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Solution

1. An Overview of Machine Design

1-4
Solution:
Manufacturing process Design problems Design revisions

Ununiform wall thickness may cause

(a) Casting
casting defects.

A rib in the element makes forging

(b) Forging
difficult.

A sharp corner may cause stress

(c) Heat treatment
concentration and cracks.

(d) Assembly A chamfer facilitates assembly.

better best

2. Strength of Machine Elements

Objective questions
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2-1 c
2-2 c
2-3 d
2-4 b
2-5 d
Calculation questions
2-1
Solution:
Steps Computation Results Units
1.Decide the  σmax=400 MPa
maximum, minimum From r = min , and  m =  max +  min
 max 2
and stress amplitude
of the fluctuating We have σmin=100 MPa
stress  max = 400 MPa, and  min = 100MPa
Finally,
 max −  min 400 - 100
a = = = 150 σa=150 MPa
2 2 MPa
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Solution
2.Draw a σ-t curve
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Figure S2-1 Solution for Calculation question 2-1

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2-2
Solution:
Steps Computation Results Units
1. When N=60000  m N =  rm N0 ,
Since rN
σrN=326.93 MPa
Therefore,
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N0 5  106
 rN =  −1 m = 200  9 = 326.93 MPa
N 60000
2.When N=600000 N0 5  106 σrN=253.13 MPa
 rN =  −1 m = 200  9 = 253.13
N 600000 MPa
3.When N=6000000 Since N=6000000>5×106, σrN =200 MPa. σrN=200 MPa
5599

2-3
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Steps Computation Results Units
1.Find out the safety Since σ0=692.3 MPa
@

factor from the 2 −  0

@

  = −1
diagram 0
so
 0 = 692.3MPa .
Working stress:
ggm

σm=100 MPa
 max +  min 280 − 80
m = = = 100 σa=180 MPa
2 2
 − 280 + 80
 a = max min = = 180
maa

2 2
The coordinates of important points are:
A (0, σ-1), E (σs,0), C(σ0/2, σ0/2), A1(0, σ-1/Kσ),
C1(σ0/2, σ0/2Kσ), M(σm, σa)
Substitute the data in the question, we have
A (0, 450), E (800,0), C(346.15, 346.15), A1(0,
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450/1.62), C1(346.15, 213.7), M (100,180)

The simplified σm- σa diagram of the material is
the lines ACGE.
The simplified σm- σa diagram of the element is
the lines A1C1G1E.
oom
m
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Solution

Figure S2-2 Solution for Calculation question

2-3
The safety factor measured from the diagram is S= 1.38
OM 1
S= = 1.38  1.3 = [ S ]
OM
Therefore, the shaft is safe.
2. Calculate the safety The safety factor for fatigue strength: Sca = 1.4
factor of the shaft  -1 450
Sca = = = 1.4  [ S ] = 1.3
K  a +   m 1.62  180 + 0.3  100
The safety factor for static strength:
s 800
Sca = = = 2.86  [ S ] = 1.3
 max 280
Therefore, the shaft is safe.
3. Revise the design Increase the fillet radius to reduce stress
of the fillet radius concentration, and the fatigue strength of the
shaft will be improved.

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Solution:
Steps Computation Results Units
1.Draw a simplified  max +  min 300 − 100 σm=100 MPa
m = = = 100MPa
σm -σa diagram of the 2 2 σa=200 MPa
shaft material  max −  min 300 + 100
a = = = 200MPa
2 2
 −1 450
= = 300MPa
K 1.5
0 700
= = 233.3MPa
2 K  2  1.5
The coordinates of important points are:
A (0, σ-1), E (σs,0), C(σ0/2, σ0/2), A1(0, σ-1/Kσ),
C1(σ0/2, σ0/2Kσ), M(σm, σa)
Substitute the data in the question, we have
A (0, 450), E (800,0), C(350, 350), A1(0, 300),
C1(350, 233.3), M (100, 200),
The simplified σm- σa diagram of the material is
the lines ACGE.
The simplified σm- σa diagram of the element is
the lines A1C1G1E.
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Solution
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Figure S2-3 Solution for Calculation question

2-4
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2.The safety factor From the diagram S= 1.34
measured from the OM 1
S= = 1.34  1.3 = [ S ]
OM
diagram
3. Fatigue strength by 2 −1 −  0 2  450 − 700 Sca= 1.37
 = = = 0.286
calculation 0 700
 −1 450
Sca = =
K  a +    m 1.5  200 + 0.286  100
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450
= = 1.37  S = 1.25
300 + 28.6
Static strength by calculation:
s 800
S ca = = = 2.66  S = 1.25
 max 300
The shaft is safe.
5599

4. Possible failure Fatigue

mode of the shaft
complete 5. Methods
document is toavailableToon
reduce stress concentration;
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improve the fatigue To improve surface quality;
strength of the shaft To use high strength material.
@

2-5
@

Solution:
Steps Computation Results Units
1. Calculate the From Eq.2-41, Sca=1.16
safety factor N0
ggm

S ca =  −1 z
m
n 
i =1
m
i i
maa

10 7
= 300  9 = 1 .1 6
4 9 5
10  500 + 10  400 9 + 10 5  350 9
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oom
m