Simple Design

Module -1

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Design of Machine Elements
VB Bhandari
Design of Machine Elements
VB Bhandari
Design process

Design of Machine Elements

VB Bhandari
 BASIC REQUIREMENTS OF
MACHINE ELEMENTS
1. Strength
2. Rigidity
3. Wear Resistance
4. Minimum Dimensions and weight
5. Manufacturability
6. Safety
7. Conformance to standards
8. Reliability
9. Maintainability
10. Minimum Life-cycle cost

Design of Machine Elements

VB Bhandari
DESIGN OF MACHINE ELEMENTS

Design of Machine Elements

VB Bhandari
DESIGN OF MACHINE ELEMENTS

Design of Machine Elements

VB Bhandari
DESIGN OF MACHINE ELEMENTS

Design of Machine Elements

VB Bhandari
DESIGN OF MACHINE ELEMENTS

Design of Machine Elements

VB Bhandari
Classification of Design

Design of Machine Elements

VB Bhandari
 Elementary Equations

For Direct loading or Axial loading

For transverse loading

For tangential loading or twisting

Where I and J  Resistance properties of cross sectional area

I  Area moment of inertia of the cross section about the axes lying on the section
(i.e. xx and yy)

J  Polar moment of inertia about the axis perpendicular to the section

 Necking

Ductile fracture of Al-Mg-Si alloy Brittle fracture of Cast Iron

Why ductile materials fail in 45° plane? Why brittle materials fail in 0° plane?
Types of Loading
 Pure shear

Normal stress σn = τ sin 2θ  At θ = 45° σn = σmax = τ

Shear stress τ = τ cos 2θ  At θ = 0°, τ max = τ

 Under pure shear, ductile materials will fail in 0° plane and brittle materials will fail
in 45° plane. Because, at 0° plane shear stress is maximum and at 45° plane normal
stress is maximum.
Direct load Shear Stress

Design of Machine Elements

VB Bhandari
 Bending load

Shear Stress

Design of Machine Elements

VB Bhandari
Torsional load

Design of Machine Elements

VB Bhandari
Source: Khurmi & Gupta
Source: Khurmi & Gupta
 Stress transformations
Mechanics of Materials. Beer, Johnston, DeWolf and Updike

• Most general state of stress at a point may be

represented by 6 components,

Source: Khurmi & Gupta

 How are the components of the stress
changed under transformation of axes ?

Source: Khurmi & Gupta

We will look at plane stresses.

Source: Khurmi & Gupta

Stress transformation

Source: Khurmi & Gupta

Stress transformation

Source: Khurmi & Gupta

Solving the equations we get

Source: Khurmi & Gupta

Principal stresses

Source: Khurmi & Gupta

Maximum shearing stress

Source: Khurmi & Gupta

Source: Khurmi & Gupta
Source: Khurmi & Gupta
 Eccentric loading
Eccentric load on bolts Eccentric load on crane hook

Eccentric load on column

Eccentric load on hydraulic punching
press
 Eccentric Loading
If the line of action of a load is not passing through the Centroid of
the machine component, then that is knows as eccentric load.

There are different kinds of stresses will be induced during

eccentric loading

For eccentric axial load,

 Direct stress and bending stress

 To find out the magnitude of resultant stress, these combination of

stresses have to be super imposed.
For eccentric plane load,

 Direct shear and torsional shear stress

 Theories of Failure

 Predicting failure in the members subjected to uniaxial stress is very

simple and straightforward. Because all failure criterions are reaching
the critical limit at an instant.

 But, in multi axial loading the prediction of failure is much

complicated. Because, predicting the cause of failure i.e. which
quantity of failure criterion is causing failure is difficult to find.

Thus, theories were formulated to predict this issue, which are known
as failure theories.
 Real life examples for Combined loading

Torsion and bending

Crank Shaft
Side thrust from cylinder
wall, force due to piston

Thrust and torsional shear

Connecting rod
Lifting Jack

Axial, bending and Torsion

Coupling

Propeller shaft
Tensile and direct shear
Why failure theories?

Principal stress < Yield stress [safe]

but, Shear stress exceeds its limit.
Ductile fracture Brittle fracture

Shear plane Normal plane

 Purpose of Tensile test

1 2

3 4
 Simple Tension Test
 In simple tension test, all six quantities reaches its critical
values simultaneously (at a single instant).

Any one of the following will cause failure.

• Principal normal stress yield stress σmax = σy or σu

• Principal shear stress yield shear stress τmax = σy /2

• Principal strain energy strain energy at yield point Utotal = ½ [σy εy]

• Principal strain strain at yield point εmax = σy /E (or) σu /E

• Distortion energy distortion energy at yield point

𝟏 𝝁
Udistortion = [σy2]
𝟑𝑬
 Maximum Principal or Normal Stress Theory
(Rankine’s Theory)

According to this theory, the failure or yielding occurs at a point in a

member when the maximum principal or normal stress in a bi-axial
stress system reaches the limiting strength of the material in a simple
tension test.

This theory is based on failure in tension or compression and ignores

the possibility of failure due to shearing stress, therefore it is not used
for ductile materials.

For Brittle materials which are relatively strong in shear but weak in
tension or compression, this theory is generally used.

