Example 6.1;Determinethe design stress fora piston rod where the load is completely reversed.

The

surface ofthe rod is ground and the surface finish factor is 0.9. There is no stress concentration. The
load is predictable and the factor ofsafety is 2.

Solution:

Given:

Ksur = 0.9; F.S.= 2

The piston rod is subjected to reversed axial loading. We know that for reversed axial loading,

the load correction factor (K.) is 0.8. If Ge is the endurance limit for reversed bending load, then

endurance limit for reversed axial load,

Oea =e X K X Ksur = Ope X 0.8 x 0.9 = 0.72 a,

We know that design stress,

Cea0.72
F.S. 2
a
=0.36a Ans.

Example 6.2:Find the maximum stress induced in the following cases taking stress concentration into

account:

1. A rectangular plate 60 mm x 10 mm with a hole 12 diameter as shown in Fig. 6.13 (a) and
subjected to a of12 KN.
2. A steppedshaft as shown in Fig. 6.13 (b) and carrying a tensile load of 12 kN.

Stepped shat

r=Smm
60 mm D= 50 mm
12 KN 12 KN
25 mun
12 KN 12 kN

10 mm
ta) (b)
Solution:

Case 1. Given:b= 60mm:t=10 mm: d= 12 mm:W= 12 kN =12 x 10 N

We know that cross-sectional area of the plate,

=(b-d)t = (60-12)10=480mm
A
W 12x103
Nominal stress="= =25 N/mm² = 25 M Pa
A 480
Ratio of diameter of hole to width of plate,

d 12 =0.2
b 60

From Table 6.1, we find that for d/b = 0.2, theoretical stress concentration factor,

Kt= 2.5

Maximum stress =KtX Nominal stress =2.5 x 25=62.5 MPa Ans.

Case 2. Given : D = 50 mm ;d= 25 mm; r=5 mm;W= 12 kN = 12 x 10° N

We know that cross-sectional area for the stepped shaft

A =xd² =x(25)? = 491 mm²

Nominal
12x10
stress= A = 491 =24.4 N/mm² =24.4M Pa
Ratio of maximum diameter to minimum diameter,
D/d = 50/25 =2

Ratio of radius of fillet to minimum diameter,

r/d = 5/25 = 0.2

From Table 6.3, we find that for D/d=2 and r/d= 0.2, theoretical stress concentration factor, K= 1.64.

Maximum stress =Kx Nominal stress = 1.64 x 24.4 =40MPa Ans.

Example 6.3: A machine component is subjected to a flexural

stress which fluctuates between +300 MN/m2 and-150 MN/m2.

Determine the value of minimum ultimate strengthaccording to1.

Gerber relation; 2. Modified Goodman relation; and 3. Soderberg
relation.

Take yield strength =0.55 Ultimate strength;Endurance strength =

0.5 Ultimate strength;and factor of safety =2.

Springs offen undergo variatbie stresses.

Solution; Given := 300MN/m²; o =-150 MN/m²; o, =0.55 ou; o, = 0.5 ou ;F.S. =2

Let o, = Minimum ultimate strength in MN/m2

We know that according to Gerber relation,

300+(-150)
Om 2 2 = 75 MN/m?
300+(-150)
And variable stress,
2 2 = 225 MN/m²
[Link] to Gerber relation

We know that according to Gerber relation,

1
F.S.
(Om) F.S. +

2+ 225 11 250 50 11 250 + 450 u

0.50,, (o)2 (o)2

(a,) =22500 + 00o, 9

Or (a)2– 9 00o, -22 500 =0

900t/(900)2 +4 x 1 x 22 500 900 ±948.7

2 X1 2

Ou =924.35 MNm² Ans. ..Takingtve sign)

2. According to modified Goodman relation

We know that according to modified Goodman relation,

1 Om
F.S.

Or 1 + 225O0.5
525

Jy = 2 x 586.36 = 1172.72 MN/m² Ans.

Example 6.4: A bar of circular cross-section is subjected to alternating tensile forces varying from a minimum
of 200 kN to a maximum of 500 kN. It is to be manufactured ofa material with an ultimate tensile strength of

900 MPa and an endurance limit of 700MPa. Determine the diameter of bar using safety factors of3.5 related

to ultimate tensile strength and 4 related to endurance limit and a stress concentration factor of 1.65 for fatigue
load. Use Goodman straight line as basisfor design.

