UNIVERSITI TEKNOLOGI MALAYSIA

MODULE: SME3523 COMPONENTS DESIGN

SEM 2 SESSION 2012/2013

TEST 1
Time Allowed: 2 hours and 15 minutes.
Answer Question 1 and 2 and choose Question 3 or 4

QUESTION 1.0

Figure 1.0: Dimensions are in mm.

A beam is fixed to the concrete wall as shown in Fig. 1.0. Sections S1 is 12x12mm square whereas S2 is
8x8mm square. Two holes, H1 (5mm dia) are drilled at A & B and one hole, H2 (3mm dia) at C. Given
L1 = 14.00mm and L2 = 87.373mm. The force Px is 800N. Static stress concentration is ignored.
1
i.
ii.
iii.
iv.

2
i.
ii.
iii.
iv.

Find the stress acting at hole A by determining,

the force and moment acting at A
the moment of area, I and the cross-sectional area, A.
the axial and bending stress at A
principal stresses
Find the stress acting at hole C by determining,
the force and moment acting at C
the moment of area, I and the cross-sectional area, A.
the axial and bending stress at C
principal stresses
If the beam is made from brittle Gray Cast Iron ASTM 20 (Table A-24), determine the safety factor.

QUESTION 2.0

wall
8mm dia.

12mm dia.

Figure 2.0
A shaft machined and ground from AISI 1095HR steel rod is shown in Fig. 2.0 fixed rigid into a wall
(ditanam padu ke dalam dinding). The larger section is 12mm diameter and the long shaft is 8mm
diameter. There are fillet at A, holes at B, C and D. Loadings consisting of reversed moment M and
reversed torque T are both in phase. (Given: M = 10Nm, T = 15Nm). The shoulder fillet at A is 1.6mm
radius. The hole at B and C is 1.20mm diameter and hole at D is 1.6mm diameter.
i.
ii.
iii.
iv.
v.

Explain why hole D is more critical than hole C in fatigue stresses? 6

Calculate the endurance limit of the shaft 10
Find the stress concentration factor, bending stress and shear stress at A 6
Find the stress concentration factor, bending stress and shear stress at C 6
Find the stress concentration factor, bending stress and shear stress at D 6

vi.

Calculate the mean and alternating stresses m, a acting at the most critical section 10

vii.

Assuming that endurance limits is 410MPa, m = 0, a = 925MPa, calculate the safety factor
using Modified Goodman fatigue criterion. If the life is finite, calculate the number of cycles to
failure. (use minimum safety factor as 1.0) 8

QUESTION 3.0

Referring to Figure 3.0, answer the following

question.
a.
b.
c.
d.
e.
f.

Determine the centroid of bolts, c.

Determine the eccentricity, e.
Draw the free body diagram.
Explain why bolt 4 is most critical.
Calculate the primary load, the secondary load
and the resultant load for the critical bolt.
If the bolt is SAE Grade No. 4, metric thread
and the safety factor is 3, determine the size of
bolts, Ar which based on DET.

Figure 3.0: Bolt

QUESTION 4.0

Referring to Figure 4.0, answer the following

question.
a.
b.
c.
d.
e.

Figure 4.0: Weld

f.

Determine the centroid of weld, c.

Determine the eccentricity, e.
Draw the free body diagram.
Explain why the critical weld point is at N.
Calculate the primary stress, the secondary stress
and resultant stress for the critical weld point.
If the electrode number is AWS 8023 and the
safety factor is 3, determine the size of weld, h
which based on DET.