ME 452 - Machine Design II Name of Student:______________________________

Spring Semester 2018 Lecture Division Number:______________________

Homework No. 1 (50 points). Due on Blackboard before 8:00 am on Friday, January 19th.
Notes for the homework assignments (applicable to all homework this semester):
(i) All homework must be submitted to the blackboard page of your lecture division. See the assignment
tab. Please include this cover page with your name and lecture division number.
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appropriate software.
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(iv) Homework that is marked late cannot be graded.
(v) Write your solutions to all of the problems clearly and explicitly. Credit will not be given to work
that is presented in a manner which is difficult to read or understand. Any work that cannot be followed
will be assumed to be in error.
Please note that your homework will not be graded if these instructions are not followed. For example,
late homework will not be graded and cannot receive any credit.
Problem 1 (10 Points). Solve Problem 3-137, page 146.
Problem 2 (10 Points). Solve Problem 3-139, page 146.
Problem 3 (10 Points). A cast iron beam AD with a 4 cm by 6 cm rectangular cross-section (see the left
side of Figure 1) is simply supported at sections B and D as shown in the figure. A mass M = 25.5 kg is
suspended from a steel rope at section A (gravity is vertically downward as shown in the figure). Also, a
constant vertically downward force F  750 N is applied at section C of the beam.

g = 9.81m/s2
Y
F = 750 N

6 cm A B C D
X

4 cm 0.5 m 1.5 m 1m

Figure 1. A simply supported rectangular cast iron beam.

1
(i) Draw the free body diagram, shear force diagram, and bending moment diagram for the beam.
Include the important numerical values, such as, the reaction forces at the simple supports B and D, the
maximum and minimum shear forces, and the maximum and minimum bending moments.
(ii) Assuming that the compressive strength of the beam material is greater than the tensile strength,
locate the critical section of the beam and the critical element at the critical section. Draw the critical
element showing the state of stress on this element. Include the fixed XYZ coordinates.
(iii) Determine the maximum normal stress, the minimum normal stress, and the maximum shear stress
acting on the critical element of the beam.
Problem 4 (20 Points). A solid circular shaft is rigidly attached to a concrete wall as shown in Figure 2.
The length of the shaft is 4 m and there is a step change in the diameter at the mid-point of the shaft. A
constant vertical load P = 40 kN acts vertically downward on the shaft at a distance e from the step in
the shaft. Neglect the effects of stress concentration at the step and the effects of shear stress due to the
transverse shear force.
Part I. Given that the load P = 40,000 N is applied at a distance e = 0.5m from the step, and a constant
counterclockwise torque T = 50,000 Nm is applied at the end of the shaft (location C). (i) Draw the
shear force and the bending moment diagrams for the shaft. (ii) Given that the shaft material is ductile,
with a yield strength Sy = 200 MPa, determine the static factor of safety for the critical element at the
wall using von Mises theory. (iii) Given that the shaft material is brittle, with an ultimate tensile strength
Sut = 200 MPa and an ultimate compressive strength Suc = 250 MPa, determine the static factor of
safety for the critical element of the shaft at the wall using the Coulomb-Mohr theory.
Part II. Using von Mises theory determine the maximum distance e that the load P = 40,000 N can be
applied in order for the constant torque T = 35,000 e Nm and the static factor of safety for the critical
element at section A to be N = 1. Assume that the yield strength of the shaft material is Sy = 200 MPa.

Figure 2. A solid circular stepped shaft.

2
Solution to Homework No. 1.
Problem 3-137, page 146. (10 Points).
(i) Consider the aluminum plate–steel ball interface.
The radius (or the half-width) of the contact patch can be written from Eq. (3-68), see page 123, as

 3F  (1  1 ) / E1  (1  2 ) / E2
2 2
a3  (1)
 8  1/ d1  1/ d 2

Notation: The subscript 1 will be used to denote the steel ball and the subscript 2 will be used to denote
the aluminum plate. Since the aluminum plate is flat then the diameter d 2  . Substituting the known
data for AISI 1018 steel and 2024 T3 aluminum, see Table A-5, page 1007, and the given geometry into
Eq. (1), the radius of the contact patch can be written in terms of the weight F as

