Mechanical Design: An Integrated Approach - Ansel Ugural: TL GJ o T

Mechanical Design: An Integrated Approach - Ansel Ugural
Chapter 14, Problem 1

A steel torsion bar is used as a counterbalance spring for the trunk lid of an automobile
(Figure 14.2a). Determine, when one end of the bar rotates 80 relative to the other end,
(a) The change in torque.
(b) The change in shear stress.
Given: L = 1.25 m, d = 8 mm, G = 79 Pa
Figure 14.2
Chapter 14, Solution 1

(a) J
or
( b )
32
TL
GJ
(8)4 402124
.
mm2
;
80 o 1396
.
rad
T (1.25 )
79(109 )( 402.12410 12 )
T 35.48 N m
16dT3
16 ( 35.48 )
( 810 3 )3
353 MPa

A steel bar supports a load of 2 kN with a moment arm R = 150 mm (Figure 14.2a).
Calculate
(a) The wire diameter.
Copyright 2004 The McGraw-Hill Companies Inc.

(b) The length for a deflection of 40 mm.
Given: n = 1.5, Sys = 350MPa, G = 79 GPa
Figure 14.2

(a)
d3
16 PR
all
16 ( 2103 )( 0.15)
( 350106 1.5 )
d 18.71mm
( b )Equation (14.2):
d 4 G
32 PR 2
(18.71) 4 ( 79 )( 40 )
32 ( 2103 )(150 ) 2
0.845m 845mm

A helical spring must exert a force of 1 kN after being released 20 mm from its most
highly compressed position. Determine the number of active coils.
Design Assumptions: The loading is static, all = 450MPa, G = 29 GPa, d = 7mm, and
C = 5.
D Cd 5( 7 ) 35 mm
all K s
Thus
8 PC
d2
; 450
8 P2 ( 5 )
( 7 )2
(1
0.615
5
), P2 1.542 kN
k P22 P11 1542201000 27.1 N m m
and
Na
dG
8 C 3k
7( 29103 )
8( 5 )3 ( 27.1)
7.49 coils

A helical compression spring used for static loading has d = 3 mm, D = 15 mm, Na = 10,
and squared ends. Determine
(a) The spring rate and the solid height.
(b) The maximum load that can be applied without causing yielding.
Design Decision: The spring is made of ASTM A227 hard-drawn steel wire of G = 79
GPa.

C 15 3 5
Table 14.2: b 0.201,

S u Ad 1510(30.201 ) 1,211 MPa
S ys 0.42 S u 509 MPa
Table 14.3:
A 1510
( a)
10 )
k 8 CdG3Na 38((795)3 (10)
237
. N mm
N t N a 2 12, hs ( N t 1)d 13(3) 39 mm

( b ) S ys
Ks
Thus
8 Pmax C
d2
Pmax
Pmax
S ysd 2
8CK s
( 509 )( 3) 2
0.615
8 ( 5 )(1
)
5
320.4 N

A helical compression spring is to support a 2 kN load. Determine
(b) The free height.
(c) Whether buckling will occur in service.
Given: The spring has rc = 10%, C = 5, and k = 90 N/mm.
Assumptions: Both ends are squared and ground and constrained by parallel plates.
Design Decisions: The spring is made of steel of Sys = 500 MPa, Ses 280 MPa , G = 79
GPa. Use a safety factor of 1.3.

(a)
d2
or
8 PCn
S ys
(1 0.C615 )
(1 0.615
5 )
d 8.62 mm
( b ) D 8.62(5) 431
.
Na
dG
8 C3K
mm, s 110
.
3
( 8.62 )( 7910 )
8( 5 )3 ( 90 )
hs ( N a 2 )d 82.49 mm,
s
(c) h
f
8 ( 2103 )( 5 )(1.3)
( 500106 )
24.44
106
023
.
hf
D
2 (103 )
90
24.44 mm
7.57
h f 24.44 82.49 106.9 mm
106431..9 248
. Spring is safe (Curve A, Fig.14.10)

A helical compression spring with ends squared and ground has d = 1.8 mm, D = 15 mm,
rc = 15%, and hs = 21.6 mm. Determine, using a safety factor of 2,
(a) The free height.
(b) Whether the spring will buckle in service, if one end is free to tip.
Design Decision: The spring is made of steel having Sys = 900 MPa and G = 79 GPa.

