DESIGN OF MACHINE ELEMENTS

U5MEA20

Prepared by
Mr. Kishkorekumar & Mr. Sultan Batcha.Y
Assistant Professor, Mechanical Department
VelTech Dr.RR & Dr.SR Technical University

UNIT-I

Failure Theories

Stress in machine components should be

accurately computed.
Designer must understand material limits to

ensure a safe design.

Design Factor
Factor of Safety (N)

Expected Stress
N
Stress at Component Failure
Suitable values depend on inherent danger,

certainty of calculations, certainty of

material properties, etc.

Static Stresses - Brittle Materials

Percent elongation < 5%

sut

suc

1 1 2

N sut suc

for parts in tension

for parts in compression

for parts with general stress

Example
The Gray Cast Iron (Grade 40) cylinder carries
an axial compressive load of 75,000 lbs and a
torque of 20,000 in lbs. Compute the resulting
design factor.
R0.25
R0.25

4.00
5.00

Static Stresses - Ductile Materials

Percent elongation > 5%
Distortion Energy Theory
Define von Mises Stress
' 12 22 1 2
sy

For nominal stress

For localized stress

su
N
'

'

Static Stresses - Ductile Materials

Percent elongation > 5%
Maximum Shear Stress Theory
For nominal stress
For localized stress

s ys

max

sus

m ax

sy
2 max

Example
Specify a diameter for the middle portion of
the rod, if it is to be made from AISI 1040-hot
rolled steel.
450

5000 lbs

Example
For the seat support shown, specify a standard
structural tube to resist static loads shown.
The tube has properties similar to AISI 1020
hot-rolled steel. Use a design factor of 3.
400 lb

14

200 lb

20

Stress

Repeated Loads

alt

mean
Time

Example
The notched bar is machined from AISI 1020
steel. This bar is subjected to a load that
varies from 2000 lb to 3000 lb. Determine the
mean and alternating nominal stresses.

1.25

0.1 R
1

.75

Fatigue Strength
R.R. Moore Test
Motor
Alternating Stress, a

Endurance Strength, sn
103

104

105

106

107

108

Cycles to Failure, N (log)

Endurance Strength
sn = Endurance strength
Listed in tables
If no information is available, use
sn 0.5 su
(Steel)
sn 0.4 su
(Aluminum)

Adjusted Endurance Strength

The data from the standard R.R. Moore

test is adjusted for a particular

application.
sn = Adjusted endurance strength
= (Cs) (Cm) (Cst) (CR) (sn)

Size and Stress Type Factors

Cs = Size Factor
D< 0.4 in
Cs = 1.0
0.4 < D 2.0 in
Cs = (D/0.3)-0.068
2.0 < D 10.0 in
Cs = D-0.19
For rectangular sections, D=.808(h b)1/2

Cst = Stress Type Factor

= 1.0 for bending
= 0.80 for axial tension
= 0.50 for torsion

Material and Reliability Factor

Cm = Material Factor
= 1.0 for wrought steel
= 0.80 for cast steel
= 0.70 for cast iron

CR = Reliability Factor
50%
CR = 1.0
90%
CR = 0.90
99%
CR = 0.81
99.9%
CR = 0.75

Example
The notched bar is machined from AISI 1020
steel. This bar is subjected to a load that
varies from 2000 lb to 3000 lb. Determine the
endurance limit of the material.

1.25

0.1 R
1

.75

Repeated Stresses - Ductile Materials

Distortion Energy Theory
Define repeated von Mises Stress
'm 12m 22m 1m 2m

'a 12a 22a 1a 2a

Solderberg criterion
1 'm K t 'a

N
sy
s 'n

Repeated Stresses - Ductile Materials

Maximum Shear Stress Theory
1 ( m ) m ax K t ( a ) m ax

N
ssy
s 'sn

ssy = 0.5 sy
ssn = 0.5 sn

Example
The notched bar is machined from AISI 1020
steel. This bar is subjected to a load that
varies from 2000 lb to 3000 lb. Comment on
the robustness of the design.

1.25

0.1 R
1

.75

Example
Comment on the robustness of a 1-1/4 round
bar made from AISI 1213 C-D steel. It carries
a constant tensile load of 1500 lbs, a bending
load that varies from 0 to 800 lbs at the senter
of the 48 length and a constant torque of
1200 in lbs.

