Design of Machine Elements Page

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DESIGN OF MACHINE ELEMENTS Page |1
UNIT -I
STEADY STRESSES AND VARIABLE STRESS IN MACHINE MEMBES
MACHINE DESIGN
 Machine design is the creation of new and better machines and improving the
existing one. A new or better machine is one which is more economical in the overall
cost of production and operation.
CLASSIFICATION OF MACHINE DESIGN

1. Adaptive design: The designers work is concerned with adaptation of existing
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design.
2. Development design: This type of design needs considerable scientific training
and design ability in order to modify the existing designs into a new idea.
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3. New design: This type of design needs a lot of research technical ability and
designers and creative thinking.
GENERAL CONSIDERATION IN MACHINE DESIGN

(i) Type of load and stresses caused by the load.
(ii) Motion o parts
(iii) Selection of materials
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(iv) Frictional resistance and lubrication
(v) Convenient and economical features
(vi) Safety of operation
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FACTORS INFLUENCING MACHINE DESIGN
(i) Strength and stiffness
(ii) Surface finish and tolerances
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(iii) Manufacturability
(iv) Ease of handling
(v) Working atmosphere
(vi) Cooling and lubrication
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(vii) Safety
(viii) Noise requirement
(ix) Cost
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BENDING STRESS IN STRAIGHT BEAMS

Consider a straight beam subjected to a bending moment Mb as shown in figure. The
following assumption are usually made delivering the bending formula
(i) The material of the beam is perfectly homogeneous and isotropic.
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(ii) The material of the beam obeys Hooks law.

(iii) The Young’s modulus is same in tension and compression.
(iv) The loads are applied in the plane of bending.
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Fig. Bending Stress in Straight Beams


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When a beam is subjected to the bending moment the fibers on the upper side of the
beam will be compress and lower side elongate due to tension.
 The surface between the top and bottom fibers are neither shorten nor lengthened.
Such a surface is called neutral surface.
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 The intersection of the neutral surface with any normal cross section of the beam is
known is neutral axis.
 The bending equation is given by
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M- Bending moment acting at the given section
σ - Bending stress
I - moment of inertia of the cross section about the neutral axis
y- Distance from the neutral axis to the extreme fiber
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E- Youngs modulus of the material of the beam
R- Radius of curvature of the beam
BENDING STRESS IN CURVED BEAMS

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 In straight beams the neutral axis of the section coincides with its centroidal axis
and the stress distribution is linear.
 But in curved beams the neutral axis of the cross section is shifted towards the
centre of curvature of the beam causing a nonlinear distribution of stress.
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 Application of curved beam principle is used in crane hooks, chain links planers etc.
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 Consider a curved beam subjected to a bending moment M as shown in figure.

 The general expression for bending stress (σb) in a curved beam at any fiber at a
distance y from the neutral axis is

M- Bending moment acting at the given section about the centroidal axis
A- Area of cross-section
e- Radius of curvature of the neutral axis
R- Radius of curvature of the centroidal axis
Rn- radius of curvature of the neutral axis
y- Distance from the neutral axis to the fiber under consideration. It is positive
for the distances towards the center of curvature and negative for the distance
away from the center of curvature.
STRESS CONCENTRATION
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 When every a machine component changes the shape of cross section the simple
stress distribution no longer holds good and the neighborhood of the discontinuity
is different.
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 This irregularity in the stress distribution caused by abrupt changes of form is called
stress concentration.
 Consider a plate with transverse elliptical hole and subjected to a tensile load as
shown in figure.
 From the figure the stress at the point away from the hole is practically uniform and
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the maximum stress will be induced at the edge of the hole.
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 Kt depends upon material and geometry of the part.

 Methods of Reducing Stress Concentration
o Avoiding sharp corners
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o Providing fillets
o Use of multiple holes instead of single hole.
o Undercutting the shoulder part
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PRINCIPLE STRESSES AND PRINCIPLE PLANES

 The planes which have no shear stress are known as principle planes (τ=0). The
normal stresses acting on the principle planes are known as principle stresses.
 Two principle stresses are
1 2
𝜎1,2 = 𝜎𝑥 + 𝜎𝑦 ± 𝜎𝑥 − 𝜎𝑦 + 4𝜏𝑥𝑦 2
2
 The planes of maximum shear stress are at right angles to each other and are
inclined at 45° to the principal planes.

 The maximum shear stress is given by one-half the algebraic difference between the
principal stresses, i.e.
1 2
𝜏𝑚𝑎𝑥 = ± 𝜎𝑥 − 𝜎𝑦 + 4𝜏𝑥𝑦 2
2
THEORIES OF FAILURE
 Stress produce in a body due to the application of the load is beyond the elastic limit
the permanent deformation occurs in the body.
 If the load is removed the body will not retain its original shape. There are some
permanent deformations in the body.
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 Whenever permanent deformation occurs in the body the body is said to be failed.
 The failure of a component due to increase of tensile stress or due to other
quantities such as shear stress and strain energy also attain definite values and any
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one of these may be deciding factor of the failure have advanced to explain the cause
of failure.
 According to the important theories the failure takes place when a certain limiting
value is reached by one of the following
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(i) Maximum principal stress (or) maximum normal stress (or) Ranking theory
 Failure occurs when the maximum normal stress is equal to the tensile yield
strength.
σ1(or) σ2 (or) σ3 (which is maximum) = σy/n (for ductile material)
σ1(or) σ2 (or) σ3 (which is maximum) = σu/n (for brittle material)
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Where σY-yield stress, σu -ultimate stress, n-factor of safety
 This theory is based on failure in tensile or compression and ignores the possibility
of failure due to shearing stress, ductile material mostly fail by shearing. So this
theory is used for brittle material.
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(ii) Maximum shear theory (or) Guest’s theory (or) Coloumb theory
 Failure occurs when the maximum shear stress developed in the machine member
becomes equal to the maximum shear stress at yielding in a tensile test.
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(σ1- σ2) or (σ2- σ3) or (σ3- σ1) (which is maximum) = σy/n.

 This theory is mostly used for ductile materials.
(iii) Maximum strain theory (or) Venant’s theory

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 Failure occurs when the maximum strain in the member equal in the tensile yield
strain.
σ1-ν(σ2- σ3) (or) σ2-ν(σ3- σ1) (or) σ3-ν(σ2- σ1) (which is maximum) =σy/n
ν- Poisson ratio
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(iv) Maximum strain energy theory

 Failure is induced in the member when the strain energy stored per unit volume of
the member becomes equal to the strain energy per unit volume at the yield point.
2
𝜎𝑦
𝜎1 2 + 𝜎2 2 + +𝜎3 2 + 2𝜈 𝜎1 𝜎2 + 𝜎2 𝜎3 + 𝜎3 𝜎1 = 𝑛

(v) Distortion energy theory (Von-Mises Henky theory)

 Failure or yielding occurs at a point in a member when the distortion strain energy
(also called shear strain energy) per unit volume in a bi-axial stress system reaches
the limiting distortion energy (i.e. distortion energy at yield point) per unit volume
as determined from a simple tension test.. .
2
𝜎𝑦
𝜎1 2 + 𝜎2 2 + +𝜎3 2 + 𝜎1 𝜎2 + 𝜎2 𝜎3 + 𝜎3 𝜎1 = 𝑛
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 This theory is mostly used for ductile materials in place of maximum strain energy
theory.
DESIGN OF VARIABLE LOADING
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 Consider a rotating beam of circular cross section and carrying a load of W, this load
induces stresses in the beam which are cyclic in nature.
 Upper fibers of beam(a) under compression and lower fiber (B) tensile after half
revolution the point B occupies the position of point A and point A occupies the
point of B. thus point B is now compression and point A is tensile.
tas
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 The stresses which vary from one value of compressive to same value of tensile or
vice versa are known as completely reversed or cyclic stresses.
o Mean or average stress
𝜎𝑚𝑎𝑥 + 𝜎𝑚𝑖𝑛
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𝜎𝑚 =
2
o Reversed stress or alternating or variable stress
𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛
𝜎𝑎 =
2
 The stresses which vary from a minimum value to a maximum value of same nature
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is called fluctuating stresses.

 The stresses which vary from zero to a certain maximum value are called repeated
stresses.
 The stresses which vary from a minimum value to a maximum value of the opposite
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nature is called alternative stresses (from a certain minimum compressive to a

maximum tensile or minimum tensile to a certain maximum compressive).
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NOTCH SENSITIVITY (q)

 This is defined as the degree to which the actual stress concentration effect
compares with theoretical stress concentration effect.
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ENDURANCE LIMIT (σ-1)
 It is defined as maximum value of completely reversed bending stress which a
polished specimen can withstand without failure for infinite number of cycles.
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FACTORS AFFECTING ENDURANCE STRENGTH
1. Load factor (Kl)
2. Surface finish factor(Ksur)
3. Size factor(Ksz) tas
4. Reliability factor(Kr)
5. Miscellaneous factors(Kmis)
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Gerbers Formula for variable stresses:

σm 2
σa = σ−1 1 −
σu
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Soderberg Equations:
𝟏 𝝈𝒎 𝝈𝒂
= +
𝒏 𝝈𝒚 𝝈−𝟏
𝟏 𝝉𝒎 𝝉𝒂
= +
𝒏 𝝉𝒚 𝝉−𝟏
Goodman Equations
= +
𝒏 𝝈𝒖 𝝈−𝟏

= +
𝒏 𝝉𝒖 𝝉−𝟏
Sodererg Equation with stress concentration:

= + 𝑲𝒇
𝒏 𝝈𝒚 𝝈−𝟏
= + 𝑲𝒇
𝒏 𝝉𝒚 𝝉−𝟏
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Goodman Equation with stress concentration
= 𝑲𝒕 +
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𝒏 𝝈𝒖 𝝈−𝟏
= 𝑲𝒕 +
𝒏 𝝉𝒖 𝝉−𝟏
Combined Stresses:
𝝈𝒚 𝝈𝒂 𝝈𝒚
𝝈𝒆𝒒 = = 𝝈𝒎 + 𝑲 𝒇
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𝒏 𝝈−𝟏
𝝉𝒚 𝝉𝒂 𝝉𝒚
𝝉𝒆𝒒 = = 𝝉𝒎 + 𝑲 𝒇
𝒏 𝝉−𝟏
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Combine loading (Bending and Torsion)
𝟐 𝟐
𝟏 𝝈𝒆𝒒 𝝉𝒆𝒒
= +
𝒏 𝝈𝒚 𝝉𝒚
Max. shear stress theory:
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𝝈𝒚
𝝉𝒚 =
𝟐
Octahedral shear theory:
𝝈𝒚
𝝉𝒚 =
𝟑
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UNIT -II
DESIGN OF SHAFT AND COUPLINGS
SHAFT
 A shaft is a rotating machine element which is used to transmit power from one
place to other place.
 Carbon steels of grade 40C8, 45C8, 50C4, 50C12 are normally used as shaft
materials.
Material properties
 It should have high strength
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 It should have good machinability.
 It should have low notch sensitivity factor.
 It should have good heat treatment properties.
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 It should have high wear resistance.
TYPES OF SHAFT
1. Transmission shaft: These shafts transmit power between the source and machines
absorbing power. The counter shafts, line shafts, overhead shafts all shafts are
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transmission shafts.
2. Machine shafts: These shafts from an integral part of the machine itself.
STRESSES IN SHAFT
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Following stresses are induced in the shaft.
1. Shear stress due to transmission of torque
2. Bending stress due to forces acting upon machine elements like gears, pulleys etc.
3. Stresses due to combined torsional and bending loads.
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DESIGN OF SHAFTS
The shaft may be designed on the basis of 1. Strength 2. Rigidity and stiffness.
In designing shaft on the basis of strength the following cases may be consider
1. Shafts subjected to twisting moment only
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2. Shaft subjected to bending moment only

3. Shaft subjected to combined twisting moment and bending moment
4. Shaft subjected to fluctuating loads
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1. SHAFTS SUBJECTED TO TWISTING MOMENT ONLY

The Torsional Equation is
𝑴𝒕 𝝉
=
𝑱 𝒓
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For Solid shaft

16𝑀𝑡
𝜏𝑚𝑎𝑥 =
𝜋𝑑 3
For Hollow shaft
16𝑀𝑡 𝑑𝑜
𝜏𝑚𝑎𝑥 =
𝜋 𝑑0 4 − 𝑑𝑖 4
Twisting moment may be obtained by using the following relation
𝑃 × 60
𝑀𝑡 =
2𝜋𝑁
 In case of belt drives Mt = (T1-T2) R

T1- Tension in the tight side

T2- Tension in the slack side
R- Radius of the pulley
2. SHAFT SUBJECTED TO BENDING MOMENT ONLY

 The bending moment equation is
𝑴𝒃 𝝈
=
𝑰 𝒚
For Solid shaft
32𝑀𝑏
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𝜎𝑚𝑎𝑥 =
𝜋𝑑 3
For Hollow shaft
32𝑀𝑏 𝑑𝑜
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𝜎𝑚𝑎𝑥 =
𝜋 𝑑0 4 − 𝑑𝑖 4
Mb- Bending moment
I- moment of inertia of cross sectional area of the shaft about the axis of rotation
σb- Bending stress
3.
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SHAFT SUBJECTED TO COMBINED TWISTING MOMENT AND BENDING MOMENT
When the shaft is subjected to combined twisting moment ad bending moment then
the shaft must be designed on the basic of two moments simultaneously.
 For solid shaft
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Let τ = Shear stress induced due to twisting moment, and
σb = Bending stress (tensile or compressive) induced due to bending moment.
 According to maximum shear stress theory, the maximum shear stress in the shaft,
16𝑀𝑡𝑒𝑞
𝜏𝑚𝑎𝑥 =
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𝜋𝑑 3
𝑀𝑡𝑒𝑞 = 𝐾𝑏 𝑀𝑏 2 + 𝐾𝑡 𝑀𝑡 2
 According to maximum principal stress theory, the maximum tensile stress in the
shaft,
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32𝑀𝑏𝑒𝑞
𝜎𝑚𝑎𝑥 =
𝜋𝑑 3
1
𝑀𝑏𝑒𝑞 = 𝐾𝑏 𝑀𝑏 + 𝐾𝑏 𝑀𝑏 2 + 𝐾𝑡 𝑀𝑡 2
2
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4. SHAFT SUBJECTED TO COMBINED TWISTING MOMENT, BENDING MOMENT AND

AXIAL LOAD
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P, axial load
Mt, twisting moment
Mb, bending moment
[τ], design shear stress
Kb, combined shock and fatigue factor applied to Mb
Kt, combined shock and fatigue factor applied to Mt
τ, shear stress
sb, bending stress

D E S I G N O F M A C H I N E E L E M E N T S P a g e | 10
, column action factor

= 1 for tensile load
= 1/(1 - 0.0044(l/r)) for l/r <115
= σy(l/r)2/(p2 n E) for l/r >115
E, Young's modulus
σy, yield stress
r, radius of gyration
l, length of shaft under axial load
n - end condition coefficient
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Type Kb Kt
Stationary Shaft
Gradually applied load 1 1
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Suddenly applied load 1.5-2 1.5-2
Revolving Shaft
Gradual loading 1.5 1
Minor shock loading 1.5-2 1-1.5
KEY
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Heavy shock loading 2-3 1.5-3
 A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley
to connect these together in order to prevent relative motion between them.
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TYPES OF KEYS
1. Sunk key, 2.Saddle key, 3.Tangent key, 4. Round key 5.Splines
Sunk Keys:
 The sunk keys are provided half in the keyway of the shaft and half in the keyway of
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the hub or boss of the pulley.
TYPES OF SUNK KEYS

1. Rectangular sunk key
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2. Square sunk key

 The only difference from the rectangular sunk key is the width and thickness is
equal
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3. Parallel sunk key

 The parallel sunk key may be of rectangular or square cross section. The cross
section is uniform in width and thickness throughout length.
4. Gib head key

 A gib head key is similar to a square or rectangular key but it has a head at one end,
generally at the larger end of the taper sunk key.
 The gib head is used for driving the key while assembling or disassembling.

5. Feather key
 Feather key is used where it is necessary to slide a keyed gear, pulley assembly
along the shaft.
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 Keys are tight fitted or screwed on the shaft.
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6. Woodruff key tas
 A woodruff key is used to transmit small amount of torque in automotive and
machine tool industries.
 The keyway in the shaft is milled in a curved shape whereas the keyway in the hub is
usually straight.
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 The main advantage of this key is that it will align itself in the keyway.
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TYPES SADDLE KEYS

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1. Flat saddle key: A flat saddle key is a taper key which fits in a keyway in the hub and is
flat on the shaft.
2. Hollow saddle key: A hollow saddle key is a tapper key which fits in the keyway in the
hub and the bottom of the key is shaped to fit the curved surface of the shaft.
FORCES ACTING ON A SUNK KEY

1. Forces due to tight fit of the key and thus compressive stress is induced.

2. Force due to torque transmitted by the shaft and this force produced shearing and
crushing stresses in the key.
 The induced shearing and crushing stresses may be checked. The torque transmitted
,
 Where w = width of the key, t = thickness of key. l = length of the key,
τ = Shear stress of the key material, σc =Crushing stress induced in the key material.
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EFFECT OF KEYWAYS
The keyway cut into the shaft reduces the load carrying capacity of the shaft. This is due
to the stress concentration near the corners of the keyway and reduction in the cross
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sectional area of the shaft. Torsional strength of shaft is reduced. The following relation
for the weakening effect of the keyway is based on the experiments results by
H.F.Moore.
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e = Shaft strength factor. It is the ratio of the strength of the shaft with keyway to
the strength of the same shaft without keyway,
w = Width of keyway,
d = Diameter of shaft, and
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h = Depth of keyway = Thickness of key (t) / 2
DESIGN OF COUPLING
 Shaft couplings are used in machinery for several purposes
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1. To provide for connection of shaft of units those are manufactured

separately.
2. To provide for misalignment of the shaft or to introduce mechanical
flexibility.
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3. To reduce the transmission of shock loads from one shaft to another.

4. To introduce protection against over loads.
REQUIREMENT OF A GOOD SHAFT COUPLING

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1. It should be easy to connect or disconnect.

2. It should transmit the full power from one shaft to the other shaft without
losses.
3. It should hold the shaft in perfect alignment.
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4. It should have no projecting parts.
TYPES OF SHAFT COUPLINGS

1. Rigid coupling: It is used to connect two shafts which are perfectly aligned. The types
are
 Sleeve (or) muff coupling
 Clamp(or) split muff (or) compression coupling
 Flange coupling
2. Flexible coupling: It is used to connect two shafts having lateral and angular
misalignments. The types are

 Bushed pin type coupling

 Universal coupling
 Oldham coupling
SLEEVE (or) MUFF COUPLING:

 It is made of cast iron. It consists of a hollow cylinder whose inner diameter is that
same as that of the shaft.
 It is fitted over the ends of two shafts by means of a gib head key.
 The power transmitted from one shaft two other shafts by means of a key and a
sleeve.
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Outer diameter of sleeve D=2d+13mm
Length of sleeve L=3.5d
d- diameter of shaft
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DESIGN OF MUFF COUPILNG
1. Design for sleeve
 The sleeve is designed by considering it as a hollow shaft
2. Design for key

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 The length of coupling key is at least equal to the length of the sleeve.
 The coupling key is usually made into two parts so that the length of key in each
shafts,
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After that the induced shearing and crushing stresses may be checked. The torque
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transmitted ,
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w.
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CLAMP (or) COMPRESSION COUPLING:

 In this case the muff or sleeve is made into two halves are bolted together. The
halves of the muff are made of cast iron.
 The shaft end is made to abut each other and a single key is fitted directly in the
keyway of both the shaft.

