MEE 313 Machine Design

Lecture 1 Introduction

Asst. Prof. Kitchanon Ruangjirakit, Ph.D.

Course Information
General Information
• Lecturers
≫ Assoc. Prof. Dr. Pongpan Kaewtatip
≫ Assoc. Prof. Dr.-Ing. Vitoon Uthaisangsuk
≫ Asst. Prof. Dr. Kitchanon Ruangjirakit

• Prerequisite
≫ MEE111 Engineering Drawing
≫ MEE213 Mechanics of Solids

• Related Fundamental Courses

≫ Engineering Mechanics, Engineering Materials, Statistics for Engineers

3
Course Objectives
1. To analyze simple mechanical component based on failure theories.

2. To analyze and design typical machine elements and conform with codes
and standards.

3. To design simple mechanical systems using common machine elements.

4
 Course Objectives
Course Plan of MEE 313 Machine Design Plan For 1/2020 Semester

Lecturers: (1) Assoc. Prof. [Link] Uthaisangsuk, (2) Assoc. Prof. [Link] Kaewtatip, (3) Asst. Prof. [Link] Ruangjirakit

Course Syllabus
Phases of design, Theory of failure used in design of machine elements subjected to static and varying loads, Mechanical springs, Power screws and threaded fasteners, Welded joints, Flexible drives, Design of spur gears, helical gears, bevel gears and worm gears,
Design of shafts, Design of rolling bearing, Lubrication and journal bearings, Design of Keys, splines and couplings, Clutches and brakes, Form design.

Learning Outcome (LO) Level 1 Level 2 Level 3 Level 4 Level 5

1. Analyze simple mechanical Identify functions of mechanical Select and explain appropriate static failure Select and explain appropriate fatigue failure Apply appropriate static or fatigue theory
component based on failure components and describe loading types as theory to component analysis theory to component analysis and evaluate failure of simple
theories well as failure mechanism components correctly
Activity - Lecture and examples - Lecture and examples - Lecture and examples - Lecture and examples
- Online materials - Online materials - Online materials - Online materials
Assessments - Examination - Examination - Examination - Examination

2. Analyze and design typical Identify functions and describe loading Apply appropriate theories to determine Perform safety analysis and evaluate lifetime Theoretically select and/or design
machine elements and conform types of machine components critical forces/stresses of each machine of each machine elements individual machine elements
with codes and standards elements
Activity - Lecture and examples - Lecture and examples - Lecture and examples - Lecture and examples
- Online materials - Online materials - Online materials - Online materials
Assessments - Examination - Examination - Examination - Examination

3. Design simple mechanical Define specifications of machine and Select and draw schematic diagram of the Correctly perform calculations and analyses Determine details of each machine Provide suitable design and corresponding
systems using common machine required elements based on desired machine and relevant free body diagram for each designed machine element element according to the calculation machine elements as well as
elements functions (FBD) of machine components recommendation for improvement
Activity - Class project - Class project - Class project - Class project - Class project
Assessments - Class project presentation and report - Class project presentation and report - Class project presentation and report - Class project presentation and report - Class project presentation and report

5
Exam and Grading
• The exam will be opened book.

• Only one scientific calculator is allowed.

• All students must take all exams otherwise o ill ecei e he Fe

grade. Only extenuating circumstances will be accepted as excuse for
missing an exam. Health related excuses require medical reports and the
signature of a physician that provided treatment.

• Class participation (including the timely completion of any assignments) is a

basic expectation for all. Students failing to meet this expectation may see
their final grades substantially lowered.

6
Exam and Grading (continued)
• Grading system: the final grade will be determined by the weighting
scheme below
≫ Midterm Exam -- 40%
≫ Final Exam -- 40%
≫ Class Project and Homework -- 20%

• Student who obtains the score lower than 35% will not pass this course, i.e.
they will receive the F g ade.