Solution: Given : Wmin = 200 KN;Wmax = 500 kN ; ou =900 MPa = 900 N/mm²;oe = 700 MPa =700
N/mm²; (F.S.), = 3.5; (F.S.). =4; K;= 1.65
Let d= Diameter of bar in nmm.
 Area, A ="x d' =0.7854 d² mm?
We know that mean or average force,

500+200
Wm Wmax+Wmin
2 2 = 350 kN = 350 × 10 N

446x103
Mean stress, Om = Wm 4
350x10

0.7854 d2 N/mm?

d
Variable force, W,, =(Wnay-Wmin)
2
(500-200)
2 = 150 kN = 150 >x 10°N

Variable stress, Oy =W 150x103

0.7854 d2
191x10
N/mm?

We know that according to Goodman's formula,

[Link]
Ge/(F.S.)e
=1 Ou/(F.S.),u

191X103 446X10x1.65
=1–
700/4 900/3.5

Oil and resin

blended
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together natural ols andresins called alkycs. Thin ner is oddedto make
tho miture oasio topumo through a flter that removes any
solid particles from the blended liquids Plgmant is rnixed into
Thinner
the blnder blenc in a powerful mixer caledadisperser.
added
Bead mill Holding tank
Disperser

Filter tank Pigment and paint thin Final adjustments made

Setting tank ner added

Note: This picture is given as additional information and is not a direct example of the current chapter.

+ 2860
1100
d2
=1-
2860
or
1100
d2
= 1

d' =3960 or d=62.9 say 63mm Ans.

Example 6.5: Determine the thickness of a 120 mm wide uniform platefor safe continuous operation if the plate
is to be subjected to a tensile load that has a maximum value of 250 kN anda minimum value of 100kN. The
properties of the plate material are as follows:

Endurance limit stress =225MPa,and Yield point stress =300MPa.

The factor of safety based on yield point may be taken as 1.5.

Solution;Given :b =120 mm; Wmax=250kN; Wmin = 100 kN; de 225 MPa = 225 N/mm²;oy =300
MPa = 300 N/mm²; F.S. = 1.5

Let t= Thickness of the plate in mm.

Area, A =bxt= 120 mm² t

We know that mean or average load,

250+100
Wm = Wnax 2+Wmin 2
=175 kN = 175 x 103 N
Mean stress,Om =Wm A
175x103
120 t
N/mm2

According
Variable load, W,

Variable stress,

to Soderberg's
,
formula,
= (Wmax-Wmin

WA
2

75x103
120 t
(250-100)

N/mm²
2
= 75 kN= 75 x 10N

F.S.
= m 4

1 175X10 75X103 4.86 2.78 7.64

1.5 120t x 300 120t x 225 t t

t=7.64 × 1.5 = 1146 say 11.5 mm Ans.

Example 6.6: Determine the diameter of a circular rod made of ductile material with a fatigue strength

(complete stress reversal), o, = 265MPa and a tensile yield strength of 350MPa. The member is subjected to a
varying axial load from Wmin =-300 x 10° N to Wmax = 700x 10³ N and has a stress concentrationfactor =
1.8.

Use factor of safetyas 2.0.

Solution;Given : o = 265 MPa =265 N/mm²; oy =350MPa =350N/mm²; Wmin =-300 x 10 N;

Wmax = 700 x 10N;K= 1.8; F.S. =2

Let d= Diameter thecircular rod in mm.

of
Area, A =x = d² 0.7854d² mm?

We know that the mean or average load,

 Wm = Wmax +
2
Wmin 700x10³ +(-300x10)
2
=200x 10³N

o, ="nA
200x103 254.6x103
Mean stress,
0.7854 d²
N/mm²

Variable load, W. =Wmax-Wmin) 2

700x103-(-300x10)–o0×10
2 N

500x103
Variable stress,o,, ="= A 0.7854 d2
636.5x103

d2
N/mm²

We know that according to Soderberg's formula,

1 Om
F.S. Oy

1_
2 ²x350
+ 636.5X10x1.8
254.6X103
x 265 d²
727
d2
+ 4323 5050

d' =5050x2=10 100 or d=100.5 mm Ans.

