Unit - I Introduction to Design Process

Dr. Bhaskar Lokavarapu

School of Mechanical and Building Sciences

VIT Chennai Campus
Digitally signed by Bhaskar
DN: CN = Bhaskar, C = IN, OU =

Bhaskar VIT
Reason: I have reviewed this
document
Date: 2013.08.19 16:19:25
+05'30'

8/19/2013 Dr. L. Bhaskar 1

 COURSE OUTLINE

Unit-I Introduction to Design Process

Unit-II Fatigue Strength and Design of Springs

Unit-III Design of Shafts and Joints

Unit-IV Design of Couplings

Unit-V Design of Engine Components

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 Overview of the Presentation

¾ Introduction to Design process

¾Factors- Materials selection.
¾Direct stress.
¾Bending.
¾Torsional stress equation.
¾Impact and Shock loading.
¾Stress concentration factor.
¾Size factor - Surface limits factor.
¾Factor of safety.
¾Design stress.
¾Theories of failures.

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 Introduction to Design Process

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 What is Machine Design ?

What is the importance of Machine Design for

engineers?

What is Machine Design?

Creation of new and better machines AND

Improving existing ones

So that it is economical in the cost of production and operation.

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 Factors – Material Selection

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Phases in Design Design is a highly Iterative Process

Identification of Need

Definition of Problem

Synthesis

Analysis and Optimization

Evaluation

Presentation
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 Direct stress
Refer Strength of materials notes

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 Problems-Tensile Stress

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 Problems-Tensile Stress

¾ Example:1 In a steam engine cylinder of 300

mm diameter , the maximum pressure across
the piston is 65 N/cm2 . Design the diameter
of the piston rod if maximum tensile or
compressive stress on the piston rod is
limited to 40 N/mm2.

¾ Given : d = 300 mm = 0.3 m

p = 65 N/cm2 = 65x104 N/m2
σT/C = 40 N/mm2 = 40x106 N/m2

¾ TO Find: Diameter of the piston= dPiston

9Ans: dPiston= 38.2426 mm = 40 mm [From Design Data Book]

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 Problems-Tensile Stress

¾ Example:2 A tensile load of 75 kN is

applied on a carbon steel link as shown
in Figure. Determine the induced
stresses at sections A-A and B-B.

¾ Given : F = 75 kN = 75x1000 N

¾ TO Find: σA-A, σB-B

9Ans: (i) Stress at section A-A = σA-A = 33.333 MPa
(ii) Stress at section B-B= σB-B = 50 Mpa
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 Problems-Tensile Stress

¾ Example:3 A wire rope of 110 mm2 cross-

sectional area, is made-up of 0.1 cm diameter
strands. The ultimate tensile strength of the
rope is 145 kN. Factor of safety used for the
rope is 9. The permissible tensile stress for
the rope material is 140 MPa. When 12
strands are found broken , is the rope fit for
further use?
¾ Given : Ae = 110 mm2 = 110x10-6m2
d = 0.1 cm = 0.0001 m
Fult = 145 kN = 145x1000 N; N=9
σallo= 140 MPa=140x106 N/m2
no. of strands broken = 12
¾ TO Find: Is the rope fit for further use
9Ans: The rope is not fit for further use. Because Here
σIndu (160.1897 MPa) >σAllo (140 MPa)
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 Problems-Compressive Stress

¾ Example:4 The cylinder of an I.C engine is 80

mm in diameter and maximum explosion
pressure is 1.5 N/mm2 . The connecting rod is of
circular cross-section of mean diameter 30 mm
and is made of chromium molybdenum steel. At
the instant of firing inside the cylinder, what
type of stress is induced in the connecting rod
and what is its value?
¾ Given : d = 80 mm = 0.008 m
Pex= 1.5 N/mm2 = 1.5x106 N/m2
dm = 30 mm = 0.003 m

¾ TO Find: Type of stress induced in the C.R

9Ans: The compressive stress induced in the connecting
rod = σc =10.667 MN/m2
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 Problems-Tensile & Compressive Stress

