budy_sm_ch01.

qxd 11/21/2006 15:23 Page 1

Chapter 1

Problems 1-1 through 1-4 are for student research.

1-5
(a) Point vehicles
v

cars v 42.1v v 2
Q= = =
hour x 0.324
Seek stationary point maximum
dQ 42.1 2v
=0= v* = 21.05 mph
dv 0.324
42.1(21.05) 21.052
Q* = = 1368 cars/h Ans.
0.324
(b) v

l x l
2 2

1
v 0.324 l
Q= = +
x +l v(42.1) v 2 v
Maximize Q with l = 10/5280 mi

v Q
22.18 1221.431
22.19 1221.433
22.20 1221.435
22.21 1221.435
22.22 1221.434

1368 1221
% loss of throughput = = 12% Ans.
1221
22.2 21.05
(c) % increase in speed = 5.5%
21.05
Modest change in optimal speed Ans.
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2 Solutions Manual Instructors Solution Manual to Accompany Mechanical Engineering Design

1-6 This and the following problem may be the students first experience with a figure of merit.
Formulate fom to reflect larger figure of merit for larger merit.
Use a maximization optimization algorithm. When one gets into computer implementa-
tion and answers are not known, minimizing instead of maximizing is the largest error
one can make.

FV = F1 sin W = 0

FH = F1 cos F2 = 0
From which
F1 = W/sin
F2 = W cos /sin
fom = $ = (volume)
.
= (l1 A1 + l2 A2 )
F1 W l1
A1 = = , l2 =
S S sin cos
 
 F2  W cos
A2 =   =
S S sin


l2 W l2 W cos
fom = +
cos S sin S sin


W l2 1 + cos2
=
S cos sin
Set leading constant to unity

fom
* = 54.736 Ans.
0 fom* = 2.828
20 5.86
30 4.04 Alternative:


40 3.22 d 1 + cos2
45 3.00 =0
d cos sin
50 2.87
54.736 2.828 And solve resulting tran-
60 2.886 scendental for *.

Check second derivative to see if a maximum, minimum, or point of inflection has been
found. Or, evaluate fom on either side of *.
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Chapter 1 3

1-7
(a) x1 + x2 = X 1 + e1 + X 2 + e2
error = e = (x1 + x2 ) ( X 1 + X 2 )
= e1 + e2 Ans.
(b) x1 x2 = X 1 + e1 ( X 2 + e2 )
e = (x1 x2 ) ( X 1 X 2 ) = e1 e2 Ans.
(c) x1 x2 = ( X 1 + e1 )( X 2 + e2 )
e = x1 x2 X 1 X 2 = X 1 e2 + X 2 e1 + e1 e2


. e1 e2
= X 1 e2 + X 2 e1 = X 1 X 2 + Ans.
X1 X2


x1 X 1 + e1 X 1 1 + e1 / X 1
(d) = =
x2 X 2 + e2 X 2 1 + e2 / X 2

1


e2 . e2 e1 e2 . e1 e2
1+ =1 and 1+ 1 =1+
X2 X2 X1 X2 X1 X2


x1 X 1 . X 1 e1 e2
e= = Ans.
x2 X2 X2 X1 X2

1-8
(a) x1 = 5 = 2.236 067 977 5
X 1 = 2.23 3-correct digits

x2 = 6 = 2.449 487 742 78
X 2 = 2.44 3-correct digits

x1 + x2 = 5 + 6 = 4.685 557 720 28

e1 = x1 X 1 = 5 2.23 = 0.006 067 977 5

e2 = x2 X 2 = 6 2.44 = 0.009 489 742 78

e = e1 + e2 = 5 2.23 + 6 2.44 = 0.015 557 720 28
Sum = x1 + x2 = X 1 + X 2 + e
= 2.23 + 2.44 + 0.015 557 720 28
= 4.685 557 720 28 (Checks) Ans.