7
Textbooks
• Main Textbook
≫ Richard G. Bundynas and J. Keith Nisbett, Shigle Mechanical
Engineering Design, 10th Edition in SI units, McGraw-Hill, 2015.

Contents (4 parts)

Part 1 Basics Prerequisite

Part 2 Failure Prevention

Covered in
Part 3 Design of Mechanical Elements this course

Part 4 Special Topics Extra topics

8
Textbooks (continued)
• Related Thai Textbook (to be used as references)
≫ จ ญ ตนตพ ก ,ก ก บบชน น ค งจกก 1 2, พ พค งท 4, ค ช ก ค งก
จธ., 2550

≫ Joseph E. Shigley, Charles R. Mischke and Richard [Link], ก ก บบ ค งจก ก ( ป

บ งด ณ ทธ กต ทต), บ ท นกพ พท ปจ กด, 2547

9
Course Outlines (Tentative)
No. of lecture Contents
1 Introduction to mechanical engineering design, Failure resulting from
(11 Aug.) static loading (Static strength, Stress concentration, Failure theories,
failure of ductile materials)
2 Failure resulting from static loading (Failure of brittle materials, Selection
(18 Aug.) of failure criteria)
Fatigue failure resulting from variable loading (Introduction to fatigue in
metals, The stress-life methods, Endurance limit)
3 Fatigue failure resulting from variable loading (Fatigue Strength,
(25 Aug.) Endurance limit modifying factor, Stress concentration and notch
sensitivity, Fluctuating stress)
4 Fatigue failure resulting from variable loading (Combination of loading
(1 Sep.) modes)
Shaft and shaft components (Materials, Layout, Shaft design for stress)

10
Course Outlines (Tentative)
No. of lecture Contents
5 Shaft and shaft components (Deflection, Critical speed)
(8 Sep.) Flexible mechanical elements (Flat- and round-belt drives)
6 Flexible mechanical elements (V-Belts)
(15 Sep.) Welding, bonding and the design of permanent joints (Symbols, Butt and
fillet welds, Stresses in welded joint in torsion and bending)
7 Welding, bonding and the design of permanent joints (Strength of welded
(22 Sep.) joints, Static loading, Fatigue loading)
Midterm exam: 40% (Date and Time to be announced later)
8 Screws, fasteners and the design of Nonpermanent joints (Thread
(17 Oct.) standard, Threaded fasteners, Joints stiffness, Bolt strength, Tension
Make-up joints, Relating bolt torque to bolt tension)

11
Course Outlines (Tentative)
No. of lecture Contents
9 Screws, fasteners and the design of Nonpermanent joints (Tension joint
(20 Oct.) with preload, Fatigue loading, Bolted and riveted joints in shear)
Mechanical springs (Stresses in helical springs, The curvature effect)
10 Mechanical springs (Deflection of helical springs, Compression springs,
(27 Oct.) Stability, Spring materials, Helical compression spring design for static
service, Critical frequency of helical springs, Fatigue loading of helical
compression springs)
11 Mechanical springs (Helical compression spring design for fatigue loading)
(31 Oct.) Spur gears (Types of gears, Nomenclature, Fundamentals, Contact ratio,
Make-up Interference, Gear trains, Force analysis)

12
Course Outlines (Tentative)
No. of lecture Contents
12 Spur gears (The Lewis bending equation, surface durability, AGMA stress
(3 Nov.) equations, AGMA strength equations, geometry factors, The elastic
coefficient, Dynamic factor, Overload factor, Surface condition factor, Size
factor, Load-distribution factor, Hardness-ratio factor, Stress cycle life
factors, Reliability factor, Temperature factor, Rim-thickness factor)
13 Spur gears (Analysis, Design of a gear mesh)
(10 Nov.) Rolling-contact bearing (Bearing types, Bearing life, Bearing load life at
rated reliability, Bearing survival: reliability versus life, Related load, Life
and reliability, Combined radial and trust loading, Selection of ball and
cylindrical roller bearings,)
Lubrication and journal bearings (Types of Lubrication, Viscosity, Pe off
Equation, Stable Lubrication)

