ME 452: Machine Design II Spring Semester 2017

Name of Student: ____________________________________________________

Circle your lecture division number: Division 1 Division 2

9:30 am – 10:20 am 1:30 pm – 2:20 pm

FINAL EXAM
Thursday, May 4th, 8:00 am – 10:00 am

MTHW 210 AND LILY 3118

OPEN BOOK AND CLOSED NOTES

For full credit you must show your solutions clearly and logically on the sheets of paper attached to the
end of each problem.

Use only the blank pages for your solutions and write on one side of the paper only. In general, do not
write your work on the exam pages unless instructed to do so.

Draw any free body diagrams, and other diagrams, clearly and to a reasonable size.

Staple each problem separately at the end of the exam with this cover sheet in front of Problem 1.

Problem 1 (25 points)

Problem 2 (25 points)

Problem 3 (25 points)

Problem 4 (25 points)

Total (100 points)

1
 
ME 452: Machine Design II FINAL EXAM SPRING 2017

Name of Student: ____________________________ Circle one: Division 1 Division 2

Problem 1 (25 points). For the spur gearset shown in Figure 1, the gear is rotating at 500 rpm and
transmits 6 horsepower to the pinion. The pitch diameter of the pinion is 5 inches, the diametral pitch of
the gear is 5 inches1 , and the gear ratio is 2. The commercial gearset has full-depth teeth with a pressure
angle of 20 o and the face widths of the gear and pinion are 0.8 inches. The gear is subjected to a light
shock load and the pinion a moderate shock load where the loads are applied at the tips of the teeth. The
gear and pinion operate at room temperature. The gear is nitrided through-hardened Grade 2 steel with a
Brinell hardness H B  300. The known AGMA factors for the gear are: dynamic factor K v  1.25, size
factor K s  1.0, and load distribution factor K m  1.0. The backup ratio for the gear is m B  1.5.
(i) Determine the load transmitted by the gearset.
(ii) Determine the AGMA bending stress on the teeth of the gear.
(iii) Determine the AGMA safety factor guarding against bending fatigue failure for the gear for 108
load cycles and 95 percent reliability.

Gear

Input

Pinion
Output

Figure 1. A spur gearset (Not drawn to scale).

2
 
ME 452: Machine Design II FINAL EXAM SPRING 2017

Name of Student: ____________________________ Circle one: Division 1 Division 2

Problem 2 (25 points). The mean coil diameter of a linear helical compression spring is D = 2.25 inch
and the spring index is C = 9. The spring has squared and ground ends and is placed between two flat
parallel plates as shown in Figure 2. The spring material is music wire A228 and the spring is peened.
When the spring is assembled between the plates, the spring is subjected to a preload of 45 lbs and the
spring length is 5 inches (shown on the left). The spring is then subjected to a fluctuating load. At the
maximum working load of 95 lbs, the spring length is 3.75 inches (shown on the right). Determine:
(i) The number of active coils (round up to the nearest quarter of a coil).
(ii) The free length and the shut height of the spring.
(iii) The alternating component and the mean component of the shear stress.
(iv) The fatigue factor of safety using the Gerber-Zimmerli failure criterion.

F = 45 lbs

F = 95 lbs

5 in

3.75 in

F = 45 lbs F = 95 lbs

Figure 2. The loads acting on the compression spring (Not drawn to scale).

3
 
ME 452: Machine Design II FINAL EXAM SPRING 2017

Name of Student: ____________________________ Circle one: Division 1 Division 2

Problem 3 (25 points). A UNF 3/ 4 inch - 16 SAE grade 8 steel bolt with rolled threads is used to
clamp together two identical plates. Each plate is 1.5 inches thick as shown in Figure 3. The length of
the bolt is 3.75 inches and the diameter of the washer face under the bolt head is d w  1.5 d (where d is
the diameter of the bolt shank). The half-apex angle of the pressure cone distribution in the plates is
  300. The bolt is preloaded to 30 x 103 lbs and then the bolted connection is subjected to an external
load which fluctuates between 6 x 103 lbs and 9 x 103 lbs. The modulus of elasticity of the bolt is
E  30 x 106 lbs/in 2 and the modulus of elasticity of each plate is E  36 x 106 lbs/in 2 . Determine:
b p
(i) The stiffness of the bolt and the total stiffness of the plates (use the pressure-cone method).
(ii) The factor of safety guarding against joint separation.
(iii) The load factor, that is, the factor of safety guarding against overloading.
(iv) The factor of safety guarding against fatigue using the modified Goodman criterion.

