Chap 08 SM

Mechanical Design: An Integrated Approach - Ansel Ugural
Chapter 8, Problem 1
A structural steel bar of thickness t with full-fillets is loaded by reversed axial force P
(Figure P8.1). Calculate
(a) The maximum stress.
(b) The maximum fatigue stress concentration factor.
Given: P = 15 kN, t = 10 mm
Figure P8.1
Chapter 8, Solution 1
To determine the K t , we use Fig.C.1. Structural steel: Su 400 MPa (Table B.1).
At section C:
D
d
38
30
1.267
r
d
4
30
0.133
K t 1.7
(a)
15(10 )
max 1.7 0.03(0.01)
85 MPa
( b ) Figure 8.8:
r 4 mm : q 0.78
K f 1 0.78(1.7 1) 1.55
(Eq.8.13b)
Similarly, at D:
D
d
38
34
1.118
r
d
2
34
0.059
K t 1.8
(a)
15(10 )
max 1.8 0.034(0.01)
79.41 MPa
( b ) Figure 8.8:
r 2 mm : q 0.72
K f 1 0.72(1.8 1) 1.58
Abar with full-fillets is forged from a structural steel (Figure P8.1). Determine the value
of the endurance limit Se .
Copyright 2004 The McGraw-Hill Companies Inc.
Assumptions: A survival rate of 95% is used. The operating temperature is 475C

maximum.
Figure P8.1
Table B.1:
Su 400 MPa, S y 250 MPa

Se C f Cr CsCt
where
1
Kf
Se'
K f 1.58
at D (from Solution of Prob.8.1)

S 0.45Su 180 MPa
'
e
C f ASub 272(400) 0.995 0.7
Cr 0.87 (Table 8.3)

Cs 1 (axial loading)
Ct 1 0.0058(475 400) 0.565
Thus
1
Se (0.7)(0.87)(1)(0.565) 1.58
(180) 39.2 MPa
A machined and full-filleted AISI 4140 annealed steel bar carries a fluctuating axial
loading, as shown in Figure P8.3. What is the value of endurance limit Se?
Given: b = 20 mm, D = 30 mm, r = 2 mm
Assumptions: A reliability of 90% is used.
Figure P8.3
Se C f Cr Cs Ct (1 K f ) Se'
(a)
r
2
D
d 1.154
We have d 26 0.077,
K t 2.5 (Fig.C.3)
Table B.4: Su 655 MPa, H B 197
Se' 0.45Su 294.8 MPa

Table 8.3: Cr 0.89
q 0.8,
K f 1 0.8(2.5 1) 2.2
Fig.8.8:
C ASub 4.51(655) 0.265 0.809
Table 8.2: f
Ct 1
Use Cs 1 (axial loading)
Equation (a) is therefore
1
Se (0.809)(0.89)(1)(1)( 2.2
)(294.8) 96.48 MPa
A stepped cantilever beam of diameters d and D, machined from an AISI 1060 annealed
steel bar, is subjected to a fluctuating moment M, as depicted in Figure P8.4. Determine
the modified endurance limit Se .
Given: d = 25 mm, D = 35 mm, r = 4 mm
Design Assumption: Reliability is 90%.
Figure P8.4
Su 626 MPa
H B 179
Table B.4:
From Eq.(8.1):
Se' 0.5Su 313 MPa
(Note: by Eq.(2.22): Su 3500(179) 626.5 MPa. )
Cr 0.89
Ct 1
Using Table 8.3:
Cs 0.85
From Eq.(8.9):
By Eq.(8.7):
For Fillet:
r
d
4
25
0.16
C f ASub 4.51(6260.265 ) 0.819
D
d
35
25
1.4
K t 1.45
Hence, from Fig.C.9:
From Fig.8.8, q=0.82
K f 1 0.82(1.45 1) 1.37
Equation (8.13):
Thus
1
Se C f Cr Cs Ct ( K1f ) Se' (0.819)(0.89)(0.85)(1)( 1.37
)313 141.6 MPa
A notched beam, machined from AISI 1030 hot-rolled steel, is subjected to reversed
bending. Determine the endurance limit Se .
Assumptions: A survival rate of 98% and Cs = 0.7 are used. The fatigue stress
concentration factor is Kf = 2.5.
Table B.3: Su 470 MPa. We apply

