MACHINE DESIGN

With some notion of arrangement of machine elements, we may begin the calculations.
From data, such as the work done or power consumed, we compute forces on each part for a
sequence of positions of the machine’s cycle using the principles of mechanics then we 1design
each element so that it will perform its allotted function without failure.

We must necessarily use the principles of strength of materials, but this course should
not be thought of as a review of those principles. Rather, it is an application to engineering
problems with the aim of finding suitable dimensions of the machine elements. In the process
the designer makes a stress analysis, deciding upon the points in the various parts subjected to
the maximum stress conditions (and the kind of stress).

Since it is seldom possible to use any theoretical equation to determine a dimension and
adopt the result unthinkingly, the important requisite now is judgement. Computed results only
provide evidence for eventual decisions.

FOR THE STUDENTS

Education without misrepresentation is impossible. There are so many things that need
to be said at once to the beginner that many statements must be simplifications in order to be
intelligible. For pedagogical reasons, safe design procedures are often given in this book –
usually into too much detail. Although it is a convenience to the teacher to be confronted with
some uniformity of approach for grading purposes, there are likely to be other “correct” points
of view. Your teacher or supervisor may ask for another. After few years of experience, your
conclusions will rest more and more on your own background, but it is hoped that you will
always be in search of better design approaches. Since there is no single correct answer to a
design problems unless the procedure is specified correctly, including the design factor and the
material, your instructor is more interested on how you attack a problem and in the decisions
you make than in the results. Therefore, work for a good solution, not so much for an answer.

In any subject, there is a certain amount of new language to be learned. Since difficulty
with a new subject is often synonymous with an ignorance of the language of the subject, pay
close attention to new words, making a real effort to master them. Comprehending study prior
to working a problem is truly a time – saver, student practice to the contrary notwithstanding.
The attitudes that you might begin to acquire have been expressed in Report on Engineering
Design from which the following is quoted:

1) Willingness to proceed in the face of incomplete and often contradictory data and
incomplete knowledge of the problem.
2) Recognition of the necessity of developing and using engineering judgement.
3) Questioning attitude toward every piece of information, every specification, every
method, every result.
4) Recognition of experiment as the ultimate arbiter.

1
 5) Willingness to assume final responsibility for a useful result.

Engineering is the art of applying the physical sciences to the solution of the problems of
mankind. If, after completion of your study of this book, you feel somewhat knowledgeable yet
uncertain, our aim will have been at least partially accomplished. The art is never perfected.
Moreover, since uncertainty is the father of progress, only the ignorant can afford to certain. As
you will see, machine design is engineering.

The Essence of Designing

Thorough understanding of materials for design

1. Know the properties and strength of the materials (done by std. test)

2. Apply a suitable “factor of ignorance” (factor of safety) to produce a “working” or

“allowable” or design strength.

Design strength = strength of material / factor of safety

3. Equate the design strength with the induced stress due to the load.

Sufficient knowledge on the strength theory and effects of load on a material:

1. Know the load on the material.

2. Compute the failure causing stress (induced stress).

3. For good design, equate the induced stress with the “allowable” or design strength of
the material.

DUCTILE MATERIAL BRITTLE MATERIAL

Low and medium carbon steels Cast iron, high carbon and alloy
steel, glass, rubber
High resistance to deformation Low resistance to deformation
Basically soft Basically hard
High capacity for impact load Low capacity for impact load
Fails by yielding or necking Fails by structure
Has a defined yield point No defined yield point

Low carbon  0.10% - 0.25%

Medium carbon  0.25% - 0.50%

2
 Last two digits in a four digit number give the approximate average carbon content in
“points” or hundredths of percent.

Example: AISI C1030 has 0.30% carbon or 30 points of carbon.

Standard Tensile Test

PEL – proportional elastic limit

Ou – max. stress that would cause failure

Oy – max. stress without causing failure

3
Super Imposed Stress-Strain Curve

Ductile Material: Tensile Stress Properties

Resilience (Modulus of Resilience)  ability to absorb impact loads within the elastic zone

Toughness (Modulus of Toughness)  ability to absorb impact loads within the elastic zone.

Hooke’s Law (ut tension sic vis)

Within the PEL, the stress is directly proportional to the strain.

4
Facts from the Stress-Strain Curve

Suggested Factors of Safety for Novice in Machine Design

LOAD DUCTILE BRITTLE

Steady 1.5 – 2.0 3.0 – 4.0
Minor shock 3.0 – 4.0 6.0 – 8.0
Heavy shock 6.0 – 8.0 12.0 – 16.0

NOTE: Ơ  sigma (fiber stresses)

Ʈ  tau (shear stresses)

Direct Loads: Axial or Normal (F A)

Loads are applied at the neutral or symmetric axis

5
Definitions

Age Hardening - (precipitation hardening) occurs in some metals, notably certain

stainless steel, aluminium, and copper alloys at ambient temperature after the
solution heat treatment, the process being one of a constituent precipitating from
solid solution.

Alloy - is a substance w/ metallic properties, composed to be the metallic

elements added which at least one is metal.

Alloying elements - in steel are usually considered to be the metallic elements added for
the purpose of modifying the properties.

Anisotropy - is the characteristic of exhibiting different properties when tested in

different directions.

Brittleness - is a tendency to fracture without appreciable deformation.

Charpy test - is one in which a specimen supported at both ends as a simple beam is
broken by the impact of a falling pendulum.

