eandy Stresses & Varlable Stresses in Machine Mombers www.srbooks.org 1.

183

K,=1tq(K,-1) [Refer PSG DB Py No. 7.6|l

|K.M D.B Pg. No. 23|
When q=0, K,=l
When q= 1.0, K,= K,
When K, is given and q=1, then K,= K,
1.37. MODIFIED GOODMAN'S DIAGRAM [For brittle materials]
Explain the modified Goodman diagram for bending stresses.
The components which are subjected to fluctuating stresses are designed
by constructing the modified Goodman's diagram.
The problems are classified into two groups.
1 Components subjected to axial (or) bending stresses due to fluctuating
force (or) bending moment.
2
Components subjected to fluctuating torsional shear stresses.

Separate diagrams are used in these two cases.

The modified Goodman diagram for axial or bending stresses is shown

in Fig. 1.35.
and a line
The is plotted on both the axes (abscissa and ordinate)
yielding.
is constructed to join these points to define failure by
the abscissa,
t A line is constructed to join o_ on ordinate with g,, on
which is the Goodman line.
lines is B'.
The point of intersection of these two
components subjected
The area OABC represents the region of safety for
to fluctuating loads.
is constructed.
While solving a problem, a line OE with slope tan 0

tan =
 www.airwalkbook..
Elements -
1.184 Design of Machine

Failure by
yielding

o.1
Om
Goodman line

fa

Cyt C Cut Cm
Im Fig. 1.35

load
P,= Amplitude of variable
Oa P/A Pa = Mean load.
P/A Pm of
f. f are the limiting values
Permissible stresses oa stresses which are used to calculaie
FOS the dimensions of the component.

Om FOS
(VARIABLE)LOADING
FOR FATIGUE
1.38. DESIGN EQUATIONS
machine member
(a) Endurance limit of the
Þ_ABC

Where Endurance limit of the specimen

A = Load correction factor
1for reversed bending
0.7 for eversed axial loading
0.6 for reversed torsion
 Steady Stresses & Variable Stresses in Machine Members www.srbooks.org 1.185

B Size factor
0.85 for parts of size 12.5 mm to 50 mm
C =
Surface finish factor
0.9 for ground or cold rolled surface
0.7 to 0.85 for machined surface
0.3 to 0.7 for hot rolled surface
K = Fatigue stress concentration factor

Note: Factor A is used to modify the flexural endurance limit usable for torsion
or axial loading problems.
(b) Using Fig 1.31, the following equations are obtained.

1 Oa .... (2)
for ductile materials.
, (o)m

4
for ductile materials subjected to torsional loading: (3)

Similarly.
.... (4)
-= KOm
1
for brittle materials.
(6_Da
n= Factor of safety
K, = Theoetical stress concentration factor
(t ).=Endurance limit in reversed torsion
-,BC

I1 , is not known, Ao_, is used.

(c)Equivalent Static Stresses-Bending / Axial Loading
Eqn. (2) is multiplied by , on both sides.
... (5)
(0_m
 www..
Elements - aiwalkb00ks.con
1.186 stress
Design of Machine
equivalent
static
problem. We may
and he
The RH side can be considered as anloading wrile
LH side is the permissible stress for a static
, Oa
(0_m
(or) o, S[o]
For safety, °eq
tensile stress
Where [¡] = Permissible
Torsional Loading
Tay
Teg m( m
eg S
Design equation, to [|
=Permissible shear stress
Where [t]
available, take , =0.6 ,
If , is not
Loading (Bending and Torsion)
1.38.1. Combined

eg

based on principal stress theory,

Designequation is, o, S[o],

+ s[tJ
'max

Tmar S[T], based on shear stress theory,

Design equation is,

Where [ t]= 0.5y n

1.38.2. Design for Finite Life

calculated by using e
The fatigue strength for finite life is
G,=10°(w
o,= Fatigue strength for finite life
 Stresss Vi