Example 6.7: A steel rod is subjected toa reversed axial loadof 180kN. Find the diameter ofthe rodfor afactor

of safety of 2. Neglect column action. The material has an ultimate tensile strength of 1070 MPa and yield

strength of 910MPa. The endurance limit in reversed bending may be assumed to be one-half of the ultimate
tensile strength. Other correction factors may be taken as follows:

For axial loading =0.7; For machined surface = 0.8; For size =0.85; For stress concentration = 1.0.

Solution:Given :Wmax =180 kN;Wmin =-180 kN; F.S. =2; ou = 1070 MPa =1070 N/mm²; oy = 910
MPa = 910 N/mm² ;= o 0.5 ou; K =0.7; Ksur = 0.8; Ksz=0.85; K;= 1

Let d= Diameter of the rod in mm.

Area, A =x d' = 0.7854 d²mm²

We know that the mean or average load,

= Wmax t Wmin 180+(-180)

Wm 2 2
=0

Mean stress, o,m = A

=0

Variable load, W, =Wmax-Wmin)

2
180-(-180)
2
1g0kN = 180 ×10° N
180x103 229x103
Variable stress, o, ="= A 0.7854 d2 N/mm²

Endurance limit in reversed axial loading,

Jea = Je x Ka =0.5 oy x 0.7= 0.35 Ou ...(oe =0.5 ou)

= 0.35 x 1070 =374.5 N/mm?

We know that according to Soderberg's formula for reversed axial loading,

1
Cm
F.S. Oy Oea XKsurXKsz

229x10Sx1 900
2
=0+ d2 x 374.5 X 0.8 >x 0.85

d' =900x2=1800 or d=42.4 mm Ans.

Example 6.8: A circular bar of 500mm length is supported freely at its two ends. It is acted upon by a central

concentrated cyclic load having a minimum value of 20 kN and a maximum value of 50 KN. Determine the
diameter of bar by taking a factor of safety of 1.5, sze effect of 0.85,surface finish factor of 0.9. The material

properties bar are given by :ultimate strength of 650 MPa, yield strength of 500MPa and endurance strength
of
of 350 MPa.

Solution: Given:l=500 mm;Wmin =20 kN =20 x 10³ N; Wmay= 50 kN= 50x 10³N; = 1.5; F.S. Ksz =
0.85; Ksur = 0.9;Ou =650 MPa =650 N/mm²;oy =500 MPa =500 N/mm²; de = 350 MPa =350
N/mm?

Let d= Diameter of the bar in mm.

We know that the maximum bending moment,

50X103x500
Mmax
WmaxXl
4 4
=6250x10® N mm
And minimum bending moment,

20x10²x500
Mmin =WminXl 4
=2550×10 N- mm

: Mean or averagebending moment,

M,n = Mmax+Mmin
2
6250x10'+2500x103 =4375x 103
2
N -mm
And variable bending moment,

M,, =Mmay-Mmin
2
6250×10³-2500x1o3
2 =1875x10*N- mm

Section modulus of the bar,

-xd³ = 0.0982 d3 mm³

22

: Mean or averagebending stress,

4375X103 44.5X106

0.0982 d3 d3 N/mm²
and variable bending stress,

1875X103 19.1X106
0.0982 d3 d3
N/mm?

We know that according to Goodman's formula,

F.S. GXKsurXKsz

1 44.5X106 19.1x106x1
d3 x 650 ..(Taking K;= 1)
1.5 d³x350x0,9x0.85

89x103 71x103 160x103

d3 d3 d'

d =160x10 x1.5=240x103 or d=62.1 mm Ans,

Taking larger of the two values, we have d= 62.1 mm Ans.

Example 6.9; A 50mm diameter shaft is made from carbon steel having ultimate tensile strength of 630 MPa. It

is subjected to a torque which fluctuates between 2000N-m to - 800 N-m. Using Soderberg method, calculate

the factor of safety. Assumesuitable valuesfor any other data needed.