 Both the halves are held together by means of mild steel bolts and nuts. The number
of bolt may be two or four or six.
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 The usual proportions of the muff for the clamp or compression coupling are :
 Diameter of muff D=2d+13mm

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Length of muff or sleeve L=3.5d
DESIGN OF CLAMP (or) COMPRESSION COUPILNG

1. Design for sleeve
 The sleeve is designed by considering it as a hollow shaft
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2. Design for key
 The length of coupling key is at least equal to the length of the sleeve. The coupling
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key is usually made into two parts so that the length of key in each shaft
 After that the induced shearing and crushing stresses may be checked.
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5. Design of clamping bolts

 Force exerted by each bolt
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 Force exerted by each side of the shaft

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 Torque transmitted by the coupling

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Where
T - torque transmitted by the shaft
d - diameter of shaft
db - root or effective diameter of bolt
n - number of bolt
σ - Permissible stress for bolt
µ - coefficient of friction between the muff and shaft
L - length of muff

FLANGE COUPLING
 A flange coupling usually applied to a coupling having two separate cast iron flanges.
Each flange is mounted on the shaft and keyed to it.
 The faces are turned up at right angle to the axis of the shaft. One of the flange has a
projected portion and the other flange has a corresponding recess. This helps to
bring the shaft into line and to maintain alignment.
 The two flanges are coupled together by means of bolt and nuts.
1. Design for hub
 The hub is designed by considering it as a hollow shaft
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D=2d, Length of hub L=1.5d
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2. Design for key
 The key is designed with equal properties and then checked for shearing and
crushing stress. The length of key is taken equal to the length of hub.
 After that the induced shearing and crushing stresses may be checked.
tas
da
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3. Design for flange

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tf - thickness of flange(d/2)
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4. Design for bolt

 The bolts are subjected to shear stress due to torque transmitted. The number of
bolts (n) depends upon the diameter of shaft and pitch circle diameter is taken as
D1=3d
Torque transmitted , d1- diameter of bolt

For crushing

UNIT-III
DESIGN OF FASTNERS AND WELDED JOINTS

KNUCKLE JOINT
 A knuckle joint is used to connect two rods which are under the action of tensile
loads.
 It consists of mainly three elements a fork or double eye rod, a single eye rod and
knuckle pin.
 Its use may be found in the link of a cycle chain, tie rod joint for roof truss.
Dimension of various parts of the knuckle joint
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 d- diameter of rod
 d1- diameter of pin = d
 Outer diameter of eye d2=2d
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 Diameter of knuckle pin head and collar d3=1.5d
 Thickness of single eye or rod end t=1.25d
 Thickness of fork t1=0.75d
 Thickness of pin head t2=0.5d
tas
da
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METHODS OF FAILURE OF KNUCKLE JOINT

 In determining the strength of the joint for the various methods of failure, it is
assumed that 1. There is no stress concentration, and 2. The load is uniformly
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distributed over each part of the joint

 Let σt , τ and σc = Permissible stresses for the joint material in tension, shear
and crushing respectively.
1. Failure of the solid rod in tension
𝜋
Load transmitted by the joint 𝑃 = 𝑑 2 𝜎𝑡
4
From this equation, diameter of the rod (d) is obtained.
2. Now the various dimensions are fixed as follows :
If d is the diameter of rod, then

Diameter of pin, d1 = d
Outer diameter of eye, d2 = 2 d
Diameter of knuckle pin head and collar, d3 = 1.5 d
Thickness of single eye or rod end, t = 1.25 d
Thickness of fork, t1 = 0.75 d
Thickness of pin head, t2 = 0.5 d
Other dimensions of the joint are shown in Fig.
3. Failure of the knuckle pin in shear
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𝜋
Load transmitted by the joint 𝑃 = 2 × 𝑑1 2 𝜏
4
 From this equation, diameter of the knuckle pin (d1) is obtained.
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 This assumes that there is no slack and clearance between the pin and the fork
and hence there is no bending of the pin.
 But, in actual practice, the knuckle pin is loose in forks in order to permit
angular movement of one with respect to the other; therefore the pin is
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subjected to bending in addition to shearing.
 By making the diameter of knuckle pin equal to the diameter of the rod ( i.e., d1
= d), a margin of strength is provided to allow for the bending of the pin.
𝑃 𝑡1 𝑡
𝑀𝑏 +
 Bending Stress induced in the pin 𝜎𝑡 = = 2 3 4
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𝜋
𝑍 𝑑 3
32 1
From this expression, the value of d1 may be obtained.
4. Failure of the single eye or rod end in tension
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Load transmitted by the joint P = (d2 – d1) t × σt

From this equation, the induced tensile stress (σt) for the single eye or rod end
may be checked.
5. Failure of the single eye or rod end in shearing
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Load transmitted by the joint P = (d2 – d1) t × τ

From this equation, the induced shear stress (τ) for the single eye or rod end
may be checked.
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6. Failure of the single eye or rod end in crushing

Load transmitted by the joint P = d1 × t × σc
From this equation, the induced crushing stress (σc) for the single eye or pin may
be checked.
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7. Failure of the forked end in tension

Load transmitted by the joint P = (d2 – d1) × 2t1 × σt
From this equation, the induced tensile stress for the forked end may be checked.
8. Failure of the forked end in shear
Load transmitted by the joint P = (d2 – d1) × 2t1 × τ
From this equation, the induced shear stress for the forked end may be checked.
9. Failure of the forked end in crushing
Load transmitted by the joint P = d1 × 2 t1 × σc

From this equation, the induced crushing stress for the forked end may be
checked.
WELDED JOINTS:
 Welding is the most commonly used process for permanently joining machine parts.
 Welding is done by fusing the metallic parts with heat at their junction with or
without pressure.
ADVANTAGES OF WELDING OVER RIVETING

 Possibility of joining curvilinear parts
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 Cost is less
 Tightness of joint
 Noiseless process
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 Greater strength
DESIGN OF WELDED JOINTS

 In order to determine the strength of fillet joint, it is assumed that the section of
other two sides AB and BC.

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fillet is a right angle triangle ABC with hypotenuse AC making equal angles with
 The length of each side is known as leg or size of the weld and the perpendicular
distance of hypo tenuous from intersection of legs (BD) is known as the throat
thickness.
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Take s= h (as in data book)
 In the triangle BDA,

𝐵𝐷
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= 𝑠𝑖𝑛𝜃
𝐴𝐵
𝐵𝐷 = 𝐴𝐵 𝑠𝑖𝑛𝜃 = ℎ. 𝑠𝑖𝑛45 = 0.707ℎ
STRENGTH OF TRANSVERSE FILLET WELDED JOINT

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 The fillet or lap joint is obtained by overlapping the plates and then welding the
edges of the plates.
 The transverse fillet welds are designed for tensile strength.
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 Assumed that the weld section is right angle triangle ABC with hypotenuse AC
making equal with other two sides AB and BC.
t - throat thickness
h - thickness of plate
l - length of weld
Throat thickness, t=h x sin45=0.707h
Minimum area of the weld =t x l = 0.707 hl
 σt is the allowable tensile stress for the weld then tensile strength of joint for
single fillet weld

𝑃 = 0.707 ℎ × 𝑙 × 𝜎𝑡
 Tensile strength of joint for double fillet weld
𝑃 = 2 × 0.707 ℎ × 𝑙 × 𝜎𝑡 = 1.414 ℎ × 𝑙 × 𝜎𝑡
STRENGTH OF PARALLEL FILLET WELD

 The parallel filet weld joints are designed for shear strength. Consider a double
parallel fillet weld as shown in figure
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 Shear strength of joint due to double parallel fillet weld
𝑃 = 2 × 0.707 ℎ × 𝑙 × 𝜏 = 1.414 ℎ × 𝑙 × 𝜏
 Combination of single transverse and double parallel fillet weld then the strength
of joint tas
𝑃 = 0.707 ℎ × 𝑙1 × 𝜎𝑡 + 1.414 ℎ × 𝑙2 × 𝜏
STRESS CONCENTRATION FACTOR FOR WELDED JOINTS

 The reinforcement provided to the weld produces stress concentration at the
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junction of the weld and parent metal.
 When the parts are subjected to fatigue loading the stress concentration factor as
given in the following table is taken into account
Type of joint Stress concentration factor
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Reinforced butt welding 1.2

Toe of transverse fillet weld 1.5
End of parallel fillet weld 2.7
T-butt joint with sharp corner 2.0
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AXIALLY LOADED UNSYMMETRICAL WELD SECTIONS

 Unsymmetrical sections such as angles, channels T-sections etc, welded on the
flange edges are loaded axially as shown in figure.
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 In such case the length of weld should be proportioned in such a way that the
sum of resisting moments of the welds about the gravity axis is zero.
la- length of weld at the top
lb- length of weld at the bottom
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l- total length of weld

a- distance of top weld from gravity axis
b- distance of bottom weld from gravity axis
𝑙×𝑏 𝑙×𝑎
𝑙𝑎 = 𝑎+𝑏 , 𝑙𝑏 = 𝑎+𝑏
𝑙 = 𝑙𝑎 + 𝑙𝑏
ECCENTRICALLY LOADED WELD JOINTS

 When a welded joint is eccentrically loaded the principle stress will be applied
because the welded part undergoing direct load and a bending moment
Maximum normal stress

𝜎𝑏 𝜎𝑏 2
𝜎𝑡𝑚𝑎𝑥 = + + 𝜏2
2 2
Maximum shear stress

𝜎𝑏 2
𝜏𝑚𝑎𝑥 = + 𝜏2
2
Case (i)
 Consider a t-T-joint fixed at one end and subjected to an eccentric load P at a
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distance e.
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Eccentrically loaded weld joint
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The joint subjected to two types of stresses
 Direct shear stress due to the shear force P acting at the welds
 Bending stress due to the bending moment P × e.
Area of the throat,
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𝐴 = 𝑇ℎ𝑟𝑜𝑎𝑑 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 × 𝐿𝑒𝑛𝑡ℎ 𝑜𝑓 𝑤𝑒𝑙𝑑 = 𝑡 × 𝑙 × 2 = 2𝑡 × 𝑙 = 2 × 0.707ℎ × 𝑙

= 1.414ℎ × 𝑙
Shear stress in the weld (assuming uniformly distributed),

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𝑃 𝑃
𝜏= =
𝐴 1.414 × ℎ × 𝑙
Section modulus of the weld metal through the throat,
𝑡×𝑙 2 0.707ℎ×𝑙 2 ℎ×𝑙 2
𝑍= ×2= × 2 = 4.242 (For both sides weld)
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Bending Moment, Mb = P x e
Bending stress,
𝑀𝑏 𝑃 × 𝑒 × 4.242
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𝜎𝑏 = =
𝑍 ℎ × 𝑙2
Case (ii)
 When a welded joint is loaded eccentrically as shown in figure subjected to two

types of stresses
1. Direct or primary shear stress
2. Shear stress due to turning moment
P- Eccentric load

e- Eccentricity (i.e.) perpendicular distance between the line of action of load and
center of gravity(G) of throat section
l- length of single weld
t- throat thickness
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Eccentrically loaded weld joint
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 Direct or primary shear stress
𝑃
𝜏1 =
1.414 ℎ × 𝑙
 Shear stress due to turning moment (i.e.) secondary shear stress
tas 𝑃 × 𝑒 × 𝑟2
𝜏2 =
𝐽
 Resultant shear stress at A,
𝑟1
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𝑐𝑜𝑠𝜃 =
𝑟2
SCREWED FASTENERS
 A screw thread is obtained by cutting a continuous helical groove on a cylindrical
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surface (external thread).

