
13
t= in
64
360
s= = 295 psi
13
(6)
64
12 vs2 e f 1
(c) F1 F2 = bt s
32.2 e f
= 0.035 lb cu. in.
3665
vs = = 61.1 fps
60
F1 F2 = 240 lb
13 12(0.035)(61.1) e f 1
2
F1 F2 = 240 = (6 ) 295 f
64 32.2 e
e f 1
= 0.7995
e f
D D1
= 2
C
12 8
= = 3.075 rad
5(12)
e f = 4.9875
f = 1.607
f (3.075) = 1.607
f = 0.5226
Page 11 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
b = 10 in
Cm = 1.0 (assumed)
C p = 0 .6
C f = 0.74
848. A 10-in. medium double leather belt, cemented joints, transmits 60 hp from a 9-
in. paper pulley to a 15-in. pulley on a mine fab; dusty conditions. The
compensator-started motor turns 1750 rpm; C = 42 in . This is an actual
installation. (a) Determine the horsepower from the ALBA tables. (b) Using the
general equation, determine the horsepower for this belt. (c) Estimate the service
factor from Table 17.7 and apply it to the answer in (b). Does this result in better
or worse agreement of (a) and (b)? What is your opinion as to the life of the belt?
Solution:
D n (9 )(1750)
vm = 1 1 = = 4123 fpm
12 12
(a) hp = (hp in )(b )CmC pC f
Table 17.1 and 17.2
Medium double leather belt
20
t= in
64
vm = 4123 fpm
hp in = 11.15
Cm = 0.67
C p = 0 .7
C f = 0.74
b = 10 in
hp = (11.15)(10)(0.67 )(0.7 )(0.74) = 38.7 hp
12 vs2 e f 1
(b) F1 F2 = bt s f
32.2 e
b = 10 in
= 0.035 lb cu. in.
s = 400
= 1.0 cemented joint
s = 400 psi
D D1
= 2
C
Page 12 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
15 9
= = 2.9987 rad
42
Leather on paper pulleys, f = 0.5
f = (0.5)(2.9987 ) = 1.5
e f 1
= 0.77687
e f
4123
vs = = 68.72 fps
60
20 12(0.035)(68.72 )
2
F1 F2 = (10 ) 400 (0.77687 ) = 822 lb
64 32.2
hp =
( F1 F2 )vm (822)(4123)
= = 102.7 hp
33,000 33,000
MISCELLANEOUS
849. Let the coefficient of friction be constant. Find the speed at which a leather belt
may transmit maximum power if the stress in the belt is (a) 400 psi, (b) 320 psi.
(c) How do these speeds compare with those mentioned in 17.9, Text? (d)
Would the corresponding speeds for a rubber belt be larger or smaller? (HINT:
Try the first derivative of the power with respect to velocity.)
Solution:
12 vs2 e f 1
F1 F2 = bt s
32.2 e f
hp = 1
(F F2 )vm
33,000
60(F1 F2 )vs
hp =
33,000
60vs bt 12 vs2 e f 1
hp = s
33,000 32.2 e f
60bt e f 1 12 vs2
hp = s v s
33,000 e f 32.2
Page 13 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
850. A 40-in. pulley transmits power to a 20-in. pulley by means of a medium double
leather belt, 20 in. wide; C = 14 ft , let f = 0.3 . (a) What is the speed of the 40-in
pulley in order to stress the belt to 300 psi at zero power? (b) What maximum
horsepower can be transmitted if the indicated stress in the belt is 300 psi? What
is the speed of the belt when this power is transmitted? (See HINT in 849).
Solution:
12 vs2 e f 1
F1 F2 = bt s f
32.2 e
Page 14 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
60(F1 F2 )vs
hp =
33,000
60bt e f 1 12 vs2
hp = s v s
33,000 e f 32.2
d (hp ) 60bt e f 1 12 vs2 24 vs2
= s =0
d (vs ) 33,000 e f 32.2 32.2
36 vs2
s= for maximum power
32.2
(a) At zero power:
12 vs2
s=
32.2
s = 300 psi
= 0.035 lb cu. in.
12(0.035)vs2
300 =
32.2
vs = 151.6575 fps
vm = 9100 fpm
12vm 12(9100 )
Speed, 40 in pulley, n2 = = = 869 rpm
D2 (40)
(b) Maximum power
36 vs2
s=
32.2
36(0.035)vs2
300 =
32.2
vs = 87.5595 fps
vm = 5254 fpm
60bt e f 1 12 vs2
hp = s v s
33,000 e f 32.2
20
t= in
64
b = 20 in
D D1
= 2
C
40 20
= = 3.0225 rad
14(12)
f = 0 .3
Page 15 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
f = (0.3)(3.0225) = 0.90675
e f 1
= 0.5962
e f
20
60(20)
64 (0.5962)300 12(0.035)(87.5595) (87.5595) = 118.64
2
hp =
33,000 32.2
vm = 5254 fpm
Solution:
(a) F1 = sbt
b = 12 in
20
t= in
64
20
F1 = (375)(12 )
64
33,000hp
(b) F1 F2 =
vm
D n (12)(1200 )
vm = 1 1 = = 3770 fpm
12 12
Table 17.7, N sf = 1.2
33,000(1.2 )(100 )
F1 F2 = = 1050 lb
3770
F2 = F1 1050 = 1406 1050 = 356 lb
12 vs2 e f 1
(c) F1 F2 = bt s f
32.2 e
3770
vs = = 62.83 fps
60
Page 16 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
Compressor Pulley
= 2403o = 240 = 4.1888 rad
180
f (4.1888) = 2.006
f = 0.4789
(d) Force:
Page 17 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
1 2.356
1 = 1 1 = 3.3685 2.356 = 0.6197 rad = 35.5o
2 2
2 3.9273
2 = + 2 2 = + 4.1888 3.9273 = 0.6544 rad = 37.5o
2 2
Q = F1 (sin 1 + sin 2 ) = 1406(sin 35.5 + sin 37.5) = 1672 lb of force exerted
Size of pulley; For medium double leather belt,
vm = 3770 fpm , width = 12 in > 8 in
D = 6 + 2 = 8 in
Page 18 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
852. A 40-hp motor, weighing 1915 lb., runs at 685 rpm and is mounted on a pivoted
3
base. In Fig. 17.11, Text, e = 10 in ., h = 19 in . The center of the 11 -in.
16
motor pulley is 11 in. lower than the center of the 60-in. driven pulley;
C = 48 in . (a) With the aid of a graphical layout, find the tensions in the belt for
maximum output of the motor if it is compensator started. What should be the
width of the medium double leather belt if s = 300 psi ? (c) What coefficient of
friction is indicated by the general belt equation? (Data courtesy of Rockwood
Mfg. Co.)
Solution:
(a)
R = 1915 lb
Graphically
b 26 in
a 9 in
[ M B =0 ]
eR = F1a + F2b
(10)(1915) = (F1 )(9) + (F2 )(26)
9 F1 + 26 F2 = 19,150
For compensator started
hp = 1.4(rated hp ) = 1.4(40 ) = 56 hp
33,000hp
F1 F2 =
vm
Page 19 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
D1n1 (11.5)(685)
vm = = = 2062 fpm
12 12
33,000(56 )
F1 F2 = = 896 lb
2062
F2 = F1 896
Substituting
9 F1 + 26(F1 896) = 19,150
F1 = 1213 lb
F2 = 1213 896 = 317 lb
20
For medium leather belt, t = in
64
F1 = sbt
20
1213 = (300 )(b )
64
b = 13 in
12 vs2 e f 1
(c) F1 F2 = bt s
32.2 e f
2062
vs = = 34.37 fps
60
= 0.035 lb cu. in.
20 12(0.035)(34.37 ) e f 1
896 = (13) 300 e f
64 32.2
e f 1
= 0.775
e f
f = 1.492
D D1 60 11.5
= 2 = = 2.1312 rad
C 48
f (2.1312 ) = 1.492
f = 0.70
853. A 50-hp motor, weighing 1900 lb., is mounted on a pivoted base, turns 1140 rpm,
3
and drives a reciprocating compressor; in Fig. 17.11, Text, e = 8 in .,
4
5
h = 17 in . The center of the 12-in. motor pulley is on the same level as the
16
center of the 54-in. compressor pulley; C = 40 in . (a) With the aid of a graphical
layout, find the tensions in the belt for maximum output of the motor if it is
compensator started. (b) What will be the stress in the belt if it is a heavy double
Page 20 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
leather belt, 11 in. wide? (c) What coefficient of friction is indicated by the
general belt equation? (Data courtesy of Rockwood Mfg. Co.)
Solution:
(a) For compensator-started
hp = 1.4(50) = 70 hp
33,000hp
F1 F2 =
vm
D n (12 )(1140)
vm = 1 1 = = 3581 fpm
12 12
33,000(70 )
F1 F2 = = 645 lb
2062
b 25 in
a 5 in
R = 1900 lb
eR = F 1a + F2b
(8.75)(1900) = F 1 (5) + F2 (25)
F 1+5F2 = 3325 lb
645 + F 2+5F2 = 3325 lb
F2 = 447 lb
F1 = 645 + F2 = 645 + 447 = 1092 lb
Page 21 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
F1 1092
s= = = 276 psi
bt 20
(11)
64
12 vs2 e f 1
(c) F1 F2 = bt s
32.2 e f
3581
vs = = 59.68 fps
60
= 0.035 lb cu. in.
23 12(0.035)(59.68) e f 1
645 = (11) 276 e f
64 32.2
f = 1.241
D D1 54 12
= 2 = = 2.092 rad
C 40
f (2.092 ) = 1.492
f = 0.60
RUBBER BELTS
854. A 5-ply rubber belt transmits 20 horsepower to drive a mine fan. An 8-in., motor
pulley turns 1150 rpm; D2 = 36 in ., fan pulley; C = 23 ft . (a) Design a rubber
belt to suit these conditions, using a net belt pull as recommended in 17.15,
Text. (b) Actually, a 9-in., 5-ply Goodrich high-flex rubber belt was used. What
are the indications for a good life?
Solution:
D2 D1 36 8
(a) = = = 3.040 rad = 174o
C 23(12 )
K = 0.976
bv N K
hp = m p
2400
K = 0.976
D n (8)(1150)
vm = 1 1 = = 2409 fpm
12 12
Np = 5
b(2409 )(5)(0.976 )
hp = 20 =
2400
b = 4.1 in
min. b = 5 in
Page 22 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
855. A 20-in., 10-ply rubber belt transmits power from a 300-hp motor, running at 650
rpm, to an ore crusher. The center distance between the 33-in. motor pulley and
the 108-in. driven pulley is 18 ft. The motor and crusher are so located that the
belt must operate at an angle 75o with the horizontal. What is the overload
capacity of this belt if the rated capacity is as defined in 17.15, Text?
Solution:
bv N
hp = m p
2400
b = 20 in
D n (33)(650)
vm = 1 1 = = 5616 fpm
12 12
N p = 10
hp =
(20)(5616)(10 ) = 468 hp
2400
468 300
Overlaod Capacity = (100% ) = 56%
300
V-BELTS
NOTE: If manufacturers catalogs are available, solve these problems from catalogs as
well as from data in the Text.
856. A centrifugal pump, running at 340 rpm, consuming 105 hp in 24-hr service, is to
be driven by a 125-hp, 1180-rpm, compensator-started motor; C = 43 to 49 in .
Determine the details of a multiple V-belt drive for this installation. The B.F.
Goodrich Company recommended six C195 V-belts with 14.4-in. and 50-in.
sheaves; C 45.2 in .
Solution:
Table 17.7
N sf = 1.2 + 0.2 = 1.4 (24 hr/day)
Design hp = N sf (transmitted hp) = (1.4)(125) = 175 hp
Fig. 17.4, 175 hp, 1180 rpm
Dmin = 13 in , D-section
D2 1180 50
= =
D1 340 14.4
use D1 = 14.4 in > 13 in
D2 = 50 in
Page 23 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
D1n1 (14.4)(1180 )
vm = = = 4449 fpm
12 12
103 0.09 c vm2 vm
Rated hp = a
K D e 106 103
vm d 1
Table 17.3, D-section
a = 18.788 , c = 137.7 , e = 0.0848
D
Table 17.4, 2 = 3.47
D1
K d = 1.14
103
0.09
137.7 (4449) 4449
2
Rated hp = 18.788 (1.14)(14.4) (0.0848) 106 103 = 28.294 hp
4449
Page 24 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
B + B 2 32(D2 D1 )
2
C=
16
B = 4 L 6.28(D2 + D1 ) = 4(197.9) 6.28(50 + 14.4) = 387.2 in
387.2 + (387.2)2 32(50 14.4)2
C= = 44.9 in
16
Solution:
Table 17.7, (12 hr/day)
N sf = 1.4 0.2 = 1.2
Design hp = (1.2)(1.75)(50) = 105 hp
Fig. 17.4, 105 hp, 1160 rpm
Dmin = 13 in , D-section
D2 1160 46.4
=
D1 330 13.2
use D1 = 13.2 in > 13 in
D2 = 46.4 in
D n (13.2)(1160 )
vm = 1 1 = = 4009 fpm
12 12
103 0.09 c vm2 vm
Rated hp = a
K D e 106 103
vm d 1
Table 17.3, D-section
a = 18.788 , c = 137.7 , e = 0.0848
D 46.4
Table 17.4, 2 = = 3 .5
D1 13.2
K d = 1.14
103
0.09
137.7 (4009) 4009
2
Rated hp = 18.788 (0.0848) = 24.32 hp
4009 (1.14)(13.2) 106 103
Dmin = 9 in
Page 25 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
D2 1160 32
=
D1 330 9.1
use D1 = 9.1 in
D n (9.1)(1160 )
vm = 1 1 = = 2764 fpm
12 12
103
0.09
38.819 (2764)2 2764 = 10.96 hp
Rated hp = 8.792 (0.0416)
2764 (1.14)(9.1) 106 103
L 2C + 1.57(D2 + D1 ) +
( D2 D1 )
2
4C
B + B 2 32(D2 D1 )
2
C=
16
B = 4 L 6.28(D2 + D1 ) = 4(160.9) 6.28(32 + 9.1) = 385.5 in
385.5 + (385.5)2 32(32 9.1)2
C= = 46.8 in
16
Use 10-C158 belts, D1 = 9.1 in
D2 = 32 in , C = 46.8 in
858. A 200-hp, 600-rpm induction motor is to drive a jaw crusher at 125 rpm; starting
load is heavy; operating with shock; intermittent service; C = 113 to 123 in .
Recommend a multiple V-flat drive for this installation. The B.F. Goodrich
Company recommended eight D480 V-belts with a 26-in. sheave and a 120.175-
in. pulley; C 116.3 in .
Solution:
Page 26 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
Table 17.7
N sf = 1.6 0.2 = 1.4
hp = (1.4)(200) = 280 hp
Fig. 17.14, 280 hp, 600 rpm
Use Section E
But in Table 17.3, section E is not available, use section D
Dmin = 13
D2 600
= = 4 .8
D1 125
For D1max :
D + D2
min C = 1 + D1
2
D + 4.8 D1
113 = 1 + D1
2
D1 = 28 in
min C = D2
D2 = 113 in
113
D1 = = 23.5 in
4 .8
1
use D1 (13 + 23.5) = 18 in
2
D2 = (4.8)(18) = 86.4 in
L 2C + 1.57(D2 + D1 ) +
(D2 D1 )2
4C
Page 27 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
K d = 1.14
103
0.09
137.7 (2985)2 2985 = 29.6 hp
Rated hp = 18.788 (0.0848)
2985 (1.14)(19) 106 103
Therefore, Fig. 17.14, section D is used.
Adjusted rated hp = K K L (rated hp )
Table 17.5,
D2 D1 91.2 19
= = 0.612
C 118
K = 0.83 (V-flat)
Table 17.6, D420
L = 420.8 in
K L = 1.12
Adjusted rated hp = (0.83)(1.12)(29.6) = 27.52 hp
Design hp 280
No. of belts = = = 10 belts
Adjusted rated hp 27.52
859. A 150-hp, 700-rpm, slip-ring induction motor is to drive a ball mill at 195 rpm;
heavy starting load; intermittent seasonal service; outdoors. Determine all details
for a V-flat drive. The B.F. Goodrich Company recommended eight D270 V-
belts, 17.24-in sheave, 61-in. pully, C 69.7 in .
Solution:
Table 17.7,
N sf = 1.6 0.2 = 1.4
Design hp = (1.4)(150) = 210 hp
Fig. 17.4, 210 hp, 700 rpm
Dmin = 13 in , D-section
103 0.09 c v2 v
Rated hp = a e m6 m3
vm K d D1 10 10
d (hp )
For Max. Rated hp, =0
vm
d 3
10
0.91 3
v c vm vm
Rated hp = a m3 e
10 K d D1 103 103
v
Let X = m3
10
Page 28 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
c
hp = aX 0.91 X eX 3
K d D1
v D1n1 D1 (700)
X = m3 = =
10 12 103 12 103
12 103 X
D1 =
700
700c
hp = aX 0.91 3
eX 3
12 10 K d
d (hp )
= 0.91aX 0.09 3eX 2 = 0
d (X )
0.91a
X 2.09 =
3e
Table 17.3, D-section
a = 18.788 , c = 137.7 , e = 0.0848
2.09
v 0.91(18.788)
X 2.09 = m3 =
10 3(0.0848)
vm = 7488 fpm
D n
vm = 1 1 = 7488
12
D (700)
vm = 1 = 7488
12
D1 = 40.86 in
max D1 = 40.86 in
1
ave. D1 = (13 + 40.86 ) = 26.93 in
2
use D1 = 22 in
D2 700 79
=
D1 195 22
D1 = 22 in , D2 = 79 in
D + D2 22 + 79
Min. C = 1 + D1 = + 22 = 72.5 in
2 2
Or Min. C = D2 = 79 in
L 2C + 1.57(D2 + D1 ) +
(D2 D1 )2
4C
C=
16
Page 29 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
860. A 30-hp, 1160-rpm, squirrel-cage motor is to be used to drive a fan. During the
summer, the load is 29.3 hp at a fan speed of 280 rpm; during the winter, it is 24
hp at 238 rpm; 44 < C < 50 in .; 20 hr./day operation with no overload. Decide
upon the size and number of V-belts, sheave sizes, and belt length. (Data
courtesy of The Worthington Corporation.)
