Faculty of Engineering 2023 / Semester 2

Mechanical Engineering Design 2 MED260S

Fatigue failure , Tut#3
Answer the following problems (Shigley’s Ch6):

Q.1)
A rectangular bar is cut from an AISI 1018 cold-drawn steel flat. The bar
is 60 mm wide by 10 mm thick and has a 12 mm hole drilled through the
centre. The bar is concentrically loaded in push-pull fatigue by axial forces
Fa, uniformly distributed across the width.
Using a design factor of nd = 1.8, estimate the largest force Fa that can be
applied ensuring infinite life.

Q.2)
A bar of steel has the minimum properties Se = 276 MPa, Sy = 413 MPa,
and Sut = 551 MPa.
The bar is subjected to a steady torsional stress of 138 MPa and an
alternating bending stress of 69 MPa.
Find the factor of safety guarding against a static failure, and either the
factor of safety guarding against a fatigue failure or the expected life of the
part. For the fatigue analysis use: a) Modified Goodman criterion,
b) Gerber criterion, and c) ASME-elliptic criterion.

Q.3)
A circular cross-section cantilever beam made of cold drawn carbon steel
shown in figure below, is subjected to a load which varies from
( – F to 3 F ). Based on Goodman’s criteria, determine the maximum load
that this member can withstand for a factor of safety n = 2.
The theoretical stress concentration factor is Kt = 1.4 and the notch
sensitivity is q = 0.8. Assume the following values:
Ultimate stress Sut = 580 MPa, Yield stress Sy = 480 MPa, Size factor
kb = 0.84, Surface finish factor ka = 0.87
3F
300
250

25 18

All Dimensions in mm -F
Q.4)
The part on the figure is a ground polished surfaces of a machine
elements that is undergoing cyclic axial loading ranging from 8.25 kN to
16.5 kN. Use both Soderberg and modified Goodman criteria to calculate
the safety factor.
(Material properties: Sy = 500 MPa, Sut = 700 MPa).

8.5 mm

5.5 mm
Faculty of Engineering 2023 / Semester 2
Mechanical Engineering Design 2 MED200S
Fatigue failure/ shaft design, Tut#3 (Memo)

Q.1):

Q.2):

1
 -F
Q.3):
300
250

25 18

All Dimensions in mm 3F

Sut = 580 MPa d= 18 mm

Sy = 480 MPa r= 2 mm
Se = 290 MPa
ka = 0.84
kb = 0.87

n =2
Kt = 1.4
q = 0.8

At point A
Mmax = 250(3F) 750 F N.mm
Mmin = 250(-F) -250 F N.mm

Mm=(Mmax+Mmin)/2 250 F N.mm

Ma=(Mmax-Mmin)/2 500 F

Z section modulus 572.55 mm3

Stress
concentration Kf =1 + q (Kt -1) 1.320
σm =Kf (32)Mm/(πd3) 0.576 F N/mm2
σa =Kf (32)Ma /(πd3) 1.153 F N/mm2

Se =ka kb Se` 211.93 MPa

Goodman
½ =(σm/Sut) + (σa/Se)
½ = 0.006 F
F= 77.7 N

2
Faculty of Engineering 2019 / 1st semester
Mechanical Engineering Design 2: MED200S
Shaft Design (Tolerances and Fatigue failure), Tut#4 Dr A Rugbani
Answer the following problems (Shigley’s ch6&7):

Q.1)
The part on the figure is a ground polished surfaces of a machine elements that
undergoing cyclic axial loading ranging from 8.25 kN to 16.5 kN.
Use Soderberg and modified Goodman criteria to calculate the safety factor.
Material properties: Sy = 500 MPa, Sut = 700 MPa

8.5 mm

5.5 mm

w = 8.5mm, h = 5.5mm, r = 1.5mm, t = 3mm

Using r/d = 1.5mm/5.5mm = 0.27 , and, D/d = 8.5mm/5.5mm = 1.54 =>

Stress concentration Kt = 1.6
Using r = 1.5mm , and, Sut = 700MPa = 0.7GPa =>

notch sensitivity from Fig (6-20) q = 0.8

Kf = 1 + q ( Kt -1) = 1 + 0.8 ( 1.6 – 1) = 1.48
Endurance Limit
Su ≤ 1400MPa => Se’ = 0.5 Su = 350MPa
Se = ka kb kc kd ke kf Se’
ka = a Sutb
for ground surface from Table 6-2, a = 1.58 and b = -0.085
ka = 0.905
(there is no size effect, axial loading) then kb = 1
(axial loading) kc = 0.85
There is no information about kd , ke , kf so, kd =1, ke =1, kf =1
Se = (0.905)(1)(0.85)(1)(1)(1)(350MPa) = 269.2 MPa