 The threaded portion engages with corresponding threaded hole (internal
thread) forming screwed fastener.
 Screwed fasteners such as bolts, studs and nuts in combination, machine screws
are used for fastening components that require frequent assembly and
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disassembly.
 Screwed fasteners are to hold parts together and to transmit power.
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SCREW THREAD NOMENCLATURE

1. Major diameter: This is the largest diameter of a screw thread, touching the crests
on external thread or the roots on internal thread. This is also called nominal
diameter.
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2. Minor diameter: This is the smallest diameter of a screw thread, touching the roots
or core of external thread or the crests of internal thread. This is also called core or
root diameter.
3. Pitch diameter: This is the diameter of an imaginary cylinder, passing through the
threads at the points where the width of thread is equal to the space between
threads.
4. Pitch: It is the distance measured parallel to the axis, between corresponding

points on adjacent screw threads.

5. Lead: It is the distance, a screw advances axially in one turn. For a single threaded
screw, the pitch and lead are equal. For a double threaded screw the lead is twice the
pitch and so on.
FORMS OF THREADS:
 Bureau of Indian Standards (BIS) adopts ISO (International Organization for
Standards) metric threads which are followed by number of countries.
1. V-Thread: This thread profile has a larger contact area providing more frictional
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resistance to motion. It is used where effective positioning is required.
2. British Standard Whitworth (B.S.W) thread: This thread is adopted in Britain in
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inch units. The profile has rounded ends making it less liable to damage than sharp
V-threads.
3. Square thread: This is an ideal thread form for power transmission. In this as the
threaded flank is at right angle to the axis. The normal force between the threads
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acts parallel to the axis with zero radial components. This enables the nut to
transmit very high pressure as in case of a screw jack and other similar applications.
4. Buttress thread: This thread form is combination of V-thread and square thread. It
exhibits the advantages of square threads like the ability to transmit power and low
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frictional resistance and the strength of a V-thread. It is used where power
transmission takes place in one direction only.
5. ACME thread: It is a modification form of square thread. It is much stronger than

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square thread because of the wider base and it is easy to cut. The inclined sides of
thread facilitate quick and easy engagement and disengagement as for example the
split nut with the lead screw of lathe.
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tas
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COMMON TYPES OF SCREW FASTENINGS
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LOCKING DEVICES
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THREAD SERIES
 BIS recommends two thread series, coarse and fine series. Based on the relative
values of pitches. tas
 It must be noted that the concept of quality is not associated with these terms.
 For any particular diameter there is only largest pitch called coarse pitch and the
rest are designated as fine pitches.
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THREAD DESIGNATION
 The diameter pitch combination of an ISO metric screw thread is designated by
the letter M followed by the value of nominal diameter and pitch, the two values
being separated by the sign ‘x’.
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 For example a diameter pitch combination of nominal diameter 10mm and pitch
1.25mm is designated as M10x1.25.
FAILURE MODES OF BOLTED JOINTS
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STRESSES IN SCREW THREADS

 The following types of stresses are induced in screwed fasteners under static
loading
o Stresses due to initial tightening of the nut
o Stresses due to external forces
o Stresses due to the combination of above
Initial Stresses due to Screwing up Forces:

 Tensile stress due to stretching of bolt Pi = 2840 d N for fluid tight joint.
 For Non fluid tight purpose the tensile stress in the bolt Pi = 1420 d N
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 If the bolt is not initially stressed, then the maximum safe axial load which may be
applied to it, is given by
P = Permissible stress × Cross-sectional area at bottom of the thread(i.e. stress
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area).
 The stress area may be obtained from Table PSGDB 5.42.
 Torsional shear stress caused by the frictional resistance of the threads during its
tightening.
 Shear stress across the threads:

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 Compression or crushing stress on threads:
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 Bending stress if the surfaces under the head or nut are not perfectly parallel to the
bolt axis.
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STRESSES DUE TO EXTERNAL FORCES:

 Tensile stress:
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 In case the standard table is not available, then for coarse threads, dc = 0.84 d,
where d is the nominal diameter of bolt.

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Shear stress:
 Combined tension and shear stress:
STRESS DUE TO COMBINED FORCES:

 The resultant axial load on a bolt depends upon the following factors :
o The initial tension due to tightening of the bolt,

o The external load, and

o The relative elastic yielding (springiness) of the bolt and the connected
members.
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 When the connected members are very yielding as compared with the bolt, which is
a soft gasket, as shown in Fig. (a), then the resultant load on the bolt is
approximately equal to the sum of the initial tension and the external load.
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 On the other hand, if the bolt is very yielding as compared with the connected
members, as shown in Fig. (b), then the resultant load will be either the initial
tension or the external load, whichever is greater.
 The actual conditions usually lie between the two extremes. In order to determine
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the resultant axial load (P) on the bolt, the following equation may be used :
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Where
 For soft gaskets and large bolts, the value of stiffness Kc is high and the value of K is
approximately equal to unity, so that the resultant load is equal to the sum of the
initial tension and the external load.
 For hard gaskets or metal to metal contact surfaces and with small bolts, the value
of Kc is small and the resultant load is mainly due to the initial tension (or external
load, in rare case it is greater than initial tension).
 The value of ‘Kc’ may be estimated by the designer to obtain an approximate value
for the resultant load. The values of K for various type of joints are shown in Table.

Bolts of Uniform Strength

 When a bolt is subjected to shock loading, as in case of a cylinder head bolt of an
internal combustion engine, the resilience of the bolt should be considered in order
to prevent breakage at the thread.
 In an ordinary bolt, the effect of the impulsive loads applied axially is concentrated
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on the weakest part of the bolt i.e. the cross-sectional area at the root of the threads.
 In other words, the stress in the threaded part of the bolt will be higher than that in
the shank. Hence a great portion of the energy will be absorbed at the region of the
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threaded part which may fracture the threaded portion because of its small length.
 If the shank of the bolt is turned down to a diameter equal or even slightly less than
the core diameter of the thread (Dc) as shown in Fig. (b), then shank of the bolt will
undergo a higher stress.
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 This means that a shank will absorb a large portion of the energy, thus relieving the
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material at the sections near the thread.
 The bolt, in this way, becomes stronger and lighter and it increases the shock
absorbing capacity of the bolt because of an increased modulus of resilience. This
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gives us bolts of uniform strength.

 The resilience of a bolt may also be increased by increasing its length.
 A second alternative method of obtaining the bolts of uniform strength is shown in
Fig. (c).
 In this method, an axial hole is drilled through the head as far as the thread portion
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such that the area of the shank becomes equal to the root area of the thread.
BENEFITS OF INITIAL TENSION

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 Greater the initial tension larger can be the externally applied load.
 Higher the initial tension, the greater the friction force resisting the sliding of the
parts.
 Greater is the frictional resistance in the threads to prevent thread loosening
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 Greater the initial tension, reducing the fatigue effects in the bolt if the loading is
variable.
 Torque required to tighten the bolts Mt = 0.2 d Fi
BOLT DESIGN FOR VARIABLE LOADING

 Maximum bolt load with initial tension

 Minimum bolt load with initial tension
 Mean bolt load with initial tension
 Variable bolt load with initial tension
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 By Soderberg equation
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BOLTED JOINTS UNDER ECCENTRIC LOADING
 The eccentric load may be
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o Parallel to the axis of the bolts,
o Perpendicular to the axis of the bolts, and
o In the plane containing the bolts.
Eccentric Load Acting Parallel to the Axis of Bolts

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 Each bolt is subjected to a direct tensile load

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 Further the load W tends to rotate the bracket about the edge A-A.

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Due to this, each bolt is stretched by an amount that depends upon its distance from
the tilting edge.
 Since the stress is a function of elongation, therefore each bolt will experience a
different load which also depends upon the distance from the tilting edge.

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Tensile load on each bolt at distance L2,
 The total tensile load on the most heavily loaded bolt, Wt = Wt1 + Wt2
 If dc is the core diameter of the bolt and σt is the tensile stress for the bolt material,
then total tensile load,

Eccentric load acting perpendicular to the axis of bolts
 In this case, the bolts are subjected to direct shearing load which is equally shared
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by all the bolts. Therefore direct shear load on each bolts, Ws = W/n, where n is
number of bolts.
 The eccentric load W will try to tilt the bracket in the clockwise direction about the
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edge A-A.
 As discussed earlier, the bolts will be subjected to tensile stress due to the turning
moment.
 The maximum tensile load on a heavily loaded bolt (Wt) may be obtained in the
similar manner.
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 Equivalent tensile load,
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 Equivalent shear load,
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Eccentric load on a bracket with circular base

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 When the direction of the load W changes with relation to the bolts as in the case of
pillar crane.
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 Maximum load in a bolt

 But if the direction of load is fixed, then the maximum load on the bolts may be
reduced by locating the bolts in such a way that two of them are equally stressed as
shown in Fig. as in the case of flanges.
 In such a case, maximum load is given by
Eccentric Load Acting in the Plane Containing the Bolts

 When the line of action of the load does not pass through the centroid of the bolt
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system and thus all bolts are not equally loaded, then the joint is said to be an
eccentric loaded bolted joint, as shown in Fig. (a).
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 The eccentric loading results in secondary shear caused by the tendency of force to
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twist the joint about the centre of gravity in addition to direct shear or primary
shear.
 Let P = Eccentric load on the joint, and e = Eccentricity of the load i.e. the distance
between the line of action of the load and the centroid of the bolt system i.e. G.
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1. First of all, find the centre of gravity G of the bolt system.

