Tut 1 CH 6

INSTITUTE OF ENGINEERING
THAPATHALI CAMPUS
DEPARTMENT OF AUTOMOBILE AND
MECHANICAL ENGINEERING
MACHINE DESIGN I
[TUTORIAL SHEETS]
AUTOMOBILE & MECHANICAL (III/I & III/II)
Prepared by: Lecturer Sunil Adhikari

TUTORIAL 1
FATIGUE FAILURE
6.1 A 10-mm drill rod was heat-treated and ground. The measured hardness was found to be 300
Brinell. Estimate the endurance strength in MPa if the rod is used in rotating bending.
6.3 A steel rotating-beam test specimen has an ultimate strength of 840 MPa. Estimate the life of
the specimen if it is tested at a completely reversed stress amplitude of 490 MPa.
6.5 A steel rotating-beam test specimen has an ultimate strength of 1610 MPa. Estimate the
fatigue strength corresponding to a life of 150 kcycles of stress reversal.
6.9 For the interval 103 ≤ N ≤ 106 cycles, develop an expression for the axial fatigue strength
(S’f)ax for the polished specimens of 4130 used to obtain Fig. 6–10. The ultimate strength is Sut =
875 MPa and the endurance limit is (Se’)ax = 350 MPa.
6.15 A solid round bar with diameter of 50 mm has a groove cut to a diameter of 45 mm, with a
radius of 2.5 mm. The bar is not rotating. The bar is loaded with a repeated bending load that
causes the bending moment at the groove to fluctuate between 0 and 2825 N.m. The bar is hot-
rolled AISI 1095, but the groove has been machined. Determine the factor of safety for fatigue
based on infinite life and the factor of safety for yielding.
6.17 The shaft shown in the figure is machined from AISI 1040 CD steel. The shaft rotates at
1600 rpm and is supported in rolling bearings at A and B. The applied forces are F1 = 10 kN and
F2 = 4 kN. Determine the minimum fatigue factor of safety based on achieving infinite life. If
infinite life is not predicted, estimate the number of cycles to failure. Also check for yielding.
(dimensions are in mm)
6.20 A bar of steel has the minimum properties Se = 276 MPa, Sy = 413 MPa, and Sut = 551 MPa.
The bar is subjected to a steady torsional stress of 103 MPa and an alternating bending stress of
172 MPa. Find the factor of safety guarding against a static failure, and either the factor of safety
guarding against a fatigue failure or the expected life of the part. For the fatigue analysis use:
(a) Modified Goodman criterion.
(b) Gerber criterion.

(c) ASME-elliptic criterion.
6.24 Repeat Prob. 6–20 but with an alternating torsional stress of 103 MPa and a steady bending
stress of 103 MPa.
6.25 The cold-drawn AISI 1040 steel bar shown in the figure is subjected to a completely
reversed axial load fluctuating between 28 kN in compression to 28 kN in tension. Estimate the
fatigue factor of safety based on achieving infinite life and the yielding factor of safety. If
infinite life is not predicted, estimate the number of cycles to failure.
6.30 The figure shows the free-body diagram of a connecting-link portion having stress
concentration at three sections. The dimensions are r = 6 mm, d = 20 mm, h = 12 mm, w1 = 90
mm, and w2 = 60 mm. The forces F fluctuate between a tension of 18 kN and a compression of
72 kN. Neglect column action and find the least factor of safety if the material is cold-drawn
AISI 1018 steel.
6.33 The torsional coupling in the figure is composed of a curved beam of square cross section
that is welded to an input shaft and output plate. A torque is applied to the shaft and cycles from
zero to T. The cross section of the beam has dimensions of 5 × 5 mm, and the centroidal axis of
the beam describes a curve of the form r = 0.75 + 0.4375 θ/π, where r and θ are in mm and
radians, respectively (0 ≤ θ ≤ 4π). The curved beam has a machined surface with yield and
ultimate strength valuesof 420 and 770 MPa, respectively.
(a)Determine the maximum allowable value of T such that the coupling will have an infinite life
with a factor of safety, n = 3, using the modified Goodman criterion.
(b) Repeat part (a) using the Gerber criterion.
(c) Using T found in part (b), determine the factor of safety guarding against yield.