Se C f Cr Cs Ct ( K1f ) Se'
where
K f 2.5,
S e' 0.5Su 235 MPa
Cr 0.84 (Table 8.3),
Cs 0.7 ,
Ct 1
C f ASub 57.7(470) 0.718 0.696
Thus
1
Se (0.696)(0.84)(0.7)(1)( 2.5
)(235) 38.5 MPa
A stepped cantilevered beam, machined from steel having ultimate tensile strength Su, is
under reversed bending (Figure P8.4). Determine the maximum value of the bending
moment M, using the Goodman criterion.
Given: d = 1 in., D = 1.5 in., r = 0.05 in., Su = 100 ksi
Design Assumptions: A survival rate of 95% is used. The factor of safety n = 1.5.
Figure P8.4
Equation (8.10):
C f AS ub 2.7(100 ) 0.265 0.797
Also
Table 8.3:
Cr 0.87
Ct 1
Equation (8.9):
Cs 0.85
Equation (8.1):
S e' 0.5(100 ) 50 ksi
.,
From Fig. C.9, with D d 15
r d 0.05:
K t 2 .1
By Fig.8.8:
and
q 0.77
K f 1 0.77( 2.1 1) 1.85
Hence
S e C f Cr Cs Ct ( K1f ) S e'
(0.797)(0.87)(0.85)(1)( 1.185 )(50) 15.9 ksi
Thus, Eq.(8.24):
n Sea ;
or
1.5
15, 900
10.2 M
M 1.039 kip in.
A cold drawn AISI 1020 annealed steel link is subjected to axial loading (that fluctuates
from 0 to F) by pins that go through holes (Figure P8.7). What is the maximum value of
F with a factor of safety of n, according to the Goodman criterion?
Given: R = 10 mm, r = 4 mm, t = 2.5 mm, n = 1.4
Assumption: A reliability of 99.99% is used.
Figure P8.7
S 470 MPa
H B 131
Table B.3: u
Tensile area through the hole:
2( R r )t 2(10 4)(2.5) 30 mm2
and
m a
F
2A
F
2(30)
S e' 0.45Su 211.5 MPa
F
60
We have
Cr 0.70 (Table 8.3)
(a)
Ct 1
C f ASub 4.51(470) 0.265 0.88
From Fig.C.5:
d
D 0.4,
K t 2.8
q 0.8
By Fig.8.8:
K 1 0.8(2.8 1) 2.44
Hence f
Therefore,
Se C f Cr Cs Ct (1 K f ) S e'
(0.88)(0.7)(1)(1)(1 2.44)(211.5) 53.4 MPa
By Eq.(8.20):
m
470 1.4
470
) 1
53.4
(1)(
34.25 MPa
(b)
From Eqs.(a) & (b):

34.25 60F
or
F 2.06 kN
A cold drawn AISI 1050 steel plate with a central hole is under a tension load P that
varies from 5 kN to 25 kN (Figure P8.8). Based on the Goodman criterion, determine the
factor of safety n
(a) Against yielding.
(b) Against fatigue failure.
Given: D = 25 mm, d = 5 mm, t = 10 mm
Assumption: A reliability of 98% and Cr = 0.7 are used.
Figure P8.8
A 10(25 5) 200 mm
Pm 12 (5 25) 15 kN ,
Pa 10 kN
( a ) Stress concentration factor is neglected for ductile materials under static loading.
Thus
max
Pmax
A
25(103 )
200(106 )
125 MPa
580
n maxy 125
4.64
( b )We now have

d
D 0.2,
K t 2.45 (Fig.C.5)
S y 580 MPa,
H B 197
Su 690 MPa,
q 0.83 (Fig.8.8)
K f 1 0.83(2.45 1) 2.2
Cr 0.84 (Table 8.3)
(Table B.3)
Ct 1
C f ASub 4.51(690) 0.265 0.798
Se' 0.45Su 310.5 MPa

Hence
1
Se (0.798)(0.84)(1)(1)( 2.2
)(310.5) 94.61 MPa
We have
m
Pm
A
15(103 )
200(106 )
75 MPa,
a 50 MPa
Equation (8.22) gives