48

UNIT-II

Shafts
Connect power transmission components.

Inherently subjected to transverse loads and

torsion.

Shaft Forces
Gears

As before
Wt
Wr

Shaft Forces
Chains
Ftight

Ftight

2T

D
D
T

Fslack = 0

Shaft Forces
V-belts

Ftight

Ftight
2.5T

D
D

Fslack

2D

Fslack

Shaft Forces
Flat belts
Ftight
3T
Ftight
D
D

Fslack

Fslack

Material Properties
For steady load (torsion)

sys=.5sy

For fatique load ( bending)

sn=cs cR sn
cT = 1 (bending)
cm = 1 (wrought steel)

Stress Concentrations
Keyseats
Sled Runner Kt = 1.6

Profile

Kt = 2.0

Woodruff

Kt = 1.5

Stress Concentrations
Shoulders
Sharp, Bearing (r/d .03) Kt = 2.5
Round, Gear Bore (r/d .17) Kt = 1.5
Grooves
Retaining Rings Kt = 1.5

Try not to let Kts overlap.

Leave .10 - .15 between

Strength Analysis
Kt M c Kt M
Bending stress

I
S
For round sections

Torsion stress

D3
32

Tr T

J
2S

For round sections

J
I
2
r
c

Strength Analysis
Mohrs circle and Solderberg
3
2

K t M / sn ' T / s y
1
4

N
S
2

Suggested Design Factors:

N=2 smooth operation
N=3 typical industrial operation

N=4 shock or impact loading

Minimum Acceptable Diameter

The designer must size the shaft.
Solve for appropriate diameters
32 N
D

3
2
K t M / sn ' T / s y
4

Example
Determine a suitable diameter for a shaft
made from AISI 1144 OQT 1000. It is
subjected to a reversing bending moment of
3000 ft lbs and a steady torque of 1800 ft lbs.
The shaft has a profile keyway.

Example
The shaft shown is part of a grain drying system
At A, a 34 lb. propeller-type fan requires 12 hp
when rotating at 475 rpm.
A flat belt pulley at D delivers 3.5 hp to a screw
conveyor handling the grain.
All power comes to the shaft through the v-belt at
C.

Using AISI 1144 cold drawn steel, determine the

minimum acceptable diameter at C.

Example

A
12

Sheave C

C
10

10

E
4

150
Sheave D

Shafts Accessories
Components used to securely mount power

transmitting elements on a shaft.

Axial
Rotational

Keys
Allow torque to be transferred from a shaft

to a power transmitting element (gear,

sprocket, sheave, etc.)

Key Design
Use a soft, low strength material
H
L

(ie, low carbon steel)

Standard size H=W=1/4 D

Design length

based on strength

Standard Key Sizes

Shaft Dia. (in)

W (in)

W
T

D H D2 W 2
S
2
D H D2 W 2
T
.005 in.
2

Key Design
T
2T
F

D/2 D

Key Shear

F
2T

A DLW

Failure Theory N
Length

4TN
L
DWs y

sy
2

s y LW
4TD

Example
Specify a key for a gear (grade 40, gray cast
iron) to be mounted on a shaft (AISI 1144, hot
rolled) with a 2.00 in. diameter. The gear
transmits 21000 lb-in of torque and has a hub
length of 4 in.

Retaining Rings
Also known as snap rings
Provides a removable shoulder to lock

components on shafts or in bores.

Made of spring steel, with a high shear

strength.
Stamped, bent-wire, and spiral-wound.

Retaining Ring Selection

Based on shaft diameter & thrust force

Set Screws
Setscrews are fasteners that hold collars,

pulleys, or gears on shafts.

They are categorized by drive type and

point style.

Standard Set Screw Sizes

Set Screw Holding

Pins
A pin is placed in double shear
Holds torsion and axial loads

8T N
d
D sy

D
d

Hole is made slightly smaller than the pin

(FN1 fit)

Example
Specify a pin for a gear (grade 40, gray cast
iron) to be mounted on a shaft (AISI 1144, hot
rolled) with a 2.00 in. diameter. The gear
transmits 21000 lb-in of torque and has a hub
length of 4 in.

