MECH 237-101 Name ____ Solution by Milano ____

Exam 2, October 29, 2010

1. A steel shaft is to be manufactured either as a solid circular bar or as a circular tube. The
shaft is required to transmit a torque of 1200 N-m without exceeding an allowable shear stress of
40 MPa nor an allowable rate of twist of 0.75 per meter of length. The shear modulus of
elasticity of the steel is G = 78 GPa.
(a) Determine the required diameter of the solid shaft. (10 pts.)
(b) Determine the required outer diameter of the hollow shaft if the thickness of the shaft is
specified as one-tenth of the outer diameter. (10 pts.)
t = d2
10 Given:
T = 1200 N-m
 = 40 x 106 N/m²
/L = 0.75/m (/180) = 0.0131 rad/m
G = 78 x 109 N/m²

do Treat as two separate problems;

d1
one solid and one hollow.
d2

Part (b) Take a look at the geometry of the hollow shaft

d2 = t + d1 + t = d1 + 2t = d1 + 2[d2/10] = d1 + 1/5 d2 = d1 + .2 d2
or .8 d2 = d1 use this to determine the Polar Moment of Inertia

 = Tr/J = Tr / ½  r4 = 2T / r³ or 16T / d³ from your FE Handbook

 d = ³ ( 16 T /   ) substitute the values and check the units
D = ³ { 16 (1200 N-m) /  (40 x 106 N/m²) = ³ 152.7887 x 10-6 m³ = 53.46 x 10-3 m
But you should change the units to something more appropriate  d = 53.5 mm
And the other criteria:
 = TL / JG   / L = T / JG = T  d = 4 32 T /  G (/L)
4
(d /32) G
 d =  32 (1200 N-m) m² =
4 4
 11.9623 x 10-6 m4 = 58.81 x 10-3 m
 (78 x 109 N)(0.0131 rad/m)
Changing units to something more appropriate  d = 58.8 mm

Use the larger of the two diameters to satisfy BOTH criteria  d = 58.8 mm ANS
Part (b), redo the analysis using formulas for hollow cylinder, where J = /32 [ d24 – d14 ]
So, J = /32 [d24 - (.8 d2)4 ] = /32 [ .5904 d24 ] = 0.05796 d24
 = Tr = T ( d2 / 2 ) = T rearrange to solve for d2
4
J 0.05796 d2 0.1159 d2³
d2 = ³ T / 0.1159  = ³ (1200) / 0.1159 (40x106) = ³ 258.8 x 10-6 m³
 d2 = 63.7 x 10-3 m = 63.7 mm
And the other criteria:
 / L = T / JG = T / ( 0.05796 d24 ) G rearrange and solve for d2
d2 =  (1200 N-m) / (0.05796)(78 x 10 N/m²)(0.0131 rad/m) = 0.0671 m = 67.1 mm
4 9

Compare and use the larger of the diameters, therefore, your answer = d2 = 67.1 mm

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 2 of 5

2. A stepped steel shaft AC is subjected to external torques at section B and C. The diameter of
section AB is d1 = 2 in. The diameter of section BC, d2, is to be determined by the following
specifications.
 Shear modulus of steel, G = 11.5 x 106 psi.
 Maximum shear stress in the stepped shaft should not exceed the allowable shear stress
allow = 8 ksi.
 Total angle of twist should not exceed allow = 0.06 radians.
Give your final answer to the nearest 1/8 inch that satisfies both of these criteria.
(20 min – 20 pt)
T = 12 kip-in
d1 = 2” The first thing you recognize is
10 kip-in
that these are shafts in SERIES.
d2 = ?
Total deformation = AB + BC
A

2 kip-in
And once again, you must satisfy
B BOTH criteria; solve for the shear
C stress AND for the allowable
40 in x angular deformation.

32 in

Solve for the “resisting” moment at the support = 12 kip-in = 12 x 10³ in-lb

 = Tr/J = Tr / ½  r4 = 2T / r³ or 16T / d³

The allowable shear stress is the same for both sections.
You should check the shear stress in section AB to be sure it’s within the allowable.
Apply a SECTION CUT to AB to determine the T in that section. T = 12 x 10³ in-lb.
 = Tr/J = Tr / ½  r4 = 2T / r³ = 2 (12x10³) /  (1”)³ = 7.6394 x 10³ < 8 ksi Good!