690
n
1.57
690
75
94.61
(50)
Resolve Problem 8.8 for the condition that the load varies from 5 kN to 25 kN.
Assumption: Buckling does not occur.
Chapter 8. Problem 8
A cold drawn AISI 1050 steel plate with a central hole is under a tension load P that
varies from 5 kN to 25 kN (Figure P8.8). Based on the Goodman criterion, determine the
factor of safety n
(a) Against yielding.
(b) Against fatigue failure.
Given: D = 25 mm, d = 5 mm, t = 10 mm
Assumption: A reliability of 98% and Cr = 0.7 are used.
Figure P8.8
Refer to Solution of Prob.8.8
(a)
Sy
max
580
125
4.64
( b )We now have

Pm 12 [25 ( 5)] 10 kN ,
Pa 15 kN
m 50 MPa
Hence a 75 MPa,
Thus
690
n
1.16
690
50
94.61
(75)

A machined AISI 4130 normalized steel bar of diameter D carries an axial load P, as
shown in Figure P8.10. Calculate the value of
(a) The static force P to produce fracture.
(b) The completely reversed force P to produce fatigue failure.
1
Given: D = 2 8 in.
Assumptions: The survival rate is 95%. The operating temperature is 900F maximum.
Figure P8.10
A
D2
4
3.547 in.2
H B 197 (Table B.4)

( a ) Su 97.17 ksi
P Su A 97.17(3.547) 344.7 kips
and
(b)
Se C f Cr Cs Ct (1 K f ) S e'
where
Kf 1
Cr 0.87 (Table 8.3)
Cs 1 (axial load)
C f ASub 2.7(97.17) 0.265 0.803
Ct 1 0.0032(900 840) 0.81

Se 0.45Su 43.73 ksi
and
Thus
Se (0.803)(0.87)(1)(0.81)(43.73) 24.75 ksi

P ASe (3.547)(24.75) 87.79 kips
10
Redo Problem 8.10 for the case of a grooved shaft shown in Figure P8.11.
Given: D = 2
1
8
in., d = 2 in., r = 0.05 in.
Figure P8.11
A machined AISI 4130 normalized steel bar of diameter D carries an axial load P, as
shown in Figure P8.10. Calculate the value of
(a) The static force P to produce fracture.
(b) The completely reversed force P to produce fatigue failure.
1
Given: D = 2 8 in.
Assumptions: The survival rate is 95%. The operating temperature is 900F maximum.
Figure P8.10
2
2
Refer to Solution of Prob.8.10. We now have A d 4 3.142 in.
( a ) For a static fracture of a ductile material, the groove has little effect. Hence,
P Su A 305.3 kips
11

r
( b ) d 0.025,
12
K t 2.6 (Fig.C.10)
From Fig.8.8, with Su 97.17 ksi and r 0.05 in. q 0.75
K f 1 q ( K t 1) 1 0.75(2.6 1) 2.2
and
We now have
Se 24.75 2.2 11.25 ksi
Thus
D
d
1.063
P ASe 3.142(11.25) 35.35 kips
A stepped shaft ground from AISI 1040 annealed steel is subjected to torsion, as shown in
Figure P8.12. Determine the value of
(a) The torque T to produce static yielding.
(b) The torque T to produce fatigue failure.
Given: D = 50 mm, d = 25 mm, r = 1.25 mm
Assumption: Reliability is 98%.
Figure P8.12
S 519 MPa,
S y 353 MPa,
From Table B.4: u
S 0.577 S y 203.7 MPa
By Eq.(7.20), ys
( a ) Thus,
S ys 16T d 3 :
T
(b)
H B 149
(0.025)3 (203.7 106 )

16
624.9 N m
Ses C f Cr CsCt (1 K f ) S es'
where

Cr 0.84 (Table 8.3)
Cs 0.85 (Eq.8.9)
Ct 1
C f ASub 1.58(519) 0.085 0.929
S 0.29Su 150.5 MPa

'
e
r
d
0.05 and
13
D
d
(Eq.8.7)
(Eq.8.4)
2 K t 1.72
From Fig.C.8, with

q 0.9, K f 1 q( K t 1) 1.65
From Fig.8.9:
Hence
1
Ses (0.929)(0.84)(0.85)(1)( 1.65
)(150.5) 60.5 MPa
3
Refer to Eq.(8.24): Ses 16T d .
Thus
3
6
T (0.025) 16(60.510 ) 185.6 N m
Repeat Problem 8.12 for the condition that the shaft is subjected to axial loading and no
torsion.
Given: D = 50 mm, d = 25 mm, r = 1.25 mm
Figure P8.12
14
Refer to Solution of Prob.8.12.

