Section 1a

SECTION 1– DESIGN FOR SIMPLE STRESSES
1
2(d − 0.9129 D )(0.4302 ) = π D 2
4
d = 1.8257 D
Equate (6) and (1)
1 
F = ss (4mb ) = s π D 2 
4 
1
0.6(4m )(0.4302 D ) = π D 2
4
m = 0.7607 D
Equate (7) and (1)
1 
F = ss (2nb ) = s π D 2 
4 
1
0.6(2n )(0.4302 D ) = π D 2
4
n = 1.5214 D
Equate (8) and (1)
1 
F = s (d − c )a = s π D 2 
4 
(1.8257 − D − 0.9129 D )a = 1 π D 2
4
a = 0.8604 D
Summary
a = 0.8604 D
b = 0.4302 D
c = 0.9129 D
d = 1.8257 D
m = 0.7607 D
n = 1.5214 D
47. Design a connection similar to the one shown for a gradually applied and reversed
load of 12 kips. Base design stresses on yield strengths and let the material be
AISI C1040 steel, annealed. Examine the computed dimensions for proportion,
making changes that you deem advisable.
Solution: (See figure in Prob. 45 and refer to Prob. 46)

N = 4 based on yield strength for gradually applied and reversed load.
For AISI C1040, annealed
s y = 47 ksi (Fig. AF 7)
Page 66 of 131
ssy = 0.6 s y = 28 ksi

sy 47
s= = = 11.75 ksi
N 4
1 
F = s π D 2 
4 
1 
12 = 11.75 π D 2 
4 
D = 1.14 in
1
say D = 1 in
8
 1
a = 0.8604 D = 0.86041  = 0.97 in
 8
but a > D
1
say a = 1 in
4
 1
b = 0.43021  = 0.48 in
 8
1
say b = in
2
 1
c = 0.91291  = 1.030 in
 8
say c = 1 in
 1
d = 1.82571  = 2.05 in
 8
say d = 2 in
 1
m = 0.76071  = 0.86 in
 8
7
say m = in
8
 1
n = 1.52141  = 1.71 in
 8
3
say n = 1 in
4
Dimension:
1
a = 1 in
4
1
b = in
2
c = 1 in
Page 67 of 131
d = 2 in
7
m = in
8
3
n = 1 in
4
1
D = 1 in
8
48. Give all the strength equations for the union of rods shown.
Problems 48 – 68.
Solution:
1 
F = s π d 2  Equation (1)
4 
F = ss (π ad ) Equation (2)
F = ss (2tc ) Equation (3)
Page 68 of 131
F = ss [2(D − e )b] Equation (4)
F = set Equation (5)
F = s (D − e )t Equation (6)
1 
(
F = s  π k 2 − e2  ) Equation (7)
4 
1 
( )
F = s  π m 2 − e 2 − (m − e )t  Equation (8)
4 
F = ss (2ef ) Equation (9)
Page 69 of 131
1 
F = s π e 2 − et  Equation (10)
4 
49-68. Design a union-of-rods joint similar to that shown for a reversing load and
material given in the accompanying table. The taper of cotter is to be ½ in. in 12
in. (see 172). (a) Using design stresses based on yield strengths determine all
dimensions to satisfy the necessary strength equations. (b) Modify dimensions as
necessary for good proportions, being careful not to weaken the joint. (c) Decide
upon tolerances and allowances for loose fits. (d) Sketch to scale each part of the
joint showing all dimensions needed for manufacture, with tolerances and
allowances.
Prob. No. Load, lb. AISI No., As Rolled
49 3000 1020
50 3500 1030
51 4000 1117
52 4500 1020
52 5000 1015
54 5500 1035
55 6000 1040
56 6500 1020
57 7000 1015
58 7500 1118
59 8000 1022
60 8500 1035
61 9000 1040
62 9500 1117
63 10,000 1035
64 10,500 1022
65 11,000 1137
66 11,500 1035
67 12,000 1045
68 12,500 1030
Page 70 of 131
Solution: (For Prob. 49 only)
(a) For AISI 1020, as rolled
s y = 48 ksi
s ys = 0.6 s y = 0.6(48) = 28.8 ksi
For reversing load, N = 4 based on yield strength
s 48
s= y = = 12 ksi
N 4
s 28.8
ss = ys = = 7.2 ksi
N 4
F = 3000 lb = 3 kips
Equation (1)
1 
F = s π d 2 
4 
1 
3 = 12 π d 2 
4 
d = 0.5642 in
9
say d = in
16
Equation (2)
F = ss (π ad )
9
3 = 7.2(π a ) 
 16 
a = 0.236 in
1
say a = in
4
Equation (5)
F = set
3 = 12et
et = 0.25
Equation (10)
1 
F = s π e 2 − et 
4 
1 
3 = 12 π e 2 − 0.25 
4 
e = 0.798 in
13
say e = in
16
et = 0.25
Page 71 of 131
 13 
 t = 0.25
 16 
t = 0..308 in
5
say t = in
16
Equation (6)
F = s (D − e )t
 13  5 
3 = 12 D −  
 16  16 
D = 1.6125 in
5
say D = 1 in
8
Equation (4)
F = ss [2(D − e )b]
  5 13  
3 = 7.221 − b 
  8 16  
b = 0.256 in
1
say b = in
4
Equation (7)
1 
F = s  π (k 2 − e 2 )
4 
 1   13  
2
3 = 12 π  k 2 −   
 4    16  
k = 0.989 in
say k = 1 in
Equation (9)
F = ss (2ef )
 13 
3 = 7.2(2 )  f
 16 
f = 0.256 in
1
say f = in
4
Equation (8)
1 
( )
F = s  π m 2 − e 2 − (m − e )t 
4 
 1   13   
2
13  5 
3 = 12 π m 2 −    −  m −  
 4   16    16  16 
Page 72 of 131
0.25 = 0.7854m 2 − 0.5185 − 0.3125m + 0.2539

0.7854m 2 − 0.3125m − 0.5146 = 0
m 2 − 0.3979m − 0.6552 = 0
m = 1.032 in
say m = 1 in
Equation (3)
F = ss (2tc )
5
3 = 7.2(2 ) c
 16 
c = 0.667 in
11
say c = in
16
DIMENSIONS:
9
d = in
16
1
a = in
4
1
b = in
4
11
c = in
16
1
f = in
4
13
e = in
16
5
t = in
16
k = 1 in
5
D = 1 in
8
m = 1 in
(b) Modified dimensions

9
d= in
16
1
a = in
4
3
b = in
4
11
c = in
16
Page 73 of 131
1
f = in
2
13
e = in
16
5
t = in
16
k = 1 in
5
D = 1 in
8
1
m = 1 in
4
(c) Tolerances and allowances

No fit, ± 0.010 in
d = 0.5625 ± 0.010 in
a = 0.250 ± 0.010 in
f = 0.500 ± 0.010 in
D = 1.625 ± 0.010 in
k = 1.000 ± 0.010 in
m = 1.250 ± 0.010 in
Fits, Table 3.1, loose-running fits, say RC 8
Female Male
+ 0.0035 − 0.0045
b = 0.750 in b = 0.750 in
− 0.0000 − 0.0065
allowance = 0.0045 in
+ 0.0028 − 0.0035
c = 0.6875 in c = 0.6875 in
− 0.0000 − 0.0051
+ 0.0035 − 0.0045
e = 0.8125 in e = 0.8125 in
− 0.0000 − 0.0065
allowance = 0.0045
+ 0.0022 − 0.0030
t = 0.3125 in t = 0.3125 in
− 0.0000 − 0.0040
Page 74 of 131
(d)
ROD
COTTER
Page 75 of 131
SOCKET
CHECK PROBLEMS
1 1
69. The connection shown has the following dimensions: d = 1 in , D = 2 in ,
4 2
1 5 1
D1 = 1 in , h = in , t = in ; it supports a load of 15 kips. Compute the tensile,
2 8 2
compressive, and shear stresses induced in the connection. What is the
corresponding design factor based on the yield strength if the rod and nut are
made of AISI C1045, as rolled, and the plate is structural steel (1020)?
Page 76 of 131
Problem 69.
Solution:
Tensile Stresses
F 15
(1) s1 = = 2
= 12.22 ksi
1 2 1  1 
πd π 1 
4 4  4
F 15
(2) s2 = = 2
= 8.4 ksi
1 2 1  1 
π D1 π 1 
4 4  2
Compressive Stress
F 15
(3) s3 = = = 4.78 ksi
1
( 2
π D − D1 )
2 1  2
   