¾ Example:5 A steel bolt, 300 mm long between

end washers and 25 mm in diameter is enclosed
in a copper tube of 26 mm inner diameter and 45
mm outer diameter . Determine the stresses
induced in both the bolt and tube, if the nut is
turned through 1800 on 3 mm pitch bolt threads.
Assume that the bolt is unstressed initially. Def.
is 1.5 mm.Take ES = 2x105 MPa and ECU = 1x105
MPa
¾ Given : lS = 300 mm = 0.3 m;dS=25 mm=0.025 m
dID= 26 mm = 0.026 m
dOD= 45 mm = 0.045 m
¾ TO Find: Stresses induced in the bolt and tube

9Ans: σBolt =1000 N/mm2 [Tensile] Tube =1000 N/mm2 [Compressive]

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 Problems-Tensile & Compressive Stress

¾ Example:6 Two plates are tightened by a bolted joint,

using a washer between the top plate and nut. The
tightening load in the bolt is 20 kN. The nominal diameter
of the bolt is 20 mm. the inner diameter of the washer is
22 mm, and the outer diameter is 45 mm. if the allowable
crushing stress in the plates and washer is 75 MPa; are
the plates and washer safe, from the crushing point of
view? If the allowable tensile stress in the bolt is 60 MPa,
is the bolt safe? Take root diameter of the thread as
0.84xnominl diameter of the threaded (bolt).
¾ Given : F = 20 kN = 20,000 N; dB=20 mm=0.02 m
dID= 22 mm = 0.022 m
dOD= 45 mm = 0.045 m
σcrush =75 MPa; σTen =60 MPa
¾ TO Find: Stresses induced in the bolt and tube
9Ans: (i) Plates and washers are safe from crushing point of view.
(ii) The bolt is not safe from tension point of view
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 Problems-Bearing Pressure

¾ Example:7 A 30 mm diameter shaft is

supported in a journal bearing is 3000
N. If the design bearing pressure is 3.1
N/mm2. determine the required length of the
bearing. .

¾ Given : d = 30 mm = 0.03 m
F = 3000 N
P = 3.1 N/mm2 = 3.1x 106 N/m2
¾ TO Find: Length of the bearing=L
9Ans: L= 0.032258 m = 32.258 mm
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 Problems-Shear [double]

¾ Example: 8. A gudgeon pin of uniform circular

cross section is used to connect the piston and
connecting rod of an I.C engine. If the
maximum pressure on the piston is 150 N/cm2
and the diameter of the piston is 80 mm.
Determine the diameter of the pin against
failure by shear. Allowable shear stress for the
pin material is 30 N/mm2.
¾ Given : dp = 80 mm = 0.08 m
p = 150 N/cm2 = 150x104 N/m2
τ = 30 N/mm2 = 30x106 N/m2
¾ TO Find: Diameter of the pin
9Ans: dpin= 12.6491 mm = 14 mm [From Design Data Book]
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 Problems-Shear [double]

¾ Example: 9. A load of 70 kN is transmitted

between the two rods through a pin as shown
in figure. Determine the induced stresses in the
pin whose diameter is 25 mm.

¾ Given : F = 70 kN = 70x1000 N
d = 25 mm = 0.025 m

¾ TO Find: Induced stresses in the pin

9Ans: τ = 71.3 MPa; σRod End = 56 MPa; σFork End = 46.667 MPa

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 Indirect Stresses

{ Bending stress

{ Torsional shear stress

Refer Strength of material notes

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 Bending Stress

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 Problems-Bending stress

¾ Example: 1. An electric motor weighing 625 N

is mounted on a short cantilever beam of
uniform rectangular cross-section. The
weight of the motor acts at a distance of 285
mm from the support. The depth of the
section is twice the width. Determine the
section of the beam. The permissible stress in
the beam is 50 N/mm2.

