Exam 2 Review Questions

1. The rotating solid steel shaft is simply supported by bearings at B and C and is driven by a gear
which meshes with the spur gear at D which has a 6-in pitch diameter. The force F from the
drive gear acts at a pressure angle of 20°. The shaft transmits a torque to point A of TA = 3000
lbf-in. the shaft is machined from steel with a yield strength of 60 kpsi and an ultimate tensile
strength of 80 kpsi. Using a factor of safety of 2.5, determine the minimum allowable diameter
of the shaft based on (a) a static yield analysis using the distortion energy theory and (b) a
fatigue-failure analysis using the Goodman criteria. Use stress concentration factors Kf = 1.8 and
Kfs = 1.3.

2. A stepped shaft with a larger diameter of D=75 mm, a smaller diameter of d=25 mm and a notch
radius r=2.5 mm is loaded in bending that the maximum and minimum bending moments are Mmax = 125
Nm and Mmin = -15 Nm and in torsion such that the maximum and minimum torques are Tmax = 80 Nm
and Tmin = -10 Nm. The shaft is machined steel with an ultimate tensile strength of 700 MPa and a yield
strength of 560 MPa.

A) Find the mean and alternating moments and torques.

B) Estimate the endurance limit of the shaft.

C) Calculate the fatigue stress concentration factors Kf and Kfs.

D) Calculate the factor of safety for the shaft using the modified Goodman criteria given a desired
reliability of 99%.

E) Calculate the factor of safety of failure due to yielding using the distortion energy theory.

f) If the shaft was made from ASTM grade 30 cast iron with an ultimate tensile strength of 214 MPa and
an ultimate compressive stress of 752 MPa, what would the factor of safety be for static failure?
3. A rotating bar is made of 1020 CD steel with an ultimate tensile strength of 68 kpsi, an
ultimate shear strength of 45.6 kpsi and a yield strength of 57 kpsi. The bar is 1 inch in
diameter and has a 0.1 inch deep groove with a 0.1 inch radius machined into it. The
rotating bar is subjected to a purely reversing torque of 1800 lb-in. For the S-N curve of
this material, let f = 0.9.
a) Find the endurance strength at a reliability of 50%
b) Find the shear stress concentration factor (Hint: Use charts at end of exam)
c) Calculate the mean and alternating shear and normal stresses.
d) Estimate the number of cycles to failure (Hint: Use ultimate shear strength in place of
ultimate tensile strength when calculating lifetime for fatigue in shear.)

4. A round 2 inch diameter bar is designed to have a groove cut into it with a diameter of
1.8 in and a groove radius of 0.1 in. The bar is not rotating and is designed to be loaded
with a repeated bending load that causes the bending moment at the groove to fluctuate
between 0 and 25,000 lbs. The bar is hot-rolled AISI 1095 steel with an ultimate tensile
strength of 120 kpsi and a yield strength of 66 kpsi. The groove has machined surface
finish.
a) Find the endurance strength of the bar at a reliability of 50%
b) Find the stress concentration factor Kf (Hint: Use charts at end of exam)
c) Find the alternating and mean stresses
d) Find the factor of safety for fatigue based on infinite life using the Goodman failure
theory
e) Find the factor of safety for yielding using distortion energy theory