13
Course Outlines (Tentative)
No. of lecture Contents
14 Rolling-contact bearing (Selection of tapered roller bearing, design
(17 Nov.) assessment)
Lubrication and journal bearings (Types of Lubrication, Viscosity, Pe off
Equation, Stable Lubrication, Thick-Film Lubrication, Hydrodynamic
Theory, Design Considerations)
15 Lubrication and journal bearings (The Relations of Variables, Steady-State
(24 Nov.) Conditions in Self-Contained Bearings, Clearance, Pressure-Fed bearings)

Final exam: 40% (Date and Time to be announced later)

14
Contents before mid-term exam
• Part 1 (Prerequisite)
• Part 2
≫ Chap. 5: Failures resulting from static loading
≫ Chap. 6: Fatigue failure resulting from variable loading
• Part 3
≫ Chap. 7: Shaft and shaft components
≫ Chap. 9: Welding, bonding, and the design of permanent joints
≫ Chap. 17: Flexible mechanical elements

15
Contents after mid-term exam
• Part 3
≫ Chap. 8: Screws, fasteners, and the design of nonpermanent joints
≫ Chap. 10: Mechanical springs
≫ Chap. 11: Rolling-contact bearings
≫ Chap. 12: Lubrication and journal bearings
≫ Chap. 13: Gears General
≫ Chap. 14: Spur and helical gears (spur gear only)

16
Important Dates
• The first lecture will start from August 11th, 2020.

• Midterm exam will be announced later.

• Final exam will be announced later.

17
Lectures

The presentation of each lecture can be downloaded from

18
Part 1: Basics
Design?

To formulate a plan for the satisfaction of a specified need

or
What
To solve a problem
is
Design? Which leads to

Product that is
Functional, safe, reliable, competitive, usable,
manufacturable, and marketable

20
Design process
Identification of need

Recognition of the need and phrasing the need

often constitute a highly creative act, because
the need may be only a vague discontent, a
feeling of uneasiness, or a sensing that
something is not right.

21
Design process
Definition of problem

More specific and must include all the

specifications for the object that is to be
designed. The specifications are the input and
output quantities, the characteristics and
dimensions of the space the object must
occupy, and all the limitations on these
quantities.

22
Design process
Synthesis

Sometimes called the in en ion of he conce

o conce de ign . This is the first and most
important step in the synthesis task. Various
schemes must be proposed, investigated, and
quantified in terms of established metrics.

23
Design process
Analysis and optimization

Analyses must be performed to assess whether

the system performance is satisfactory or
better, and, if satisfactory, just how well it will
perform. System schemes that do not survive
analysis are revised, improved, or discarded.
Both analysis and optimization require that we
construct or devise abstract models of the
system that will admit some form of
mathematical analysis. We call these models
ma hema ical model .

24
Design process
Evaluation

Significant phase of the total design process.

Evaluation is the final proof of a successful
design and usually involves the testing of a
prototype in the laboratory. The project
designer or design team will need to address a
myriad of engineering and non-engineering
questions.

25
Design process
Evaluation

Significant phase of the total design process.

Evaluation is the final proof of a successful
design and usually involves the testing of a
prototype in the laboratory. The project
designer or design team will need to address a
myriad of engineering and non-engineering
questions.

• Iterative in nature.
• Requires initial estimation, followed
by continued refinement.

26
Design process
Presentation

Communicating the design to others is the final,

vital presentation step in the design process.
Presentation is a selling job. The engineer,
when presenting a new solution to
administrative, management, or supervisory
persons, is attempting to sell or to prove to
them that their solution is a better one.

