Machine Elements

CHAPTER Design

1 Introduction To–
Mechanical
Engineering Design

[Link] Sobhy 1
 Machine Design

What is the importance of Machine Design for

engineers?

What is Machine Design?

Creation of new and better machines AND

Improving existing ones

So that it is economical in the cost of production and operation.

2
Machine Design
How a design is born
Market
survey

Aesthetic
marketability
Ease of
Requirement handling

Safety
Availability of
Creation FUNDS
Economical
Model Available
(Rough idea) material Recyclability

Manufacturing
resources
Material/s
Analysis Force/stress Sizes
used 3
What is the basic knowledge required for Machine
Design?

••Mathematics
Mathematics
• Mechanics of Machines
••Engineering
EngineeringMechanics
Mechanics
• Mechanics of Materials
••Strength
Strengthof
ofMaterials
Materials • Fluid Mechanics & Thermodynamics

••Workshop
WorkshopProcesses
Processes

••Engineering
EngineeringDrawing
Drawing

• Computing

• Finite Element Analysis, Computational Fluid Dynamics etc

4
Important considerations in Machine Design

1. Type of LOAD and STRESSes caused by the load

• Dead loads • Stress and strain

(Tensile, compressive, shear)
• Live loads

Steady loads • Thermal stresses

Variable loads
• Torsional stresses

• Shock loads (suddenly) • Bending stress

• Impact loads (applied

with some velocity)

5
Important considerations in Machine Design…..

2. KINEMATICS of the machine (Motion of the parts)

Find the simplest arrangement that would give the most

efficient motion that is required.

3. Selection of MATERIALs

Knowledge of the properties of the materials and their

behaviour under working conditions is required.

Strength, hardness, durability, flexibility, weight, resistance

to heat and corrosion, electrical conductivity, machinability,
etc.

6
Important considerations in Machine Design…..
3. Selection of MATERIALs

Metal Non-metal

Ferrous Non-ferrous

Physical properties: Density, Melting point, Elec/thermal properties

Mechanical properties:
• STRENGTH – resist externally applied loads without breaking
or yielding
• STIFFNESS – resist deformation under stress
• ELASTICITY – regain original shape once the force is removed
• PLASTICITY – property which retains deformation (required for
forging etc)
• DUCTILITY – ability to be drawn into a wire by a tensile force
• BRITTLENESS – sudden breaking with minimum distortion
• TOUGHNESS – resist fracture due to high impact load
• CREEP – deformation under stress and high temperature
• FATIGUE – ability to withstand cyclic stresses
• HARDNESS – resistance to wear, scratching, deformation,
machinability 7etc
Important considerations in Machine Design…..

4. Form and size of the parts

Use I-beam or Angle-iron?

The size will be determined by the forces/torques

applied (stresses on the object) and the material used
such that failure (fracture or deformation) would not
occur

8
General procedure in Machine Design…..

Need or aim Recognize and specify the problem

Synthesis Select the mechanism that would give the desired

motion and form the basic model with a sketch etc

Analysis of the FORCES

Material selection

Determine the stresses and thereby the

Design of elements
sizes of components s.t. failure or
deformation does not occur

Modification Modify sizes to ease construction & reduce overall

cost

Detailed drawing Production 9

 Standards and Codes

 Standard
◦ A set of specifications for parts, materials, or processes
◦ Intended to achieve uniformity, efficiency, and a specified
quality
◦ Limits the multitude of variations
 Code
◦ A set of specifications for the analysis, design, manufacture,
and construction of something
◦ To achieve a specified degree of safety, efficiency, and
performance or quality
◦ Does not imply absolute safety
 Various organizations establish and publish standards and codes
for common and/or critical industries
10
 Standards and Codes

 Some organizations that establish standards and codes of

particular interest to mechanical engineers:

11
Material Designation Systems

12
Material Designation Systems

13
Material Designation Systems

14
Material Designation Systems

15
 Types of Loads
I- LOADS GENERATED NORMAL STRESS
A- Normal force
-F +F
Normal force can be found as:
y z x y z x
A. Tensile force.
B. Compressive force x x y
y

F
n =
A

Where:
 : Normal stress N/mm2 z
z
A : The cross-section area, mm2
F : Applied Load, N
16
 Types of Loads
Tensile Stress and Strain

Tensile stress

Compressive stress

17
Yield Strength

18
Young's Modulus or Modulus of Elasticity Strain

Hooke's law states that, when a material is loaded within elastic limit, the
stress is directly proportional to strain, i.e.