1.5 in

1.5 in

Figure 3. Two identical plates clamped together by a bolt.

4
 
ME 452: Machine Design II FINAL EXAM SPRING 2017

Name of Student: ____________________________ Circle one: Division 1 Division 2

Problem 4 (25 points). An actuating force is applied at point A on the arm of an external rim-type brake
as shown in Figure 4. The radius of the drum is 5 inches, the distance from the hinge pin O to the center
of the drum C is 7 inches, and the distance from point C to point A is 9 inches. The drum is rotating
counterclockwise, the shoe lining material is cermet, and the face width of the shoe is 3 inches.
(i) Determine the magnitude of the limiting actuating force F acting at point A.
(ii) Determine the braking capacity of the brake.
(iii) Determine the magnitude and direction of the reaction force at pin O. Show this force on Figure 4.

OC = 7 inches CA = 9 inches

Drum Rotation

r = 5 in

C A
O
30o 30o
60o

120o
F

Figure 4. The external contracting rim-type brake.

5
 
Solution to Problem 1.
(i) 5 Points. The transmitted (or tangential) load can be written from Eq. (13-35), see page 707, as
H
Wt  33000 (1)
Vt

The pitch line velocity can be written from Eq. (13-34), see page 707, as

 dG nG  d p np
Vt   ft/min (2)
12 12
The gear ratio (or speed ratio), see page 694 and Eq. (14-22), see page 754, can be written as
NG dG
mG   (3)
NP dP

Substituting the given gear ratio mG  2 and pitch diameter of the pinion d P  5 in into Eq. (3), and
rearranging, the pitch diameter of the gear is

dG  mG d P  2 x 5  10 inches (4)

Substituting Eq. (4) and the given speed of the gear nG  500 rpm into Eq. (2), the pitch line velocity is

 10  500
Vt   1309 ft/ min (5)
12
Substituting Eq. (5) and the given horsepower H  6 hp into Eq. (1), the transmitted load is

33000  6
Wt   151.26 lb (6)
1309
Check: The horsepower input can be written from Eq. (13-33), see page 706, as
T n
H  in G (7)
63000
Rearranging Eq. (7), the input torque can be written as
63000 H
Tin  (8)
nG

Substituting the given horsepower input H  6 hp and speed of the gear nG  500 rpm into Eq. (8), the
input torque is
63000 x 6
Tin   756 lbs-in (9)
500
Check: The input torque can be written from Eq. (b), see page 706, and Figure 13-13, see page 707, as

Tin  rG Wt (10a)

6
 
Substituting Eq. (9) and the radius of the pitch circle of the gear rG  5 in, see Eq. (4), and into Eq.
(10a), and rearranging, the transmitted load acting on the pinion is
756
Wt   151.2 lbs (10b)
5
Note that this answer is in good agreement with Eq. (6).
(ii) 10 Points. The AGMA bending stress in the gear can be written in US customary units from Eq. (14-
15), see page 746, as
W P
  t ( Ko Kv K s Km K B ) (11)
FJ

The diametral pitch of the gear and the pinion can be written from Eq. (13-1), see page 676, as
NG N P
P  (12)
dG d P

Substituting Eq. (4) and the given diametral pitch P  5 inches 1 into Eq. (12), and rearranging, the
number of teeth on the gear is
NG  P dG  5 10  50 (13a)

and the number of teeth on the pinion is

N p  P d p  5  5  25 (13b)

Since the loads are applied at the tips of the teeth and the number of teeth on the gear is NG  50, see
Eq. (13a), then the bending strength geometry factor for the gear teeth from Figure 14-6, see page 753, is
J  0.28 (14)
The problem states that the input gear is subjected to a light shock load and the output pinion is
subjected to a moderate shock load, therefore, the overload factor for the gearset from the table at the
bottom of page 766, see Figure 14-17, is
K o  1.5 (15a)

The dynamic factor for the gear (see Section 14.7, page 756) is given in the problem statement as

K v  1.25 (15b)

The size factor for the gear (see Eq. (a), page 759) is given in the problem statement as

K s  1.0 (15c)

The load distribution factor for the gear (see Eq. (14-30), page 759) is given in the problem
statement as
K m = 1.0 (15d)

The backup ratio for the gear is given as m B  1.5, therefore, the rim-thickness factor for the gear
from Eq. (14-40), see page 764, is

7
 
 K B = 1.0 (15e)

Substituting the given face width of the gear F  0.8 inches, diametral pitch P  5 inches 1 and Eqs.
(6), (14), and (15) into Eq. (11), the AGMA bending stress in the gear can be written as
151.26  5
  (1.5 1.25 1.0 1.0 1.0) kpsi (16a)
0.8  0.28

