AME 30363 Mechanical Engineering Design

Homework 6 · Solutions
11.36 Gears 3 and 4 act on the shaft shown in sketch b. The resultant gear force, PA = 600 lb, acts at an
angle of 20◦ from the y axis. The yield stress for the shaft, which is made of cold-drawn steel, is
71,000 psi and the ultimate stress is 85,000 psi. The shaft is solid and of constant diameter. The safety
factor is 3.0. Assume the DET throughout. Also, for fatigue loading conditions assume completely
reversed bending with a bending moment amplitude equal to that used for static conditions. The
alternating torque is zero. Determine the safe shaft diameter due to fatigue loading, rounding your
answer to the next highest quarter-inch. Show shear and moment diagrams in the various planes.
Ans. dfatigue = 2.50 in.

20 in.

16 in.
0
10 in. PC

20°

B
z C
Gear 3 A
(24-in. diam) 2

PA
Gear 4
x
20° (10-in. diam)

Sketch b, for Problem 11.36

Solution: The reaction forces and their labels have been added in red to the problem sketch. It is
assumed that there is no torque loss in the bearings.
The first step is to determine the force on Gear C. This is done by equating torques applied at the
gears:
∑ T = 0 = PA cos 20◦ (12 in.) − PC cos 20◦ (5 in.)
or PC = 1440 lbs. The torque between the gears is T = PA cos 20◦ (12 in.) = 6766 in-lb = 6.76 kip-in.

(a) Determination of Reactions and Shear and Moment Diagrams. Now obtain the reactions by
looking at the x-y and x-z planes separately. In the xy plane:

∑ MO = 0 = (PA cos 20◦ )(20 in.) + By(36 in.) − PC sin(20◦ )(46 in.)
or By = 316 lbs.
∑ Fy = 0 = Oy + PA cos 20◦ + By − PC sin 20◦
or Oy = −387 lbs. In the x-z plane:

∑ MO = 0 = PA sin 20◦ (20 in.) − Bz (36 in.) − PC cos 20◦ (46 in.)
or Bz = −1615 lbs.
∑ Fz = 0 = Oz + Bz − PA sin 20◦ + PC cos 20◦

1
y
x
x
600 cos20° lb 1440 sin20° lb 600 sin20° lb 1440 cos20° lb
387 lb 316 lb 467 lb 1615 lb
= 564 lb = 493 lb =205 lb =1353 lb
z
V V
378 lb 1353 lb

-177 lb -467 lb -262 lb

493 lb
9.34 kip-in. 13.53 kip-in.
M M

-7.74 kip-in. -4.93 kip-in.

Shear and moment diagrams for Problem 11.5.

or Oz = 467 lbs. The shear and bending moment diagrams can then be constructed for the xy
and xz planes as shown.
The moments at A and B are calculated from the Pythagorean theorem and are 12.1 kip-in. at A
and 14.4 kip-in. at B. This means that the section of the shaft just inside the gear at B is critical, so
we take T=6.76 kip-in., and M=14.4 kip-in. For the shaft material, S y = 71, 000 psi, Su = 85, 000
psi.
(b) Static Analysis. Using the distortion-energy theory, Eq. (11.12) gives:
r !1/3 r !1/3
32ns 3 32 ( 3.0 ) 3
d= M2 + T 2 = (14, 400 in.-lb)2 + (6760 in.-lb)2 = 1.88 in.
π Sy 4 π (71, 000 psi) 4

This is rounded up to d = 2.0 in.

(c) Fatigue Analysis. For fatigue analysis, using M M = 0 and M A = 14.4 kip-in., TA = 0 and
TM = 6.76 kip-in., we need the endurance limit:
S0e = 0.5Sut = 0.5(85, 000 psi) = 42, 500 psi
k f = 2.70(85)−0.265 = 0.83 ks = 0.869(2)−0.112 = 0.8041
or Se = 28.43 ksi. From Eq. (11.37):
2 1/3
 s 
2
Sy Sy
 