Solution:
Table 17.7
N sf = 1.6 + 0.2 = 1.8
Design hp = (1.8)(30) = 54 hp
Speed of fan at 30 hp
30 24
n2 = (280 238) + 238 = 286 rpm
29.3 24
at 54 hp, 1160 rpm. Fig. 17.4
use either section C or section D
Minimum center distance:
C = D2
Page 30 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
D1 + D2
or C = + D1
2
D2 1160
= = 4.056
D1 286
use C = 4.056 D1
44 in < C < 50 in , use C = 47 in
47
D1max = = 11.6 in
4.056
use C-section, Dmin = 9 in
Let D1 = 10 in , D1 = 41 in
L 2C + 1.57(D2 + D1 ) +
( D2 D1 )
2
4C
C=
16
B = 4 L 6.28(D2 + D1 ) = 4(175.9) 6.28(41 + 10.1) = 328.7 in
382.7 + (382.7 )2 32(41 10.1)2
C= = 45.2 in 44 in
16
C173, satisfies 44 in < C < 50 in
0.91 3
v c vm vm
Rated hp = a m3 e
10 K d D1 103 103
D n (10.1)(1160)
vm = 1 1 = = 3067 fpm
12 12
Table 17.4
D2
= 4.056 , K d = 1.14
D1
Table 17.3, D-section
a = 8.792 , c = 38.819 , e = 0.0416
103
0.09
38.819 (3067 )2 3067 = 12.838 hp
Rated hp = 8.792 (0.0416)
3067 (1.14)(10.1) 106 103
Adjusted rated hp = K K L (rated hp )
Table 17.5,
D2 D1 41 10.1
= = 0.68
C 45.2
K = 0.90
Page 31 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
Table 17.6
L = 175.9 , C173
K L = 1.04
Adjusted rated hp = (0.90)(1.04)(12.838) = 12.02 hp
Design hp 54
No. of belts = = = 4.5 belts use 5 belts
Adjusted rated hp 12.02
POWER CHAINS
NOTE: If manufacturers catalogs are available, solve these problems from catalogs as
well as from data in the Text.
Solution:
Page 32 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
N + N 2 ( N 2 N1 )
2
(b) L 2C + 1 + pitches
2 40C
24
C= = 64
3
8
N1 = 21
N 2 = 42
21 + 42 (42 21)
2
L = 2(64) + + = 159.67 pitches 160 pitches
2 40(64 )
Amount of slack
1
(
h = 0.433 S 2 L2 )
2
L = C = 24 in
Page 33 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
(160159.67) 3 in
S = 24 in + 8 = 24.062 in
2
1
[
h = 0.433 (24.062) (24)
2
]
2 2
= 0.75 in =
3
4
in
Solution:
Table 17.7
N sf = 1.2 0.2 = 1.0 (8 hr/day)
design hp = 1.0(2) = 2.0 hp
1750
n1 = = 50 rpm
35
n2 = 12 rpm
Minimum number of teeth = 12
Page 34 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
Use N1 = 12
[Link Plate Fatigue]
hp = 0.004 N ts1.08 n 0.9 P 30.07 P
hp 2 .0
P 3 0.07 P P 3 = = = 1 .0
0.004(12 ) (50 )
1.08 0.9 1.08 0.9
0.004 N ts n
Use Chain No. 80, P = 1.0 in
To check for roller-bushing fatigue
1.5
100 N ts 0.8
hp = K r P
n
K r = 29
1.5
100(12 )
hp = 17 (1)0.8 = 2747 hp > 2 hp
1000
(a) N1 = 12
n 50
N 2 = 1 N1 = (12) = 50 teeth
n2 12
D
C = D2 + 1
2
PN1 (1.0 )(12 )
D1 = = 3.82 in
D2
PN1
=
(1.0)(50) = 15.92 in
3.82
C 15.92 + = 17.83 in
2
use C = 18 in
C = 18 pitches
chain pitch = 1.0 in, Chain No. 80
N1 + N 2 ( N 2 N1 )
2
(b) L 2C + +
2 40C
12 + 59 (50 12)
2
L 2(18) + + = 69 pitches
2 40(18)
use L = 70 pitches
Page 35 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
J = 0.125 in
PN ts n1 (1)(12 )(50 )
vm = = = 50 fpm
12 12
3
A = C (E + 2 J ) = 0.141 + 2(0.05) = 0.04054 in 2
16
FV
= 60 hp
33,000
33,000(2 )
F= = 1320 lb
50
F 1320
pb = = = 4835 psi
C (E + 2 J ) 5
0.312 + 2(0.125)
8
Solution:
Table 17.7
N sf = 1.2
design hp = 1.2(5) = 6 hp
D2 500
= =2
D1 250
D
C = D2 + 1
2
D
16 = 2 D1 + 1
2
D1 = 6.4 in
D2 = 2 D1 = 2(6.4) = 12.8 in
D n (6.4)(500)
vm = 1 1 = = 838 fpm
12 12
Page 36 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
1.08
20.11
(500 ) P
0.9 3 0.07 P
hp = 0.004
P
6 = 27.47 P1.920.07 P
P = 0.45 in
1
use P = in , Chain No. 40
2
D1 (6.4)
N1 = = 40
P 1
2
N 2 = 2 N1 = 80
1
Size of sprocket, N1 = 40 , N 2 = 80 , P = in .
2
(b) C = 16 in
16 in
C= = 32 pitches
1
in
2
N1 + N 2 ( N 2 N1 )
2
L 2C + +
2 40C
40 + 80 (80 40)
2
L 2(32) + + = 125.25 pitches
2 40(32)
use L = 126 pitches
864. A roller chain is to transmit 20 hp from a split-phase motor, turning 570 rpm, to a
reciprocating pump, turning at 200 rpm; 24 hr./day service. (a) Decide upon the
tooth numbers for the sprockets, the pitch and width of chain, and center
distance. Consider both single and multiple strands. Compute (b) the chain
length, (c) the bearing pressure between the roller and pin, (d) the factor of safety
against fatigue failure (Table 17.8), with the chain pull as the force on the chain.
(e) If a catalog is available, design also an inverted-tooth chain drive.
Solution:
Table 17.7
N sf = 1.4 + 0.2 (24 hr/day)
design hp = 1.6(20) = 32 hp
n 570
(a) 1 = = 2.85
n2 200
Page 37 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
D2 n1
= 2.85
D1 n2
Considering single strand
hp = 0.004 N ts1.08 n 0.9 P 30.07 P
min N ts = 17
hp = 32 = 0.004(17 ) (570)0.9 P 30.07 P
1.08
P 3 0.07 P = 1.24
P = 1.07 in
use P = 1.0 in
3 0.07 (1)
hp = 32 = 0.004( N1 ) (570 ) (1)
1.08 0.9
N1 = 21
570
N2 = (21) = 60
200
5
Roller width = in
8
D
C = D2 + 1
2
PN1 (1)(21)
D1 = = 6.685 in
D2
PN 2
=
(1)(60) = 19.10 in
6.685
C = 19.10 + = 22.44 in
2
Use C = 23 in
23
C= pitches
1
Considering multiple strands
1
Assume, P = in
2
1.08 0.9 3 0.07 P
hp = 0.004 N ts n P
hp = 0.004(21)
1.08
(570)0.9 (0.5)30.07 (0.5) = 4.148 hp
32 hp
No. of strands = = 7 .7
4.148 hp
Use 8 strands
Page 38 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
21 + 60 (60 21)
2
L 2(23) + + = 88.15 pitches
2 40(23)
use L = 88 pitches
Fu
(d) Factor of Safety = , based on fatigue
4F
865. A 5/8-in. roller chain is used on a hoist to lift a 500-lb. load through 14 ft. in 24
sec. at constant velocity. If the load on the chain is doubled during the speed-up
period, compute the factor of safety (a) based on the chains ultimate strength, (b)
based on its fatigue strength. (c) At the given speed, what is the chains rated
capacity ( N s = 20 teeth ) in hp? Compare with the power needed at the constant
speed. Does it look as though the drive will have a long life?
Solution:
Table 17.8
5
P = in
8
Fu = 6100 lb
Page 39 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
Fu
(a) Factor of Safety =
F
F = (500)(2 ) = 1000 lb
6100
Factor of Safety = = 6 .1
1000
F
(b) Factor of Safety = u (fatigue)
4F
6100
Factor of Safety = = 1.5
4(1000)
14 ft 60 sec
(c) vm = = 35 fpm
24 sec 1 min
N s = 20
5
P = in
8
Rated hp = 0.004 N ts1.08 n 0.9 P 30.07 P [Link Plate Fatigue]
5
(20)n
PN s n 8
vm = = = 35 fpm
12 12
n = 33.6 rpm
5
3 0.07
0.9 5 8
Rated hp = 0.004(20) (33.6 )
1.08
= 0.6 hp
8
Hp needed at constant speed
hp =
Fvm
=
(500)(35) = 0.53 hp < 0.6 hp
33,000 33,000
Therefore safe for long life.
WIRE ROPES
866. In a coal-mine hoist, the weight of the cage and load is 20 kips; the shaft is 400
ft. deep. The cage is accelerated from rest to 1600 fpm in 6 sec. A single 6 x 19,
IPS, 1 -in. rope is used, wound on an 8-ft. drum. (a) Include the inertia force
but take the static view and compute the factor of safety with and without
allowances for the bending load. (b) If N = 1.35 , based on fatigue, what is the
expected life? (c) Let the cage be at the bottom of the shaft and ignore the effect
of the ropes weight. A load of 14 kips is gradually applied on the 6-kip cage.
How much is the deflection of the cable due to the load and the additional energy
absorbed? (d) For educational purposes and for a load of 0.2 Fu , compute the
energy that this 400-ft rope can absorb and compare it with that for a 400-ft., 1
-in., as-rolled-1045 steel rod. Omit the weights of the rope and rod. What is the
energy per pound of material in each case?
Page 40 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
Solution:
(a)
1 min
(1600 fpm )
v2 v1 60 sec = 4.445 fps 2
a= =
t 6 sec
Wh = 20 kips
For 6 x 19 IPS,
w 1.6 Dr2 lb ft
400
wL = 1.6 Dr2 2
kips = 0.64 Dr kips
1000
Ft wL Wh = ma
20 + 0.64 Dr2
m=
32.2
20 + 0.64 Dr2
Ft 0.64 Dr2 20 = (4.445)
32.2
2
Ft = 22.76 + 0.73Dr
3
Dr = 1 in
4
2
3
Ft = 22.76 + 0.731 = 25 kips
4
F Fb
N= u
Ft
Table AT 28, IPS
Fu 42 Dr2 tons
Fu = 42(1.75) = 129 tons = 258 kips
2
Page 41 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
EAm Dw
Fb =
Ds
Table At 28, 6 x 19 Wire Rope
Dw = 0.067 Dr = 0.067(1.75) = 0.11725 in
Ds = 8 ft = 96 in
E = 30,000 ksi
Am 0.4 Dr2
Am = 0.4(1.75) = 1.225 sq in
2
Fb =
(30,000)(1.225)(0.11725) = 45 kips
(96)
F Fb 258 45
N= u = = 8.52
Ft 25
without bending load
F 258
N= u = = 10.32
Ft 25
FL
(c) =
Am Er
Am = 1.225 sq in
Er 12,000 ksi (6 x 19 IPS)
F = 14 kips
L = 400 ft = 4800 in
=
(14)(4800) = 4.57 in
(1.225)(12,000)
1 1
U = F = (14 )(4.57 ) = 32 in kips
2 2
Page 42 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
FL
=
Am Er
=
(51.6)(4800) = 16.85 in
(1.225)(12,000)
1 1
U = F = (51.6 )(16.85) = 434 in kips
2 2
For 1 in, as-rolled 1045 steel rod
su = 96 ksi
Fu = su A = (96 ) (1.75) = 230.9 kips
2
4
F = 0.2 Fu = 0.2(230.9) = 46.2 kips
FL
=
AE
=
(46.2)(4800 ) = 3.073 in
(1.75) (30,000 )
2
4
1 1
U = F = (46.2 )(3.073) = 71 in kips < U of wire rope.
2 2
868. A hoist in a copper mine lifts ore a maximum of 2000 ft. The weight of car, cage,
and ore per trip is 10 kips, accelerated in 6 sec. to 2000 fpm; drum diameter is 6
ft. Use a 6 x 19 plow-steel rope. Determine the size (a) for a life of 200,000
cycles and N = 1.3 on the basis of fatigue, (b) for N = 5 by equation (v), 17.25,
Text. (c) What is the expected life of the rope found in (b) for N = 1.3 on the
basis of fatigue? (d) If a loaded car weighing 7 kips can be moved gradually onto
the freely hanging cage, how much would the rope stretch? (e) What total energy
is stored in the rope with full load at the bottom of te shaft? Neglect the ropes
weight for this calculation. (f) Compute the pressure of the rope on the cast-iron
drum. Is it reasonable?
Solution:
1 min
(2000 fpm )
a=
v2 v1
= 60 sec = 5.56 fps 2
t 6 sec
Page 43 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
For 6 x 19 IPS,
w 1.6 Dr2 lb ft
2000
wL = 1.6 Dr2 2
kips = 3.2 Dr kips
1000
Wh = 10 kips
wL + Wh
Ft wL Wh = a
32.2
a 5.56
Ft = + 1(wL + Wh ) = ( ) (
+ 1 3.2 Dr2 + 10 = 1.17267 3.2 Dr2 + 10 )
32 . 2 32 . 2
2 NFt
(a) Dr Ds =
( p su )su
Fig. 17.30, 200,000 cycles, 6 x 19
p su = 0.0028
PS: su 225 ksi
Ds = 6 ft = 72 in
N = 1 .3
Dr (72) =
(
2(1.3)(1.17267 ) 3.2 Dr2 + 10 )
(0.0028)(225)
45.36 Dr = 9.7566 Dr2 + 30.49
Dr2 4.64916 Dr + 3.1251 = 0
Dr = 0.815 in
7
say Dr = in
8
sb =
(30,000)(0.067 Dr ) = 27.92 D
r
72
Fb = sb Am
Am = 0.4 Dr2
Fb = (27.92 Dr )(0.4 Dr2 ) = 11.17 Dr3
Fu = 36 Dr2 tons for PS
Fu = 72 Dr2 kips
Fu Fb = NFt
Page 44 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
(d) F = 7 kips
Er = 12,000 ksi
L = 2000 ft = 24,000 in
7
For (a) Dr = in
8
FL
=
Am Er
2
7
Am 0.4 Dr3 = 0.4 = 0.30625 sq in
8
=
(7 )(24,000) = 45.7 in
(0.30625)(12,000)
1
For (b) Dr = 1 in
4
FL
=
Am Er
2
3 1
Am 0.4 D = 0.41 = 0.625 sq in
r
4
=
(7 )(24,000) = 22.4 in
(0.625)(12,000)
1 1
(e) For (a) U = F = (7 )(45.7 ) = 160 in kips
2 2
1 1
For (b) U = F = (7 )(22.4 ) = 78.4 in kips
2 2
(f) Limiting pressure, cast-iron sheaves, 6 x19, p = 500 psi .
Page 45 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
869. For a mine hoist, the cage weighs 5900 lb., the cars 2100 lb., and the load of coal
in the car 2800 lb.; one car loaded loaded at a time on the hoist. The drum
diameter is 5 ft., the maximum depth is 1500 ft. It takes 6 sec. to accelerate the
loaded cage to 3285 fpm. Decide on a grade of wire and the kind and size of rope
on the basis of (a) a life of 2 105 cycles and N = 1.3 against fatigue failure, (b)
static consideration (but not omitting inertia effect) and N = 5 . (c) Make a final
recommendation. (d) If the loaded car can be moved gradually onto the freely
hanging cage, how much would the rope stretch? (e) What total energy has the
rope absorbed, fully loaded at the bottom of the shaft? Neglect the ropes weight
for this calculation. (f) Compute the pressure of the rope on the cast-iron drum. Is
it all right?
Solution:
Page 46 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
2 NFt
Dr Ds =
( p su )su
Ds = 5 ft = 60 in
Ds 45 Dr
60
Dr max = = 1.33 in
45
1
use Dr = 1 in
4
2
1
Ft = 3.081 + 13.86 = 18.67 kips
4
2(1.3)(18.67 )
su = = 231 ksi
1
(0.0028)1 (60 )
4
1
Use Plow Steel, 6 x 19 Wire Rope, Dr = 1 in .
4
Fu Fb
(b) N =
Ft
EDw
sb =
Ds
1
Dw = 0.067 Dr = 0.0671 = 0.08375 in
4
Ds = 60 in
E = 30,000 ksi
sb =
(30,000)(0.08375) = 41.875 ksi
60
2
1
Am = 0.4 D = 0.41 = 0.625 in 2
2
r
4
Fb = sb Am = (41.875)(0.625) = 26.17 kips
N =5
Fu = NFt + Fb = (5)(18.67 ) + 26.17 = 119.52 kips = 59.76 tons
Fu 59.76
= = 38.25
Dr 1 2
2
1
4
Table AT 28,
Fu
Use IPS, 6 x 19, = 42 > 38.25
Dr2
Page 47 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
(c) Recommendation:
1
6 x 19, improved plow steel, Dr = 1 in
4
FL
(d) =
Am Er
F = 2100 + 2800 = 4900 lb
Er 12 106 psi
L = 1500 ft = 18,000 in
=
(4900)(18,000) = 11.76 in
(0.625)(12 106 )
1 1
(e) U = F = (4900 )(11.76 ) = 28,800 in lb
2 2
(f) p su = 0.0028
su = 231 ksi
p = 0.0028(231,000) = 646.8 psi
For cast-iron sheave, limiting pressure is 500 psi
p = 646.8 psi > 500 psi , not al right.
870. The wire rope of a hoist with a short lift handles a total maximum load of 14 kips
each trip. It is estimated that the maximum number of trips per week will be
1000. The rope is 6 x 37, IPS, 1 3/8 in. in diameter, with steel core. (a) On the
basis of N = 1 for fatigue, what size drum should be used for a 6-yr. life? (n)
Because of space limitations, the actual size used was a 2.5-ft. drum. What is the
factor of safety on a static basis? What life can be expected ( N = 1 )?