 3F  (1  0.292 ) / (30 x10 )  (1  0.333 ) / (10.4 x10 )

2 6 2 6
a 3  in. (2a)
 8  1/11/ 

Simplifying this equation, the radius of the contact patch in terms of the weight F can be written as

a  K F1/3  (3.517 x103 ) F1/3 in. (2b)

The maximum pressure can be written in terms of the radius of the contact patch and the weight F
from Eq. (3-69), see page 123, as
3 3 F 
pmax  pave    (3a)
2 2   a2 

Substituting Eq. (2b) into Eq. (3a), the maximum pressure can be written as
3F
pmax   (3.86 x104 ) F 1/3 psi (3b)
1/3 2
2 3.517 x10 F 3

The maximum principal normal stress can be written from Eq. (3-70), see page 123, as

  z 1  1 1  
 1   pmax  1  tan 1 ( )  (1  )    (4)
  a z/a  2 1  ( z / a ) 2  

and the minimum principal normal stress can be written from Eq. (3-71), see page 123, as
pmax
3   (5)
1  ( z / a)2

Note that the maximum and minimum principal normal stresses depend on Poisson’s ratio.
The maximum shear stress in the aluminum plate can be written from Eq. (3-16), see page 87, and
repeated as Eq. (3-72), see page 124, as
 3
 max  1 (6)
2

3
The maximum shear stress in the plate according to Figure 3-37, see page 124, occurs at the depth
z  0.48 a (7)

Note that the only difference in the maximum shear stress for the aluminum plate and the steel ball is
due to Poisson’s ratio, see Eqs. (4) and (6).
(a) Consider the aluminum plate. Substituting Eqs. (3b) and (7) and Poisson’s ratio for aluminum, see
Table A-5, page 1007, into Eq. (4), the maximum principal normal stress in the plate can be written in
terms of the weight F as
 1 
 1   (3.86 x104 ) F 1/3  1  0.48 tan 1 (1/ 0.48)  (1  0.333)  2 
psi (8a)
 2(1  0.48 ) 
that is
 1   (3.86 x104 ) F 1/3 (1  0.5392) x 1.333  0.4064   (3.86 x104 ) F 1/3 0.6142  0.4064 psi (8b)

Therefore, the maximum principal normal stress in the aluminum plate is

 1   8025F 1/3 psi (8c)

(b) Consider the steel ball. Substituting Eqs. (3b) and (7) and Poisson’s ratio for steel, see Table A-5,
page 1007, into Eq. (4), the maximum principal normal stress in the steel ball can be written in terms of
the weight F as

 1 
 1   (3.86 x104 ) F 1/3  1  0.48 tan 1 (1/ 0.48)  (1  0.292)  2 
psi (9a)
 2(1  0.48 ) 
that is
 1   (3.86 x104 ) F 1/3 (1  0.5392) x 1.292  0.4064   (3.86 x104 ) F 1/3 0.5954  0.4064 psi (9b)

Therefore, the maximum principal normal stress in the steel ball is

 1   7294 F 1/3 psi (9c)

Comparing Eqs. (8c) and (9c), the maximum principal normal stress in the aluminum plate is the greater.
Substituting Eqs. (3b) and (7) into Eq. (5), the minimum principal normal stress in the aluminum
plate can be written in terms of the weight F as

(3.86 x104 ) F 1/3

3     (3.137 x104 ) F 1/3 psi (10)
1  0.482

Then substituting Eqs. (8c) and (10) into Eq. (6), the maximum shear stress in the aluminum plate is

( 8025F 1/3 )  ( 3.137 x104 ) F 1/3

 max   (1.1673 x104 ) F 1/3 psi (cw) (11a)
2
Also, substituting Eqs. (9c) and (10) into Eq. (6), the maximum shear stress in the steel ball is

( 7294 F 1/3 )  ( 3.137 x104 ) F 1/3

 max   (1.2038 x104 ) F 1/3 psi (cw) (11b)
2

4
Comparing Eqs. (11a) and (11b), the maximum shear stress in the steel ball is the greater.
Check. The maximum shear stress according to Figure 3-37, see page 124 (which uses   0.3 for
Poisson’s ratio) is approximately
 max  0.3 pmax (12a)