1.B3.
Cmntive Ftigse Deme
Abewe Egnatirme givt *e t for feigtig menets ire nfimite
ife Sone miseile
efer trs Fig 1.36 Te ies
t f
aortion of ihe $N diagerar is 1
finite ife
(or designing for
component in ubjected
a sitr
o. the life is N, cycies, nd it
the ife is N, cyles ard s
If the component is tbËected c
intermittent loads leading to streaaee
o, lor n, cycles (n, N). , fo ,
cycles (M, x N,). and so on. them
accord1ng to Miner's rue, failue will

Probiem 157: Acantilever beam de fC 0 asEi of cclas c s seeion

tOS = : K = 142; =09. AU - pray

Given duta:

Facior uf saleiy =2: 75 N Rss

4=09 o=47ONa
1.198 Design of Mahine Elements
-

stand
www.ainw:lkbooks
To find: Maximum load that member can with

Solution:
For C40 steel
N/mm2;6 ,=275 N/mm²
Þ, =550 N/mm2G =470
Size factor = 0.85: Surface finish facto
given)
Assume load factor A = 1(since it is not
The beam is subjected to reversed A
bending load.
Since at A, the cross-section changes,
therefore find bending moment at A-B. 20 15

Max. Bending moment

= M.max = Wmax x 125 = (3F x 12S) N-mm

= Max. Bending stress Mmax 125

Omax Fig.

Z= Section modulus
32 -32x (15) =331.33 mm
3F x 125
maX 331.33

= (1.1316)F N/mm?
Omax
Min. Bending moment =M,min = Wmin × 125 =(-Fx125) N-mm
M
min
O.in=Min.Bending stress =
CÐx 125 -Fx125
331.33 331.33

Omin =-(0.3772)F N/mm²

min [Refer PSG D.B Pg, No
[K.M, D.B. Pg Na'
Imax
Þ = Mean stress =
mean
2
1.1316 F - 0.3772 F
2

mean =0.3772FN/mm²
 & Variable Stresses in Machine Members - 1.189
Steady Stresses www.srbooks.org

Imax min 1.1316 F -(-0.3772 F)

Amplitude stress =
Oamp = 2 2

amp =0.7544 FN/mm

K;=l+g(K, -1) q=0.9

=1+0.9 (1.42 - 1) K,= 1.42

=1.378

According to Goodman equation,

1 m [Refer PSG D.B Pg. No. 7.6]

n ABC [K.M. D.B. Pg. No. 25]

1 0.3772 (F +
1.378 (0.7544) (F)
550 275 × 1 x 0.85 x 0.89

1
i=6.858x 10-4 (F) +4.9969 x 10-3 (F)

=5.6827
2
x 10x(F)

F=87.98 N

According to Soderberg equation,

1 (K.M. Data Book Pg. No. 25]

n+K{G, ABC
1.190 Design of
Machine
1 0.3772 (F)
470
1378 (0.7544) (F)
275 × 1x0.89 x 0.85
Elernents
=8.0255 x 10*()+4.9960 x 10 3 (Ð

-5.799 x 10" ()
2

..F=86.22 N
Taking larger value,
According to Goodman's equation
The Max. value of F = 87.98N.
Problem 1.58: A machine component is subjected
fluctuates between +300 MN/m and - 150 MN/mto a fleural
minirum ultimate strength according to
1. Gerber relation, 2. Modified Goodman relation. 3
Determine
Take yield strength =0.55 Ultimate strength; Soderber tre
Ultimate strength and factor of safety = 2 Endurance
Given data:

max =+ 300 MN/m²

min
=-150 MN/m

=0.55
O_ =0.5 o
F.0.S = 2

Let, o, be the minimun ulumate strength

Now,

max min 300 +(- 150) _75 MN/m"

2 2

max 300 -(- 150) = 225 MN/m

2 2
 Steady Stresses & Variable Stresses in Machine Members www.srbooks.org 1.191

1According to Gerber relation,

1
F.0.S F.0.S +

X2+
225
0.5
11250
+
450 11250 +450 o,
(o,
’(6,-900 o,, -22500 =0
-(-900) ± V(-900) 4x1x(-22500)
2x1
=924.34 MN/m² (Considering only the +ve value)
2. According to modified Goodman relation,
-
1
FOS