Solution:
(a)
365 days 1 wk 1000 trips
No. of cycles = (6 yr ) = 312,857 cycles 3 105 cycles
1 yr 7 days 1 wk
Figure 17.30, 6 x 37, IPS
p su = 0.00225
2 NFt
Dr Ds =
( p su )su
For IPS, su 260 ksi
Ft = 14 kips
N = 1 .0
Dr = 1.375 in
2 NFt
Dr Ds =
( p su )su
Page 48 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
2(1.0)(14)
(1.375)Ds =
(0.00225)(260)
Ds = 34.8 in
(b) Ds = 2 ft = 30 in
Static Basis
F Fb
N= u
Ft
Table AT 28, 6 x 37
Dw 0.048Dr = 0.048(1.375) = 0.066 in
Am 0.4 Dr2 = 0.4(1.375) = 0.75625 in 2
2
871. A wire rope passes about a driving sheave making an angle of contact of 540o, as
shown. A counterweight of 3220 lb. is suspended from one side and the
acceleration is 4 fps2. (a) If f = 0.1 , what load may be noised without slipping on
the rope? (b) If the sheave is rubber lined and the rope is dry, what load may be
raised without slipping? (c) Neglecting the stress caused by bending about the
sheave, find the size of 6 x 19 MPS rope required for N = 6 and for the load
found in (a). (d) Compute the diameter of the sheave for indefinite life with say
N = 1.1 on fatigue. What changes could be made in the solution to allow the use
of a smaller sheave?
Page 49 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
(c) Ft = F1 = 7237 lb
F (Fb 0 ) Fu
N= u =
Ft Ft
Fu 32 Dr2 tons for MPS
Fu 64 Dr2 kips
Fu = 64,000 Dr2 lb
Fu = NFt
64,000 Dr2 = (6)(7237 )
Dr = 0.824 in
use Dr = 0.875 in
Page 50 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
2 NFt
(d) Dr Ds =
( p su )su
Indefinite life, p su = 0.0015
MPS: su 195 ksi = 195,000 psi
(0.875)Ds = 2(1.1)(7237 )
(0.0015)(195,000)
Ds = 62.2 in
To reduce the size of sheave, increase the size of rope.
872. A traction elevator with a total weight of 8 kips has an acceleration of 3 fps2; the
6 cables pass over the upper sheave twice, the lower one once, as shown..
Compute the minimum weight of counterweight to prevent slipping on the
driving sheave if it is (a) iron with a greasy rope, (b) iron with a dry rope, (c)
rubber lined with a greasy rope. (d) Using MPS and the combination in (a),
decide upon a rope and sheave size that will have indefinite life ( N = 1 will do).
(e) Compute the factor of safety defined in the Text. (f) If it were decided that
5 105 bending cycles would be enough life, would there be a significant
difference in the results?
Solution:
3 fps 2
F1 = (8 kips )1 + = 8.745 kips
2
32.2 fps
= 3(180o ) = 3
F
F2 = f1
e
Wc = weight of counterweight
F2
Wc = = 1.10274 F2
3
1
32.2
1.10274 F1
Wc =
e f
(a) Iron sheave, greasy rope, f = 0.07
1.10274(8.745)
Wc = = 4.986 kips
e (0.07 )(3 )
(b) Iron sheave, dry rope, f = 0.12
1.10274(8.745)
Wc = = 3.112 kips
e (0.12 )(3 )
(c) Rubber lined with a greasy rope, f = 0.205
1.10274(8.745)
Wc = = 1.397 kips
e (0.205 )(3 )
Page 51 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
2 NFt
(d) Dr Ds =
( p su )su
Indefinite life, p su = 0.0015
Ft = F1 = 8.745 kips total
8.745
Ft = = 1.458 kips each rope
6
Ft = 1458 lbs
N =1
Table AT 28, 6 x 19
Ds 45 Dr
2(1)(1458)
Dr (45Dr ) =
(0.0015)(195,000)
Dr = 0.47 in
1
Use Dr = in = 0.5 in
2
Fu Fb
(e) N =
Ft
Table AT 28, MPS
Fu = 32 Dr2 tons = 64,000 Dr2 lb = 64,000(0.5) lb = 16,000 lb
2
EDw Am
Fb =
Ds
E = 30 106 psi
6 x 19, Dw = 0.067 Dr
Ds 45 Dr
Am = 0.4 Dr2 = 0.4(0.5) = 0.1 sq. in.
2
Fb =
(30 10 )(0.067 )(0.1) = 4467 lb
6
45
16,000 4467
N= = 7.91
1458
Page 52 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
2(1)(1458)
Dr (45Dr ) =
(0.0017)(195,000)
Dr = 0.44 in
since Dr = 0.44 in 0.47 in as in (d), therefore, no significant difference will result.
873. A 5000-lb. elevator with a traction drive is supported by a 6 wire ropes, each
passing over the driving sheave twice, the idler once, as shown. Maximum values
are 4500-lb load, 4 fps2 acceleration during stopping. The brake is applied to a
drum on the motor shaft, so that the entire decelerating force comes on the
cables, whose maximum length will be 120 ft. (a) Using the desirable Ds in
terms of Dr , decide on the diameter and type of wire rope. (b) For this rope and
N = 1.05 , compute the sheave diameter that would be needed for indefinite life.
(c) Compute the factor of safety defined in the Text for the result in (b). (d)
Determine the minimum counterweight to prevent slipping with a dry rope on an
iron sheave. (e) Compute the probable life of the rope on the sheave found in (a)
and recommend a final choice.
Solution:
(a)
Ft = 4500 lb
Wh = 5000 lb
W + wL
Wh + wL Ft = h a
32.2
assume 6 x 19
w = 1.6 Dr2 lb ft
wL = (1.6 Dr2 )(120) = 192 Dr2 per rope
wL = 6(192 Dr2 ) = 1152 Dr2
5000 + 1152 Dr2
5000 + 1152 D 4500 =
2
r
(4)
32 .2
2 2
1152 Dr + 500 = 621.12 + 143.11Dr
Dr = 0.3465 in
3
say Dr = 0.375 in = in
8
Page 53 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
3 7
Ds 45 Dr = 45 = 16 in
8 8
3
Six 6 x 19 rope, Dr = in
8
3
(a) Dr = 0.375 in = in
8
4500
Ft = = 750 lb
6
N = 1.05
2 NFt
Dr Ds =
( p su )su
assume IPS, su = 260 ksi = 260,000 psi
Indefinite life, p su = 0.0015
(0.375)Ds = 2(1.05)(750)
(0.0015)(260,000)
Ds = 10.77 in
Fu Fb
(c) N =
Ft
Ft = 750 lb
IPS
2
2 2 3
Fu 42 D tons = 84,000 D lb = 84,000 lb = 11,813 lb
r r
8
EDw Am
Fb =
Ds
6 x 19,
Ds = 10.77 in as in (b)
3
Dw = 0.067 Dr = 0.067 = 0.025 in
8
2
23
Am = 0.4 D = 0.4 = 0.05625 sq. in.
r
8
6
E = 30 10 psi
Fb =
(30 10 )(0.025)(0.05625) = 3917 lb
6
10.77
Page 54 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
11,813 3917
N= = 10.53
750
(c) F1 = Ft = 4500 lb
F1 = F2 e f
For iron sheave, dry rope, f = 0.12
= 540o = 3
F1 4500
F2 = f
= (0.12 )(3 ) = 1452 lb
e e
a
CW 1 + = F2
32.2
4
CW 1 + = 1452
32.2
CW = 1291 lb
874. A traction elevator has a maximum deceleration of 5 fps2 when being braked on
the downward motion with a total load of 10 kips. There are 5 cables that pass
twice over the driving sheave. The counterweight weighs 8 kips. (a) Compute the
minimum coefficient of friction needed between ropes and sheaves for no
slipping. Is a special sheave surface needed? (b) What size 6 x 19 mild-plow-
steel rope should be used for N = 4 , including the bending effect? (Static
approach.) (c) What is the estimated life of these ropes ( N = 1 )?
Solution:
a = 8.05 fps 2
(a) F1 = 10 kips
8.05
F2 = (8 kips )1 = 6 kips
32.2
= 3
F1
= e f
F2
Page 55 of 56
SECTION 15 FLEXIBLE POWER-TRANSMITTING ELEMENTS
10
= e f (3 )
6
f = 0.0542
Fb =
(30 10 )(0.067 D )(0.4 D ) = 17.87 D
6
r
2
r 2
kips
r
45Dr
Fu 32 Dr2 tons = 64 Dr2 kips
64 Dr2 17.87 Dr2
N =4=
2
Dr = 0.4164 in
7
use Dr = in
16
7
(c) Ds 45 Dr = 45 = 20 in
16
2 NFt
Dr Ds =
( p su )su
Ft = 2 kips each rope
MPS, su = 195 ksi
N = 1 .0
7 2(1.0)(2)
(20) =
16 ( p su )(195)
p su = 0.0023
Expected life, Figure 17.30, 3 x 105 bending cycles.
- end -
Page 56 of 56
SECTION 16 BRAKES AND CLUTCHES
ENERGY TO BRAKES
881. A motor operates a hoist through a pair of spur gears, with a velocity ratio of 4.
The drum on which the cable wraps is on the same shaft as the gear, and the
torque cause by the weight of the load and hoist is 12,000 ft-lb. The pinion is on
the motor shaft. Consider first on which shaft to mount the brake drum; in the
process make trial calculations, and try to think of pros and cons. Make a
decision and determine the size of a drum that will not have a temperature rise
greater than t = 150o F when a 4000-lb. load moves down 200 ft. at a constant
speed. Include a calculation for the frp/sq. in. of the drums surface.
Solution:
Consider that brake drum is mounted on motor shaft that has lesser torque.
12,000 ft lb
T f= = 3000 ft lb = 36,000 in lb
4
From Table AT 29,
Assume f = 0.35 , p = 75 psi , max. vm = 5000 fpm
FD
Tf =
2
2T f
F = fN =
D
2T f
N=
fD
N
p=
A
A = Db
N 2T f 2(36,000 )
p= = = = 75
Db D bf D 2b(0.35)
2
D 2b = 873
use D 2b = 873
873
b= 2
D
Then,
U ft lb
t o F = f
Wm c
Assume a cast-iron,
= 0.253 lb in3
c = 101
Wm = V
Page 1 of 97
SECTION 16 BRAKES AND CLUTCHES
D2
V = Dbt + D 2t = t Db +
4 4
U f = (4000 )(200 ) = 800,000 ft lb
t = 150o F
Uf
Wm = V =
ct
800,000
0.253V =
(150)(101)
V = 208.7 in 3
But
D2
V = t Db +
4
873
b= 2
D
873 D 2
V = t +
D 4
For minimum V :
dV 873 D
= t 2 + = 0
dD D 2
D = 2(873)
3
D = 12 in
For t :
873 (12 )2
V = 208.7 = t +
12 4
t = 0.611 in
5
say t = in
8
873 1
b= = 6.0625 in = 6 in
(12 )2
16
5 1
Therefore use D = 12 in , t = in , b = 6 in
8 16
fhp
For fhp sq. in. =
A
Fvm
fhp =
33,000
Page 2 of 97
SECTION 16 BRAKES AND CLUTCHES
2T f 2(36,000)
F= = = 6000 lb
D 12
vm = 5000 fpm (max.)
fhp =
(6000)(5000) = 909 hp
33,000
1
A = Db = (12 ) 6 in 2
16
fhp 909
fhp sq. in. = = = 3.98 (peak value)
A 228.55
Solution:
(a) Solving for the total braking torque.
W 2
U f = KE =
2g 1
(
vs vs22 )
W = 3500 lb
vs1 = 60 mph = 88 fps
vs2 = 0 mph = 0 fps
g = 32.2 fps 2
3500
Uf =
2(32.2)
(882 02 ) = 421,000 ft lb
fhp = f
(T ft lb )m = (T f in lb )n
33,000 63,000
2 2
vs vs1 0 (88) 2
a= 2 = = 14.892 fps 2
2s 2(260)
vs vs1 0 88
t= 2 = = 5.91 sec
a 14.892
KE U 421,000
fhp = = f = = 130 hp
(t )(550) 550t 550(5.91)
Page 3 of 97
SECTION 16 BRAKES AND CLUTCHES
1
vm
(88 fps )(60 sec min )
n= = 2 = 336 rpm
D 30
ft
12
T n
fhp = f
63,000
63,000(130 )
Tf = = 24,375 in lb
336
F
(b) f =
N
3500
for each wheel, N = = 875 lb
4
24,375
Tf = = 6094 in lb
4
2T 2(6094)
F= f = = 406 in lb
D 30
F 406
f = = = 0.464
N 875
Uf
(c) t =
Wm c
U f = 421,000 ft lb
Wm = 50 lb
c = 101 ft lb lb F for cast-iron
421,000
t = = 83.4o F
(50)(101)
884. An overhead traveling crane weighs 160,000 lb. with its load and runs 253 fpm.
It is driven by a 25-hp motor operating at 1750 rpm.The speed reduction from the
motor to the 18-in. wheels is 32 to 1. Frictional energy other than at the brake is
negligible. (a) How much energy must be absorbed by the brake to stop this crane
in a distance of 18 ft.? (b) Determine the constant average braking torque that
must be exerted on the motor shaft. (c) If all the energy is absorbed by the rim of
the cast-iron brake drum, which is 8 in. in diameter, 1 in. thick, with a 3 -in.
face, what will be its temperature rise? (d) Compute the average rate at which the
energy is absorbed during the first second (fhp). Is it reasonable?
Solution:
Page 4 of 97
SECTION 16 BRAKES AND CLUTCHES
W 2
U f = KE =
2g
(vs1 vs22 )
W = 160,000 lb
g = 32.2 fps 2
vs1 = 253 fpm = 4.22 fps
vs2 = 0 fps
Uf =
160,000
2(32.2)
[ ]
(4.22)2 02 = 44,245 ft lb
fhp (63,000 )
(b) T f =
n
2 2
vs vs1 0 (4.22)2
a= 2 = = 0.495 fps 2
2s 2(18)
vs vs1 0 4.22
t= 2 = = 8.53 sec
a 0.495
U 44,245
fhp = f = = 9.43 hp
550t 550(8.53)
fhp (63,000 ) (9.43)(63,000 )
Tf = = = 68 in lb on the motor shaft.
n 1
(1750)
2
Uf
(c) t =
Wm c
V = Dbt (rim only) on the motor shaft
D = 8 in
b = 3.25 in
t = 0.5 in
V = (8)(3.25)(0.5) = 40.84 in 3
Wm = V
= 0.253 lb in3 for cast iron
c = 101 ft lb lb F for cast-iron
Wm = (0.253)(40.84) = 10.33 lb
44,245
t = = 42.4o F
(10.33)(101)
Page 5 of 97
SECTION 16 BRAKES AND CLUTCHES
U f = KE =
160,000
2(32.2)
[ ]
(4.22)2 (3.73)2 = 9680 ft lb
Uf 9680
fhp = = = 17.6 hp < 25 hp , therefore reasonable.
550t 550(1)
885. The diagrammatic hoist shown with its load weighs 6000 lb. The drum weighs
8000 lb., has a radius of gyration k = 1.8 ft ; D = 4 ft . A brake on the drum shaft
brings the hoist to rest in 10 ft. from vs = 8 fps (down). Only the brake frictional
energy is significant, and it can be reasonably assumed that the acceleration is
constant. (a) From the frictional energy, compute the average braking torque. (b)
If the average fhp/sq. in. is limited to 0.15 during the first second, what brake
contact area is needed?
Solution:
63,000 fhp
Tf =
n
I1 2 W
U f = KE1 KE2 =
2
( (
1 22 ) + 2 vs21 vs21
2g
)
vs1 = 8 fps , vs2 = 0 fps
2vs1 2(8)
1 = = = 4 rad s , 2 = 0 rad s
D 4
W k2
I1 = 1
g
W1 = 8000 lb
k = 1.8 ft
W2 = 6000 lb
Page 6 of 97
SECTION 16 BRAKES AND CLUTCHES
g = 32.2 fps 2
80000(1.8)
2
Uf =
I1 2
( W
( )
1 22 ) + 2 vs21 vs21 = (4)2 + 60000 (8)2 = 12,400 ft lb
2 2g 2(32.2) 2(32.2)
2 2
vs2 vs1
a=
2s
s = 10 ft
0 2 82
a= = 3.2 fps 2
2(10 )
vs vs1 0 8
t= 2 = = 2.5 sec
a 3.2
U 12,400
fhp = f = = 9 hp
550t 550(2.5)
60
n= rpm
2
1
= (4 rad s 0) = 2 rad s 0
2
60(2 )
n= = 19.1 rpm
2
63,000 fhp 63,000(9 )
Tf = = = 29,700 in lb
n 19.1
887. The same as 885, except that a traction drive, arranged as shown, is used; the
counterweight weighs 4000 lb. The ropes pass twice about the driving sheave; the
brake drum is on this same shaft.
Page 7 of 97
SECTION 16 BRAKES AND CLUTCHES
Problem 887.
Solution:
WT 2
(a) U f = KE = (
2g 1
)
vs vs22
Page 8 of 97
SECTION 16 BRAKES AND CLUTCHES
Uf =
10,000
2(32.2)
[ ]
(8)2 (4.8)2 = 6360 ft lb
U 6360
fhp = f = = 11.56 hp
550t 550(1)
fhp 11.56
Contact area = A = = = 77.1 in 2
fhp sq.in. 0.15
SINGLE-SHOE BRAKES
888. For the single-shoe, short-block brake shown (solid lines) derive the expressions
for brake torque for (a) clockwise rotation, (b) counterclockwise rotation. (c) In
which direction of rotation does the brake have self-actuating properties? If
f = 0.25 , for what proportions of e and c would the brake be self-actuating?
Page 9 of 97
SECTION 16 BRAKES AND CLUTCHES
FD
Tf =
2
F = fN
[ M H =0 ]
fN e + Wa = N c
N c fN e = Wa
Wa
N=
c fe
fWa
F=
c fe
fWaD
Tf =
2(c fe )
FD
Tf =
2
F = fN
[ M H =0 ]
Page 10 of 97
SECTION 16 BRAKES AND CLUTCHES
Wa = fN e + N c
Wa
N=
c + fe
fWa
F=
c + fe
fWaD
Tf =
2(c + fe )
889. The same as 888, except that the wheel and brake shoe are grooved, 2 degrees
between the sides of the grooves (as in a sheave, Fig. 17.38, Text).