Apply a SECTION CUT to BC to determine the T in that section and apply this shear stress to
find the diameter of section BC. T = 2 kip-in = 2x10³ in-lb
 = 8 ksi = 8 x 10³ psi = 8 x 10³ lb/in² = 16 (2 x 10³ in-lb) /  d³ Solve for d
 d = ³ (16)(2 x 10³ in-lb) /  (8 x 10³ lb/in²) = ³ (16)(2) in³ / (8) = 1.0839 in
 d BC = 1.084 in

Compare using the other criteria

 total  0.06 radians given = ∑ TL / JG = [ TL / JG ] AB + [ TL / JG ] BC
0.06 rad = (12x10³ in-lb)(40”) / ½  (1) 4 (11.5x106) + (2x10³in-lb)(32”) / ½  (r4)(11.5x106)
0.06 = ( 26.572x10-³ ) + ( 3.543x10-³ / r4 )
0.06 - ( 0.026572 ) = ( 3.543 x 10-3 / r4 )
0.03343 r4 = 3.543 x 10-3  r = 4 3.543 x 10-3 / 33.43 x 10-3 = 0.5706 in
d BC = 2r = 1.1411 in.
Select the larger of the two values and round up to the nearest ⅛”
Use the fractional portion = .1411 x 8th = 1.1288 eighths < 2/8” = ¼”  1-1/4” ANS

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 3 of 5

3. Two solid shafts are connected by the gears as shown. The gear at A has a radius of 80 mm
and the gear at D has a radius of 50 mm. The shafts are made of steel with an allowable shearing
stress of 60 MPa. The applied torque at C is 600 N-m. Assuming the assembly is in
equilibrium, determine the required diameter of shaft BC and shaft EF. (20 pt.)

rA = 80 mm Given the size of the gears,

determine the size of the shafts.
A

B Use the shear stress,  = 60 x106 N/m²

  = Tr / J = 16 T /  d³

Tc = 600 N-m
C
D
E
rD = 50 mm
F
TF = ?
Determined to be
375 N-m

rA = 80 mm
The input Torque is applied to Gear A
This torque produces a force ON Gear D.
T = Fr and the forces between gears are equal and
opposite, therefore;
F = T / r = 600 N-m / .080m = 7.5 x10³ N

F For the driven gear, Gear D:

T = Fr = (7.5 x 10³ N)(0.050m) = 375 N-m
F
Use these Torques to determine the size of the
shafts holding the gears.

rD = 50 mm
Now determine the size of the shafts using  = 16 T /  d³  d = ³ 16 T /  

Shaft BC: d = ³ 16 (600 N-m) /  ( 60x106 N/m²) = ³ 50.92958 x10-6 = 37.067 x10-³ m
Diameter of shaft BC  37.1 mm
Shaft EF: d = ³ 16 (375 N-m) /  ( 60x106 N/m²) = ³ 31.830989 x10-6 = 31.692 x10-³ m
Diameter of shaft EF  31.7 mm

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 4 of 5

4. In the table below, show the analogy between linear and torsional loading. Fill in the formula
or expression for the property. Include units in both metric and English units. (20 pt.)

Tensile Loading Torque Loading

Stress  = P/A, psi, ksi, or Pa, kPa  = Tr/J, psi, ksi, or Pa, kPa

Strain  = L / L , in/in, mm/mm  = r / L = radians

Deformation  = PL / AE, in or mm  = TL / JG radians or degrees

Linear Relation E = stress / strain =  /  G = stress / strain =  / 

Units = psi, ksi, or Pa, GPa Units = psi, ksi, or Pa, GPa

The main objective of your first two lab experiments was to validate the
linear relationship between stress and stress as loading is applied.

This entire analogy was written on the chalkboard and emphasized as a

comparison between the linear and torsional properties.

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 5 of 5

5. . This beam is loaded with a uniform distributed load spanning between A and B and has a
concentrated load applied at the end of the overhang. (20pt.)
a) Prepare the Shear and Bending Moment Diagrams. Identify maximum and minimum points.
b) Determine the maximum bending moment(s) and determine where on the beam they occur.

8 kN/m 16 kN Step 1. Solve for Reactions

Fy = 0 = RAy + RBy - 32 -16
 RAy + RBy = 48

A B
C MA = 0 = (32)(2) - Rby(4) +(16)(6)
32 kN RBy = 64 + 96 = 40 kN
4m 2m (4)
Back Sub:  RAy = 8 kN
 RBy = 40 kN

down Step 2. Draw V & M Diagrams

16 kN Begin with RAy = +8
16 kN
The linear load is a downward slope.
The distributed load = 32 kN
Down 32 to -24 kN.
8 kN down 32 kN Rby = up 40 kN to +16 kN
nothing until the load at the end.
Down 16 kN.

up 40 kN Use similar triangles to find X.

b=X=4  X = 1m
X=? h 8 32

area of triangle = 1/2 bh

A1 = 1/2 (1 m)(8 kN) = 4 kN-m = M1
-24 kN
A2 = 1/2 (3 m)(-24 kN) = -36 kN-m
M1 = 4 kN-m
subtract from M1 = M2 = -32 kN-m

A3 = bh = (2 m)(16 kN) = 32 kN-m

closes diagram

Not to Scale

M2 = -32 kN-m

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