Substituting Eq. (3b) into Eq. (12a), the maximum shear stress is

 max  0.3 (3.86 x104 ) F 1/3  (1.158 x104 ) F 1/3 psi (cw) (12b)

Note that this result is in good agreement with both Eq. (11a) for the aluminum plate and Eq. (11b) for
the steel ball.
For the aluminum plate. Equating Eq. (11a) with the allowable shear stress  all  20000 psi gives

20000   1.1673 x 104 F 1/3 psi (13a)

Then rearranging this equation, the weight is

3
 20000 
F 4
 5.03 lb (13b)
1.1673x10 

For the steel ball. Equating Eq. (11b) with the allowable shear stress  all  20000 psi gives

20000   1.2038 x 104 F 1/3 psi (14a)

Then rearranging this equation, the weight is

3
 20000 
F  4
 4.59 lb (14b)
1.2038 x10 

(ii) Consider the cast iron table–steel ball interface. Consistent with the notation in Eq. (1), the subscript
1 denotes the steel ball. The subscript 2 will now be used to denote the cast iron table. Using Table A-5,
see page 1007, for ASTM No. 30 gray cast iron, the radius of the contact patch can be written from Eq.
(1) as

 3F  (1  0.292 ) / (30 x10 )  (1  0.211 ) / (14.5 x10 )

2 6 2 6
a3  in. (15a)
 8  1/11/ 

Therefore, the radius of the contact patch is

a  (3.306 x103 ) F 1/3 in. (15b)

Substituting Eq. (15b) into Eq. (3a), the maximum pressure is

3F
pmax   (4.369 x104 ) F 1/3 psi (16)
1/3 2
2 3.306 x 10 F 
3

5
(a) Consider the cast iron table. Substituting the given data into Eq. (4), the maximum principal normal
stress in the steel ball is
 1 
 1   (4.369 x104 ) F 1/3  1  0.48 tan 1 (1/ 0.48)  (1  0.211)  2 
psi (17a)
 2(1  0.48 ) 
that is
 1   (4.369 x104 ) F 1/3 (1  0.5392) x 1.211  0.4064   (4.369 x104 ) F 1/3 0.5580  0.4064 psi (17b)

Therefore, the maximum principal normal stress in the cast iron table is

 1   6625 F 1/3 psi (17c)

(b) Consider the steel ball. Substituting the given data into Eq. (4), the maximum principal normal stress
in the steel ball is
 1 
 1   (4.369 x104 ) F 1/3  1  0.48 tan 1 (1/ 0.48)  (1  0.292)  2 
psi (18a)
 2(1  0.48 ) 
that is
 1   (4.369 x104 ) F 1/3 (1  0.5392) x 1.292  0.4064   (4.369 x104 ) F 1/3 0.5954  0.4064 psi (18b)

Therefore, the maximum principal normal stress in the steel ball is

 1   8257 F 1/3 psi (18c)

Substituting Eqs. (7) and (16) into Eq. (5), the minimum principal normal stress in the steel ball is

(4.369 x104 ) F 1/3

3     (3.551x104 ) F 1/3 psi (19)
1  0.482

Substituting Eqs. (17c) and (19) into Eq. (6), the maximum shear stress in the cast iron table is

( 6625 F 1/3 )  ( 3.551 x 104 F 1/3 )

 max   (1.444 x104 ) F 1/3 psi (cw) (20a)
2
Substituting Eqs. (18c) and (19) into Eq. (6), the maximum shear stress in the steel ball is

( 8257 F 1/3 )  ( 3.551 x 104 F 1/3 )

 max   (1.363 x104 ) F 1/3 psi (cw) (20b)
2
Check. The maximum shear stress according to Figure 3-37, see page 124, is approximately
 max  0.3 pmax (21a)

Substituting Eq. (16) into Eq. (21a), the maximum shear stress is

 max  0.3 (4.369 x104 ) F 1/3  (1.311x104 ) F 1/3 psi (cw) (21b)

This result is in good agreement with Eq. (20a) for the cast iron table and Eq. (20b) for the steel ball.