¾ Given : w = 625 N
L = 285 mm = 0.285 m
σper = 50 N/mm2 = 50x106 N/m2
¾ TO Find: Section of the beam=b x d

9Ans: b = 18 mm, d = 36 mm [From Design Data Book]

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 Problems-Bending stress

¾ Example: 2. A shaft is supported in bearings,

the distance between their centres being 850
mm. it carries a pulley in the centre and it
weighs 95 kg-f. Determine the diameter of the
shaft, if the allowable bending stress for the
shaft material is 50 N/mm2.

¾ Given : w = 95 kg-f = 931.95 N

L = 850 mm = 0.85 m
σAllow = 50 N/mm2 = 50x106 N/m2

¾ TO Find: Diameter of beam = d

9Ans: d = 35 mm [From Design Data Book]

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 Problems-Bending stress

¾ Example: 3. A wall bracket of uniform

rectangular section is shown in Figure is
subjected to a pull of 5000 N acting at 30o to
horizontal. The stress in the material of the
bracket is limited to 28 N/mm2. Design the
cross section of the bracket taking the depth of
the section as thrice the width.

¾ Given : F = 5000 N at 30o to horizontal

σAllow = 28 N/mm2 = 28x106 N/m2

¾ TO Find: Design the cross-section = b x d

9Ans: b = 25 mm & d = 75 mm
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 Problems-Bending stress

¾ Example: 4. Figure shows a lever mounted on a

shaft by means of a taper pin. If the allowable
stress for the lever material is 70 MPa,
determine the diameter, d of he circular section
(section shown at (i). If the section is changed
to rectangular one, but with the same cross-
sectional area, determine the maximum
bending stress induced, for the orientations of
the sections shown at (ii) and (iii).

¾ Given : σAllow = 70 MPa = 70x106 N/m2

¾ TO Find: Determine the diameter & σMax.Bending

9Ans: d = 30.9757 mm; σMax.B = 34.202 MPa& σMax.Be=102.607 MPa

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 Problems-Bending stress

¾ Example: 5. A hollow cylindrical chimney is 25 m

height, 2.5 m external diameter and 2 m internal
diameter . The density of the chimney material is
650 kg/m3. A horizontal wind pressure of 125
N/m2 of projected area is acting on the chimney
throughout its height. Determine (i) the
maximum and minimum normal stresses induced
in the base of the chimney. (ii) also determine
the limiting value of the wind pressure so that no
point in the base is under tensile stress.

¾ Given : h = 25 m; dID = 2 m; dOD=2.5m; ρ = 650 kg/m3

p = 125 N/m2
¾ TO Find: σMax. σMin & Pwind

9Ans: σMax = 267.24 MPa; σMin=51.583 MPa & Pwind =184.798 MPa
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 Problems-Bending stress

¾ Example: 6. Determine the required thickness

of the copper bracket at section B-B, when
loaded as shown in Figure in order to limit the
tensile stress to 70 MN/m2.
¾ Given : σ = 70 MN/m2 = 60x106 N/m2

¾ TO Find: t

9Ans: t = 14 mm
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 Torsional Stress

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 Problems-Torsional shear stress

¾ Example: 1. Design a suitable diameter for

circular shaft required to transmit 100 kW
power at 135 rpm. The shear stress of the shaft
is not to exceed 80 MPa and the maximum
torque exceeds the mean by 25%.

¾ Given : P = 100 kW = 100x1000 W

N = 130 rpm
τper= 80 MPa = 80x106 N/m2
Tmax = 1.25 x Tmean

¾ TO Find: Diameter of the shaft

9Ans: d = 82.5675 mm = 85 mm [From Design Data Book]
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 Problems-Torsional shear stress

¾ Example: 2. A solid shaft of length 1.5 m, transmits 125

kW at 200 rpm. If the allowable shear stress for the shaft
material is 70 MPa, and the angle of twist in the shaft is
not to exceed 0.60 , determine the diameter of the shaft.
Take modulus of elasticity as 85 GPa.