Solution; Given: d= 50 mm;ou =630 MPa = 630 N/mm²; Tmox= 2000 N-m; Tmin=- 800N-m
We know that the mean or average torque,

Im Tmax+Tmin
2
2000+(-800)
2 =600 N- m =600 ×10* N- mm
: Mean or averageshearstress,

16x600x103
Tm
16Tm
n(50)3
= 24.4 N /mm? ..(T=xx d')
Variable Torque,

2000-(-800)
T, =Tmax+Tmin
2 2 =1400N- m = 1400 x 10 N- mm

. Variable shear stress, Ty

167, 16x1400x103

n(50)3
= 57 N/mm²
Since the endurance limit in reversed bending (oe ) is taken as one-half the ultimate tensile strength (i.e. oe

=0.5 ou) and the endurance limit in shear (te)is taken as 0.55 oe, therefore

te =0.55 de = 0.55 x 0.5 ouy = 0.275 Ou

= 0.275 x 630 = 173.25 N/mm?

Assume the yield stress (o, ) for carbon steel in reversed bending as 510N/mm²,surface finish factor (Ksur)

as 0.87, size factor (Ksz) as 0.85 and fatigue stress concentration factor (Kt)as 1.
 Airy Tonk

NoIO:THis pcturo is gvon as adatonal intormaton anc is not a airoct oampo of tme curront chapior.

Since the yield stress in shear (Ty) for shear loading is taken as one-halfthe yield stress inreversed bending
(oy), therefore

Ty= 0.5 Oy = 0.5 x 510 =255 N/mm²

Let F.S.= Factor of safety.

We know that according to Soderberg's formula,

24.4 57X1
F.S.
Ty TXKuyXKsz 255 173.25x0.87x0.85

=0.096 +0.445 -0.541

FS. = 1/0.541 =1.85 Ans.

Example 6.10; A beam made of cold drawn carbon steel of

cantilever

circular cross-section asshown in Fig. 6.18,is subjected to a load which 150

varies from -F to3 F. Determine the maximum load that this member 125
A
can withstand for an indefinite life using a factor of safety as 2. The
20 13
theoretical stress concentrationfactor is 1.42 and the notch sensitivity

is 0.9. Assume the follo wingvalues : R

Ultimate stress =550MPa All dimensions in mm. 34

Yield stress =470MPa Fig. 6.18

Endurance limit = 275MPa

Size factor =0.85

Surface finish factor =0.89

Solution: Given :Wmin = -F;Wmax =3 F; F.S. =2;Kt=1.42 ;q=0.9; Ou = 550MPa = 550 N/mm?; o, =
470MPa = 470 N/mm;oe =275 MPa = 275 N/mm; Ksz = 0.85 ;Ksur = 0.89
 The beam as shown in Fig. 6.18 is subjected to a reversed bending load only. Since the point A at the

change of cross section is critical, therefore we shall find the bending moment at point A.

We know that maximum bending moment at point A,

Mmax = WNmax X 125 = 3F x 125 =375 FN-mm

and minimum bening moment at point A,

Mmin = Wmin X 125 =-Fx 125 =-125 F N-mm

:Mean or average bending moment,

Mm Mmax+Mmin
2
375 F+(-125
2
F)
= 125 FN-mm
and variable bending moment,

M, Mmax-Mmin
2
375-(-125)
2
= 250 FN- mm
Section modulus,
32 x d³ = 32 x(13)³ = 215.7 mm³ ..(d =13 mm)
Mean bending stress, Om = Mm 125
215.7
F
=0.58 F N/mm?

and variable bending stress,

ay ==1.16 215.7
F N/mm?

Fatigue stress concentration factor, K,= 1 +q (K;-1) =1 +0.9 (1.42 -1) =1.378

We know that according to Goodman's formula

1
Om
F.S. O GeXKsur XKsz

1 0.58 F 1.16FX1.378

550 275X0.89x0.85

=0.001 05 F+0.007 68 F=0.008 73 F

F= 2x0.00873
=57.3N
and according to Soderberg's formula

1F.S.
Om yXKf
Oy e XKsur XKsz

1 0.58 F 1.16 FX1.378

2 470 275X0.89x0.85

= 0.001 23 F+0.007 68 F= 0.008 91 F

 F= 2X0.00891
=56 N
Taking larger of the two values, we have F=57.3 N Ans.

Example 6.11;A simply supported beam has a concentrated load at the centre which fluctuatesfrom a value of
P to 4 P. The span of the beam is 500 mm and its cross-section is circular with a diameter of 60mm. Taking for

the beam material an ultimate stress of 700MPa, a yield stress of 500 MPa, endurance limit of 330 MPa for
reversed bending, and a factor of safetyof 1.3,calculatethe maximum value of P. Take a size factor of 0.85 and
a surfacefinish factor of 0.9.