Therefore, the AGMA bending stress in the gear is

  6.33 kpsi = 6331 lbs/in 2 (16b)

(iii) 10 points. The AGMA safety factor guarding against bending fatigue failure for the gear can be
written from Eq. (14-41), see page 765, as
S Y / ( KT K R )
SF  t N (17)

First, determine the bending strength geometry factor for the gear.
For nitrided through-hardened Grade 2 steel the repeatedly applied bending strength (for 108 load cycles
and 95 percent reliability) from Figure 14-3, see page 747, is

St  108.6 HB  15890 lbs/ins2 (18a)

Substituting the specified Brinell hardness H B  300 into Eq. (18a), the repeatedly applied bending
strength for the gear is
St  48470 lbs/ins2  48.47 kpsi (18b)

Second, determine the modification factors for the gear.

For commercial gears (nitrided through-hardened Grade 2 steel), the repeatedly applied bending strength
stress-cycle factor (for load cycles equal to, or greater than, 108 ) from Figure 14-14, see page 763, is

Yn  1.3558 N  0.0178 (19a)

Substituting the number of load cycles specified in the problem statement, that is, N  108 cycles, into
Eq. (19a), the bending strength stress-cycle factor for the gear is

Yn  1.3558 (1 x 108 ) 0.0178  0.9768 (19b)

Note the procedure of obtaining the bending strength stress-cycle factor from Figure 14.14, see page
763, is not acceptable since a scale is not provided.
Since the gear is operating at room temperature then the temperature factor is
KT = 1 (20)
The reliability factor for the specified 95 percent reliability can be written from Eq. (14-38), see page
763, is
K R  0.658  0.0759ln (1  R) (21a)

8
 
Substituting the reliability specified in the problem statement, that is R  0.95, into Eq. (21a), the
reliability factor is
K R  0.658  0.0759 ln (1  0.95)  0.8854 (21b)

Finally, determine the AGMA safety factor guarding against bending fatigue failure for the gear.
Substituting Eqs. (16b), (18b), (19b), (20), and (21b) into Eq. (17), the AGMA safety factor guarding
against bending fatigue failure for the gear can be written as

1  48.47  0.9768 
SF 
6.33  1.0  0.8854 
(22)

Therefore, the AGMA safety factor guarding against bending fatigue failure for the gear is
S F  8.5 (23)

9
 
Solution to Problem 2.
(i) 5 Points. The spring stiffness can be written from Eq. (10-9), see page 520, as

d4 G
k (1a)
8 D3 N a

Rearranging this equation, the number of active coils can be written as

d4 G
Na  (1b)
8 D3 k

The stiffness of the spring can also be written as

F Fmax  Fmin
k  (2)
x yworking

The maximum load and the minimum load (that is, the preload) are specified, respectively, as

Fmax  95 lbs and Fmin  45 lbs (3)

The working deflection of the spring can be written as

yworking  la  lm (4a)

Substituting the assembled length la  5.0 inches and minimum working length  lm  3.75 inches,   see
Figure 2, into Eq. (4a), the working deflection is

yworking  5.0  3.75  1.25 inches (4b)

Substituting Eqs. (3) and (4b) into Eq. (2), the stiffness of the spring is
95  45
k  40 lbs/in (5)
1.25
The spring index can be written from Eq. (10.1), see page 519, as
D
C (6a)
d
Substituting C  9 and D  2.25 inches into Eq. (6a), and rearranging, the wire diameter is

2.25
d  0.25 in (6b)
9
The modulus of elasticity and the modulus of rigidity of music wire A228 with a wire diameter
d  0.25 in from Table 10-5, see page 526, respectively, are

E  28.0 Mpsi and G = 11.6 Mpsi (7)

Substituting Eqs. (5), (6b), and (7) into Eq. (1b), the number of active coils is

10
 
 0.254  11.6  106
Na   12.43 (8a)
8  2.253  40
Therefore, the number of active coils (rounded up to the nearest quarter of a coil) is

N a  12.5 (8b)

(ii) 5 points. The free length of the spring (see Example 10.1, page 527) can be written as

L0  la  yinitial (9)

The initial deflection of the spring can be written from Eq. (2) as
Fmin
yinitial  (10a)
k
Substituting the preload Fi  Fmin  45 lbs and Eq. (5) into Eq. (10a), the initial deflection is

45
yinitial  in  1.125 in (10b)
40
Substituting the assembled length la  5.0 inches and Eq. (10b) into Eq. (9), the free length is