Pmin = 8.25 kN and Pmax = 16.5 kN

Alternating force Pa = (𝑃𝑚𝑎𝑥− 𝑃𝑚𝑖𝑛) / 2 = 4.12 kN
Midrange force Pm = (𝑃𝑚𝑎𝑥+ 𝑃𝑚𝑖𝑛) / 2 = 12.37 kN
Calculating Midrange and Alternating stress
𝑃𝑎 4.12 × 103
𝜎𝑎 = 𝐾𝑓 = 1.48 = 370 𝑀𝑃𝑎
𝐴 (5.5)(3)
𝑃𝑚 12.37 × 103
𝜎𝑚 = 𝐾𝑓 = 1.48 = 1110 𝑀𝑃𝑎
𝐴 (10)(20)
Calculating safety factor n
Using Goodman
1 𝜎𝑎 𝜎𝑚
= +
𝑛 𝑆𝑒 𝑆𝑢𝑡
1 370 1110
= +
𝑛 269.2 700
n = 0.34
Using Soderberg
1 𝜎𝑎 𝜎𝑚
= +
𝑛 𝑆𝑒 𝑆𝑦
1 370 1110
= +
𝑛 269.2 500
n = 0.28
Cape Peninsula University of Technology Tut # 6
Faculty of Engineering - Mechanical 2023 / Semester 2
Mechanical Engineering Design 2 MED260S
(Shigley’s Ch9): Welded Joints

Q.1)

The figure shows a horizontal steel bar 10 mm thick loaded in steady tension and
welded to a vertical support.
Find the load F that will cause a shear stress of 155 MPa in the throats of the welds.

8 mm

50 mm

50 mm

Q.2)
8 mm thick steel bar, to be used as a beam, is welded to a vertical support by four
fillet welds as illustrated.
Find the safe bending force F if the permissible shear stress in the welds is 140 MPa.

10 mm

80 mm

80 mm 200 mm

1
 Q.3)

A torque T = 20(103) lbf · in is applied to the weldment shown. Estimate the

maximum shear stress in the weld throat.

6 mm

50 mm

Q.4)
The figure shows a welded steel bracket loaded by a static force F. Estimate the factor
of safety if the allowable shear stress in the weld throat is 120 MPa.

2
Faculty of Engineering and the Built Env. 2023 / Semester 2
Mechanical Engineering Design 2 MED260S
Bolts selection and design, Tut#4
Answer the following problems (Shigley’s Ch8):

Q.1)
A bolted joint is to have a grip consisting of two 14-mm steel plates and one 14R
metric plain washer to fit under the head of the M14 × 2 hex-head bolt, 50 mm long.
a) What is the length of the thread LT for this diameter metric coarse-pitch series
bolt?
b) What is the length of the grip l?
c) What is the height H of the nut?
d) Is the bolt long enough? If not, round to the next larger preferred length
(Table A-17).
e) What is the length of the shank and the threaded portions of the bolt within the
grip? These lengths are needed in order to estimate bolt spring rate kb.

Q.2)
The figure illustrates the connection of a cylinder head to a pressure vessel using 10
bolts and a confined-gasket seal. The effective sealing diameter is 150 mm. Other
dimensions are: A = 100, B = 200, C = 300, D = 20, and E = 20, all in millimeters.
The cylinder is used to store gas at a static pressure of 6 MPa. ISO class 8.8 bolts with
a diameter of 12 mm have been selected. This provides an acceptable bolt spacing.
What load factor n results from this selection?

Cylinder head is steel; cylinder is grade 30 cast iron.

1
Q.3)
If the pressure in Q.2 is cycling between 0 and 6 MPa, determine the fatigue factor of
safety using the:
(a) Goodman criterion.
(b) Gerber criterion.
(c) ASME-elliptic criterion.

Q.4)
The figure shows a cast-iron bearing block that is to be bolted to a steel ceiling joint
and is to support a gravity load. Bolts used are M20 ISO 8.8 with coarse threads and
with 3.4-mm thick steel washers under the bolt head and nut. The joint flanges are 20
mm in thickness, and the dimension A, shown in the figure, is 20 mm. The modulus of
elasticity of the bearing block is 135 GPa.
(a) Find the force required during assembly if the joint is to be permanent.
(b) Determine the load factor for the design if the gravity load is 15 kN.

