Design of Machine Elements - Chapter 4

4.1

g
Step I Permissible stresses

rin
S yt

ee
250
t = ( fs )
= 10
= 25N / mm 2

in
S sy 0.5S yt 0.5 ( 250 )
= = = = 12.5N / mm 2

ng
( fs ) ( fs ) 10

E
Step II Diameter of rod

ile

P = 4 d 2 t or 70 103 = 4 d 2(25)
ob
om
d = 59.71 or 60 mm

Step III Width of strap

ut
fA

B1 = d = 60 mm (i)
to

Step IV Thickness of cotter

en

t = 0.3 B1 = 0.3(60) = 20 mm (iii)

tm

Step V Thickness of strap

ar

P = 2 B 1 t1 t or 70 103 = 2 (60) t1(25)

ep
D

t1 = 23.33 or 25 mm (ii)
EC

2 t3 (B1-t) = 2 B1 t1 or 2t3 (60-20) = 2(60)(25)

K

t3 = 37.5 or 40 mm (ii)

Step VI Widths of gib and cotter

P=2Bt or 70 103 = 2 B (20)(12.5)

 B = 140 mm

b1 = 0.55 B = 0.55(140) = 77 or 80 mm (iii)

b = 0.45 B = 0.45(140) = 63 or 60 mm (iii)

g
rin
4.2
Step I: Permissible tensile stress for rod

ee
in
S yt 380
t = = = 152N / mm 2

ng
( fs ) 2.5

E
Step II: Diameter of rods

ile
P= ( )
4
D2 t D =

4P
t
=
4 ( 25 10 3 )
ob
( 152 )
= 14.47 mm (i)
om

Step III: Permissible shear stress for pin

ut
fA

S sy 0.577S yt 0.577 ( 380 )

= ( fs )
= ( fs )
= 2.5
= 87.7N / mm 2
to

Step IV: Diameter of pin

en

( ) 2

2P 2 ( 25 10 3 )
tm

P=2 4
d d =
= ( 87.7 )
= 13.47 mm (ii)
ar
ep

4.3
D

Step I: Permissible shear stress for bolt

EC

S sy 0.5S yt 0.5 ( 310 )

K

max = ( fs )
= ( fs )
= 2.5
= 62N / mm 2

Step II: Cross-sectional area of bolt

A = cross sectional area of bolt

 12000 6000
t = and =
A A

max = ( ) t 2
2
+ () 2 =
( ) ( )
12000 2
2A
+
6000 2
A

g
in
( )6000 60002

er
62 =
A 2 or A= 62

ne
Step III: Diameter of bolt

gi
En
2 60002
4
d = 62
d = 13.2 mm (Ans.)

ile
4.4
ob
om
Step I: Force acting on rod
ut

The maximum force in tie-rod is denoted by P. From Fig.4.71(a),

fA

P sin(30) x 2500 = (50x103) x (2000) P = 80 000 N

to

Step II: Diameter of rod

en

S yt 250
t = = = 83.3N / mm 2
tm

( fs ) 3
ar

( ) 2
( )
2
ep

P= d
4 r
t or 80000 = d
4 r
83.3 dr = 34.96 mm (i)
D

Step III: Diameter of pin:

EC

S sy 0.5S yt 0.5 ( 250 )

= = = = 41.67N / mm 2
K

( fs ) ( fs ) 3

P=2
( ) 2
d
4 p
80000 = 2
( )
2
d
4 p
(41.67) dp = 34.96 mm (ii)
 4.5
Step I: Permissible stress

S ut 300
t = ( fs )
= 2.5
= 120N / mm 2

g
Step II: Direct and bending stresses

rin
( )

ee
P 15000 3000
= = N / mm 2

in
A ( t ) ( 5t ) t2

ng
( )
E
Pey 15000 ( 7.5t ) ( 2.5t ) 27000
= = N / mm 2

ile
I t2
[ 1
12
( t ) ( 5t ) 3
] ob
Step III: Dimensions of cross-section
om

From Eq.(4.24),
ut
fA

t =
P
+
Pey
or 120 =
( )( )( )
3000
+
27000
=
30000
to

A I t2 t2 t2
en

t = 15.81 mm (Ans.)
tm
ar

4.6
ep

Step I: Factor of safety by maximum shear stress theory

D

( 1 2) = 50N / mm 2
EC

( 1 3) = 200N / mm 2 (Maximum value)