L0  5.0  1.125  6.125 in (11)

From Table 10-1, see page 521, the shut height of a spring with squared and grounded ends is

Ls  d Nt (12)

where the total number of coils from Table 10-1, see page 521, is

Nt  N a  2 (13a)

Substituting Eq. (8b) into Eq. (13a), the total number of coils (rounded up to the nearest quarter) is

Nt  12.5  2  14.5 coils (13b)

Substituting Eqs. (6b) and (13b) into Eq. (12), the shut height of the spring is

Ls  0.25 14.5  3.625 in (14)

(iii) 5 Points. The alternating and the mean components of the shear stress can be written from Eqs.
(10.32) and (10.33), see page 537, as

 8 Fa D   8 Fm D 
 a  KB  3 
and  m  KB  3 
(15)
 d   d 
The Bergstrasser factor can be written from Eq. (10-5), see page 519, as

11
 
 4C  2
KB  (16a)
4C  3
Substituting the spring index C = 9 into Eq. (16a), the Bergstrasser factor is
49  2
KB   1.1515 (16b)
49  3
The alternating and mean components of the load can be written from Eqs. (10-31), see page 537,
respectively, as
F  Fmin F  Fmin
Fa  max and Fm  max (17)
2 2
Substituting Eq. (3) into Eqs. (17), the alternating and mean components of the load, respectively, are
95  45 95  45
Fa   25 lb and Fm   70 lb (18)
2 2
Substituting Eqs. (6b), (16b) and (18) into Eqs. (15), the alternating and the mean components of the
shear stress are
 8  25  2.25 
 a  1.1515  3 
 10.556 kpsi (19a)
   0.25 
and
 8  70  2.25 
 m  1.1515  3 
 29.557 kpsi (19b)
   0.25 
(v) 5 Points. The fatigue factor of safety using the Gerber-Zimmerli failure criterion, see Example 10-4,
page 538, can be written as 
S
n f  sa (20)
a

The alternating component of the shear strength can be written from Table 6.7, see page 307, as

  2 S se  
2
r 2 S su2 
S sa  1  1    (21)
2 S se   r S su  
 
The torsional modulus of rupture of the music wire can be written from Eq. (10.30), see page 537, as

S su  0.67 Sut (22)

The ultimate tensile strength of the music wire can be written from Eq. (10-14), see page 523, as
A
Sut  (23a)
dm
For A228 music wire with a wire diameter 0.004 in  d  0.256 in from Table 10-4, see page 525,

A  201 kpsi.in m and m  0.145 (23b)

12
 
Substituting Eqs. (23b) into Eq. (23a), the ultimate tensile strength of the music wire is
201
Sut   245.75 kpsi (24)
(0.25)0.145

Substituting Eq. (24) into Eq. (22), the torsional modulus of rupture of the music wire is

S su  0.67  245.75  164.65 kpsi (25)

The torsional endurance strength (that is, the Gerber ordinate intercept for the Zimmerli data for a
peened spring) can be written from Eq. (6.42), see page 306, or from the equation on page 536 as
S sa
S se  (26)
1   S sm / S su 
2

The alternating and mean components of the shear strength for a peened spring from Eq. (10-29), see
page 536, are
Ssa  57.5 kpsi and Ssm  77.5 kpsi (27)

Substituting Eqs. (25) and (27) into Eq. (26), the torsional endurance strength of the music wire is
57.5
S se   73.87 kpsi (28)
1   77.5 /164.65
2

The slope of the load line, see page 537 and Example 10-4, page 538, is defined as
a
r (29a)
m

Substituting Eqs. (19) into Eq. (30a), the slope of the load line is
10.556
r  0.3571 (29b)
29.557
Substituting Eqs. (25), (28), and (29b) into Eq. (21), the alternating component of the shear strength is

   
2
(0.3571) 2 (164.65) 2  2 (73.87)
S sa  1  1     39.88 kpsi (30)
2 (73.87)   (0.3571)(164.65)  
 
Substituting Eqs. (20a) and (30) into Eq. (20), the fatigue factor of safety is
39.88
nf   3.8 (31)
10.556

13
 
Solution to Problem 3.
(i) 10 Points. The stiffness of the bolt can be written from Eq. (8-17), see page 427, is
Ad At Eb
kb  (1)
Ad lt  At ld

The nominal major diameter (or bolt shank diameter) of the UNF 3/4 in – 16 bolt, see Table 8.2, page
413, is
d  0.7500 in (2a)