1 1
2

4 π  2  − 1  
4  2   2  
Shear Stresses
F 15
(4) ss4 = = = 3.82 ksi
π Dt  1  1 
π  2  
 2  2 
F 15
(5) ss5 = = = 5.09 ksi
π D1h  1  5 
π 1  
 2  8 
For AISI C1045, as rolled (rod and nut)
s y1 = 59 ksi
s ys1 = 0.6 s y = 0.6(59 ) = 35.4 ksi
For structural steel plate (1020)
s y2 = 48 ksi
s ys1 = 0.6 s y = 0.6(48) = 28.8 ksi
Solving for design factor
Page 77 of 131
s y1 59
(1) N1 = = = 4.83
s1 12.22
s y1 59
(2) N 2 = = = 6.95
s2 8.49
s y2 48
(3) N 3 = = = 10.04
s3 4.78
s ys2 28.8
(4) N 4 = = = 7.54
s s4 3.82
s ys1 35.4
(5) N 5 = = = 6.96
s s5 5.09
The corresponding design factor is N = 4.83
3 7 3
70. In the figure, let D = in , t = in , b = 3 in , and let the load, which is applied
4 16 4
centrally so that it tends to pull the plates apart, be 15 kips. (a) Compute the
stresses in the various parts of the connection. (b) If the material is AISI C1020,
as rolled, what is the design factor of the connection based on yield strengths?
Problem 70.
Solution:
(a) Tensile stresses

F 15
s1 = = = 11.43 ksi
t (b − D )  7  3 3 
  3 − 
 16  4 4 
3 3
F  (15)
s2 = 4 = 4 = 11.43 ksi
t (b − 2 D )  7   3  3 
  3 − 2 
 16   4  4 
Compressive bearing stress
F 15
s3 = = = 11.43 ksi
4 Dt  3  7 
4  
 4  16 
Page 78 of 131
Shearing stress
F 15
ss 4 = = = 4.24 ksi
1 2  3 
2
4 π D (2 ) π   (2 )
4  4
(b) For AISI C1020, as rolled
s y = 48 ksi
s ys = 0.6 s y = 28.8 ksi
sy s ys
N= or N =
s ss
sy
Using N =
s
s 48
N= y = = 4.2
s 11.43
s
Using N = ys
ss
s 28.8
N = ys = = 6.8
ss 4.24
Therefore the design factor is N = 4.2
15 9 3 1
71. For the connection shown, let a = in , b = in , c = in , d = 1 in ,
16 16 4 2
3 15
D= in , m = n = in . The material is AISI C1040, annealed (see Fig. AF 1).
4 16
(a) For a load of 7500 lb., compute the various tensile, compressive, and shear
stresses. Determine the factor of safety based on (b) ultimate strength, (c) yield
strengths.
Problem 71.
Solution:
(a) Tensile stresses
Page 79 of 131
F 7 .5
s1 = = 2
= 16.98 ksi
1 1 3
π D2 π 
4 4 4
F 7 .5
s2 = = = 8.89 ksi
2b(d − c )  9  1 3 
2 1 − 
 16  2 4 
F 7 .5
s3 = = = 10.67 ksi
a (d − c )  15  1 3 
 1 − 
 16  2 4 
Compressive Stresses (Bearing)
F 7 .5
s4 = = = 8.89 ksi
2bc  9  3 
2  
 16  4 
F 7 .5
s5 = = = 10.67 ksi
ac  15  3 
  
 16  4 
Shearing Stresses
F 7 .5
s s6 = = = 3.56 ksi
4mb  15  9 
4  
 16  16 
F 7 .5
s s7 = = = 7.11 ksi
2nb  15  9 
2  
 16  16 
For AISI C1040, annealed,Fig. AF 1
s y = 47 ksi
su = 79 ksi
s ys = 0.6 s y = 28 ksi
sus = 0.6su = 59 ksi
(b) Based on ultimate strength

s 79
N= u = = 4.65
s1 16.98
(c) Based on yield strength
s 47
N= y = = 2.77
s1 16.98
72. The upper head of a 60,000-lb. tensile-testing machine is supported by two steel
rods, one of which A is shown. These rods A are attached to the head B by split
rings C. The test specimen is attached to the upper head B so that the tensile force
Page 80 of 131
in the specimen pulls down on the head and exerts a compressive force on the
rods A. When the machine is exerting the full load, compute (a) the compressive
stress in the rods, (b) the bearing stress between the rods and the rings, (c) the
shearing stress in the rings,
Problem 72.
Solution:
F = 60,000 lbs
(a) sc =
(60,000 2) = 11,753 psi = 11.75 ksi
1  1  
2
π  3  − (3)2 
4  2  
(b) sb =
(60,000 2) = 10,186 psi = 10.19 ksi
1  2  1 
2
π (4) −  3  
4   2  
(c) sc =
(60,000 2) = 3,183 psi = 3.18 ksi
π (3)(1)
DEFORMATIONS
73. A load of 22,000 lb. is gradually applied to a 2-in. round rod, 10 ft. long. The total
elongation is observed to be 0.03 in. If the stretching is entirely elastic, (a) what is
the modulus of elasticity, and (b) what material would you judge it to be, wrought
iron or stainless steel (from information available in the tables)? (c) How much
energy is absorbed by the rod? (d) Suppose that the material is aluminum alloy
3003-H14; compute its elongation for the same load. Is this within elastic action?
Solution:
F = 22,000 lbs
D = 2 in
L = 10 ft = 120 in
δ = 0.03 in
Page 81 of 131
FL
(a) δ =
EA
FL 4 FL 4(22,000 )(120 )
E= = = = 28 ×10 6 psi
δA δπ D 2
(0.03)(π )(2)2
(b) Use both stainless steel, Table AT 4, E = 28× 106 psi and wrought iron , Table AT 7,
E = 28× 106 psi .
1 1
(c) Energy absorbed = Fδ = (22,000 )(0.03) = 330 lb − in
2 2
(d) For Aluminum alloy, 3003-H14
E = 10× 106 psi

s y = 21 ksi
FL 4 FL 4(22,000 )(120 )
δ= = = = 0.084 in
EA Eπ D 2
( )
10 × 10 6 (π )(2 )
2
4F 4(22,000 )
s= = = 7003 psi = 7.0 ksi < s y , within the elastic limit.
πD 2
(π )(2)2
74. The same as 73, except that F = 88 kips and total δ = 0.112 in . Is the
computation for part (d) valid? Explain.
Solution:
(a) F = 88 kips
δ = 0.112 in
FL 4 FL 4(88,000 )(120 )
E= = = = 30 × 10 6 psi
δA δπ D 2
(0.112)(π )(2)2
(b) Use wrought steel, Table AT 4, E = 30× 106 psi

1 1
(c) Energy absorbed = Fδ = (88,000 )(0.112 ) = 4928 lb − in
2 2
(d) For Aluminum alloy, 3003-H14
E = 10× 106 psi