Max principal stress [σ1] ≥ [σy] yield stress

(In a multi axial loading) (In a simple tension test)
σ2

σ1
Maximum Shear Stress Theory
σ2

σ1
 Maximum Distortion Energy Theory (Hencky
and Von Mises Theory)

According to this theory, the failure or yielding occurs at a point in a member when
the distortion strain energy (shear strain energy) per unit volume in a biaxial stress
system reaches the limiting distortion energy (distortion energy per unit volume) as
determined from a simple tension test.
 Total strain energy U = Uv + Ud U d = U - Uv

For triaxial loading, the distortion energy

Ud = (1+µ) / 6E [(σ1 - σ2) 2 + (σ2 - σ3)2 + (σ3 – σ1)2]

For uniaxial tension test

Ud = (1+µ) / 6E [(σ1 2 + σ1)2] Ud = (1+µ) / 3E [σy2]

[When σ1 reaches σy]

 =

Thus, the left side of the Equation is a single, equivalent, or effective

stress for the entire general state of stress given by σ1, σ2, and σ3.
This effective stress is usually called the von Mises stress, σ′, named
after Dr. R. von Mises, who contributed to the theory.
 What is VonMises Stress?

Where ε1, ε2, ε3 are strain three principal directions

𝟏 𝟏 𝟐 𝟑

𝟐 𝟐 𝟏 𝟑

𝟑 𝟑 𝟏 𝟐

Substituting the above equations,

– 2μ ( +
 Total strain energy U = Uv + Ud
Therefore, the corresponding stresses are resolved into three
components

𝟏𝒅 𝟏𝒅 𝟐𝒅 𝟑𝒅

𝟐𝒅 𝟐𝒅 𝟏𝒅 𝟑𝒅

𝟑𝒅 𝟑𝒅 𝟏𝒅 𝟐𝒅

𝟏𝒅 𝟐𝒅 𝟑𝒅 =0

Therefore, 𝟏𝒅 𝟐𝒅 𝟑𝒅 =0
 𝑽 𝑽
Strain energy for volume change Uv = 3

Volumetric Strain

𝑽
=

𝑽𝟐
Uv =

𝟐
𝟏 𝟐 𝟑
Uv =

Ud = U - Uv

Ud = 𝟐 𝟐+ 𝟐]
 Distortion strain energy in triaxial loading

Ud = + ]

In simple tension test, when yielding starts 𝟏 𝒚 𝟐 𝟑

Distortion strain energy in uniaxial loading

Ud =
Therefore, Failure criterion is,
(𝟏 𝝁) (𝟏 𝝁)
𝒚
𝟐 = 𝟏 𝟐
𝟐
𝟐 𝟑
𝟐+
𝟑 𝟏
𝟐]
𝟑𝑬 𝟔𝑬

𝟐 = 𝟐 𝟐+ 𝟐]
 Maximum Principal Strain Theory (Saint
Venant’s Theory)

According to this theory, the failure or yielding occurs at a point in a member

when the maximum principal strain in a multi axial stress system reaches the
limiting value of strain (strain at yield point) as determined from a simple
tension test.

The strain in the direction of σ1 [ε1] =

 According to this theory of failure, σ1 could be increased to a value
somewhat higher than σy without causing yielding if the second normal stress
σ2 is a tensile stress. But if σ2 is a compressive stress the maximum value of σ1
that could be applied without causing yielding would be somewhat smaller
than σy.

 This theory is not applicable if the failure in elastic behavior is by yielding. It

is applicable when the conditions are such that failure occurs by brittle
fracture.

Maximum Strain Energy Theory (Haigh’s

Theory)

According to this theory, the failure or yielding occurs at a point in a member

when the strain energy per unit volume in a biaxial stress system reaches the
limiting strain energy (strain energy at yield point) per unit volume as
determined from the simple tension test.
Definition of Transverse load: Forces
applied perpendicularly to the
longitudinal axis of a
member. Transverse loading causes
the member to bend and deflect from
its original position, with internal
tensile and compressive strains
accompanying change in curvature.
Members subjected to bending
by transverse loads are classed as
beams.
 Stress Tensor

 To define a stress at any point in a member subjected to multi axial

loading, an infinitesimally small cube around a point is assumed to
indicate the stress components in three mutually perpendicular
planes.
 Planar Assumptions

 All real world structures are three dimensional.

 For planar to be valid both the geometry and the loads must be constant across the thickness.

When using plane strain, we assume that the depth is infinite. Thus the effects from
end conditions may be ignored.
 Plane Stress

 All stresses act on the one plane – normally the XY

plane.

 Due to Poisson effect there will be strain in the Z

direction. But We assume that there is no stress in
the Z – direction.

 σx, τxz, τyz will all be zero.

Plane Strain

 All strains act on the one plane – normally the XY

plane. And hence there is no strain in the z-direction.

 σz will not equal to zero. Stress induced to prevent

displacement in z – direction.

 εx, εxz, εyz will all be zero.

 A thin planar structure with constant thickness and loading within the plane of the
structure (xy plane).

 A long structure with uniform cross section and transverse loading along its length (z –
direction).
1. Determine the wall thickness of a cylindrical vessel closed at
both ends from the following data:
Internal Pressure =20 N/mm2 Internal diameter =300 mm
Allowable tensile stress = 120 N/mm2
Use the a) Maximum Shear stress theory
b) Maximum distortion theory
c)Maximum strain theory Take 1/m=0.3
2. A steel bracket of machine component is made of C45 steel is
subjected to a pull to 6000 N acting at 45º to its horizontal axis. The
bracket has rectangular section whose breadth is twice the
thickness. Calculate the cross-section dimensions of the bracket if
the permissible stress of C45 material of the bracket is limited to 60
MPa.
15kN

Source: Khurmi & Gupta

Source: Khurmi & Gupta
 3)

4. The stress induced at a critical point of a machine component

made of C45 steel as follows =120N/mm2, =50N/mm2.
Calculate the factor of safety by
a) maximum normal stress theory
b) Maximum Shear stress theory
c) Maximum distortion theory
Source: Khurmi & Gupta
Source: Khurmi & Gupta
Source: Khurmi & Gupta
Source: Khurmi & Gupta