Q.5)
The upside-down steel A frame shown in the figure is to be bolted to steel beams on
the ceiling of a machine room using ISO grade 8.8 bolts. This frame is to support the
40-kN radial load as illustrated. The total bolt grip is 48 mm, which includes the
thickness of the steel beam, the A-frame feet, and the steel washers used. The bolts
are size M20 × 2.5.
(a) What tightening force should be used if the connection is permanent??
(b) What portion of the external load is taken by the bolts? By the members?

2
Q.6)
A beam is made up by bolting together two cold-drawn bars of AISI 1018 steel as a
lap joint, as shown in the figure. The bolts used are ISO 5.8. Ignoring any twisting,
determine the factor of safety of the connection.

Q.7)
A vertical channel 152 × 76 (see Table A–7) has a cantilever beam bolted to it as
shown. The channel is hot-rolled AISI 1006 steel. The bar is of hot-rolled AISI 1015
steel. The shoulder bolts are M12 × 1.75 ISO 5.8. For a design factor of 2.8, find the
safe force F that can be applied to the cantilever.

Dimensions in millimeters

Q.8)
An M30 × 3.5 ISO 8.8 bolt is used in a joint at recommended preload, and the joint is
subject to a repeated tensile fatigue load of P = 80 kN per bolt. The joint constant is
C = 0.33.
Find the load factors and the factor of safety guarding against a fatigue failure based
on the Gerber fatigue criterion.

3
Q.9)

Find the total shear load on each of the three bolts for the connection shown in the
figure and compute the significant bolt shear stress and bearing stress. Find the second
moment of area of the 8-mm plate on a section through the three bolt holes, and find
the maximum bending stress in the plate.

Dimensions in millimetres

4
Faculty of Engineering and the Built Env. 2023 / Semester 2
Mechanical Engineering Design 2 MED260S
Bolts selection and design, Tut#4
Answer the following problems (Shigley’s Ch8):

Q.1)
A bolted joint is to have a grip consisting of two 14-mm steel plates and one 14R metric plain
washer to fit under the head of the M14 × 2 hex-head bolt, 50 mm long.
a) What is the length of the thread LT for this diameter metric coarse-pitch series bolt?
b) What is the length of the grip l?
c) What is the height H of the nut?
d) Is the bolt long enough? If not, round to the next larger preferred length (Table A-17).
e) What is the length of the shank and the threaded portions of the bolt within the grip?
These lengths are needed in order to estimate bolt spring rate kb.

Answer:

1
Q.2)
The figure illustrates the connection of a cylinder head to a pressure vessel using 10 bolts and a
confined-gasket seal. The effective sealing diameter is 150 mm. Other dimensions are: D = 20, and
E = 20, all in millimeters. The cylinder is used to store gas at a static pressure of 6 MPa. ISO class
8.8 bolts with a diameter of 16 mm have been selected. This provides an acceptable bolt spacing.
What load factor n results from this selection?

Cylinder head is steel; cylinder is grade 30 cast iron.

10 bolts of M16
Material class ISO 8.8
Load factor

From Table 8-11, for ISO 8.8 ➔ Sp = 600 MPa

From Table 8-1, for M16 ➔ At = 157 mm2
Assuming Non-permanent joints Fi = 0.75 Sp At
Fi = 0.75 (600x106)(157x10-6) = 70650 N
External load per joint

2
bolt stiffness

LT = 2d + 6
LT = 2(16) + 6 = 38 mm
L>l+H
l = 20 + 20 = 40 mm
from Table A-31, Nut height for M16 ➔ H = 14.8 mm
L > 40 + 14.8
L > 54.8 mm
From Table A-17, choose the next available size
L = 60 mm
ld = L – LT = 60 – 38 = 24 mm
lt = l – ld = 40 – 24 = 16 mm
𝜋 𝜋
𝐴𝑑 = 4 𝑑2 = 4 (16)2 = 200.96 mm2 , Table 8-1➔ At = 157 mm2

E for the steel = 207 GPa

𝐴𝑑 𝐴𝑡 𝐸
𝑘𝑏 = 𝐴 = 935.2 x 106 N/m
𝑑 𝑙𝑡 + 𝐴𝑡 𝑙𝑑

Members stiffness
1 1 1
= +
𝑘𝑚 𝑘1 𝑘2
We can use eq (8-20) to find stiffness for each material
For the cover (Steel)
Es = 207 GPa (table A-5), t1 = 20 mm, d = 16 mm, D = 1.5d = 24 mm