Cold shortness - is a brittleness of metals at ordinary or low temperature.

Cold working - is the process of deforming a metal plastically at a temperature below

the recrystallization temperature and at rate to produce strain hardening.

Damping capacity - is the ability of a material to absorb or dump vibrations, which is the
process of absorbing kinetic energy of vibration owing to hysteresis.

De carburization - is a loss of carbon from the surface of steel, occurring during hot
rolling, forging and heat treating, when the surrounding medium reacts with the
carbon.

Ductility - is that property that permits permanent deformation before fracture in

tension.

Elasticity - is the ability of a material to be return and to return to the original shape.

Embrittlement - involves the loss of ductility because of a physical of chemical charge of

a material.

Force Carbon - is that part of the carbon content of steel or iron that is in the form of
graphite or temper carbon.

Hard Drawn – is a temper produce in a wire, rod or tube by cold drawing.

Homogeneous Materials - have the structure at all points.

6
Isotropic - materials have the same properties in all directions.

Izod test - is a test which a specimen supported at one end as a cantilever beam is
broken by the impact of a falling pendulum.

Killed Steel - is a steel that has been deoxidized with a strong deoxylizing agent such as
silicon or aluminium in order to eliminate a reaction between the carbon and
oxygen during solidification.

Machinability - is a somewhat indefinite property that refers to the relative case with
which the material can be cut.

Malleability - is a material susceptibility to extreme deformation in rolling or

hammering.

Mechanical Properties - are those that have to with stress or strain. Ultimate strength
and percentage elongation for example;

Percentage for Elongation - is the extension in the vicinity of the fracture of a tensile
specimen , express a percentage of the original gage length, as 20% in 2 inches.

Percentage reduction or area – is the smallest area at the point of rupture of a tensile
specimen divided by the original area.

Physical Properties – include not mechanical properties and other physical properties
such as density, conductivity, coefficient of thermal conduction.

Plasticity – is the ability of a metal to be deform considerably without rupture.

Poisons Ratio – is the ratio of lateral strain to the longitudinal strain with the element is
loaded with a longitudinal tensile force.

Precipitation Heat treatment – brings clout the precipitation of constituent from a super
saturated solid solution by holding a body at an elevated temperature , also called
artificial aging.

Proof stress – is that stress which causes a specified permanent deformation of a

material.

Red Shortness – is the brittleness in the steel when it is red hot.

Relaxation – associated with creep, is the decreasing stress at the constant strain;
important for metals in high temperature service.

Residual stresses – are those not due to applied loads or temperature gradients; they
exist for various reasons as un equal reasons rates cold working etc.

7
 Rimmed steel – is incompletely deoxidized steel.

Solution heat treatment – is the process of rolling an alloy at a suitably high temperature,
long enough to permit one or more constituents to pass into solid solution and
then cooling fast enough to hold the constituents as a super saturated solution.

Stiffness – is the ability to resist deformation.

Strain Hardening – is increasing the hardness and strength by plastic deformation at

temperatures lower than the recrystallization range.

Temper – is a condition produce in a non ferrous metal by mechanical or thermal

treatment.

Toughness – is the capacity of a material to withstand a shock load without breaking.

Transverse strength – refers to the results of a transverse bend test the specimens being
mounted as a simple beam ; also called rupture modulus.

Work Hardening – is the same as strain hardening.

Wrought steel – is the steel that has been hammered. Rolled or drawn in the process of
manufacture: it may be plain carbon or alloy steel.

HEAT-TREATMENT TERMS

Heat treatment - is an operation or combination of operations involving the heating and

cooling of metal or an alloy in the solid state for the purpose of altering the
properties of the metal.

Aging - is a change in a metal by which is structure recovers from an unstable or

metastable condition that has been produced by quenching or cold working.

Annealing - a comprehensive term, is a heating and slow cooling of a solid metal, usually
done to soften it.

Critical range - has the same meaning as transformation range.

Drawing - is often use to mean tempering, but this usage conflicts with the meaning of the
drawing of a material through a die and is to be avoided.

Graphitizing - causes the combined carbon to transform wholly or in parts into graphitic
or free carbon.

Hardening - is the heating of certain steels above the transformation range and then
quenching, for the purpose of increasing the hardness.

8
 Malleablizing - is an annealing process whereby combined carbon in white cast iron is
transform wholly or in part to temper carbon.

Normalizing - is the heating of an iron-base alloy to some 100°F above the transformation
range with subsequent cooling to bellow that range in still air at room
temperature.

Spheroidizing - is any heating and cooling of steel that produces a rounded or globular
form of carbide.

Stress relieving - is the heating of a metal body to a suitable temperature and holding it at
that temperature for a suitable time for the purpose of reducing internal residual
stresses.

Tempering – is a reheating of hardened or normalized steel to a temperature below the

transformation range, followed by any desired rate of cooling.

Transformation range – for ferrous metals is the temperature interval during which
austenite is formed during heating.

TYPES OF MATERIALS

ALLOY STEEL

Wrought alloy steel is a steel that contains significant quantities of recognized

alloying metals, the most common being aluminium, chromium, cobalt, copper,
manganese, molybdenum, nickel, phosphorous, silicon, titanium, tungsten and
vanadium.

WROUGHT IRON

Wrought iron is made by burning the carbon from molten iron and then putting
the product through hammering and rolling operation.