Also, the tensile stress area, see Table 8.2, page 413, is

At  0.373 in 2 (2b)

Since the length of the bolt is specified as L  3.75 in then the length of the threaded portion of the bolt
can be written from Table 8-7, see page 426, as
1
LT  2 d  in (3a)
4
Substituting Eq. (2a) into Eq. (3a), the length of the threaded portion of the bolt is
1
LT  2(0.7500)   1.75 in (3b)
4
The length of the unthreaded portion of the bolt (that is, the bolt shank) can be written from Table 8-7,
see page 426, as
ld  L  LT (4a)

Substituting the length of the bolt L  3.75 inch and Eq. (3b) into Eq. (4a), the length of the unthreaded
portion of the bolt is
ld  3.75  1.75  2.00 in (4b)

The grip is the total thickness of the two identical plates, that is
l  2(1.5) in  3.00 in (5)

The length of the threaded portion of the bolt within the grip can be written from Table 8-7, see page
426, as
lt  l  ld (6a)

Substituting Eqs. (4b) and (5) into Eq. (6a), the length of the threaded portion of the bolt within the grip
is
lt  3.00  2.00  1.00 in (6b)

The cross sectional area of the unthreaded portion of the bolt (that is, the bolt shank) is

d2  (0.7500)2
Ad    0.4418 in 2 (7)
4 4

14
 
Substituting Eqs. (2b), (4b), (6b), (7) and Eb  30 106 lbs / in 2 into Eq. (1), the stiffness of the bolt is

(0.4418)(0.373)  30  106
kb   4.162 106 lbs / in (8)
(0.4418  1.00)  (0.373  2.00)

The stiffness of the two identical plates (using the diameter of the washer face under the bold head
d w  1.5 d and the half-apex angle   300 ) can be written from Eq. (8-22), see page 429, as

0.5774  Ep d
km  (9a)
 0.5774 l  0.5 d 
2 ln  5 
 0.5774 l  2.5 d 

Substituting the modulus of elasticity of the plates Ep  36 106 lbs / in 2 , the bolt shank diameter
d  0.7500 in, and Eq. (5), into Eq. (9a), the total stiffness of the two plates is

0.5774    36  106  0.7500

km   22.847  106 lbs / in (9b)
 0.5774  3.00  0.5  0.7500 
2 ln  5 
 0.5774  3.00  2.5  0.7500 
(ii) 5 Points. The factor of safety guarding against joint separation can be written from Eq. (8-30), see
page 441, as
Fi
n0  (10)
Pmax (1  C )

The stiffness constant of the joint can be written from Eq. (f), see page 436, as
kb
C (11a)
kb  k m

Substituting Eqs. (8) and (9b) into Eq. (11a), the stiffness constant of the joint is

4.162 106
C  0.154 (11b)
4.162 106  22.857 106
which implies that the percentage of the external load taken by the bolt is 15.4%. Note that this value is
acceptable since the joint constant should, in general, be less than 0.20, see Table 8-12, page 437.
Substituting the preload Fi  30 kips, the maximum value of the external load P  Pmax  9 kips, and
Eq. (11b) into Eq. (10), the factor of safety against joint separation is

30 103
n0   3.94 (12)
9 103 (1  0.154)

(iii) 5 Points. The load factor, that is, the factor of safety guarding against overloading, can be written
from Eq. (8-29), see page 440, as
S A  Fi Fp  Fi
nL  p t  (13)
CPmax CPmax

15
 
The minimum proof strength of an SAE grade 8 steel bolt from Table 8-9, see page 433, is

S p  120 kpsi (14)

The proof load can be written from Eq. (8.32), see page 442, as
FP  S p At (15a)

Substituting Eqs. (2b) and (14) into Eq. (15a), the proof load is

FP  120 x 0.373  44.76 kips (15b)

Note that the ratio of the preload Fi  30 kips to the proof load in Eq. (15b) is

Fi 30
  0.67 (16)
FP 44.76

Note that this ratio is less than the recommended ratios in Chapter 8, see Eq. (8.31), page 442.
Substituting Eqs. (2b), (11b), (14), the preload Fi  30 kips, and the maximum value of the external
load P  Pmax  9 kips into Eq. (13), the load factor is

120 103  0.373  30 103

nL   10.64 (17)
0.1541 9 103

Check: The factor of safety guarding against the static stress exceeding the proof strength (commonly
referred to as the yielding factor of safety) can be written from Eq. (8-28), see page 440, as
S p At
np  (18a)
CPmax  Fi