27
 Standards and Codes
Standards Codes

≫ Set of specifications for parts, ≫ Set of specifications for the

materials, or processes intended to analysis, design, manufacture, and
achieve uniformity, efficiency, and a construction of something.
specified quality.
≫ To achieve a specified degree of
≫ To limit the multitude of variations safety, efficiency, and performance
that can arise from the arbitrary or quality.
creation of a part, material, or
process.

28
 Economics
Standard Sizes Large Tolerances

Since parts having large

The use of standard or tolerances can often be
stock sizes is a first produced by machines
principle of cost with higher production
reduction. rates, costs will be
significantly smaller.

Breakeven Points Cost Estimates

There are many ways of obtaining relative cost
There occurs a point figures so that two or more designs can be roughly
corresponding to compared. The design having the smaller number of
equal cost, which is parts is likely to cost less. Many other cost estimators
called the breakeven can be used, depending upon the application, such
point. as area, volume, horsepower, torque, capacity,
speed, and various performance ratios.

29
 Stress and Strength
Stress is a state property at a specific Strength is a property of a material
point within a body, which is a or of a mechanical element. The
function of load, geometry, strength of an element depends on
temperature, and manufacturing the choice, the treatment, and the
processing. processing of the material. Strength
is an inherent property of a part, a
(sigma) normal stress property built into the part
(tau) shear stress because of the use of a particular
material and process.
• 1 is a principal normal stress
• y is a normal stress component in the y
direction
S Strength
• r is a normal stress component in the
• Sy is a yield strength
radial direction.
• Ssy is a shear yield strength

30
Uncertainty
• Common sources of uncertainty in stress or strength

31
Uncertainty
• Deterministic method
≫ Establishes a design factor, nd
≫ Based on absolute uncertainties of a loss-of-function parameter and a
maximum allowable parameter

• If, for example, the parameter is load, then

32
Design Factor Method
• Often used when statistical data is not available
• Since stress may not vary linearly with load, it is more common to express
the design factor in terms of strength and stress.

• All loss-of-function modes must be analyzed, and the mode with the
smallest design factor governs.
• Stress and strength terms must be of the same type and units.
• Stress and strength must apply to the same critical location in the part.
• The factor of safety is the realized design factor of the final design,
including rounding up to standard size or available components.

33
Design Factor Method

34
Reliability and Probability of Failure
• Probability of Failure, pf the number of instances of failures per total
number of possible instances.
• Reliability method of design A method of design that relates the
distribution of stresses with the distribution of strengths to achieve an
acceptable success rate.
• Reliability, R The statistical measure of the probability that a mechanical
element will not fail in use.
• The reliability is related to the probability of failure by

Example: If 1,000 parts are manufactured, with 6 of the parts failing, the reliability is
(0.994 or 99.4%)

35
Reliability and Probability of Failure
• Series System a system that is deemed to have failed if any component
within the system fails.
• The overall reliability of a series system is the product of the reliabilities of
the individual components.

Example: A shaft with two bearings having reliabilities of 95% and 98% has an overall reliability of
(0.93 or 93%)

• Reliability is the statistical probability that machine systems and

components will perform their intended function satisfactorily without
failure.

36
Case Study: Power Transmission

37
Case Study: Power Transmission

38
Case Study: Power Transmission

39
 Chapters 2, 3 and 4 are left out for the students to
revisit. It is highly encouraged that all students must
revise the contents in the above chapters before moving
on to the next part.

40
Part 2: Failure Prevention
Failure resulting from static loading
• Failure can mean a part has separated into two or more pieces; has
become permanently distorted, thus ruining its geometry; has had its
reliability downgraded; or has had its function compromised, whatever the
reason.

• Static load stationary force or couple applied to a member. To be

stationary, the force or couple must be unchanging in magnitude, point or
points of application, and direction. A static load can produce axial tension
or compression, a shear load, a bending load, a torsional load, or any
combination of these. To be considered static, the load cannot change in
any manner.

