Zagazig University 2nd year Mechanical Engineering

Faculty of Engineering Design of Machine Elements (DPE 224)

Mech. Design and Prod. Eng. Dept. Sheet 2: Static and Fatigue Failure
2nd term 2022-2023 Duration: Two Weeks
Useful unit conversion:
inch (in) = 25.4 millimeter (mm)
foot-pound (ft·lbf) = 1.35 N.m
kilopound (kip) = 4.45 kilonewton (kN)
kilopound/inch2 (kpsi, ksi) = 6.89 Megapascal (MPa)
Static Failure
1- A solid circular shaft is subjected to a torque 4520 N.m and a bending moment 9040 N.m. Assume
that the shaft is made from steel with yield strength in tension and compression are 210 MPa. What
should be the diameter of the shaft so that failure does not takes place by yielding according to both
maximum shear stress and distortion energy theories.

2- A circular pipe has 100 mm inside diameter and a 150 mm outside diameter. This pipe is subjected
to a torque 70 kN.m and a compressive force P. If the pipe is made from brittle material having an
ultimate compressive and tensile strengths of 250 MPa and 100 MPa, respectively. Determine the
maximum value of the compressive force P so that the pipe does not fail.

3- A thick-walled cylinder has an ID of 12.5 mm. It is made from a steel alloy having a yield strength
of 630 MPa. The cylinder must resist an internal pressure of 35 MPa. Based on a factor of safety of
at least 4 and using the maximum shear stress yielding theory, specify a satisfactory outside
diameter for the cylinder.

4- A lever, shown in Fig. P4, is subjected to a downward force of 1780N. It is keyed to a 25 mm round
bar. It is required to:
(a) Find the critical stresses in the round bar.
(b) If the material of the bar is steel having a yield strength of 1190 MPa. Find the factor of safety
by using the distortion energy theory.

F=1780 N

Fig. P4
225 mm

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5- A machine member, shown in Fig. P5 is made of AISI
1006 cold-drawn steel and is loaded by the forces
F=550 N, P=4000 N, and T=25 N.m. Calculate the
factor of safety using the distortion energy, maximum 15D
shear stress, and the maximum normal stress theories.
What are your comments about the obtained results? F
T
Fig. P5
P Dim. (mm)

6- An offset tensile link is shaped to clear an obstruction with a geometry as shown in Fig. P6 is made
from 1018CD steel. The cross section at the critical location is circular with 75mm diameter.
For a load of F= 90 kN, estimate the factor of safety using the distortion energy theory.
225

F F

Fig. P6

7- For the beam shown in Fig. P7, determine the minimum yield strength that should be considered
to obtain a minimum factor of safety of 2 based on the distortion energy theory.

25

500 N 2000 N/m

75
25

250 750 mm
75 mm

Fig. P7

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 Fatigue Failure
1- A steel bar has the following properties: 𝑆𝑢𝑡 = 560 MPa, 𝑆𝑦 = 420 MPa and 𝑆𝑒 = 280 MPa.
Determine the factor of safety guarding against both static and fatigue failure for each of the
following cases:

(a) 𝜏𝑚 = 105 MPa and 𝜎𝑎 = 175 MPa.

(b) 𝜏𝑎 = 105 MPa and 𝜎𝑚 = 105 MPa.
(c) 𝜏𝑚 = 140 MPa and 𝜏𝑎 = 175 MPa.
(d) 𝜏𝑎 = 210 MPa.
(e) 𝜏𝑚 = 105 MPa, 𝜏𝑎 = 70 MPa and 𝜎𝑎 = 84 MPa.

2- A portion of machine member is shown in the Fig. PF2. It is loaded by a completely reversed axial
force F. The member is made of steel having both ultimate and yield strengths of 448 MPa and 280
MPa, respectively. For 90% reliability, find the maximum force F that can be applied for infinite
life.

Φ12
25 mm

F F
Fig. PF2

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3- The machine element shown in Fig. PF3. It is loaded by completely reversed axial force F=4450
N. It is made of steel having both ultimate and yield strengths of 560 MPa and 420 MPa,
respectively. Find the fatigue factor of safety.

R=3/16"
2.25"

Φ3/4"
1.5"

F F
Fig. PF3

1/4"

4- A short rectangular link rod, shown in Fig. PF4 is loaded by the force F acting upon the pins at each
end. The force varies from 70 to 30 kN. The rod’ material has ultimate strength of 1010 MPa and
all surfaces are finished by grinding. Based on an infinite life and reliability of 99.999%, in addition
to a factor of safety of 1.35, find the thickness t.

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 F F

t
F F
Pin
Fig. PF4

36 mm
10 Φ

5- A latching spring of a 3mm by 18mm, shown in

Fig. PF5. A preload is obtained during assembly by
shimming under the bolts to obtain an estimated
initial deflection of 2 mm. Each latching operation
itself requires an additional deflection of exactly 4
mm. The material is high-carbon steel with an
ultimate strength of 1715 MPa and machined. The
radius of the bend is 3 mm with a corresponding
Dim. (mm)
stress concentration factor of 1.7. It is required to
(a) Find the maximum and minimum latching Fig. PF5
force F.
(b) Is it likely the spring will fail in fatigue? Why?

6- A rotating shaft, shown in Fig. PF6, is loaded by completely reversed bending by a constant force
F=400ib (1779.3 N). It is made of steel having an ultimate strength of 188 kpsi (1296 MPa). With
a ground finish in the critical places and based on an infinite life, find the fatigue factor of safety.

3" F
R=1/16"
Φ1.125"

R2 R1
Φ7/8"

1" 6" 6" 1"

Fig. PF6

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7- A steel shaft, illustrated in Fig. PF7, is supported in bearings at R1 and R2 and loaded by completely
reversed bending and by static torsion. The shaft material has ultimate and yield strengths of 220
kpsi (1517 MPa) and 180 kpsi (1241 MPa), respectively, and has ground finish. Find the factor of
safety based on the possibility of fatigue failure for an infinite life at 90% reliability.

F2
2" F1
2"
3/4" D

3/4" D
3/32" R

1.125" D

7/8" D
R2 R1
T
3/8" T=1200 ib.in
3/4"
6.625" 8.625"

Fig. PF7

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