SYLLABUS

MODULE-3
Design against Fluctuating Loads: Variable stresses - reversed,
repeated, fluctuating stresses. Fatigue failure: static and fatigue
stress concentration factors, Endurance limit estimation of
endurance limit, Design for finite and infinite life, Soderberg and
Goodman design criteria, Fatigue design under combined stresses

Pre-requisite: Knowledge of
1. Strength of Materials
2. Material Technology
 Module-3:Design against fluctuating loads
RR MOORE REVERSIBLE BENDING BEAM TEST
 Module-3:Design against fluctuating loads
RR MOORE REVERSIBLE BENDING BEAM TEST
Module-3:Design against fluctuating loads
Module-3:Design against fluctuating loads
Module-3:Design against fluctuating loads
Module-3:Design against fluctuating loads
S-N CURVE
Module-3:Design against fluctuating loads
S-N CURVE(LOG GRAPH)
 Module-3:Design against fluctuating loads
STRESS CONCENTRATION AND STRESS CONCENTRATION FACTOR

Geometric discontinuities cause an object to experience a localised increase in stress.

Examples of shapes that cause stress concentrations are sharp internal corners, holes,
and sudden changes in the cross-sectional area of the object as well as unintentional
damage such as nicks, scratches and cracks.
 Module-3:Design against fluctuating loads
STRESS CONCENTRATION AND STRESS CONCENTRATION FACTOR

Geometric discontinuities cause an object to experience a localised increase in stress.

Causes of stress concentration
• Variation in Properties of Materials
• Load Application
• Abrupt Changes in Section
• Discontinuities in the Component
• Machining Scratches
Module-3:Design against fluctuating loads
THEORATICAL STRESS CONCENTRATION FACTOR
Module-3:Design against fluctuating loads
FATIGUE STRESS CONCENTRATION FACTOR
Module-3:Design against fluctuating loads
NOTCH SENSITIVITY
 Module-3:Design against fluctuating loads
RELATION BETWEEN ENDURANCE LIMIT AND ULTIMATE STRENGHT
 Module-3:Design against fluctuating loads
FACTORS EFFECTING ENDURANCE LIMIT FOR DESIGN
Load Factor
Surface Finish Factor
Size Factor
Reliability factor
Stress concentration factor
 Module-3:Design against fluctuating loads
FACTORS EFFECTING ENDURANCE LIMIT FOR DESIGN

• Load Factor
• Surface Finish Factor
• Size Factor
• Reliability factor
• Effect of Stress concentration

• Load Factor

For bending load

For axial load

For Torsional load

 Module-3:Design against fluctuating loads
FACTORS EFFECTING ENDURANCE LIMIT FOR DESIGN

• Surface Finish Factor

 Module-3:Design against fluctuating loads
FACTORS EFFECTING ENDURANCE LIMIT FOR DESIGN

• Surface Finish Factor

 Module-3:Design against fluctuating loads
FACTORS EFFECTING ENDURANCE LIMIT FOR DESIGN

• Size Factor
 Module-3:Design against fluctuating loads
FACTORS EFFECTING ENDURANCE LIMIT FOR DESIGN

• Reliability factor
 Module-3:Design against fluctuating loads

Effect of Stress concentration

Module-3:Design against fluctuating loads
THOERY OF FATIGUE FAILURE
Module-3:Design against fluctuating loads
 Module-3:Design against fluctuating loads
PROBLEM ON INFINITE LIFE

P.1 A component machined from a plate made of steel 45C8 (σut = 630 N/mm2) is shown
in Fig. It is subjected to a completely reversed axial force of 50 kN. The expected
reliability is 90% and the factor of safety is 2. Determine the plate thickness t for infinite
life.
 Module-3:Design against fluctuating loads
PROBLEM ON INFINITE LIFE
 Module-3:Design against fluctuating loads
PROBLEM ON INFINITE LIFE
 Module-3:Design against fluctuating loads
PROBLEM ON FINITE LIFE

A rotating shaft, subjected to a non rotating force of 5 kN and simply supported between
two bearings A and E is shown in Fig. The shaft is machined from plain carbon steel 30C8
(Sut = 500 N/mm2) and the expected reliability is 90%. The equivalent notch radius at the
fillet section can be taken as 3 mm. What is the life of the shaft?
 Module-3:Design against fluctuating loads
PROBLEM ON FINITE LIFE
 Module-3:Design against fluctuating loads
PROBLEM ON FINITE LIFE
 Module-3:Design against fluctuating loads
PROBLEM ON FINITE LIFE
 Module-3:Design against fluctuating loads
PROBLEM ON FINITE LIFE
 Module-3:Design against fluctuating loads
PROBLEM ON FINITE LIFE