=P ;Wmax= 4P;L= 500mm; d=60mm ;ou =700MPa = 700N/mm²;a,= 500MPa =

Solution: Given :Wmin

500 N/mm²;o = 330MPa =330 N/mm²; F.S. = 1.3 ;Ks, = 0.85; Ksur = 0.9

We know that maximum bending moment,

Mmax
WmaxXL
4
4 PX500
4
=500 PN- mm
and minimum bending moment,

Mmin
WminXL
4
- Px500
4
=125PN-mm
: Mean or average bending moment,

500 P+125
Mm = Mmax+Mmin
2 2
P
=312.5 PN-mm
and variable bending moment,

M,= 2 =
Mmax-Mmin
2
500P-125 P
187.5 PN- mm
Section modulus, Z=xd³
32 =x(60)³ = 32 21.21 mm²
:Mean bending stress, Om == Z
312.5

21.21x103
P
=0.0147 PN/mm²
and variable bending stress,

P
Oy = 187.5

21.21x10
=0.0088 P N/mm?
We know that according to Goodman'sformula

1 Om
F.S. GeXKsurX Ksz

1 0.0147P 0.0088 PX1

+ ..(Taking K;= 1)
1.3 700 330x0.9x0.85

= 21 + 106
P 34.8
106
P 55.8

106
P
 P=i3 x 55.8
105
=13785 N = 13.785 kN
and according to Soderberg's formula

F.S.
Om
Oy
+
a,XKsur XKsz

11.3
0.0147 P
500
0.0088
330x0.9x0.85
P X1 29.4

106
P 34.8 P

106
64.2 P

106

113A 10
T1982 N= 11.982kN

From the above, we find that maximum value of P= 13.785 KN Ans.

Example 6.12: A steel cantilever is 200 mm long. It is subjected to an axial load which varies from 150 N
(compression) to 450 N (tension) and also a transverse load at its free end which varies from 80 N up to 120 N
down. The cantilever is of circular cross-section. It is of diameter 2dfor the first 50mm and ofdiameter d for the
remaining length. Determine its diameter taking a factor of safety of 2. Assume thefollowing values :
Yield stress = 330 MPa

Endurance limit in reversed loading = 300 MPa

Correction factors =0.7 in reversed axial loading

= 1.0 in reversed bending

Stress concentration factor = 1.44 for bending

= 1.64 for axial loading

Size effect factor = 0.85

Surface effect factor = 0.90

Notch sensitivity index = 0.90

200mm; Wamax) = 45O N; Wa(min) =-150 N;

Solution;Given:l= (max) =120 N; (min) =-80 N; F.S. Wt Wt

=2;oy =330MPa=330 N/mm²; oe =300MPa = 300 N/mm²; Ka= 0.7; Ky = 1; Ktb = 1.44; Kto = 1.64;
Ksz =0.85; Ksur =0.90 ;q = 0.90

80N
First of all, let us find the equivalent normal stress for point
200 mm
A which is critical as shown in Fig. 6.19. It is assumed that 50 mm IS0 mmn

the equivalent normal stress at this point will be the A

150 N 450 N
algebraic sum of the equivalent normal stress due to axial 2d

loading and equivalent normal stress due to bending (i.e.

due to transverse load acting at the free end). Let us first

consider the reversed axial loading. We know that mean or 120 N

average axial load, Fig. 6.19

 Wm
Wa(max) +Wa(min) 450+(-150) =150N
2 2

and variable axial load,

Wa(max)-Wa(min)
W, = 450-(-150) -300N
2 2

: Mean or Averageaxial stress, o,m Wm

A
150x4
191 N /mm
-(4-xa)

: Variable axial stress, o,, = = A

300x4 382
=N/mm?
We know that fatigue stress concentration factor for reversed axial loading,

Kfo =1 +q (Kto -1) =1 + 0.9 (1.64- 1) = 1.576

and endurance limit stress for reversed axial loading,

Oea = Oe X Ko = 300 x0.7 =210N/mm?