+
225
2 o 0.5 o,
525

’o, = 1050 MN/m

3. According to Soderberg relation,

F.0.S

1 75
75 225
o, 0.5 o,
1 75 225
+
2 0.55 o,, 0.5 o,
 Design of Machine Elements - www.airwalkbook.s.coe

1.192
586.36
2

’o, =1172.72 MN/m2

section C445 steel member is subjected to an

circular cross
1.59: A Nto +2500 N and to a torsional moment
Problem
varies from -1000 of 1.5 and a stress
aial load that to +500N- m. Assume a factor of safety
that varies
from 0 Calculate the required diameter of the member for
concentration factor of 1.5;
indefinite life.
(EAQ)
Given Data:
Torsional moment
Axial load Max. twisting moment
+2500 N
Max. load = =+500 N-m=+500 × 10 N-mm
1000 N Min. twisting moment = 0
Min. load =-
1.5; Stress concentration factor K,=1.5;
Factor of safety =
For C 45 material,
Solution:
[K.M. D.B. Pg. No. 458, 464]
[from PSG D.B. Pg. No. 1.9],
N/mm;
, =630 - 710 N/mm; o.=360
Take o, =650 N/mm²
Pg. No. 23]
[From PSG D.B. Pg. No. 1,42), [K.M. D.B.
Endurance limit =o_=0.366, (for axial load - Reversed)
=0.36 x 650 = 234 N/mm moment Repeated
Repeated-endurance limit in shear =t_=0.3 o,, for twisting
=0.3 x 650= 195 N/mm
Consider axial load
Pmay = Max. load =+2500 N:P. = Min. load =- 1000
P
2500
where d = diameter of shaft.
max
Max. stress = =+
A
4

max
=+ 3183.09
d
 vo Stresses & Variable Stresses in Machine Members -
www.srbooks.org 1.193

P,min 1000
Min. stress
4
4
1273.23
min

3183.09 .(- 1273.23)

Mean stress =.. =
Omax tOmin 954.93
m
2 2
3183.09 (- 1273.23)
min
Stress amplitude = o, 2228.16
2 2

From PSG Databook, Page No. 7.6]

Combined stresses

e OmtKf
2228.16
x 360
954.93 Let, q 1
+ 1.5
e 234
6096.83
eq
... (1) K=l+q (K, -1)
=1+1(1.5- 1)=1.5
Consider twisting moment (Repeated load)
Max. twisting moment =T.
max =+500 × 10 N-nm

Min. twisting moment =1 min =0

Max. shear stress

=Tmax Tr T= 500x 10 N-mm
J

500 x10x d
t 2 d
max

32
2.546 x 105
r2
J=32
Min, Shear stress =Tm"min =0
1.194
Design of Machine
Elements -www
max + Tmin
Mean shear stress =mean 2

2.546 × 106
2 1.2732 x106
Tmaxmin 2.546 x 106
Amplitude of shear stress =t, 2
2 d3
1.2732 x 106

Note: For repeated load (T,meoy=Tam . Min. stress = 0)

[From PSG Databook, P.No. 7.6]

"eg n
Ty2
360
2
= 180 N/mm

1.2732 x106 +152732 x 106, x 180

dP (195)
1.2732 x 106 1.7629 x 106

3.0361 x 106

1
n
 à tresses & VanabBe Stresses in Machine Members - www.srbooks.org 1.195

6096.83 3.0361 x 106

+
dx 360 x180
Squaring on both sides

0.444 6096.83 3.0361 x 10

tx 360 x180
286.81 284.50 x 106
0.444=

The above equation can be solved by trial & emor method to

find d'
Trial 1: Put d=30 mm RHS = 0.391

RHS < LHS

Trial 2: Put d = 29 mm RHS = 0.4787

RHS > LHS

Trail 3: Put d = 29.5 mm RHS =0.4320

RHS = LHS (RHS is approximately equal to LHS)

.:. Take d= Diameter of shaft = 29.5 mmn

Problem 1.60: An autonmobile leaf spring is subjected to cyclic stress such

tnat the average stress is 150 MPa, variable stress is 35 MPa; the material
properties are; ultimate strength = 400 MPa; yield strength 350 MPa;
endurance limiu = 270 MPa; estimate the factor of safery using Goodman
method and Soderberg method?