2
2
2
S 353 MPa
( a ) A d 4 (25) 4 490.874 mm , and y
. Thus
P S y A 490.874(353) 173.3 kN
( b )We now have with

r
d 0.05,
D
d
From Fig. C.7: K t 2.52

Figure 8.8: q 0.7 and
K f 1 q ( Kt 1) 1 0.7(2.52 1) 2.06
By Eq.(8.3): Se 0.45Su 233.6 MPa

Hence
1
Se (0.929)(0.84)(0.85)(1)( 2.06
)(233.6) 75.22 MPa
Thus
P Se A (75.22)(490.874) 36.92 kN
Redo Problem 8.12 for the case in which the shaft is machined from an AISI 1095 hotrolled steel.
Given: D = 50 mm, d = 25 mm, r = 1.25 mm
Figure P8.12
S 830 MPa,
S y 460 MPa,
From Table B.3: u
By Eq.(7.20),
S ys 0.577 S y 265.4 MPa
H B 248
Refer to Solution of Prob.8.12.

d 3S ys
16
(0.025)3 (265.4 106 )

16
(a)
814.2 N m
(b)
C f ASub 4.51(830) 0.265 0.76
Ses' 0.29Su 240.7 MPa

and
Ses C f Cr Cs Ct (1 K f ) Ses'
1
(0.76)(0.84)(0.85)(1)( 1.65
)(240.7) 79.16 MPa
Therefore
T
d 3 Ses
16
(0.025)3 (79.16 106 )

16
242.9 kN m
A shaft with a transverse hole ground from AISI 1095 annealed steel is under bending
moment M that varies from 0.5 to 1.4 kip in. (Figure P8.15). Determine the factor of
safety n against fatigue failure, using the Goodman criterion.
1
Given: D = 1 in., d = 8 in.

Assumption: A reliability of 99% is used.
Figure P8.15
15
16
Su 95.43 ksi
H B 192 (Table B.4)

Se C f Cr C sCt (1 K f ) Se'
where
and
Cr 0.81 (Table 8.3)

Cs 0.85 (Eq.8.9)
C f ASub 1.34(95.43) 0.085 0.91
(Table 8.2)
'
Se 0.5Su 47.72 ksi
d
D
0.125,
K t 2.18
Fig.C.13)
K f 1 0.79(2.18 1) 1.93
q 0.79,
From Fig.8.8:
Thus
1
Se (0.91)(0.81)(0.85)(1)( 1.93
)(47.72) 15.49 ksi
We have
M m 12 (1.4 0.5) 103 950 lb in.,
Mm
( D3 32) ( dD 2 6)
950
(1)3 32 [(1 8)(1) 2 6]
M a 450 lb
in.
12.28 ksi
a 12.28( ) 5.817 ksi
(Fig.C.13)
4.5
9.5
Equation (8.22):
95.43
n
95.43
12.28
15.49
(5.817)
1.98
Resolve Problem 8.15 for the condition that shaft is ground from AISI 1060 HR steel and
is under axial loading varying from 5 to 15 kips.
A shaft with a transverse hole ground from AISI 1095 annealed steel is under bending
moment M that varies from 0.5 to 1.4 kip in. (Figure P8.15). Determine the factor of
safety n against fatigue failure, using the Goodman criterion.
1
Given: D = 1 in., d = 8 in.