Now let us considerthe reversed bending due to transverse load. We know that mean or average bending
load,

We(max)+Wt(min)
Wm
120+(-80)
=20N
and variable bending load,

12 = Wt(max)-
2
Wt(min) 120 -(-80)
2
100 N

. Mean bending moment at point A,

Mm =Wm =
(l-50) 20 (200- 50) = 3000 N-mm

and variable bending moment at point A,

M, =W, (|-50)= 100 (200- 50)=15 000 N-mm

We know that section modulus,

Z=x d' = 32 0.0982 d² mm³

: Mean or Average bending stress, Om =Mm 3000

0.0982 d3
30 550
d3
N
mm2

and variable bending stress,

My 15 000 152 750

0.0982 d N/mm²
We know that fatigue stress concentration factor for reversed bending,

Kfo = 1 + q (Ktb - 1) =1+ 0.9 (1.44 -1) =1.396

Since the correction factor for reversed bending load is 1 (i.e. Kb = 1), therefore the endurance limit for

reversed bending load, Oeb = Oe. Kb = Oe= 300 N/mm²

We know that equivalent normal stress,

Cne
Oy
F.S.
330
= 165 N/mm? Ans.

Example 6.13: A hot rolled steel shaft is subjected to a torsional moment that varies from 330 N-m clockwise to

110N-m counterclockwiseand an applied bending moment at a critical section varies from 440N-m to 220 N
m. The shaft is of uniform cross-section and no keyway is present at the critical section. Determine the required
shaft diameter. The material has an ultimatestrength of 550 MN/m² and a yield strength of 410 MN/m2. Take

the endurance limit as half the ultimate strength, factor of safety of 2, size factor of 0.85 and a surface finish

factor of 0.62.

Solution: Given :Tmax = 330 N-m (clockwise); Tmin = 110 N-m (counterclockwise) = -110 N-m
(clockwise) ; =
Mmax 440N-m; Mmin =-220 N-m ; =550MN/m² =
ou 550 x 10°N/m²; =410 MN/m?
=410 x 10° N/m²;de =12 ou = 275 x 10° N/m; F.S. =2; =0.85;
Ksz Ksur =0.62
Let d= Required shaft diameter in metres.

We know that mean torque,

Tmax+Tmin
2
330+(-110)
2
= 110 N-m
and variable torque, T Imay-Tmin
2
330-(-110)

2
= 220N- m

Mean shearstress,

167m 16X110 560

Tm TLd3 TLd3
N/m²

. Variable shearstress, Ty
167, 16×220 1120
N/mm²
Since the endurance limit in shear (te ) is 0.55 oe,and yield strength in shear (ty) is ,
0.5 oy therefore

Te = 0.55 >x 275 x 10 = 151.25 x 10 N/m?

and ry = 0.5 x 410 x 105= 205 x 10 N/m²

. Mean or average bending moment,

Mm = Mmax+Mmin
2
440+(-220)
2
= 110Nm
and variable bending moment,

M,, = max- Mmin

2
440-(-220)
2
= 330 N-m
Section modulus, Z =x 32
d³ = 0.0982 d³m³

110 1120
:Mean bending stress, Om= 0.0982d3 d3 N/m?

and variable bending stress,

My 110 3360
0.0982 d d3 N/m²

Since there is no reversed axial loading, therefore the equivalent normal stress due to reversed bending load,

Oneb One = 0m t OyXayXKfb Ceb XKsurXKsz

3360x410x106X1
=120
d3 d3x275x106x0.62X0.85
...(Taking Kb= 1)

1120 9506 10626

d3 N/m2

We know that the maximum equivalent shear stress,

Tes(max) F.S. V(One )²+4(Tes)?

205x10 x d³ =V113x106 +4x11.84X 1 06 =12.66x103

or d=0.395/10 = 0.0395 m=39.5 say 40 mm Ans.

Example 6.14; A pulley is keyed a shaft midwaybetween two bearings. The shaft is made of cold drawn steel
to

for which the ultimate strength 550MPa and the yield strength is 400 MPa. The bending moment at the pulley
is

varies from -150 N-m to +400 N-m as the torque on the shaft varies from - 50 N-m to + 150N-m. Obtain the
diameter of the shaft for an indefinite life. The stress concentrationfactors for the keyway at the pulley in

bending and in torsion are 1.6 and 1.3 respectively. Take the following values:

Factor of safety =1.5

Load correction factors =1.0 in bending, and 0.6 in torsion

Size effect factor =0.85

Surface effect factor= 0.88

Solution;Given :o, =550 MPa = 550 N/mm²; oy =400MPa =400N/mm²; Mmin =-150 N-m; Mmax =
400N-m; Tmin =-50N-m; Tmax =150 N-m; 1.6;Ks = 1.3; F.S. =1.5 ;Kb =1;K, = 0.6; Ksz =0.85;
Kfb =

Ksur = 0.88

Let d= Diameter of the shaft in mm.

