MAEG3040 MECHANICAL DESIGN

Problem Set (Topics 1–3)

2. The stretch of a uniform rod in tension is given by the formula 𝛿𝛿 = 𝐹𝐹𝐹𝐹/𝐴𝐴𝐴𝐴. Suppose the
terms in this equation are random variables and have parameters as follows:
F ∼ (14.7, 1.3) kip A ∼ (0.226, 0.003) in2
l ∼ (1.5, 0.004) in E ∼ (29.5, 0.885) Mpsi
Estimate the mean, the standard deviation, and the coefficient of variation of the
corresponding elongation 𝛿𝛿 in inches.
(Note that “F ∼ (14.7, 1.3) kip” states that the mean Force is μx = 14.7 kip and the standard
deviation is 𝜎𝜎�d = 1.3 kip.)

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3. The volume of a rectangular parallelepiped is given by 𝑉𝑉 = 𝑥𝑥𝑥𝑥𝑥𝑥. If
𝑥𝑥 = 𝑎𝑎 ± ∆𝑎𝑎, 𝑦𝑦 = 𝑏𝑏 ± ∆𝑏𝑏, 𝑧𝑧 = 𝑐𝑐 ± ∆𝑐𝑐, show that
∆𝑉𝑉 ∆𝑎𝑎 ∆𝑏𝑏 ∆𝑐𝑐
= + +
𝑉𝑉� 𝑎𝑎� 𝑏𝑏� 𝑐𝑐̅
Use this result to determine the bilateral tolerance on the volume of a rectangular
parallelepiped with dimensions
𝑎𝑎 = 1.500 ± 0.002 in 𝑏𝑏 = 1.875 ± 0.003 in 𝑐𝑐 = 3.000 ± 0.004 in

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4. A circular cross section O ring has the dimensions shown in the figure. In particular, an AS
568A standard No. 240 O ring has an inside diameter 𝐷𝐷𝑖𝑖 and a cross-section diameter d of
𝐷𝐷𝑖𝑖 = 3.734 ± 0.028 in 𝑑𝑑 = 0.139 ± 0.004 in
�𝑜𝑜 and its bilateral tolerance.
Estimate the mean outside diameter 𝐷𝐷

Topic 2:
5. Figure shows a crank loaded by a force F = 300 lbf that causes twisting and bending of a
3/4-in-diameter shaft fixed to a support at the origin of the reference system. In actuality,
the support may be an inertia that we wish to rotate, but for the purposes of a stress analysis
we can consider this a statics problem.
(a) Draw separate free-body diagrams of the shaft AB and the arm BC, and compute the
values of all forces, moments, and torques that act. Label the directions of the coordinate
axes on these diagrams.
(b) Compute the maxima of the torsional stress and the bending stress in the arm BC and
indicate where these act.
(c) Locate a stress element on the top surface of the shaft at A, and calculate all the stress
components that act upon this element.
(d) Determine the maximum normal and shear stresses at A.

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6. Find the reactions at the supports and plot the shear-force and bending-moment diagrams
for each of the beams shown in the figure. Label the diagrams properly.

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7. For each of the plane stress states listed below, draw a Mohr’s circle diagram properly
labeled, find the principal normal and shear stresses, and determine the angle from the x
axis to 𝜎𝜎1 . Draw stress elements and label all details.
(a) 𝜎𝜎𝑥𝑥 = 20 kpsi, 𝜎𝜎𝑦𝑦 = −10 kpsi, 𝜏𝜏𝑥𝑥𝑥𝑥 = 8 kpsi cw
(b) 𝜎𝜎𝑥𝑥 = 16 kpsi, 𝜎𝜎𝑦𝑦 = 9 kpsi, 𝜏𝜏𝑥𝑥𝑥𝑥 = 5 kpsi ccw
(c) 𝜎𝜎𝑥𝑥 = 10 kpsi, 𝜎𝜎𝑦𝑦 = 24 kpsi, 𝜏𝜏𝑥𝑥𝑥𝑥 = 6 kpsi ccw
(d) 𝜎𝜎𝑥𝑥 = −12 kpsi, 𝜎𝜎𝑦𝑦 = 22 kpsi, 𝜏𝜏𝑥𝑥𝑥𝑥 = 12 kpsi cw

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8. For each of the stress states listed below, find all three principal normal and shear stresses.
Draw a complete Mohr’s three-circle diagram and label all points of interest.
(a) 𝜎𝜎𝑥𝑥 = 10 kpsi, 𝜎𝜎𝑦𝑦 = −4 kpsi
(b) 𝜎𝜎𝑥𝑥 = 10 kpsi, 𝜏𝜏𝑥𝑥𝑥𝑥 = 4 kpsi ccw
(c) 𝜎𝜎𝑥𝑥 = −2 kpsi, 𝜎𝜎𝑦𝑦 = −8 kpsi, 𝜏𝜏𝑥𝑥𝑥𝑥 = 4 kpsi cw
(d) 𝜎𝜎𝑥𝑥 = 10 kpsi, 𝜎𝜎𝑦𝑦 = −30 kpsi, 𝜏𝜏𝑥𝑥𝑥𝑥 = 10 kpsi ccw

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9. Using superposition, determine the maximum deflection of the beam shown in the figure.
The material is carbon steel.

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10. Consider the uniformly loaded simply supported beam with an overhang as shown. Use
singularity functions to determine the deflection equation of the beam. Use statics to
determine the reactions.

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Topic 3:
11. The figure shows a shaft mounted in bearings at A and D and having pulleys at B and C.
The forces shown acting on the pulley surfaces represent the belt tensions. The shaft is to
be made of ASTM grade 25 cast iron using a design factor 𝑛𝑛𝑑𝑑 = 2.8. What diameter should
be used for the shaft?

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12. The gear forces shown act in planes parallel to the yz plane. The force on gear A is 300 lbf.
Consider the bearings at O and B to be simple supports. For a static analysis and a factor of
safety of 3.5, use distortion energy to determine the minimum safe diameter of the shaft.
Consider the material to have a yield strength of 60 kpsi.

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13. A bar of steel has the minimum properties 𝑆𝑆𝑒𝑒 = 276 MPa, 𝑆𝑆𝑦𝑦 = 413 MPa, and 𝑆𝑆𝑢𝑢𝑢𝑢 = 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. (c) ASME-
elliptic criterion.

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14. The cold-drawn AISI 1018 steel bar shown in the figure is subjected to an axial load
fluctuating between 800 and 3000 lbf. Estimate the factors of safety ny and nf using (a) a
Gerber fatigue failure criterion as part of the designer’s fatigue diagram, and (b) an ASME-
elliptic fatigue failure criterion as part of the designer’s fatigue diagram.

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15. In the figure shown, shaft A, made of AISI 1010 hot-rolled steel, is welded to a fixed support
and is subjected to loading by equal and opposite forces F via shaft B.A theoretical stress
concentration Kt s of 1.6 is induced by the 3-mm fillet. The length of shaft A from the fixed
support to the connection at shaft B is 1 m. The load F cycles from 0.5 to 2 kN.
(a) For shaft A, find the factor of safety for infinite life using the modified Goodman fatigue
failure criterion.
(b) Repeat part (a) using the Gerber fatigue failure criterion.

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