Assumption: A reliability of 99% is used.
17
Figure P8.15
Refer to Solution of Prob.8.15. We now have
Su 98.62 ksi,
H B 201 (Table B.3)
q 0.8 (Fig.8.8)
Also
Kt 2.65 (Fig.C.13)
K f 1 0.8(2.65 1) 2.32
d
D
0.125
Se' 0.45Su 44.38 ksi

1
Se (0.91)(0.81)(0.85)(1)( 2.32
)(44.38) 12 ksi
and
We write
Pm 12 (15 5) 10,
and
m (1)2
10
4 (1)(1 8)
Pa 5 kips
A D 2 4 Dd
(Fig.C.13)
a 7.57 ksi
15.14 ksi,
Equation (8.22) is therefore

98.62
n
1.27
98.62
15.14
12
(7.57)
A thin-walled cylindrical vessel of diameter d is subjected to an internal pressure varying
from 60 to 300 psi continuously. Apply the maximum energy of distortion theory
incorporated with the Soderberg relation to design the vessel.
Given: d = 80 in., Sy = 40 ksi, Se = 30 ksi, n = 2.5
pr
t
pr
2t
3 0.
pm 180 psi,
pa 120 psi

a
m
pa
pm
18
23 .
S
Replace Su with y in Eq.(8.30):
1
Sy
1
1 2
n [1 2 4 ] 1e 0.866 1e
or
Sy
0.866 n
1e
(a)
Similarly, Eq.(8.25):
S
1e 1m Sey 1a rt ( pm
40
t
Sy
pa )
Se
(180 43 120) 13,600

t
(b)
By Eq.(a) and (b):

40
13.6
(0.866)2.5 t , t 0.736 in.
A thin-walled cylindrical vessel of diameter d and thickness t is under internal pressure
varying from 0.6 to 2.8 MPa continuously.
Given: d = 1.5 m, t = 25 mm, Su = 350 MPa, Se = 150 MPa
Design Decision: Use the maximum energy of distortion theory incorporated with the
Goodman relation. Determine the factor of safety n.
pr
t
, 2
pr
2t
, 3 0.
pm 1.7 MPa,
pa 1.1 MPa
Refer to Solution of Prob.8.17:

Su
1e 0.866
n
Use Eq.(8.25):
1e 1m
Su
Se
(a)
1a rt ( pm
From Eqs.(a) and (b):

350
0.866 n 128,
Su
Se
35
pa ) 30[1.7 15
(1.1)] 128 MPa
n 3.16
(b)
19
A small leaf spring, 10 mm wide 100 mm long and h mm deep, is subjected to a
concentrated center load P varying continuously from 0 to 20 N. The spring may be
approximated to be a simply supported beam (Figure P8.19). Calculate the required depth
for a factor of safety of 4.
Given: Su = 980 MPa, Se = 400 MPa
Design Decision: Apply the Goodman theory, based on the maximum normal stress.
Figure P8.19
b 0.01 m, L 0.1 m, M PL 4.
M max 14 (20)(0.1) 0.5 N m, M min 0

M a M m 0.25 N m, m a
We have,
6Mm
bh2
6(0.25)
0.01h 2
150
h2
Equation (8.20) gives

m 98098 4 71.01 MPa
(1)
40
Thus
h
150
71.01106
1.45 mm
Redo Problem 8.19 using the Soderberg criterion and yield strength of Sy = 620 MPa.
20
A small leaf spring, 10 mm wide 100 mm long and h mm deep, is subjected to a

concentrated center load P varying continuously from 0 to 20 N. The spring may be
approximated to be a simply supported beam (Figure P8.19). Calculate the required depth
for a factor of safety of 4.
Given: Su = 980 MPa, Se = 400 MPa
Design Decision: Apply the Goodman theory, based on the maximum normal stress.
Figure P8.19
From Solution of Prob.8.19, we have
a m 150
n2 .
S
Equation (8.20) by replacing Su with y :
S n
m a yS y
m Se
(a)
Substituting the given data gives

m 62062 4 60.78 MPa
(1)(
40
) 1
(b)
By Eqs.(a) and (b),

60.78(106 ) 150
h2
or
h 1.57 mm
1
An electrical contact includes a flat spring in the form of a cantilever, 8 in. wide 1.5 in.
long and h in. deep, is subjected at its free end to a load P that varies continuously from 0
to 0.5 lb (Figure P8.21). Compute the value of h for a factor of safety n = 1.2.
21
Given: Su = 150 ksi, Se = 72 ksi