 P A Pxl
E= = =
 l l Axl

19
Example 1
A coil chain of a crane required to carry a
maximum load of 50 kN, Find the diameter of the
link stock, if the permissible tensile stress in the
link material is not to exceed 75 MPa.

Given:
P = 50 kN = 50 × 103 N ;
 = 75 MPa = 75 N/mm2

Let:
d = Diameter of the link stock in mm.

Area = d2/4 = 0.8754 d2

It is known that the maximum load (P),

50 × 103 = t A = 75 × 0.7854 d 2 = 58.9 d2
d 2 = 50 × 103 / 58.9 = 850
 d = 29.13  30 mm
20
Example 2
A cast iron link 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.

Given:
P = 45 kN = 45 × 103 N

Tensile stress induced at section A-A

It is known that the cross-sectional area of link at section A-A,

A1 = 45 × 20 = 900 mm2

 Tensile stress induced at section A-A,

P 45 x103
 t1 = = = 50 N / mm 2
A1 900 21
Example 2 (continued)

Tensile stress induced at section B-B

It is known that the cross-sectional area of link at section B-B,

A2 = 20 (75 – 40) = 700 mm2

 Tensile stress induced at section B-B,

P 45 x103
2= = = 64.3 N / mm 2
A1 700

22
Example .3
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.

Solution

Given:
d = 50 mm
l = 600 mm
D = 400 mm
P = 0.9 N/mm2
E = 210 kN/mm2= 2.1 × 105 N/mm2
Let:
l = Compression of the piston rod.
Therefore, the cross-sectional area of piston, can be expressed as follows:
 
A= D =
2
(400) 2 = 125680mm 2
4 4
23
Example .3 (continued)

 Maximum load acting on the piston due to steam,

P = Cross-sectional area of piston × Steam pressure

= 125 680 × 0.9 = 113 110 N

Also, cross-sectional area of piston rod,

 
A= d2 = (50)2 = 1964mm 2
4 4
Also, Young's modulus (E),

P xL
113110x 600
E = 2.1 x10 = 5
==
A xL 1964 L
34555
L = 5
= 0.165mm
2.1 x10 24
 Types of Loads
B- Bending Moment
F
+ max
1
+
3 3 3 3
D

x 3
-
2 - max
L
I
Mb = F x L
Y
Fx L

M
σ = bx
b I
x
I
25
 Types of Loads

Where,
L : Member Length (arm Length), mm
D : Member diameter, mm
F : Vertical Load, N
max : Maximum normal stress due to bending moment, [Link]
b : Maximum normal stress due to bending moment, [Link]
Ix : Moment of Inertia, mm4
Y : Coordinate of the point that required to determine the
stress on it (measured from the axis of rotation of the
moment), mm

26
 Types of Loads
2- LOADS GENERATED SHEAR STRESS
A- Shear force
Shear force can be tangent to the section in
- Clockwise direction (-)
- Anti-clockwise (+) y z x y z
+F x
-F
x y x
F y
n =
A

Where:
 : Shear stress N/mm2
A : The cross-section area, mm2
z z
F : Applied Load, N 27
 Types of Loads

B- Twisting Moment
y
Mt

x Mt

Mt r y Y + max
= 1

Ip D
1 3
1
x 3 x

1Y + max

28
 Types of Loads

Where,
D : Shaft diameter, mm
Mt : Twisting moment, [Link]
 : Shear stress due to twisting moment, N/mm2
b : Maximum normal stress due to bending moment,
[Link]
Ip : Polar moment of Inertia, mm4
r : Coordinate of the point that required to determine
the stress on it (measured from the axis of
rotation of the moment i.e. measured from the
center!!), mm
29
 Types of Loads
Important Notice

[Link] stress tends to member’s elongation

(Linear Strain).
2. Linear strain can be:
- Positive (Extension)
- Negative (Contraction).

3. Shear stress tends to member’s distortion (Shear Strain).

4. Neglect the value of shear stress; generated from shear force;

for power transmission shafts because of its low value. shear
stress generated from twisting torque.

30
 Types of Loads
Sequence of Calculation

1. Determination of the reactions at the supports (bearings)

from the known external loads.