Let A = Cross-sectional area of each bolt,
x1, x2, x3 etc. = Distances of bolts from OY, and
y1, y2, y3 etc. = Distances of bolts from OX.
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2. Introduce two forces P1 and P2 at the centre of gravity ‘G’ of the bolt system. These
forces are equal and opposite to P as shown in Fig. (b).
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3. Assuming that all the bolts are of the same size, the effect of P1 = P is to produce
direct shear load on each bolt of equal magnitude. Therefore, direct shear load on each
bolt, Ps = P/n, , acting parallel to the load P.
4. The effect of P2 = P is to produce a turning moment of magnitude P × e which tends
to rotate the joint about the centre of gravity ‘G’ of the bolt system in a clockwise
direction.
 Due to the turning moment, secondary shear load on each bolt is produced.
 In order to find the secondary shear load, the following two assumptions are made:
(a) The secondary shear load is proportional to the radial distance of the bolt under
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consideration from the centre of gravity of the bolt system.
(b) The direction of secondary shear load is perpendicular to the line joining the centre
of the bolt to the centre of gravity of the bolt system..
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Let F1, F2, F3 ... = Secondary shear loads on the bolts 1, 2, 3...etc.
l1, l2, l3 ... = Radial distance of the bolts 1, 2, 3 ...etc. from the centre of gravity ‘G’
of the bolt system.
∴ From assumption a , F1 ∝ l1 ; F2 ∝ l2 and so on or
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or
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 From the above expression, the value of F1 may be calculated and hence F2 and F3
etc. are known.
 The direction of these forces is at right angles to the lines joining the centre of bolt to
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the centre of gravity of the bolt system, as shown in Fig. (b), and should produce the
moment in the same direction (i.e. clockwise or anticlockwise) about the centre of
gravity, as the turning moment (P × e).
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5. The primary (or direct) and secondary shear load may be added vectorially to
determine the resultant shear load (R) on each bolt as shown in Fig. (c). It may also be
obtained by using the relation
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where θ = Angle between the primary or direct shear load Ps) and secondary shear
load (F).
 When the secondary shear load on each bolt is equal, then the heavily loaded bolt
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will be one in which the included angle between the direct shear load and secondary
shear load is minimum.
 The maximum loaded bolt becomes the critical one for determining the strength of
the bolted joint.
 Knowing the permissible shear stress τ , the diameter of the bolt hole may be
obtained by using the relation,
 Maximum resultant shear load

UNIT IV
DESIGN OF ENERGY STORING ELEMENTS
SPRING
 Spring is an elastic body whose function is to distort when loaded and to recover its
original shape when the load is removed.
APPLICATION OF SPRINGS
 To apply forces as in brakes, clutches and spring loaded valves.
 To store energy as in watches, toys.
 To measure forces as in spring balance and engine indicators.
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 To cushion, absorb or control energy due to either shock or vibration as in car.
TYPES OF SPRINGS
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 Helical springs
 Conical and volute spring
 Torsion spring
 Laminated or leaf spring
 Disc or bellevile spring tas
 Special purpose spring
HELICAL SPRINGS
 The helicall springs are made up of a wire coiled in the form of helix and is primarily
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intended for tensile or compressive loads.
 cross section of the wire from which the spring made may be circular, square or
rectangular.
 The two forms of helical springs are compression spring and helical tension springs.
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TERMS USED IN COMPRESSION SPRING

SOLID LENGTH
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 When the compression spring is compressed until the coils come in contact with
each other the spring is said to be solid.
 The solid length of a spring is the product of total number of coils and the diameter
of the wire.
n’ = total number of coils, d = diameter of the wire

FREE LENGTH
 It is the length of the spring in the free or unloaded condition.

 It is equal to the solid length plus the maximum deflection or compression of the
spring and the clearance between the adjacent coils.
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 Free length of the spring,
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SPRING INDEX
 It is defined as the ratio of the mean diameter of the coil to the diameter of the coil to
the diameter of the wire.
C=D/d tas
D- mean diameter of coil, d- diameter of wire
SPRING RATE
 It is defined as the load required per unit deflection of the spring.
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q=P/y
P- applied load, y- deflection of the spring
PITCH
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 The pitch of the coil is defined as the axial distance between adjacent coil in
uncompressed state.
Pitch length=free length/ n’-1)
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ENDS FOR COMPRESSION HELICAL SPRING

 In all springs the end coils produce an eccentric application of the load, increasing
the stress on one side of the spring.
 Under certain conditions, especially where the number of coils is small, this effect
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must be taken into account.

 The nearest approach to an axial load is secured by squared and ground ends, where
the end turns are squared and then ground perpendicular to the helix axis.
 It may be noted that part of the coil which is in contact with the seat is in contact
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with the seat does not contribute to spring action and hence are termed as inactive
coils.
 The turns which impact spring action is known as active turns.
 As the load increases, the number of inactive coils also increased due to seating of
the end coils and the amount of increase varies from 0.5 to 1 turn at usual working
loads.

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n- number of active turns, p-pitch of coils, d-diameter of spring
STRESSES IN HELICAL SPRING

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Maximum shear stress introduced in the wire
 Consider a helical compression spring made of circular wire and subjected to an
axial load W
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8𝑃𝐷
Maximum shear stress induced in the wire = 𝜏 = 𝐾𝑠 × 𝜋𝑑 3
Ks- Shear stress factor
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 When the springs are subjected to static loading the effect of wire curvature may be
neglected because yielding of material will relive the stresses.
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 In order to consider the effect of both direct shear as well as curvature of the wire
wahl’s stress factor is introduced.

DEFLECTION OF HELICAL SPRING OF CIRCULAR WIRE

8. 𝑃. 𝐶 3 . 𝑛
𝑦=
𝐺. 𝑑
STIFFNESS OF SPRING (or) SPRING RATE
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LEAF SPRING
 The laminated or leaf spring consists of a number of flat plates of varying lengths
held together by means of clamps and bolts. These are mostly used in automobiles.
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Leaf Spring
 A leaf spring commonly used in automobiles is of semielliptical form. It is built up of
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a number of plates.
 The leaves are usually given an initial curvature or cambered so that they will tend
to straighten under the load.
 The leaves are held together by means of a band shrunk around them at the center
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or by a bolt passing through the center.

 Since the band exerts stiffening and strengthening effect, therefore the effective
length of the spring for bending will be overall length of spring minus width of band.
 The spring is clamped to the axle housing by means of U bolts.
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 The longest leaf known as main leaf or master leaf has its ends formed in the shape
of an eye through which the bolts are passed to secure the spring to its support.
 Usually the eyes through which the spring is attached to the hanger or shackle, are
provided with bushings of some antifriction materials such as bronze or rubber.
 The other leaves of the springs are known as graduated leaves.
 Rebound clips are located at intermediate positions in the length of the spring so
that the graduated leaves also share the stress induced in the full length of leaves
when the spring rebounds.
2L1- length of span (or) overall length of spring,

l = Width of band or distance between centres of U-bolts. It is the ineffective length

of the spring,
nF = Number of full length leaves,
nG = Number of graduated leaves, and
n = Total number of leaves = nF + nG.
The effective length of the spring,
2L = 2L1 – l
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Length of master leaf = 2L1 + π d + t x 2
Bending stress in the spring,
Deflection in the leaves

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When the leaves are not initially stressed therefore maximum stress or bending stress
for
Full length leaves,
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n- number of leaves
nG- number of graduated leaves
nF- number of extra full length leaves
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For graduated leaves

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The deflection in the full length and graduated leaves

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Initialgap (or) Nip
Load on the bolt to close the nip

DESIGN OF FLYWHEEL
 A flywheel used in machines serves as a reservoir which stores energy during the
period when the supply of energy is more than the requirement and release it
during the period when the requirement of energy is more than supply.
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Turning moment diagram for single cylinder double acting steam engine
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 The fluctuation of energy may be determined by the turning moment diagram for
one complete cycle of operation.
 Consider a turning moment diagram for a single cylinder double acting steam
engine. The vertical ordinate represents the turning moment and the horizontal

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ordinate represents the crank angle. a little consideration will show that the turning
moment is zero when the crank angle is zero.
It rises to maximum value when crank angle reaches 90° and it again zero when
crank angle reaches 180°.
 This is shown by curve ABC in figure and it represents the turning moment for
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outstroke.
 The curve CDE is turning moment diagram for instroke and is somewhat similar to
the curve ABC.
 The work done is the product of turning moment and angle turned; therefore the
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area of the turning moment diagram represents the work done per revolution.
 The difference between the maximum and minimum speeds during a cycle is called
the maximum fluctuation of speed.
 The ratio of the maximum fluctuation of speed to the mean speed is called coefficient
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of fluctuation of speed.
Coefficient of fluctuation of speed

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Maximum fluctuation of energy, ΔE= maximum energy - minimum energy

Co-efficient of fluctuation of energy,
CE = maximum fluctuation of energy/ workdone per cycle
Work done per cycle=Tmean*θ
θ= angle turned in radians per revolution
= 2π in case of stream engine and two stroke I.C engine

= 4π in case of four stroke I.C engines
Energy stored in flywheel rim

Kinetic energy of the flywheel,
k may be equal to mean radius of rim(R) because the thickness of rim is very small as
compared to the diameter of rim substituting k=R
m
Mass of the flywheel rim,
A=bxt
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b-width of rim , t- thickness of rim
CONNECTING ROD
 The connecting rod is the intermediate member between the piston and the
crankshaft. Its primary function is to transmit the push and pull from the piston pin
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to the crankpin and thus convert the reciprocating motion of the piston into the
rotary motion of the crank.
 The usual form of the connecting rod in internal combustion engines is shown in Fig.
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 It consists of a long shank, a small end and a big end.