32ns 3
d =  Mm + K Ma + Tm + K Ta 
π Sy Se f 4 Se f s
 s 1/3
2
Sy

=  32ns K Ma
3 2
+ Tm
π Sy Se f 4
 s 1/3
 2
=  32(3.0) 71
(1)(14, 400)
3
+ 67602 
π (71, 000) 28.43 4
= 2.50 in. (1)

2
 A 2.50 inch diameter. is acceptable; this could be marginally increased depending on the appli-
cation.

The following Matlab code is useful for the fatigue calculations:

ns=3;
Sy=71000;
Sut=85000;
MA=14400;
MM=0;
TM=6760;
TA=0;
Seprime=0.5*Sut;
kf=2.70*(Sut/1000)^-0.265;
d=2.5;
ks=0.869*d^-0.112;
Se=kf*ks*Seprime;
Kf=1;
d=(32*ns*sqrt((Sy*Kf*MA/Se)^2 + 3*TM^2/4)/pi/Sy)^(1/3);

11.40 The shaft shown in sketch d supports two gears. The shaft is made from high carbon steel (quenched
and tempered AISI 1080), and is to be designed with a safety factor of 2.0. The gears transmit a
constant torque caused by PA =2000 N acting vertically as shown. The shaft has a constant machined
cross-section.
(a) What is the reaction force on gear C? Ans. Pc = 4000 N.
(b) What is the critical location in the shaft? Ans. At bearing B.
(c) Using the Soderberg line, obtain the required shaft diameter. (Note: Ignore all endurance limit
modification factors except the surface finish factor.) Ans. d = 50 mm.
(d) One of the gears has been attached with a keyway, the other with a shrinkfit. Which gear was
attached with a keyway, and why?

600 mm

400 mm
0
200 mm

B PC (in z-direction)
z C
Gear A A
2
(600 mm diam)

x
Gear C
PA (in y-direction) (300 mm diam)

Sketch d, for Problem 11.40

Solution: For AISI 1080 steel, Su = 615 MPa and S y = 380 MPa.

3
(a) From torque equilibrium,

∑ T = 0 = PA (300 mm) − PC (150 mm)

or PC = 2PA = 4000 N.
(b) From statics, the following forces are obtained: Oy = −800 N, By = −1200 N, Oz = 800 N,
Bz = −4800 N. The shear and moment diagrams are as drawn. At location A, the moment in the
xy plane is 480 Nm, in the yz plane it is 480 Nm, so the vector sum is M = 678 Nm. At location
B, the moment is 800 Nm in the xz plane and zero in the xy plane. Therefore, we conclude the
critical section is at bearing B.
(c) For AISI 1080 steel, the inside front cover yields S y = 380 MPa and Su = 615 MPa. From
Eq. (7.19) and Table 7.3,
f
k f = eSu = (4.51)(615)−0.265 = 0.822
Since no other modification factors are to be considered, the endurance limit is obtained from
Eqs. (7.6) and (7.18), Se = 252.8 MPa.
The Soderberg relationship that yields shaft diameter is Eq. (11.34). Note that Mm = 0, Ma = 800
Nm, Ta = 0, Tm = 600 Nm, K f = 1 (because there are no geometry changes in the shaft).
Therefore, Eq. (11.31) gives:
 s 1/3
2 2
Sy Sy
 
32ns
d= Mm + K Ma + Tm + K f s Ta = 0.0416 m = 42 mm
Se f

π Sy Se

Therefore, specify a shaft with a diameter of 50 mm.

The following Matlab code is useful.
Sy=380e6;
Sut=615e6;
Pc=4000;
Mm=0;
Ma=800;
Ta=0;
Tm=600;
e=4.51;
f=-0.265;
kf=e*(Sut/1e6)^f;
ns=2;
Se=0.5*kf*Sut;
Kf=1;
Kfs=1;
d=(32*ns/pi/Sy*sqrt((Mm+Sy/Se*Kf*Ma)^2+(Tm+Sy/Se*Kfs*Ta)^2))^(1/3);
(d) Gear A is attached with a keyway, and Gear C with a shrink fit. It is unreasonable to try to slide
a gear more than one-half of a meter onto a shaft, but this can be done at the end of the shaft.