= 6661 x 106 N/m

For the cylinder (cast iron)

Eci = 100 GPa (table A-5), t2 = 20 mm, d = 16 mm, D = 24 mm

= 3217 x 106 N/m

3
 1 1 1
= +
𝑘𝑚 𝑘1 𝑘2
1
𝑘𝑚 = 1 1 = 2170 x106 N/m
+
𝑘1 𝑘2

𝑘𝑏
𝐶=𝑘 = 0.3
𝑏 + 𝑘𝑚

Load Factor

(600×106 )(157×10−6 )−70650

𝑛𝐿 = = 7.4
0.3(10600)

Q.3)
If the pressure in Q.2 is cycling between 0 and 6 MPa, determine the fatigue factor of safety
using the:
(a) Goodman criterion.
(b) Gerber criterion.
(c) ASME-elliptic criterion.

Answer:
Given from Q.2 solution, C= 0.3, Fi = 70.6 kN, At= 157 mm2
External load cycling between Pmax= 10.6 kN and Pmin= 0 per bolt

From Table 8-11 for 8.8 bolts ➔ Sut = 830 MPa

From Table 8-17 for 8.8 bolts ➔ Se = 129 MPa

Goodman eq. (8-45)

Initial stress
𝐹 70.6×103
𝜎𝑖 = 𝐴𝑖 = 157×10−6 = 450 MPa
𝑡
Alternating stress
𝐶𝑃 (0.3)(10.6×103 )
𝜎𝑎 = 2 𝐴 = 2 (157×10−6 )
= 10.1 MPa
𝑡

129(830−450)
𝑛𝑓 = 10.1(830+129) = 5.06

(b) Gerber eq (8-46

= 7.6
(c) ASME-elliptic, using eq (8-47)

= 6.5

4
Q.4)
The figure shows a cast-iron bearing block that is to be bolted to a steel ceiling joint using 4 bolts
and is to support a gravity load. Bolts used are M20 ISO 8.8 with coarse threads and with 3.4-mm
thick steel washers under the bolt head and nut. The joint flanges are 20 mm in thickness, and the
block thickness dimension A, shown in the figure, is 20 mm. The modulus of elasticity of the
bearing block is E = 135 GPa.
(a) Find the force required during assembly if the joint is to be permanent.
(b) Determine the load factor for the design if the gravity load is 15 kN.

Answer

1 2 1 1
= + +
𝑘𝑚 𝑘1 𝑘2 𝑘3

For the bolt

l = 3.4 + 20 + 20 + 3.4 = 46.8 mm

5
Table A-31, M20 Nut ➔ H = 18 mm
L > 46.8 + 18 = 64.8 mm
Use next available size L = 80 mm
LT = 2d + 6 = 2(20) +6 = 46 mm
ld = L – LT = 80 – 46 = 34 mm
lt = l – ld = 46.8 – 34 = 12.8 mm
𝜋 𝜋
𝐴𝑑 = 4 𝑑2 = 4 (20)2 = 314.2 mm2 , Table 8-1➔ At = 245 mm2

E for the steel = 207 GPa

𝑘𝑏 1290
𝐶= = = 0.2489
𝑘𝑏 + 𝑘𝑚 1290+ 3892

6
Q.5)
The upside-down steel A frame shown in the figure is to be bolted to steel beams on
the ceiling of a machine room using ISO grade 8.8 bolts. This frame is to support the
40-kN radial load as illustrated. The total bolt grip is 48 mm, which includes the
thickness of the steel beam, the A-frame feet, and the steel washers used. The bolts
are size M20 × 2.5.
(a) What tightening force should be used if the connection is permanent?
(b) What portion of the external load is taken by the bolts? By the members?

Answer:

7
The members (frame, ceiling and the washers) are all of the same material (steel),
therefore, instead of calculating each part separately, we can use eq. (8-23)

8
Q.6)
A beam is made up by bolting together two cold-drawn bars of AISI 1018 steel as a
lap joint, as shown in the figure. The bolts used are ISO 5.8. Ignoring any twisting,
determine the factor of safety of the connection.

Answer:

6
Q.7)
A vertical channel 152 × 76 (see Table A 7) has a cantilever beam bolted to it as
shown. The channel is hot-rolled AISI 1006 steel. The bar is of hot-rolled AISI 1015
steel. The shoulder bolts are M12 × 1.75 ISO 5.8. For a design factor of 2.8, find the
safe force F that can be applied to the cantilever.