Roll Pins
Easier disassembly

Collars
Creates a shoulder on shaft without

increasing stock size.

Held with either set screw or friction
(clamped)

Mechanical Couplings
Couplings are used to join two shafts
Rigid couplings are simple and low cost.

But they demand almost perfect alignment

of the mating shafts.
Misalignment causes undue forces and

accelerated wear on the shafts, coupling,

shaft bearings, or machine housing.

Mechanical Couplings
In connecting two shafts, misalignment is

the rule rather than the exception. It comes

from such sources as bearing wear,
structural deflection, thermal expansion, or
settling machine foundations.
When misalignment is expected, a flexible

coupling must be used.

Mechanical Couplings
Selection factors include:
Amount of torque (or power & speed)
Shaft Size
Misalignment tolerance

UNIT-III

Fasteners, Powers Screws,

Connections
Helical thread screw was an important invention.
Power Screw, transmit angular motion to liner motion
Transmit large or produce large axial force
It is always desired to reduce number of screws

Definition of important
Terminologies

Major diameter d, Minor diameter dr Mean dia or pitch diameter dp

Lead l, distance the nut moves for one turn rotation

Single and Double threaded screws

Double threaded screws are stronger and moves faster

Screw Designations
United National

Standard UNS
International Standard
Organization

Roots and crest can be either flat or round

Pitch diameter produce same width in the thread and space,

Coarse thread Designated by UNC

Fine Thread UNF, is more resistance to

loosening, because of its small helix angle.

They are used when Vibration is present
Class of screw, defines its fit, Class 1 fits have
widest tolerances, Class 2 is the most commonly
used
Class three for very precision application
Example:1in-12 UNRF-2A-LH, A for Ext. Thread
and B for Internal, R root radius
Metric M10x1.5 10 diameter mm major
diameter,1.5 pitch

Some important Data for UNC, UNF

and M threads
Lets Look at the Table 8-1 on Page 398

Square and Acme Threads are used

for the power screw

Preferred pitch for Acme Thread

d, in

1/4

5/16

3/8

1/2

5/8

3/4

7/8

1 1/4

p,in

1/16

1/14

1/12

1/10

1/8

1/6

1/6

1/5

1/5

Mechanics of Power Screws

Used in design to change the angular motion to linear motion, Could

you recall recent failure of power screw leading to significant
causalities

What is the relationship between the

applied torque on power screw and
lifting force F

Torque for single flat thread

Fd m l fdm
TR
(
)
2 d m fl
Fd m fdm l
TL
(
)
2 d m fl
If the thread as an angle , the torque will be

Fd m l fd m sec
TR
(
)
2 d m fl sec
Wedging action, it
increases friction

Stresses in the power Screw

Shear stress in the base

of the screw
Bearing stress
Bending stress at the root
of the screw
Shear stress in the thread
nt number of engaged
thread

16T
d 3

F
d m nt p / 2

6F
b
d r nt p

3V
3F

2 A d r nt p

Loading to the fasteners and their

Failure considerations

Bolts are used to clamp two or more parts

It causes pre tension in the bolt
Grip length is the total thickness of parts
and washers
l

ld

t2

lt=L- ld

L effective grip= h+t2 if t2<d

=h=d/2 for t2 d

Failure of bolted or riveted joints

Type of Joints
Lap Joint (single Joint)

But Joint

Example 1

Example 2

Example 2

Example 3

Weld

Weld under Bending

UNIT-IV

Springs
Flexible machine elements
Used to:
Exert force
Store energy

Spring Rate
Effective springs have a linear deflection

curve.
Slope of the spring deflection curve is the
rate
Force
k
1
Deflection

F
k
L

Example
A compression spring with a
rate of 20 lb/in is loaded with
6 lbs and has a length of 1.5
in. Determine the unloaded
spring length (free length)

Geometry
Di

Dw

Dw

Do

Wire diameter, Dw (Standard gages)

Mean Diameter, Dm

Dm = Do - Dw

Spring Parameters
Spring index

Dm
C
Dw

C > 5 (manufacturing limits)

Active coils, Na
= N for plain ends
= N-1 for ground ends
= N-2 for closed ends

Deflection
Deflection for helical springs

8FDm3 N a 8FC3 N a

4
GDw
GDw
G = Shear modulus

Spring rate for helical springs

GD w
k
8C 3 N a

Example
A helical compression spring is formed from
35 gage music wire with 10-1/4 turns and an
O.D. if 0.850 in. Its ends are squared. The
free length is 2 inches. Determine the force to
press the spring solid.