6
For the cast iron table. Equating Eq. (20a) with the allowable shear stress  all  20 kpsi  20000 psi
gives
20000   (1.444 x 104 ) F 1/3 psi (22a)

Rearranging Eq. (22a), the weight is

3
 20000 
F  4 
 2.66 lb (22b)
1.444(10 ) 

For the steel ball. Equating Eq. (20b) with the allowable shear stress  all  20 kpsi  20000 psi gives

20000   (1.363 x 104 ) F 1/3 psi (23a)

Rearranging Eq. (23a), the weight is

3
 20000 
F  4
 3.16 lb (23b)
1.363 x 10 
Now compare the four answers for the weight F , that is, Eq. (13b), Eq. (14b), Eq. (22b), and Eq.
(23b). The maximum amount of weight is the lowest value, that is, Eq. (22b), where
F  2.66 lb (24)

Therefore, the critical interface is the cast iron table–steel ball interface.
Note that the only difference in the principal normal stress for the aluminum plate–steel ball
interface and the cast iron table–steel ball interface is due to Poisson’s ratio, see Eq. (4). The smaller
Poisson’s ratio will create the greater principal normal stress (that is, a less compressive principal
normal stress). This, in turn, provides the largest value of the maximum shear stress, see Eqs. (11a),
(11b), (20a), and (20b). Therefore, the cast iron table is known to be the critical element which means
that the answer for the weight F could have been obtained more directly by considering only Eq. (22b).
Problem 3-139, page 146. (10 Points). From Table A-5, see page 1007, Poisson’s ratio and the
modulus of elasticity of carbon steel gears, respectively, are
v = 0.292 and E = 30 Mpsi (1a)
The given geometry is the length (or face width), and the two diameters
l = 0.75 in, d = 2 x 0.47 = 0.94 in, and d = 2 x 0.62 = 1.24 in (1b)
1 2

The maximum pressure can be written from Eq. (3-74), see page 124, as

 2  F 
pmax      (2)
   bl 

The half-width of the contact patch for two cylinders can be written from Eq. (3-73), see page 124, as

7
  (1  12 ) (1   2 2 ) 

 2 F   E1 E2 

b   (3a)
  l  1 1
 
 d1 d 2 
 

Substituting Eqs. (1a) and (1b) and the transmitted load F  40 lb into Eq. (3a), the half-width of the
contact patch is
1/ 2
  2 x 40   2(1  0.2922 ) / (30 x106 )  
b      1.052  103 in (3b)
   x 0.75   1/ 0.94  1/1.24 

Then substituting F  40 lb and Eqs. (1b) and (3b) into Eq. (2), the maximum pressure is

2  40
pmax   32275 psi  32.275 kpsi (4)
 1.052  103  0.75

The maximum shear stress from Figure 3-39, see page 126, can be approximated as

 max  0.30 pmax (5a)

Substituting Eq. (4) into Eq. (5a), the maximum shear stress is

 max  0.3 32275  9682.5 psi  9.6825 kpsi (cw) (5b)

Check: The maximum shear stress can be written from Eq. (3-16), see page 87, repeated as Eq. (3-72),
see page 124, as
 3
 max  1 (6a)
2
Assume here that the maximum principal normal stress  1   y , then from pages 125 and 126 the ratio

z
 0.436 (6b)
b
Therefore, the maximum principal normal stress can be written from Eq. (3-76), see page 125, as

 2  
  1  2  z   
   2 
b z
 1   y   pmax    (7a)
2  b
 z 
 1   b   
    
The minimum principal normal stress from Eq. (3-77), see page 125, is

8
 pmax
3   Z   (7b)
2
z
1  
b

Note that the maximum shear stress according to Figure 3-39, see page 126, occurs at the depth
z  0.786 b (8)

Also, note that the maximum and minimum principal normal stresses , see Eqs. (7a) and (7b), depend on
the maximum pressure and the width of the contact patch, which in turn depends on Poisson’s ratio, see
Eq. (3a).
Substituting Eqs. (4) and (8) into Eq. (7a), the maximum principal normal stress can be written as