4
 y
x
x
2000 N 800 N 4800 N 4000 N
800 N 1200 N
z
V V

800 Nm
M M

480 Nm

11.41 The rotor shown in sketch e has a stiff bearing on the left. Find the critical speed when the shaft is
made of steel with E = 207 GPa. Ans. N = 3018 rpm.

ma = 100 kg
d = 80 mm

l = 500 mm

Sketch e, for Problem 11.41

Note: This is a single mass system; the critical speed is given by Eq. (11.52) as soon as the end deflec-
tion is determined. This is the most work in the problem; the approach is the same as in Ch. 5, or else
one can use the solution, readily available in Appendix D.1 as

Fl 3
ymax =
3EI

Solution: This is a single mass system, and the critical speed is given by Eq. (11.52) as
r
g
ω=
δ

δ is the maximum deflection of the beam, and for the system shown in the sketch, it is the deflection
caused by the 100 kg mass (981 N force). We need to derive the deflection of the cantilevered beam.

(a) Calculation of Mass Deflection. In case the cantilever deflection from the Appendix is not to
be used (discretion of the instructor), the deflection needs to be determined. The moment as a
function of x can be found from statics (and is left for the student to derive) as

M = −W ( l − x )

5
 Where W is the 981 N load at the free end and l is the beam length (500 mm or 0.5 m). From
Eq. (5.3),
d2 y M W (l − x)
2
= =−
dx EI EI
Integrating two successive times yields:
 
dy W 1
=− lx − x2 + A
dx EI 2
 
W 1 2 1 3
y=− lx − x + Ax + b
EI 2 6
The boundary conditions for a clamped end are that the slope and the displacement are zero;
therefore, A and B are zero. At x = l, which is the position of the mass and also of maximum
deflection,
Wl 3
 
W 1 3 1 3
y=− l − l =−
EI 2 6 3EI
Note that this could have been taken from the inside front cover. The negative sign indicates
the deflection is downwards; for determination of the critical frequency the absolute deflection
is used, so we use the value of δ = Wl 3 /3EI.
(b) Determination of Critical Frequency. From Eq. (11.52) and noting that W = mg and I = πd4 /64,
r r r s
g 3gEI 3Eπ d4 3(207 GPa)π (0.08 m)4
ω= = 3
= 3
= = 316 rad/s
δ Wl 64ml 64(100 kg)(0.5 m)3

The shaft speed is then calculated as

 
1
Na = (316 rad/s)(60 s/min) rev/rad = 3018 rpm
2π

The following Matlab code is useful.

ma=100;
g=9.81;
W=ma*g;
E=207e9;
d=0.08;
I=pi/64*d^4;
l=0.5;
delta=W*l^3/3/E/I;
omega=sqrt(g/delta);
Na=omega*60/2/pi;

11.45 Determine the first critical speed by the Dunkerley and Rayleigh methods for the steel shaft shown in
sketch i. Neglect the shaft mass. The area moment of inertia is I = πr4 /4, where r = shaft radius. The
method of superposition may be used with the following given:

bx3 xb(l 2 − b2 )
  
P 3
δ= − h x − ai −
6EI l l

Ans. NR = 708 rpm, ND = 673 rpm.

6
 120 lbm
80 lbm 2-in.-diam shaft

20 in. 40 in. 30 in.

Sketch i, for Problem 11.45

Solution:
(a) Calculation of Deflections. First of all, note that the loads are PA = 120 lb, PB = 80 lb, and
I = πd4 /64 = πr4 /4 in4 . To differentiate effects of the two loads, we will refer to deflections as
yi j where the deflection is at location i due to mass j. If we break the beam into two problems,
where only one mass exists, we get the following using deflection equations from Table 5.1:

Deflections at A
a) Use a = 20 in., b = 70 in., l = 90 in.,
P = 120 lb. Using x = 20 in gives the
deflection under gear A as y AA = 0.0367
in.
b) Use a = 60 in., b = 30 in., l = 90 in.,
P = 80 lb, x = 20 in. gives y AB = 0.0256
in.
Deflections at B
a) Use a = 20 in., b = 70 in., l = 90 in.,
P = 120 lb, x = 60 in., so that y BA =
0.0385 in.
b) Use a = 60 in., b = 30 in., l = 90
in., P = 80 lb, x = 60 in. so that y BB =
0.0407 in.

