FORMULA Machine Design

FORMULA DEFINITION
Stress P = Force or load acting on a body, and

σ = P/A A = Cross-sectional area of the body.
In S.I. units - Pascal (Pa) such that 1 Pa = 1 N/m2.
1 MPa = 1 × 106 N/m2 = 1 N/mm and
1 GPa = 1 × 109 N/m2 = 1 kN/mm2
Strain δl = Change in length of the body, and
ε = δl / l or δl = ε.l l = Original length of the body
Tensile stress P = Axial tensile force acting on the body,

σt = P/A A = Cross-sectional area of the body,
Tensile strain l = Original length, and
ε t = δl / l δl = Increase in length.
Compressive stress the stress induced at any
σc = P/A section of the body
Compressive Strain
εc = δl/l
Hooke’s law
σ ∝ε or σ = E.ε
Shear stress,
area resisting the shear off the rivet
shear stress on the rivet cross-section
double shear when the shearing takes

place at two cross-sections
of the rivet
and shear stress on the rivet cross-
section
Shear Modulus or Modulus of τ = Shear stress,

Rigidity φ = Shear strain, and
C = Constant of proportionality, known as
τ ∝ φ or τ = C . φ or τ / φ = C shear modulus or modulus
of rigidity. It is also denoted by N or G.
Bearing Stress/ Crushing stress d = Diameter of the rivet, A localised compressive
t = Thickness of the plate, stress at the surface of
d.t = Projected area of the rivet, and contact between two
n = Number of rivets per pitch length in members of a machine
bearing or crushing. part, that are relatively at
rest
the average bearing pb = Average bearing pressure,

pressure for a journal supported in a P = Radial load on the journal,
bearing l = Length of the journal in contact, and
d = Diameter of the journal.
Stresses in Composite Bars P1 = Load carried by bar 1,

A1 = Cross-sectional area of bar 1,
P = P1 + P2 (1) σ1 = Stress produced in bar 1,
E1 = Young's modulus of bar 1,
P2, A2, σ2, E2 = Corresponding values of
bar 2,
P = Total load on the composite bar,
l = Length of the composite bar, and
δl = Elongation of the composite bar.
1. A coil chain of a crane required to carry a maximum load of 50 kN, is shown in Fig. 4.3.
Fig 4.3
Find the diameter of the link stock, if the permissible tensile stress in the link material is not to exceed 75 MPa.
2. A cast iron link, as shown in Fig. 4.4, is required to transmit a steady tensile load of 45 kN. Find the tensile
stress induced in the link material at sections A-A and B-B.
3. A hydraulic press exerts a total load of 3.5 MN. This load is carried by two steel rods, supporting the upper
head of the press. If the safe stress is 85 MPa and E = 210 kN/mm2,
find :
1. diameter of the rods, and
2. extension in each rod in a length of 2.5 m.
4. A rectangular base plate is fixed at each of its four corners by a 20 mm diameter bolt and nut as shown in
Fig. 4.5. The plate rests on washers of 22 mm internal diameter and 50 mm external diameter. Copper washers
which are placed between the nut and the plate are of 22 mm internal diameter and 44 mm external diameter.
5. The piston rod of a steam engine is 50 mm in diameter and 600 mm long. The diameter of the piston is 400
mm and the maximum steam pressure is 0.9 N/mm2. Find the compression of the piston rod if the Young's
modulus for the material of the piston rod is 210 kN/mm2.
6. Calculate the force required to punch a circular blank of 60 mm diameter in a plate of 5 mm thick. The
ultimate shear stress of the plate is 350 N/mm2.
7. A pull of 80 kN is transmitted from a bar X to the bar Y through a pin as shown in Fig. 4.8.
If the maximum permissible tensile stress in the bars is 100 N/mm2 and the permissible shear stress in the pin is
80 N/mm2, find the diameter of bars and of the pin.
8. Two plates 16 mm thick are