¾ Given : L = 1.5 m
P = 125 kW = 125x1000 W
N = 200 rpm
τper= 70 MPa = 70x106 N/m2
θallow= 0.60
G = 85 GPa = 85x109 N/m2
¾ TO Find: Diameter of the shaft
9Ans: d = 100.6075 mm [From Design Data Book]
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 Problems-Torsional shear stress

¾ Example: 3. A bore is made in a solid shaft, in

order to reduce its weight to 60% what will be
the percentage reduction in its torsional
strength?

¾ Given : 60 %

¾ TO Find: % reduction in its torsional strength

9Ans: d = 16%
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 Problems-combined stress

¾ Example: 4. A cylindrical bar of 60 mm

diameter and 275 mm long is fixed at one end.
At the free end it is loaded as shown in figure
with an axial load of 20 kN, a downward
transverse load of 10 kN and a torque of 5 kN-
m. Determine the maximum stress at point A of
the bar.
¾ Given : d = 60 mm = 0.06 m
L = 275 mm = 0.275 m
Wa = 20 kN = 20000 N
WT = 10 kN = 10000 N: T = 5 kN-m
¾ TO Find: σA & τA
9Ans: σA = 214.979 MPa & τA = 146.603 MPa
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 Impact and Shock Loading

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 Energy balance
{ Fe is the equivalent static force
necessary to create an amount
of deflection equal to δ
{ Energy Balance of falling
weight, W
1δ2
W (h + δ ) = W
1 2 δs
W (h + δ ) = Feδ
2 1δ2
W = kδ static = kδs h +δ =
2 δs
Fe = kδ
⎛ 2h ⎞
⎡δ ⎤ δ = δ s ⎜1 + 1 + ⎟⎟
⎜
Fe = ⎢ ⎥W ⎝ δs ⎠
⎣ δs ⎦
⎛ 2h ⎞
Fe δ ⎜
Fe = W ⎜1 + 1 + ⎟
= δ ⎟
W δs ⎝ s ⎠
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 Impact, cont.
{ Sometimes we know velocity at impact rather
than the height of the fall
{ An energy balance gives:

v 2 = 2 gh
⎛ v 2 ⎞⎟
⎜
δ = δs 1+ 1+
⎜ gδ s ⎟⎠
⎝
⎛ v 2 ⎞
Fe = W ⎜1 + 1 + ⎟
⎜ gδ s ⎟⎠
⎝

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 Problems-Impact stress

¾ Example: 1. A weight W falls 9.5 mm on to a

collar rigidly attached in the lower end of
vertical bar, 7.2 m long and 390 mm2 in cross
section. The maximum instantaneous extension
is found to be 1.85 mm. Determine the value of
W and corresponding stress produced in bar.
The modulus of elasticity for the material is
2x105 N/mm2.
¾ Given : h = 9.5 mm
L = 7.2 m = 7200 mm
A = 390 mm2
δL = 1.85 mm; E = 2x105 N/mm2
¾TO Find: Weight and stress produced w and σ
9Ans: (i) The value of falling weight = W = 1765.7856 N
(ii) Stress produced in bar = σA = 55.55 MPa
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 Problems-Impact stress

¾ Example: 2. An I-section beam of depth 250

mm is supported at two points 4 m apart. It is
loaded by a weight of 4 kN falling through a
height h and striking the beam at mid span.
Moment of inertia of the section is 8x107 mm4.
Modulus of elasticity for the material is 2.1x105
N/mm2. Determine the allowable value of h if
the stress is limited to 120 N/mm2.
¾ Given : d = 250 mm
L = 4 m = 4000 mm
W = 4 kN = 4000 N; σ= 120 N/mm2
I = 8x107 mm4 ; E = 2.1x105 N/mm2
¾TO Find: Allowable value of h

9Ans: (i) The allowable value of height = h = 52.419 mm

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 Problems-Impact stress

¾ Example: 3. The brasses of an automobile

engine connecting rod have worn-out so as to
allow some play which gives shock loading,
equivalent to a weight of 7.5 kN, falling through
a height of 0.5 mm. The connecting rod is 275
mm long having cross-sectional area of 325
mm2. Determine the stress induced in the
connecting rod. Compare the maximum stress
induced, with that by a static load of 7.5 kN.
¾ Given : w = 7.5 kN = 7500 N
h = 0.5 mm
L = 275 mm
A= 325 mm2
¾TO Find: Compare the max. and static stresses