3 6
 Module-3:Design against fluctuating loads
PROBLEM ON THOERY OF FATIGUE FAILURE
A solid circular shaft, 15 mm in diameter, is subjected to bending stress,
which varies from 0 to 35 N/mm2 and at the same time, is subjected to an
axial stress that varies from –15 to +30 N/mm2. The frequency of variation of
these stresses is equal to the shaft speed. The shaft is made of steel FeE
400 (Sut= 540 N/mm2 and Syt = 400 N/mm2) and the corrected endurance limit
of the shaft is 200 N/mm2. Determine the factor of safety.
Module-3:Design against fluctuating loads
Module-3:Design against fluctuating loads
 Module-4: Design of Shaft

Types of transmission shafts

Axle Counter shaft

Jack shaft Line shaft

Spindle
 Module-4: Design of Shaft
Shaft designing Basis

1.SHAFT DESIGN ON STRENGTH BASIS

Module-4: Design of Shaft
Shaft designing Basis
Module-4: Design of Shaft
Shaft designing Basis
 Module-4: Design of Shaft
Shaft designing Basis

2.SHAFT DESIGN ON TORSIONAL RIGIDITY BASIS

 Module-4: Design of Shaft
Shaft designing Basis

3.ASME CODE FOR SHAFT DESIGN

 Module-4: Design of Shaft
Shaft designing Basis

3.ASME CODE FOR SHAFT DESIGN

Module-4: Design of Shaft
Module-4: Design of Shaft
 Module-4: Design of Shaft

Shaft with Belt analysis

 Module-4: Design of Shaft

Shaft with Gear analysis

 Module-4: Design of Shaft

Shaft with Gear analysis

 Module-4: Design of Shaft
P1.A line shaft is driven by means of a motor placed vertically below it. The pulley
on the line shaft is 1.5 metre in diameter and has belt tensions 5.4 kN and 1.8 kN
on the tight side and slack side of the belt respectively. Both these tensions may be
assumed to be vertical. If the pulley be overhang from the shaft, the distance of
the centre line of the pulley from the centre line of the bearing being 400 mm, find
the diameter of the shaft. Select appropriate material and other parameter.
Module-4: Design of Shaft
 Module-4: Design of Shaft
P.2.Design the hollow shaft from strength and rigidity considerations with
following data
• Power to be transmitted =50 kW AT 1440 r.p.m
• Ratio of inner to outer diameter =0.5
• Overhang =250
• Bending load =18 kn
• Permissible angle of twist=0.5 °
Select suitable materials
Module-4: Design of Shaft
Module-4: Design of Shaft
 Module-4: Design of Shaft
P.3 A shaft is supported in bearings A and B 1000 mm apart. An involute gear having
PCD of 400 mm is located 300 mm to the right of LH bearing and 600 mm diameter
pulley is mounted 350 mm to the left of RH bearing. The gear is driven by a pinion
located vertically above, while the pulley transmits power via belt to a pulley located
vertically below. The ratio of belt tensions is 2. The pulley weigh 2500 N. Design the
shaft, if power transmitted is 30 KW at 400 rpm. The shaft rotates clockwise when
viewed from left side.Take pressure angle of gear 20 degree.

GEAR PULLEY
 Module-4: Design of Shaft

LH GEAR PULLEY

RH
Module-4: Design of Shaft
Module-4: Design of Shaft
Module-4: Design of Shaft
 Module-4: Design of Shaft
P.4 A shaft is supported by two bearing placed 1.5 m apart .A 450 mm diameter flat
belt pulley is mounted at distance of 350 mm to the right of L.H bearings and drives a
pulley directly below it with help of flat belt having tension on the tight side of 2.8
kN . Another V-groove pulley 300 mm P.C.D is placed 300 mm to the left of RH
bearing and is driven with help of electric motor and V-belt. The motor is placed
horizontally in front .The angle of contact of both pulley is 180° and μ =0.25 ,The
angle of V-groove is 35° .Select suitable material for the shaft and determine the
diameter of the shaft What Will be the diameter of the shaft if it is a hollow shaft
with diameter ratio 0.57 ? Which one will you prefer? Comment on it
Module-4: Design of Shaft
Module-4: Design of Shaft