Substituting Eqs. (2b), (11b), and (14) into Eq. (18a), the yielding factor of safety is
120  0.373
np   1.4 (18b)
0.154  9  30
Comparing the answers for the three factors of safety, that is, Eqs. (12), (17), and (18b), note that
nL  nO  n p (19)

(iv) 5 Points. The fatigue factor of safety using the modified Goodman line can be written from Eq.
(8.38), see page 446, as
Se ( Sut   i )
nf  (20)
Sut a  Se ( m   i )

The ultimate tensile strength of the SAE grade 8 steel bolt from Table 8-9, see page 433, is

Sut  150 kpsi (21)

The fully corrected endurance strength of the bolt with d  0.75 in from Table 8-17, see page 445, is

16
 
 Se  23.2 kpsi (22)

The preload stress can be written from Example 8.3, see page 439, as
Fi
i  (23a)
At

Substituting the preload Fi  30 kips and Eq. (2b) into Eq. (23a), the preload stress is

30 103
i   80.429 kpsi (23b)
0.373
The mean component of the normal stress can be written from Eq. (8.36), see page 445, as
C ( Pmax  Pmin ) Fi
m   (24)
2 At At

Substituting the maximum external load Pmax  9 kips, the minimum external load Pmin  6 kips, the
preload Fi  30 kips, and Eqs. (2b) and (11b) into Eq. (24), the mean component of the normal stress
can be written as
0.1541(9x103  6x103 ) 30 x103
m  psi  psi (25a)
2 x 0.373 0.373

Therefore, the mean component of the normal stress is

 m  3098.5 psi  80429 psi  83.53 kpsi (25b)

The alternating component of the normal stress can be written from Eq. (8-35), see page 445, as
C ( Pmax  Pmin )
a  (26a)
2 At

Substituting the maximum external load Pmax  9 kips, the minimum external load Pmin  6 kips, and
Eqs. (2b) and (11b) into Eq. (26a), the alternating component of the stress is
0.1541 (9000  6000)
a   619.71psi (26b)
2 x 0.373

Comparing the alternating component of the normal stress with the mean stress and the preload stress,
that is, Eqs. (23b), (25b) and (26b), note that

a  m i (27a)
that is
0.619 kpsi  83.53 kpsi  80.429 kpsi (27b)

This indicates that the slope of the load line is not 1, see Figure 8.20, page 446. In fact, the slope of the
load line for this problem is

17
 
 a 0.619
r   0.1996 (28)
m i 83.53  80.429

Substituting Eqs. (21), (22), (24b), (25b), and (26b) into Eq. (20), the fatigue factor of safety using the
modified Goodman line can be written as
23.2(150  80.429)
nf  (29a)
150 x 0.619  23.2(83.53  80.429)

Therefore, the fatigue factor of safety using the modified Goodman line is
1614
nf   9.8 (29b)
92.85  71.94

18
 
Solution to Problem 4.
(i) 10 Points. The free body diagram of the shoe is shown in Figure 1. The x axis points from the center
of the drum, point C, to the hinge pin O and the y axis is directed from point C toward the shoe.
  D
 

Mf
MN

60o
O a = 7 inches C OA = 16 inches A
x Rx 1 2 Ff
FN 60 o

F

Ry

y
Figure 1. The free body diagram of the shoe with the x and y axes.
From static equilibrium, the sum of the moments about the hinge pin O can be written as

M O =0 (1a)

From the free body diagram, see Figure 1, the sum of the moments about the hinge pin O is
cF  M f  MN  0 (1b)

Rearranging Eq. (1b), the actuating force on the shoe, see Eq. (16-4), see page 835, can be written as
MN  M f
F (2)
c
Therefore, the shoe is self-energizing for the given counterclockwise rotation of the drum. The moment
arm of the actuating force F about the hinge pin O, see Figure 1, is

c  16sin 60o  13.8564 ins (3)

19
 
 The moment due to the normal force about the hinge pin O can be written from Eq. (16-3), see page
835, as

p br a 2 2
sin  a 1
MN  a sin  d (4a)

where the integral, see Eq. (16-8), see page 836, can be written as
2  1   1 
B   sin 2 d   2  sin (2 2 )    1  sin(21 )  (4b)
1
2 4  2 4 
The angles to the heel of the shoe and the toe of the shoe, respectively, are

1  30 and  2  120  1  150 (5)

Substituting Eqs. (5) into Eq. (4b) gives

 (150o ) 1   (30o ) 1 
B  sin (300o )     sin (60o )  (6a)
 2 4   2 4 
that is
B  (1.5255  0.453)  1.4802           (6b)