42
Failure resulting from static loading

43
Static Strength
• Ideally, in designing any machine element, the engineer should have
available the results of a great many strength tests of the particular
material chosen. These tests should be made on specimens having the
same heat treatment, surface finish, and size as the element the engineer
proposes to design; and the tests should be made under exactly the same
loading conditions as the part will experience in service.
• More often than not it is necessary to design using only published values of
yield strength, ultimate strength, percentage reduction in area, and
percentage elongation.

How can one use such meager data to design against both static and dynamic
loads, two- and three-dimensional stress states, high and low temperatures, and
very large and very small parts?

44
Stress Concentration
• Any discontinuity in a machine part alters the stress distribution in the
neighborhood of the discontinuity so that the elementary stress equations
no longer describe the state of stress in the part at these locations. Such
discontinuities are called re rai er , and the regions in which they occur
are called areas of re concen ra ion .

• Stress concentrations can also arise from some irregularity not inherent in
the member, such as tool marks, holes, notches, grooves, or threads.

45
Stress Concentration
• A theoretical, or geometric, stress-concentration factor (SCF) Kt or Kts is
used to relate the actual maximum stress at the discontinuity to the
nominal stress. The factors are defined by the equations

Normal Stresses Shear Stresses

The nominal stress 0 or

0 is the stress calculated by
using the elementary stress
equations and the net area, or
net cross section.

46
Stress Concentration

47
Stress Concentration

48
Stress Concentration
• Note on Stress Concentration
≫ In static loading, stress-concentration
factors are applied as follows. In
ductile materials ( f 0.05), he
stress-concentration factor is NOT
usually applied to predict the critical
stress (i.e. Kt = 1), because plastic
strain in the region of the stress
concentration is localized and has a
strengthening effect.

49
Stress Concentration
• Note on Stress Concentration
≫ In brittle materials ( f < 0.05), the geometric stress-concentration factor
Kt is applied to the nominal stress before comparing it with strength.
≫ Materials often thought of as being ductile can fail in a brittle manner
under certain conditions, e.g., any single application or combination of
cyclic loading, rapid application of static loads, loading at low
temperatures, and parts containing defects in their material structures.
≫ An exception to this rule is a brittle material that inherently contains
microdiscontinuity stress concentration, worse than the
macrodiscontinuity that the designer has in mind. When a tensile test
on a cast iron is performed, the strength reported in the literature
includes this stress concentration. In such cases Kt or Kts need not be
applied.

50
Stress Concentration
• Note on Stress Concentration
≫ For dynamic loading, the stress concentration effect is significant for
both ductile and brittle materials and must always be taken into
account.

51
Stress Concentration

~ 2.5

~ 2.7
~ 2.5

52
 Failure Theories
• There is no universal theory of failure for the general case of material
properties and stress state. Instead, over the years several hypotheses
ha e been fo m la ed and e ed, leading o oda acce ed ac ice .

Brittle (fracture criteria) Ductile (yield criteria)

• Maximum normal • Maximum shear
stress stress
• Brittle Coulomb- • Distortion energy
Mohr • Ductile Coulomb-
• Modified Mohr Mohr

53
 Revision: Plane Stress and Plane Strain

Nine (9) stress components

• Normal: x, y, z
• Shear: xy, yz, xz, yx, zy, zx
Source: [Link]

54
Re i ion: Moh Ci cle
• Formulas for the o inci al e e 1 and 2 (plane
stress condition) are

• In a similar manner the two extreme-value shear stresses

1 and 2 are found to be

55
Re i ion: Moh Ci cle
• A graphical method for expressing the relations developed in this section,
called Moh ci cle diag am, is a very effective means of visualizing the
stress state at a point and keeping track of the directions of the various
components associated with plane stress.

• The parametric relationship between and is that of a circle plotted in

the , plane, where the center of the circle is located at
and has a radius of

56
Re i ion: Moh Ci cle

57
Re i ion: Moh Ci cle

58
Maximum-Shear-Stress (MSS) Theory
• The MSS theory is also referred to as the Tresca or Guest theory.

Yielding begins whenever the maximum shear stress in any element

equals or exceeds the maximum shear stress in a tension-test specimen of
the same material when that specimen begins to yield.