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 The cross-section of the shank may be rectangular, circular, tubular, I-section or H-

section.
 Generally circular section is used for low speed engines while I-section is preferred
for high speed engines.
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 The length of the connecting rod ( l ) depends upon the ratio of l / r, where r is the
radius of crank. It may be noted that the smaller length will decrease the ratio l / r.
 This increases the angularity of the connecting rod which increases the side thrust of
the piston against the cylinder liner which in turn increases the wear of the liner.
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The larger length of the connecting rod will increase the ratio l / r.
 This decreases the angularity of the connecting rod and thus decreases the side
thrust and the resulting wear of the cylinder. But the larger length of the connecting
rod increases the overall height of the engine. Hence, a compromise is made and the
ratio l/r is generally kept as 4 to 5.
 The small end of the connecting rod is usually made in the form of an eye and is
provided with a bush of phosphor bronze. It is connected to the piston by means of a
piston pin.
 The big end of the connecting rod is usually made split (in two halves) so that it can
be mounted easily on the crankpin bearing shells.

 The split cap is fastened to the big end with two cap bolts. The bearing shells of the
big end are made of steel, brass or bronze with a thin lining (about 0.75 mm) of
white metal or babbit metal.
 The wear of the big end bearing is allowed for by inserting thin metallic strips
(known as shims) about 0.04 mm thick between the cap and the fixed half of the
connecting rod.
 As the wear takes place, one or more strips are removed and the bearing is trued up.
 The connecting rods are usually manufactured by drop forging process and it should
have adequate strength, stiffness and minimum weight.
 The material mostly used for connecting rods varies from mild carbon steels (having
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0.35 to 0.45 percent carbon) to alloy steels (chrome-nickel or chromemolybdenum
steels). The carbon steel having 0.35 percent carbon has an ultimate tensile strength
of about 650 MPa when properly heat treated and a carbon steel with 0.45 percent
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carbon has a ultimate tensile strength of 750 MPa. These steels are used for
connecting rods of industrial engines.
 The alloy steels have an ultimate tensile strength of about 1050 MPa and are used
for connecting rods of aeroengines and automobile engines.
 The bearings at the two ends of the connecting rod are either splash lubricated or
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pressure lubricated.
 The big end bearing is usually splash lubricated while the small end bearing is
pressure lubricated.
Forces Acting on the Connecting Rod
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 The various forces acting on the connecting rod are as follows :
1. Force on the piston due to gas pressure and inertia of the reciprocating parts,
2. Force due to inertia of the connecting rod or inertia bending forces,
3. Force due to friction of the piston rings and of the piston, and
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4. Force due to friction of the piston pin bearing and the crankpin bearing.
 Load due to gas or steam pressure
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 Inertia force due to reciprocating parts

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 Effective force on the piston
 Axial load on the connecting rod

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 By Johnson's formula

INERTIA FORCE:
 Inertia force on the connecting rod at 1/3l from the crank pin
(for a = 900)
 Bending stress due to inertia force
 At mid section
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 Depth at the big end 1.1 to 1.2 times the depth at the mid section
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UNIT V
DESIGN OF BEARINGS
 A bearing is a machine element which supports another moving machine element.
 It permits a relative motion between the contact surfaces of the members while
carrying the load.
 Due to the relative motion between the surfaces a certain amount of power is
wasted in overcoming frictional resistance and if the rubbing surfaces are indirect
contact there will be rapid wear.
 In order to reduce frictional resistance and wear resistance in some cases to cases
carry away the heat generated a layer of fluid may be provided.
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DEPEND UPON THE NATURE OF CONTACT
(i) Sliding contact bearing: The sliding takes place along the surfaces of contact
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between the moving element and fixed element
(ii) Rolling contact bearing: The steel balls or rollers are interposed between the
moving and fixed element. The balls offer rolling friction at the two points for
each ball or roller.
JOURNAL BEARING
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 A sliding contact bearing that supports a load in a radial direction is known as
journal bearing. It consists of two main parts, a shaft and a hollow cylinder.
 The portion of the shaft inside the hollow cylinder also known as bearing is called as
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journal. In most applications the journal rotates while the bearing is stationary.
 However there are some applications where the journal is stationary and the
bearing rotates and even somewhere both the journal and bearing rotates.
 This journal bearing may be classified as full journal bearing and partial journal
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bearing depending upon whether the journal is fully or partially covered by bearing.
TERMS USED IN HYDRODYNAMIC JOURNAL BEARING

1. Diameter clearance: It the different between the diameter of journal and the
bearing. c= D-d
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2. Radial clearance: it is the different between the radial of the bearing and the
journal. c1=R-r=D-d/2
3. Diameteral clearance ratio: It is the ratio of the diameteral clearance to the
diameter of the journal. =c/d= (D-d)/d
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4. Eccentricity: It is the radial distance between the center of the bearing and the
displaced center of the bearing under load.
5. Minimum oil film thickness: It is the minimum distance between the bearing and
the journal under complete lubrication condition. It is denoted by ho and occurs
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at the line of centers.
COEFFICENT OF FRICTION FOR JOURNAL BEARINGS

 To determine the coefficient of friction for well lubricated full journal bearings, the
following empirical relation established by McKee based on the experimental data
µ- Coefficient of friction
Z- Absolute viscosity of oil

N- Speed of journal in r.p.m

p- bearing pressure on the projected bearing area
d- diameter of journal
l-length of bearing
c- diameter clearance
k- factor to correct for end leakage.
CRITICAL PRESSURE OF THE JOURNAL BEARING

 The pressure at which the oil film breaks down so the metal to metal contact begins,
is known as critical pressure or the minimum operating pressure of the bearing. It
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may be obtained by the following relation.
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SOMMERFELD NUMBER
 The Somerfield number is also a dimensionless parameter used extensively in the
design of journal bearings.
HEAT GENERATED IN A JOURNAL BEARING

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 The heat generated in a bearing due to the fluid friction and friction of the parts
having relative motion.
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Qg=WVµ
 After the thermal equilibrium is reached heat will be dissipated at the outer surface
of the bearing at the same rate at which it is generated in the oil film.
 The amount of heat will depend upon the temperature difference size and mass of
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the radiating surface and on the amount of air flowing around the bearing.
 However for the convenience in bearing design the actual heat dissipating area may
be expressed in terms of the projected area of the journal.
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Heat dissipated by the bearing
C- heat dissipation coefficient

A- projected area of the bearing
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tb-temperature of the bearing surface

ta- temperature of the surrounding air
DESIGN PROCEDURE FOR JOURNAL BEARING

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 Determine the length of bearing.

 Calculate the bearing pressure.
 Select the type of oil used.
 Determine the amount of heat generated.
 Determine the amount of heat rejected.
ROLLING CONTACT BEARING

 The advent of automobiles and many high speed machineries make very much use
another type of bearings known as rolling contact bearings.

 The friction produced in these bearing is very low. These bearings also called as
antifriction bearings.
 They differ from sliding contact bearings in their structure and usage.
COMPONENTS OF ROLLING CONTACT BEARINGS

 The rolling bearing consists of four main components (1) the inner ring, (2) outer
ring, (3) the balls or rollers, (4) the retainers or separators.
 The inner ring is forced to fit with machine shaft and outer ring is fitted with
machine housing.
 The shaft rotates because of relative rotations of balls or rollers.
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 The retainers are used to prevent the balls or rollers from ejecting out during
operation.
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CLASSIFICATION OF ROLLING CONTACT BEARINGS
 The rolling contact bearings are classified into two major groups with respect to
their structure
 Ball bearings
 Roller bearings tas
 Basically the structure of ball bearings are similar expect that whether the rolling
element between the inner ring and outer ring are balls or rollers.
 Also these ball bearings are many types such as deep grove ball bearings, angular
contact bal bearings and so on.
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 Both type of bearing can carry radial loads and axial loads acted individually or in
combined form.
 Generally the ball bearings are used for light loads and the roller bearings are
usually used for heavier loads.
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 Also in the case of ball bearings the nature of contact is the point contact hence the
friction produced is very less compared to roller bearings where the nature of
contact is the line contact which produce more friction.
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Types of radial ball bearing

SELECTION OF BEARINGS FOR STEADY LOADING
 The size of bearing required is judged by the magnitude and nature of applied load,
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life and reliability.

 The bearing load is composed of weights involved forces derived from power
transmitted and additional force based on method of operation.
1
𝐿 𝑘
𝐶= ×𝑃
𝐿10
C- basic dynamic load rating
L- life of bearing in million revolutions
L10- life of bearing for 90% survival at 1 million revolutions
k- exponent (3 for ball bearing, 10/3 for roller bearings)
P- Equivalent load =(XFr+YFa)S

Fr- radial load

Fa- axial load
X- radial load factor
Y- axial load factor
S- service factor
SELECTION OF BEARING FOR VARIABLE LOADING

 The rolling contact bearing are frequently operate under variable load and speed
conditions.
 This is due to many causes like power fluctuation in electrical machineries or
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requirement of different cutting forces for different kinds of machining tools, or
running with loading and unloading condition as in automobiles.
 Such as variable loaded bearings are designed by considering all these different
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loaded conditions of work cycle and not solely upon most sever operating
conditions.
 The work cycle may be divided into a number of portions in each of which operation
condition may be taken as constant.
 For variable speed