(a)
N t ds 211.8.6 12
N a 12 2 10
C 115.8 833
.
K s 1 08.615
.
.33 1074
( S ys n ) d 2
8 K sC
( 900 2 )(1.8 ) 2
8 (1.074 )( 8.33 )
64 N
10 )
k 8CdG3N a (1.8(88)(.3379)3(10)
3075
.
N mm
Thus
s 1.15 Pk 1.15 3.64

075 23.93 mm
h f hs s 21.6 23.93 45.53 mm
s
hf
(b)
hf
D
0.53
3.04
Spring is safe
(Curve B, Fig.14.10)

Design a helical compression spring with squared and ground ends for a static load of 40
lb, C = 8, k = 50 lb/in., rc = 20%, and n = 2.5. Also check for possible buckling.
Assumption: The ends are constrained by parallel plates.
Design Decision: The spring is made of steel of Sys = 60 ksi and G = 11.5 106 psi.
d2
8CP
S ys n
(1
0.615
C
8 ( 8 )( 40 )
( 60103 ) 2.5
(1
0.615
8
), d 0.191in.
D 0191
.
(8 ) 1528
.
in.
Na
dG
8 C 3k
0.191(11.5106 )
8( 8 )3 ( 50 )
10.73
N t 10.73 2 12.73, hs (12.73)( 0191

. ) 2.431 in.
40
s 120
. 50
0.96 in.
h f 2.431 0.96 3391
.
in.
Therefore
hf
s
Spring is safe (Curve A, Fig.14.10)
hf
D
0283
. , 222
.

A machine that requires a helical compression spring of k = 120 lb/in., all = 75 ksi,
rc = 10%, D = 3 in., and is to support a static load of 400 lb. Determine
(c) Whether the spring will buckle in service, if one end is free to tip.
Assumption: The ends are squared.
Design Decision: The spring is made of steel having G = 11.5 106 psi.

(a)
all
(b)C
8 PD
d3
d3
8 PD
all
8 ( 400 ) 3
( 75103 )
, d 0.344 in.
D d 3 0.344 8.72
N a 8dG
C 3k
0.344(11.5106 )
8( 8.72 )3 (120)
6.215, hs ( N a 2 1)d 317

. in.
400
s 110
. Pk 110
. 120
3.667 in., h f hs s 6.837 in.
s
(c) h
f
046
. , Df 228
. Spring is safe (Curve B, Fig.14.10)

Redo Problem14.5 for a load that varies between 2 kN and 4 kN, using the Soderberg
relation. Also determine the surge frequency.
A helical compression spring is to support a 2 kN load. Determine
(c) Whether buckling will occur in service.
Given: The spring has rc = 10%, C = 5, and k = 90 N/mm.
Assumptions: Both ends are squared and ground and constrained by parallel plates.
Design Decisions: The spring is made of steel of Sys = 500 MPa, Ses 280 MPa , G = 79
GPa. Use a safety factor of 1.3.

( a ) Pm
4 2
2
3kN
Kw
4 C 1
4C4
a
m
K w Pa
K s Pm
Pa
0.615
.
C 1311
42
2
1 kN
C 153 5
K s 1 0.615
.
C 1123
311 1
11..123
3 0.389
Equation (14.24), with replacing S us by S ys :

1.3
m ( 0.389 )(500
192.3 MPa
2500 280 )
280
and
d 2 Ks
8 Pm C
310 )( 5 )
1.123 8((192
, d 14.94 mm
.3106 )
( b ) D 14.94(5) 74.7 mm
s 110
. 4000
90 48.89 mm
Na
dG
8 C 3k
14.94( 79103 )
8 ( 5 )3 ( 90 )
hs ( N a 2 )d 225.7 mm
s
(c) h
f
hf
D
018
. ,
1311
.
h f 274.6 mm
368
. Spring is safe (Curve A, Fig.14.9)
Also
, 620(14.94 )
d
f n 356000
356
72.8 cps 4,370 cpm
D2 N a
( 74.7 )2 (13.11)