6.35 A part is loaded with a combination of bending, axial, and torsion such that the following
stresses are created at a particular location:
Bending: Completely reversed, with a maximum stress of 60 MPa
Axial: Constant stress of 20 MPa
Torsion: Repeated load, varying from 0 MPa to 50 MPa
Assume the varying stresses are in phase with each other. The part contains a notch such that
Kf,bending = 1.4, Kf,axial = 1.1, and Kf,torsion = 2.0. The material properties are Sy = 300 MPa and Su
= 400 MPa. The completely adjusted endurance limit is found to be Se = 200 MPa. Find the
factor of safety for fatigue based on infinite life. If the life is not infinite, estimate the number of
cycles. Be sure to check for yielding.
6.38 A countershaft carrying two V-belt pulleys is shown in the figure. Pulley A receives power
from a motor through a belt with the belt tensions shown. The power is transmitted through the
shaft and delivered to the belt on pulley B. Assume the belt tension on the loose side at B is 15
percent of the tension on the tight side. Determine the minimum factor of safety for fatigue based
on infinite life, using the modified Goodman criterion. The shaft rotates at a constant speed, has
a constant diameter, and is made from cold-drawn AISI 1018 steel.

6.57 A schematic of a clutch-testing machine is shown in figure 4. The steel shaft rotates at a
constant speed ω. An axial load is applied to the shaft and is cycled from zero to P. The torque T
induced by the clutch face onto the shaft is given by
T=(fP(D+d))/4
where D and d are defined in the figure and f is the coefficient of friction of the clutch face. The
shaft is machined with Sy=800 MPa and Sut=1000 MPa. The theoretical stress-concentration
factors for the fillet are 3.0 and 1.8 for the axial and torsional loading, respectively. Assume the
load variation P is synchronous with shaft rotation. With f = 0.3, find the maximum allowable
load P such that the shaft will survive a minimum of 106 cycles with a factor of safety of 3. Use
the modified Goodman criterion. Determine the corresponding factor of safety guarding against
yielding.

Answers
6.1 Se= 434 MPa, 6.3 N =117000 cycles, 6.5 Sf = 990.8 MPa, 6.9 (Sf)ax =1379.4 N-0.0851 MPa for
103 ≤ N ≤ 106 cycles, 6.15 nf =0.71, ny =1.46, 6.17 nf =0.46, N =2700 cycles, 6.20 ny = 1.67 (a) nf
= 1.06, (b) nf =1.31, (c) nf = 1.32, 6.24 ny = 2.0 (a) nf =1.20, (b) nf =1.44, (c) nf = 1.44, 6.25 ny =
3.3, using goodman: nf = 0.64, N =34000 cycles 6.30 The design is controlled by fatigue at the
hole, nf = 1.38, 6.33 (a) T = 3.22 N.m, (b) T = 3.96 N.m, (c) ny = 2.03 6.35 nf = 1.21, ny = 1.43
6.38 nf = 0.56, 6.46 nf = 6.18 6.47 nf = 1.50, 5.51 nf = 0.53, N = 18 cycles, 6.57 P = 17.6kN, ny =
5.10.

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INSTITUTE OF ENGINEERING

DEPARTMENT OF AUTOMOBILE AND

AUTOMOBILE & MECHANICAL (III/I & III/II)

Prepared by: Lecturer Sunil Adhikari

Prepared by: Lecturer Sunil Adhikari

Prepared by: Lecturer Sunil Adhikari

Prepared by: Lecturer Sunil Adhikari

Prepared by: Lecturer Sunil Adhikari

Prepared by: Lecturer Sunil Adhikari

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