9Ans: σmax/σStatic = 6.8387

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 Problems-Impact stress

¾ Example: 4. In a hoisting operation, a mass of

1150 kg is being lifted by means of a steel wire
rope of 525 mm2 cross-sectional area. The
velocity of movement is 1.2 m/s. When the free
length of the rope is 14.5 m, the sheave got
stuck-up. Determine the stress induced in the
rope, due to the sudden stoppage of the
sheave, Take E=2x105 MPa.
¾ Given : m = 1150 kg
A = 525 mm2
v = 1.2 m/s
h = 14.5 m; E=2x105 MPa
¾TO Find: Stress induced in the rope

9Ans: Stress induced in the rope is = σRope = 208.5842 N/mm2

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 Stress Concentration

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 Stress Concentration

¾ In almost engineering components and machine have to

incorporate design features which introduce changes in thin
cross-section.
¾ Changes in cross section causes localized stress concentrations
and severity depends on the geometry of the discontinuity and
nature of the material.
¾ Stress concentration factor,
• Kt = Smax/Sav
Smax, maximum stress at discontinuity and Sav, nominal
stress.
Kt, value depends only on geometry of the part.
¾ Applies to brittle & notch sensitive materials. Should consider
when using high-strength, low ductility, case-hardened & / or
heavily cold work materials.
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 Stress Concentration
Stress Concentration

¾ Stress concentration in fatigue.

• Kf, fatigue stress concentration factor,
Kf = endurance limit of notch free
endurance limit of notched part
9 Notch sensitivity factor, q = Kf - 1
Kt - 1
¾ Generally , q 1 as material strength increases and
sensitive to notches.
Kf = Kt
¾ q also depend on component size.
9 Stress-raiser, dangerous in larger masses.
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 Stress Concentration
{ Localized increase of stress near discontinuities
{ Kt is Theoretical (Geometric) Stress Concentration
Factor

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 Stress Concentration
Stress Concentration

9 Guidelines for design.

9 Abrupt changes in cross-section should be avoided.
9Fillet radii or stress-relieving groove should be provided.
Fig. 11.3(d)
9 Slot and grooves should be provided with generous run-out
radii and with fillet radii in all corners. Fig. 11.3(b)
9 Stress relieving grooves or undercut should be provided at
the end of threads and splines. Fig. 11.3(c)
9 Sharp internal corners and external edges should be avoided
9 Weakening features like bolt and oil holes, identification
marks, and part number should not be located in highly
stressed areas.
9 Weakening features should be staggered to avoid the
addition of their stress concentration effects, Fig. 11.3(d)
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 Design to avoid stress concentrations

¾ Avoid sudden changes in cross-section

¾ Avoid sharp inside corners
¾ Force-flow analogy
ƒ Imagine flow of incompressible fluid
through part
ƒ Sudden curvature in streamlines…
{ High stress concentration!

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 Design to avoid stress concentrations

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 Design to avoid stress concentrations

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 Problems-stress concentration

SOLUTION:
• Determine the geometric ratios and
find the stress concentration factor
Example.1. Determine the from Fig. 2.64b.
largest axial load P that can • Find the allowable average normal
be safely supported by a flat stress using the material allowable
steel bar consisting of two normal stress and the stress
concentration factor.
portions, both 10 mm thick,
and respectively 40 and 60 • Apply the definition of normal stress
mm wide, connected by to find the allowable load.
fillets of radius r = 8 mm.
Assume an allowable
normal stress of 165 MPa.
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 • Determine the geometric ratios and
find the stress concentration factor
from Fig. 2.64b.
D 60 mm r 8 mm
= = 1.50 = = 0.20
d 40 mm d 40 mm
K = 1.82