Design Decision: Employ the Goodman criterion, based on the maximum normal stress.
Figure P8.21
At fixed end M max PL 0.5(1.5) 0.75 lb in. Hence
M
M
M M m M a max 2 min 0.375 lb in.
m a
6M
bh2
6(0.375)
0.125 h2
m
Equation (8.20):
Thus
18
40,541 psi,
h2
18
h2
150 1.2
150
1
72
(1)
40.541 ksi
h 0.021 in.
A cantilever spring is subjected to a concentrated load P varying continuously from 0 to
Po (Figure P8.22). What is the greatest allowable load Po for n = 4?
Given: Sy = 850 MPa, Se = 175 MPa, b = 5 mm, h = 10 mm, Kf = 2
Assumption: Failure occurs due to bending stress at the fillet.
Design Decision: Use the Soderberg criterion.
Figure P8.22
22
Pm Pa
P0
2
m
Eq.(8.20):
Also
Thus
M m 0.2 Pm 0.1P0 ,
850 4
85
1
17.5
(1)
6M m
bh 2
Pa Pm 1
a m 1
36.28 MPa
6(0.1) P0
0.005 100(106 )
1.2 P0 36.28,
1.2(106 ) P0
P0 30.23 N
Resolve Problem 8.22 for the load varying from Po/2 upward to Po downward, n = 2.
A cantilever spring is subjected to a concentrated load P varying continuously from 0 to
Po (Figure P8.22). What is the greatest allowable load Po for n = 4?
Given: Sy = 850 MPa, Se = 175 MPa, b = 5 mm, h = 10 mm, Kf = 2
Assumption: Failure occurs due to bending stress at the fillet.
Design Decision: Use the Soderberg criterion.
Figure P8.22
M max 0.2 P0 , M min 0.2( 0.5 P0 ) 0.1P0
Mm
P0
2
(0.2 0.1) 0.05 P0 , M a
P0
2
(0.2 0.1) 0.15 P0
850 2
85
1
35
1.5(3)
23
35.629 MPa
Equation (8.20):
P0 )
m 6bhM2m 0.0056(0.05
0.6(106 ) P0
100(106 )
Also
Thus
0.6 P0 35.629,
P0 59.38 N
A 24-mm wide, 4-mm thick, and 3-mm long leaf spring, made of AISI 1050CD steel, is
straight and unstressed when the cam and shaft are removed (Figure P8.24). Use the
Goodman theory to calculate the factor of safety n for the spring.
Given: Se = 250 MPa, E = 200 GPa, = 0.3
Assumption: The cam rotates continuously. Leaf spring is considered as a wide cantilever
beam.
Figure P8.24
I
bh3
12
24(4)3
12
128 mm 4 . Table B.3: Su 690 MPa
For a wide cantilever beam (see Secs 4.4 and 4.10, and Case 1 of Table A.9):
3
3
(1 2 ) 3PLEI 0.91 3PLEI
This gives
Pmin
3 EI
0.91 L3
min
3(200 109 )(128 1012 )

0.91(0.3)3
(0.01)
31.26 N and hence Pmax 62.52 N
Thus
Pm 46.89 N ,
Pa 15.63 N and
103 )
m 46.89(0.3)(2
219.8 MPa
9
0.128(10 )
24
a 219.8( 15.63
46.89 ) 73.27 MPa
Eq. (8.22):
n
Su
Su
a
Se
219.8
690
690
(73.27)
250
1.63
Repeat Problem 8.24 for the case in which the cantilevered spring is made of normalized
AISI 1095 steel and employing the Soderberg criterion.
A 24-mm wide, 4-mm thick, and 3-mm long leaf spring, made of AISI 1050CD steel, is
straight and unstressed when the cam and shaft are removed (Figure P8.24). Use the
Goodman theory to calculate the factor of safety n for the spring.
Given: Se = 250 MPa, E = 200 GPa, = 0.3
Assumption: The cam rotates continuously. Leaf spring is considered as a wide cantilever
beam.
Figure P8.24
Table B.4:
S y 500 MPa
S
Refer to Solution of Prob.8.24. Replacing Su by y in Eq.(8.22):
n
Sy
Sy
Se
219.8
500
500
(73.27)
250
1.36
25
Figure P8.26 shows a circular aluminum bar having two shoulder fillets supporting a
concentrated load P at its midspan. Determine the allowable value for diameter D if stress
conditions at the fillets are to be satisfactory for conditions of operation. Dimensions
shown are in millimeters.
Given: Su = 600 MPa, Sy = 280 MPa, n = 2.5, Kf Se = 150 MPa
Assumptions: The load P varies from 2 kN to 6 kN. The Soderberg relation is employed.
Figure P8.26
I 4 (0.03)4 0.636 106 m 4 ,
Pm 4 kN ,
m MIm c 2000(0.5)(0.03)
47.2 MPa
0.636 106
Pa 2 kN
a 23.6 MPa
S
Eq. (8.16), with replacing Su by y :
Sy
Sy
280
280
n m Se a ;
2.5 47.2 150 K f (23.6)
Solving
K f 1.47
From Fig.8.8: q=0.8