Since  2  90o then the location of the maximum pressure acting on the shoe, see page 834, is

 max   a  90 (7)

Since the shoe is self-energizing then the limiting pressure is equal to the maximum pressure of the
frictional material, that is
pa  pmax (8a)

For cermet material, the maximum pressure from Table 16.3, see page 862, is

pmax  150 lbs/ins 2 (8b)

The face width of the shoe is specified as

b  3 ins (9)

The radius of the drum and the distance from the center of the drum to the hinge pin are specified as
r  5 ins and a  OC  7 ins (10)
Substituting Eqs. (6b), (7), (8), (9), and (10) into Eq. (4a), the moment due to the normal force about the
hinge pin O is
 150  3  5  7 
MN   1.4802  23.313  10 lbs.ins
3
(11)
 1 
The moment due to the friction force about the hinge pin O can be written from Eq. (16-2), see page
835, as

20
 
 
f pa b r 2
sin  a 1
Mf  sin  (r  a cos  ) d (12)

The coefficient of friction for cermet, see Table 16.3, page 862, is
f  0.32 (13)
The integral in Eq. (12) can be written as
2 150o
D   sin  (r  a cos  ) d   sin  (5  7 cos  ) d  8.6603 (14)
1 30 o

Substituting Eqs. (5b), (7), (8), (12b), and (13) into Eq. (12), the moment of the friction force about the
hinge pin O is
 0.32  150  3  5 
Mf   8.6603  6.235  10 lbs.ins
3
(15)
 1 
Check: Equation Eq. (12) can also be written as
f pa b r
Mf  (r C  a A) (16)
sin  a
where the integrals can be written as
2 2
1 
A   sin  cos  d   sin 2   (17a)
1 2 1
and
2
C   sin  d   cos  1  cos 1  cos  2

(17b)
2
1

Substituting Eqs. (5) into Eqs. (17) gives

A
1
2
 sin 2 150o  sin 2 30o   0 and C  cos 30o  cos 150o  1.732 (18)

Then substituting Eqs. (18) into Eq. (16), the moment of the friction force about the hinge pin O is

 0.32  150  3  5 
Mf   (5 x1.732)  6.235  10 lbs.ins
3
(19)
 1 
Note that Eq. (19) is in complete agreement with Eq. (15).
Substituting Eqs. (2), (11), and (14) into Eq. (3), the limiting actuating force for the shoe is

23.313 103  6.235 103

F  1232.5 lbs (20)
13.8564
Note that the x and y components of the limiting actuating force on the shoe are

Fx  1232.5cos 600   616.25 lbs and Fy   1232.5sin 60o   1067.4 lbs (21)

21
 
(ii) 5 Points. The braking torque (or the braking capacity) generated by the shoe can be written from Eq.
(16-6), see page 835, as
f pa b r 2 (cos 1  cos  2 )
T (22)
sin  a

Substituting Eqs. (5b), (6), (7), (8) and (13) into Eq. (22), the braking torque generated by the shoe can
be written as
0.32 150  3  52 (cos 30o  cos150o )
T  6.235 103 lbs.ins (23)
1
(iii) 10 points. For an external contracting self-energizing shoe, the x and y components of the reaction
force at the hinge pin O (that is, Rx and Ry ) can be written from Eqs. (16-14), see page 842, as
pa b r
 Rx  Fx  ( A  f B) (24a)
sin  a
and
pa b r
 Ry  Fy  ( f A  B) (24b)
sin  a

Note that the x and y components of the reaction force are assumed to be positive as shown in the free
body diagram, see Figure 1. Substituting Eqs. (6b), (18), and (21) into Eqs. (24), the x and y components
of the reaction force are
p br
 Rx  616.25  a (0 1.4802 f ) (25a)
sin  a
and
p br
 Ry  1067.4  a (0  1.4802) (25b)
sin  a

Substituting Eqs. (7), (8b), (9), and (13) into Eq. (25a), and rearranging, the x-component of the reaction
force is
150  3  5
Rx  616.25  (0  0.32 1.4802)   1065.75 lbs (26a)
1
The negative sign on the right hand side of this equation indicates that the x-component of the resultant
of the friction force and normal force on the shoe is in the positive x–direction, that is
Rx  616.25  1065.75  0 (26b)

Rearranging Equation (26b), the x-component of the reaction force is

Rx   616.25 1065.75   1682 lbs (26c)

The negative sign indicates that the x-component of the reaction force at the hinge pin O is acting to the
right (that is, in the opposite direction to the known x-component of the actuating force Fx ).
Substituting Eqs. (7), (8b), and (9) into Eq. (25b) gives

