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Machine Design - 2013 PDF
Machine Design - 2013 PDF
Clamping forces
Fe
kc
Fc Fi Fe
kb kc
Fb
Fi
Fc
Fe
T = 0.20 Fid
2
Design of bolts in tension
Fb = At Sp
Example M1a
Given: Two plates are bolted with initial clamping force of
2250 lbs. The bolt stiffness is twice the clamping material
stiffness.
Solution
kc
Fc Fi Fe
kb k c
1
225 2250 Fe
1 2
Fe 6075 lbs
kb 2
Fb Fi Fe 2250 ( )(6075) 6300 lbs
kb k c 3
Example M1b
3
Fb ,design 6300(2.5) 15750
Fb ,design S p At
(15750)
At At 0.286 in 2
55000
Example M1c
4
Design of Bolt Groups in Bending
F
D
Example M3
Answer: - 10UNC
5
Design of Bolt Groups in Torsion
Example M4
L
6
Design of Bolts in Fatigue Loading
max min
500 400
a 50 MPa
2 2
129(830) 400(129)
Sa 57.8
129 830
57.8
n 1.15
50
7
Gear Geometry
dp np ng dg
Np
Pressure Line Ng
Terminology
Diametral pitch (or just pitch) P : determines the size of the
tooth. All standard pairs of meshing gears have the same
pitch.
N
P Teeth per inch
d
d
p Inches per tooth
N
d
m mm per tooth
N
Pp
8
I) Regular Gear Trains (External gears)
n1 N2
n2 N1 1
2
Internal gears
n1 N 2
n2 N1
1 2
9
II) Epicyclic (Planetary) Gear Trains
ARM 2
10
Planetary gear trains can be solved by the following two
relationships. (two equations in three unknowns)
Ring Gear = N2 + 2 N3 = 60
n2 / A n2 nA 100 nA
n4 / A n4 nA 0 nA
n2 / A n2 / A n3 / A N3 N 4
( ) 2.5
n4 / A n3 / A n4 / A N 2 N3
100 nA 2.5(nA ) nA 28.5 cw
11
Problem #M5: Gear kinematics
12
Substituting for the number of teeth on each gear
n2 / A 30 34
( )( ) 3.187
n6 / A 20 16
n A 114.3
Also
n4 / A n4 n A n4 (114.3)
n2 / A n2 n A 250 (114.3)
n4 / A N 20
( 2 )
n2 / A N4 30
From above:
n4=-357.1 rpm
13
Kinematics of Automobile Differential
14
Gear Force Analysis
Fn Ft
d
Fr
Fn : Normal force
Ft : Torque-producing tangential force
Fr : Radial force.
33000(hp) nd
Ft and V
V 12
and
Fr Ft tan
In SI units:
d
Watts T and T Ft ( )
2
15
Helical gears
Geometric parameters
Pn : Normal pitch
P : Plane of rotation pitch
: Helix angle
n: Normal pressure angle
: Plane of rotation pressure angle
N : Number of teeth
d: pitch diameter
pn and p : circular pitches
pa : axial pitch
Geometric relationships:
N
P and P Pn cos( )
d
tan(n )
tan( )
cos( )
p
Pp Pn pn and pa
tan( )
Helical gear forces
Ft From Power
Fr Ft tan( )
Fa Ft tan( )
When shaft axes are parallel, the helix hands of the two gears must
be opposite of each other.
16
Straight Bevel gears
Geometric Parameters Pinion
(Pinion) d
davg
dp: pitch diameter
davg,p: average diameter
b: Face width
pPitch cone angle
33000(hp) nd avg
Ft where Vavg and
Vavg 12
d avg d b sin( )
Fr Ft tan( ) cos( )
Fa Ft tan( ) sin( )
These forces are for pinion and act through the tooth
midpoint. Forces acting on the gear are the same but
act on opposite directions.
17
Worm Gear Kinematics
dw
dg
L pa NW
The worms axial pitch pa must be the same as the gears
plane of rotation circular pitch p.
18
Example
L
tan( )
d w
Worm Gear Forces
The forces in a worm gearset when the worm is driving is
Fwt Fwa
Fwr
19
The worm and gear radial forces are:
sin(n )
Fwr Fwt
cos(n ) sin( ) f cos( )
f cos(n ) tan( )
Note: In a RH worm, the teeth spiral away as they turn in a
CW direction when observed along the worm axis. When
the worm in turning in CW direction, the teeth sweep
toward the observer seen along the axis of the worm
(imagine a regular bolt and nut).
RH Worm
20
Bearing Reaction Forces
Bearing
Ft Fa
F
Fa
For the radial reaction forces for spur gears (no axial
forces) combine the radial and tangential forces into F:
F Fr2 Ft 2
21
Flat Belts
Dd
d 2 sin 1 ( )
2C
Dd
D 2 sin 1 ( )
2C
Closed (Crossed)
Dd
d D 2 sin 1 ( )
2C
Where
C: Center-to-center distance
D,d: Diameters of larger and smaller rims
: Angle of wrap around pulley
22
Slippage Relationship
Tight side
(True only at the verge of slippage)
F1
F1
e Driver
F2
F2
is in radians.