• Find the allowable average

normal stress using the material
allowable normal stress and the
stress concentration factor.
σ max 165 MPa
σ ave = = = 90.7 MPa
K 1.82

• Apply the definition of normal

stress to find the allowable load.
P = Aσ ave = (40 mm )(10 mm )(90.7 MPa )

= 36.3 × 103 N
P = 36.3 kN
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 Problems-stress concentration

¾ Example: 2. A tie bar has to carry a

load of 100 kN. What must be the
thickness of bar of 110 mm width, if
there is a rivet hole of 22 mm diameter
on its centre line? Working stress for
the tie bar is 75 MPa.
¾ Given : F = 100 kN = 100x1000 N
b = 110 mm
d = 22 mm;
σw= 75 N/mm2
¾TO Find: thickness of bar=t

9Ans: The thickness of bar = t = 40 mm

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 Factor of Safety

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 Allowable stresses
Allowable stress must not be exceeded anywhere in the structure

Allowable stress = Yield strength / Factor of safety

tension shear
σallow = σY / n1 τallow = τY / n2

OR…
Allowable stress = Ultimate strength / Factor of safety

tension shear
σallow = σU / n3 τallow = τU / n4

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 THEORIES OF FAILURE

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 THEORIES OF FAILURE

¾ When engineers design for a material, there is a

need to set an upper limit on the state of stress that
defines the material’s failure.
¾ For ductile material, failure is initiated by yielding.
¾ For brittle material, failure is specified by fracture.
¾ However, criteria for the above failure modes is not
easy to define under a biaxial or tri-axial stress.
¾ Thus, four theories are introduced to obtain the
principal stresses at critical states of stress.

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 THEORIES OF FAILURE

{ Maximum principal (or normal) stress

theory [Rankine’s theory]-Brittle
{ Maximum shear stress theory [Guest’s
or Tresca’s theory]-Ductile
{ Maximum principal (or normal) strain
theory [St. Venant’s theory]-not in
general used
{ Maximum strain energy theory
[Haigh’s theory]-Ductile
{ Maximum distortion energy theory
[Von Mises and Henky theory]-Ductile

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 THEORIES OF FAILURE
Maximum principal (or normal) stress [Rankine’s
theory]-Brittle

¾ This theory states that failure of the mechanical

component subjected to bi-axial of tri-axial
stresses may occur when the maximum principal
stress, σ1 is equal to the yield or ultimate strength
of the materials in tension, σy . Thus, failure may
occur when,
σ1 = σy or σy for failure criterion
σ1 = σy/FOS for ductile materials for safe design
σ1 = σu/FOS for brittle materials for safe design

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 THEORIES OF FAILURE
Maximum shear stress [Guest’s theory]-Ductile

¾ This theory states that failure of the mechanical component

subjected to bi-axial of tri-axial stresses may occur when the
maximum shear stress induced because of complex loading
is equal to the shear stress at the yield limit in simple
tension test. Assuming that the shear stress at yielding is
half of yield strength in tension, failure may occur when,
τmax = τyt For failure criterion
[σ1 - σ2]/2 = σy/2 → [σ1 - σ2] = σy For FC
τmax = τyt /F.S. for safe design
τmax = σyt /2xF.S. for safe design

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 THEORIES OF FAILURE
Maximum principal (or normal) strain theory
[St. Venant’s theory]

¾ This theory states that failure may occur when the

maximum principal strain is equal to the maximum
strain at the elastic limit in simple tension test.
Thus, failure may occur when,
εmax = εelastic limit For failure
1/E[σ1 - νσ2] = σy/E → [σ1 – ν σ2] = σy For failure
[σ1 – ν σ2] = σy /FOS for safe design

¾ Where ν is Poisson’s ratio.

¾ This theory is not used, in general, because it only
gives reliable results in particular cases.
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 THEORIES OF FAILURE
{Maximum strain energy theory [Haigh’s theory]-Ductile

¾ This theory states that failure may occur when the

maximum strain energy per unit volume is equal to
the strain energy per unit volume at the elastic limit
in simple tension test. Thus, failure may occur
when,
[σ12 + σ22 - 2νσ1σ2] = σy 2 For failure criterion
[σ12 + σ22 - 2νσ1σ2] = (σy/FOS) 2 For safe design

¾ Where ν is Poisson’s ratio.