(b) X 1 = 2.24, X 2 = 2.45

e1 = 5 2.24 = 0.003 932 022 50

e2 = 6 2.45 = 0.000 510 257 22
e = e1 + e2 = 0.004 442 279 72
Sum = X 1 + X 2 + e
= 2.24 + 2.45 + (0.004 442 279 72)
= 4.685 557 720 28 Ans.
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4 Solutions Manual Instructors Solution Manual to Accompany Mechanical Engineering Design

1-9
(a) = 20(6.89) = 137.8 MPa
(b) F = 350(4.45) = 1558 N = 1.558 kN
(c) M = 1200 lbf in (0.113) = 135.6 N m
(d) A = 2.4(645) = 1548 mm2
(e) I = 17.4 in4 (2.54) 4 = 724.2 cm4
(f) A = 3.6(1.610) 2 = 9.332 km2
(g) E = 21(1000)(6.89) = 144.69(103 ) MPa = 144.7 GPa
(h) v = 45 mi/h (1.61) = 72.45 km/h
(i) V = 60 in3 (2.54) 3 = 983.2 cm3 = 0.983 liter

1-10
(a) l = 1.5/0.305 = 4.918 ft = 59.02 in
(b) = 600/6.89 = 86.96 kpsi
(c) p = 160/6.89 = 23.22 psi
(d) Z = 1.84(105 )/(25.4) 3 = 11.23 in3
(e) w = 38.1/175 = 0.218 lbf/in
(f) = 0.05/25.4 = 0.00197 in
(g) v = 6.12/0.0051 = 1200 ft/min
(h)  = 0.0021 in/in
(i) V = 30/(0.254) 3 = 1831 in3

1-11
200
(a) = = 13.1 MPa
15.3
42(103 )
(b) = = 70(106 ) N/m2 = 70 MPa
6(102 ) 2
1200(800) 3 (103 ) 3
(c) y = = 1.546(102 ) m = 15.5 mm
3(207)109 (64)103 (103 ) 4
1100(250)(103 )
(d) = 9 4 3 4
= 9.043(102 ) rad = 5.18
79.3(10 )(/32)(25) (10 )

1-12
600
(a) = = 5 MPa
20(6)
1
(b) I = 8(24) 3 = 9216 mm4
12

(c) I = 324 (101 ) 4 = 5.147 cm4
64
16(16)
(d) = = 5.215(106 ) N/m2 = 5.215 MPa
(253 )(103 ) 3
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Chapter 1 5

1-13
120(103 )
(a) = = 382 MPa
(/4)(202 )
32(800)(800)(103 )
(b) = = 198.9(106 ) N/m2 = 198.9 MPa
(32) 3 (103 ) 3

(c) Z = (364 264 ) = 3334 mm3
32(36)
(1.6) 4 (103 ) 4 (79.3)(109 )
(d) k = = 286.8 N/m
8(19.2) 3 (103 ) 3 (32)
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FIRST PAGES

Chapter 2

2-1 From Table A-20

Sut = 470 MPa (68 kpsi), S y = 390 MPa (57 kpsi) Ans.

2-2 From Table A-20

Sut = 620 MPa (90 kpsi), S y = 340 MPa (49.5 kpsi) Ans.

2-3 Comparison of yield strengths:

620
Sut of G10 500 HR is = 1.32 times larger than SAE1020 CD Ans.
470
390
Syt of SAE1020 CD is = 1.15 times larger than G10500 HR Ans.
340
From Table A-20, the ductilities (reduction in areas) show,
40
SAE1020 CD is = 1.14 times larger than G10500 Ans.
35
The stiffness values of these materials are identical Ans.

Table A-20 Table A-5

Sut Sy Ductility Stiffness
MPa (kpsi) MPa (kpsi) R% GPa (Mpsi)
SAE1020 CD 470(68) 390 (57) 40 207(30)
UNS10500 HR 620(90) 340(495) 35 207(30)

2-4 From Table A-21

1040 Q&T S y = 593 (86) MPa (kpsi) at 205C (400F) Ans.

2-5 From Table A-21

1040 Q&T R = 65% at 650C (1200F) Ans.

2-6 Using Table A-5, the specific strengths are:

Sy 39.5(103 )
UNS G10350 HR steel: = = 1.40(105 ) in Ans.
W 0.282
Sy 43(103 )
2024 T4 aluminum: = = 4.39(105 ) in Ans.
W 0.098
Sy 140(103 )
Ti-6Al-4V titanium: = = 8.75(105 ) in Ans.
W 0.16
ASTM 30 gray cast iron has no yield strength. Ans.
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FIRST PAGES

Chapter 2 7

2-7 The specific moduli are:

E 30(106 )
UNS G10350 HR steel: = = 1.06(108 ) in Ans.
W 0.282
E 10.3(106 )
2024 T4 aluminum: = = 1.05(108 ) in Ans.
W 0.098
E 16.5(106 )
Ti-6Al-4V titanium: = = 1.03(108 ) in Ans.
W 0.16