 2  
  1  2  0.786   
 1   32275   2(0.786)  psi (9a)
  1   0.786  
2

 
Therefore, the maximum principal normal stress is

  2.235592  
 1   32275     1.572    5991.6 psi (9b)
  1.271926  
Substituting Eqs. (4) and (8) into Eq. (7b), the minimum principal normal stress can be written as
32275 32275
3      25374.9 psi (10)
1  (0.786) 2 1.271926

Substituting Eqs. (9b) and (10) into Eq. (6a), the maximum shear stress is
 5991.6  (  25374.9)
 max   9691.65 psi  9.69 kpsi (cw) (11)
2
Note that this result for the maximum shear stress is in good agreement with Eq. (5b).
Problem 3. (10 Points). (i) 2 points. The weight acting at section A is

FW = Mg  25.5  9.81 = 250.155 N (1)

The sum of the moments about the z-axis at the simple support at section D is

M D =0 (2a)
that is
1 m  F  2.5 m  R B  3 m  FW  0 (2b)

Substituting F  750 N and Eq. (1) into Eq. (2b) gives

 750  2.5 R B  750.465  0 (2c)

9
Rearranging this equation, the reaction force at section B is

R B   600.186 N (2d)

The sum of the moments about the z-axis at the simple support at section B is

M B =0 (3a)
that is
 0.5 m  250.155 N  1.5 m  750 N + 2.5 m  R D  0 (3b)
or
 125.0775 N.m  1125 N.m + 2.5 R D N.m  0 (3b)

Rearranging this equation, the reaction force at section D is

R D   399.969 N (3c)

Check: From the sum of the forces, observe that the following two equations are in complete agreement

FW + F = 250.155 + 750 =  1000.155 N (4a)

and
R B + R D = 600.186 + 399.969 =  1000.155 N (4b)

(ii) 5 points. The shear force and bending moment diagrams for the beam, see Figure 1 on the handout.
(a) Section 1 (0 m ൏ x ൏ 0.5 m). A cut through this section gives the free body diagram shown in Figure
2. The sum of the forces in the Y-direction can be written as

F = 0
y (5a)
that is
 V  FW  0 (5b)

Substituting the weight, see Eq. (1), into Eq. (5b), and rearranging, the shear force is
V   250.155 N (5c)

Section 1
M

A
X
x

Fw = 250.155 N

Figure 2. The free body diagram for the section of the beam between A and B.

10
 The sum of the moments about the z-axis at section A can be written as

M A =0 (6a)
that is
M xV0 (6b)

Substituting Eq. (5c) into Eq. (6b), and then rearranging, the bending moment is
M   (250.155 x) N.m (6c)

(b) Section 2: (0.5 m < x < 2 m). A cut through this section gives the free body diagram shown in Fig. 3.

RB = 600.186 N
Section 2

M
A B
X

0.5 m
x V

FW = 250.155 N

Figure 3. The free body diagram for the section of the beam between B and C.
The sum of the forces in the Y-direction are

F = 0
y (7a)
that is
 V  R B  FW  0 (7b)

Substituting Eqs. (1) and (2d) into Eq. (7b), and rearranging, the shear force is
V   600.186  250.155   350.031 N (7c)

The sum of the moments about the z-axis at point A can be written as

M A =0 (8a)
that is
 M  x V  0.5  RB  0 (8b)

Substituting Eqs. (2d) and (7c) into Eq. (8b), and rearranging, the moment about point A is
M  (350.031 x  300.093) Nm (8c)

(c) Section 3: (2 m < x < 3 m). A cut through this section gives the free body diagram shown in Figure 4.

11
 RB = 600.186 N F = 750 N Section 3
M

A B C
X
x
V
0.5 m 1.5 m

FW = 250.155 N

Figure 4. The free body diagram for the section of the beam between C and D.
The sum of the forces in the Y-direction can be written as

F = 0
y (9a)
that is
 V  RB  FW  F  0 (9b)

Substituting Eqs. (1) and (2d) and the load F  750 N, into Eq. (9b), and rearranging, the shear force is

V  600.186  250.155  750   399.969 N (9c)

The sum of the moments about the z-axis at point A can be written as

M A =0 (10a)
that is
 M  x V  2  F  0.5  RB  0 (10b)

Substituting Eqs. (1), (2d), (9c), and the load F  750 N, into Eq. (10b), and rearranging, the moment
about the z-axis at point A is
M   399.969 x  1500  300.093   (399.969 x  1199.907) Nm (10c)

The free body diagram of the beam is shown in Figure 5. Then the shear force diagram and the
bending moment diagram for the beam are shown in Figures 6 and 7, respectively.
Note that the sign conventions for these three diagrams are consistent with those given in Chapter 3, see
page 75. These sign conventions must be used, in this course, consistently throughout the semester.