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Fm=[(F13 n1+F23n2+…….. / n 1] /3 (revolutions varying)
 For variable time
Fm=[(F13 t1+F23t2+…….. / t]1/3 (time varying)
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o F1- constant load during n1 revolution (or) during the period of time t1
o F2- constant load during n2 revolution (or) during the period of time t2
Σn=n1+n2+n3+…+nn
Σt=t1+t2+t3+…+tn
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DoME / III YEAR/ V SEMESTER/ DESIGN OF MACHINE ELEMENTS/ ANNA UNIVERSITY QUESTIONS.
2. A sqaure bar of 20mm side is subjected to a
UNITl bending moment of 1000 Nmm. Calculate the
stress induced in the top and bottom fibres of the
SIMPLE STRESSES bar. What will be stress in the above fibres, if
the bar is additionally acted upon by a tensile
1. A load of 5 kN is to be raised by means of a stress of 50 MPa along the axis.
steel wire. Find the minimum diameter
required, if the permissible stress in the wire is A"iI'lIAA. :: 2oxZo;:;. 400 rYlf'I\2... li~~(1)
not to exceed 100 MPa. Nb ~ I tf1J'D N,..ffl. ~ ;:: ~D Mf", •
1'= ?XI03 N [O'I:J':. IUD ",-\p", . a) ~he.-'\ ~ btZHltkU MIM'\eN- ttcM'~ "'" 11IL.
llt'C' tt-n ;Ie S}v¢Iv) ~oW.ced tM 11-\ e. "",ve... b~·
d.uL ro fCM.-,'c. {Ptl\.~ - The baA hv.~le-c.tc-d. to ~~ 1'Y\o-nI~
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tv\ b aN\cl.. be-n~ '(J t1 ~ .
:: .L-
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A
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BtIYloL:)\-.t~
V
<5b'" ~ ~.
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><. a
6b -;. Il51Ib 1- I J N- ('flf'f)
b3 ('f)f'I)S
cI. = r.'1 7- ~ mrtJ
-c.
:;:.. IlIP t1 X.ID lo Xb
ta s -
-
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- A + ~e top cP'hye., '*toe \oe.-t'l~'8 $~ ,....,
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Page 1 of70
DoME / III YEARI v SEMESTER/ DESIGN OF MACHINE ELEMENTS/ ANNA UNIVERSITY QUESTIONS.
3. A cicular shaft is to transmit a torque of 500 4. A hole and shaft have a basic size of 25mm and
N-m at a speed of 1000 rpm. Find out the to have a clearance fit with maximum clearance
diameter of the shaft, if the permissible shear of 0.02 mm and a minimum clearance of
stress in the shaft material is 70 MPa. O.Olmm, the hole tolerance: is to be 1.5 times the
M ::?w iN -m -= ?V'D~<'IO?> f'J ~mro . shaft tolerance. Determine the limits for both
t hole and shaft using (i) Hole basis system (ii)
N -; \VVO~· ['1:::] ~ ':to M~~ Shaft basis system.
hrc IUl..,w 'the .¢~ >~ ~olM.ce:.ol ~ d ': :'2 c; (vHf'> '
t:\. e> ItM. I> ~~ t· C-1~ce fi't
[-r;J = .It> M~=

Tr d.3.·
'3
m
W ':.. ! 6 X t?1~ x 1'0
IT )(. d ~
clo: 33·l3mn')
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Page 2 of70
5. Two links made of 30C8 steel having Sy=330 6. Give the limit dimensions for the shaft and hole
MPa are connected by a pin of same material. for the following: (i) 12 mm electric motor
The links are subjected to an axial tensile load sleeve bearing, (ii) medium force fit on a
of 5 kN and have a rectangular cross section 200mm shaft (iii) 50 mm sleeve bearing on the
with width to thickness ratio 2: 1. Design the elevating mechanism of a road grader.
links and the pin. Take Pb = 50 MPa. a.) 12 m~ d.e.ctYtc- ~hN slf!eve ~ .
~ -:: 3~o evt-fa. ~: 5x/o 3 ",. ~ ~fc. ~ (3'4-) £.J~ d1'f\d.
PSA DB
Ja ~. 2 .:) 'tn2t- Pb 0:: '50 M rA . ~ a.k <l:v-r /!WI ~"""-c. m.oM" hleeve b~~' tI
t 1T h\-lU"-t \0\ be ~e~ h,tI't'h 1-11- "-ole.
A'1?wm~ ro~ ~
o '::J ~~ Goow\
1)&-,'0-'" 11 ~n ~ :- .f.rom ~ Ie J), p~e NO:.3· , .
c-..blf)l\ s.~ ~ 3·
.1.' (\ do ~fZ.. to I eAA-WII ce. dvr- ~h4 ell ~I!. tt-t 12. t")
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T ~ ;\ ~ s '"' &II') "';'oLt.tc.c J . Oa-J .. 5.- ';
. , -fO~.3
'331) U' -II, 1/ . .:r84 m d) -:M.... S"'dr
~ fJ, ~ ~ ~ec.tl'''''' f}
~ 1I01'-1 rtll.. J1- = \ 2 - 54 ":: \. ~ bh rt) n') ;"Mtn
t1I~ hflk..-.
+ [oc J ~ 0' I?gr-J
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b
[oj: ":.. '317 MPa. •
f/'r ,2. -0·0'
mrn
-0· 034 O. Ij
? x /0'; 12 mtv'l
110 ~ {)·ooo
bx l:- {I \ ~ b'IIt' Ho Ie 12 ,.. rr- : ;.
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DoME /111 YEARj V SEMESTERj DESIGN OF MACHINE ELEMENTSj ANNA UNIVERSITY QUESTIONS.
7. A Visit : www.Civildatas.com
medium force fit is used for a hub shrunk on a 8. Detennine the safey factors for the bracket rod shown in
50mm shaft. In a batch, hub sizes vary from figure based on both the distortion-energy theory and
maximum shear theroy and compare them. The material
50.000 mm to 50.024 mm and shaft sizes vary is 2024-T4 aluminum with a yield strength of 324 MPa.
from 50.034 to 50.052 mm. If the requirement! The rod length 1= 150 mm and arm a = 200 mm. The rod
of fit is 0.040 mm maximum interference and outside diameter, d = 37.5 mm load, F = 4545 N. The
0.028 mm minimum interference by selective load is static and the assembly is at room temperature.
assembly, how many groups are to be formed. Consider shear due to transverse loading as well as other
stresses.
Give the sizes of shafts and hubs in those
groups.
Ba"i C I>i'ze ;:: S01'f)('i) .
H- 1"I'lM,. := '?o· 000 mm i+m~::-?'O . 02-4- mdl
SMt-fl ":0- 50-0?>It'fYlm .sm~ :;:1?O,Ol?l"'l'Il>.
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n
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't:;~ ":- ~ ";:- 4545' _

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:;: :. 4·115 tJltf\d\'2..-

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9. If a medium force fit (0.040 mm) is desire, 10. A 150 mm diameter steel shaft is to have a press
which axle should be fitted to each car wheel in fit with a 300 mm outer diameter by 250 mm
the following group long hub of cast iron. The maximum tangential
stress is to be 35 MPa. E = 200 GPa for steel
Wheel A B 0 and 100 GPa for cast iron; Poisson's ratio is 0.3
lfaIe DiameIs " . '1&.016
75.010 75.000 dime.GBiaas assumed for both steel and cast iron; coefficient
tn.mm
.i\:zte A' . B' e of friction = 0.12. (i) Determine the maximum
Diame&w '15:JHO '1.055 '11.050 diameteral interference (ii) What axial force will
be required to press the hub on the shaft? (iii)
I ':. o· 040 mm What torque may be transmitted with the fit?
~Ie V ; tvrYIcJ-Gt -:: I-ro 'e D'ormd~l t- ~.
m
fi.f hIh.eeL A -= 75, 0 10 -t- O· 040
:: 9- S 40 r:;O yY) t'9
.', Axle-. c ~ J-t I~Jw"'11, W'n~-A.
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fi.r hlhe.ei 13 ~""1 5. 015 + 0·0 40
4~ S
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;q 5" oSIi5 m f'fJ
rl> J1 Hc-cl ~'th \-J~.ee.l B
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; 9 5. 0 4-0 ('II"'" , I
ta s
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Visit : www.Civildatas.com Page 5 of 70

DoME / III YEAR/ V SEMESTER/ DESIGN OF MACHINE ElEMENTS/ ANNA UNiIVERS~TY QUESTIONS.
11. A transmission shaft supporting a spur gearB and pulley 12. A 80mm running shaft has to be assembled on a
D is shown in Fig. The shaft is mounted on two bearings housing (i) Specify the type of fit for the Same.
A and C. The diameters of pulley and the gear are 450 and
350 mm respectively. A 20 kW power at 500 rpm is
(ii) Mark the letter symbol (iii) Speciiy the
transmitted from the pulley to the gear. PI and P2 are the maximum and minimum clearance values. (iv)
belt tensions in the tight and loose sides, while Pt and Pr Specify the surface finish condition to achieve
are tangential and radial Components of the gear tooth the tolerances and manufacturing method, (v) If
force. Assume PI =3 P2 and Pr =Pt tan (20°). The Gear and a 200mm pitch circle diameter gear is mounted
pulley are keyed to the shaft. The material for the shaft is
steel C 60 (ultimate strength = 700 N/mm2, yield strength
on the shaft and transmite a force of 1000N at
= 460 N/mm 2 ). Detennine the diameter of shaft. For the 1500 rpm. What is the toique capacity of the
problem stated in above select the rolling element bearing Gear?
at the bearing reactions at A and C and select the type of d ___ ~omm .
fit and dimensions of the shaft and Gear assembly and
also specify the surface finish achieving the dimensional
~e.. G:;v.I1 -h:t~ VVO-Cffl,J- YIA.l'\~ J,'t;
om
tolerances.
a) I\JwmA1. "f't.tI'lM.O C).€AA..a.-nce q; t .
t 4 (" tv '04-6
c) fW. l-tole 8011'3·-:- B'D :: -gO
toO to,ooo
s.c
e. -60 8~rJ'D60
.....
'. j)
gh~t" 80 e8::.
Btl -106 -::
- 0-106
b- H (("I~
-- 80. D Lrb mdJ SmD)t ~ i-Cf·Q40 fYlO)
.~
- 90' 000 rom gnu." :: -=fe;. 814 mm.
ta Hm,in
::. t),}t?2- m(YJ.