and
K f 1 q ( K t 1); 1.47 1 0.8( K t 1), K t 1.59
Then from Fig. C.9:

K t 1.59
r
d
9
60
0.15
D
3
d

and
D 3d 3(60) 180 mm
The filleted flat bar shown in Figure P8.27 is made from 1040 steel OQ&T at 650C.
What is the factor of safety n, if the bending moment M varies from 0.6 to 3 kN m?
Given: Kf Se = 400 MPa, D = 120 mm, d = 60 mm, r = 4 mm, t = 20 mm
Design Assumption: The Goodman criterion of fatigue failure is applied.
Figure P8.27
Table B.4: Su 634 MPa, H B 192
3
3
I bh12 0.02(0.06)
0.36 106 m 4
12
M m 1.8 kN m
Figure C.2:
120
D
d 60 2
r
d
4
60
0.067
M a 1.2 kN m
K t 2.1
400
K 1 0.82(2.1 1) 1.902. Se 1.902
210.3 MPa
Figure 8.8: q 0.82 and f
We have
m MImc 1800(0.03)
150 MPa
0.36 106
a 150( 1.2
1.8 ) 100 MPa
Equation (8.22):
Su
n
Su
m
Se
150
634
634
(100)
210.3
1.4
26
27

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Mechanical Design: An Integrated Approach - Ansel Ugural

Mechanical Design: An Integrated Approach - Ansel Ugural

Assumptions: A survival rate of 95% is used. The operating temperature is 475C

Su 400 MPa, S y 250 MPa

at D (from Solution of Prob.8.1)

C f ASub 272(400) 0.995 0.7

Cr 0.87 (Table 8.3)

Ct 1 0.0058(475 400) 0.565

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

Se' 0.45Su 294.8 MPa

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

C f ASub 4.51(6260.265 ) 0.819

Mechanical Design: An Integrated Approach - Ansel Ugural

Table B.3: Su 470 MPa. We apply

S e' 0.5Su 235 MPa

Cr 0.84 (Table 8.3),

C f ASub 57.7(470) 0.718 0.696

S e' 0.5(100 ) 50 ksi

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

M 1.039 kip in.

S e' 0.45Su 211.5 MPa

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

C f ASub 4.51(470) 0.265 0.88

From Eqs.(a) & (b):

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

( b )We now have

C f ASub 4.51(690) 0.265 0.798

Se' 0.45Su 310.5 MPa

Equation (8.22) gives

Mechanical Design: An Integrated Approach - Ansel Ugural

( b )We now have

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

H B 197 (Table B.4)

Ct 1 0.0032(900 840) 0.81

Se (0.803)(0.87)(1)(0.81)(43.73) 24.75 ksi

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

in., d = 2 in., r = 0.05 in.

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

P ASe 3.142(11.25) 35.35 kips

(0.025)3 (203.7 106 )

Ses C f Cr CsCt (1 K f ) S es'

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

C f ASub 1.58(519) 0.085 0.929

S 0.29Su 150.5 MPa

From Fig.C.8, with

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

Refer to Solution of Prob.8.12.

( b )We now have with

From Fig. C.7: K t 2.52

By Eq.(8.3): Se 0.45Su 233.6 MPa

Copyright 2004 The McGraw-Hill Companies Inc.

Mechanical Design: An Integrated Approach - Ansel Ugural

Refer to Solution of Prob.8.12.