s y = 21 ksi
FL 4 FL 4(88,000 )(120 )
δ= = = = 0.336 in
EA Eπ D 2
( )
10 × 10 6 (π )(2 )
2
Page 82 of 131
4F 4(88,000 )
s= = = 28,011 psi = 28.0 ksi > s y , not within the elastic limit, therefore
πD 2
(π )(2)2
not valid.
75. (a) A square bar of SAE 1020, as rolled, is to carry a tensile load of 40 kips. The
bar is to be 4 ft. long. A design factor of 5 based on the ultimate stress is desired.
Moreover, the total deformation should not exceed 0.024 in. What should be the
dimensions of the section? (b) Using SAE 1045, as rolled, but with the other data
the same, find the dimensions. (c) Using SAE 4640, OQT 1000 F, but with other
data the same as in (a), find the dimensions. Is there a change in dimensions as
compared with part (b)? Explain the difference or the lack of difference in the
answers.
Solution:
L = 4 ft = 48 in
(a) For SAE 1020, as rolled
su = 65 ksi , E = 30,000 ksi
s F
s= u =
N A
65 40
=
5 x2
x = 1.754 in
FL
δ=
EA
0.024 =
(40)(48)
(30,000)x 2
x = 1.633 in
3
Therefore say x = 1 in
4
(b) For SAE 1045, as rolled
su = 96 ksi , E = 30,000 ksi
s F
s= u =
N A
96 40
=
5 x2
x = 1.443 in
FL
δ=
EA
0.024 =
(40)(48)
(30,000)x 2
x = 1.633 in
Page 83 of 131
5
8
(c) For SAE 4640, as rolled
su = 152 ksi , E = 30,000 ksi
s F
s= u =
N A
152 40
= 2
5 x
x = 1.15 in
FL
δ=
EA
0.024 =
(40)(48)
(30,000)x 2
x = 1.633 in
5
8
There is lack of difference in the answers due to same dimensions required to satisfy the
required elongation.
76. The steel rails on a railroad track are laid when the temperature is 40 F. The rails
are welded together and held in place by the ties so that no expansion is possible
due to temperature changes. What will be the stress in the rails when heated by
the sun to 120 F (i1.29)?
Solution:
s δ α L∆t
= =
E L L
For steel α = 0.000007 in in − F
E = 30 × 106 psi
s = α ∆tE = (0.000007 )(120 − 40)(30 × 106 )
s = 16,800 psi
77. Two steel rivets are inserted in a riveted connection. One rivet connects plates that
have a total thickness of 2 in., while the other connects plates with a total
thickness of 3 in. If it is assumed that, after heading, the rivets cool from 600 F
and that the coefficient of expansion as given in the Text applies, compute the
stresses in each rivet after it has cooled to a temperature of 70 F, (no external
load). See i1.29. Also assume that the plates are not deformed under load. Is such
a stress likely? Why is the actual stress smaller?
Page 84 of 131
Solution:
s = α ∆tE
For steel α = 0.000007 in in − F
E = 30 × 106 psi
s = (0.000007 )( 600 − 70)(30,000) = 111.30 ksi
The stress is unlikely because it is near the ultimate strength of steel.

Actual stress must be smaller to allow for safety.
78. Three flat plates are assembled as shown; the center one B of chromium steel,
AISI 5140 OQT 1000 F, and the outer two A and C of aluminum alloy 3003-H14,
are fastened together so that they will stretch equal amounts. The steel plate is 2 x
½ in., the aluminum plates are each 2 x 1/8 in., L = 30 in ., and the load is 24,000
lb. Determine (a) the stress in each plate, (b) the total elongation, (c) the energy
absorbed by the steel plate if the load is gradually applied, (d) the energy
absorbed by the aluminum plate. (e) What will be the stress in each plate if in
addition to the load of 24,000 lb. the temperature of the assembly is increased by
100 F?
Problem 78, 79.

Solution:
For chromium steel, AISI 5140 OQT 1000F (Table AT 7)
α1 = 0.000007 in in − F
E1 = 30 ×106 psi = 30,000 ksi
For aluminum alloy, 3003-H14 (Table AT 3)
α 2 = 0.0000129 in in − F
E2 = 10 ×106 psi = 10,000 ksi
(a) PA = PC
PA + PB + PC = F
(1) 2 PA + PB = F = 24 kips
1
A2 = (2 )  = 0.25 in 2
8
1
A1 = (2 )  = 1 in 2
2
Page 85 of 131
δA = δB
PA L PL
= B
A2 E2 A1 E1
PA PB
=
(0.25)(10,000) (1)(30,000)
(2) PB = 12 PA
(1) 2 PA + 12 PA = 24 kips
PA = 1.714 kips
PB = 12(1.714) = 20.568 kips
Stresses:
Aluminum plate
P 1.714
s A = sC = A = = 6.856 ksi
A2 0.25
Chromium steel plate
P 20.568
sB = B = = 20.568 ksi
A1 1
(b) δ =
PA L
=
(1.714 )(30) = 0.021 in
A2 E2 (0.25)(10,000 )
1 1
(c) Energy absorbed by steel plate = PBδ = (20.568)(0.021) = 0.216 kips − in
2 2
1 1
(d) Energy absorbed by aluminum plate = PAδ = (1.714 )(0.021) = 0.018 kips − in
2 2
(e) 2 PA + PB = F = 24 kips
δ TA + δ A = δ TB + δ B
δ T = α 2 L∆t
A
δ T = α1 L∆t
B
δ T = (0.0000129)(30)(100 ) = 0.0387 in
A
δ T = (0.000007 )(30 )(100) = 0.021 in

B
PA L PA (30 )
δA = = = 0.012 PA
A2 E2 (0.25)(10,000 )
PL PB (30 )
δB = B = = 0.001PB
A1E1 (1)(30,000 )
Then
0.0387 + 0.012 PA = 0.021 + 0.001PB
0.0177 + 0.012 PA = 0.001(24 − 2 PA )
0.0177 + 0.012 PA = 0.024 − 0.002 PA
Page 86 of 131
PA = 0.45 kips
PB = 24 − 2(0.45) = 23.1 kips
Stresses:
Aluminum plate
P 0.45
sA = A = = 1.8 ksi
A2 0.25
P 23.1
sB = B = = 23.1 ksi
A1 1
79. The same as 78, except that the outer plates are aluminum bronze, B150-1,
annealed.
Solution:
For aluminum bronze, B150-1, annealed (Table AT 3)

E2 = 15,000 ksi
α 2 = 0.0000092 in in − F
(a)
(1) 2 PA + PB = F = 24 kips
δA = δB
PA L PL
= B
A2 E2 A1 E1
PA PB
=
(0.25)(15,000) (1)(30,000)
(2) PB = 8PA
2 PA + 8PA = 24 kips
PA = 2.4 kips
PB = 8(2.4) = 19.2 kips
Stresses:
Aluminum plate
P 2 .4
s A = sC = A = = 9.6 ksi
A2 0.25
P 19.2
sB = B = = 19.2 ksi
A1 1
Page 87 of 131
(b) δ =
PA L
=
(2.4)(30) = 0.019 in
A2 E2 (0.25)(15,000 )
1 1
(c) Energy absorbed by steel plate = PBδ = (19.2 )(0.019 ) = 0.182 kips − in
2 2
1 1
(d) Energy absorbed by aluminum plate = PAδ = (2.4 )(0.019 ) = 0.023 kips − in
2 2
(e) 2 PA + PB = F = 24 kips
δ TA + δ A = δ TB + δ B
δ T = α 2 L∆t
A
δ T = α1 L∆t
B
δ T = (0.0000092)(30)(100 ) = 0.0276 in
A
δ T = (0.000007 )(30 )(100) = 0.021 in

B
PA L PA (30 )
δA = = = 0.008 PA
A2 E2 (0.25)(15,000 )
PL PB (30 )
δB = B = = 0.001PB
A1E1 (1)(30,000 )
Then
0.0276 + 0.008PA = 0.021 + 0.001PB
0.0066 + 0.008PA = 0.001(24 − 2 PA )
0.0066 + 0.008PA = 0.024 − 0.002 PA
PA = 1.74 kips
PB = 24 − 2(1.74) = 20.52 kips
Stresses:
Aluminum plate
P 1.74
sA = A = = 6.96 ksi
A2 0.25
P 20.52
sB = B = = 20.52 ksi
A1 1
80. A machine part shown is made of AISI C1040, annealed steel; L1 = 15 in .,

3 1
L2 = 6 in ., D1 = in ., and D2 = in . Determine (a) the elongation due to a force
4 2
F = 6000 lb ., (b) the energy absorbed by each section of the part if the load is
gradually applied.
Page 88 of 131
Problems 80, 81
Solution:
For AISI C1040, annealed steel
E = 30 × 106 psi
(a) δ = δ1 + δ 2
FL
δ1 = 1 =
(6000)(15) = 0.0068 in
A1E  π  3  2
   (30 × 10 )
6
 4  4 
FL
δ2 = 2 =
(6000)(6) = 0.0061 in
A2 E  π  1  2
   (30 × 10 )
6
 4  2 
δ = δ1 + δ 2 = 0.0068 + 0.0061 = 0.0129 in
(b) Energy absorbed

1 1
U1 = Fδ1 = (6000 )(0.0068) = 20.4 lb = in
2 2
1 1
U 2 = Fδ 2 = (6000 )(0.0061) = 18.3 lb = in
2 2
81. A rod as shown is made of AISI 2340 steel, OQT 1000 F, and has the following
7 3
dimensions: L1 = 20 in ., L2 = 12 in ., D1 = in ., and D2 = in . The unit strain at
8 4
point A is measured with a strain gage and found to be 0.0025 in./in. Determine
(a) the total elongation, and (b) the force on the rod.
Solution:
For steel E = 30000 ksi