K

( 2 3) = 150N / mm 2

From Eq.(4.39)
 S yt 460
( 1 3) = ( fs )
or (200) = ( fs )
(fs) = 2.3 (i)

Step II: Factor of safety by distortion energy theory

From Eq.(4.44)

g
rin
S yt
( fs )
= ( 2
1
1 2 + 22 )

ee
460
(200) 2 (200)(150) + (150) 2

in
( fs )
= (fs) = 2.55 (ii)

E ng
4.7

ile
Step I: Principal stresses
ob
( )( )
x + y
om
100 + 40
= = 70N / mm 2
2 2
ut
fA

( )( )
x y
2
=
100 40
2
= 30N / mm 2
to
en

From Eqs. (4.31) and (4.32),

tm

( ) ( ) x y 2
ar

x + y
1, 2 = 2

2
+ ( xy) 2 = 70 (30) 2 + (80) 2
ep
D

1 = 155.44N/mm2 2 = 15.44N / mm 2 3 = 0
EC

Step II: Principal shear stress

K

From Eq.(4.34),
 max = ( ) x y 2
2
+ ( xy) 2 = (30) 2 + (80) 2 = 85.44 N/mm2

Step III: Factor of safety by maximum normal stress theory

g
S yt 380

rin
(fs) = 1
= 155.44
= 2.44 (i)

ee
Step IV: Factor of safety by maximum shear stress theory

in
ng
S sy 0.5S yt 0.5 ( 380 )
(fs) = max
= max
= 85.44
= 2.22 (ii)

E
Step V: Factor of safety by distortion energy theory

ile
From Eq.(4.44) ob
om

( 2
1
1 2 + 22 = ) [(155.44) 2 (155.44)( 15.44) + ( 15.44) 2 ] = 163.71N
ut
fA

S yt 380
(fs) =
( 163.71 )
= 163.71
= 2.32 (iii)
to

4.8
en

Step I: Permissible tensile stress

tm
ar

S yt 380
max = ( fs )
= 4.5
= 84.44N / mm 2
ep

Step II: Calculation of eccentricity

D
EC

From Eq.(4.60),
K

( R o + R i ) 2 ( ( 4.5d ) + ( 3.5d ) ) 2
RN = = = (3.9843d)mm
4 4

e = R R N = 4d 3.9843d = (0.0157d)mm
 Step III: Bending stress

Refer to Fig.4.73.

R=4d R i = 4d 0.5d = (3.5d)mm

g
R o = 4d + 0.5d = (4.5d)mm

rin

A = d 2 = (0.7854d 2)mm 2

ee
4

in
M b = (1 10 3)(4d) = (4000d)N mm

ng
h i = R N R i = 3.9843d 3.5d = (0.4843d)mm

E
ile
From Eq.(4.56),
ob
( )
om
M bh i ( 4000d ) ( 0.4843d ) 44886.51
bi = = = N / mm 2
AeR i ( 0.7854d 2 ) ( 0.0157d ) ( 3.5d ) d2
ut
fA

Step IV: Direct tensile stress:

( )
to

P 1000 1273.24
t = = = N / mm 2
en

A ( 0.7854d 2 ) d2
tm

Step V: Dimensions of link

ar

P M bh i 1273.24 44886.51
ep

max = + 84.44 = +
A AeR i d2 d2
D

d = 23.38 mm (Ans.)
EC
K

4.9
Step I: Permissible tensile stress

S ut 300
max = = = 120N / mm 2
( fs ) 2.5
 Step II: Calculation of eccentricity

Refer to Fig.4.74. At section XX,

Ri = 4 t bi = 4 t h=6t R=7t

Ro = 10 t bo = 4 t

g
ti = to = t

rin
From Eq. (4.64),

ee
[ t ( 4t t ) + t ( 4t t ) + t ( 6t ) ]

in
= RN = (6.3098 t) mm
{ ( ) 4t + t
( )
10t t
( )}10t

ng
4tlog e 4t
+ tlog e 4t + t
+ 4tlog e 10t t

E
e = R RN = (7 6.3098)t = (0.6902t)mm

ile
Step III: Bending stress ob
om
h i = R N R i = (6.3098 4)t = (2.3098t)mm

M b = (100 10 3)(4t + R) = (100 10 3)(4t + 7t) = (11 10 5)tN mm

ut
fA

A = 4t 2 + 4t 2 + 4t 2 = (12t 2)mm 2
to

From Eq.(4.56),
en

( )
tm

M bh i ( 11 10 5t ) ( 2.3098t ) 9.2031 10 5
bi = = = N / mm 2
AeR i ( 12t 2 ) ( 0.6902t ) ( 4t ) 12t 2
ar
ep