Given: °avg(or) =150 MPa, or (or) , =35 MPa

,=400MPa, o, = 350 MPa,o_, (or) o, =270MPa
 Feents www
Accordinp to Goodman's forrnula.

Þ XABC

0.01474 P Ix 0.008842 P
4
330 x 1x 0.85 x 0.9
1.3 700

P=13 5.608 x 10

P-13716.20 N=13.716 kN
Problemn l.62: A steel rod is subjected to a reversed axial load of
Find the diameter of the rod for a factor of safety of 2.
Neglectand colyieldumn t
The material has an ultimate tensile strength of 1070 Mpa
reversed bending may be assumea
of 910 Mpa. The endurance limiu is
one half of the ultimate tensile strengih. The correction factors are m
Load factor 0.7; surface finish factor = 0.8
Size factor 0.85; stress concentration factor = 1.
Given: Reversed axial load =Wn
max
=- W= 180 kN

thax
= 180 kN, Wmin - 180 kN

n=2, o =1070 MPa, o,=910 MPa,

o. =G, ,A = 0.7, B= 0.85,C=0.8, K,= 1
To find: Diameier of the rod, (d)

Solution:
Imax
+ Wmin
Mcan load, W=
2

180 - 180
=0
2

Amplitude load, W,=

W.max Wi
2

180-( - 180) 180 kN

2
 Variable Stresses in
Steady Stresses & Machine Members -
www.srbooks.org 1.199

W.m
Mean stress, o,, = A =)

W 180 229.183 x10

Amplitude stress, = N/mm?
4
According to soderberg's formula
1
- XABC
1x 229.183 x 10
=0+: 1070
dx0.7x 0.85 x0.8 x 2
900

d'= 1800
d=42.43 mm
Problem 1.63: A hot rolled 070M26 steel rod is to be subjected to atorsional
load that will vary from - 110Nm to 440 Nm. Determine the required diameter
of the rod using a factor of safety N= 1.75.
Given: Tmay =440 N-m, Tmin -110 N-m, n= 1.75
The properties of 070 M26 steel are
o, =460 MPa, G,=310MPa
y_310 = 155 MPa,
2 2 o_= 0.5,
=0.5 x460
= 230 MPa
To find: Diameter of the rod, d
Solution:
+T
Mean torque, T, = min
2
440- 110
2
= l65 N-m
 Deskgn ot Mahne fenenta

440 ( I10)
-278 Nm

Mran shear stress, {,

840 8 10 N mm?

167.
Amplitude shear stiess ,

l6 x275x 10

1400.563 x10 N/mm?

According to sodererg equation

840.338 x 10 1400.563 x 10
4 (.e0
1.75 I55 x 0.55 x 230 x

=16493.18 x 1.75
=28863.06
d= 30.67 31 mm
diameter is sube
Problem l.64: Aspherical vessel of a S00 mm iner
MPa to 6 MPa. The mil
an intenal pressure, which varies from 2 strengih
pressure vessel is cold drawn C20 steel having ultimate
vessel is
and yield strength 240 MN/m. If the reliability of the Pressure Vsse
required factor of safety is 3, find the thickness of
infinite life period.
Given: d= 500 mm, P.
max
=6 MPa, Pimin =2 MPa
S Sesses &Variable Stresses in Machine Members www.srbooks.org 1.201

MN/m', o, =240 MN/m', R= 95%

Tolind:
Thickness of pressure vessel,
Solution:
Maximum circumferential stress
P d
max 6x 500 750
(o,'ma 41 4t
Nmm?
Minimum circumferential stress
min d 2x 500 250
(o min' 4 41
N/mm?
(o max t(Omin 750 +250 1000 500 N/mm
Mean stress 2 2r

(omax t(G,}min 750 -250 500 250 N/mm?