δ F
(a) 2 = ε =
L2 A2 E
Page 89 of 131
F = ε A2 E
2
ε A2 EL1 A  D 
δ1 = = ε  2  L1 = ε  2  L1
A1 E  A1   D1 
 D  2   3 4  2 
δ T = δ1 + δ 2 = ε   L1 + L2  = 0.0025
2
 (20) + 12 = 0.067 in
 D1    7 8  
2
 π  3 
(b) F = ε A2 E = 0.0025   (30,000 ) = 33.13 kips
 4  4 
82. A rigid bar H is supported as shown in a horizontal position by the two rods
(aluminum 2024 T4, and steel AISI 1045, as rolled), whose ends were both in
contact with H before loading was applied. The ground and block B are also to be
considered rigid. What must be the cross-sectional area of the steel rod if, for the
assembly, N = 2 based on the yield strengths?
Problem 82.
Solution:
For aluminum 2024-T4 (Table AT 3)

s y1 = 47 ksi , E1 = 10,000 ksi
For steel AISI 1045, as rolled (Table AT 7)
s y2 = 59 ksi , E2 = 30,000 ksi
[∑ M G =0 ] R1 (24) + R2 (12) = 24(20)

2 R1 + R2 = 40 Equation (1)
Page 90 of 131
δ1 δ2
=
24 12
δ1 = 2δ 2
RL
δ1 = 1 1
E1 A1
RL
δ2 = 2 2
E2 A2
L1 = 8 ft = 96 in
L2 = 12 ft = 144 in
A1 = 0.5 in 2
δ1 = 2δ 2
R1 L1 2 R2 L2
=
E1 A1 E2 A2
R1 (96 ) 2 R2 (144 )
=
(10,000 )(0.5) (30,000)A2
0.5 R2
R1 =
A2
R sy
But s2 = 2 = 2
A2 N
R2 59
= = 29.5
A2 2
R1 = 0.5(29.5) = 14.75 kips
R sy
s1 = 1 = 1
A1 N
R1 47
=
0 .5 2
R1 = 11.75 kips
use R1 = 11.75 kips
R2 = 40 − 2(11.75) = 16.5 kips
R 16.5
A2 = 2 = = 0.56 in 2
29.5 29.5
Page 91 of 131
83. The bar shown supports a static load F = 2.5 kips with θ = 0 ; d = 3 in .,
3
L = 10 in ., h = 2 in . b = 1 in . It is made of AISI 1035, as rolled. (a) How far
4
does point C move upon gradual application of the load if the movement of A and
B is negligible? (b) How much energy is absorbed?
Problem 83.
Solution:
[∑ M A =0 ] dRB = (d + L )F
3RB = (3 + 10)(2.5)
RB = 10.83 kips
[∑ M B =0 ] dRA = LF
3RA = 10(2.5)
RA = 8.33 kips
Page 92 of 131
M = RA x − RB x − 3
d2y
M = EI 2 = 8.33x − 10.83 x − 3
dy
dy 2
EI = 4.165 x 2 − 5.415 x − 3 + C1
dy
3
EIy = 1.388 x 3 − 1.805 x − 3 + C1 x + C2
When x = 0 , y = 0
3
EI (0 ) = 1.388(0 ) − 1.805 0 + C1 (0 ) + C2
3
C2 = 0
When x = 3 , y = 0
3
EI (0 ) = 1.388(3) − 1.805 0 + C1 (3) + 0
3
C1 = −12.492
3
EIy = 1.388 x 3 − 1.805 x − 3 − 12.492 x
When x = d + L = 13 in
3
EIy = 1.388(13) − 1.805 10 − 12.492(13) = 1082
3
For AISI 1035, as rolled , E = 30,000 ksi

bh 3 (1)(2.75)
3
I= = = 1.7331 in 4
12 12
EIy = 1082
(30,000)(1.7331) y = 1082
y = 0.021 in , upward.
Page 93 of 131
PRESSURE VESSELS
84. A storage tank for air, 36 in. in diameter, is to withstand an internal pressure of
200 psi with a design factor of 4 based on su . The steel has the strength
equivalent of C1020 annealed and the welded joints should have a relative
strength (efficiency) of 90 %. Determine a suitable plate thickness. Compute the
stress on a diametral section and compare it with the longitudinal stress.
Solution:
For C1020 annealed
su = 57 ksi
su 57
s= = = 14.25 ksi
N 4
Solving for plate thickness
pD
s=
2 tη
p = 200 psi = 0.2 ksi
D = 36 in
s = 14.25 =
(5.2)(36)
2 t (0.9 )
t = 0.281 in
5
say t = in
16
Stress on diametral section
s=
pD
=
(0.2 )(36 ) = 6.40 ksi
4 tη 5
4 (0.9 )
 16 
Stress on longitudinal section
s=
pD
=
(0.2)(36) = 12.80 ksi
2 tη 5
2 (0.9 )
 16 
Stress on diametral section < stress on longitudinal section
85. A spherical air tank stores air at 3000 psig. The tank is to have an inside diameter
of 7 in. (a) What should be the wall thickness and weight of the tank if it is made
of 301, ¼-hard, stainless steel, with a design factor of 1.5 based on the yield
strength and a joint efficiency of 90 %. (b) Compute the wall thickness and
weight if annealed titanium (B265, gr. 5) is used? (c) What is the additional
saving in weight if the titanium is hardened? Can you think of circumstances for
which the higher cost of titanium would be justified?
Page 94 of 131
Solution:
(a) For 301, ¼ hard, stainless steel

s y = 75 ksi (Table AT 4)
sy 75
s= = = 50 ksi
N 1.5
p = 3000 psi = 3 ksi
pD
s=
4 tη
50 =
(3)(7)
4t (0.90)
t = 0.117 in
γ = 0.286 lb in3
W = 4π r 2t γ = π D 2t γ = π (7 ) (0.117 )(0.286 ) = 5.2 lb
2
(b) For annealed titanium B265, gr. 5

sy 130
s= = = 86.67 ksi
N 1.5
p = 3000 psi = 3 ksi
pD
s=
4 tη
86.67 =
(3)(7)
4t (0.90)
t = 0.061 in
γ = 0.160 lb in3
W = 4π r 2t γ = π D 2t γ = π (7 ) (0.061)(0.160 ) = 1.5 lb
2
(c) For hardened titanium

sy 158
s= = = 105 ksi
N 1.5
p = 3000 psi = 3 ksi
pD
s=
4 tη
105 =
(3)(7)
4t (0.90)
Page 95 of 131
t = 0.056 in
γ = 0.160 lb in3
W = 4π r 2t γ = π D 2t γ = π (7 ) (0.056 )(0.160 ) = 1.38 lb
2
1.50 − 1.38
Savings in weight = (100%) = 8%
1.50
Circumstances: less in weight and small thickness.
86. Decide upon a material and estimate a safe wall thickness of a cylindrical vessel
to contain helium at –300 F and 2750 psi. The welded joint should have a relative
strength ≥ 87 %, and the initial computations are to be for a 12-in.-diameter, 30-
ft.-long tank. (Note: Mechanical properties of metals at this low temperature are
not available in the Text. Refer to INCO Nickel Topics, vol. 16, no. 7, 1963, or
elsewhere.)
Solution:
From Kent’s Handbook, Table 8
Material – Hot Rolled Nickel
At – 300 F, su = 100 ksi , N = 4 (Table 1.1)
s 100
s= u = = 25 ksi
N 4
pD
s=
2 tη
p = 2750 psi = 2.75 ksi
D = 12 in
η = 87%
s = 25 =
(2.75)(12)
2 t (0.87 )
t = 0.759 in
3
say t = in
4
CONTACT STRESSES
87. (a) A 0.75-in. diameter roller is in contact with a plate-cam surface whose width is
0.5-in. The maximum load is 2.5 kips where the radius of curvature of the cam
surface is 3.333 in. Compute the Hertz compressive stress. (b) The same as (a)
except that the follower has a plane flat face. (c) The same as (a) except that the
roller runs in a grooved face and contacts the concave surface. (d) What is the
maximum shear stress for part (a) and how far below the surface does it exist?
Solution:
Page 96 of 131
(a) 2r1 = 0.75 in , r1 = 0.375 in