Dimensions in millimeters

7
Answer:

8
Q.8)
An M30 × 3.5 ISO 8.8 bolt is used in a joint at recommended preload, and the joint is
subject to a repeated tensile fatigue load of P = 80 kN per bolt. The joint constant is
C = 0.33.
Find the load factors and the factor of safety guarding against a fatigue failure based
on the Gerber fatigue criterion.

Answer

9
Q.10)
Find the total shear load on each of the three bolts for the connection shown in the
figure and compute the significant bolt shear stress and bearing stress. Find the second
moment of area of the 8 mm plate on a section through the three bolt holes, and find
the maximum bending stress in the plate.

Dimensions in millimetres

Answer:

10
11
Cape Peninsula University of Technology Tut # 6
Faculty of Engineering - Mechanical 2023 / Semester 2
Mechanical Engineering Design 2 MED200S
(Shigley’s Ch9): Welded Joints

Q.1)
The figure shows a horizontal steel bar 10 mm thick loaded in steady tension and
welded to a vertical support.
Find the load F that will cause a shear stress of 155 MPa in the throats of the welds.

8 mm

60 mm

60 mm

Answer:

There are 2 weld lines. The line of action of the load intersects the weld centroid.
Therefore, there will be uniform distribution of load.

Total weld area

A = 0.707 h l
A = 0.707 (8)(2x60) = 688.3 mm2

F = Aτ

F = (688.3 x10-6)(155 x106) = 106.6 kN

1
 Q.2)
8 mm thick steel bar, to be used as a beam, is welded to a vertical support by four
fillet welds as illustrated.
Find the safe bending force F if the permissible shear stress in the welds is 140 MPa.

10 mm

80 mm

80 mm 200 mm

Answer:

Torsional shear on the weld, From Table 9-1 we have case no. 5

τall 140 MPa

A = 1.414 h ( b + d )
A= 2262.4 mm2
Primary
τA’ = V/A=F / 2262.4 = 0.442 F kPa

Secondary
table 9-1
Ju = (b +d)3 /6 682666.7 mm3
J = 0.707 h Ju 4826453 mm4

M = F (200+80/2)= 240 F
2 2 0.5
rA =(40 +40 ) = 56.56 mm
τA``= M rA / J 2.813 F kPa

τx = τA`` cos(45) 1.989 F kPa

τy = τA`` sin(45) 1.989 F kPa
2
 τxA= 1.989 F kPa
τyA= 2.431 F kPa

3.14 F kPa

F = τall / τA 44.5 kN

Q.3)
A torque T = 750 N.m is applied to the weldment shown. Estimate the maximum
shear stress in the weld throat.

6 mm

50 mm

Because the loading is pure torsion, there is no primary shear. From Table 9-1, case 6:

Primary
τA’ = 0
The total shear is coming from the secondary shear
Secondary
Ju = 2 r3= = 2 (25)3 98125 mm3
J = 0.707 h Ju = 0.707(6)( 98125) 416.2x103 mm4
τA’’=T r / J = 450 MPa

3
P.22)
The figure shows a welded steel bracket loaded by a static force F. Estimate the factor
of safety if the allowable shear stress in the weld throat is 120 MPa.

Answer:

4
Faculty of Engineering and the Built Environment 2023 / 2nd semester
Mechanical Engineering Design 2 MED260S
Mechanical Springs

1
2
3
4
10-20
An as-wound helical compression spring, made of music wire, has a wire size of 2.5 mm
an outside coil diameter of 14.5 mm, a free length of 39 mm, 21 active coils, and both
ends squared and ground. The spring is unpeened. This spring is to be assembled with a
preload of 22.5 N and will operate with a maximum load of 160 N during use.
Estimate the factor of safety guarding against fatigue failure using a torsional
Gerber fatigue failure criterion with Zimmerli data.

Answer:

D = OD – d =
C = D/d
KB = (4 C + 2) / (4 C - 3)
Fa = (Fmax – Fmin ) / 2
Fm = (Fmax + Fmin ) / 2

5
 τa = KB 8 Fa D / ( d3)
τm = KB 8 Fm D / ( d3)

From Table 10-4 we find A = , and m =

Sut = A /dm
Ssu = 0.67 Sut
The load-line slop r = τa/τm
The Gerber ordinate intercept for the Zimmerli data eq. (10-28)
Sse = Ssa / (1- Ssm/Ssu)2
The amplitude component of strength Ssa from table 6-7
Ssa =
The failure factor of safety nf is given by
nf = Ssa / τa