Stress Analysis
Spring wire is in torsion

T r 8K F C

2
J
Dw

Wahl factor, K

Accounts for the

curvature of the wire
4C 1 .615
K

4C 4
C

Example
A helical compression spring is formed from
35 gage music wire with 10-1/4 turns and an
O.D. if 0.850 in. Its made from A228 and
the ends are squared. The free length is 2
inches.
If the spring is repeatedly compressed to 1.3
in, do you expect problems?

Design Procedure
Select a material
Compute required spring rate
Estimate Dm based on size constraints

Determine required Dw (use K=1.2)

Select standard wire

Verify actual stress is satisfactory.

Compute number of coils required.

Example
Design a helical compression spring to exert a
force of 22 lbs when compressed to a length
of 1.75 in. When its length is 3.0 in, it must
exert 5 lb. The spring will be cycled rapidly.
Use ASTM A401 steel wire.

UNIT-V

Rolling Element Bearings

Provides support for machine elements,

while allowing smooth motion.

m=0.001 - 0.005

Types
Single-row
Radial Ball

Angular
Contact Ball

Radial Roller

Angular
Roller

Types
Spherical
Roller

Tapered Roller

Needle
Thrust

Ball Bearings

Stress Analysis
Contact Stress

c=300,000 is not unusual

Balls, rollers and races are made from

extremely high strength steel

ex. AISI 52100
sy = 260,000 psi
su=322,000 psi

Bearing Load/Life
Test (fatigue) data
Radial Load (lbs)

Empirical relationship:

L2 P1

L1 P2

k=3.0 (ball)

k=3.33 (roller)

L10 Life (cycles)

Example
A bearing is mounted on a shaft rotating at
1200 rpm. The bearing has been tested to have
a L10 life of 300 hrs, when loaded with 500
lbs. Determine the expected L10 life, if the
load is increased to 700 lbs.

Manufacturers Data
Vendors publish the

Basic Dynamic Load

rating (C) of a bearing at
an L10 life of 1 million
cycles.

Bearing Selection
Determine the design life (in cycles)

Determine the design load

Pd = V R

V=1 for inner race rotation

V=1.2 for outer race rotation

Calculate the required

basic
dynamic
load
1
Ld k
Creq'd Pd 6
10
Select a bearing with (C > Creqd) and a bore

that closely matches the shaft diameter.

Example
Specify suitable bearings for a shaft used in an
grain dryer. The shaft rotates at 1700 rpm.
The required supporting loads at the bearing
are
R =589 lb
Bx

RBy=164 lb

and the minimum acceptable diameter is

2.16.

Mounting of Bearings
Shaft/bearing bore has a light interference

fit.
Housing/outer race has a slight clearance fit.
Check manufacturers catalog
Match maximum permissible fillet radius.
Shaft or housing shoulders not to exceed

20% of diameter.

Mounted Bearings
Pillow block

Bearing is inserted into a cast housing, with

base or flange slots, which can be readily

attached to a machine base.

Bearings with Varying Loads

Compute a weighted average load based on

duty cycle.

Fi p N i
Fm
Ni

1
p

Fm=equivalent load
Fi= load level for
condition i
Ni= cycles for
condition i
p = exponent for
load/life

Example
Bearing 6211 is carrying the following load
cycle, while rotating at 1700 rpm.
Stage
Load (lbs)
Time (min)
1
600
480
2
200
115
3
100
45
Compute the bearing L10 life in minutes.

Radial & Thrust Loads

Calculate an equivalent load

P=VXR +YT
T=thrust load
X
factors depending
=
Y
on bearing

Thrust factors, Y
Deep -groove, ball bearings

X = 0.56 for all values of Y

Example
A bearing is to carry a radial load of 650 lb
and a thrust load of 270 lb. Specify a suitable
single-row, deep-groove ball bearing if the
shaft rotates at 1150 rpm and the design life is
20,000 hrs.

 Thank you