r2 = 3.333 in
F = 2.5 kips
b = 0.5 in
1
  1 1 2
 0.35 F  +  
sc max =   r1 r2  
  1 1  
 b +  
  E1 E2  
E = 30,000 ksi
1
  1 1 2
 0.35(2.5) + 
sc max =  0.375 3.333   = 279 ksi
  2  
 0.5  
  30,000  
1
  1 1 2
 0.35(2.5 ) + 
(b) sc max =  3 .333 3 .333   = 126 ksi
  2  
 0.5  
  30,000  
1
  1 1 2
 0.35(2.5 ) − 
(c) sc max =   0.375 3.333  
= 249 ksi
  2  
 0.5  
  30,000  
(d) Maximum shear stress

ss max = 0.3sc max = 0.3(279) = 84 ksi
Location:
 1 1   2 
( ) (
4sc max 1 − µ 2  +  4(279) 1 − 0.32 
E1 E2 
) 
w=  =  30,000 
= 0.023 in
1 1  1 1 
 +   + 
 r1 r2   0.375 3.333 
88. Two 20o involute teeth are in contact along a “line” where the radii of curvature
of the profiles are respectively 1.03 and 3.42 in. The face width of the gears is 3
in. If the maximum permissible contact stress for carburized teeth is 200 ksi, what
normal load may these teeth support?
Page 97 of 131
Solution:
r1 = 1.03 in
r2 = 3.42 in
b = 3 in
sc max = 200 ksi
1
  1 1 2
 0.35 F  +  
sc max =   r1 r2  
  1 1  
 b +  
  E1 E2  
E = 30,000 ksi
1
  1 1 2
 0.35 F  + 
sc max = 200 =   1.03 3.42  
  2  
 3  
  30,000  
F = 18 kips
TOLERANCES AND ALLOWANCES
89. The pin for a yoke connection has a diameter of D of ¾ in., a total length of 2 ½
in., with a head that is 1 ¼ in. in diameter and 3/8 in. thick. The tolerance on D
(both pin and hole) is 0.003 in., with an allowance of 0.001 in., basic-hole system.
Sketch the pin showing all dimensions with appropriate tolerances.
Solution:
D = 0.75 in
For pin
+ 0.000
D = 0.749 in
− 0.003
For hole
+ 0.003
D = 0.750 in
− 0.000
Sketch
Page 98 of 131
90. A shaft with a nominal diameter of 8 in. is to fit in a hole. Specify the allowance,
tolerances, and the limit diameters of the shaft and hole on a sketch for: (a) a close
sliding fit, (b) a precision-running fit, (c) medium-running fit, (d) a loose-running
fit.
Solution: D = 8 in
(a) For close-sliding fit, RC 1
Hole, in Shaft, in
+0.0008 - 0.0006
-0.0000 -0.0012
Allowance = 0.0006 in
With tolerances,
+ 0.0008
Hole D = 8.0000 in
− 0.0000
+ 0.0000
Shaft D = 7.9994 in
− 0.0006
Limit dimension,
Hole D = 8.0000 to 8.0008 in
Shaft D = 7.9994 to 7.9988 in
Sketch
Page 99 of 131
(b) For a precision-running fit, RC 3

Hole, in Shaft, in
+0.0012 -0.0020
-0.0000 -0.0032
With tolerances,
+ 0.0012
Hole D = 8.0000 in
− 0.0000
+ 0.0000
Shaft D = 7.9980 in
− 0.0012
Limit dimension,
Hole D = 8.0000 to 8.0012 in
Shaft D = 7.9980 to 7.9968 in
Sketch
(c) For medium-running fit, RC5, RC 6. Say RC 5
Hole, in Shaft, in
+0.0018 -0.0040
-0.0000 -0.0058
With tolerances,
+ 0.0018
Hole D = 8.0000 in
− 0.0000
+ 0.0000
Shaft D = 7.9960 in
− 0.0018
Limit dimension,
Hole D = 8.0000 to 8.0018 in
Shaft D = 7.9960 to 7.9942 in
Sketch
Page 100 of 131

(d) For loose-running fit, RC 8, RC 9. Say RC 8
Hole, in Shaft, in
+0.0070 -0.0100
-0.0000 -0.0145
With tolerances,
+ 0.0070
Hole D = 8.0000 in
− 0.0000
+ 0.0000
Shaft D = 7.9900 in
− 0.0045
Limit dimension,
Hole D = 8.0000 to 8.0070 in
Shaft D = 7.9900 to 7.9855 in
Sketch
91. The same as 90, except that the nominal diameter is 4 in.
Solution:
D = 4 in
(a) For close-sliding fit, RC 1
Page 101 of 131

Hole, in Shaft, in
+0.0006 -0.0005
-0.0000 -0.0009
With tolerances,
+ 0.0006
Hole D = 4.0000 in
− 0.0000
+ 0.0000
Shaft D = 3.9995 in
− 0.0004
Limit dimension,
Hole D = 4.0000 to 4.0006 in
Shaft D = 3.9995 to 3.9991 in
Sketch
(b) For a precision-running fit, RC 3

Hole, in Shaft, in
+0.0009 -0.0014
-0.0000 -0.0023
With tolerances,
+ 0.0009
Hole D = 4.0000 in
− 0.0000
+ 0.0000
Shaft D = 3.9986 in
− 0.0009
Limit dimension,
Hole D = 4.0000 to 4.0009 in
Shaft D = 3.9986 to 3.9977 in
Sketch
Page 102 of 131

(c) For medium-running fit, RC5, RC 6. Say RC 6
Hole, in Shaft, in
+0.0022 -0.0030
-0.0000 -0.0052
With tolerances,
+ 0.0022
Hole D = 4.0000 in
− 0.0000
+ 0.0000
Shaft D = 3.9970 in
− 0.0022
Limit dimension,
Hole D = 4.0000 to 4.0022 in
Shaft D = 3.9970 to 7.9948 in
Sketch
(d) For loose-running fit, RC 8, RC 9. Say RC 9
Hole, in Shaft, in
+0.0090 -0.0100
-0.0000 -0.0150
Page 103 of 131

With tolerances,
+ 0.0090
Hole D = 4.0000 in
− 0.0000
+ 0.0000
Shaft D = 3.9900 in
− 0.0050
Limit dimension,
Hole D = 4.0000 to 4.0090 in
Shaft D = 3.9900 to 3.9850 in
Sketch
92. A cast-iron gear is to be shrunk onto a 3-in, steel shaft. (a) Determine the
tolerance and the maximum, minimum, and average interferences of metal for
class FN 1 fit. (b) Sketch and dimension the shaft and hole with proper tolerances.
(c) Compute the stresses by the method given in the Text (i3.8) for the maximum
and minimum interferences of metal.
Solution: D = 3 in
(a) For class FN 1 fit, Table 3.2
Tolerances
Hole, in Shaft, in
+0.0007 +0.0019
-0.0000 +0.0014
Max. interference = 0.0019 in
Min. interference = 0.0014 – 0.0007 = 0.0007 in
Ave. interference = 0.5(0.0019 + 0.0007) = 0.0013 in
(b)
Page 104 of 131

(c) For maximum interference
Ei
s=
D
E = 23,000 ksi
s=
(23,000)(0.0019) = 14.6 ksi
3
For minimum interference
s=
(23,000)(0.0007 ) = 5.4 ksi
3
93. The same as 92, except that the gear hub is C1035 steel and class of fit is FN 3.
Solution: D = 3 in
(a) For class FN 3fit, Table 3.2
Tolerances
Hole, in Shaft, in
+0.0012 +0.0037
-0.0000 +0.0030
Max. interference = 0.0037 in
Min. interference = 0.0030 – 0.0012 = 0.0018 in
Ave. interference = 0.5(0.0037 + 0.0018) = 0.0028 in
(b)
Page 105 of 131

(c) For C1035 steel, E = 30,000 ksi
For maximum interference
Ei
s=
D
s=
(30,000 )(0.0037 )
= 37 ksi
3
For minimum interference
s=
(30,000)(0.0018) = 18 ksi
3
94. For a No. 7 ball bearing, the New Departure Handbook states that the maximum
bore should be 1.3780 in. and the minimum, 1.3775 in.; for average conditions,
the shaft should have a maximum diameter of 1.3784 in. and a minimum of
1.3779 in. (a) Determine the corresponding tolerances and allowances. (b) What
class of fit is this? (c) New Departure states: “. . . bearing bores are held
uniformly close, . . . averaging within 1.3778 in. to 1.3776 in.” What will be the
maximum and minimum interference of metal with these diameters (if maximum
and minimum sizes are deliberately chosen for assembly)?
Solution:
(a) Tolerances:
For No. 7 ball bearing

Bore, 1.3780 – 1.3775 in = 0.0005 in
+ 0.0005
Therefore, D = 1.3775 in
− 0.0000
Page 106 of 131

Shaft, 1.3784 – 1.3775 = 0.0009 in

1.3779 – 1.3775 = 0.0004 in
+ 0.0000
D = 1.37845 in
− 0.0005
Tolerances
Hole, in Shaft, in
+0.0005 +0.0009
-0.0000 +0.0004
Allowance = 0 – 0.0009 in = - 0.0009 in
(b) Since allowance is < 0.