CAST IRON

Cast iron in a general sense includes white cast iron , malleable iron and nodular
cast iron, but when cast iron is such in used without qualifying adjective, gray iron
is meant.

MALLEABLE IRON

Malleable iron is a heat treated white cast iron.

9
NODULAR CAST IRON

It was a good resistance to thermal shock and its “growth” at high temperature is
less than of gray iron.

CAST STEEL

The combination of highest strength and highest ductility is a cast ferrous metal is
obtained in cast steel.

STAINLESS STEEL

Stainless steel is a relatively expensive but where the environment is significantly

corrosive or at high of quite low temperatures. It provides an economical answer
for many problems.

COPPER ALLOYS

Copper and its alloy have characteristics that determine the advisability of their
use; among these may be mentioned: electrical and thermal conductivity,
resistance to corrosion, malleability and formability, ductility, strength and
excellent machinability, non – magnetic, pleasing finish, case of being plated and
castability.

ALUMINUM ALLOYS

The characteristics of aluminium alloys that suggest their use included: high
electrical and thermal conductivity; resistance to some corrosive effects; ease of
casting; working and high mechanical properties.

PLASTICS

Plastics are divided into two main classes – thermosetting, which undergo
chemical change and harden on being heated, usually under pressure; and
thermoplastic, which soften as the temperature rises and remain soft in the
heated state.

SYSTEM OF SPECIFICATION

STEEL SAE

Plain Carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10XX

Free Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11XX

Manganese . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13XX

10
 Boron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14XX

Nickel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2XXX

Nickel chromium . . . . . . . . . . . . . . . . . . . . . . . . . . .3XXX

Heat and corrosion resistant . . . . . . . . . . . . . . . . . 303XXX

Molybdenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4XXX

Molybdenum-chromium. . . . . . . . . . . . . . . . . . . . .41XX

Molybdenum-chromium-nickel. . . . . . . . . . . . . . . .43XX

Molybdenum-nickel. . . . . . . . . . . . . . . . . . . . . . . . .46XX

Molybdenum-chromium-nickel. . . . . . . . . . . . . . . .47XX

Molybdenum-nickel. . . . . . . . . . . . . . . . . . . . . . . . .48XX

Chromium. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5XXX

Heat and corrosion resistant. . . . . . . . . . . . . . . . . 514XX

Chromium vanadium. . . . . . . . . . . . . . . . . . . . . . . . 515XX

Nickel-chromium-molybdenum. . . . . . . . . . . . . . . . .6XXX

Nickel-chromium-molybdenum(except 92XX). . . . . .9XXX

Silicon-manganese. . . . . . . . . . . . . . . . . . . . . . . . . . . 92XX

1. A journal bearing with of 76.2 mm is subjected to a load of 4900N while rotating at 100 rpm.
If each coefficient of friction is 0.02 and the L/D=2.5, find its projected area in mm².

Solution:

L/D=2.5 area= DxL

L=D (2.5) =76.2x 190.5

L= 76.2(2.5) = 190.5mm area= 14516 mm²

11
2. What modulus of elasticity in tension is required to obtain a unit deformation of 0.00105m/m
from a load producing a unit stress of 44000psi?

Solution:

E = Stress/Strain

= 44000/0.00105

E = 41.905x106 psi

3. The shaft whose torque varies from 2000 to 6000 in-lbs. has 1 1/2 inches in diameter and
60000psi yield strength. Compute for the shaft mean average stress.

Solution:

Tave = (2000+6000)/2

= 4000 in-lbs

Ss = (16T/π d3); d = 5 in.

= [(16)(4000 in – lb)]/ π(1.5 in)3

Ss = 6036.099 psi

4.) How many 5/16 inch holes can be punch in one motion in a steel plate made of SAE 1010
steel, 7/16 inch thick using a force of 55tons. The ultimate strength for shear is 50ksi and
use 2 factor of safety.

Ss = 50 ksi = 50000 psi F = Ss x A

A = π dt = 50000 lb/in2 (.4295 in2)

= π(5/16 in)(7/16 in) F = 21475.73 lb

A = 0.4295 in2

12
1. The simple beam shown, 30 inch long =(a+L+d), is mode of ASI C1022 steel, as rolled, left as
forged. At a= 10, F1= 3000 lb is a dead load. At d= 100 inch, F 2= 2400 lb is a repeated,
reversed load. For N= 15, indefinite life and h= 3b, determine b and h (Ignore stress
concentration)

Given
L = 30 in F1 = 30000 lb F.S. = 15
a = 10 in d = 10 in
h = 3b F2 = 2400 lb

AISI C1022 as rolled (Table AT 7; Faires p.576)

Oy= 52 ksi
Ou= 72 ksi
Required
Dimension b and H

Solution
Since it is a ductile material use Soderberg equation

1/FS =Om/Oy + O a/On

Solving for Om

Om= (Omax +O min)/2

Where Omax= Mmax C/1

Omin= Omin C/1

Solving for Mmax, Mmin

10in 10in 10in

R1 R2
A 30 B
Solving for support reactions

13
 + ∑M =0 A

F1 (10) + F2 (20) - R2 (30)= 0

(3000)(10) + (2400)(20) - R2(30)=0
R2=2600lb

∑ FY =0

R1=3000 + 2400 – R2

R1= 2800lb

M diagram

Mmax = 28000 lb-in

Mmin= 0

Om= Omax +O min/2

Om= (2800lb-in)(3b/2)/(27b4/12)/2

Om=9333.335 lb-in/b3

Solving for On

14
On = 0.8 O ‘n (surface factor)

Where O ‘n = 0.5 Ou (wrought iron)

