TUTORIAL 4

Design of Machine Elements

ME 351 (02/02/17)

NOTE: STEP MARKS ARE SHOWN AGAINST EACH STEP MM:35

Q1. A 25 mm diameter solid round bar has a groove 2.5 mm deep with a 2.5 mm radius machined into it. The bar is
made of AISI 1018 CD steel and is subjected to a purely reversing torque of 200 N-m. For the S-N curve of this material,
let f = 0.9.
(a). Estimate the number of cycles to failure.
(b). If the bar is also placed in an environment with a temperature of 450 F, estimate the number of cycles to failure.
Sol. 1. D = 25 mm, d = 20 mm, T = 200 N-m, f = 0.9, and from Table A-20: Sy = 370 MPa = 54 kpsi, Sut = 440 MPa =
64 kpsi (AISI 1018, CD).
r 2.5 D 25
(a). Fig. A-15-15: 0.125 , 1.25 , K ts 1.40 [1]
d 20 d 20
Get the notch sensitivity either from Fig. 6.21, or from the curve fit Eqs. (6.34) and (6.35b). We will use the equations.
a 0.190 2.5110 3 S ut 1.3510 5 S ut2 2.6710 8 S ut3 0.077 , q s
1 1
0.803 . [1]
a 1 0.077
1
r 0.3136
Eq. (6-32): K fs 1 q s K ts 1 1.32 . For a purely reversing torque of T = 200 N-m,
Tr 16T 16200
a K fs K fs 3 1.32 168.21 MPa. [2]
J d 20 10 3
3

Eq. (6-8): S e 0.5440 220 MPa. [1]
Eq. (6-19): k a 4.51440
0.265
0.898 . [1]
Eq. (6-20): k b 1.2420
0.107
0.899 . [1]
Eq. (6-26): k c 0.59 . [1]
Eq. (6-18): (labeling for shear) S se 0.898(0.899)(0.59)(220) 104.89 MPa. [1]
For purely reversing torsion, use Eq. (6-54) for the ultimate strength in shear.
Eq. (6-54): S su 0.67Sut 294.8 MPa. [1]
Adjusting the fatigue strength equations for shear,
fS su 2 1 fS
Eq. (6-14): a 671.128MPa. Eq. (6-15): b log su 0.134 [2]
S se 3 S se
1
b
Eq. (6-16): N a 30.54(103 ) cycles. [1]
a
Ans .

(b). For an operating temperature of 450 F, the temperature modification factor,

k d 0.975 0.432 103 TF 0.115 105 TF2 0.104 108 TF3 0.595 1012 TF4 1.006 . [1]
S se 0.898(0.899)(0.59)1.006(220) 105.52 MPa. [1]
fS su 2

a 667.12 MPa. [1]

S se
1 fS
b log su 0.133 . [2]
3 S se
1
b
N a 31.54(103 ) cycles. [2]
a
Ans.
Q2. The rotating shaft shown below (all the dimensions are in mm) is machined from AISI 1020 CD steel. It is subjected
to a force of F = 10 kN. Find the minimum factor of safety for fatigue based on infinite life. If the life is not infinite,
estimate the number of cycles. Be sure to check of yielding.

1000

350

50 D 70 D 6R 100 D 50 D

40 40

40 360 560 40

Sol. 2. Left bearing reaction force: 3.5 kN, right bearing reaction: 6.5 kN. [1]
The critical location will be at the shoulder fillet between the 70 mm and the 100 mm diameters, where the bending
moment is large, the diameter is smaller, and the stress concentration exists. The bending moment at this point is
M 3.5400 1400kN-mm. With a rotating shaft, the bending stress will be completely reversed.

rev
Mc 1400 2


70
0.0415 kN/mm2 = 41.5MPa.
I
704
64
This stress is far below the yield strength of 390MPa, so yielding is not predicted. Find the stress concentration factor
for the fatigue analysis. [2]
r 6 D 100
Fig. A-15-9: 0.086 , 1.43 , K t 1.7 . [1]
d 70 d 70
Get the notch sensitivity either from Fig. 6.21, or from the curve fit Eqs. (6.34) and (6.35a). We will use the equations
with Sut = 470 MPa = 68.2 kpsi and r = 6 mm = 0.236 in.
a 0.246 3.0810 3 S ut 1.5110 5 S ut2 2.6710 8 S ut3 0.0977 , q
1 1
0.832 . [1]
a 1 0.0977
1
r 0.236
Eq. (6-32): K f 1 qK t 1 1.582 . [1]

Eq. (6-8): S e 0.5S ut 0.5(470) 235 MPa. [1]
0.265
Eq. (6-19): k a aS 4.51(470)
b
ut 0.88 . (a and b from Table 6.2) [1]
0.157 0.107
Eq. (6-20): k b 1.51d 1.24(70) 0.774 . [1]
Eq. (6-26): k c 1. [1]

Eq. (6-18): S e k a k b k c S e 0.880.7741235 160.26 MPa. [1]
Se 160.26
nf 2.441. Infinite life is predicted. [4]
K f rev 1.58241.5
Ans.