E 14.5(106 )
Gray cast iron: = = 5.58(107 ) in Ans.
W 0.26

E 2G
2-8 2G(1 + ) = E =
2G
From Table A-5
30 2(11.5)
Steel: = = 0.304 Ans.
2(11.5)
10.4 2(3.90)
Aluminum: = = 0.333 Ans.
2(3.90)
18 2(7)
Beryllium copper: = = 0.286 Ans.
2(7)
14.5 2(6)
Gray cast iron: = = 0.208 Ans.
2(6)

2-9

E
U
80

70

60
Stress PA0 kpsi

50

Y
40 Su 85.5 kpsi Ans.
Sy 45.5 kpsi Ans.
30 E 900.003 30 000 kpsi Ans.
A0 AF 0.1987 0.1077
20 R (100) 45.8% Ans.
A0 0.1987
l l l0 l A0
10
1 1
l0 l0 l0 A

0
0 0.002 0.004 0.006 0.008 0.010 0.012 0.014 0.016 (Lower curve)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 (Upper curve)
Strain,

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8 Solutions Manual Instructors Solution Manual to Accompany Mechanical Engineering Design

2-10 To plot true vs. , the following equations are applied to the data.
(0.503) 2
A0 = = 0.1987 in2
4
l
Eq. (2-4) = ln for 0 L 0.0028 in
l0
A0
= ln for L > 0.0028 in
A
P
true =
A
The results are summarized in the table below and plotted on the next page.
The last 5 points of data are used to plot log vs log
The curve fit gives m = 0.2306
Ans.
log 0 = 5.1852 0 = 153.2 kpsi
For 20% cold work, Eq. (2-10) and Eq. (2-13) give,
A = A0 (1 W ) = 0.1987(1 0.2) = 0.1590 in2
A0 0.1987
= ln = ln = 0.2231
A 0.1590
Eq. (2-14):
S y = 0 m = 153.2(0.2231) 0.2306 = 108.4 kpsi Ans.
Eq. (2-15), with Su = 85.5 kpsi from Prob. 2-9,
Su 85.5
Su = = = 106.9 kpsi Ans.
1W 1 0.2

P L A true log log true

0 0 0.198 713 0 0
1 000 0.0004 0.198 713 0.000 2 5032.388 3.699 01 3.701 774
2 000 0.0006 0.198 713 0.000 3 10 064.78 3.522 94 4.002 804
3 000 0.0010 0.198 713 0.000 5 15 097.17 3.301 14 4.178 895
4 000 0.0013 0.198 713 0.000 65 20 129.55 3.187 23 4.303 834
7 000 0.0023 0.198 713 0.001 149 35 226.72 2.939 55 4.546 872
8 400 0.0028 0.198 713 0.001 399 42 272.06 2.854 18 4.626 053
8 800 0.0036 0.198 4 0.001 575 44 354.84 2.802 61 4.646 941
9 200 0.0089 0.197 8 0.004 604 46 511.63 2.336 85 4.667 562
9 100 0.196 3 0.012 216 46 357.62 1.913 05 4.666 121
13 200 0.192 4 0.032 284 68 607.07 1.491 01 4.836 369
15 200 0.187 5 0.058 082 81 066.67 1.235 96 4.908 842
17 000 0.156 3 0.240 083 108 765.2 0.619 64 5.036 49
16 400 0.130 7 0.418 956 125 478.2 0.377 83 5.098 568
14 800 0.107 7 0.612 511 137 418.8 0.212 89 5.138 046
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FIRST PAGES

Chapter 2 9

160000

140000

120000

true (psi)
100000

80000

60000

40000

20000

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
true

5.2

5.1

y 0.2306x 5.1852

log 
5

4.9

4.8
1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0
log 

2-11 Tangent modulus at = 0 is

 . 5000 0
E0 = = = 25(106 ) psi
 0.2(103 ) 0
At = 20 kpsi
. (26 19)(103 )
E 20 =
= 14.0(106 ) psi Ans.
(1.5 1)(10 )
3

(103 )
60
(kpsi)
50
0 0
0.20 5 40
0.44 10
 (kpsi)

(Sy)0.001
35 kpsi Ans.
0.80 16 30
1.0 19
1.5 26 20
2.0 32
2.8 40 10

3.4 46
0
4.0 49 0 1 2 3 4 5
5.0 54  (103)
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10 Solutions Manual Instructors Solution Manual to Accompany Mechanical Engineering Design

2-12 Since |o | = |i |







R+h

R

R + N


ln
=
ln
=
ln


R+ N

R+ N

R

R+h R+N
=
R+N R
( R + N ) 2 = R( R + h)
From which, N 2 + 2R N Rh = 0
   
h 1/2
The roots are: N = R 1 1 +
R
The + sign being significant,
  
h 1/2
N=R 1+ 1 Ans.
R
Substitute for N in
R+h
o = ln
R+N

 
R+h h 1/2
Gives 0 = ln   = ln 1 + Ans.
h 1/2 R
R+ R 1+ R
R
These constitute a useful pair of equations in cold-forming situations, allowing the surface
strains to be found so that cold-working strength enhancement can be estimated.