= 0.5 (72000 psi)
O ‘n= 36000 psi

Surface factor = 0.5273 (forged)

Fig. AF 5 (Faires, page 583)

On= 0.8 (36psi)(0.5273)

On= 151186.24psi

Substituting the value of FS, Om, Oy, Oa, and On to Soderberg Equation

1/FS = O m/Oy + O a/On

1/1.5 = (9333.335 lb-in/b3)/52000 lb/ in2 + (9333.335 lb- in/b3)/15186.24 lb/in2

1/1.5 = 0.79407877 in3/ b3
b3 = 1.191118163 in3
b = 1.06 in
h = 3.18 in

Therefore
The dimension of the beam to satisfy the given conditions are b= 1.06 in and h= 3.18 in

2. The same as Problem 1, except that the cycle of F@ will not exceed 100,00 and all surface
are machined.

Given:
Same value to problem 1 except of On
FS= 1.5 nc= 105

Om= 933.335 lb-in/b3

Oy= 52,000 lb/in2
On= 0.8 On1 (surface factor)

On1= O ‘n (106/105) 0.09

On1= 36000 psi (106/105) 0.09

On1= 44,289.68 psi

AF 5 (Faires , p. 583) For machined surface factor 0.89

On= 44,289.68 psi (0.8)(0.89)

On= 31,524.2522 psi

15
Substituting the value to Soderberg Equation

1/FS = O m/Oy + O a/On

1/1.5 = (9333.335 lb-in)/b3(52000 psi) + (9333.335 lb- in)/ b3 31,524.2522psi

1/1.5 = 0.4755/ b3
b3 = 0.7132 in3
b = 0.8934 in
h = 2.6803 in

Therefore
The dimension of the beam to satisfy the given condition are b= 0.8934 in and h= 2.6803
in

3. The beam shown has a circular section and supports a load F that varies from 1000 lb to
3000 lb, it is machined from AISI C1020 steel as soled. Determine the diameter D if r=0.2D
and n=2; indefinite life.

Given:

F= 3000lb Material
r/d= 0.2 C1020 as rolled
h= 1.5D Faires at 7
F= 1000LB TO 3000 lb Ou= 65 ksi
Oy= 49 ksi
BHN= 143

Required: Diameter D

Solution:
Using Soderberg Equation for ductile material

1/FS = O m/Oy + kf (O a/On)

O m = ((3000(16)/πD3 )+ (1000(16)/ πD3))/2

16
O m = 32 kips/ πD3

O n = 0.8 O ‘n (surface factor)

O ‘n = 0.5(65)
O ‘n = 32.5 ksi
O n = 0.8 (32.5)(0.9) = 23.4 ksi

AF 5 (Faires, p. 583) for surface factor of 0.9

For Fillet

O a =(6Mmax-6Mmin)/2 = (6(3000lb)(6in)/D3)- (6(1000)(6) lb-in/D3)/2

O a = 36,000/D3
Solving for Kf

Kf=q (Kt-1)+1

q=( 1/1+ a)/r

=(1/1+0.01)/0.2D

For Kt=1.72 Table AF 9 (Faires,P.583)

Kf= (1/D+0.050)(1.72-1)+1
Kf= (0.72/D+0.05)+1

Substituting the values to Spderberg Equation

1/FS = O m/Oy + kf (O a/On)

1/1.5 = (32kips/πD3 /49ksi + 36kips/ πD3/32.5ksi)(0.72/(D+ 0.05)+1)
1/1.5= (0.6531/ πD3)+(1.1077/D3)(0.72/(D+0.05)(+1))
D= 1.4084

Therefore diameter D= 1.4084in to satisfy the given condition

4. The same as Problem 3, except that the load Fos steady at F= 3000 lb and the beam rotates
as a shaft.

Given

F= 3000 lb Ou= 65 ksi Kf= (0.72/D+0.05)+1

r= 0.2D O y= 45 ksi O”n= 32.5 ksi
h=1.5D BHN=143

For reversed load Om = 0

17
On= 0.6 O ‘n (size factor)(surface factor)
On= 0.6 (32.5)(0.85)(0.5)
On= 14.9175 ksi

For Fillet

Oa= 6Mmax/tD2
Oa = 6(3000lb)(6in)/D3
Oa= 108 kips-in

1/FS = O m/Oy + kf (O a/On)

1/1.5= (108 kips in/D3(14.9175ksi)) ((0.72/D+0.05)+1)

D= 22.4122in

5. A connecting link is as shown, except that there is a 1/8 in radial hole drilled through it at
the center section. It is machined from AISI 2330, WQT 1000ᵒF, and is subjected to a
repeated, reversed axial load whose maximum value is 5 kips. For N=1.5, determine the
diameter of the link at the hole a) for indefinite life b) for a life of 10 6 repetitions (no column
action) c) in the link found in (a) what is the maximum tensile stress.

