UE15ME301 Design of Machine Elements I (2017-18 5th Semester) Unit II

Classroom Problems

Unit II:
Design Against Fluctuating Load

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

UE15ME301 Design of Machine Elements I (2017-18 5th Semester) Unit II
Classroom Problems
Problem 1:
Determine the maximum stress induced in a plate of breadth 60 mm, length 80 mm and thickness 10
mm, with a hole of 12 mm diameter at the centre of the plate is subjected to a tensile load of 12 kN as
shown in Figure 1. Consider the stress concentration factor (SCF) into account.

12
12 kN 12 kN
60

10
80
Fig. 1
Problem 2:
Determine the maximum stress induced in a plate of breadth 60 mm, length 80 mm and thickness 10
mm, with a hole of 10 mm diameter at the centre of the plate is subjected to a transverse bending
moment of 25 Nm as shown in Figure 2. Consider the stress concentration factor (SCF) into account.

10

60

80
10

25 Nm 25 Nm
Fig. 2
Problem 3:
Determine the maximum stress induced in a plate of breadth 60 mm, length 80 mm and thickness 10
mm, with a notch of 10 mm radius is subjected to a tensile load of 12 kN as shown in Figure 12.
Consider the stress concentration factor (SCF) into account.
r10

12 kN 12 kN
60
r10

10
80

Fig. 3

2 | Department of Mechanical Engineering, PESU, Bangalore, Dr. C V Chandrashekara

UE15ME301 Design of Machine Elements I (2017-18 5th Semester) Unit II
Classroom Problems
Problem 4:
Determine the maximum stress induced in a plate of breadth 60 mm, length 80 mm and thickness 10
mm, with a notch of 10 mm radius is subjected to a transverse bending moment of 25 Nm as shown in
Figure 4. Consider the stress concentration factor (SCF) into account.
r10

M 60 M
r10

80
10

25 Nm 25 Nm
Fig. 4
Problem 5:
Find the value of maximum stress induced in the fillet as shown in Figure 5, if the stress concentration
factor for the filleted flat bar is considered and having a B/b ratio of 1.2. Also determine the factor of
safety if the flat bar is made of steel having a yield stress of 640 N/mm2. The thickness of the bar is 25
mm.

r10

120 kN

25
Fig. 5
Problem 6:
A plate of rectangular cross section is subjected to an axial pull of 100 kN, as shown in Figure 6.
Assuming the stress in the plate is limited to 200 MPa, determine the thickness of the plate.

A B r20 r10
C

100 kN 160 20
100 kN

A B C
Fig. 6
3 | Department of Mechanical Engineering, PESU, Bangalore, Dr. C V Chandrashekara
UE15ME301 Design of Machine Elements I (2017-18 5th Semester) Unit II
Classroom Problems
Problem 7:
A grooved shaft shown in Figure 7 is to transmit 5 kW at 120 rpm. Determine the diameter of the shaft at
the groove if it is made of C15 steel and take FOS 2.

T T

D = 1.4d d

r = 0.1d
Fig. 7

Problem 8:
A stepped shaft shown in Figure 8 is subjected to a transverse load. The shaft is made of FeE400 steel.
Determine the diameter d of the shaft based on the factor of safety 2. Consider the stress concentration
into account.
F = 8 kN

d/5
A B

d 2d d

RA d/10 RB
250 100 125 25

Fig. 8 [Note: Not to scale]

Problem 9:
A flat plate subjected to a tensile force of 5 kN is shown in Figure 9. The plate material is grey cast iron
FG 200 and the factor of safety is 2.5. Determine the thickness of the plate.

Fig. 9

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

UE15ME301 Design of Machine Elements I (2017-18 5th Semester) Unit II
Classroom Problems
Problem 10:
Determine the maximum stress induced in the semi-circular grooved shaft shown in Figure 10, if it is
subjected to:
(i). An axial load of 40 kN [Ans: 44.30 N/mm2]
(ii). A bending moment of 400Nm and [Ans: 61.30 N/mm2]
(iii). A twisting moment of 500 Nm [Ans: 29.85 N/mm2]

Take the stress concentration into account.

T T

60

r = 5mm
Fig. 10

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

UE15ME301 Design of Machine Elements I (2017-18 5th Semester) Unit II
Classroom Problems
Problems on Fluctuating load:
Problem 11:
A steel rod of material SAE9260 oil quenched is subjected to a tensile load which varies from 120 kN to
40 kN. Design the safe diameter of the rod using Soderberg Diagram. Adopt factor of safety as 2,
stress concentration factor as unity and notch sensitivity factor as 0.8. It is given correction factor for
load, size and surface as 0.75, 0.85 and 0.91 respectively.