Amplitude stress = 2 2r2r
=

According to soderberg's formula

1 Om

500 250
3 240 0.868 x 0.5 x 450 xt
.'o-=0.5 G,
For 90% Reliability
1 3.363 K,=0.868
3
(=10.1 mm .".0=0.868 x0.5 x450

Problem 1.65: A cantilever rod of length 120 mn with circular section is

subjected to a cyclic transverse load; varying fromn - 100Nto 300 Nat the
Jree end. Determine the diameter 'd' for the rod, by (i) Goodman method and
(n) Soderberg method using the following data.
Factor of safety =2; Theoretical stress concentration factor= 1.4; Notch
sensi
MPa;tivitEndurance
y factor =limit
0.9; Ultimate strength =550 MPa; Yield strength= 320
=275 MPa; Size correction factor=0.85; Surface
correction factor =0.9 (AU Nov/Dec. 2015)
Given: Factor of safety =2
 Design of Machine
1.202 Elements - ww
Theoretical stress concentration factor 14
Notch sensitivity factor - 0.9

Ultimate strength, o, - 550 N/mm

Yield strength. o = 320 N/mm'
Endurance strength, o ,-275 N/mm
Size correction factor = 0.85

Surface correction factor = 0.9

Maximum load, W. = 300 N
Imax
()
Minimum load, W.min =- 100 N(T)
Length of rod = 120 mm
Solution:
W + W
Imax Min 400
Mean load, Wmean = 200 N
2
W - W
max min 300- 100
Amplitude load, Wamp 2 2
= 100 N

Mean Bending moment, M,mean = W mean x Length

= 200x 120
= 24 x 10 N-mm
Amplitude Bending moment, Mamp = W
amp x Length

= 12× 10 N.mm
M
Mean bending stress, O,, = Imean

24 x 103
T/32 d3
244.46 x 103 N/mm²
 Varlable Sresses in Machine Members www.srbooks.org 1.203
Stresses&

M,amp
Amplitudebending
stress,
Op-amp
12 x 10
T/32 d
122.23 x 10 N/mm

) Goodmanmethod,

PSG Data book, Pg. No. 7.6

Ref
Om
O-1
Endurance strength,
210.37 N/mm ['.o-1=0-| Xksfx ksl
=275x 0.85 x0.9 =
10
244.46 x10 122.23 x
(550) 210.37)
444.47 581.024
0.5=1.4|

0.5 1025.5
14

d=14.21 mm

(b) Soderberg method

No. 7.6
Ref PSG Data book, Pg.

where,
k=l+qk,-1)
=1+0.9 (14- 1)
=1.36
 Design of Machine Elements - wwW.
1.206

find: Diameter of the shaft, d

To
Soution:
T,max +Imin
Mean torque, 7 = 2
400- 100
- 150 N-m
2
- 150 x 10 N-mm
Tmax -T min
Amplitude torque, T=
400 -(- 100) = 250 N-m
2

= 250 x 10 N-mm
16T.
Mean shear stress, T,

16x 150× 103 763.944x 10

N/mm?

16 T,
Amplitude shear stress,
16x 250x 10

1273.239 x 103
N/mm

G=0.5 g,
=0.5 × 500

=250 MPa
then
In the question we have asked to assume distortion energy
failure.