Step IV: Direct tensile stress

D

( )
EC

P 100 10 3 10 5
t = = = N / mm 2
A ( 12t 2 ) 12t 2
K

Step V: Dimensions of cross-section

S ut P M bh i 300 10 5 9.2031 10 5
= + = +
( fs ) A AeR i ( 2.5 ) 12t 2 12t 2
 t = 26.62 mm (Ans.)

4.10
Step I: Permissible stresses

g
S yt 300

rin
t = ( fs )
= 5
= 60N / mm 2

ee
S sy 0.5S yt 0.5 300
= = = = 30N / mm 2

in
( fs ) ( fs ) 5

ng
Step II: Diameter and length of fulcrum pin

E
Refer to Fig.4.1-solu, (7.5 10 3) 100 = P 500 or P = 1500 N

ile
R= (7500) 2 + (1500) 2 = 7648.53 N From Eq.(4.51), ob
om
R=p(dxl) or 7648.53 = 10 ( d x 1.5 d )
ut

d = 22.58mmandl = 1.5d = 1.5 22.58 = 33.87mm (i)

fA

Step III: Shear stress in pin

to

R 7648.53
= = = 9.55N / mm 2 (ii)
en

2
( ) (
2
4
d 2

4
( 22.58 ) 2
)
tm

Step IV: Dimensions of boss

ar
ep

The dimensions of the boss of lever at the fulcrum are as follows,

D

inner diameter = 23 mm
EC

outer diameter = 46 mm
K

length = 34 mm ( iii )

Step V: Cross-section of lever

For the lever, d=4b Mb = ( 7500 x 100 ) N- mm

 M by ( 7500 100 ) ( 2b )
b = I
or 60=

[ 1
12
b ( 4b ) 3
]
b = 16.74 mm d = 4 b = 4 x 16.74 = 66.94 mm ( iv )

g
rin
4.11

ee
Step I: Permissible tensile stress

in
S yt 200
t = = = 50N / mm 2

ng
( fs ) 4

E
Step II: Bending stress

ile
Components of force P: -

P v = P cos ( 30 ) = 5000 cos ( 30 ) = 4330.13 N

ob
om

Ph = P sin ( 30 ) = 5000 sin ( 30 ) = 2500 N

ut
fA

Mb = Ph x 250 + Pv x 125 = 2500 x 250 +4330.13 x 125 = 1166 266.25 N-mm

M by 1749.4 10 3
to

1166266.25 t
b = = = N / mm2 (i)
I t3
[ 1
]
en

t ( 2t ) 3
12
tm

Step III: Direct tensile stress

ar

PV 4330.13 2165.07
ep

t = = = N / mm2 (ii)
A 2t 2 t2
D

Step IV: Dimensions of cross-section

EC

1749.4 10 3 2165.07
50 = + or t3 - 43.3 t = 34988
K

t3 t2

The cubic equation is solved by trial and error

t t3 - 43.3 t
 35 41 359.5

34 37 831.8

33 34 508.1 t = 33.5mm (Ans.)

g
rin
4.12
Step I: Permissible tensile stress

ee
in
S ut 400
t = = = 100N / mm 2

ng
( fs ) 4

E
Step II: Dimensions of cross-section

ile
At inner fibre,

P M by 25 10 3
ob
( 25 10 3 140 ) t
t = + or 100 = +
om
A I ( t 2t )
[ 1
12
t ( 2t ) 3
]
ut

t3 - 125 t = 52 500
fA

The cubic equation is solved by trial and error.

to

t t3 - 125 t
en
tm

40 59 000
ar

39 54 444 t = 38.5 or 40 mm (Ans.)

ep

38.5 52 254 b = 2 t = 80 mm
D
EC
K