2-13 From Table A-22

AISI 1212 S y = 28.0 kpsi, f = 106 kpsi, Sut = 61.5 kpsi
0 = 110 kpsi, m = 0.24, f = 0.85
From Eq. (2-12) u = m = 0.24
A0 1 1
Eq. (2-10) = = = 1.25
Ai 1W 1 0.2
Eq. (2-13) i = ln 1.25 = 0.2231 i < u
Eq. (2-14) S y = 0 im = 110(0.2231) 0.24 = 76.7 kpsi Ans.
Su 61.5
Eq. (2-15) Su = = = 76.9 kpsi Ans.
1W 1 0.2

2-14 For H B = 250,

Eq. (2-17) Su = 0.495 (250) = 124 kpsi
Ans.
= 3.41 (250) = 853 MPa
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FIRST PAGES

Chapter 2 11

2-15 For the data given,

 
H B = 2530 H B2 = 640 226

2530 640 226 (2530) 2 /10
H B = = 253 H B = = 3.887
10 9
Eq. (2-17)
Su = 0.495(253) = 125.2 kpsi Ans.
su = 0.495(3.887) = 1.92 kpsi Ans.

2-16 From Prob. 2-15, H B = 253 and HB = 3.887

Eq. (2-18)
Su = 0.23(253) 12.5 = 45.7 kpsi Ans.
su = 0.23(3.887) = 0.894 kpsi Ans.

2-17
. 45.52
(a) uR = = 34.5 in lbf/in3 Ans.
2(30)
(b)

P L A A0 /A 1 = P/A0
0 0 0 0
1 000 0.0004 0.0002 5 032.39
2 000 0.0006 0.0003 10 064.78
3 000 0.0010 0.0005 15 097.17
4 000 0.0013 0.000 65 20 129.55
7 000 0.0023 0.001 15 35 226.72
8 400 0.0028 0.0014 42 272.06
8 800 0.0036 0.0018 44 285.02
9 200 0.0089 0.004 45 46 297.97
9 100 0.1963 0.012 291 0.012 291 45 794.73
13 200 0.1924 0.032 811 0.032 811 66 427.53
15 200 0.1875 0.059 802 0.059 802 76 492.30
17 000 0.1563 0.271 355 0.271 355 85 550.60
16 400 0.1307 0.520 373 0.520 373 82 531.17
14 800 0.1077 0.845059 0.845 059 74 479.35
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12 Solutions Manual Instructors Solution Manual to Accompany Mechanical Engineering Design


90000

80000

70000

60000

50000

40000

30000

20000

10000

0 
0 0.2 0.4 0.6 0.8
All data points


50000

45000

40000

35000

30000

25000

20000
A1 A2
15000

10000

5000

0 
0 0.001 0.002 0.003 0.004 0.005
First 9 data points


90000

80000

70000

60000

50000

40000 A4 A5

30000

20000
A3
10000

0 
0 0.2 0.4 0.6 0.8
Last 6 data points

. 
5
1
uT = Ai = (43 000)(0.001 5) + 45 000(0.004 45 0.001 5)
i=1
2
1
+ (45 000 + 76 500)(0.059 8 0.004 45)
2
+ 81 000(0.4 0.059 8) + 80 000(0.845 0.4)
.
= 66.7(103 )in lbf/in3 Ans.
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FIRST PAGES

Chapter 2 13

2-18 m = Al
For stiffness, k = AE/l, or, A = kl/E.
Thus, m = kl 2 /E, and, M = E/. Therefore, = 1
From Fig. 2-16, ductile materials include Steel, Titanium, Molybdenum, Aluminum, and
Composites.
For strength, S = F/A, or, A = F/S.
Thus, m = Fl /S, and, M = S/.
From Fig. 2-19, lines parallel to S/ give for ductile materials, Steel, Nickel, Titanium, and
composites.
Common to both stiffness and strength are Steel, Titanium, Aluminum, and
Composites. Ans.