Therefore, y A = y AA + y AB = 0.0626 in. and y B = y BA + y BB = 0.0792 in.

The following Matlab code can be used for calculations using the equation given in the problem
statement:
P=80;
E=30e6;
d=2;
I=pi/64*d^4;
l=90;
a=60
b=l-a;
x=20;

delta1=b*x^3/l;

if x>a
delta2=-(x-a)^3;
else
delta2=0
end

delta3=-x*b*(l^2-b^2)/l;

delta=P/6/E/I*(delta1+delta2+delta3);

7
 (b) Rayleigh Method. Equation (11.59) gives the critical frequency as a function of load and deflec-
tions. For this case, Eq. (11.59) becomes:
s
g(WA δ A + WB δ B )
ωcr =
WA δ 2A + WB δ 2B
s
(386.4 in./s2 ) [(120lb)(0.0626 in.) + (80 lb)(0.0792 in.)]
=
(120 lb)(0.0626 in.)2 + (80 lb)(0.0792 in.)

This is solved as ωcr = 74.2 rad/s = 708 rpm.

(c) Dunkerly Method. Equations (11.60) and (11.52) combine to give the estimate of critical speed
as:
1 1 1 1 1 δ1 + δ2
= 2 + 2 = p 2 + p 2 =
ω2cr ω1 ω2 g
g/δ1 g/δ2

Therefore, r
g
ωcr =
δ1 + δ2
Substituting for δ1 and δ2 gives ωcr = 52.2 rad/s = 499 rpm.
The following Matlab code is helpful.

Wa=120;
Wb=80;
deltaa=0.0626;
deltab=0.0792;
g=32.2*12;
Rayleigh=sqrt(g*(Wa*deltaa+Wb*deltab)/(Wa*deltaa^2+Wb*deltab^2));
Dunkerly=sqrt(g/(deltaa+deltab));

11.55 The output torque of a flywheel for each revolution of a shaft is 10 N-m from 0 to π and 120 N-m
from π to 2π. The coefficient of fluctuation is 0.04 at an average speed of 2000 rpm. Assume that the
flywheel disk is an AISI 1040 steel plate of 25-mm constant thickness. Determine the following:
(a) Average load torque. Ans. 65 Nm.
(b) Locations θωmax and θωmin . Ans. θωmax = π
(c) Energy required. Ans. Ke = 172.8 Nm.
(d) Outside diameter of flywheel. Ans. d = 270 mm.
Solution:
The plot of torque as a function of phase from 0 to 2π is:

8
 160

120

Torque (N-m) 80

40

0
0 π 2π
Position (rad)

Since the intervals are equal, Tave is easily calculated as 65 N-m. If this torque is applied, the shaft
will accelerate over the 0 to π interval, and decelerate between π and 2π. Therefore, the maximum
angular velocity will be at π, the minimum at 2π. The energy needed is
Z 2π
Ke = ( T − Tave ) dφ = 55π = 172.8 N-m
π

The mass moment of inertia required is given by Eq. (11.82):

Ke 55π N-m
Im = = = 0.098 N-m sec2 = 0.098 kg-m2
C f ω2ave
 2
2π
(0.04) 2000 × sec−2
60

If the flywheel is a disk of thickness 0.025 m, and recognizing for steel ρ = 7850 kg/m3 ,

π d2 tm ρ d2
  
2
Im = 0.098 kg-m =
4 8

Solving for d,
32Im (32)(0.098)
d4 = =
π tm ρ π (0.025)(7850)
or d = 0.267 m = 267 mm. This can be rounded to 270 mm or another convenient dimension.
The following Matlab code is useful.

Cf=0.04;
Nave=2000;
omega_ave=Nave*2*pi/60
t=0.025;
rho=7850;
Ke=55*pi;
Im=Ke/Cf/omega_ave^2;
d=(32*Im/pi/t/rho)^(1/4);