12
 RB = 600.186 N F = 750 N RD = 399.969 N

A B C D
X

0.5 m 1.5 m 1m

Fw = 250.155 N
Figure 5. The free body diagram of the beam.
V

+ 350.031 N
+ 300 N

0 2m 2.5m 3m
0.5m 1m 1.5m X

- 300 N - 250.155 N
- 399.969 N
Figure 6. The shear force diagram for the beam.
M

+ 399.969 Nm
+ 400 Nm

0.5m
0 1m 1.5 m 2m 2.5 m 3m X
- 125.0775 Nm
- 200 Nm

Figure 7. The bending moment diagram for the beam.

Summary.

Maximum shear force - 399.969 N

Minimum shear force - 250.155 N
Maximum bending moment + 399.969 Nm
Minimum bending moment - 125.0775 Nm
13
(iii) 3 points. Since the maximum bending moment occurs at section C (or to the right of section C) then
the maximum normal moment stress due to bending occurs at section C. Therefore, the critical elements
will be at the cross-section of the beam at section C (or to the right of section C). Figure 8 shows the
nine possible candidates for the critical element at the cross-section C.

Figure 8. The critical elements at the cross-section C.

Since the problem states that the compressive strength of the beam material is greater than the tensile
strength, that is, Sc  St , then the critical elements are at the bottom of the beam, that is, the elements
K, L, and M (which are in tension due to the bending moment). The notation for the stress distribution in
elements K, L, and M are as shown in Figure 9.

Figure 9. The stress distribution in elements K, L, and M.

Note that the free surface of the beam is the negative Y-face (that is, the bottom of the beam), therefore,
the shear stresses that must be zero are

 xy   yz  0 (11a)

The third shear stress is the shear stress inside the beam due to the transverse load F, that is

 xz   transverse  0 (11b)

14
 The normal stresses in elements K, L, and M that are zero are
y 0 and z  0 (12a)

The normal stress in the x-direction is due to the maximum bending moment M, that is
Mc
 x   bending   (12b)
I
Sign Convention. The positive sign must be used here because the critical elements K, L, and M are in
tension. Also, the second moment of area of the beam is

b h3 0.04  0.063
I   0.72  106 m 4 (13a)
12 12
and the cross-sectional area is
A  b h  2.4 103 m2 (13b)

Substituting Eq. (13a), c  0.03 m, and the bending moment M   399.969 Nm (see Figure 7) into Eq.
(12b), the normal stress in the X-direction is
399.969  0.03
 x   bending     16.665 MPa (14)
0.72  10 6
For the sake of completeness, and comparison, the stresses on the remaining elements at section C
will be included here. The stress distribution in element F is shown in Figure 10.

Figure 10. The stress distribution in element F.

The normal compressive stress due to the maximum bending moment can be written as
Mc
 x   bending   (15a)
I
The correct sign here is negative because the element is in compression, that is

15
 399.969  0.03
 bending     16.665 MPa (15b)
0.72  10 6

Therefore, the principal normal stresses in ordered form ( 1   2   3 ) are

1  0, 2  0 and  3   16.665 MPa (15c)

(which is a uniaxial state of stress). The shear stresses are

 xy   yz  0 (16a)

The shear stress due to the transverse load is

 transverse   xz  0 (16b)

Note that the maximum shear stress from Eq. (15c) is

1   3 0  (  16.665)
 max    8.333 MPa (cw) (16c)
2 2
Elements H, I, and J (i.e., the points on the neutral axis). The stress distribution in elements H, I and J is
shown in Figure 11.

Figure 11. The stress distribution in elements H, I, and J.