Solution:
[ F V =0 ]
2 N1 sin = N
F = 2 f N1
Page 11 of 97
SECTION 16 BRAKES AND CLUTCHES
N fN
F =2f =
2 sin sin
Wa
N=
c + fe
fWa
F=
(c + fe)sin
fWaD
Tf =
2(c + fe ) sin
c > fe
with f = 0.25
c > 0.25e
890. Consider the single-shoe, short-block brake shown (solid lines) with the drum
rotating clockwise; let e be positive measured downward and D = 1.6c . (a) Plot
the mechanical advantage MA (ordinate) against f values of 0.1, 0.2, 0.3, 0.4,
0.5 (abscissa) when e c has values 2, 0.5, 0, -0.5, -1. (b) If f may vary from 0.3
to 0.4, which proportions give the more nearly constant brake response? Are
proportions good? (c) What proportions are best if braking is needed for both
directions of rotation?
Solution:
Page 12 of 97
SECTION 16 BRAKES AND CLUTCHES
Tf
(a) MA = , Clockwise rotation
Wa
fD
MA =
2(c fe )
D = 1 .6 c
1.6 fc
MA =
2(c fe )
0 .8 f
MA =
fe
1
c
Tabulation:
Values of MA
ec
f 2 0.5 0 -0.5 -1
0.1 0.100 0.084 0.08 0.076 0.073
0.2 0.267 0.178 0.16 0.145 0.133
0.3 0.600 0.284 0.24 0.209 0.185
0.4 1.600 0.400 0.32 0.267 0.229
0.5 0.533 0.40 0.320 0.267
Page 13 of 97
SECTION 16 BRAKES AND CLUTCHES
Plot:
fe
They are good because 1 > except e c = 2 .
c
(c) e c = 0 is the best if braking is needed for both directions of rotation with MA the
same.
Solution:
Page 14 of 97
SECTION 16 BRAKES AND CLUTCHES
D = 15 in
a = 32.5 in
c = 9.375 in
e = 4.6875 in
b = 2 in
Page 15 of 97
SECTION 16 BRAKES AND CLUTCHES
Db (1.3963)(15)(2)
A= = = 21 sq. in.
2 2
F (785)
= 13,200
21
F = 353 lb
FD (353)(15)
Tf = = = 2650 in lb
2 2
f Wa
F=
c fe
F = 353 lb
f = 0.35
a = 32.5 in
e = 4.6875 in
c = 9.375 in
F (c fe ) (353)[9.375 (0.35)(4.6875)]
W= = = 240 lb
fa (0.35)(32.5)
(c) Solving for MA
MA =
fD
=
(0.35)(15) = 0.34
2(c fe ) 2[9.375 (0.35)(4.6875)]
U f , ft lb
t o F =
Wm c
Wm = Dbt
D = 15 in
b = 2 in
3
t = in = 0.375 in
8
= 0.253 lb in3 for cast iron
Page 16 of 97
SECTION 16 BRAKES AND CLUTCHES
U f = 550t ( fhp )
t = 1 min = 60 sec
U f = 550(60 )( fhp ) = 33,000 fhp
fhp =
Tf n
=
(2650)(200) = 8.4127 hp
63,000 63,000
U f = 33,000(8.4127 ) = 277,619 ft lb
Uf 277,619
t = = = 310o F
Wm c (8.942)(101)
Page 17 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M A =0]
aW + efN = cN
Wa
N=
c ef
f Wa
F=
c ef
From Table AT 29, f = 0.35 for molded asbestos
W = 300 lb
a = 26 in
c = 7.5 in
e = 3.75
F=
(0.35)(300)(26) = 442 lb
7.5 (3.75)(0.35)
Page 18 of 97
SECTION 16 BRAKES AND CLUTCHES
fhp =
Tf n
=
(3315)(600) = 31.6 hp
63,000 63,000
2
A = 27.5 in
31.6 hp
fhp in 2 = = 1.15 hp in 2
27.5 in 2
T 3315
(c) MA = f = = 0.425
Wa (300)(26)
U , ft lb
(d) t o F = f
Wm c
Wm = Dbt
3
t = in = 0.375 in
8
D = 15 in
b = 3.5 in
= 0.253 lb in3 for cast iron
c = 101 ft lb lb F for cast iron
For 1 min
Page 19 of 97
SECTION 16 BRAKES AND CLUTCHES
LONG-SHOE BRAKES
FIXED SHOES
893. The brake is as described in 891 and is to absorb energy at the same rate but the
pressure varies as p = P sin . Derive the equations needed and compute (a) the
maximum pressure, (b) the moment M F H of F about H , (c) the moment M N H
of N about H , (d) the force W , (e) the braking torque, (f) the x and y
components of the force at H .
Solution:
p = P sin = P sin
D
r=
2
dN = pbrd
dF = fpbrd
Page 20 of 97
SECTION 16 BRAKES AND CLUTCHES
T f = rdF
T f = fpbr 2 d
T f = fbr 2 P sin d
T f = fbr 2 P(cos 1 cos 2 )
D
r=
2
c
tan =
r e
c = 9.375 in
15
r = = 7.5 in
2
e = 4.6875 in
9.375
tan =
7.5 4.6875
= 73.3o
= 80o
80
1 = = 73.3 = 33.3o
2 2
80
2 = + = 73.3 + = 113.3o
2 2
f = 0.35
b = 2 in
r = 7.5 in
Tf
P=
fbr 2 (cos 1 cos 2 )
Tf Tf
P= = psi
(0.35)(2)(7.5)2 (cos 33.3 cos113.3) 48.5
63,000 fhp
Tf =
n
( )
fhp = fhp in 2 ( A)
Db
A=
2
= 80 = 1.396 rad
180
Page 21 of 97
SECTION 16 BRAKES AND CLUTCHES
A=
(1.396)(15)(2) = 21 in 2
2
fhp in 2 = 0.4
fhp = (0.4)(21) = 8.4 hp
n = 200 rpm
63,000(8.4 )
Tf = = 2646 in lb
200
T 2646
P= f = = 55 psi = max .P (2 > 90o )
48.5 48.5
(c) M N H = R sin dN
2
MN H = RP sin 2 brd
1
2
MN H = brRP sin 2 d
1
brRP 2
MN H =
2 1
(
1 cos 2 d )
brRP 1
2
MN = sin 2
2
H
2 1
brRP
MN H = [2(2 1 ) (sin 22 sin 21 )]
4
2 1 = = 1.396 rad
22 = 2(113.3) = 226.6o
21 = 2(33.3) = 66.6o
Page 22 of 97
SECTION 16 BRAKES AND CLUTCHES
MN =
(2)(7.5)(9.788)(55) [2(1.396) (sin 226.6 sin 66.6)]
H
4
MN H = 8956 in lb
(d) M H =0
Wa + M F H M N H =0
a = 32.5 in
W (32.5) + 1900 8956 = 0
W = 217 lb
(e) T f = 2646 in lb
(f) F x =0
H x W cos + dN sin + dF cos = 0
2 2
H x = W cos Pbr sin 2 d fPbr sin cos d
1 1
brP
H x = W cos [2(2 1 ) (sin 22 sin 21 )] fbrP sin 2 2 sin 2 1
( )
4 2
H x = 217 cos 73.3
(2 )(7.5)(55)
[2(1.396) (sin 226.6 sin 66.6)]
4
F y =0
H y + W sin dN cos + dF sin = 0
2 2
H y = brP sin cos d fbrP sin 2 d W sin
1 1
brP fbrP
Hy =
2
(
sin 2 2 sin 2 1
4
) [2(2 1 ) (sin 22 sin 21 )] W sin
Hy =
(2)(7.5)(55) sin 2 113.3 sin 2 33.3
( )
2
Page 23 of 97
SECTION 16 BRAKES AND CLUTCHES
894. The brake is as described in 892, but the pressure varies as p = P sin . Assume
the direction of rotation for which a given W produces the greater T f , derive the
equations needed, and compute (a) the maximum pressure, (b) the moment of F
about A , (c) The moment of N about A , (d) the braking torque, (e) the x and y
components of the force at A .
Solution:
p = P sin
dN = pbrd
dN = Pbr sin d
dF = fdN = fPbr sin d
Page 24 of 97
SECTION 16 BRAKES AND CLUTCHES
c
tan =
r+e
D
r= = 7.5 in
2
7 .5
tan =
7.5 + 3.75
= 33.69o
60
1 = = 3.69o
= 33.69
2 2
60
1 = + = 33.69 + = 63.69o
2 2
M F A = (R cos r )dF
2
MF A = (R cos r ) fPbr sin d
1
2
M F A = fPbr (R sin cos r sin )d
1
R
( )
M F A = fPbr sin 2 2 sin 2 1 + r (cos 2 cos 1 )
2
R = c 2 + (e + r ) = (7.5)2 + (3.75 + 7.5)2
2
= 13.52 in
13.52
M F A = (0.35)P(3.5)(7.5) (sin 63.69 sin 3.69) + 7.5(cos 63.69 cos 3.69)
2 2
2
M F A = 11.43P
MN A = R sin dN
2
MN A = RPbr sin 2 d
1
brPR 2
MN A =
2 1
(
1 cos 2 d )
brPR
MN A = [2(2 1 ) (sin 22 sin 21 )]
4
2 1 = = 1.047 rad
22 = 2(63.69) = 127.38o
21 = 2(3.69) = 7.38o
MN A =
(3.5)(7.5)P(13.52) [2(1.047 ) (sin 127.38 sin 7.38)]
4
M N A = 126.68 P
(a) M A =0
Wa + M F A M N A =0
W = 300 lb
Page 25 of 97
SECTION 16 BRAKES AND CLUTCHES
a = 26 in
(300)(26) + 11.43P 126.68P = 0
P = 67.68 psi
T f = 2587 in lb
(e) [ F x =0 ]
H x W cos + dN sin dF cos = 0
2 2
H x = W cos Pbr sin 2 d + fPbr sin cos d
1 1
Pbr
H x = W cos [2(2 1 ) (sin 22 sin 21 )] + fPbr sin 2 2 sin 2 1
( )
4 2
H x = 300 cos 33.69
(67.68)(3.5)(7.5) [2(1.047 ) (sin 127.38 sin 7.38)]
4
+
(0.35)(67.68)(3.5)(7.5) sin 2 63.69 sin 2 3.69
( )
2
H x = 136 lb
H x = 136 lb
[ F y =0 ]
H y + W sin dN cos dF sin = 0
2 2
H y = Pbr sin cos d + fPbr sin 2 d W sin
1 1
Pbr fPbr
Hy =
2
(
sin 2 2 sin 2 1 +
4
)
[2(2 1 ) (sin 22 sin 21 )] W sin
Hy =
(67.68)(3.5)(7.5) sin 2 63.69 sin 2 3.69
( )
2
+
(0.35)(67.68)(3.5)(7.5)
[2(1.047) (sin 127.38 sin 7.38)] 300 sin 33.69
4
Page 26 of 97
SECTION 16 BRAKES AND CLUTCHES
H y = 766 lb
895. (a) For the brake shown, assume p = P cos and the direction of rotation for
which a given force W results in the greater braking torque, and derive equations
for T f in terms of W , f , and the dimensions of the brake. (b) Under what
circumstances will the brake be self-acting? (c) Determine the magnitude and
location of the resultant forces N and F .
Solution:
Page 27 of 97
SECTION 16 BRAKES AND CLUTCHES
2
MF H = fPbr (r cos + c sin cos )d
1
2
1
M F H = fPbr r sin + c sin 2
2 1
1
[
M F H = fPbr r [sin ( 2 ) sin ( 1 )] + c sin 2 ( 2 ) sin 2 ( 1 ) ]
2
1
(
M F H = fPbr r (sin 2 + sin 1 ) + c sin 2 2 sin 2 1 )
2
2
MN H = cos dN
1
2
MN H = cPbr cos 2 d
1
cPbr 2
2 1
MN H = (1 + cos 2 )d
cPbr
MN H = [2 + sin 2 ]21
4
cPbr
MN H = [2( 2 + 1 ) + (sin 2 2 + sin 21 )]
4
[
MH = 0 ]
Wa + M F H M N H =0
1 cPbr
(
Wa + fPbr r (sin 2 + sin 1 ) + c sin 2 2 sin 2 1 = )
[2( 2 + 1 ) + (sin 2 2 + sin 21 )]
2 4
Wa
P=
cbr
[2( 2 + 1 ) + (sin 2 2 + sin 21 )] fbr 2r (sin 2 + sin 1 ) + c sin 2 2 sin 2 1
[ ( )]
4 2
4Wa
P=
{ [ (
br c[2( 2 + 1 ) + (sin 2 2 + sin 21 )] 2 f 2r (sin 2 + sin 1 ) + c sin 2 2 sin 2 1 )]}
T f = rdF
2
Tf = fPbr 2 cos d
1
Page 28 of 97
SECTION 16 BRAKES AND CLUTCHES
[ ]
(b) c[2( 2 + 1 ) + (sin 2 2 + sin 21 )] > 2 f 2r (sin 2 + sin 1 ) + c (sin 2 2 sin 2 1 )
4 fr (sin 2 + sin 1 )
c>
2( 2 + 1 ) + (sin 2 2 + sin 21 ) 2 f (sin 2 2 sin 2 1 )
(c) N = dN
2
N = Pbr cos d
1
2 1
M F Loc . = Pfbr A cos r (1 + cos 2 ) d
1
2
2
1 1
M F Loc . = Pfbr A sin r + sin 2
2 2 1
1 1
M = Pfbr [ A(sin 2 + sin 1 )] r ( 2 + 1 ) + (sin 2 2 + sin 21 )
F Loc .
2 2
Then M F Loc . = 0
Page 29 of 97
SECTION 16 BRAKES AND CLUTCHES
896. For the brake shown with 1 2 , assume that the direction of rotation is such
that a given W results in the greater braking torque and that p = P sin . (a)
Derive equations in terms of 1 and 2 for the braking torque, for the moment
M F H and for M N H . (b) Reduce the foregoing equations for the condition
1 = 2 . (c) Now suppose that , taken as = 1 + 2 , is small enough that
sin , cos 1 , 1 = 2 = . What are the resulting equations?
2
Solution:
p = P sin
dN = Pbr sin d
dF = fdN = fPbr sin d
1 = 90 1
2 = 90 + 2
T f = rdF
Page 30 of 97
SECTION 16 BRAKES AND CLUTCHES
2
T f = fPbr 2 sin d
1
M F H = (r c cos )dF
2
M F H = fbPr (r c cos )sin d
1
2
M F H = fPbr (r sin c sin cos )d
1
2
1
MF H = fPbr r cos c sin 2
2 1
1
(
M F H = fPbr r (cos 1 cos 2 ) c sin 2 2 sin 2 1 )
2
1
[ ]
M F H = fPbr r [cos(90 1 ) cos(90 + 2 )] c sin 2 (90 + 2 ) sin 2 (90 1 )
2
1
(
M F H = fPbr r (sin 1 + sin 2 ) c cos 2 2 cos 2 1 )
2
1
[( ) (
M F H = fPbr r (sin 1 + sin 2 ) c 1 sin 2 2 1 sin 2 1 )]
2
1
(
M F H = fPbr r (sin 1 + sin 2 ) + c sin 2 2 sin 2 1 )
2
MN H = r sindN
2
MN H = bPr 2 sin 2 d
1
2
Pbr 2
2 1
MN H = (1 cos 2 )d
Pbr 2
MN H = [2 sin 2 ]12
4
Pbr 2
MN H = [2(2 1 ) (sin 22 sin 21 )]
4
Pbr 2
MN H = {2[(90 + 2 ) (90 1 )] [sin 2(90 + 2 ) sin 2(90 1 )]}
4
Pbr 2
MN H = [2( 2 + 1 ) ( sin 2 2 sin 21 )]
4
Page 31 of 97
SECTION 16 BRAKES AND CLUTCHES
Pbr 2
MN H = [2( 2 + 1 ) + (sin 2 2 + sin 21 )]
4
(b) 1 = 2
(c) = 1 + 2
sin
cos 1
1 = 2 =
2
T f = 2 fbPr 2 sin 1
T f = 2 fbPr 2 sin = 2 fbPr 2 = fbPr 2
2 2
MF H = 2 fPbr 2 sin 1
M F H = 2 fbPr 2 sin = 2 fbPr 2 = fbPr 2
2 2
Page 32 of 97
SECTION 16 BRAKES AND CLUTCHES
897. The brake shown is lined with woven asbestos; the cast-iron wheel is turning at
60 rpm CC; width of contact surface is 4 in. A force W = 1300 lb . is applied via
linkage systemnot shown; = 90o . Let p = P sin . (a) With the brake lever as a
free body, take moments about the pivot J and determine the maximum pressure
and compare with permissible values. Compute (b) the braking torque, (c) the
frictional energy in fhp. (d) Compute the normal force N , the average pressure
on the projected area, and decide if the brake application can safely be
continuous.
Solution:
(a)
dF = fdN
p = P sin
dN = pbrd = Pbr sin d
dF = fPbr sin d
M F J = (R cos r )dF
2
M F J = fPbr (R cos r )sin d
1
Page 33 of 97
SECTION 16 BRAKES AND CLUTCHES
2
M F J = fPbr (R sin cos r sin )d
1
1
2
M N J = R sin dN
2
M N J = PbrR sin 2 d
1
PbrR
MN J = [1 cos 2 ]12
2
PbrR
MN J = [2(2 1 ) (sin 22 sin 21 )]
4
P(4)(10)(16)
MN J = 2(96.34 6.34) (sin 2(96.34) sin 2(6.34))
4 180
MN J = 572.9 P
M J = Wa +M F J M N J = 0
Page 34 of 97
SECTION 16 BRAKES AND CLUTCHES
(b) T f = rdF
2
T f = fPbr sin d
1
Tf n
(c) fhp = , n = 60 rpm
63,000
fhp =
(9188)(60) = 8.75 hp
63,000
(d) N = dN
2
N = Pbr sin d
1
N
ave. p =
2br sin
2
o
= 90
2297
ave. p = = 40.6 psi
90
2(4 )(10 )sin
2
Dn
pvm = p = (40.6 ) (20 )(60 ) = 12,755 ft lb sq. in. min
12 12
Page 35 of 97
SECTION 16 BRAKES AND CLUTCHES
PIVOTED-SHOE BRAKES
898. In the brake shown, the shoe is lined with flexible woven asbestos, and pivoted at
point K in the lever; face width is 4 in.; = 90o . The cast-iron wheel turns 60
rpm CL; let the maximum pressure be the value recommended in Table At 29.