It is a force and shrink fil class.
(c)
1.3778 – 1.3775 = 0.0003 in

1.3776 – 1.3775 = 0.0001 in
New tolerances
Hole, in Shaft, in
+0.0005 +0.0003
-0.0000 +0.0001
Maximum interference = 0.0003 in

Minimum interference = 0.0000 in (since 0.0001 – 0.0005 = - 0.0004 < 0)
95. For a roller bearing having a bore of 65 mm. an SKF catalog states that the largest
diameter should be 2.5591 in. and the smallest, 2.5585 in. If this bearing is to be
used in a gear transmission, it is recommended for the shaft (where the bearing
fits) to have a maximum diameter of 2.5600 in. and a minimum of 2.5595 in. (a)
Determine the tolerances and allowances (or interferences of metal) for this
installation. (b) What class of fit would this be?
Solution:
(a) 65 mm = 2.5591 in
2.5591 – 2.5585 = 0.0006 in

2.5600 – 2.5585 = 0.0015 in
2.5595 – 2.5585 = 0.0010 in
Page 107 of 131

Tolerances
Hole, in Shaft, in
+0.0006 +0.0015
-0.0000 +0.0010
Maximum interference = 0.0015 in

Minimum interference = 0.0010 – 0.0006 = 0.0004 in
(b) Class of fit, Force and shrink fit
TOLERANCES, STATISTICAL CONSIDERATION
96. (a) A machine tool is capable if machining parts so that the standard deviation of
one critical dimension is 0.0006 in. What minimum tolerance may be specified for
this dimension if it is expected that practically all of the production be acceptable?
Assume that it is possible to “center the process.” (b) The same as (a), except that
it has been decided to tolerate approximately 4.56 % scrap.
Solution:
(a)
T = NS = 6σ = 6(0.0006) = 0.0036 in
(b)
0.0456
A= = 0.0228 in
2
Page 108 of 131

From Table 3.3

z
= 2 .0
σ
z = 2σ
T = 2 z = 4σ
T = 4(0.0006) = 0.0024 in
97. A pin and the hole into which it fits have a nominal diameter of 1 ½ in. The pin
tolerance has been set to 0.002 in., the bore tolerance at 0.003 in., and the
allowance at 0.001 in., basic hole system. The parts are to be a natural spread of
0.0015 in. for the pin and 0.002 in. for the hole. Assuming that the processes are
centered, determine the expected minimum clearance and the maximum
clearance. What is the most frequent clearance?
Solution:
1.5015 – 1.4980 = 0.0035 in

NS 0.0015
σ 1 ( pin ) = 1 = = 0.00025 in
6 6
NS 2 0.0020
σ 2 (hole ) = = = 0.00033 in
6 6
σ D2 = σ 12 + σ 22 = (0.00025)2 + (0.00033)2
σ D = 0.00041 in
Natural Spread of Difference = 6σ D = 6(0.00041) = 0.00246 in
Page 109 of 131

Expected minimum clearance = 0.00227 in

Expected maximum clearance = 0.00473 in
Most frequent clearance = 0.0035 in
98. A rod and the hole into which it fits has a nominal diameter of 2 in. The
tolerances are 0.003 in. for both rod and hole, and the allowance as 0..001 in.,
basic hole system. The natural spread of the process of manufacturing the hole is
0.002 in., and for the rod, 0.0015 in. What are the probable maximum and
minimum clearances, provided that the tolerances are met, but assuming that the
processes might simultaneously operate at their extreme permissible position?
Solution:
NS1 0.0015
σ 1 (rod ) = = = 0.00025 in
6 6
NS 2 0.0020
σ 2 ( pin ) = = = 0.00033 in
6 6
σ D2 = σ 12 + σ 22 = (0.00025)2 + (0.00033)2
σ D = 0.00041 in
Page 110 of 131

NS = 6σ D = 6(0.00041) = 0.00246 in
2.0020 – 1.99675 = 0.00525 in
Probable maximum clearance = 0.00648 in

Probable minimum clearance = 0.00402 in
99. It is desired that the clearance in a 4-in. bearing neither exceed 0.004 in. nor be
less than 0.002 in. Assume that the natural spread of the processes by which the
journal and the bearing surfaces are finished is the same. (a) What should be the
natural spread of these processes? (b) Assuming this natural spread to be equal to
the tolerance, determine the corresponding allowance. (c) If the foregoing
conditions are not practical decide upon practical tolerances and allowances for
the computed natural spread.
Solution:
(a) NS = 6σ D
NS 0.002
σD = = = 0.00033 in
6 6
(b) σ D = 2σ
σ 0.00033
σ= D = = 0.000233 in
2 2
Page 111 of 131

NS = 6σ = 6(0.000233) = 0.0014 in
Tolerance = 0.0014 in
Corresponing allowance = 0.0016 in
(c) From Fig. 3.4, T > NS
Tolerance = T = 1.3NS = 1.3(0.0014) = 0.0018 in

Allowance = 0.003 – 0.0018 = 0.0012 in
100. A 4-in, journal-bearing assembly is made for class RC 6 fit. Assume that the
natural spread of the manufacturing process will be about 75 % of the tolerance.
Compute the probable maximum and minimum clearances (which occur when the
processes are not centered) and compare with the allowance. Make a sketch of the
journal and hole properly dimensioned.
Page 112 of 131

Solution:
From Table RC 6, D = 4 in
Hole Shaft
+0.0022 -0.0030
-0.0000 -0.0052
or
+ 0.0022
D (hole ) = 4.000 in
− 0.0000
+ 0.0000
D (shaft ) = 3.997 in
− 0.0022
NS = 6σ
0.00165
σ= = 0.00028 in
6
σ D = 2σ = 2 (0.00028) = 0.0004 in
NS D = 6σ D = 6(0.0004) = 0.0024 in
Page 113 of 131

Maximum clearance = 0.00912 in

Minimum clearance = 0.00336 in
Sketch
101. The same as 100, except that class RC 3 fit is used.
Solution:
From Table RC 3, Table 3.1, D = 4 in
Hole Shaft
+0.0009 -0.0014
-0.0000 -0.0023
or
+ 0.0009
D (hole ) = 4.000 in
− 0.0000
+ 0.0000
D (shaft ) = 3.9986 in
− 0.0009
Page 114 of 131

NS = 6σ
0.000675
σ= = 0.0001125 in
6
σ D = 2σ = 2 (0.0001125) = 0.00016 in
NS D = 6σ D = 6(0.00016) = 0.00096 in
Maximum clearance = 0.001595 in

Minimum clearance = 0.002555 in
Sketch
102. It is desired that the running clearance for a 3-in. bearing be between
approximately 0.003 in. and 0.007 in. The natural spread of the processes of
finishing the journal and bearing are expected to be virtually the same ( σ 1 = σ 2 ).
Decide upon a suitable tolerance and allowance with a sketch properly
dimensioned (to a ten thousandth). (Suggestion: compute first a theoretical natural
spread for bearing and journal from the given spread of the clearances. Let the
tolerances be approximately equal to this computed NS, and assume that
manufacturing processes are available that produce an actual NS of about 70 % of
this computed NS.) Check for processes being off center but within ± 3σ limits
so that virtually no scrap is manufactured.
Solution:
Page 115 of 131

σ D = 0.00067 in
σ 12 + σ 22 = σ D2
2σ 12 = (0.00067 )
2
σ 2 = 0.00047 in
NS = 0.70 NS1
NS = 0.70(6)(0.00047 ) = 0.00197 in
T = NS1 = (6)(0.00047 ) = 0.00282 in
Page 116 of 131