¾ This theory may be used for ductile materials.
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 THEORIES OF FAILURE
{Maximum Distortion energy theory [Von Mises and Henky
theory]-Ductile

¾ This theory states that failure of the mechanical component

subjected to bi-axial of tri-axial stresses may occur when the
distortion strain energy (also called shear strain energy) per
unit volume is equal to the distortion energy per unit volume
at the yield limit in simple tension test. Thus, failure may
occur when,
[σ12 + σ22 - σ1σ2] = σy 2 for failure criterion
[σ12 + σ22 - σ1σ2] = (σy /FOS)2 for safe design
¾ Where ν is Poisson’s ratio.
¾ This theory is mostly used for ductile materials in place of
maximum strain energy theory.

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 Problems-Theories of failures

¾ Example: 1. A bolt is subjected to an axial pull of

12.5 kN and a transverse shear force of 7.5 kN.
The yield strength of the bolt material is 300 MPa.
Considering a factor of safety of 2.5. Determine the
diameter of the bolt, using (i) maximum normal
stress theory, (ii) maximum shear stress theory,
and (iii) maximum principal strain theory. Take
Poisson’s ratio as 0.25.
¾ Given : FA = 12.5 kN = 12500 N
FS = 7.5 kN = 7500 N
σy = 300 MPa
N = 2.5
¾TO Find: Diameter of the rod = d
9Ans: The diameter of the rod (i) d = 10.4 mm;
(ii) d = 18.2818 mm & (iii) d = 21.85 mm
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 Problems-Theories of failures

¾ Example: 2. At a critical section in a shaft, the

following stresses are induced; Bending stress =
80 MPa. Torsional shear stress = 60 MPa.
Determine the factor of safety, according to (i)
maximum normal stress theory, (ii) maximum
shear stress theory, and (iii) maximum principal
strain theory. The proportional limit in a simple
tension test is found to be 300 MPa. Take
Poisson’s ratio as 0.25
¾ Given : σb = 80 MPa
τ = 60 MPa
σy = 300 MPa; ν = 0.25

¾TO Find: Factor of safety = N

9Ans: The factor of safety (i) N = 2.67 (ii) N = 2.08 &
(iii) N = 2.487
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 Problems-Theories of failures

¾ Example: 3. A machine shaft made of stainless

steel of yield strength 800 MPa is subjected to
static loads consisting of bending moment 15
kN-m and a torsional moment 46 kN-m.
Determine the diameter of the shaft using two
different theories of failure, and assuming a
factor of safety of 2.5. Take E = 215 GPa and
poisson's ratio = 0.25.
¾ Given : σy = 800 MPa
M = 15 kN-m
T = 46 kN-m
E = 215 GPa; ν = 0.25
¾TO Find: diameter of the shaft = d

9Ans: The factor of safety (i) d = mm (ii) d = mm

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 Problems-Theories of failures
¾ Example: 4. A rotating shaft of 16 mm diameter is
made of plain carbon steel. It is subjected to axial load
of 5000 N, a steady torque of 50 N-m and maximum
bending moment of 75 N-m. Calculate the factor of
safety available based on 1. Maximum normal stress
theory; and 2. Maximum shear stress theory. Assume
yield strength as 400 MPa for plain carbon steel. If all
other data remaining same, what maximum yield
strength of shaft material would be necessary using
factor of safety of 1.686 and maximum distortion energy
theory of failure. Comment on the result you get
¾ Given : d = 16 mm Plain carbon steel
Wa = 5000 N
T = 50 N-m
M = 75 N-m
σy = 400 MPa
¾TO Find: Factor of safety = N

9Ans: The factor of safety (i) N = 1.752 (ii) N = (iii) σ = 400

MPa
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