First of all, let us find the equivalent normalstress due to bending.
 We know that the mean or average bending moment,

Mm =
Mmax+Mmin
2
400+(-150)
2 = 125 N- m

and variable bending moment,

M, Mmax-Mmin
2
400-(-150)
2
= 275 N- m
Section modulus, Z =x d³ = 0.0982 d²m³

Mn 125x103 1273x103
.Mean bending stress, Om= 0.0982d3 d3
N/mm?

and variable bending stress,

M 275×103 2800x103
N/mm?
3
0.0982
d
Assuming the endurance limit in reversed bending as one-half the ultimate strength and since the load

correction factor for reversed bending is 1 (i.e. Kb = 1), therefore endurance limit in reversed bending,

Oeb =O === 2
550

2 275 N/mm²

Since there is no reversed axial loading, therefore the equivalent normal stress due to bending,

XKrb
Oneb One = Om + ayXOy
Oeb XKsur XKsz

1273x103 2800x10x400x1.6
d3x275x0.88x0.85
d
1273x103
d
+ 8712x103 g985X10 N/mm²
Now let us find the equivalentshear stress due to torsional moment.

We know that mean torque,

Tm =
Tmax+Tmin_150+(30
2 2
= 50N -m
and variable torque, T, = nax-Tmin
2
150–(-50)
2
= 100 N- m

Mean shearstress,

16Tm 16x50x103 255x10

Tm N/mm²

: Variable shearstress, Ty
16T, 16X100x103 510X10 N /mm²
d
Ans.
Example 6.15: A centrifugal blower rotates at 600r.p.m. A belt drive is used to connect the blower to a 15 kW
and1750r.p.m. electric motor. The belt forces a torque of 250N-m and a force of 2500N on the shaft. Fig. 6.20

shows the location of bearings, the steps in the shaft and the plane in which the resultant belt force and torque
act. The ratio ofthe journal diameter to the overhung shaft diameter is 1.2 and the radius of the fillet is 1/10th
of overhung shaft diameter. Find the shaft diameter, journal diameter and radius of fillet to have a factor of

safety 3. The blower shaft is to be machined from hot rolled steel having the following values of stresses:

Endurance limit = 180MPa; Yield point stress = 300MPa; Ultimate tensile stress =450 MPa.

Solution;Given: *Ng =600r.p.m.; *P=15kW; *NM= 1750 r.p.m.;T= 250N-m = 250

N-mm;F= x 10

2500 N; F.S. = 3; e =180MPa = 180 N/mm²;o,=300MPa =300N/mm²; ou =450MPa = 45O N/mm²

100 mn
25 mm 10mm Keyway

2500 N

Fig, 6.20

Let D= Journal diameter,

d= Shaft diameter, and r = Fillet radius.

. Ratio of journal diameter to shaft diameter,

D/d =1.2 ..(Given)

and radius of the fillet, r=1/10x Shaft diameter (d)= 0.1 d

r/d= 0.1 ...(Given)

From Table 6.3, for D/d= 1.2 and r/d = 0.1, the theoretical stress concentrationfactor,

Kt =1.62
The two points at which failure may occur are at the end of the keyway and at the shoulder fillet. The
critical section will be the one with larger product of Kfx M. Since the notch sensitivity factor q is dependent
upon the unknown dimensions of the notch and since the curves for notch sensitivity factor (Fig. 6.14) are not

applicable to keyways, thereforethe product Kt xM shall be the basis of comparison for the two sections.

: Bending moment at the end of the keyway,

Ktx M=1.6 x 2500[100-(25+10)] =260 x 10° N-mm

..(K, for key ways = 1.6)

and bending moment at the shoulder fillet,

K x M= 1.62 x 2500(100-25) = 303 750N-mm

 Since Kt x M at the shoulder fillet is large, therefore considering the shoulder fillet as the critical

We know that

0)
section.

K,x M +T2
0.5x300 2
3 x 303 750) +(250x103)2

d =2877 x 10³/50 =57 540 or d= 38.6 say 40 mm Ans.