Dr B R Ambedkar National Institute of Technology Jalandhar

Department of Mechanical Engineering

Course Name: Design of Machine Elements Course code: MEPC-301
Assignment No: 01

Design against static loading

1. The principal stresses induced at a point in a machine component made of steel 50C4 are as follows: s1=
200N/mm2; s 2 = 150 N/mm2; s 3 = 0 Calculate the factor of safety by (i) the maximum shear stress
theory, and (ii) the distortion energy theory.
2. The stresses induced at a critical point in a machine component made of steel 45C8 are as follows: sx=
100 N/mm2; s y = 40 N/mm2; t xy = 80 N/mm2; Calculate the factor of safety by (i) the maximum normal
stress theory, (ii) the maximum shear stress theory, and (iii) the distortion energy theory.
3. A bracket, made of steel FeE 200 and subjected to a force of 5 kN acting at an angle of 30° to the vertical,
is shown in Fig. 1. The factor of safety is 4. Determine the dimensions of the cross section of the bracket.

Fig. 1
 Design against fluctuating loading
4. A rectangular plate, 15 mm thick, made of a brittle material is shown in Fig. 2. Calculate the stresses at
each of three holes of 3, 5 and 10 mm diameter.

Fig. 2
5. A round shaft made of a brittle material and subjected to a bending moment of 15 N-m is shown in Fig.
3. The stress concentration factor at the fillet is 1.5 and the ultimate tensile strength of the shaft material
is 200 N/mm2. Determine the diameter d, the magnitude of stress at the fillet and the factor of safety.

Fig. 3
6. A shaft carrying a load of 5 kN midway between two bearings is shown in Fig. 4. Determine the
maximum bending stress at the fillet section. Assume the shaft material to be brittle.

Fig. 4
7. A plate, 10 mm thick, subjected to a tensile load of 20 kN is shown in Fig. 5. The plate is made of cast
iron and the factor of safety is 2.5. Determine the fillet radius.
 Fig. 5
8. A 25 mm diameter shaft is made of forged steel 30C8. There is a step in the shaft and the theoretical
stress concentration factor at the step is 2.1. The notch sensitivity factor is 0.84. Determine the endurance
limit of the shaft if it is subjected to a reversed bending moment.
9. A 40 mm diameter shaft is made of steel 50C4 and has a machined surface. The expected reliability is
99%. The theoretical stress concentration factor for the shape of the shaft is 1.6 and the notch sensitivity
factor is 0.9. Determine the endurance limit of the shaft
10. A cantilever beam made of steel Fe 540 and subjected to a completely reversed load (P) of 5 kN is shown
in Fig. 6. The beam is machined and the reliability is 50%. The factor of safety is 2 and the notch
sensitivity factor is 0.9. Calculate (i) endurance limit at the fillet section; and (ii) diameter d of the beam
for infinite life.

Fig. 6
11. A solid circular shaft made of steel Fe 620 (Sut = 620 N/mm2 and Syt = 380 N/mm2) is subjected to an
alternating torsional moment, which varies from –200 N-m to + 400 N-m. The shaft is ground and the
expected reliability is 90%. Neglecting stress concentration, calculate the shaft diameter for infinite life.
The factor of safety is 2. Use the distortion energy theory of failure.
12. A solid circular shaft, 15 mm in diameter, is subjected to torsional shear stress, which varies from 0 to
35 N/mm2 and at the same time, is subjected to an axial stress that varies from –15 to +30 N/mm2. The
frequency of variation of these stresses is equal to the shaft speed. The shaft is made of steel FeE 400
(Sut = 540 N/mm2 and Syt = 400 N/mm2) and the corrected endurance limit of the shaft is 200 N/mm2.
Deter mine the factor of safety.
13. Design a cotter joint for the transmission of 25 kN tensile.
14. Design a knuckle joint to transmit 5 kN axial tensile load.
 Design of shaft numerical

15. A centrifugal pump is driven by 10 kW power 1440 rpm electric motor. There is a reduction gearbox
between the motor and the pump. The pump shaft rotates at 480 rpm. The design torque is 150% of the
rated torque. The motor and pump shafts are made of plain carbon steel 40C8 and the factor of safety is
4. Calculate: (i) diameter of the motor shaft; (ii) diameter of the pump shaft.
16. A transmission shaft is supported between two bearings, which are 750 mm apart. Power is supplied to
the shaft through a coupling, which is located to the left of the left-hand bearing. Power is transmitted
from the shaft by means of a belt pulley, 450 mm in diameter, which is located at a distance of 200 mm
to the right of the left-hand bearing. The weight of the pulley is 300 N and the ratio of the belt tension of
tight and slack sides is 2:1. The belt tensions act in vertically downward direction. The shaft is made of
steel FeE 300 and the factor of safety is 3. Determine the shaft diameter, if it transmits 12.5 kW power
at 300 rpm from the coupling to the pulley.
17. A rotating shaft, 40 mm in diameter, is made of steel FeE 580. It is subjected to a steady torsional moment
of 250 N-m and bending moment of 1250 N-m. Calculate the factor of safety based on (i) maximum
principal stress theory (ii) maximum shear stress theory.
18. A propeller shaft is required to transmit 50 kW power at 600 rpm. It is a hollow shaft, having an inside
diameter 0.8 times of the outside diameter. It is made of steel 40C8 and the factor of safety is 4. Calculate
the inside and outside diameters of the shaft.
19. An intermediate shaft of a gearbox, supporting two spur gears A and B and mounted between two
bearings C1 and C2, is shown in Fig. 7. The pitch circle diameters of gears A and B are 500 and 250 mm
respectively. The shaft is made of alloy steel 20MnCr5. The factors kb and kt of the ASME code are 2
and 1.5 respectively. The gears are keyed to the shaft. Determine the shaft diameter using the ASME
code.

Fig. 7

20. Assume the data of the intermediate shaft illustrated in question 17. The permissible angle of twist for
the shaft is 0.25° per metre length and the modulus of rigidity is 79 300 N/mm2. Determine the shaft
diameter on the basis of torsional rigidity.
21. A transmission shaft, supporting two pulleys A and B and mounted between two bearings C1 and C2 is
shown in Fig. 8. Power is transmitted from the pulley A to B. The shaft is made of plain carbon steel
45C8. The pulleys are keyed to the shaft. Determine the shaft diameter using the ASME code if, kb = 1.5
and kt = 1.0 Also, determine the shaft diameter on the basis of torsional rigidity, if the permissible angle
of twist between the two pulleys is 0.5° and the modulus of rigidity is 79 300 N/mm2.

Fig. 8

22. A countershaft in a gear box supports two spur gears, as shown in Fig. 9. Pitch-circle diameters of gears
A and B are 150 mm and 250 mm, respectively. Both gears have 20° pressure angle involute teeth. The
tangential load on smaller gear is 400 N. Determine the shaft diameter as per the ASME code. Suggest
the location of shoulders for bearing. How are the gears mounted on the shaft? The shaft is made of 30
C8. Take factors Kb and Kt as 1.5 and 2.0, respectively.

Fig. 9