A helical compression spring for a cam follower supports a load that varies between 30
and 180 N. Determine
(a) The factor of safety, according to the Goodman criterion.
(c) The surge frequency.
(d) Whether the spring will buckle in service.
Design Decisions: The spring is made of music wire. Both ends are squared and ground;
one end is free to tip.
Given: d = 3mm, D = 15mm, Na = 22, rc = 10%, G = 79 GPa

( a ) C 15 3 5
Pm 180230 105 N
Pa 180230 75 N
K w 44CC14 0.C615 1.311
K s 1 0.C615 1.123
a
m
K w Pa
K s Pm
311 75
11..123
105 0.834
Thus
m Ks
8 PmC
5)
1123
. 8((105)(
3 2 166.8 MPa
310 )
a 0.834(166.8 ) 1391
. MPa
Table 14.2 and Eq.(14.12):
S u Ad b 2060(30.163 ) 1,722 MPa
Table 14.3: S es' 0.23S u 396 MPa Equation (8.5):
S us 0.67 S u 1154
,
MPa
Equation (14.25) results in
1,154 ( 396 )
n 139.1( 21,154396 )166.8396 138
.
( b ) hs
( N a 2)d 72 mm,
s 1.10
( c ) fn
(d)
hf
180
10.77
k 8CdG3N 38((795)3(1022 )) 10.77 N mm

a
18.38mm,
h f 72 18.38 90.4 mm
356, 620( 3)
d
12 356D,2620
108 cps 6,480 cpm

Na
2(15)2 ( 22 )
hf
D
0.2,
6.03
(for fixed-free ends)
Buckling will occur
(Curve B,
Fig.14.10)

A helical compression spring, made of 0.2-in. diameter music wire, carries a fluctuating
load. The spring index is 8 and the factor of safety is 1.2. If the average load on the spring
is 100 lb, determine the allowable values for the maximum and minimum loads. Employ
the Goodman theory.
D Cd 8( 0.2) 16
. in.
Kw
4 C 1
4C 4
m Ks
0.615
C
8 PmC
K s 1 0.615
.
8 1077
1184
.
)( 8 )
1.077 8(100
54.85ksi
( 0 .2 ) 2
Table 14.3 and Eq.(14.12):

S u Ad b 186( 0.2 0.163 ) 242 ksi
10
. ksi
Equation (8.5): S us 0.67( 242) 1621
'
Table 14.3: S es 0.23( 242 ) 55.66 ksi
Equation (14.23) gives
a
Thus
and
Pa
1
( 55.66 )(162.1 1.254.85 )
2
162.1( 12 )55.66
Ks a
Kw m
16.63 ksi
16.63
Pm 11..077
184 54.85 (100) 27.6 lb
Pmin 100 27.6 72.4 lb

Pmax 100 27.6 127.6 lb

A helical compression spring made of a music wire has d = 5 mm, D = 24 mm, and G =
79 GPa. Determine
(a) The factor of safety, according to the Goodman relation.
(b) The number of active coils.
Requirements: The height of the spring varies between 65 and 72 mm with corresponding
loads of 400 and 240 N.

( a ) C 24 5 48
.
Kw
4 C 1
4 C 4
Pm 6402 320 N
0.615
.
C 1325
Pa 1602 80 N
K s 1 0.615
.
C 1128
Table 14.2 and Eq.(14.12):

S u Ad b 2060(50.163 ) 1,585 MPa
S es' 0.23S u 365 MPa
Table 14.3:
Equation (8.5): S us 0.67S u 1,062 MPa
Therefore we obtain
m Ks
8 PmC
1128
.
8( 320 )( 4.8 )
( 0.005 )2
176.5 MPa
11
K w Pa
K s Pm m
.325 80
11128
. MPa
.
320 (176.5) 5183
Equation (14.25):
1, 062 ( 365 )
n 51.83( 21,062
365 ) 176.5 ( 365) 2.49
( b )Load of 160 N causes deflection of 72-65=7 mm.
Na
Gd
8 PC 3
7( 79 , 000 )( 5 )
8(160)( 5 )3
17.3