. ,=0.577 o, =0.577 x 300= 173.1 MPa

T-=0.577 o_,= 0.577 x250 =144.25 MPa
 data:
Given Sce oor 90
equation
Soderberg Assume lutor ofPrNm oblem
factor Size
finish factor LorqueMaximum
torquediameter
Shaft l. 2, to
28506.
30.55d=
mm918d=
SlressSurface surenguh
Yieldsrength FactorMinimum
Ulimate safety of
A=1
B=find 1.68:
0.85 1800 4413.3109840.149 763.944 10
x AccordinR
concentration the shaft A x1731
(If and Nm. toVari
Stressos
able in
dianeter Soderberg's
not surface Assuming of
given) diameter dx
factor of 1273.23910
x
finish the 144.25
shaft.factor a'd' Method
(k) (C) (B) (o,) (n) (d) factor Macherne
(Tmin (Tma) is x
Takesubjected
of 897 0
C= safety o Menbers
05. 650 =
12 0.5 0.85 N-900m 1800
N-m ?
2 to
Nnn480 N/65m0n (d (AU Nnån, atorquend a
in concentration
- stress a
mn) Nov avarying
/Dec. 480
2014) Nn between
 Design of Machine
1208
Elements - www:
ABC
ainwako
Tmax t min 1800 + 900
mean - 1350 N-m
2 2

=1350 >x 10
N-mm
T mean16Em d

m
1350x 16x 10

6875.49 x 103
N/mm
T T
max min 1800 900
= 450N-m

16 ,

450x 16 x 10
=Ta

2291.83x 10 N/mm

=0.5 x480
t, =0.5x9,
- 240 N/mm

T_=0.275 o, =0.275 x 650= 178.75 N/mm

T TAxBxC
 Varinhble Streeses i Machie Mes
&

2291 83 x12 x10

' x240
10 36 20 x 10
2864x
|

x 10
fhdB416

d-51mm.
Prablem 1.69: Ahot rolled sMeel shaf is tubjected 8o a s i lmment thet
330 N-m clockwise to 110 N-m couner clock wie tnd n ied
hendimg mOment at a crítical section varies from 440 N -1O Nm he
wniformcrOSs-section and no key is presemt af the eritiesl eetion
etermine the required shaft diameter. The material hs an sirimute trength
and yield strengih of 41O MNh Toe the enurance imi s
halfthe ultimate strength. factor of safery of 2 size factor of 0N$ und rfuee
0.62. (AU ov/Dee. 0)
fmishfactor of
Grven:
330 Nm, Tmin -|10 Nm

M ma =440 Nm, Mmin =-220 Nm

6=550 MN/m, =410 MN/m

0. =0.5 6 =0.5x 550 =275 MN/m
n=2,B= (0.85. C= 0.62
lo find: The shaft diameler, d
Solution:
Mean torque 1, = Mean bending monenL M
2
330 -110 440-220
2 2
= |10 Nm =l10 N-m
=l10x 10 N-mm = l10 × 10 N-mm
1.210 Design of Machine Elements.
www.ain
Amplitude torque Amplitude bending moment
Tmax -min
T,= 2 M,= Mmax-2 M
min
330 -(-110)
2
= 220 N-m
440-(-2
-330 N-m
20)
= 220 × 10 N-mm =330 x10 N
-Tmm
167,,
Mean shear stress, T,, = Mean bending stresSs, G, = 32M.
16× 110x 103 32 x 110x10
560.225 x 103
1120.451 x1
16 T
Amplitude shear stress, T= Amplitude bending stress, o,s
16x 220x 10 32 x 330x1

1120.451x10 3361.352 x¢

Now, equivalent shear stress,

+ K,x,Xy
Tey"nXABC 410
In the above equation, the yield strength in shear, t ==
2
= 205 MPa
MP
The endurance limit in shear t- =0.55o_ =0.55 x 275 =151.25!

560.225 x 10° lx|120.451 x 10x 205 (Assume K

dx 151.25 x 1x 0.85 x 0.62
560.225 x 10 2881.647x 10 3441.872 x 10 N/mm?
 Stresses & Variable Stresses in Machine Members -
Steady
www.srbooks.org 1.211

Equivalent bending stress,

K,xo,xo,
0. XABC
1120.451 x 103 1x 3361.352 x 10 x
410
x275 x 1x 0.85 x 0.62
1120.451x 10 9509.431 >x 10

10629.882 x 10
N/mm
We know that,

Thus maximunm equivalent shear stress,

Oo
eq 2
2
+(Te4

10629.882 x 10° |2 3441.872x 103 )2

205 +
2 2d
6332.067x 10 x2
205

=61776.270
d= 39.53 mm = 40mm