59
Maximum-Shear-Stress (MSS) Theory
Analysis
Simple Tensile = P/A
Test max = /2 At yield max = Sy/2

or

General State =(
of Stress 1 2 3 max 1 3)/2

Design

60
Maximum-Shear-Stress (MSS) Theory
Plane Stress Analysis (One of the principal stresses = 0)
• Label two non-zero principal stresses as A and B.

61
Maximum-Shear-Stress (MSS) Theory

Factor of safety (n)

guarding against
yield

n = Ob/Oa

62
Distortion-Energy (DE) Theory
• The DE theory is also called
≫ The von Mises or von Mises-Hencky theory.
≫ The shear-energy theory
≫ The octahedral-shear-stress theory

Yielding occurs when the distortion strain energy per unit volume reaches
or exceeds the distortion strain energy per unit volume for yield in simple
tension or compression of the same material.

63
 Distortion-Energy (DE) Theory
Strain Energy per unit
+ +
volume for simple tension
1
uv =
1 2
6E
( 2
1 + 2
2 + 2
3 +2 1 2 +2 2 3 +2 3 1 ) av = 1 2
3
3

u= Note: ud =0 if 1 = 2 = 3
2
u d = u uv =
1+ ( 1 2 ) +(
2
2 3 ) +(
2
3 1 )
2

1 3 2 3E 2
u= 2
1 + 2
2 + 2
3 2 ( 1 2 + 2 3 + 3 1 ) uv = (1 2
av
)
2E 2E
1
u= 1 1 + 2 2 + 3 3
2

1
1 = 1 ( 2 + 3 )
E
1
2 = 2 ( 1 + 3 )
E
1
3 = 3 ( 1 + 2 )
E

64
 Distortion-Energy (DE) Theory
General state of stress Simple tensile test ( 1 = Sy, 2 = 3 = 0)
1+ ( )2 + ( )2 + ( )2 1+
u d = u uv = 1 2 2 3 3 1
ud = S y2
3E 2 3E

Equivalent or Effective stress or von Mises stress

65
Distortion-Energy (DE) Theory
Principal Stresses xyz Components

Plane Stress Analysis (One of the principal stresses = 0)

• Label two non-zero principal stresses as A and B.

Principal Stresses

xyz Components

66
Distortion-Energy (DE) Theory
At this point, MSS predicts
failure while DE suggests
no yielding occur.
Hence,
MSS is more conservative
than DE.

Design

67
Distortion-Energy (DE) Theory

68
Example

69
Example

70
Coulomb-Mohr Theory
• This theory is used when Syt Syc.
• It is also called Internal friction theory.

Failure envelope

Pure compression Pure shear Pure tension

71
Coulomb-Mohr Theory
• Coulomb-Mohr Theory assumes boundary BCD is straight. Therefore, only
compressive and tensile strengths are necessary.

Similar triangles

or

B1C1 = St/2 OC1 = St/2

B2C2 = ( 1 3)/2 OC2 = ( 1 + 3)/2

B3C3 = Sc/2 OC3 = Sc/2

72
Coulomb-Mohr Theory

Canceling the 2 in each term,

cross-multiplying, and simplifying

Either yield strength or ultimate

strength can be used

73
Coulomb-Mohr Theory
Plane Stress Analysis (One of the principal stresses = 0)
• Label two non-zero principal stresses as A and B.

74
Coulomb-Mohr Theory
For pure shear

• 1 =- 3=

• Torsional yield strength

occurs when max = Ssy

• Substituting
1 = - 3 = Ssy
and simplifying gives
Design

75
Example

76
Summary: Failure Theories for Ductile Materials

77
Example

78
Example

79
Example

80
Example

81