For processes off-center
running clearance = 0.00385 in to 0.00785 in
running clearance = 0.00215 in to 0.00615 in
since allowance = 0.00218 in ≈ 0.00215 in, it is checked.
103. If the tolerances shown are maintained during manufacture, say with the processes
centered, what would be the approximate overall tolerances and limit dimensions?
Page 117 of 131

Problem 103.
Solution:
T1 = 4.004 − 4.000 = 0.004 in
T2 = 5.008 − 5.000 = 0.008 in
T3 = 6.707 − 6.700 = 0.007 in
T 2 = T12 + T22 + T32 = (0.004) + (0.008) + (0.007 )

2 2 2
T = 0.0114 in
Limit dimensions
4.000 to 4.0114 in
5.000 to 5.0114 in
6.700 to 6.7114 in
104. If a cylindrical part needs to have the following tolerances, what process would
you recommend for finishing the surface in each instance? (a) 0.05 in., (b) 0.01
in., (c) 0.005 in., (d) 0.001 in., (e) 0.0001 in., (f) 0.00005 in.?
Solution:
Use fi. 3.9, page 95., Text.
(a) 0.05 in
Surface finishes = 500 or greater

Processes:
1. Flame cutting-machine
2. Rough turning
3. Contour sawing
4. Rough grinding
5. Shaping and planning
6. Drilling
7. Milling – high speed steel
8. Boring
(b) 0.01 in
Surface finishes = 63 to 250
Page 118 of 131

Processes:
1. Contour sawing
2. Rough grinding
4. Drilling
6. Finish turning
7. Broaching
8. Boring
9. Reaming
10. Commercial grinding
11. Barrel finishing
(c) 0.005 in
Processes:
2. Drilling
4. Finish turning
5. Broaching
6. Boring
7. Reaming
8. Commercial grinding
9. Milling – carbides
10. Gear shaping
11. Barrel finishing
12. Honing
(d) 0.001 in
Processes:
1. Finish turning
2. Broaching
3. Boring
4. Reaming
5. Commercial griniding
6. Milling – carbides
7. Gear shaping
8. Barrel finishing
9. Roller burnishing
10. Diamond turning
Page 119 of 131

11. Diamond and precision boring

12. Precision finish grinding
13. Honing
14. Production lapping
15. Superfinishing
(e) 0.0001 in
Surface finishes = 1 to 8 µin, rms
Processes:
1. Barrel finishing
2. Roller burnishing
3. Diamond turning
4. Diamong and precision boring
5. Precision finish grinding
6. Honing
8. Superfinishing
(f) 0.00005 in
Surface finishes = 0 to 2 µin.
Processes:
1. Honing
3. Superfinishing
105. If it cost $100 to finish a certain surface to 500 microinches rms, what would be
the approximate cost to finish it to the following roughness: (a) 125, (b) 32, (c) 8,
(d) 2 µin. rms?
Solution:
From Fig. 3.9
Relative cost of 500 µin rms = 1.75
(a) Relative cost of 125 µin rms = 3
 3 
Cost = $100  = $171
 1.75 
Page 120 of 131

(b) Relative cost of 32 µin rms = 5
 5 
Cost = $100  = $286
 1.75 
(c) Relative cost of 8 µin rms = 7.75
 7.75 
Cost = $100  = $443
 1.75 
(d) Relative cost of 2 µin rms = 11.5
 11.5 
Cost = $100  = $657
 1.75 
DATA LACKING – DESIGNER’S DECISIONS*

*
Properties of rolled structural sections are found in various handbooks.
106-125. Design a bell crank, similar to the one shown, to carry a mild shock load. The
mechanical advantage ( L1 L2 = F2 F1 ), the force F1 , the length L1 , and the
material are given in the accompanying table. (a) Make all significant dimensions,
including tolerances and allowances. One approach could be to compute
dimensions of the yoke connections first; t should be a little less than a . An
assumption for the shaft may be that, on occasion, the torque for F1 is transmitted
through the shaft (ignoring bending for local convenience). (b) Check all
dimensions for good proportion; modify as desirable. (c) Sketch to scale each
part, showing all dimensions with tolerances necessary to manufacture.
Prob. No. Load F1 L1 AISI No. As Mech,

Rolled Advantage
106 700 12 C1020 1.5

107 650 14 C1020 2
108 600 15 C1022 2.5
109 550 18 C1035 3
110 500 20 C1040 4

111 800 12 C1020 1.5
112 750 14 C1020 2
113 750 14 C1020 2.5
114 650 18 C1035 3

115 600 20 C1040 4
116 900 12 C1020 1.5
117 850 14 C1020 2
Page 121 of 131

118 800 15 C1022 2.5

119 750 18 C1035 3
120 700 20 C1040 4
121 1000 12 C1020 1.5
122 950 14 C1020 2

123 900 15 C1022 2.5
124 850 18 C1035 3
125 800 20 C1040 4
Problems 106 to 125.

Solution:
F1 = 700 lb = 0.7 kip
L1 = 12 in
MA = 1.5
For AISI C1020 as rolled (Table AT 7)
su = 65 ksi
sus = 49 ksi
Designing based on ultimate strength
N = 6 (Table 1.1) mild shock, one direction
su 65
s= = = 10 ksi
N 6
s 49
ss = us = = 8 ksi
N 6
Consider yoke connection A
Page 122 of 131

F1 F1
ss = =
1  1
π d12
2 π d12 
4  2
0 .7
8=
1
π d12
2
d1 = 0.24 in
1
say d1 = in
4
F1
s=
a1d1
0 .7
10 =
1
a1  
4
a1 = 0.28 in
5
say a1 = in
16
since t1 < a1
1
say t1 = in
4
F1
s=
D1t1
0 .7
10 =
1
D1  
4
D1 = 0.28 in
5
say D1 = in
16
Consider yoke connection B.
L1
= 1 .5
L2
12
L2 = = 8 in
1 .5
F2
= 1 .5
F1
F2 = 1.5(0.7 ) = 1.05 kip
F2 F2
ss = =
1  1
π d 22
2 π d 22 
4  2
Page 123 of 131

1.05
8=
1
π d 22
2
d 2 = 0.29 in
5
say d 2 = in
16
F2
s=
a2 d 2
1.05
10 =
5
a2  
 16 
a2 = 0.34 in
3
say a2 = in
8
since t 2 < a2
5
say t 2 = in
16
F1
s=
D1t1
1.05
10 =
5
D2  
 16 
D2 = 0.34 in
3
say D2 = in
8
For shaft diameter
Assume torque, T1 = F1 L1 = (0.70 )(12) = 8.4 in − kips
16T1
ss =
π d s3
16(8.4 )
8=
π d s3
3
d s = 1.75 in = 1 in
4
Tolerances and allowances, consider RC 4 (Table 3.1)
Hole Shaft
+ 0.0006 + 0.0000
d1 = 0.2500 in d1 = 0.2495 in
− 0.0000 − 0.0006
Page 124 of 131

+ 0.0006 + 0.0000
d 2 = 0.3125 in d 2 = 0.3120 in
− 0.0000 − 0.0006
+ 0.0010 + 0.0000
d s = 1.7500 in d s = 1.7490 in
− 0.0000 − 0.0010
Female Male
+ 0.0006 + 0.0000
a1 = 0.3125 in a1 = 0.3120 in
− 0.0000 − 0.0006
+ 0.0006 + 0.0000
a2 = 0.3750 in a2 = 0.3745 in
− 0.0000 − 0.0006
(b) For good proporion use the following dimension

D1 = D2 = 1 in
3
d1 = d 2 = in
4
3
t1 = t 2 = in
4
a1 = a2 = 1 in
d s = 2 in
Tolerances and allowances, consider RC 4 (Table 3.1)
Hole Shaft
+ 0.0008 + 0.0000
d1 = 0.7500 in d1 = 0.7492 in
− 0.0000 − 0.0008
+ 0.0008 + 0.0000
d 2 = 0.7500 in d 2 = 0.7492 in
− 0.0000 − 0.0008
+ 0.0012 + 0.0000
d s = 2.0000 in d s = 1.9988 in
− 0.0000 − 0.0012
Female Male
+ 0.0008 + 0.0000
a1 = 1.0000 in a1 = 0.9992 in
− 0.0000 − 0.0008
+ 0.0008 + 0.0000
a2 = 1.0000 in a2 = 0.9992 in
− 0.0000 − 0.0008
Page 125 of 131