D
Given:

Fmax= 5 kips
Load= repeated and reversed axial load
Material AISI 2330 WQT, 1000 ᵒF AT 7 (Faires, 576)

Ou= 105 ksi

O y= 85 ks
BHN=207
Required

Diameter D a. for indefinite life

b. for a life of 106 repitition

Solution:
Using Soderberg Equation for ductile material

1/FS = O m/Oy + kf (O a/On)

18
a. Kf=q(Kt-1)+1

q= 1/(1+(a/r)) ; a=0.0025
q= 1/(1+(0.0025/0.0625))
q= 0.9615

Use AF 8 B/h flat

Kt=?
d/D= o.125/1.25 = 0.1; assume D=1.25’’
Kt= 2.7
Kf=0.9615(2.7-1)+1
Kf=2.6346

For reversed load ; Om=0

Substituting the values; Solving for On

1/FS = O m/Oy + kf (O a/On) O ‘n= 0.4Ou=0.2(105)

1/FS= Kf(O a/On) O ‘n= 42 ksi
1/1.5= ((5kips/(πD4/4)-(dD/8))/28.56)(2.6346) O n=0.8 O ‘n (surface factor)
28.56/(1.5(2.6346))= 5kips/(( πD4/4)-(D(1/8)) Surface factor = 0.85 at
7.2263(πD4/4)-(D(1/8))=5 Table AF5 (Faire, p.583)
5.676 D2-0.09034 D-5= 0 O n=0.8(42)(0.85)
D=1.25in O u=28.56ksi

Therefore;
Diameter D= 1.25 in for indefinite life

b) For definite life 106

Solving for O n
O n=0.8 O n1(surface factor)
O‘n1= O ‘n(106/nc) 0.09
O n1= 42(1)0.09
O n1= 42
Using the same value of Kf, FS, O a substitute the data to the same equation

1/FS= Kf(O a/On)

42/1.5= ((5kips/(πD4/4)-(dD/8))(2.6346)
(28ksi/2.6346)((πD4/4)-((D)(1/8)))-5=0
8.346D2-1.3285 D-5= 0

D=0.8577in

Therefore;
Daimeter D=0.8577 in for definite life of 10 6

19
6. Design the size of solid steel shaft to be used for a 500hp, 250 rpm application if the
allowable tortional deflection is 1 degree and the allowable stress is 10000 psi and modulus
of rigidly is 13x106 psi.
Given:
P=500 ho
N= 250 rpm
Ss= 10,000 psi
G= 13x106 psi

Solution:
Solve for the shaft diameter

P=2πTN
T=P/(2πN)
T= (500(33000/1)/(2π(250))

T=10,504.2262 ft-lb = 126,050.7149 in-lb

Thus,
Ss=16T/πD3
3
D= √ ¿¿
D=4.0041in

Solve for the shaft diameter based on deflection (torsional)

Let torsional deflection is per 20D length

Ɵ=TL/JG

where: Ɵ= 1ᵒx (180/π)rad; 1ᵒ (π/180)

T= 126,050.7149 in-lb
L= 20D
J= (π/32)D4
G=13x106psi
1ᵒ (π/180)= (126,050.7149(20D))/((π/32)D 4(13x106psi)

π
√
3
D= 126,050.7149(20)/1( π /180)(

D= 4.8371 in
32
)(13 x 10 ᶝ )

7. A short stub shaft, made of SAE 1035 as rolled, receives 30 hp at 300 rpm via 12 in spur gear,
the power being delivered to another shaft through a flexible coupling. The gear is keyed
midway between the bearings. The pressure angle of the gear teeth is 20 degrees, N= 1.5
based on the octahedral shear stress theory with varying stresses. A) neglecting the radial
component R of the tooth load W, determine the shaft diameter B) considering both the
tangential and the radial components, compute the shaft diameter.

20
Material SAE 1035 as rolled AT 7 Faires, p.576
Ou=85 ksi
Oy= 55 ksi
Repeated: Om= Oa

Given:

P= 30 hp
n= 300 rpm
d super gear= 12 in
Ο= 20ᵒ
FS= 1.5

Required: shaft diameter

Solution: Using equivalent stress theory

1/FS= √(Oe/On)2+ ¿e/Ҽn)2
Where
Oe=(Om/Oy)(Om)+Kf Oa

Ҽe= (Ҽn/Ҽy)(Ҽm)+Kf Ҽa

On= 0.80’n (0.85)(surface factor)

O ‘n= 0.5Ou
=0.5 (85000 psi)
O’’n= 42,500 psi

Surface factor: .8827 (machined)

On=0.8(42500psi)(0.85)(0.8827)
On=25510.03 psi

Om= Omax/2 =Oa

Omax= 32Mmax/πD3

21
 Mmax=(Rmax)(L)/4

Rmax=Fmax/cosƟ from cosƟ= Fmax/Rmax

Fmax= Tmax/rgear

Tmax= 63025P/n

Tmax=63025x30hp/300rpm

Tmax= 6302.5lb-in

Fmax= Tmax/ rgear

Fmax=6302.5lb-in/6in

Fmax=1050.416667 lb

Rmax= Fmax/cosƟ

Rmax=1050.416667lb/cos20

Rmax= 1117.830069 lb

Mmax=( (Rmax)(L))/4 = 1117.830069 lb (16in)/4 = 4471.320275 lb-in

Omax=32Mmax/πD3

Omax= (32(4471.320275lb-in))/πD 3

Omax=(143082.2488lb-in/ πD3)/2

Om=Omax/2 =( 71541.12441 lb-in/πD3)/2 = 71541.12441 lb-in/πD3=Oa

Kf= 1.6 from Faires table AT 13

Substituting
Oe=(On)( On)+ Kf Oa
Oe= (25510.03psi/55000psi)(71541.12441lb-in/πD 3)+1.6(71541.124441lb in/ πD3)
Oe= (33182.11327+114465.7991)/πD3