On the assumption that K will be closely at the center of pressure, as planned,
compute (a) the brake torque, (b) the magnitude of force W , (c) the rate at which
frictional energy grows, (d) the time of an application if it is assumed that all this
energy is stored in the 1-in. thick rim with t rim = 350 F , (e) the average pressure
on projected area. May this brake be applied for a long time without damage?
(f) What would change for CC rotation?
Problem 898.
Solution:
a = 27 in , b = 4 in , n = 60 rpm CL
2 D sin
c= 2
+ sin
D = 20 in , r = 10 in
= 90o = 1.571 rad
90
2(20)sin
c= 2 = 11.0 in
1.571 + sin 90
(a) T f = 2 fPbr 2 sin
2
For woven asbestos, Table AT 29, f = 0.4
P = 50 psi
90
T f = 2(0.4 )(50 )(4 )(10 ) sin
2
= 11,314 in lb
2
Page 36 of 97
SECTION 16 BRAKES AND CLUTCHES
(b)
(c) fhp =
Tf n
=
(11,314)(60) = 10.78 hp
63,000 63,000
rate of frictional energy = 33,000 fhp = 33,000(10.78) = 355,740 ft lb min
Uf
(d) Time (min) =
33,000 fhp
U f ft lb
t o F =
Wm c
Wm = Dbt
For cast iron
= 0.253 lb in3
c = 101 ft lb lb F
t = 1 in
N 2571
(e) Ave. p = = = 45.45 psi
90
2br sin 2(4 )(10 ) sin
2 2
Page 37 of 97
SECTION 16 BRAKES AND CLUTCHES
899. The pivoted-shoe brake shown is rated at 450 ft-lb. of torque; = 90o ; contact
width is 6.25 in.; cast-iron wheel turns at 600 rpm; assume a symmetric
sinusoidal distribution of pressure. (a) Locate the center of pressure and compute
with the location of K. Compute (b) the maximum pressure and compare with
allowable value, (c) the value of force W , (d) the reaction at the pin H , (e) the
average pressure and pvm , and decide whether or not the application could be
continuous at the rated torque. (f) Compute the frictional work from T and
estimate the time it will take for the rim temperature to reach 450 F (ambient, 100
F).
Problem 899.
Solution:
2 D sin
(a) c = 2
+ sin
D = 18 in
= 90o = 1.571 rad
90
2(18)sin
c= 2 = 9.9011 in
1.571 + sin 90
but location of K = 9.8125 in
then, c location K
(b) T f = 2 fPbr 2 sin
2
T f = 450 ft lb = 5400 in lb
Page 38 of 97
SECTION 16 BRAKES AND CLUTCHES
b = 6.25 in
r = 9 in
use f = 0.4 (on cast-iron)
T f = 2 fPbr 2 sin
2
90
5400 = 2(0.4 )P(6.25)(9 ) sin
2
2
P = 18.86 psi < allowable (Table AT 9)
N 1364
(e) Ave. p = = = 17.15 psi
90
2br sin 2(6.25)(9 ) sin
2 2
n = 600 rpm
p Dn (17.15)( )(18)(600 )
pvm = = = 48,490 ft lb sq. in. F
12 12
2 (600 rpm )
(f) Frictional work = T = (450 ft lb ) = 28,275 ft lb per sec
60 sec min
U ft lb
t o F = f
Wm c
Wm = Dbt
For cast iron
= 0.253 lb in3
c = 101 ft lb lb F
(18) 2
Wm = (0.253) (18)(6.25)t + t = 154 t
4
t = 450 100 = 350 F
U f = tWm c = (350 )(154 t )(101) = 5,443,900 t ft lb
Page 39 of 97
SECTION 16 BRAKES AND CLUTCHES
U f = 2,248,260 ft lb
5,443,900 t
Time = = 192.5 t sec
28,275
1
Assume t = in
2
Time = 96 sec
TWO-SHOE BRAKES
PIVOTED SHOES
900. The double-block brake shown is to be used on a crane; the force W is applied
by a spring, and the brake is released by a magnet (not shown); = 90o ; contact
width = 2.5 in. Assume that the shoes are pivoted at the center of pressure. The
maximum pressure is the permissible value of Table AT 29. Compute (a) the
braking torque, (b) the force W , (c) the rate of growth of frictional energy at 870
rpm, (d) the time it would take to raise the temperature of the 0.5-in.-thick rim by
t = 300 F (usual assumption of energy storage), (e) pvm . (f) Where should the
pivot center be for the calculations to apply strictly?
Problem 900.
Solution:
90
2 D sin 2(10)sin
c= 2 = 2 = 5.5 in
+ sin
+ sin 90
2
Page 40 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M R1 =0 ]
F1 (5.5 0.875) + 12.75W = 6.75 N1
fN1 (4.625) + 12.75W = 6.75 N1
12.75W
N1 =
6.25 4.625 f
[ M R2 =0 ]
12.75W = F2 (5.5 0.875) + 6.75 N 2
12.75W = 4.625 fN 2 + 6.75 N 2
12.75W
N2 =
6.25 + 4.625 f
12.75W
N1 = = 2.898W
6.25 4.625(0.40)
F1 = fN1 = (0.4)(2.898W ) = 1.16W
Page 41 of 97
SECTION 16 BRAKES AND CLUTCHES
12.75W
N2 = = 1.574W
6.25 + 4.625(0.40)
F2 = fN 2 = (0.4)(1.574W ) = 0.63W
max . T f = T f1
2 fPbr 2 sin = F1c
2
2
10 90
2(0.40 )(50 )(2.5) sin = (1.16W )(5.5)
2 2
W = 277 lb
(c) fhp =
Tf n
=
(2727 )(870) = 37.66 hp
63,000 63,000
(d) Solving for tine:
U ft lb
t o F = f
Wm c
t o F = 300o F
c = 101 , = 0.253 for cast iron
Wm = V
D 2t (10)2 (0.5)
V = Dbt + = (10 )(2.5)(0.5) + = 78.54 in 3
4 4
Wm = (0.253)(78.54) = 19.87 lb
U f = (300 )(19.87 )(101) = 602,061 ft lb
Uf 602,061
Time = = = 0.4844 min = 29 sec
33,000 fhp 33,000(37.66)
(e) pvm :
Dn (10)(870)
vm = = = 2278 fpm
12 12
pvm = (50)(2278) = 113,900
(f) c = 5.5 in
901. A pivoted-shoe brake, rated at 900 ft-lb. torque, is shown. There are 180 sq. in. of
braking surface; woven asbestos lining; 600 rpm of the wheel; 90o arc of brake
contact on each shoe. The effect of spring A is negligible. (a) Is the pin for the
Page 42 of 97
SECTION 16 BRAKES AND CLUTCHES
shoe located at the center of pressure? (b) How does the maximum pressure
compare with that in Table AT 29? (c) What load W produces the rated torque?
(d) At what rate is energy absorbed? Express in horsepower. Is it likely that this
brake can operate continuously without overheating? (e) Does the direction of
rotation affect the effectiveness of this brake?
Problem 901.
Solution:
90
2 D sin 2(18) sin
(a) c = 2 = 2 = 9.9 in
+ sin
+ sin 90
2
13
19
and 16 9.9 in , therefore the pin located at the center of pressure
2
(b)
4
tan =
13
19
16
o
= 11.4
[ M Q =0 ]
4 FA cos = 8.5W
Page 43 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M R1 =0 ]
N1 (10.375) = 20.375Qh
N1 (10.375) = 20.375(2.125W )
N1 = 4.173W
F1 = f N1
For woven asbestos lining, f = 0.40 , p = 50 psi
F1 = (0.40)(4.173W ) = 1.67W (either direction)
Page 44 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M R2 =0 ]
10.375 N 2 = 20.375FA cos
20.375
N2 = (2.168W ) cos11.4 = 4.174W
10.375
F2 = (0.40)(4.174W ) = 1.67W (either direction)
T f = (F1 + F2 )c
(900)(12) = (1.67 + 1.67 )(W )(9.9)
W = 326.6 lb
T f1 = T f 2 = Fc = 2 fPbr 2 sin
2
but A = br
Ar
br 2 =
90
2(0.4)(P )(180)(9)sin
(1.67)(326.6)(9.9) = 2
2
P = 9.26 psi < 50 psi
(c) W = 326.6 lb
(d) fhp =
Tf n
=
(900)(12)(600) = 103 hp
63,000 63,000
Dn (18)(600)
vm = = = 2827 fpm
12 12
pvm = (9.26)(2827 ) = 26,178 ft lb sq.in. F
(e) Since the value of F is independent of rotation, the direction doesnt affect the
effectiveness of this brake.
902. Refer to the diagrammatic representation of the brake of Fig. 18.2, Text, and let
9 9
the dimensions be: a = b = m = t = 4 , c = 14 , D = 15 , h = 9 in ., and the
16 16
o
contact width is 4 in.; arc of contact = 90 ; lining is asbestos in resin binder,
wheel rotation of 100 rpm CC; applied load W = 2000 lb . (a) Locate the center of
pressure for a symmetrical sinusoidal pressure distribution and compare with the
actual pin centers. Assume that this relationship is close enough for approximate
Page 45 of 97
SECTION 16 BRAKES AND CLUTCHES
results and compute (b) the dimensions k and e if the braking force on each
shoe is to be the same, (c) the normal force and the maximum pressure, (d) the
braking torque, (e) pvm . Would more-or-less continuous application be
reasonable?
Figure 18.2
Solution:
90
2 D sin 2(15) sin
(a) c = 2 = 2 = 8.25 in
+ sin
+ sin 90
2
On Centers:
9 9
K :t + m = 4 + 4 = 9.125 in > c
16 16
9 9
B : a + b = 4 + 4 = 9.125 in > c
16 16
[ M RC =0 ]
Page 46 of 97
SECTION 16 BRAKES AND CLUTCHES
eRF = (e + c )W
e+c
RF = W
e
RC = RF W
e+c cW
RC = W W =
e e
[ M RH =0 ]
N1h F1b = RF a
N1h fN1b = RF a
R a
N1 = F
h fb
fRF a
F1 =
h fb
fa(e + c )W
F1 =
e(h fb )
[ M RE =0 ]
N 2 h + F2t = RC k
Page 47 of 97
SECTION 16 BRAKES AND CLUTCHES
N 2 h + fN 2t = RC k
R k
N2 = C
h + ft
fR k
F2 = C
h ft
fkcW
F2 =
e(h + ft )
(b) T f 1 = T f 2
F1c = F2c
F1 = F2
fa(e + c )W fkcW
=
e(h fb ) e(h + ft )
a(e + c ) kc
=
h fb h + ft
For asbestos in resin binder,
f = 0.35 , Table AT 29
9
a = 4 in = 4.5625 in
16
9
b = 4 in = 4.5625 in
16
9
m = 4 in = 4.5625 in
16
9
t = 4 in = 4.5625 in
16
c = 14 in
9
h = 9 in = 9.5625 in
16
4.5625(e + 14) k (14)
=
9.5625 0.35(4.5625) 9.5625 + 0.35(4.5625)
e + 14 = 2.1903k
but k + m = e
or e = k + 4.5625
then k + 4.5625 + 14 = 2.1903k
k = 15.6 in
e = 15.6 + 4.5625 = 20.1625 in
(c) N = N1 = N 2 =
kcW
=
(15.6)(14)(2000) = 2720 lb
e(h + ft ) (20.1625)[9.5625 0.35(4.5625)]
Page 48 of 97
SECTION 16 BRAKES AND CLUTCHES
Dn (15)(100)
(e) vm = = = 393 fpm
12 12
pvm = (64.11)(393) = 25,195 ft lb sq.in. F
FIXED SHOES
903. A double-block brake has certain dimensions as shown. Shoes are lined with
woven asbestos; cast-iron wheel turns 60 rpm; applied force W = 70 lb . For each
direction of rotation, compute (a) the braking torque, (b) the rate of generating
frictional energy (fhp). (c) If the maximum pressure is to be P = 50 psi (Table
AT 29), what contact width should be used? (d) With this width, compute pvm
and decide whether or not the applications must be intermittent.
[ M =0
B ]
4Q = 26W
Page 49 of 97
SECTION 16 BRAKES AND CLUTCHES
Q = 6.5W
[ M R =0 ]
2.25S = 6Q = 6(6.5W )
S = 17.33W
RH = S = 17.33W
RV = Q = 6.5W
e = 10 in
R = 12.5 in
a = 2.25 + 9 + 12.5 = 23.75 in
M H = Sa M F1 H M N1 H = 0 (CC)
M H = Sa + M F1 H M N1 H = 0 (CL)
R
M F1 H ( )
= fbrP r (cos 1 cos 2 ) sin 2 2 sin 2 1
2
brRP
M N1 H = [2(2 1 ) (sin 22 sin 21 )]
4
T f1 = 2 fPbr 2 sin
2
T f1
Pbr =
2 fr sin
2
r = 10 in
Page 50 of 97
SECTION 16 BRAKES AND CLUTCHES
2r sin = 11 in
2
2(10 ) sin = 11 in
2
= 66.43o = 1.165 rad
CC:
M H = Sa M F1 H M N1 H =0
(17.33)(70)(23.75) T f 1
2.960T f1 = 0
T f1 = 7276 in lb
CL:
M H = Sa + M F1 H M N1 H =0
Page 51 of 97
SECTION 16 BRAKES AND CLUTCHES
(17.33)(70)(23.75) + T f 1
2.960T f1 = 0
T f1 = 14,700 in lb
e = 10 in
d = 12.5 in
CC: [ M H =0 ]
RH a RV d + M F2 H M N2 H =0
CL: [ M H =0 ]
RH a RV d M F2 H M N2 H =0
T f2
M F2 = M = Tf
H F1 H
Tf 2
1
Tf
M N 2 H = M N1 H 2 = 2.960T f 2
Tf
1
CC:
RH a RV d + M F2 H M N 2 H = 0
[(17.33)(21.5) (6.5)(12.5)](70) + T f 2
2.960T f 2 = 0
T f 2 = 10,405 in lb
CL:
RH a RV d M F2 H M N 2 H =0
[(17.33)(21.5) (6.5)(12.5)](70) T f 2
2.960T f 2 = 0
T f 2 = 5150 in lb
Page 52 of 97
SECTION 16 BRAKES AND CLUTCHES
CC:
T f = T f1 + T f 2 = 7276 + 10,405 = 17,681 in lb
CL:
T f = T f1 + T f 2 = 14,700 + 5150 = 19,850 in lb
(c) p = 50 psi
T f1 or T f 2 = 2 fPbr 2 sin
2
T f1 10,405
CC: b = = = 4.73 in
66.73
2(0.4)(50)(10) sin
2 2
2 fPr sin
2 2
T f2 14,700
CL: b = = = 6.68 in
66.73
2(0.4)(50)(10) sin
2 2
2 fPr sin
2 2
(d) pvm
Dn (20)(60)
vm = = = 314 fpm
12 12
pvm = (50)(314) = 15,700 < 55,000
pvm = (50)(314) = 15,700 < 28,000
904. If the brake shown has a torque rating of 7000 lb-in. for counter-clockwise
rotation, what braking torque would it exert for clockwise rotation, force W the
same?
Solution:
CC:
Sa M F1 H M N1 H =0
M F1 H = T f1
M N1 H = 2.960T f1
Page 53 of 97
SECTION 16 BRAKES AND CLUTCHES
S = 17.33W
a = 23.75 in
(17.33W )(23.75) T f 1
2.96T f1 = 0
T f1 = 103.9W
RH a RV d + M F2 H M N2 H =0
RH = 17.33W
RV = 6.53W
a = 21.5 in
d = 12.5 in
M F2 H = T f2
M N2 H = 2.960T f 2
(17.33W )(21.5) (6.5W )(12.5) + T f 2
2.960T f 2 = 0
T f 2 = 148.65W
T f = T f1 + T f 2
7000 = 103.9W + 148.65W
W = 27.7 lb
CL:
Sa + M F1 H M N1 H =0
(17.33)(27.7 )(23.75) T f 1
2.96T f1 = 0
T f1 = 5817 in lb
RH a RV d M F2 H M N2 H =0
[(17.33)(21.5) (6.5)(12.5)](27.7) + T f 2
2.960T f 2 = 0
T f 2 = 2038 in lb
905. A double-block brake is shown for which = 90o , b = 5 in ., n = 300 rpm , rim
thickness = in., and W = 400 lb . The shoes are lined with asbestos in resin
binder. Determine the frictional torque for (a) clockwise rotation, (b)
counterclockwise rotation. (c) How much energy is absorbed by the brake?
Express in horsepower. (d) Will the brake operate continuously without danger of
overheating? How long for a t rim = 300 F ? How does pvm compare with Text
values?