joined by a double riveted lap joint as shown in
Fig. 4.11. The rivets are 25 mm in diameter.
Find the crushing stress induced between
the plates and the rivet, if the maximum tensile
load on the joint is 48 kN.
Solution. Given : t = 16 mm ; d = 25 mm ;
P = 48 kN = 48 × 103 N
9. A journal 25 mm in diameter supported in sliding bearings has a maximum end reaction of 2500 N. Assuming an
allowable bearing pressure of 5 N/mm2, find the length of the sliding bearing.
10 .A mild steel rod of 12 mm diameter was tested for tensile strength with the gauge length of 60 mm. Following
observations were recorded :
Final length = 80 mm; Final diameter = 7 mm; Yield load = 3.4 kN and Ultimate load = 6.1 kN.
Calculate : 1. yield stress, 2. ultimate tensile stress, 3. percentage reduction in area, and
4. percentage elongation.
11. A bar 3 m long is made of two bars, one of copper having E = 105 GN/m2 and the other of steel having E =
210 GN/m2. Each bar is 25 mm broad and 12.5 mm thick. This compound bar is stretched by a load of 50 kN.
Find the increase in length of the compound bar and the stress produced in the steel and copper. The length of
copper as well as of steel bar is 3 m each.
12. A central steel rod 18 mm diameter passes through a copper tube 24 mm inside and 40 mm outside
diameter, as shown in Fig. 4.15. It is provided with nuts and washers at each end. The nuts are tightened until a
stress of 10 MPa is set up in the steel.
13. A thin steel tyre is shrunk on to a locomotive wheel of 1.2 m diameter. Find the internal diameter of the tyre
if after shrinking on, the hoop stress in the tyre is 100 MPa. Assume E = 200 kN/mm2. Find also the least
temperature to which the tyre must be heated above that of the wheel before it could be slipped on. The
coefficient of linear expansion for the tyre is 6.5 × 10–6 per °C.
Solution. Given : D = 1.2 m = 1200 mm ; σ = 100 MPa = 100 N/mm2 ; E = 200 kN/mm2
= 200 × 103 N/mm2 ; α = 6.5 × 10–6 per °C
14. A composite bar made of aluminium and steel is held between the supports as shown in Fig. 4.16. The bars
are stress free at a temperature of 37°C. What will be the stress in the two bars when the temperature is 20°C,
if (a) the supports are unyielding; and (b) the supports yield and come nearer to each other by 0.10 mm?
It can be assumed that the change of temperature is uniform all along the length of the bar.
Take Es = 210 GPa ; Ea = 74 GPa ;
αs= 11.7 × 10–6 / °C ; and αa = 23.4 × 10–6 / °C.
15. A copper bar 50 mm in diameter is placed within a steel tube 75 mm external diameter and 50 mm internal
diameter of exactly the same length. The two pieces are rigidly fixed together by two pins 18 mm in diameter,
one at each end passing through the bar and tube. Calculate
the stress induced in the copper bar, steel tube and pins if the temperature of the combination is
raised by 50°C.
Take Es= 210 GN/m2 ; Ec = 105 GN/m2 ; αs= 11.5 × 10–6/°C and αc = 17 × 10–6/°C.
16. A mild steel rod supports a tensile load of 50 kN. If the stress in the rod is limited to 100 MPa, find the size
of the rod when the cross-section is 1. circular, 2. square, and 3. rectangular with width = 3 × thickness.
17. A steel bar 2.4 m long and 30 mm square is elongated by a load of 500 kN. If poisson's ratio is 0.25, find the
increase in volume. Take E = 0.2 × 106 N/mm2.
18. An unknown weight falls through 10 mm on a collar rigidly attached to the lower end of a vertical bar 3 m
long and 600 mm2 in section. If the maximum instantaneous extension is known to be 2 mm, what is the
corresponding stress and the value of unknown weight? Take E = 200 kN/mm2.
19 . A wrought iron bar 50 mm in diameter and 2.5 m long transmits a shock energy of 100 N-m. Find the
maximum instantaneous stress and the elongation. Take E = 200 GN/m2.

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FORMULA DEFINITION

Stress P = Force or load acting on a body, and

Tensile stress P = Axial tensile force acting on the body,

area resisting the shear off the rivet

shear stress on the rivet cross-section

double shear when the shearing takes

Shear Modulus or Modulus of τ = Shear stress,

the average bearing pb = Average bearing pressure,

Stresses in Composite Bars P1 = Load carried by bar 1,

8. Two plates 16 mm thick are

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