Machine Design Course for Communication / Electrical Department

Sheet 1 Solution
Problem 1
Determine the maximum Moment in the steel I section shown in Figure 1. The flanges are 6 mm
wide and the web is 3 mm thick.

Figure 1.

Solution
1. The Force Analysis
Free Body Diagram s shown in the following figure:

Beam reaction calculation:

!1 = !2 = 7000 "

The Beam moment calculations:

#$= #% = !1 125 = 7000 125 = 875000 ". &&

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Problem 2
A ship's propeller shaft transmits 8 MW at 5 rev/s. The shaft has the inner diameter of 150 mm.
Calculate the maximum permissible external diameter if the shearing stress in the shaft is
limited to 150 MPa.

Solution

3
 1
254647.91× 2
2 = 150 #9$
3
1 5 − 1505
32 2

1296911×12
= 150 #9$
125 − 1505

By using Matlab code or try and error

12 = 150.096 &&

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Problem 3
The press frame shown in the Figure is planned to be made of cast iron having ultimate
strength of 240 MPa in tension and 900 MPa in compression. Based upon stress calculations
made at section A-A, would the press frame be more likely to fail in tension or compression?

Solution

By study section A-A:

1. The force analysis:

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6
The failure will occur due to tension stress

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Problem 4
A steel column is 3m long and 0.4 m diameter. It carries a load of 50 MN. Given
that the modulus of elasticity is 200 GPa, calculate the compressive stress and
strain. Also determine how much the column is compressed.

Givens:
L = 3 m= 3000 mm, d = 0.4 m = 400 mm. F= 60 MN= 50 ×10K N,
E= 200 GPa = 200,000 MPa.

Solution:
N 50×10K 50×10K
LM = = 3 =3 = 397.88 MPa
O ×P Q ×400Q
4 4

LM 397.88 50×10K
TM = = = = 0.00198
U 200×10V 3 ×400Q
4
NX 50×10K ×3000
W= = = 5.69 mm
UO 200×10V × 3 ×400Q
4

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Problem 5
A composite shaft AC is made by connecting a 20-mm diameter solid steel shaft
AB to a 40-mm diameter solid aluminum shaft BC at flange B. The shear modulus
of the steel is 72 GPa and the shear modulus of the aluminum is 24 GPa. A
concentrated torque of 500 N.m is applied to the flange in the direction indicated.

Givens:
GST=72 GPa Galu=24GPa
Solution:
(a):
T=T1+T2
500*1000=Tst+Talu à1
ƟB)st=ƟB)Alu

Z[\ ∗ X[\ Z`a ∗ X`a

=
^[\ ∗ _[\ ^`a ∗ _`a

Z[\ ∗ 400 ∗ 32 Z`a ∗ 1200

=
72 ∗ 10V ∗ 3 ∗ 205 24 ∗ 10V ∗ 3 ∗ 405

Z[\ = 0. Z`a
à2
From 1&2:
Z[\ =180 N.m
Z`a =320 N.m

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(B):
τmax=(Tst*rst)/Jst = def∗dfff∗Qf/Q
3
∗ Qfh
=114.6 Mpa
32
(C):
Ɵ= = 0.063 rad
i[\∗j[\
k[\∗l[\
o
Ɵ = 0.063*180/ 3 =3.65

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Problem 6
For the key length of 50 mm and allowable shear stress of 65 MPa; find the applied
force W.

Given:
Leq=50 mm , τall=65 Mpa

Solution:

Design eqn:
τmax≤τall
P/A≤65
A=t*L=12*50=600 mm2
∴ P≤3900N
From equilibrium:
W*1000=P*d/2
∴ W≤780N

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Problem 7
Two lengths of pipe are joined with a bolted-flange connection consisting of six
bolts. The diameter of the bolt circle (see sketch) is 150 mm. A torque of T = 12
kN.m is applied to the pipes as shown. Assume the allowable shear stress for the
bolts is 200 MPa; determine the minimum diameter required for the bolts in the
connection. (Disregard friction between the two flanges.)

Solution:

T=12*106 N.mm
τshear of bolts=200 Mpa
F=T/(r*nof bolts)=12*106/(150/2*6)=26.667*103 N
τshear=Fb/Ab à 200=26.667*103 /(Π/4*d2)
∴ d=12.029 mm

we will not find a bolt with a diameter of 12.029 in the market because bolts
are manufactured in standard diameters. Therefore, we will look in the
market for the next bigger diameter

d ≈ 13 mm

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Problem 8
The pipe shown has an outside diameter of 160 mm and an inside diameter of 144
mm. A concentrated load of 3,000 N acts at the free end K. Determine the normal
and shear stresses produced at point H on the surface of the pipe. Show these
stresses on a stress element.

Do=160mm ,Di=144mm

Req:Ln`o, qn`o

Solution
- move force from (k) à (A)
F=3000N, M1=F* AK =3000*500=1500000 N.mm

- move force from (A) à (B)

F=3000N, T=F* AB =3000*500=1500000 N.mm

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- move force from (B) à (H)
F=3000N, M2=F* BH =3000*500=1500000 N.mm

M= M2+ M1=3*106 N.mm

T=15*105 N.mm
F=3000N

Bending stress
# r 3 ∗ 10K ∗ 160 ∗ 0.5
L= = 3 = 21.6 #v$
s (1605 − 1445 )
64
Torsional stress

Z ∗ w 1.5 ∗ 10K ∗ 160 ∗ 0.5

q= = 3 = 5.42337#v$
_ (1605 − 1445 )
32
Shear due to bending
q=0

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Problem 9
A vertical force P of magnitude 240 N is applied to the crank at point A. Knowing
that the shaft BDE has a diameter of 18 mm. Determine the normal and shear
stresses acting at point H located at the top of the shaft, 50 mm to the right of
support D.
Request: ơmax , τmax at point H

Solution

à Move F from A to A''

It will be (F ,T=F*200*sin(60)=41559.2)

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à Move from A'' to A
It will be (F +M=F*100=24000 N.mm)
ơ=ơben=M*y/I =32*M /( 3 *183) = 42Mpa
ơx=ơben =42 Mpa
τ=(16*T)/( /( 3 *d3 ) = 36.3 Mpa

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Problem 10
Determine the normal and shear stresses at points A and B of the solid shaft shown
below. The vertical force F = 2 KN , the horizontal force P = 5 kN , the moment T
= 4 N.m.

Solution :

F=2 KN
M=2*1000*100=2*105 N.mm
L t=f/A=5*1000/( 3 /4*202)=15.915 Mpa
T àτ
τ=T*r/J=(4*1000*20/2)/( 3 /32*204)=2.5465 Mpa

Point A:
L a=M*y/I=(2*105*20/2)/( 3 /64*204)=254.64 Mpa
L t=f/A=5*1000/( 3 /4*202)=15.915 Mpa
τ=T*r/J=(4*1000*20/2)/( 3 /32*204)=2.5465 Mpa
τshear due to bending=0

Point B:
L B=0
L t=f/A=5*1000/( 3 /4*202)=15.915 Mpa
τ=T*r/J=(4*1000*20/2)/( 3 /32*204)=2.5465 Mpa
τshear due to bending=(4/3)*(f/A)=8.485 Mpa

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