Page 54 of 97
SECTION 16 BRAKES AND CLUTCHES
Problem 905
Solution:
4
tan =
4+4
= 26.565o
[ M R =0 ]
(Q cos )(4) = 16W
(Q cos 26.565)(4) = 16(400)
Q = 1789 lb
Page 55 of 97
SECTION 16 BRAKES AND CLUTCHES
R
(
M F H = fbrP r (cos 1 cos 2 ) sin 2 2 sin 2 1 )
2
brRP
MN H = [2(2 1 ) (sin 22 sin 21 )]
4
T f = 2 fPbr 2 sin
2
R
T f r (cos 1 cos 2 ) (sin 2 2 sin 2 1 )
=
2
MF H
2r sin
2
RT f [2(2 1 ) (sin 22 sin 21 )]
MN H =
8 fr sin
2
20
r= = 10 in
2
4
tan =
12
= 18.435o
= 90o = 1.571 rad
90
1 = 90 = 90 18.435 = 26.565o = 0.464 rad
2 2
21 = 2(26.565) = 53.13o
90
2 = 90 + = 90 + 18.435 = 116.565o = 2.034 rad
2 2
22 = 2(116.565) = 233.13o
R = 4 2 + 12 2 = 12.65 in
Page 56 of 97
SECTION 16 BRAKES AND CLUTCHES
12.65
T f 10(cos 26.565 cos 116.5656) (sin 2 116.565 sin 2 26.565)
= = 0.6803T
2
MF H f
90
2(10) sin
2
(12.65)T f [2(2.034 0.464) (sin 233.13 sin 53.13)]
MN H = = 3.03T f
90
8(0.35)(10) sin
2
(a) Clockwise
[ M H1 =0 ]
(Q sin )(2.5) + (Q cos )(24) + M F H M N H = 0
1 1 1 1
[ M H2 =0 ]
2.5 RV 24 RH + M N 2 H2 + M F2 H2 =0
2.5(1200 ) 24(1600 ) + 3.03T f 2 + 0.6803T f 2 = 0
T f 2 = 9541 in lb
Page 57 of 97
SECTION 16 BRAKES AND CLUTCHES
(b) Counterclockwise
[ M H1 =0 ]
24Q cos + 2.5Q sin M F1 H1 M N1 H1 =0
(24)(1789 cos 26.565) + (2.5)(1789 sin 26.565) 0.6803T f 1
3.03T f1 = 0
T f1 = 10,890 in lb
[ M H2 =0 ]
2.5 RV 24 RH M F2 H2 + M N2 H2 =0
2.5(1200 ) 24(1600 ) 0.6803T f 2 + 3.03T f 2 = 0
T f 2 = 15,066 in lb
Page 58 of 97
SECTION 16 BRAKES AND CLUTCHES
(c) CL:
fhp =
Tf n
=
(26,736)(300) = 127.3 hp
63,000 63,000
CC:
fhp =
Tf n
=
(25,956)(300) = 123.6 hp
63,000 63,000
Dn (20)(300)
(d) vm = = = 1571 fpm
12 12
For p :
T f = 2 fPbr 2 sin = T f1 (CL)
2
90
17,195 = 2(0.35)(P )(5)(10 ) sin
2
2
P = 69.48 psi
pvm = (69.48)(1571) = 109,153 > 28,000
the brake operate continuously with danger of overheating.
For time:
U ft lb
t o F = f
Wm c
c = 101 , = 0.253
Wm = V
D 2t
V = Dbt +
4
3 (20) 3
2
V = (20 )(5) + = 471.24 in
3
4 4 4
Wm = V = (0.253)(471.24) = 119.22 lb
U f = Wm ct = (119.22 )(101)(300 ) = 3,612,366 ft lb
Uf
Time =
33,000 fhp
Uf 3,612,366
CL: Time = = = 0.886 min = 53 sec
33,000 fhp 33,000(123.6)
Uf 3,612,366
CC: Time = = = 0.860 min = 52 sec
33,000 fhp 33,000(127.3)
pvm > 28,000 , not good for continuous application.
Page 59 of 97
SECTION 16 BRAKES AND CLUTCHES
906. The double-block brake for a crane has the dimensions: a = 14.3 , b = 2.37 ,
D = 10 , e = 11.05 , g = 7.1 , h = 12 , j = 6.6 , k = 10.55 , m = 3.5 in ., the width of
shoes is 4 in., and the subtended angle is = 90o ; wocen asbestos lining. Its
rated braking torque is 200 ft-lb. The shoes contact the arms in such a manner
that they are virtually fixed to the arms. What force W must be exerted by a
hydraulic cylinder to develop the rated torque for (a) counterclockwise rotation,
(b) clockwise rotation? Is the torque materially affected by the direction of
rotation? (c) Compute the maximum pressure and compare with that in Table AT
29. (Data courtesy of Wagner Electric Corporation.)
Problem 906.
Solution:
b 2.37
tan = =
e c 11.05 0.83
= 13.056o
Page 60 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M R=0 ]
bQ cos + cQ sin = eW
(2.37)(Q cos13.056) + (0.83)(Q sin 13.056) = 14.3W
Q = 5.7286W
k 5.275
tan = =
2j 6.6
o
= 38.63
90
1 = 90 = 90 38.63 = 6.37o = 0.1112 rad
2 2
21 = 12.74o
90
2 = 90 + = 90 + 38.63 = 96.37 o = 1.6820 rad
2 2
22 = 192.74o
2 2
k 10.55
+ (6.6 ) = 8.449 in
2
R = + j2 =
2 2
D 10
r= = = 5 in
2 2
Page 61 of 97
SECTION 16 BRAKES AND CLUTCHES
R
T f r (cos 1 cos 2 ) (sin 2 2 sin 2 1 )
=
2
MF H
2r sin
2
RT f [2(2 1 ) (sin 22 sin 21 )]
MN H =
8 fr sin
2
For woven asbestos lining, f = 0.40
8.449
T f 5(cos 6.37 cos 96.37 ) (sin 2 96.37 sin 2 6.37 )
MF H = = 0.1985T
2
f
90
2(5) sin
2
8.449T f [2(1.682 0.1112) (sin 192.74 sin 12.74 )]
MN H = = 2.6755T f
90
8(0.4 )(5) sin
2
(a) CC:
[ M H1 =0 ]
RH (12 ) RV (0.25) M F1 H1 M N1 H1 =0
(5.58W )(12) (0.294W )(0.25) 0.1985T f 1
2.6755T f1 = 0
T f1 = 23.3W
Page 62 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M H2 =0 ]
12Q cos + 0.25Q sin + M F2 H2 M N2 H2 3.5W = 0
12(14.3W ) cos 13.056 + 0.25(14.3W )sin 13.056 3.5W = 2.6755T f 2 0.1985T f 2
T f 2 = 66.4W
T f = T f1 + T f 2
T f = 200 ft lb = 2400 in lb
2400 = 23.3W + 66.4W
W = 26.8 lb
(b) CL:
Page 63 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M H1 =0 ]
RH (12 ) RV (0.25) + M F1 H1 M N1 H1 =0
(5.58W )(12) (0.294W )(0.25) + 0.1985T f 1
2.6755T f1 = 0
T f1 = 27.0W
[ M H2 =0 ]
12Q cos + 0.25Q sin M F2 H2 M N2 H2 3.5W = 0
12(14.3W ) cos 13.056 + 0.25(14.3W )sin 13.056 3.5W = 2.6755T f 2 + 0.1985T f 2
T f 2 = 57.2W
T f = T f1 + T f 2
2400 = 27.0W + 57.2W
W = 28.5 lb
Since W has different values, torque is materially affected by the direction of rotation.
(c) T f = 2 fPbr 2 sin
2
For woven asbestos lining, f = 0.40
Use T f = 66.4W = 66.4(26.8) = 1780 in lb
b = 4 in
r = 5 in
= 90o
90
T f = 1780 = 2(0.4 )P(4 )(5) sin
2
2
P = 31.47 psi
Page 64 of 97
SECTION 16 BRAKES AND CLUTCHES
INTERNAL-SHOE BRAKES
908. Assuming that the distribution of pressure on the internal shoe shown is given by
p = P sin , show that the moments M N B , M F B , and TF O of N with respect to
B and of F with respect to B and to O are ( b = face width)
p = P sin
d (M N B ) = kdN
dN = P sin (brd ) = Pbr sin d
k = a cos( 90) = a sin
MN B = sin 2 =
2 2 1 2 2
but 2 1 =
Page 65 of 97
SECTION 16 BRAKES AND CLUTCHES
MN =
Pabr
(sin 22 sin 21 )
B
2
2
d (M F B ) = edF
dF = fdN = fPbr sin d
e = r + a sin ( 90) = r a cos
d (M F B ) = (r a cos )( fPbr sin d ) = fPbr (r sin a sin cos )d
[
M F B = fPbr r cos a sin 2 1 ]2
M F B = fPbr r (cos 1 cos 2 )
(
a sin 2 2 sin 2 1 )
2
909. The same as 908, except that a pressure distribution of p = P cos is assumed.
[ ( ) ]
M N B = Pbr h(2 + sin 2 2 + sin 21 ) 4 + c sin 2 2 sin 2 1 2 ,
[ ( )
M F B = fPbr r (sin 2 + sin 1 ) + h sin 2 2 sin 2 1 2 c(2 + sin 2 2 + sin 21 ) 4 ]
M F O = fPbr 2 (sin 2 + sin 1 ) .
Solution:
k = h cos + c sin
e = r + h sin c cos
dN = pbrd = Pbr cos d
dF = fdN = fPbr cos d
but = 1 + 2
M N B = Pbr +
[
h[2( 2 + 1 ) + sin 2 2 sin ( 21 )] c sin 2 2 sin 2 ( 1 )
]
4 2
Page 66 of 97
SECTION 16 BRAKES AND CLUTCHES
(
h(2 + sin 2 2 + sin 21 ) c sin 2 2 sin 2 1
M N B = Pbr +
)
4 2
M F B = fPbr r (sin 2 + sin 1 ) +
(
)
h sin 2 2 sin 2 1 c(2 + sin 2 2 + sin 21 )
2 4
910. The same as 909, except that the is to be measured from OG , a perpendicular
to OB ; limits from 1 to + 2 .
Solution:
k = a cos
e = r + a sin
Pbar
dM N B = kdN = a cos (Pbr cos d ) = Pbar cos 2 d = (1 + cos 2 )d
2
Pbar 2 + sin 2 2 Pbar
MN B = = [2( 2 + 1 ) + sin 2 2 sin 2( 1 )]
2 2 1 4
Pbar
MN B = (2 + sin 2 2 sin 21 )
4
MF B
= fPbr r sin +
a sin 2
2
= fPbr
r [sin sin ( )] +
[ ]
a sin 2 2 sin 2 ( 1 )
2 1
2 2
1
M F B = fPbr r (sin 2 + sin 1 ) +
(
a sin 2 2 sin 2 1 )
2
dM F O = rdF = r ( fPbr cos d ) = fPbr cos d
2
Page 67 of 97
SECTION 16 BRAKES AND CLUTCHES
911. The following dimensions apply to a two-shoe truck brake somewhat as shown:
face b = 5 , r = 8 , h = 5.1 , c = 2.6 , w = u = 6.4 in ., = 110 o , 1 = 15o . Lining is
asbestos in rubber compound. For a maximum pressure on each shoe of 100 psi,
determine the force Q , and the braking torque for (a) clockwise rotation, (b)
counterclockwise rotation. See 908. (Data courtesy of Wagner Electric
Corporation.)
Page 68 of 97
SECTION 16 BRAKES AND CLUTCHES
Q(h + w) + M F B M N B =0
MN =
(100)(5)(5.7245)(8) 1.92 (sin 250 sin 30) = 30,224 in lb
B
2 2
M F B = (0.35)(100)(5)(8)8(cos 30 cos 125)
(
5.7245 sin 2 125 sin 2 30 ) = 14,436 in lb
2
h = 5.1 in , w = 6.4 in
Q(h + w) M N B M F B = 0
Page 69 of 97
SECTION 16 BRAKES AND CLUTCHES
913. The data are the same as 911, but the shoe arrangement is as shown for this
problem. For a maximum pressure on the shoes of 100 psim determine the force
Q and TF O for (a) Cl rotation, (b) CC rotation, See 908.
Problem 913.
Solution:
TF O = T f = fPbr 2 (cos 1 cos 2 )
Tf
Pbr =
fr (cos 1 cos 2 )
MN B =
Pbar
(sin 22 sin 21 ) = aT f
(sin 22 sin 21 )
2 2 2 fr (cos cos )
1 2 2
M F B = fPbr r (cos 1 cos 2 )
( )
a sin 2 2 sin 2 1
2
MF B =
Tf
r (cos cos )
( )
a sin 2 2 sin 2 1
2r (cos 1 cos 2 )
1 2
2
From 911:
1 = 15o , 21 = 30o , 2 = 1 + = 15 + 110 = 125o , 21 = 250o
= 110o = 1.92 rad
a = h2 + c 2 = (5.1)2 + (2.6)2 = 5.7245 in
f = 0.35
Page 70 of 97
SECTION 16 BRAKES AND CLUTCHES
MN B =
5.7245T f
1.92
(sin 250 sin 30) = 1.753T
2(0.35)(8)(cos 15 cos 125) 2 f
MF B =
Tf
8(cos 15 cos 125 )
(
5.7245 sin 2 125 sin 2 15 ) = 0.43T
28(cos 15 cos 125)
f
2
(a) CL rotation:
Left Side
[ M B =0 ]
Q(h + w) M N1 B M F1 B =0
Q(5.1 + 6.4 ) 1.753T f1 0.43T f1 = 0
T f1 = 5.268Q
Right Side:
[ M B =0 ]
Page 71 of 97
SECTION 16 BRAKES AND CLUTCHES
Q(h + w) + M F2 B M N 2 B =0
Q(5.1 + 6.4 ) + 0.43T f 2 1.753T f 2 = 0
T f 2 = 8.6924Q
T f max = T f 2 = 8.6924Q
Q = 1984 lb
(b) CC rotation
Left Side
[ M B =0 ]
Q(h + w) + M F1 B M N1 B =0
Q(5.1 + 6.4 ) + 0.43T f1 1.753T f1 = 0
T f1 = 8.6924Q
Right Side:
Page 72 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M B =0 ]
Q(h + w) M F2 B M N2 B =0
Q(5.1 + 6.4 ) 0.43T f 2 1.753T f 2 = 0
T f 2 = 5.268Q
Since values are just interchanged
Q = 1984 lb
Total TF O = 27,698 in lb as in (a)
Page 73 of 97
SECTION 16 BRAKES AND CLUTCHES
Problem 914.
Solution:
MN B =
Pbar
(sin 22 sin 21 )
2
2
M F B = fPbr r (cos 1 cos 2 )
( )
a sin 2 2 sin 2 1
,
2
TF O = fPbr (cos 1 cos 2 )
2
2 2
2 2 9 1
a = h + c = 4 + 1 = 4.70 in
16 8
5
8
pL wR
= = 16 = 0.8926
pR wL 9 5
16
For asbestos in rubber compound, f = 0.35 , p = 75 psi
pR = 75 psi
pL = 0.8926(75) = 67 psi
Left Side:
Page 74 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M BL =0 ]
QL wL M FL BL M NL BL =0
M FL
= fPLbr r (cos 1 cos 2 )
(
a sin 2 2 sin 2 1 )
BL
2
1 = 30o
21 = 60o
2 = + 1 = 120 + 30 = 150o
22 = 300o
= 120o = 2.094 rad
5
QL 9 5849 11,185 = 0
16
QL = 1829 lb
T( F O )L = fPL br 2 (cos 1 cos 2 )
T( F O )L = (0.35)(67 )(4 )(6 ) (cos 30 cos 150 ) = 5849 in lb
2
Right side:
Page 75 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M BR =0 ]
QR wR + M FR BR M NR BR =0
M FR =
M FL BL PR
=
(5849)(75) = 6547 in lb
BR
PL 67
M NR =
M NL BL PR
=
(11,185)(75) = 12,520 in lb
BR
PL 67
5
QR 8 + 6547 12,520 = 0
16
QR = 719 lb
T( F O )L PR (5849)(75)
T( F O )R = = = 6547 in lb
PL 67
Left side:
Page 76 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M BL =0 ]
QL wL + M FL BL M NL BL =0
5
QL 9 + 5849 11,185 = 0
16
QL = 573 lb
T( F O )L = 5849 in lb
Right Side:
[ M BR =0 ]
QR wR M FR BR M NR BR =0
5
QR 8 6547 12,520 = 0
16
QR = 2294 lb
T( F O )R = 6547 in lb
Page 77 of 97
SECTION 16 BRAKES AND CLUTCHES
BAND BRAKES
915. The steel band for the brake shown is lined with flexible asbestos and it is
expected tha the permissible pressure of Table AT 29 is satisfactory; = 245o ,
1
a = 20 in ., m = 3 in ., D = 18 in ., and face width b = 4 in .; rotation CL. The
2
cast-iron wheel turns 200 rpm. Set up suitable equations, use the average f
given and compute (a) the force in each end of the band, (b) the brake torque and
fhp. (c) Determine the mechanical advantage for the limit values of f in Table
AT 29 and its percentage variation fron that for the average f . (d) Investigate
the overheating problem using relevant information given in the Text.
Problem 915.
Solution:
F1
(1) = e f
F2
[ M Fixed point =0 ]
Wa = F2 m
Wa
(2) F2 =
m
Page 78 of 97
SECTION 16 BRAKES AND CLUTCHES
(3) F = F1 F2 = fpA
FD
(4) T f =
2
Page 79 of 97
SECTION 16 BRAKES AND CLUTCHES
MA =
[ ]
18 e (0.35 )(4.276 ) 1
= 8.914
2(3.5)
f = 0.45
MA =
[ ]
18 e (0.45 )(4.276 ) 1
= 15.042
2(3.5)
MA =
[ ]
18 e (0.40 )(4.276 ) 1
= 11.652
2(3.5)
Percentage variation from f = 0.40 .
f = 0.35
11.652 8.914
% var = (100% ) = 23.5%
11.652
f = 0.45
15.042 11.652
% var = (100% ) = 29.1%
11.652
fhp 88
= = 0.57 fhp in 2
A 154
Therefore, a problem of overheating is expected as Rasmussen recommends 0.2 to 0.3
fhp per square inch of brake contact area.
916. (a) For the band brake shown, derive the expressions for the braking torque in
terms of W , etc., for CL rotation and for CC rotation, and specify the ratio c b
for equal effectiveness in both directions of rotation. Are there any proportions of
b and c as shown that would result in the brae being self locking? (b) When
= 270o , a = 16 in ., b = c = 3 in ., and D = 12 in ., it was found that a
force W = 50 lb . Produced a frictional torque of 1000 in-lb. Compute the
coefficient of friction.
Page 80 of 97
SECTION 16 BRAKES AND CLUTCHES
Problem 916.
Solution:
(a)
CL:
[ M O =0 ]
aW = F1b + F2c
F1 = F2 e f
aW = F2e f b + F2 c
aW
F2 = f
be + c
aWe f
F1 = F2 e f = f
be + c
aWe f aW aW (e f 1)
F = F1 F2 = =
be f + c be f + c
Page 81 of 97
SECTION 16 BRAKES AND CLUTCHES
FD WaD e f 1
Tf = =
2 2 be f + c
CC:
[ M O =0 ]
aW = F2b + F1c
WaD e f 1
Tf =
2 ce f + b
No proportions of b and c as shown that would result in the brake being self-locking.