(c) Sketch
126. A simple beam 12 ft. long is to support a concentrated load of 10 kips at the
midpoint with a design factor of at least 2.5 based on yield strength. (a) What is
the size and weight of the lightest steel (C1020, as rolled) I-beam that can be
used? (b) Compute its maximum deflection. (c) What size beam should be used if
the deflection is not to exceed ¼ in.?
Solution:
N = 2 .5
(a) For AISI C1020, as rolled, Table AT 7
s y = 48 ksi
Mc s y
s= =
I N
Page 126 of 131

48
s= = 19 ksi
2 .5
FL (10 )(144 )
M= = = 360 lb − in
4 4
M
s=
Z
Z = section modulus
M 360
Z= = = 18.95 in 3
s 19
From Table B-3, Strength of Material by F. Singer, 2nd Edition
Select 10I35 Section Index
Unsupported length = 12 ft
Weight per foot = 35 lb
Section Modulus = Z = 29.2 in 3
I = 145.8 in 4 , moment of inertia
Size (Depth) = 10.0 in
Weight of beam = (35)(12) = 420 lb
FL3
(b) δ =
48EI
E = 30,000 ksi
δ=
(10)(144 )3 = 0.142 in
48(30,000 )(145.8)
FL3
(c) δ =
48EI
0.25 =
(10 )(144)3
48(30,000)I
I = 82.9 in 4
From Table B-3, Strength of Material by F. Singer, 2nd Edition
Select 10I35 Section Index
Unsupported length = 12 ft
Weight per foot = 35 lb
I = 145.8 in 4 , moment of inertia
Size (Depth) = 10.0 in
127. A 10-in., 35-lb. I-beam is used as a simple beam, supported on 18-ft. centers, and
carrying a total uniformly distributed load of 6000 lb. Determine the maximum
stress and the maximum deflection.
Solution:
Page 127 of 131

6000 + 630
w= = 30.7 lb in
(18)(12)
Table B.3, From Strength of Materials, F.L. Singer, 2nd Edition
For 10-in., 35-lb. I-beam
I = 145.8 in 4
Z = 29.2 in 3
M max
smax =
Z
wL2 (30.7 )(216 )
2
M max = = = 179,042 lb − in = 179 kips − in
8 8
179
smax = = 6.13 ksi
29.2
5FL3
δ max =
384 EI
E = 30,000 ksi
F = wL = (30.7 )(216) = 6631 lbs = 6.631 kips
5(6.631)(216)
3
δ max = = 0.20 in
384(30,000)(145.8)
128. The same as 127, except the beam is a cantilever.
Solution:
wL2 (30.7 )(216 )

2
M max = = = 716,170 lb − in = 716.17 kips − in
8 2
M 716.17
smax = max = = 24.53 ksi
Z 29.2
Page 128 of 131

6000 + 630
w= = 30.7 lb in
(18)(12)
δ max =
wL4
=
(30.7 )(216) = 1.91 in
4
8EI 8(30,000)(145.8)
129. Two equal angles, placed back to back as shown, act as a simple beam and are to
support a load of F = 2,000 lb .; L = 40 in .; a = 15 in . What size angles should
be used if the maximum stress is not to exceed 20 ksi? The stress due to the
weight of the angles is negligible.
Problems 129, 130.

Solution:
Table AT 2
M
s=
Z
Fab
M=
L
a = 15 in
L = 40 in
b = L − a = 40 − 15 = 25 in
M=
(2 )(15)(25) = 18.75 kips − in
40
M 18.75
Z= = = 0.9375 in 3
s 20
1
For each angles, Z = (0.9375) = 0.46875 in 3
2
From Strength of Materials, F.L. Singer, 2nd Edition

Table B-5
Say size 3” x 3”, thickness = ¼ in
I
Z = = 0.58 in 3
c
130. The same as 129, except that a rolled T-section is to be used.
Solution:
From Table AT 1, No. 6
Page 129 of 131

aH 2 + bt 2
c1 =
2(aH + bt )
c2 = H − c1
Bt 3 ah 3
Ix = + (Bt )d 2 + + (ah )e 2
12 12
say a = t
h=B
B = 4t
H = h+t = B+t
b = B−a
t (B + t ) + (B − t )t 2
2
c1 =
2[t (B + t ) + (B − t )t ]
t (B + t ) + (B − t )t 2 t (5t ) + (3t )t 2
2 2
c1 = = = 1.75t
2(2 Bt ) 4(4t 2 )
c2 = H − c1
H = B + t = 5t
c2 = 5t − 1.75t = 3.25t
Bt 3 ah 3
Ix = + (Bt )d 2 + + (ah )e 2
12 12
t
d = c1 − = 1.75t − 0.5t = 1.25t
2
a=t
h = B = 4t
h
e = c2 − = 3.25t − 0.5(4t ) = 1.25t
2
Ix =
(4t )t 3 + (4t )t (1.25t )2 + t (4t )3 + t (4t )(1.25t )2 = 18.17t 4
12 12
Mc2
s=
I
M = 18.75 kips − in
Page 130 of 131

s = 20 =
(18.75)(3.25t )
18.17t 4
t = 0.55 in
9
say t = in
16
9 1
B = 4t = 4  = 2 in
 16  4
1 9
H = B + t = 2 + = 2.8125 in
4 16
say H = 3 in
″ ″
1 9
Size: 2 × 3′′ × T section
4 16
- end -
Page 131 of 131

Section 1a

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Section 1a

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SECTION 1– DESIGN FOR SIMPLE STRESSES

Solution: (See figure in Prob. 45 and refer to Prob. 46)

ssy = 0.6 s y = 28 ksi

F = ss (2tc ) Equation (3)

F = ss [2(D − e )b] Equation (4)

F = set Equation (5)

F = ss (2ef ) Equation (9)

Prob. No. Load, lb. AISI No., As Rolled

Solution: (For Prob. 49 only)

(a) For AISI 1020, as rolled

0.25 = 0.7854m 2 − 0.5185 − 0.3125m + 0.2539

(b) Modified dimensions

(c) Tolerances and allowances

Fits, Table 3.1, loose-running fits, say RC 8

(a) Tensile stresses

(a) Tensile stresses

(b) Based on ultimate strength

E = 10× 106 psi

(b) Use wrought steel, Table AT 4, E = 30× 106 psi

E = 10× 106 psi

The stress is unlikely because it is near the ultimate strength of steel.

Problem 78, 79.

δ T = (0.000007 )(30 )(100) = 0.021 in

For aluminum bronze, B150-1, annealed (Table AT 3)

δ T = (0.000007 )(30 )(100) = 0.021 in

80. A machine part shown is made of AISI C1040, annealed steel; L1 = 15 in .,

(b) Energy absorbed

For steel E = 30000 ksi

For aluminum 2024-T4 (Table AT 3)

[∑ M G =0 ] R1 (24) + R2 (12) = 24(20)

For AISI 1035, as rolled , E = 30,000 ksi

(a) For 301, ¼ hard, stainless steel

(b) For annealed titanium B265, gr. 5

(c) For hardened titanium

(a) 2r1 = 0.75 in , r1 = 0.375 in

(d) Maximum shear stress

TOLERANCES AND ALLOWANCES

(a) For close-sliding fit, RC 1

(b) For a precision-running fit, RC 3

(c) For medium-running fit, RC5, RC 6. Say RC 5

Page 100 of 131

(d) For loose-running fit, RC 8, RC 9. Say RC 8

(a) For close-sliding fit, RC 1

Page 101 of 131

(b) For a precision-running fit, RC 3

Page 102 of 131

(c) For medium-running fit, RC5, RC 6. Say RC 6

(d) For loose-running fit, RC 8, RC 9. Say RC 9

Page 103 of 131

(a) For class FN 1 fit, Table 3.2

Page 104 of 131

(c) For maximum interference

For minimum interference

(a) For class FN 3fit, Table 3.2

Page 105 of 131

(c) For C1035 steel, E = 30,000 ksi

For maximum interference

For minimum interference

For No. 7 ball bearing

Page 106 of 131

Shaft, 1.3784 – 1.3775 = 0.0009 in

Allowance = 0 – 0.0009 in = - 0.0009 in

(b) Since allowance is < 0.

1.3778 – 1.3775 = 0.0003 in