The normal compressive stress due to the maximum bending moment is
 bending  0 (17a)

The applied normal stresses

y 0 and z  0 (17b)

For a rectangular cross-section, the shear stress across the neutral axis due to the shear force V is
3 V 3  399.969
 transverse   xy    0.25 MPa (18a)
2 A 2  2.4  10 3

16
The shear stresses
 yz  0 and  xz  0 (18b)

Note that the normal stress on the elements at the top, or the bottom, of the beam compared to the
transverse shear stress on the elements at the neutral axis is
 3 16.665 MPa
  66.67 (19)
 xy 0.25 MPa

That is, the normal stresses on the elements at the top, or the bottom, of the beam are 66.67 times greater
than the transverse shear stresses on the elements at the neutral axis.
Problem 4. (20 Points). Part I. (i) 5 points. The shear force at the wall, section O, is

V  4 x 104 N (a)

The sum of the moments about the wall, at section O, is

 MO = 0 (b)
that is
MO  R  F  2.5   40   10 104 Nm (c)

The sum of the moments at section B is

MB = 0 (d)

The sum of the moments at section C is

MC = 0 (e)

The free body diagram, the shear force diagram, and the bending moment diagram for the stepped
shaft are shown in Figures 1a, 1b, and 1c, respectively.

P = 40 kN
Y

e
M
V
A B C
X

L1 L2

Figure 1a. The free body diagram of the shaft.

17
 V

104 N
4

0 A B C
- 0.5
0.5 1 1.5 2 2.5 3 3.5 4 X
m
Figure 1b. The shear force diagram.

104 N m
0

-2
-4

-6
-8
-10
A B C
0 0.5 1 1.5 2 2.5 3 3.5 4 X
m

Figure 1c. The bending moment diagram.

(ii) 6 points. The stresses acting on the important elements at the cross section of the shaft at the wall
(i.e., the critical section) are shown in Figure 2.

18
 Figure 2. The critical cross-section at the wall.

The bending moment at the wall is a function of the force P, the length L 1 , and the distance e, that
is
Mw = P (L1 + e) (1a)

Substituting the load P = 40,000 N, the length L1 = 2 m, and the distance e = 0.5 m into Eq. (1a), the
bending moment at the wall is

Mw = 40,000 (2 + 0.5) = 100,000 Nm (1b)

The normal stress due to bending (referred to as the bending stress) at the wall can be written as

 σb w = MIw c = MZw = 32π M

d
w
3
(2a)
1 1

Substituting Eq. (1b) and d1  0.2 m into Eq. (2a), the normal stress due to bending at the wall is

 σb w = 32πxx100,000
0.2 3
= 127.32 MPa (2b)

The shear stress at the wall due to the torque can be written as
T r 16 T
τw = = (3a)
J1 π d13

Substituting T = 50,000 Nm and d1  0.2 m into Eq. (3a), the shear stress due to the torque (referred to
as the torsional stress) at the wall is

19
 16 x 50,000
τw = = 31.831 MPa (3b)
π x 0.23

The principal normal stresses, see Eq. (3-13), page 81, can be written as
2
(σ b ) w  (σ ) w 
σ1, σ3 = ±  b  + τw 2 (4a)
2  2 

Substituting Eqs. (2b) and (3b) into Eq. (5a), the principal normal stresses can be written as
2
127.32  127.32  2
σ1, σ3 = ±   + 31.831 (4b)
2  2 

Therefore, the maximum and the minimum principal normal stresses are

σ1 =  134.83 MPa and σ3 =  7.514 MPa (4c)

The principal normal stresses in ordered form ( 1   2   3 ) are

1   134.83 MPa, 2  0 and  3   7.514 MPa (4d)

The static factor of safety guarding against yielding according to the distortion energy theory see Eq.
(5.19), page 224, is
Sy
N= (5)
σ
The von Mises stress can be written in terms of the principal normal stresses, see Eq. (5.13), page 223,
as
σ = σ12  σ1σ3 + σ32 (6a)

Substituting Eq. (4c) into Eq. (6a), the von Mises stress is

σ = 134.832  (134.83)(  7.514) + (  7.514) 2 = 138.73 MPa (6b)