A steel helical compression spring is to exert a force of 4 lb when its height is 3 in. and a
maximum load of 18 lb when compressed to a height of 2.6 in. Determine, using the
Soderberg criterion with a safety factor of 1.6,
(b) The solid deflection.
(d) Whether the spring will buckle in service, if ends are constrained by parallel plates.
Given: The spring has C = 6, Sys = 80 ksi, Ses 45 ksi , G = 11.5 106 psi, rc = 10%.
Design Assumption: Ends will be squared and ground.

( a ) Pa 1824 7 lb
Kw
a
m
4 C 1
4 C 4
0.615
C
K w Pa
K s Pm
Pm 1824 11 lb
1253
.
K s 1 0.615
.
C 1103
.253 7
11103
.
11 0.723
Use Eq.(14.24) with replacing S us by S ys .

80 1.6
Thus m 0.723( 28045) 17.56 ksi
45
d 2 Ks
8 PmC
m
(11)( 6 )
1103
. 8(17,
. in.
560 ) , d 0103
.
( 6 ) 0.618 in.
( b ) D dC 0103
18 4
3 2.6
35 lb in.
12
0.103(11.510 )
N a 8dG
19.6, N t 19.6 2 21.6
3
Ck
8( 6 )3 ( 35 )
hs 21.6(0.103) 2.22 in.,
h f 3 1.10( 354 ) 3.126 in.
s h f hs 3.126 2.22 0.906 in.
( c ) fn
(d)
hf
14, 040( 0.103)

d
14D,040
154.5 cps 9,270 cpm

2
Na
( 0.618 )2 ( 24.5 )
hf
D
0.29,
5.1
Spring is safe (Curve A, Fig.14.10)

Resolve Problem 14.13 for the case in which the helical spring is to exert a force of 2 lb
at 5 in. height and a maximum load of 10 lb at 4.2 in. height.
A steel helical compression spring is to exert a force of 4 lb when its height is 3 in. and a
maximum load of 18 lb when compressed to a height of 2.6 in. Determine, using the
Soderberg criterion with a safety factor of 1.6,
(b) The solid deflection.
(d) Whether the spring will buckle in service, if ends are constrained by parallel plates.
Given: The spring has C = 6, Sys = 80 ksi, Ses 45 ksi , G = 11.5 106 psi, rc = 10%.
Design Assumption: Ends will be squared and ground.

( a ) Kw
4 C 1
4 C 4
0.615
.
C 1253
Pa 1022 4 lb
K s 1 0.615
.
C 1103
Pm 1022 6 lb

a
m
K w Pa
K s Pm
.253 4
11103
.
6 0.757
Thus
13
80 1.6
0.757 ( 280 45 )
1
45
17.04 ksi
Hence
d 2 Ks
8 PmC
m
6)
1.103 8(17( 6 )(,040
)
d 0.077 in.
or
( b ) D 0.077( 6 ) 0.462 in.
Na
10 2
5 4 .2
dG
8 C 3k
10 lb in.
0.077(11.5106 )
8( 6 )3 (10)
5124
.
N t 5124
. 2 53.24
hs 53.24( 0.077 ) 4.099 in.
h f 5 1.10( 102 ) 5.22 in.
s h f hs 5.22 4.099 1.121 in.
( c ) fn
(d)
hf
14040 ( 0.077 )
( 0.462 )2 ( 51.24 )
98.85 cps 5,931 cpm
0.21,
hf
D
11.3
Spring will buckle
(Curve A,
Fig.14.10)

An engine valve spring must exert a force of 300 N when the valve is closed (as shown in
Figure P14.15) and 500 N when the valve is open. Apply the Goodman theory with a
safety factor of 1.6 to calculate
(b) The number of active coils.
Given: The lift is 8 mm.
Design Decisions: The spring is made of steel having Sus = 720MPa, Ses 330MPa ,
G = 79 GPa, and C = 6.
Figure P14.15