Ҽe=(Ҽn/Ҽy)Ҽm+ kfsҼa
Ҽy= 0.6Oy
=0.6(55000psi)
Ҽy=33000psi

22
 Ҽn= 0.6 O’’n (0.85)(surface factor)
= 0.6 (42500psi)(0.85)(0.8827)
Ҽn= 19132.5225 psi

Ҽe=16Tmax/ πD3 Ҽm=Ҽmax/2

= 16(6302.2)/ πD3
Ҽm=Ҽmax/2 = (100840 lb-in/ πD3)/2 = 50420 lb-in/ πD3 =Ҽa

Kfs=1.3 from table AT13

Substituting;

Ҽe=(Ҽn/Ҽy)Ҽm+ kfsҼa

=(19132.5225psi/33000psi)(50420 lb-in/ πD3) +1.3(50420lb-in/ πD3)

=(29232.1759+65546)/ πD3

Ҽe=94778.17529 lb-in/ πD3

Substituting to the equivalent stress theory equation:

1/FS= √(Oe/On)2+ ¿e/Ҽn)2

147647.9123 2 94778.17529 2
1/1.5=
(
√ πDᶟ
25510.03
) +(
πDᶟ
19132.5225
)

4.9537731 2
(1/1.5=√ (5.787837658/ πDᶟ )2 +( ))
πDᶟ

4.9537731 2
1/2.25=(5.787837658/ πDᶟ )2 +( ))
πDᶟ

1/ 2.25=(33.49906476/π2D6)+(24.53986793/π2D6)

58.05893269
1/2.25=
πDᶟ
π2D6= 130.5875985 in6
D6= 13.23129005 in6
D= 1.537919835 in

Therefore;
11
Use standard size, D= 1 ∈¿
16

23
8. A beam 2 ft long is made of AISI C1045 as rolled. The dimensions of the beam are 1’’x3’’. At
the midpoint is repeated, reversed load of 4000 lb. What is the factor of safety?

4000

1ft 1ft 3’’

R R
1’’
Given:
Material AISI C1045 as rolled
Ou= 96 ksi
L= 2ft
b= 1 in
h= 3 in
Solution

Ou/FS= Mc/I ; I= bh3/12

Ou/FS= (FL(12)(h))/(4(bh 3)(2)) M=FL/4

Ou= 3FL C= h/2

FS= 2bh2
FS= ((2bh2)( Ou))/(3FL)
FS = (2 (1in)(3in)2()96000)psi)/(3(4000)(2)(12)in-lb)
FS= 6

1. A thin walled cylindrical pressure vessel is subjected to internal pressure which varies from
750kPa to 3550kPa continuously. The diameter of a shell is 150 cm. find the required
thickness of the cylinder wall based on yield point of 480MPa. Net endurance of 205MPa
and factor of safety equal to 2.5.

Given:

Pmin = 750kPa

Pmax = 3550kPa

d = 150 cm = 1.5m

24
Oy = 480MPa

On = 205MPa

Fs = 2.5

Solution:

Soderberg Equation

1/Fs = (Om/Oy)+ (Oa/On)

Om = (Omax + Omin)/2

Omin = PD/2t

= (750)(1.5)/2t

Omin = 56.25/t

Omax = 3550(1.5)/2t

= 266.25/t

Om = (56.25/t) + (266.25/t)

Om = 161.25/t

2. A connecting link shown is under a maximum load of 10kips, repeated and reversed. The link
has a radial hole drilled through it at the center of the section. It is machined from AISI 2330
WQT, 1000oF. Determine the:

a. Diameter of the link for a FS = 1.5

b. Diameter for a 105 cycle

Given:

Fmax = 10kips

D = 1/8 in

Material Spec’s:

AISI 2330 WQT, 1000oF

25
Ou = 105ksi

Oy = 85ksi

BHN = 207

FS = 1.5

Solution:

1/Fs = (Om/Oy) + Kf (Oa/On)

Solve for Kf

Kf = a (Kt - 1) +1

a = 1/(1 + (a/t)) ; a = 0.0025

a = 1/(1 + (0.0025)/(1/16))

a = 0.96154

for Kt assume D=1.35in

d/h = d/D = 0.125/1.25 = 0.1

use solid curve

Kt = 2.7

Solve for Kf

Kf = 0.96154 (2.7-1)+1 = 2.634618

For Om and Oa repeated and reversed wll prevail

Omax = Omin Om = 0 Oa = Omax

Oa = Fmax/A

= 10kips/(πd2/4)-d

Om = 10/(πd2/4)-0.125D

1/1.5 = 2.65385 [10/(0.785D2-0.125D)][1/35.7]

0.7854D2 – 0.124D – 1.11506 = 0

Quadratic formula

26
D = 1.2737 in

b. Nc = 105 cylce

Fs = 1.5

Kf = 2.634615 ; D=1.25

Oa= 10 `

0.7854D2 – 0.125D

On = 0.8On(Surf)

On1 = antilog[log 0.8(105)2/52.5 – 1/3 log 0.9(105)/52.5 log 105]

On = 63.074

On1 = 52.5 (106/105)0.09 = 64.589

On = 0.8(63.074)(0.85)

1/1.5 = 2.65 [10/(0.785D2-0.125D)][1/12.89]

