ME 307 MACHINE ELEMENTS I

HOMEWORK 1 Solution

PROBLEM 1.
For a gear and shaft assembly, the specified fit is H7/s6. If the nominal dimension is 40 mm,
answer the following questions using the tolerance tables at the web page.
a) Which system is used to define the fit?
b) What is the tolerance on the hole?
c) What is the tolerance on the shaft?
d) Sketch the dimensions of the fit showing the lower and upper limits of the shaft and hole.
e) Find the minimum and/or maximum interference and/or clearance.
f) According to the values found above, specify the type of fit.
g) What is the tolerance on the fit?
h) What is the allowance on the fit?
i) Repeat the calculations using the tolerance formula instead of the tolerance table.

Solution:
a) Basic hole system (BHS)
b) Hole tolerance is H7. From Tolerance Table, the upper and lower limits of H7 for 40mm
+0.025
basic dimension are 40 0 , i.e. 40.025mm and 40.000mm. So tolerance on hole, 𝑇ℎ is
25𝜇m = 0.025mm.
c) Shaft tolerance is s6. From Tolerance Table, the upper and lower limits of s6 for 40mm
+0.059
basic dimension are 40+0.043 , i.e. 40.059 and 40.043. So tolerance on shaft, 𝑇𝑠 is 16𝜇m
= 0.016mm.
d)
𝑑𝑚𝑎𝑥 = 40.059
s6
𝑇𝑠
shaft
𝑑𝑚𝑖𝑛 = 40.043
𝐼𝑚𝑖𝑛 𝐼𝑚𝑎𝑥
𝐷𝑚𝑎𝑥 = 40.025
40.059
H7 𝑇ℎ
hole

𝐷𝑚𝑖𝑛 = 40.000
 e) 𝐼𝑚𝑖𝑛 = 𝑑𝑚𝑖𝑛 − 𝐷𝑚𝑎𝑥 = 40.043 − 40.025 = 0.018 mm
𝐼𝑚𝑎𝑥 = 𝑑𝑚𝑎𝑥 − 𝐷𝑚𝑖𝑛 = 40.059 − 40.000 = 0.059 mm

f) Since there is always interference, it is an interference fit.

g) 𝑇 = 𝑇ℎ + 𝑇𝑠 = 25 + 16 = 41 𝜇m
h) Allowance = 𝐼𝑚𝑎𝑥 = 0.059 mm
i) For the hole 𝐼𝑇𝑛 is 7. Therefore
1
3
𝑖 = 0.45𝐷3 + 0.001𝐷 = 0.45√40 + 0.001 × 40 = 1.58
𝐾 = 10 × 1.6(𝐼𝑇𝑛−6) = 10 × 1.6(7−6) = 16
𝑇ℎ = 𝐾 𝑖 = 16 × 1.58 = 25𝜇m
Since BHS is used, 𝐷𝑚𝑖𝑛 = 40.000mm. Hence 𝐷𝑚𝑎𝑥 = 𝐷𝑚𝑖𝑛 + 𝑇ℎ = 40.025mm.
For the shaft 𝐼𝑇𝑛 is 6. 𝑖 depends only on 𝐷 ≡ 𝑑, hence it is the same as above.
𝐾 = 10 × 1.6(𝐼𝑇𝑛−6) = 10 × 1.6(6−6) = 10
𝑇𝑠 = 𝐾 𝑖 = 10 × 1.58 = 15.8 ≅ 16𝜇m
From Table A-12, the fundamental deviation for 𝑑 = 40mm and deviation letter 𝑠 is
found as +43𝜇m. Therefore 𝑑𝑚𝑖𝑛 = 40.043mm, and 𝑑𝑚𝑎𝑥 = 𝑑𝑚𝑖𝑛 + 𝑇𝑠 = 40.059mm.
Since the upper and lower limits of the hole and shaft are same as above, 𝐼𝑚𝑖𝑛 , 𝐼𝑚𝑎𝑥 , 𝑇
and allowance are also the same.

PROBLEM 2.
A composite open-ended thick cylinder is formed by shrinking an outer cylinder on an inner
cylinder as shown. The inner cylinder has radii of 𝑟𝑖 = 20 mm and 𝑐𝑖 = 30.020 mm. The outer
cylinder has radii of 𝑐𝑜 = 29.985 mm and 𝑟𝑜 = 50 mm. The composite cylinder has an internal
pressure of 𝑝𝑖 = 200 MPa. Find the stress components 𝜎𝑟 and 𝜎𝑡 at the inner surface of the
composite cylinder.