2. Draw The Load distributions. (B.M.D., S.F.D., N.F.D., T.D.)

3. Determine the critical section from the load distributions
(It is defined as the section which has the maximum loads)

4. Draw the stress distribution diagrams at the critical

section.

5. Determine the critical point on the critical section.

6. Use the suitable design equation according to the generated

stresses at the critical point.

31
Example No. 4

A solid shaft 50 mm diameter and 450 mm long is used to transmit a

mechanical power of 45 HP at speed of 1500 rpm. The modulus of
rigidity for the shaft material is 9.95x104 N/mm2 Determine:
[Link] shear stress acting on the shaft.

[Link] torsional deflection of the shaft.

Twisting Moment
P = Mt x 

P
Mt =


746  45
Mt = = 219 N .m
2  1500
60
32
Example No. 4 (continued)
Shear Stress
  D4   504
Ip = = = 613281 mm4
32 32
Mt r 219000  25
= = = 9 N / mm2
Ip 613281
Torsional Deflection
G M t  
= =
L Ip r Y
Y

R=D/2  D

L
X X
T
Y
Cross-section Y Stress Distribution
33
Example No. 4 (continued)

Mt L
=
GI p

219000  450
= 4
= 0.0016 rad
9.95  10  613281 Ip

360
 = 0.0061 rad = 0.0061 = 0.0925 deg ree
2

34
Example No.5

A pulley of diameter 750 mm and a gear of 280 mm diameter

are mounted on a steel shaft. The belt pulls on the pulley
with 1670 N and 1330 N at 450. The gear tooth force is 900 N
. The allowable shear stress and tensile stress for the shaft
material are 57 N/mm2 and 71 N/mm2 respectively.
Determine the shaft diameter.
Y
1670 N
900 N
450
A B
X

1330 N
375 mm 375 mm 500 mm
Z
35
Example No.5 (continued)

Reactions

-Pulling forces of the belt should be resolved in the vertical

and horizontal directions.

i.e., Fv : Vertical tension component.

Fh : Horizontal tension component.

Fv = Fh = (1670+1330)sin 450
= 3000 sin 45
=2120 N

36
Example No.5 (continued)

Vertical Reactions 2120 N 900 N

A
From Equilibrium: B
 M @ B ➔:
375 375 500 RB
RA  (375+375+500) = RA
(900500)+2120(375+500)

1250 RA = 450000+ 1855000

= 2305000 RA = 1844 N
 M @ A ➔:
RB  (375+375+500) = 900(375+375)+2120375
1250 RB = 675000 + 795000 RB = 1176 N

CKECK :  FY = 0 ➔: RA + RB = 1844+1176 = 2120 + 900 = 3020

 Vertical reactions are right.

37
Example No.5 (continued)
Horizontal Reactions 2120 N
From Equilibrium:
A B
 M @ B ➔:
HA  (375+375+500) = 2120(375+500) 375 375 500

1250 HA = 1855000 HA HB

HA = 1484 N

 M @ A ➔:
HB  (375+375+500) = 2120375

1250 HB = 795000
HB = 636 N

CKECK :  FY = 0 ➔:HA + HB = 1484 + 636 = 2120

 Horizontal reactions are right.

38
Example No.5 (continued)
Vertical Load Diagrams
Horizontal
2120 N 900 N 2120 N
C D B A B
A
375 375 500 375 375 500

1844 N 1176 N 1484 N 636 N

1844 N 1484
+ +
S.F.D
_
276 . 636
1176
B.M.D.
+ +
588 N.m 556.5
619
127.5 N.m

MT.D. 39
T =127.5 N.m
Example No.5 (continue)

Critical Section

Section at “C” is the critical one

This section loaded by:

1. Shear force Qx =1484 N & Qy =1844 N

(Neglected values)

2. Bending Moment Mx =556.5 N.m & My =619 N.m

3. Torque Mt = 127.5 N.m

40
Example No.5 (continue)

Shaft Design
Design Based on twisting Moment (Torque)
Mt =127.5 N.m

And, all = 57 N/mm2 (given)

127.5  103  D 2
Mt r =
D 4
= 32
Ip 57 =
127500  16
D3

127500  16
D=3 = 22 .49 mm
  57
D = 23 mm

41
Thank You

42