22
 
 150  3  5
Ry  1067.4  (0  1.4802)   3330.45 lbs (27a)
1
The negative sign on the right hand side of this equation indicates that the y-component of the resultant
of the friction force and normal force on the shoe is in the positive y–direction, that is
Ry  1067.4  3330.45  0 (27b)

Rearranging Eq. (27b), the y-component of the reaction force is

Ry   3330.45  1067.4   2263 lbs (27c)

The negative sign indicates that the y-component of the reaction force is acting upward (that is, in the
same direction as the known y-component of the actuating force Fy ).
The magnitude of the reaction force at the hinge pin O, from Eqs. (26b) and (27b), is

R  Rx 2  Ry 2  ( 1682) 2  (  2263) 2  2819.6 lbs (28)

The direction of the reaction force at the hinge pin O is

Ry
tan   (29a)
Rx

Substituting Eqs. (26) into Eq. (29a), the direction of the reaction force at the hinge pin O is
 2263
  tan 1 ( )  tan 1 ( 1.3454)  53.4o (29b)
 1682

The magnitude and direction of the reaction force at the hinge pin O are shown in Figure 2.

Ry = 22635 lbs R = 2819.6 lbs

O C A
x 1 Ff
Rx = 1682 lbs
FN 60o
2
F = 1232.5 lbs

Figure 2. The magnitude and direction of the reaction force at the hinge pin O.
23
 
Check. From static equilibrium, the sum of the forces in the x-direction can be written as

 Fx = 0 (30a)

From the free body diagram, see Figure 1, Eq. (28a) can be written as
R x  Fx  (FN ) x  (Ff ) x = 0 (30b)

Substituting Eq. (21) into Eq. (30b), the x-component of the hinge pin reaction force can be written as
R x  616.25  (FN ) x  (Ff ) x = 0 (31)

The x-component of the normal force can be written as

pa b r
(FN ) x  ( A) cos  (32a)
sin  a

Note from the symmetry of the shoe that the angle   900 ,  therefore 

 150  3  5 
(FN ) x    (0)(0)  0 (32b)
 1 
The x-component of the friction force can be written as
pa b r
(Ff ) x  ( f B) sin  (33a)
sin  a
or as
 150  3  5 
(Ff ) x    (0.32 1.4802)1  1065.74 lbs (33b)
 1 
The negative sign indicates that the x-component of the friction force is acting to the right (which is
intuitively correct). Substituting Eq. (32b) and (33b) into Eq. (31), the x-component of the hinge pin
reaction force is
R x  616.25lbs  0 1065.74 lbs  0 (34a)

Therefore, the x-component of the hinge pin reaction force is

R x   1065.74 lbs  616.25lbs   449.49 lbs (34b)

The positive sign indicates that the x-component of the reaction force at the hinge pin O is acting to the
left.
From static equilibrium, the sum of the forces in the y-direction can be written as

 Fy = 0 (35a)

From the free body diagram, see Figure 1, Eq. (35a) can be written as
R y  Fy  (FN ) y  (Ff ) y = 0 (35b)

24
 
Substituting Eq. (21) into Eq. (35b), the y-component of the hinge pin reaction force can be written as
R y  1067.4  (FN ) y  (Ff ) y  0 (36)

The y-component of the normal force can be written as

 p br 
(FN ) y   a ( B)  sin  (37a)
 sin  a 
or as
150  3  5
(FN ) y  (1.4802)(1)   3330.45 lbs (37b)
1
The positive sign indicates that the y-component of the normal force is acting downward (which is
correct).
The y-component of the friction force can be written as
pa b r
(Ff ) y  ( f A) cos  (38a)
sin  a
or as
150  3  5
(Ff ) y  (0)(0)  0 (38b)
1
Substituting Eqs. (37b) and (38b) into Eq. (36), the y-component of the hinge pin reaction force is
R y  1607.4  0  3330.45  0 (39a)

Therefore, the y-component of the hinge pin reaction force is

R y  1607.4  3330.45   1723.05 lbs (39b)

Note that Eqs. (34b) and (39b) are in complete agreement with Eqs. (26b) and (27b).

Check: The graphical approach. The arm and shoe is a three-force member. The three forces are the two
known forces: (i) the actuating force F acting at point A; and (ii) the contact force FR acting on the
shoe (this is the resultant of FN and Ff ). The third force is the unknown reaction force R acting at the
hinge pin O. The force polygon is shown in Figure 3.

25
 
 R

F = 1232.5 lbs

FR

Figure 3. The force polygon.

26