Problem 12:
A piston rod is subjected to a maximum reversed axial load of 110 kN. It is made of steel having an
ultimate stress of 900 N/mm2 and the surface is machined. The average endurance limit is 50% of the
ultimate strength. Take the size correction factor as 0.85 and factor of safety as 1.75. Determine the
diameter of rod.

Problem 13:
A stepped shaft of circular cross-section shown in Figure 31 is subjected to variable load which is
completely reversed with a value equal to 100 kN. It is made of SAE104 steel annealed. Determine the
diameter d and radius r, so that the maximum stress will be limited to a value corresponding to a
factor of safety of 2. Notch sensitivity index = 1, size correction factor = 0.85.

Problem 14:
Determine the maximum load for a simply supported beam cyclically loaded as shown in Figure 11. The
ultimate strength is 700 MPa, the yield point in tension is 520 MPa and endurance limit in reversed
bending is 320 MPa. Use factor of safety as 1.25 and A, B and C values as 1, 0.75 and 0.9 respectively.

1W to 3W
200 mm 200 mm

50 mm

Fig. 11

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

UE15ME301 Design of Machine Elements I (2017-18 5th Semester) Unit II
Classroom Problems
Problem 15:
A cantilever beam shown in Figure 12 is subjected to a load variation from (F) N to (+3F) N.
Determine the maximum load that the member can withstand for an infinite life, using a factor of safety
as 2. The material of the beam is SAE1025, water quenched steel, B = 0.85 and rough machined surface.
Assume Notch sensitivity factor = 1.
r
-FN
= 40 mm
= 30 mm
+ 3F N
100 mm 200 mm

Fig. 12

Problems on stresses due to fluctuating combined load:

Problem 16:
A steel member of circular section is subjected to a torsional stress that varies from 0 to 35 MPa and at
the same time it is subjected to an axial stress that varies from -14 MPa to +28 MPa. Neglecting stress
concentration and assuming that the maximum stresses in torsion and axial load occur at the same time,
determine

a) Maximum equivalent shear stress and

b) Factor of safety based upon yield in shear.

The material has endurance limit 206 MPa and yield strength 480 MPa. Take load correction factor =1,
surface correction factor =1 and size correction factor = 1. Assume estimated fatigue stress
concentration factor for shear stress = 1

Problem 17:
A hot rolled steel shaft is subjected to a torsional load that varies from 330 Nm (cw) to 110Nm (ccw)
and an applied bending moment at the critical section varies from + 440 Nm to - 220 Nm. The shaft is
uniform cross-section and no keyway is present at the critical section. Determine the required shaft
diameter. The material has an ultimate strength of 550 MN/m2 and yield strength of 410 MN/m2. Factor
of safety = 1.5 and size correction coefficient is 0.85. Take the endurance limit as half the ultimate
strength.

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

UE15ME301 Design of Machine Elements I (2017-18 5th Semester) Unit II
Classroom Problems
Problem 18:
A round rod of diameter 1.2d reduced to a diameter d with a fillet radius of 0.1d. This stepped rod is to
sustain a twisting moment that fluctuates between +2.5 kN-m and + 1.5 kN-m together with a bending
moment that fluctuates between +1 kN-m and - 1 kN-m. The rod is made of carbon steel C40. Determine
a suitable value of d. Assume factor of safety = 2 and endurance limit as half of the ultimate stress.

Problem 19:
A steel cantilever member shown in Figure 13 is subjected to a transverse load at its end that varies from
45 N up to 135 N down and an axial load varies from 110 N compression to 450 N tension. Determine
the required diameter at the change of section for infinite life using a factor of safety of 2. The strength
properties of material are u = 550 N/mm2, yp = 470 N/mm2and en = 275 N/mm2. Notch sensitivity
index is 1.

45 kN
200 mm
0.2d
110 kN 450 kN
2d d

125mm
135 kN
Fig. 13

Problem 20:
A shaft of circular cross-section is subjected to a turning moment that fluctuates between 800 kN-m
to 600 kN-m and also a bending moment that fluctuates between + 500 kN-m to - 300 kN-m. The
material selected for the shaft has a shear stress value of 100MPa at endurance limit and shear stress
value of 120 MPa at the yield point. Determine the diameter of the shaft taking the value of factor of
safety as 2.5. Load factor, size factor and surface factor can be taken as 1.0, 0.85 and 0.9 respectively.
Shear stress concentration factor is 1.8 and the notch sensitivity index is 0.95.

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