Then substituting Eq. (6b) and the given yield strength into Eq. (5), the static factor of safety guarding
against yielding is
200
N=  1.44 (7)
138.73
Equation (7) implies that yielding is not predicted to have occurred.
(iii) 5 points. The static factor of safety guarding against fracture according to the Coulomb-Mohr
theory, see Eq. (5.26), page 229, can be written as

1 σ1 σ
=  3 (8)
N Sut Suc

20
Note that the ultimate strengths are used here because the material is specified as brittle. Substituting Eq.
(4c) and the ultimate tensile strength and the ultimate compressive strength into Eq. (8), the static factor
of safety can be written as
1 134.83  7.514
   0.674  0.030 (9a)
N 200 250
Therefore, the static factor of safety guarding against fracture is
N = 1.42 (9b)

Equation (9b) implies that fracture is not predicted to have occurred.

Part II. (4 points). The von Mises stress at the step of the shaft can be written in terms of the applied
stresses see Eq. (5.15), page 223, as

 σ b S  3 τS
2
σS = 2
(10)

The normal stress due to bending at the step of the shaft can be written as
MS c MS 32 MS
 σb S = I1
=
Z
=
π d 23
(11a)

The bending moment is a function of the force P and the unknown distance e, that is

MS = P e (11b)

Substituting Eq. (11b) into Eq (11a), the normal stress due to bending at the step of the shaft is

 σb S = 32π dP e 3
(11c)
2

The shear stress due to torsion at the wall can be written as

T r 16 T 16 (35,000 e)
τS = =  (12)
J 2 π d 23 π d 23

Since the static factor of safety guarding against yielding for the critical element at section A (the step of
the shaft) is specified as N = 1 and the yield strength of the shaft material is Sy = 200 MPa then the von
Mises stress is
σS  Sy = 200 MPa (13)

Substituting Eqs. (11c), (12), and (13) into Eq. (10) gives
2 2
6
 32 P e   16 (35,000 e) 
200 x 10 =   + 3   (14a)
 πd 3  π d 23
 2   

21
Rearranging Eq. (14a), and substituting in the known values, the distance is

200 x 106
e=  1.32 m (14b)
2 2
 32 (40,000)   16 (35,000) 
 3  + 3 3 
 π (0.15)   π (0.15) 

This result implies that the load can be extended to the distance e = 1.32 m before yielding is expected
to occur at the step.
Check: Note that the problem can also be solved using the principal normal stresses. The maximum and
the minimum principal normal stresses can be written as
2
(σ b )S  (σ ) 
σ1, σ3 = ±  b S  + τS 2 (15a)
2  2 
which can be written as
2 2
16 P e  16 P e   16 (35,000 e) 
σ1, σ3 = ±  3 
 
+  (15b)
π d 23  π d2   π d 23 

Therefore, the maximum principal normal stress can be written as

  16 P   16 (35,000)  
2 2
 16 P
+ 
 π d 3   π d 3  
σ1 = e + (16a)
 π d 3
 2  2   2  
or as
  16 (40,000)   16 (35,000)  
2 2
 16 (40,000)
σ1 = e +  3 
+ 3 
= (1.4057 x 109 ) e Pa (16b)
 π (0.15) 3
 π (0.15)   π (0.15)  


The minimum principal normal stress can be written as

  16 P   16(35,000)  
2 2
 16 P
 
 π d 3   π d 3  
σ3 = e + (17a)
 π d 3
 2  2   2  
which can be written as
  16 (40,000)   16 (35,000)  
2 2
 16 (40,000)
σ3 = e   3 
+ 3 
=  (1.985 x 107 ) e Pa (17b)
 π (0.15)3  π (0.15)   π (0.15)   


For a static factor of safety N = 1 , the yield strength is the same as the von Mises stress, that is

Sy  σ  σ12  σ1σ3 + σ32 (18)

22
Substituting the yield strength Sy  200 x 106 Pa and Eqs. (16b) and (17b) into Eq. (18) gives

200 x 106 = e (1.4057 x 109 ) 2  (1.4057 x 109 )(  1.985 x 107 ) + (  1.985 x 107 ) 2 (19)

Rearranging this equation, the unknown distance from the step of the shaft is
e = 1.32 m (20)
Note that the answer given by Eq. (20) is in complete agreement with the answer given by Eq. (14b).

23