Slack side
Transmitted Hp is
( F1 F2 )V
Hp
33000
Initial Tension
23
Problem M7
P1 Pc
e / sin
P2 Pc
where
Pc m ' 2 r 2
m=Mass per unit length
r=Pulley radius
24
Disk Brakes and Clutches
fp a d
T (D 2 d 2 )
8
Where
f: Coefficient of friction
pa: Maximum pressure on brake pad
d,D: Inner and outer pad diameters
fp a
T ( D3 d 3 )
12
25
Maximum clamping forces to develop full torque
Example M8
26
Energy Dissipation in Clutches and Brakes
The time it takes for two rotational inertia to reach the same
speed after engagement through a clutch is:
I2
I1
I 1 I 2 (1 2 )
t
T ( I1 I 2 )
where
T: Common transmitted torque
: angular speed in rad/sec
I1I 2 (1 2 ) 2
E
2( I1 I 2 )
If the answer is needed in BTU, divide the energy in in-lb
by 9336.
27
Problem M9
I1
I2
Solution hints:
28
Springs
Coverage:
Helical compression springs in static loading
Terminology:
d: Wire diameter
D: Mean coil diameter
C: Spring index (D/d)
Nt: Total # of coils
N: Num. of active coils
p: Coil pitch
Lf: Free length = N*p
Ls: Solid length
29
Spring Rate of Helical Springs (compression/extension)
d 4G dG
k 3
3
8D N 8 NC
where : N is the number of active coils
G: shear modulus = E/2(1+)
G=11.5*106 psi for steels
1
where K s 1 2C and C is the spring index.
30
Spring Surge Frequency
1 kg
fn
2 Wa
Where g is the gravitational acceleration and Wa is the
weight of the active coils:
1
Wa 2 d 2 DN
4
with being the specific gravity of spring material. For
steel springs when d and D are in inches:
13900d
fn 2
HZ
ND
Example M10
31
Design of Welds
3 P
P
OR
Weld Geometry
Throat: t
Leg : h
Analysis Convention
32
Analysis Methodology
Direct tension/compression:
F 1.41
Lt Lh
Direct shear:
1.41V
Lh
Bending:
Mc Mc
I Iut
Torsion:
Tr
J ut
33
34
35
Problem M11a -Welds subject to direct shear
Two steel plates welded and are under a direct shear load P.
The weld length is 3 inches on each side of the plate and
the weld leg is 0.375 inches. What maximum load can be
applied if the factor of safety is 2 against yielding? The
weld material is E60.
3
P
L = 2d = 6
1.41V 1.41P
0.6284 P psi
Lh 6(.375)
The design strength of the weld material in shear is:
Sys=0.3 Sut = 0.3(60) = 18 ksi
Using a factor of safety of 2, the allowable shear stress is:
all = 18/2 = 9 ksi
Equating stress and strength
.6284P = 9000 P=14322 lbs
36
Problem M11b Welds subject to torsion
A round steel bar is welded to a rigid surface with a
fillet weld all around. The bars outer diameter is 4.5.
Determine the critical shear stresses in the weld when the
bar is subjected to a 20,000 lb-in pure torque.
Tc (20000)(2.25)
3571 psi
Jt 12.6
I u r 3 (2.25) 3 35.78 in 3
I t 35.78(0.25)(0.707) 6.32 in 4
Mc (35000)(2.25)
12460 psi
It 6.32
37
Problem M11d Welds subject to combined loads
FS = 27800/12961=2.14
38
Ball and Roller Bearings
Terminology
Rated or catalog Capacity, C10 : Radial load for a life
of 1000,000 cycles (or other L10) and 90% reliability.
Application or design radial load Fr.
Application or design life L
F1L10.333 F2 L02.333
This means if we double the load, the life of the ball
bearing would be reduced by a factor of 10. This formula
is for ball bearings. For roller bearings use 0.3 as the
exponent.
Example: Given:
02 series Deep Groove ball bearing,
Radial load is 4 KN,
Application factor KD = 1.2
Design life 540 million cycles
95% reliability
Find: Suitable bearing catalog rating based on 106 cycle L10 life.
39
Solution:
40
Problem M12 Bearings
An angular contact 02-series ball bearing is required to run
for 50000 hours at 480 rpm. The design radial load is 610
lbs and the application factor (load multiplier) is 1.4. For a
reliability of 90%, what is the required capacity of this
bearing? Answer: 42.9 KN (capacities are in SI units)
RD n Rsys
41
Keys
Square keys
2T d 8T
( L)
d 4 d 2L
4T
Dd 2 D
d
The torque capacity is
Dd 2
T (0.58S y )
4
Other key types and splines are all treated similarly: Equating the
shear area to the force created by the transmitted torque.
42
Power Screws
LOAD
Collar
43
Condition for self locking:
L
f tan( )
d m
Efficiency of power screws (includes collar losses)
FL
e
2TR
44