(b) W = 50 lb
T f = 1000 in lb
D = 12 in
a = 16 in
b = c = 3 in
= 270o = 4.7124 rad
(50)(16)(12) e f 1
T f = 1000 =
2 3e f + 3
e f 1
= 0.625
e f + 1
e f = e 4.7124 f = 4.333
f = 0.311
917. (a) For the brake shown, assume the proper direction of rotation of the cast-iron
wheel for differential acion and derive expressions for the braking torque. (b) Let
3
D = 14 in ., n = 1 in ., m = 4 in ., = 235o , and assume the band to be lined with
4
woven asbestos. Is there a chance that this brake will be self-acting? If true, will
Page 82 of 97
SECTION 16 BRAKES AND CLUTCHES
it always be for the range of values of f given in Table AT 29? (c) The ratio
n m should exceed what value in order for the brake to be self-locking? (d) If the
direction of rotation of the wheel is opposite to that taken in (a), what is the
braking torque with a force W = 10 lb . at a = 8 in .? (e) Suppose the brake is
used as a stop to prevent reverse motion on a hoist. What is the frictional
horsepower for the forward motion if the wheel turns 63 rpm?
(a) Assume CL
[ M O =0 ]
Wa + F1n = F2 m
F1 = F2 e f
Wa = F2 m F2 ne f = F2 (m ne f )
Wa
F2 =
(m ne f )
Page 83 of 97
SECTION 16 BRAKES AND CLUTCHES
Wae f
F1 =
(
m ne f )
Wa (e f 1)
F = F1 F2 = , Braking force.
m ne f
FD WaD e f 1
Tf = = , Braking torque.
2 2 m ne f
(b) D = 14 in
3
n = 1 in
4
m = 4 in
= 235o = 4.10 rad
Table AT 29, woven asbestos
f = 0.35 to 0.45
use f = 0.40
ne f = 1.75e(0.40 )(4.10 ) = 9.0 > m
use f = 0.35
ne f = 1.75e(0.35 )(4.10 ) = 7.35 > m
use f = 0.45
ne f = 1.75e (0.45 )(4.10 ) = 11.07 > m
n 1
> f
m e
n 1
> (0.4 )(4.10 )
m e
n
> 0 .2
m
Page 84 of 97
SECTION 16 BRAKES AND CLUTCHES
[ M O =0 ]
Wa + F2 n = F1m
Wa = F1m F2 n
F1 = F2 e f
Wa = F2 e f m F2 n = F2 (me f n )
Wa
F2 =
me f n
Wae f
F1 =
me f n
Wa (e f 1)
F = F1 F2 =
me f n
FD WaD e f 1
Tf = =
2 2 me f n
(10)(8)(14) e (0.40 )(4.10 ) 1
Tf =
2 4e (0.40 )(4.10 ) 1.75 = 123.3 in lb
(e) fhp =
Tf n
=
(123.3)(63) = 0.1233 hp
63,000 63,000
918. A differential band brake similar to that shown and lined with woven asbestos,
has the dimensions: D = 18 in ., n = 2 in ., m = 12 in ., = 195o . (a) Is there a
chance that this brake will be self-acting? (b) If W = 30 lb . and a = 26 in . ,
compute the maximum braking torque and the corresponding mechanical
advantage. (c) What is the ratio of the braking torque for CL rotation to the
braking torque for CC rotation? (d) A 1/16-in.-thick steel band, SAE 1020 as
rolled, carries the asbestos lining. What should be its width for a factor of safety
of 8, based on the ultimate stress? What should be the face width if the average
pressure is 50 psi?
Solution:
Page 85 of 97
SECTION 16 BRAKES AND CLUTCHES
For CC:
n > me f
me f < n
12e 0.4(3.4 ) = 46.8 > n , not self-acting
Page 86 of 97
SECTION 16 BRAKES AND CLUTCHES
722.3
s = 8125 =
b(0.0625)
b = 1.422 in
With p = 50 psi
F = fpA
bD
A=
2
Wa (e f 1) (30)(26)(e 0.4(3.4 ) 1)
max. F = = = 536.9 lb
m ne f 12 2e 0.4(3.4 )
fpbD
F=
2
536.9 =
(0.4)(50)(3.4)(b )(18)
2
b = 0.88 in
919. A differential band brake is to be design to absorb 10 fhp at 250 rpm. (a)
Compute the maximum and minimum diameters from both equations (z) and (a),
p. 495, Text. Decide on a size. (b) The band is to be lined with woven asbestos.
The Rasmussen recommendation (18.4) will help in deciding on the face width.
Also check the permissible pressure in Table AT 29. Choose dimensions of the
lever, its location and shape and the corresponding . Be sure the brake is not
self locking. What is the percentage variation of the mechanical advantage from
the minimum value ( f min ) for the f limits in Table AT 29?
Solution:
63,000hp 63,000(10 )
Tf = = = 2520 in lb
n 250
(a) Eq. (z)
1 1
Tf 3 2520 3
Dmin = = = 7.96 in
5 5
1 1
Tf 3 2520 3
Dmax = = = 8.57 in
4 4
Eq. (a)
1 1
Dmin = (60 fhp )3 = [60(10)]3 = 8.44 in
1 1
Dmin = (80 fhp )3 = [80(10)]3 = 9.28 in
use D = 8.5 in
(b) By Rasmussen
Energy absorption capacity = 0.2 to 0.3 fhp per sq. in. of brake contact area.
Page 87 of 97
SECTION 16 BRAKES AND CLUTCHES
For MA :
MA =
Tf
=
(
D e f 1)
(
WA 2 c be f )
Not self-locking
c > be f
c
> e f
b
c
> e 0.4
b
c
> 3 .5
b
c
say = 4 or c = 4b
b
For f = 0.40
T
MA = f =
(
D e f 1 )
=
( )
8.5 e 0.4 1
=
21.96
(
WA 2 c be f
) (
2 4b be )
0.4
b
For f = 0.35 = f min
Page 88 of 97
SECTION 16 BRAKES AND CLUTCHES
MA =
Tf D e f 1
=
(
=
) ( )
8.5 e 0.35 1
=
8.54
WA 2 c be (f
) (
2 4b be )
0.35
b
21.96 8.54
% variation = (100%) = 157%
8.54
DISK CLUTCHES
920. An automobile engine develops its maximum brake torque at 2800 rpm when the
bhp = 200. A design value of f = 0.25 is expected to be reasonable for the
asbestos facing and it is desired that the mean diameter not exceed 8.5 in.;
permissible pressure is 35 psi. Designing for a single plate clutch, Fig. 18.10,
Text, determine the outer and inner diameters of the disk.
Solution:
1
Dm = (Do + Di ) = 8.5 in
2
ro + ri = 8.5 in
63,000hp 63,000(200 )
Tf = = = 4500 in lb
n 2800
p = 35 psi
f N (ro + ri )
Tf =
2
4500 =
(0.25)(N )(8.5)
2
N = 4235 lb
N
ave. p =
(ro ri 2 )
2
4235
35 =
(ro2 ri 2 )
ro2 ri 2 = 38.5
ro = 8.5 ri
(8.5 ri )2 ri2 = 38.5
72.25 17 ri + ri 2 ri 2 = 38.5
ri = 1.985 in
say ri = 2.0 in
ro = 8.5 2.0 = 6.5 in
Do = 2ro = 2(6.5) = 13 in
Di = 2ri = 2(2.0) = 4 in
Page 89 of 97
SECTION 16 BRAKES AND CLUTCHES
921. An automobile engine can develop a maximum brake torque of 2448 in-lb.
Which of the following plate clutches, which make up a manufacturers standard
7 1
line, should be chosen for this car? Facing sizes: (a) Do = 8 , Di = 6 in ., (b)
8 8
1 1 1
Do = 10 , Di = 6 in ., (c) Do = 11 , Di = 6 in . In each case, assume f = 0.3 .
8 16 8
The unit pressures are (a) 34 psi, (b) 30 psi, and (c) 26.2 psi.
Solution:
f N (ro + ri )
Tf =
2
f N (Do + Di )
Tf =
4
(
N = pave Do2 Di2 )
4
Tf =
( )
pave Do2 Di2 (Do + Di )
16
Tf =
[ ]
(0.3)(34)(8.875)2 (6.125)2 (8.875 + 6.125)
= 1239 in lb
16
Tf =
[ ]
(0.3)(30)(10)2 (6.125)2 (10 + 6.125)
= 1780 in lb
16
Tf =
[ ]
(0.3)(26.2)(11.0625)2 (6.125)2 (11.0625 + 6.125)
= 2251 in lb
16
use (c)
Page 90 of 97
SECTION 16 BRAKES AND CLUTCHES
922. A single-disk clutch for an industrial application, similar to that in Fig. 18.11,
Text, except that there are two disks attached to one shaft and one attached to the
other. The clutch is rated at 50 hp at 500 rpm. The asbestos-in-resin-binder facing
1 3
has a Do = 8 in . and Di = 4 in . What must be the axial force and average
2 4
pressure? How does this pressure compare with that recommended by Table AT
29?
Solution:
n = 2 pairs in contact
f = 0.35 (Table AT 29)
p = 75 psi
63,000hp 63,000(50 )
Tf = = = 6300 in lb
nm 500
Do = 8.5 in
Di = 4.75 in
nf N (ro + ri )
Tf =
2
nf N (Do + Di )
Tf =
4
6300 =
(2)(0.35)(N )(8.5 + 4.75)
4
N = 2717 lb
4N 4(2717 )
ave. p = = = 69.6 psi < 75 psi
[
(Do Di ) (8.5)2 (4.75)2
2 2
]
923. A multiple-disk clutch similar to Fig. 18.11, Text, is rated at 22 hp at 100 rpm.
The outside and inside diameters of the disks are 14 and 7 in., respectively. If
f = 0.25 , find (a) the axial force required to transmit the rated load, and (b) the
unit pressure between the disks.
Solution:
(a) Fig. 18-11, n = 4 pairs in contact
63,000hp 63,000(22 )
Tf = = = 13,860 in lb
nm 100
nf N (Do + Di )
Tf =
4
Do = 14 in
Di = 7.5 in
4(0.25)( N )(14 + 7.5)
13,860 =
4
Page 91 of 97
SECTION 16 BRAKES AND CLUTCHES
N = 2579 lb
4N 4(2579 )
(b) p = = = 23.5 psi
(2
Do Di2
) [
(14)2 (7.5)2]
924. A multiple-disk clutch for a machine tool operation has 4 phosphor-bronze
driving disks and 5 hardened-steel driven disks. This clutch is rated at 5.8 hp at
100 rpm when operated dry. The outside and inside diameters of the disks are 5
and 4 3/16 in., respectively. (a) If the pressure between the disks is that
recommended for metal on metal in Table AT 29, what coefficient of friction is
required to transmit the rated power? (b) What power may be transmitted for f
and p as recommended in Table AT 29?
Solution:
Do = 5.5 in
Di = 4.1875 in
63,000hp 63,000(5.8)
Tf = = = 3654 in lb
nm 100
n = 8 pairs in contact
T f = 3654 =
(8)( f )(1498)(5.5 + 4.1875)
4
f = 0.126
925. A multiple-disk clutch with three disks on one shaft and two on the other, similar
to that in Fig. 18.11, Text, is rated at 53 hp at 500 rpm. (a) What is the largest
value of Di if f and p are given by Table AT 29 for asbestos in resin binder
and Do = 10.5 in . (b) For the diameter used of Di = 7 in .,what is the required
axial force and the average pressure?
Solution:
Page 92 of 97
SECTION 16 BRAKES AND CLUTCHES
( )
4T f = nfp Do2 Di2 (Do + Di )
4
63,000hp 63,000(53)
Tf = = = 6678 in lb
nm 500
n = 4 pairs in contact
( )
4T f = nfp Do2 Di2 (Do + Di )
4
[ ]
4(6678) = (4 )(0.3)(75) (10.5) Di2 (10.5 + Di )
4
2
Di = 9.5607 in
(b) Di = 7 in
nf N (Do + Di )
Tf =
4
6678 =
(4 )(0.3)( N )(10.5 + 7 )
4
N = 1272 lb
4N 4(1272 )
ave. p = = = 26.44 psi
[ ]
(Do Di ) (10.5)2 (7 )2
2 2
926. For the cone brake shown, find an expression for the braking torque for a given
applied force W on the bell crank. Consider the force F , Fig. 18.12, Text, in
obtaining the expression.
Page 93 of 97
SECTION 16 BRAKES AND CLUTCHES
Problems 926-928.
Solution:
927. For the cone brake similar to that shown, certain dimensions are: Dm = 15 in .,
1
c = 2 in ., = 12o , b = 9 in ., and a = 20 in . The contact surfaces are metal and
2
asbestos. (a) For an applied force W = 80 lb ., what braking torque may be
expected of this brake? Consider the resistance F , Fig. 18.12, Text. (b) If the
rotating shaft comes to rest from 300 rpm during 100 revolutions, what frictional
work has been done? (c) What must be the diameter of the steel pin P , SAE
1020 as rolled, for a factor fo safety of 6 against being sheard off? The diameter
1
of the hub d = 4 in . (d) What is the unit pressure on the face of the brake?
2
Solution:
f Dm R f Dm aW
(a) Tf = =
2(sin + f cos ) 2b(sin + f cos )
Table AT 29, asbestos on metal, f = 0.40
Tf =
(0.40)(15)(20)(80) = 890 in lb
2(9)(sin 12 + 0.4 cos 12)
2 (300 )
(b) 1 = = 31.42 rad sec
60
2 = 0 rad sec
= 100(2 ) = 628.3 rad
1
= (1 + 2 )t
2
1
628.3 = (31.42 + 0 )t
2
Page 94 of 97
SECTION 16 BRAKES AND CLUTCHES
t = 40 sec
1
nm = (300 + 0 ) = 150 rpm
2
T n
fhp = f m =
(890)(150) = 2.119 hp
63,000 63,000
U f = 550( fhp )(t ) = 550(2.119 )(40 ) = 46,618 ft lb
N
(d) p =
Dm c
R 177.8
N= = = 297 lb
sin + f cos sin 12 + 0.4 cos 12
297
p= = 2.52 psi
(15)(2.5)
928. A cone clutch for industrial use is to transmit 15 hp at 400 rpm. The mean
diameter of the clutch is 10 in. and the face angle = 10o ; let f = 0.3 for the
cast-iron cup and the asbestos lined cone; permissible p = 35 psi . Compute (a)
the needed axial force, (b) the face width, (c) the minimum axial force to achieve
engagement under load.
Solution:
63,000hp 63,000(15)
Tf = = = 2362.5 in lb
n 400
f Dm R
(a) T f =
2(sin + f cos )
Page 95 of 97
SECTION 16 BRAKES AND CLUTCHES
2362.5 =
(0.3)(10)R
2(sin 10 + 0.3 cos 10)
R = 739 lb
N
(b) p =
Dm c
R 739
N= = = 1575 lb
sin + f cos sin 10 + 0.3 cos 10
1575
35 =
(15)c
c = 1.44 in
929. An Airflex clutch, Fig. 18.15, Text, has a 16-in drum with a 5-in. face. This
clutch is rated at 110 hp at 100 rpm with an air pressure of 75 psi. What must be
the coefficient of friction if the effect of centrifugal force is neglected? (Data
courtesy of Federal Fawick Corporation.)
Solution:
D = 16 in
b = 5 in
hp = 110 hp
rpm = 100 rpm
p = 75 psi
63,000hp 63,000(110 )
Tf = = = 69,300 in lb
n 100
FD
Tf =
2
F (16 )
69,300 =
2
F = 8662.5 lb
N = p( Db ) = (75)( )(16)(5) = 18,850 lb
F 8662.5
f = = = 0.46
N 18,850
Page 96 of 97
SECTION 16 BRAKES AND CLUTCHES
930. The same as 929 except that the diameter is 6 in., the face width is 2 in., and the
rated horsepower is 3.
Solution:
63,000hp 63,000(3)
Tf = = = 1890 in lb
n 100
FD
Tf =
2
F (6 )
69,300 =
2
F = 630 lb
N = p( Db ) = (75)( )(6)(2 ) = 2827 lb
F 630
f = = = 0.22
N 2827
- end -
Page 97 of 97
SECTION 18 MISCELLANEOUS PROBLEMS
981. A closed cylindrical tank is used for a steam heater. The inner shell, 200 in.
outside diameter and 50 ft. long, is subjected to an external pressure of 40 psi.
The material is equivalent to SA 30 (ASME Pressure-Vessel Code: min.
su = 55 ksi ); assume an elastic limit of s y = su 2 ; let N = 5 . (a) What thickness
of shell is needed from a stress standpoint? (b) For this thickness, what must be
the maximum length of unsupported section to insure against collapse? (c)
Choose a spacing L to give a symmetric arrangement and determine the moment
of inertia of the steel stiffening rings. (d) For a similar problem, the Code
recommends that t 0.76 in , L = 50 in , and I = 96 in 4 . How do these values
check with those obtained above? (e) Without stiffening rings, what thickness
would be needed?
Solution:
pc D
t=
2s y
pc = 5 p = 5(40) = 200 psi
s 55,000
sy = u = = 27,500 psi
2 2
D = 200 in
p D (200)(200)
t= c = = 0.73 in
2s y 2(27,500)
say t = 0.75 in
(b) Solving for the maximum length of unsupported section, use Eq. (20-1)
5
t 2
2.60 E
pc = D psi
1
L t 2
0.45
D D
5
t 2
2.60 E 1
L D t 2
= + 0.45
D pc D
E = 30 106 psi
pc = 200 psi
t = 0.75 in
Page 1 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
D = 200 in
5
0.75 2
(
2.60 30 106 ) 1
L 200 + 0.45 0.75 2
=
200 200 200
L = 72.68 in
(c) Solving for the moment of inertia of the steel stiffening rings.
(e) L = 50 ft = 600 in
5 1
137.886t + 6.364t = 600
2 2
t = 1.791 in
Page 2 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
13
say t = 1 in
16
982. The same as 981, except that p = 175 psi , D = 4 ft , and the length of the tank is
18 ft.
pc D
t=
2s y
pc = 5 p = 5(175) = 875 psi
s 55,000
sy = u = = 27,500 psi
2 2
D = 4 ft = 48 in
p D (875)(48)
t= c = = 1.53 in
2s y 2(27,500)
9
say t = 1 = 1.5625 in
16
(b) Solving for the maximum length of unsupported section, use Eq. (20-1)
5
t 2
2.60 E
pc = D psi
1
L t 2
0.45
D D
5
t 2
2.60 E 1
L + 0.45
D t 2
=
D pc D
E = 30 106 psi
pc = 875 psi
t = 1.5625 in
D = 48 in
5
1.5625 2
(
2.60 30 10 6
)
1
1.5625 2
L 48
+ 0.45
=
48 875 48
L = 822 in
(c) Since length of shell = 18 ft = 216 in < 822 in, there is no need for stiffeners.