D = 1.1656 in

Oa = (Omax – Omin)/2

= (266.25-56.25)/t

Oa = 1050/t

1 /2.5 = (161.25/t) + (1050/t)

480000 205000

1 /2.5 = (1.36x10-3)/t + (5.12x10-3)/t

1 /2.5 = 8.48/t x10-3

t = 0.0212m

3. The link shown is machined from AISI 1035 steel as rolled and subjected to a repeated
tensile load that varies to 0 to 10 kips, h = 1.5b

27
 a. Determine these dimension for FS = 1.4 at a section without stress concentration
b. How much would these dimensions be decreased if the surfaces of the links were
mirror polished

Materials spec’s: Oy = 55ksi Ou = 85 BHN = 190

Given:

Fmin = 0kips

Fmax = 10kips

FS = 1.4

Solution:

a. Soderberg Equation

1/FS = (Om/Oy) + (Oa/On)

Om = Omax + Omin

Omax = F/A = 10/bh = 10/1.5b2

Omin = 0

Om = Oa

On = 0.5(85)

On = 42.5

Om = (10/1.5b2 + 0)/2

Om = 3.33/b2

b. Mirror polished

S.F = 1

On = 0.8(47.5)(1)

On = 38

1/FS = (Om/Oy) + (Oa/On)

= (3.33/b2(55)) + (3.33/38b2)

1/1.4 = (0.061 + 0.0876)/b2

28
b = 0.456in

h = 0.68in

BHN < 400

O`n = 0.5Ou

O`n = (0.25)(190)

= 47.5

On = 0.8O`n(SF)

= 0.8(47.5)(0.87)

On = 33.06

by Soderberg Equation

1/1.4 = (3.33/55b2) + (3.33/33.06b2)

1/1.4 = (0.061 + 0.1007)/b2

b = 0.48in

h = 0.714in

b; 0.48 – 0.456 = 0.024in diff

h; 0.714 – 0.68 = 0.034in diff

4. A cantilever beam as shown is to be subjected to a reversing load of 3000lb. Let the radius
of the fillet bar = 1/8inch and the material cold rolled SAE1015. Determine the dimensions t,
h (b=1.3h) for a design factor of 1.8 based on variable stresses. Consider section A and B,
indefinite life.

Given:

F = 3000lb

r = 1/8 in

b = 1.3h

t = 0.5h

29
Material Spec’s:

SAE 1015

Ou = 77ksi

Oy = 63ksi

BHN = 140

FS = 1.8

Solution:

Soderberg Equation:

1/Fs = (Om/Oy) + Kf (Oa/Ou)

reversed Om = 0

Oa = Omax

On = 0.8h

O`n = 0.5Ou

= 38.5

On = 0.8(38.5)(0.89)

= 27.412ksi

a. Consider fillet

Oa = OMmax/td2; Mmax=3000lb(22)

= 6(66)/0.5h2h

Oa = 792/h3

Kf = 9(kt - 1) + 1

9 = 1/(1+ (9/r))

= 1/(1+(0.01/0.125))

= 0.9259

r/d = 0.125/h ; assume h = 2.8

h/d = 1.3h/h = 1.3

30
Kf = 0.9259 (2.3-1)+1

= 2.2037

1/Fs = Kf (Oa/On)

1/1.8 = 2.2037 (792h3/27.412)

h = 4.85467 : wrong assumption

h = 4.85

r/d = 0.125/4.85 = 0.02577

h/d = 1.3h/h = 1.3

Kf = 0.9259 (25-1)+1 = 2.388

1/Fs = 2.388(7922/h3)(1/27.412)

h = 4.9898

assuming h = 5.2

r/d = 0.125/5.2 = 0.0240

Kf = 0.9259(285-1)+1 = 2.7129

1/1.8 = 2.7129(792/h3)(1/27.412)

h = 5.2059in

therefore use: h = 5.2059in, b=6.7677in, t = 2.60295in

Shafts

Shafts – a rotating member transmitting power

Axle – a stationary member carrying rotating wheels, pulleys, etc.

Spindle – a short shaft or axle on machines

Machine shaft – a shaft which is an integral part of the machine

Transmission – shaft which is used to transmit between the source and the machine
absorbing the power

Line shaft or main shaft – transmission shaft driven by the prime mover

Counter shaft, jack shaft, head shaft, short shaft – transmission shaft intermediate
between the line shaft and driven machine

31
Materials for transmission shaft:

Cold rolled, hot rolled, forge carbon steel

Relation of power, torque and speed:

P=2 πTN And T =Fr

Where:

P = power transmitted (KW)

T = torque (KN-m)

N = speed (rev/sec)

F = transmitted load or force (KN)

r = radius (m)

Stresses in shafts, subject to torsion only:

Tc Tl
SS = And θ= (radians)
J JG
16 T
SS = (For solid circular shaft)
π D3
16 T D O
SS = (For hollow circular shaft)
π [ D O4 −D4i ]
Where:
SS = torsional shear stress
T = torque
C = distance from the neutral axis to the outermost fibre
r = radius
DO = outside diameter
Di = inside diameter
D = diameter of shaft
J = polar moment of inertia
π
=( ) D 4 (for solid circular shaft)
32
π
=( )
32
( D4O −D 4i ) (for hollow circular shaft)
L = length of shaft
θ = angular deformation in length, radius
G = modulus of rigidity in year
= 11,500,000 psi to 12, 000,000 psi for steel
Stresses in solid circular shaft subject to torsion and bending
16
SSmax = 3
√ M 2+ T 2
πD