( a ) Pm 400 N
Kw
4 C 1
4C4
Pa 100 N
0.615
C
m Ks
K s 1 0.615
.
C 1103
1253
.
8 PmC
K w Pa
K s Pm
)( 6 )
1103
. 8(400
(d2 )
6, 741
d2
.253 1 6, 741
m 11103
( 4 )( d 2 ) 1,d9142
.
Equation (14.23) leads

1,914
d2
6, 741
( 720 3302 ) 3302 ( 720
1.6 d 2 )
or
6, 438
d2
450 6,d7412 ,
d 541
. mm
( b ) D 5.41( 6 ) 32.46 mm
Na
dG
8 PC 3
5.41( 79 , 000 )( 8 )
8 ( 500300 )( 6 )3
9.89
14
A helical spring, made of hard-drawn wire having G = 29 GPa, supports a continuous

load. Determine
(a) The factor of safety based on the Soderberg criterion.
(d) Whether the spring will buckle in service.
Given: d = 6mm, D = 30mm, rc = 20%
Design Requirements: The ends are squared and ground; one end is free to tip. In the
most compressed condition, the force is 600 N; after 13 mm of release, the minimum
force is 340 N.
( a ) Pm 470 N , Pa 130 N , C 30 6 5
Table 14.2 and Eq.(14.12):
S u Ad b 1510( 6 0.201 ) 1053 MPa
Table 14.3:
S ys 0.42(1053) 442 MPa ,
K s 1 0.615
. ,
C 1123
0.615
.
C 1311
P P
1Gd
3
8 PC
1
m Ks
4 C 1
4C4
k 22 11 60013340 20 N mm,
We have
Na
Kw
S es' 0.21(1053) 221 MPa
8 PmC
d 2
K w Pa
K s Pm
1 340
20 17 mm
)( 6 )
178((29000
8.7
340 )( 5 )3
1123
.
8 ( 470 )( 5 )
( 6 )2
186.7 MPa
311 13
m 11..123
( 47 )(186.7) 60.29 MPa
It follows that
442 ( 221)
n 60.29( 2 442 221)186.7( 221) 12
.
(Eq.14.25)
( b ) hs ( N a 2 )d (10.7 )6 64.2 mm
6( 79000 )
k 8CdG3N a 8( 5)3 ( 8.7 ) 54.48 N mm

s 120
. 54600
h f 64.2 13.22 77.42 mm
.48 13.22 mm,
15
( c ) fn
s
(d)h
f
( 6)
d
12 356D,2620
2356( 30, 620
136.6 cps 8,196 cpm
Na
) 2 ( 8 .7 )
16
(fixed-free ends)
hf
D
017. , 26. Spring is safe (Curve B, Fig.14.10)

A helical tension spring has d1 = 3 mm and D1 = 30 mm. If a second spring is made of the
same material and the same number of coils with D2 = 240 mm, find the wire diameter d2
that would be required to give the same spring rate as the first spring.

Gd 4
8 D3 N a
k
d14
d4
2,
D13 D23
Since k1 k 2 :
D3
d24 d14 D123 34 ( 81 )3 ,
d2 1427
. mm

An extension coil spring is made of 0.02-in. music wire and has a mean diameter of coil
of 0.2 in. The spring is wound with a pretension of 0.2 lb, and the load fluctuates from
this value up to 1.0 lb. Determine the factor of safety guarding against a fatigue failure.
Use the Goodman criterion.
C 00..022 10
K s 1 0.615
.
C 10615
K w 44CC14 0.615
. ,
Pm 0.6 lb,
C 1145
a
m
K w Pa
K s Pm
0.719
m Ks
Pa 0.4 lb
8 PmC
8( 0.6 )(10)
10615
.
40.5 ksi
( 0.02 )2
a 0.719( 40.5) 2912

. ksi
17
Table 14.2 and Eq.(14.12):

S u Ad b 186( 0.02 0.163 ) 352 ksi
Equation (8.5): S us 0.67 S u 235.8 ksi
Table 14-3: S es' 0.23S u 81 ksi
Equation (14.25) is therefore

235.8 ( 81)
n 29.12( 2235.881) 40.5( 81) 130
.