Page 3 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
(d) L = 216 in
5 1
4886.428t + 56.833t = 3937.5
2 2
t = 0.9122 in
15
say t = in
16
19
but minimum t = 1 in
16
19
use t = 1 in
16
Approximate ratio of weight of this shell to the weight of the shell found in (a) =
thickness of shell without stiffening rings / thickness of shell with stiffening rings
= 0.34375 / 0.09375 = 3.6667
Page 4 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
their moment of inertia and the cross-sectional dimensions h and b if they are
rectangular with h = 2b . (d) Suppose that the tank had no stiffening rings. What
thickness of shell would be needed? What is the approximate ratio of the weight
of the shell found in (a)? Material costs are roughly proportional to the weight.
Solution:
(b) Solving for the maximum length of unsupported section, use Eq. (20-1)
5
t 2
2.60 E
pc = D psi
1
L t 2
0.45
D D
5
t 2
2.60 E 1
L + 0.45
D t 2
=
D pc D
E = 30 106 psi
pc = 68.5 psi
t = 0.09375 in
D = 72 in
5
0.09375 2
(
2.60 30 10 6
) 1
0.09375 2
L 72
+ 0.45
=
72 68.5 72
L = 6.2 in
Page 5 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
(d) L = 10 ft = 120 in
5 1
25.8865t + 0.053t = 1.667
2 2
t = 0.3314 in
11
say t = in = 0.34375 in
32
Page 6 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
984. A long lap-welded steel tube, 8-in. OD, is to withstand an external pressure of
120 psi. with N = 5 . (a) What should be the thickness of the wall of the tube? (b)
What is the ratio D t ? Is it within the range of the Stewart equation? (c)
Assuming the internal pressure to be negligible relative to the external pressure,
calculate the maximum principal stress from equation (8.13), p. 255, text. What
design factor is given by this stress compared with s y for AISI C1015 annealed?
(d) Compute the stress from the thin shell formula.
Solution:
Stewarts formula
3
t
pc = 50,200,000
D
pc = Np = (5)(120) = 600 psi
3
t
600 = 50,200,000
8
t = 0.1829 in
3
say t = in = 0.1875 in
16
D 8
(b) ratio = = 42.67
t 0.1875
or D = 42.67t
outside the range of the Steward equation ( D < 40t )
pi ri 2 po ro2 + ri 2 ro2 ( pi po ) r 2
t =
ro2 ri 2
po = 120 psi
pi 0
OD 8
ro = = = 4 in
2 2
ri = 4 0.1875 = 3.8125 in
r = ri
po ro2 + ro2 (0 po ) 2 po ro2 2(120 )(4 )
2
t = = 2 2 = 2 = 2621 psi
2
ro ri 2
ro ri (4) (3.8125)2
s y of AISI C1015, annealed = 42 ksi
Page 7 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
sy 42,000
Design factor, N y = = = 16
t 2621
(d) Solving for the stress from the thin shell formula
s=
pD
=
(120)(8) = 2560 psi
2t 2(0.1875)
985. A long lap-welded steel tube, 3 in. OD, is to withstand an external pressure of
150 psi with N = 5 . Parts (a) (c) are the same as in 984.
Solution:
D 3
(b) ratio = = 38.4
t 0.078125
or D = 38.4t
within the range of the Steward equation ( D < 40t )
po = 150 psi
OD 3
ro = = = 1.5 in
2 2
ri = 1.5 0.078125 = 1.421875 in
2(150 )(1.5)
2
2 po ro2
t = = = 2957 psi
2
ro ri 2
(1.5)2 (1.421875)2
s y of AISI C1015, annealed = 42 ksi
sy 42,000
Design factor, N y = = = 14.2
t 2927
Page 8 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
986. A long lap-welded tube, 3-in. OD, is made of SAE 1015, annealed. Let the shell
thickness t = D 40 and N = 5 . (a) What is the corresponding safe external
pressure? (b) Compute the maximum principal stress (p. 255, Text), assuming a
negligible internal pressure. What design factor is given by this stress compared
with s y ? (c) Compare with stress computed from the thin-shell formula.
Solution:
3
t
pc = 50,200,000
D
t 1
=
D 40
3
1
pc = 50,200,000 = 784 psi
40
p 784
p= c = = 157 psi
N 5
pD (157 )(3)
s= = = 3140 psi
2t 2(0.075)
FLAT PLATES
987. A circular plate 24 in. in diameter and supported but not fixed at the edges, is
subjected to a uniformly distributed load of 125 psi. The material is SAE 1020, as
Page 9 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
rolled, and N = 2.5 based on the yield strength. Determine the thickness of the
plate.
Solution:
988. The cylinder head of a compressor is a circular cast-iron plate (ASTM class 20),
mounted on a 12-in. cylinder in which the pressure is 250 psi. Assuming the head
to be supported but not fixed at the edges, compute its thickness for N = 6 based
on ultimate strength.
Solution:
Solving for the thickness of the head
2
r
s = p psi
t
for cast-iron (ASTM class 20), su = 20 ksi
s 20,000
s= u = = 3333 psi
N 6
p = 250 psi
12
r= = 6 in
2
2
6
s = 3333 = 250
t
t = 1.6432 in
21
say t = 1 in = 1.65625 in
32
Page 10 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
989. A 10x15-in. rectangular opening in the head of a pressure vessel, whose internal
pressure is 175 psi, is covered with a flat plate of SAE 1015, annealed. Assuming
the plate to be supported at the edges, compute its thickness for N = 6 based on
ultimate strength.
Solution:
Solving for the thickness of the head
a 2b 2 p
s= 2 2 psi
2t (a + b 2 )
for SAE 1015, annealed, su = 56 ksi
s 56,000
s= u = = 9333 psi
N 6
a = 10 in
b = 15 in
p = 175 psi
s = 9333 =
(10 )2 (15)2 (175) psi
2t 2 [(10 ) + (15) ]
2 2
t = 0.8056 in
13
say t = in = 0.8125 in
16
CAMS
990. The force between a 5/8-in. hardened steel roller and a cast-iron (140 BHN) cam
is 100 lb.; radius of cam curvature at this point is 1 in. Compute the contact
width.
Solution:
P = 100 lb
1 5
r1 = = 0.3125 in
28
1
r2 = 1 = 1.25 in
4
N = 1.15
Page 11 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
900b
100 =
1 1
1.15 +
0.3125 1.25
b = 0.511 in
991. A radial cam is to lift a roller follower 3 in. with harmonic motion during a 150o
turn of the cam; 1 1.2-in. roller of hardened steel. The reciprocating parts weigh
10 lb., the spring force is 175 lb., the external force during the lift is 250 lb. The
cast-iron (225 BHN) cam turns 175 rpm. The cam curvature at the point of
maximum acceleration is 1 -in. radius. Compute the contact width.
Solution:
Neglecting frictional forces
Q + Fg + Fs + Fre = P cos
Q = external force during lift = 250 lb
Fg = weight of reciprocating parts = 10 lb
Fs = spring force = 175 lb
Fre = reversed effective force = qma
Fre = 2ma for harmonic motion
2
L
a = &x& = cos
2
L = 3 in
2 (175)
= = 18.326 rad sec
60
150
= 150o = = 2.618 rad
180
at maximum acceleration
2
3 (18.326 )
&x& = = 726 in sec 2
2 2.618
P cos = Q + Fg + Fs + Fre = 250 + 10 + 175 2m&x&
Fg 10 lb 10 lb sec 2
m= = =
g (32.2 ft sec 2 )(12 in ft ) 386.4 in
assume cos 1
10
P = 435 2 (726 ) = 397 lb
386.4
Page 12 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
992. The same as 991, except that the motion of the follower is cycloidal.
10
P = 435 1.1 (924 ) = 409 lb
386.4
Page 13 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
1
r1 = 1 in = 1.5 in
2
1
r2 = 1 in = 1.5 in
2
N = 1.15
2100b
409 =
1 1
1.15 +
1 .5 1 .5
b = 0.30 in
993. The same as 991, except that the motion of the follower is parabolic.
Page 14 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
2100b
389 =
1 1
1.15 +
1 .5 1 .5
b = 0.284 in
994. A cast-iron flywheel with a mean diameter of 36 in. changes speed from 400 rpm
to 380 rpm while it gives up 8000 ft-lb of energy. What is the coefficient of
fluctuation, the weight, and the approximate sectional area of the rim?
Solution:
Page 15 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
995. The energy required to shear a 1-in. round bar is approximately 1000 ft-lb. In use,
the shearing machine is expected to make a maximum of 40 cutting strokes a
minute. The frictional losses should not exceed 15 % of the motor output. The
shaft carrying the flywheel is to average 150 rpm. (a) What motor horsepower is
required? (b) Assuming a size of flywheel and choosing appropriate C f , find the
mass and sectional dimensions of the rim of a cast-iron flywheel. The width of
the rim is to equal the depth and is not to exceed 3 in. It would be safe to
assume that all the work of shearing is supplied by the kinetic energy given up by
the flywheel.
Solution:
hp =
(Energy required )(Strokes per min )
(1 Frictional losses )(33,000 ft lb hp min )
hp =
(1000)40 = 1.426 hp
(1 0.15)(33,000 ft lb hp min )
(b) Solving for the mass of the rim and size of section
32.2KE
w=
C f vs2
w = V
assume = 0.254 lb in3 for cast iron
V = DA
32.2KE
w = DA =
C f vs2
assume C f = 0.06 (Table 20-3)
KE = 1000 ft lb
Page 16 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
Dn
vs =
12(60)
n = 150 rpm
32.2KE
w = DA = 2
5 D
Cf
24
32.2KE
D3 = 2
5
Cf A
24
using width = depth = 3 in
A = (3.5)(3.5) = 12.25 in 2
32.2(1000 )
D3 = 2
5
0.06 (0.254 )( )(12.25)
24
D = 50.42 in
assume D = 51 in
5 ( 51)
vs = = 33.38 fps
24
32.2(1000 )
w= = 482 lb
0.06(33.38)
2
w 482
m= = = 15 slugs
g 32.2
w 482
A = (depth )(width ) = = = 11.84 in 2
D 0.254 (51)
depth = width = 11.84 in 2 = 3.44 in
1
say depth = width = 3 in
2
996. The same as 995, except that the capacity of the machine is such as to cut 1 -in.
round brass rod, for which the energy required is about 400 ft-lb./sq. in. of
section.
Solution:
hp =
(Energy required )(Strokes per min )
(1 Frictional losses )(33,000 ft lb hp min )
Page 17 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
( )
Energy required = 400 ft lb in 2 (1.5 in ) = 707 ft lb
2
4
hp =
(707 )(40) = 1.01 hp
(1 0.15)(33,000 ft lb hp min )
(b) Solving for the mass of the rim and size of section
32.2KE
D3 = 2
5
Cf A
24
KE = 707 ft lb
C f = 0.06
= 0.254 lb in3
A = (3.5)(3.5) = 12.25 in 2
32.2(707 )
D3 = 2
5
0.06 (0.254 )( )(12.25)
24
D = 45 in
use D = 45 in
32.2KE
w=
C f vs2
5 D 5 (45)
vs = = = 29.45 fps
24 24
32.2(707 )
w= = 438 lb
0.06(29.45)
2
w 438
m= = = 13.6 slugs
g 32.2
w 438
A = (depth )(width ) = = = 12.20 in 2
D 0.254 (45)
depth = width = 12.20 in 2 = 3.49 in
1
say depth = width = 3 in
2
997. A 75-hp Diesel engine, running at 517 rpm, has a maximum variation of output
of energy of 3730 ft-lb. The engine has three 8 x 10 in. cylinders and is
directly connected to an a-c generator. (a) What should be the weight and
sectional area of the flywheel rim if it has an outside diameter of 48-in.? (b) The
actual flywheel and generator have Wk 2 = 6787 lb ft 2 . Compute the
corresponding coefficient of fluctuation and compare.
Page 18 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
Solution:
32.2KE
w= lb
C f vs2
assume C f = 0.0035 , Table 20-3
KE = 3730 ft lb
Dn
vs =
12(60)
n = 570 rpm
assume D = 48 in
(48)(517 )
vs = = 108.28 rps
12(60)
32.2(3730 )
w= = 2927 lb
(0.0035)(108.28)2
w = DA
w
A=
D
assume = 0.254 lb in3 (cast iron)
2927
A= = 76.42 in 2
(0.254)( )( 48)
(b) Solving for coefficient of fluctuation
Ig = Wk 2 = 6787 lb ft 2
I (12 22 )
KE = ft lb
2
Wk 2 (12 22 )
KE = ft lb
g 2
KE =
Wk 2
(1 2 ) (1 + 2 ) ft lb
g 2
(1 + 2 ) =
2
2 (517 )
= = 54.14 rad sec
60
KE = 3730 ft lb
6787
KE = 3730 = (1 2 )54.14
32.2
1 2 = 0.327
Page 19 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
1 2 0.327
Cf = = = 0.006 > 0.0035
54.14
998. A 4-ft flywheel, with an rim 4 in. thick and 3 in. wide, rotates at 400 rpm. If there
are 6 arms, what is the approximate stress in the rim? Is this a safe stress? At
what maximum speed should this flywheel rotate if it is made of cast iron, class
30?
Solution:
s=
(83.78)2 (439) = 665 psi
144(32.2)
since v = (83.78)(60) fpm = 5027 fpm < 6000 fpm (cast iron)
this is a safe stress
999. A hollow steel shaft with Do = 6 in and Di = 3 in rotates at 10,000 rpm. (a) What
is the maximum stress in the shaft due to rotation? Will this stress materially
affect the strength of the shaft? (b) The same as (a), except that the shaft is solid.
Solution:
2
st =
4go
[(3 + )r
o
2
+ (1 )ri
2
] psi
where
D 6
ro = o = = 3 in
2 2
Di 3
ri = = = 1.5 in
2 2
Page 20 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
g o = 386 in sec
10,000
= 2 = 1047 rad sec
60
2
st =
4go
[(3 + )r
o
2
+ (1 )ri
2
] psi
st =
(0.284)(1047 )
2
[(3 + 0.3)(3)2 + (1 0.3)(1.5)2 ] = 6306 psi
4(386)
(does not affect the strength of the shaft)
1000. A circular steel disk has an outside diameter Do = 10 in and an inside diameter
Di = 2 in . Compute the maximum stress for a speed of (a) 10,000 rpm, (b)
20,000 rpm. (c) What will be the maximum speed without danger of permanent
deformation if the material is AISI 3150, OQT at 1000 F?
Solution:
2
st =
4go
[(3 + )r
o
2
+ (1 )ri
2
] psi
where
= 0.284 lb in3
= 0.30
D 10
ro = o = = 5 in
2 2
D 2
ri = i = = 1 in
2 2
g o = 386 in sec
st =
(0.284)(1047 )
2
[ ]
(3 + 0.3)(5)2 + (1 0.3)(1)2 = 16,776 psi
4(386)
Page 21 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
st =
(0.284)(2094)
2
[ ]
(3 + 0.3)(5)2 + (1 0.3)(1)2 = 67,104 psi
4(386 )
Solution:
Di = 1 in
D 1
ri = i = in = 0.5 in
2 2
use other data as in 1000.
st =
(0.284)(1047 )
2
[
(3 + 0.3)(5)2 + (1 0.3)(0.5)2 = 16,670 psi ]
4(386)
st =
(0.284)(2094)
2
[
(3 + 0.3)(5)2 + (1 0.3)(0.5)2 = 66,680 psi ]
4(386 )
Page 22 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
1002. A circular steel disk, with Do = 8 in and Di = 2 in , is shrunk onto a solid steel
shaft with an interference of metal i = 0.002 in . (a) At what speed will the
pressure in the fit become zero as a result of the rotation? Assume that the shaft is
unaffected by centrifugal action. (This effect is relatively small.) (b) Compute the
maximum stress in the disk and the pressure at the interface when the speed is
10,000 rpm. Note: The maximum stress in the disk is obtained by adding
equations (8.15) of i8.26, Text, and (n of i20.9. The resulting equation together
with equation (s) of i8.27 can then be used to obtain pi and th ; where
ts = pi for a solid shaft.
Solution:
Page 23 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
but po = 0
pi (ro2 + ri 2 )
ti =
ro2 ri 2
D 8
ro = o = = 4 in
2 2
D 2
ri = i = = 1 in
2 2
pi = 0
ti = 0
From Equation (n) i20.9
2
st =
4go
[(3 + )r o
2
+ (1 )ri
2
] psi
= 0.284 lb in3
= 0.30
ro = 4 in
ri = 1 in
g o = 386 in sec
th = ti + st
30,000 = 0 +
(0.284) 2 [(3 + 0.3)(4)2 + (1 0.3)(1)2 ]
4(386)
= 1746 rad sec
60 60(1746 )
RPM = = = 16,673 rpm
2 2
(b) Solving for the maximum stress in the disk and the pressure within the interface.
+ h pi ts + s pi
i = Di th
Eh Es
+ 0.3 pi ( pi + 0.3 pi )
0.002 = 2 th
30 10
6
30 10
30,000 = th + pi
th = 30,000 pi
th = ti + st
(
pi ro2 + ri 2 )
4 2 + 12 17
ti = 2 2 = pi 2 2 = pi
ro ri 4 1 15
2
st =
4go
[(3 + )r o
2
+ (1 )ri
2
] psi
Page 24 of 25
SECTION 18 MISCELLANEOUS PROBLEMS
2 (10,000 )
= = 1047 rad sec
60
st =
(0.284)(1047 )
2
[ ]
(3 + 0.3)(4)2 + (1 0.3)(1)2 = 10,788 psi
4(386)
th = ti + st
17
th = 30,000 pi = pi + 10,788
15
pi = 9000 psi (interface pressure)
th = 30,000 pi = 30,000 9000 = 21,000 psi (maximum stress)
- end -
Page 25 of 25