32
 16 (
STmax = 3
M + √ M 2 +T 2)
πD
Where:
SSmax = maximum shear stress
STmax = maximum tensile or compressive stress
M = bending moment
T = torsional moment
Strength of shaft with assumed allowable stress (PSME code p.18)
For main power transmitting shafts (assumed stress = 4000 psi)
D3 N 3 80 P
P=
80
Or D=
N√
For line shafts carrying pulleys: (assumed stress = 6000 psi)
D3 N 3 53.5 P
P=
53.5
Or D=
√
N
For small, short shafts (assumed stress = 8500 psi)
D3 N 3 38 P
P=
Where:
38
Or D=
N √
P = power transmitted in HP
D = diameter of shaft in inches
N = speed in rpm
Empirical formula from machinery’s handbook
Diameter of shaft
1. For allowable twist not exceeding 0.08 deg per ft length
HP

Where:
D=0.29 4√T Or D=4.6
4

√ N

D = shaft diameter; inches

T = torque; in-lb
HP = horse power
N = speed, rpm
In S.I. units (allowable twist 0.26 deg per meter length)
P

Where:
D=2.26 4√ T Or D=125.7
4

√ N

D = shaft diameter; mm
T = torque; N mm
P = power; KN
N = speed, rpm
2. For allowable twist not exceeding 1 deg per 20D length
HP

Where:
D=0.1 √3 T Or D=4
3

√ N

D = shaft diameter; inches

T = torque; in-lb

33
 HP = horse power
N = speed, rpm
3. For short ,solid shaft subjected only to heavy transverse shear
1.7 V

Where:
D=
√ SS

V = max traverse shearing loads, lbs

SS = max torsional shearing stress, lb/ in2

Linear deflection of shafting

For steel line shafting, it is considered good practice to limit the linear deflection to a
maximum of 0.01 inch per foot of length.
Maximum distance:
1. For shafting subject to no bending action except its own weight
3
L=8.95 √ D2
2. For shafting subjected to bending action of pulleys, etc
3
L=5.2 √ D2
Where:
L = maximum distance between bearing, ft
D = diameter of shafts, inches

Note:

1. Pulleys should be placed as closed to the bearings as possible

2. In general, shafting up to three inches in diameter is almost always made
from cold – rolled steel
Sample Problems:

1. What power would a spindle 55 mm in diameter transmit at 480 rpm. Stress allowed for
short shaft is 59 N/mm2

Solution:

Ss = 16T/ π D3 P = 2 π TN = 2 π (1.92739)(480/60) = 96.88 kw

59 = 16T/ π (55)3
T = 1,927,390 N-mm = 1.92739 kN-m

2. A hollow shaft has a inner diameter of 0.035 m and an outer diameter of 0.06 m.
Compute for the torque if the shear stress is not to exceed 120 Mpa in N-m.

Solution:

Ss = 16TDo/ π (Do4 - Di4)

120,000,000 = 16T(0.06)/ π [( 0.06)4 –(0.035) 4]
T = 4500 N-m

34
 3. A short 61 mm shaft transmits 120 HP. Compute the linear speed of a pulley 55 cm
mounted on the shaft.

Solution

For short shaft (PSME CODE):

P = D3N/38
where: D = 61 mm = 2.4 in
120 = (2.4)3N/38
N = 330 rpm
V = π DN = π 0.55 x 3.28)(330) = 1870 ft/min

Keys

Definitions:
1. Key – a machine member employed at the interface of a fair of mating female and male
circular cross – sectional members to prevent relative angular motion between these
mating members.
2. Key way – a groove in the shaft and mating member to which
the key fits
3. Splines – permanent keys made integral with the shaft and fitting into keys ways
broached into the mating hub

Stresses in keys:

P=2 πTN
T T
F= =
r P
2
Where:
P= power transmitted
T torque
r = radius
D = diameter
N = speed
Crushing (compressive) stress:
F
SC = ( L)
h
s
Shearing stress;
F
SS =
WL
Generally, when the key and shaft are of the same material
D
W= And L=1.2 D
4
Where:

35
 W = width of key
h= thickness of key
L= length of key

Sample Problems:

1. A rectangular key was used in a pulley connected to a line shaft with a power of 125 KW
at a speed of 900 rpm. If the shearing stress of the shaft is 40 N/mm² and the key to be
22 N/mm². Determine the length of the rectangular key if the width is one fourth that of
the shaft diameter.

Solution:

P=2 π TN
125=2 π T(900/60)
T=1.326291 kN-m=1,326,291 N-mm

Ss = 16T/ π D3
40=16(1326291)/ π D3

D= shaft diameter = 55.27mm

F=T/(D/2) = 1326291/(55.27/2)= 47,993N

W=D/4 = 55.27/4= 13.82mm

SS=F/wL
22=47,993/13.82L
L= 157.85mm

2. A keyed sprocket delivers a torque of 778.8N-m thru the shaft of 54mm OD. The key
thickness is 1.5875cm and the width is 1.11cm. Compute the length of the same key.
The permissible stress value of 60MPa for shear and 90MPa for tension.

Solution:

Force, F=T/r= 778.8/(0.054/2)= 28,844.4N

Ssk= shearing stress of the key= F/(wL)

60,000,00N/m²= 28,844.4N/(0.0111m*L)

L=0.0433m= 4.33cm

36