Design a window-shade spring similar to that depicted in Figure 14.15. Determine
(a) The number of active coils, if a pull on shade of 15 N is exerted after being wound up
to 16 revolutions. (b) The maximum bending stress.
Assumptions: The spring will be made of 1.2-mm square wire having E = 207 GPa,
D = 18 mm, and a roller diameter of 32 mm.

. ) 4 12 01728
.
mm4 ,
( a ) I bh 3 12 (12
ML
EI
C D d 18 12
. 15
L MEI (162 )( 20724010 )( 0.1728 ) 14,983 mm
Hence N a
L
D
14 , 983
(18)
265
( b ) Pa 15(16) 240 N mm
Ki
3C 2 C 0.8
3C ( C 1)
1.046,
i Ki
6 Pa
bh 2
)
1.046 6((1240
3 871.7 MPa
.2 )

Design a helical torsion spring similar to that shown in Figure 14.14. Calculate
(a) The maximum operating moment.
(b) The maximum angular rotation.
Assumptions: A safety factor of 1.4 is used. The spring is made of oil-tempered steel
wire.
Given: E = 30 106psi, d = 0.08 in., D = 0.6 in., Na = 6
Figure 14.14

( a ) C 0.6 0.08 7.5
Table 14.2 and Eq.(14.12):
S u Ad b 146( 0.08 0.193 ) 238 ksi
Table 14.3:
Sy
Equation (14.36):
S ys
0.577
Ki
0.45 Su
0.577
186 ksi
4 C 2 C 1
4 C ( C 1)
1.11
Equation (14.39) is therefore

3
10 ) 1.4
M Pa ( 0.08)32((186
6.016 lb in
1.11)
(b)L
(0.6)6 11.31in.,
ML
EI
6.016 (11.31)
30 ( 2.011)
I 64d 2.011(10 6 ) in.4

4
1.128 rad 64.6o

A multileaf steel spring is to support a center load that varies between 300 and 1100 N
(Figure 14.17). Estimate, using the Goodman criterion with a safety factor of 1.2,
(a) The appropriate values of h and b for a spring of proportions b = 40h.
(b) The spring rate.
18
19
Given: Su = 1400MPa, Se 500MPa , G = 207 GPa, and = 0.3. The total length 2L is to
be 800 mm.
Assumptions: Use Cr = Cf = Cs = 1. Stress concentration at the center is such that
Kf = 1.4.
Figure 14.17

( a ) Pm 700 N
m
Also
6 Pm L
bh 2
Pa 400 N
6 ( 700 )( 0.4 )
40 h ( h 2 )
a
m
Pma 47
42
h3
Su n
a
Su
1
'
m ( Se K f )
1400 1.2
4 1400
( )(
) 1
7 500 1.4
360.1 MPa
Thus we obtain
3601. (10 6 ) 42h3 ,
h 4.89 mm
Hence b 195.6 mm
(b)
Ebh3
3
3 L (1 2 )
( 207 103 )(195.6 )( 4.89 )3

3( 400 )3 ( 0.91)
271
. N mm
20
21

A helical compression spring used for static loading has d = 3 mm, D = 15 mm, Na = 10,
and squared ends. Determine
(a) The spring rate and the solid height.
(b) The maximum load that can be applied without causing yielding.
Design Decision: The spring is made of ASTM A227 hard-drawn steel wire of G = 79
GPa.
Note: This problem is for student research only. No standard solution is available.
Check the site at www.acxesspring.com to review the common spring materials
presented. List five commonly employed wire spring materials and their mechanical
properties.
Note: This problem is for student research only. No standard solution is available.

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Mechanical Design: An Integrated Approach - Ansel Ugural

Chapter 14, Problem 1

Chapter 14, Solution 1

Chapter 14, Problem 2

Copyright 2004 The McGraw-Hill Companies Inc.