𝑐𝑖 𝑐𝑜 𝑟𝑜
𝑟𝑖 𝑝𝑖
Solution:
Wall thickness of the inner cylinder is smaller than the outer cylinder. Check the inner cylinder
whether thin walled assumption can be used:
2𝑡 2×(30−20) 1
= = 1 > 20 . Therefore the inner and outer cylinders and the composite cylinder are
𝑑𝑖 20

thick walled cylinders.

The general expression for the radial and tangential stresses at arbitrary radius r of a thick
cylinder due to internal pressure 𝑝𝑖 and outside pressure 𝑝𝑜 are
2 2
𝑟 𝑟𝑜 (𝑝𝑜 −𝑝𝑖 ) 2 2
𝑟 𝑟𝑜 (𝑝𝑜 −𝑝𝑖 )
𝑝𝑖 𝑟𝑖2 −𝑝𝑜 𝑟𝑜2 + 𝑖 2 𝑝𝑖 𝑟𝑖2 −𝑝𝑜 𝑟𝑜2 − 𝑖 2
𝜎𝑟 = 𝑟
, 𝜎𝑡 = 𝑟
(1)
𝑟𝑜2 −𝑟𝑖2 𝑟𝑜2 −𝑟𝑖2

and the longitudinal stress 𝜎ℓ = 0 because it is open-ended.

To find the stresses due to the internal pressure 𝑝𝑖 , set 𝑝𝑜 = 0 in equations(1). Then, substituting
𝑝𝑖 = 200 MPa, 𝑟𝑖 = 20mm, 𝑟𝑜 = 50mm and for the inner surface 𝑟 = 𝑟𝑖 = 20mm, the stresses
at the inner surface are found as
𝑝 𝑟2 𝑟2 200×400
𝜎𝑟 = 𝑟 2𝑖−𝑟𝑖 2 (1 − 𝑟𝑜2 ) = (1 − 2.52 ) = −200 MPa
𝑜 𝑖 2100

𝑝𝑖 𝑟𝑖2 𝑟2 200×400
𝜎𝑡 = (1 + 𝑟𝑜2 ) = (1 + 2.52 ) = 276 MPa
𝑟𝑜2 −𝑟𝑖2 2100

The composite cylinder is also subject to contact pressure 𝑝 due to the interference 𝛿 = 𝑐𝑜 −
𝑐𝑖 = 0.035mm at the shrink fit.
𝐸𝛿 (𝑟𝑜2 −𝑅 2 )(𝑅 2 −𝑟𝑖2 )
𝑝 = 2𝑅3 𝑟𝑜2 −𝑟𝑖2

where 𝑅 is the nominal radius at the contact, i.e. 𝑅 = 𝑐. Inserting 𝐸 = 200 GPa for steel, 𝑟𝑖 =
20mm, 𝑟𝑜 = 50mm, 𝛿 = 0.035mm and 𝑅 = 30mm, 𝑝 is calculated as
200×109 ×0.035×10−3 (1600×10−6 )(500×10−6 )
𝑝= = 49.5 × 106 Pa = 49.5 MPa.
2(30×10−3 )3 2100×10−6

The contact pressure 𝑝 is an outside pressure for the inner cylinder. So, to find the stresses at the
inner surface, use equations (1) where 𝑝𝑖 = 0, 𝑝𝑜 = 𝑝 = 49.5 MPa, 𝑟𝑖 = 20mm and 𝑟𝑜 = 𝑐 =
30mm
2 2
𝑟 𝑐 𝑝
−𝑝 𝑐 2 + 𝑖 2 −𝑝 𝑐 2 𝑟2
𝜎𝑟 = 𝑟
= 𝑐 2 −𝑟 2 (1 − 𝑟𝑖2 )
𝑐 2 −𝑟𝑖2 𝑖

𝑟2𝑐2 𝑝
−𝑝 𝑐 2 − 𝑖 2 −𝑝 𝑐 2 𝑟2
𝜎𝑡 = 𝑟
= 𝑐 2 −𝑟 2 (1 + 𝑟𝑖2 )
𝑐 2 −𝑟𝑖2 𝑖
At the inner surface 𝑟 = 𝑟𝑖 = 20mm. This yields
−49.5×900
𝜎𝑟 = (1 − 1) = 0
500
−49.5×900
𝜎𝑡 = (1 + 1) = −178.2 MPa
500

Adding the stresses due to inside pressure and the contact pressure, the total tangential and radial
stresses at the inner surface are found as
𝜎𝑟 = −200 + 0 = −200 MPa,
𝜎𝑡 = 276 − 178.2 = 97.8 MPa.