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~ Or06 mm .
l
01) SlM.~U ~•.w-,~ cP.~ be ~~ed. 7"

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,- 1000 00 N ~ mm <
~ \: -::: \ 110 N -<f) ,
PuW-tA. ~~~ -:. JXTi~I\.I)( ~\;

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:- 2x IT):, f 9fV" 'vU
- 60
::: )59Vg N4tJo·
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Page 6 of 70
13. The stress induced at a critical point in a 14. A plate 10mm thick subjected to a tensile load
machine component made of steel 45C8 (yield of 20 kN is shown in figure. The plate is made
strength = 380 MPa) are as follows: O'x = 100 of cast iron (Yield strength = 350 MPa) and the
MPa,: O'y = 40 MPa. Calculate the factor of factor of safety "is 2.5. Determine the fillet
safey by (i) the maximum normal stress theory, radius.
(ii) the maximum shear stress theory and (iii)
distortion energy theory.
OJ :: 380 MPt:lt.. lSi ~ IVVt\..fPA. ~ ~ 40 Mf'A. p~ 2ok.~
Jd T~ -::. 0 1v\ fA .
~ Prin~poJ. $~e.?·(7·:2.)
0" Z 0 {- [Co", 6',,) t J(6'.. _O,v·~~~
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:. + (140
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DoME /111 YEAR! V SEMESTER/ DESIGN OF MACHINE ELEMENTS/ ANNA UNIVERSJTY QUESTIONS.
'115. A Visit : www.Civildatas.com

plate of 12 mm thick, with two holes as 16. A cast iron pulley transmits 10 kW at 400 rpm.
indicated in figure is subjected to tensile load of The diameter of the pulley is 1.2 m and it has
I 20 kN. Calculate the stresses at both the holes. four straight arms of elliptical cross section, in
which the major axis is twice the minor axis.
!p
Determine the dimensions of the arm if the
+-~~~\ ~~!~~++-+~~~~ allowable bending str,ess is 15 MPa.
l2.mm p-;: 10 x!03 hi N -:.411'O ~Ij. D~ "2 m
2tlt-:@.b))(.2 [Cb}::)? l'VIfet. ::: 12tromm
n '= 4- . 2.a~: MtlLjll" MtA..-? ~ me e.1.LI:~
.2 b '=' Mi.!f\.o'l' ~ '1 the ~j»-
Q..a.:: 4b R ".. 1?.
2-
c:t -: ab :=. 600 mtl)
PIJLct
om
PcvJet ;y-amorn1Hu{ h(j 1he
p::
--
2m Mt-
60
:. 'TW~Le t-ytV1f1,»~ I:Ica/
Mr :. Px 00 :: ID1"tfxbl>
2X1J)c..N Zx'if)l. 4t1J
s.c
-;: 2 g g.9-.3 N-I'f)
$
:: 23B. y3X)O ",-mm.
The s~ ~c,e.1~HCh1 fl::tt.-w kb
gIL!- the 'lWt\MC- ::: TtWGlet1I1'~ be( on P~ x
~ PS&' D13C~'IO) 1\
~~vthep~
K/; ~ ~ ki;~~--&.
2· 4-4-
ta MI; ': FI; x R.
3
Q'!fl.j-
.~ -;::: 0·213 . ,'. F ::. ~ ~ .238·13xIV;:, 3~8 N
iN t
R
(12VD/!2)
da
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~~:: Kb )( Onoffl : : 2.. 4-lf)( ?? b ";:":- 'tb ~ ~ -= qq, r:> N
1 , -n- .
@... : - 135."f N/ 2"J m tv the ~evth'c..{

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..c:-;....... = ,20)(/ amW't'l'i: ~IY\ etIn t:::t ~ P'
~ i1lteA }ixed tlJr- ~
D
1l?c f\J'crmlri"J g~ U d""""., -
{40 -20)>'-12-
fIVle. ~d Qlnd &,u.Jc.d tAA m R
:: 83>.S M Pb; ,
71;( S~ &.1 (Pi? mxfl~ bthiJL evtd .
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~ ki o::2·lb, .'. Be¥\ch(J rtlttme-tLt. "'~b -= F~ R =- '19'>x 6vo

1?'1''7vvN-I!'VI4\')p
f.rv ~ ~ j). s- ~
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Page 8of70
18. Determine the maximum stress involved in the
following cassea taking stress concentration into
account. (i) a rectangular plate with a hole
under an axial load of 10 kN (ii) A circular shaft
with a step under an axial load of 10 kN (iii) a
shaft under a bending moment of 50 Nm (iv) a
shaft under a twisting moment of 50 Nm
~:;::~:::~~
() C-C..-VVV'J ltV fh t ho I.e
/044 ~,o",
S'ect'\lm. Kt \..\.
Th~ lVt~t')'1MIrl/ S~ l.£::::-
m
0:. -:. k t )( ~om. A
f'YIlJ)(.. IO)c..'O~ W PSAPI3
;:;. Kt )( - -) (=1.10)
(w-~
.co
r " 6;,,~ -:. ,0 X. I 0'3 k~ rJ/ fY\",'l--
(w-A)
ta s
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71 cJ2-
-
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--:::: 12 r~)( Kr N/ IV\rJI'2..-

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DoME /II! YEAR! V SEMESTER! DESIGN OF MACHINE ELEMENTS/ ANNA UNIVERSITY QUESTIONS.
119. Determine
the maximum and minimum 20. A gear coupling is to shrunk on a standard shaft
I dimension of shaft and bearing housing for having 180 mm diameter. Determine suitable fit
fixing a bearing and determine the maximum and select the size of bore.
and minimum clearance/interference. The
bearing size is ID = 25, OD = 52, breath = 15
d. :::I~o mfY') •
~i
mm. eLe c r
hi £ U:::vv! 11 7- J b
I"> h hv\IL ~ \I<- J-,'\:;-
It+ w) l>elecr H:::;' m 6 ~ 1~(;{tvl C(: dw O~¥d ..6hYl-Wllt-Ji't- VII 4 ~~

h"~,hl h'l/Vl d't'i;: Jtv tf1-,lC)..j the ~h~[; Ml~ ;)h~~. p~e(3'?)
ball ~ Jwm p~e (lJ'o ' 3·5 '
2'3 H~m6.
om
+0· Ol~
25Hr ::: 25 +tro' -::- 1&0
= 0,,0»1
-)-0 ,o2~1
::. .2?
+0. 0 «,0
yntl:l 0:- I go ,() 14- f I~". q 8" ffl(Y)
s.c
;: 2'3. D2-1 I 2'3'·DOO mm.
+2'1·' ~
5h(jt A>i"Ze' 25tv1 b -:: ?t? +0'6 (g,~
T D' /)2-1
~ 2c?
1- 0 -0 o~
ta 0;: 18{)·09-D mM
I ~ 0-:00;;;;;;; .
;; 25.02.1, 25.f)ogmt'l?
~ JiO'V90fflOlJ
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Sm~
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M~ ~CWj ~ -: HYYI tM.- - S (lII.i.t) S~n
md)' Mt'i)
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Page 10 of 70
21. A flat bar 32 mm wide and 12 mm thick is 22. A flat plate of width 60mm has a central hole of
loaded by a steady tensile load of 85 kN. The 10mm diameter. If the plate is subjected to an
material is mild steel with yield point stress of axial tensile load of 10 kN, determine the
315 MPa. Find the factor of safety based on the thickness of plate. Assume yield point stress
yield point. 300 MPa and factor of safety as 2.5
}
p:;S2t)')m 1:~-12mm P-;.8?X/DN·
-- J) \A e +0 +en yS ile 10 c..d. t ."., e .f 1<:t.. t- P I"'L Ie=-
m
A ~U:-fc.J. f-o ~jr ~ h ~ .
A-1f?C cLue +0 t1,e hole ( ~e p""-~ ~U-?ft!C..h cf
'l? 5)<.1 o~
-3\1$
-=
tr> /) ~ (..uy,~ ~ M'"".
.co
h (3 12 )(.12) J.J e h-rltfW k" Om~
s~ /; - f'
It n :: I· 423 7 ~ C/!?Y1 tvz:'- hlN) U r1 OTt?
~c-1VY'
fYvrn Pt:Uf e.. ('10. -=1- • I 0 ~
ta s }<{; '; '2'?'?
a ,.
Jwr
0.1'=1- . 2·55
)<c -::
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DoME / III YEAR! V SEMESTER/ DESIGN OF MACHINE ELEMENTS/ ANNA UNIVERSITY QUESTIONS,
23. A mild steel bracket is shown in figure. It is 24. The piston of a reciprocating compressor has a
0
subjected to a pull of 5000 N acting at 45 to the diameter of 60 mm, The maximum pressure on
horizontal axis. The bracket has a rectangular the piston fall is 1.25 MPa assuming the
section whose depth is twice the thickness. Find gudgeon pin passing through the small end of
the cross sectinal dimensions of the bracket if the connecting rod Ccffi be safely loaded in shear
the permissible stress in the material is 50 MPa, up to 10 MPa, caicuJlate the minimum diameter
b::: 2 t Pi'! '" .5',5'36 Ie.N of the gudgeon pin.
[1St J 0::. S"v Nf~ '. ,.
Pp-:::h oM (()' [pJ ::1·2t;MP"'I,
45" o~
-..{) .
[-cj:::
Th e
10 M('&1
c.. u.~ ec»1 P,',.,. CJ'1r

';op
p,'Q-nm 1?1f1 ~'ec fi:cl
DiJV...b/e nit etM- bf¥1"'a rh~
m
loo.cU.·,O . : : l-oc..d a.Cf7'"OVIl
.'. The. ~twi ~tJ f.f'II p,'n 1',,,>,",,
.co
;: .!2- Dp X CJ.?J
~2. .:+
60 ><1·2:!r-::.. 3 S' 3Lt· 3 N'
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Page 12 of 70
25. A bolt is subjected to a direct tensile load of 25 26. A cast iron pulley transmits 12kW at 330 rpm.
kN and a shear load of 15 kN. Considering The diameter of the pulley is 1.3 m and it has
various theories of failure, determine the four straight arms of elliptical cross section in
suitable size of bolt if the yield stress in tension which the manor axis is twice the minor axis.
is 250 MPa. Take F.O.S as 2 and Poisson's Determine the dimensions of the arm if the
ratio as 0.3 allowble bending stress is 18 MPa.
Pt = 25){J0 3 ", Ps -=- ) 5)( 10:31'1 .
V1.-=2. '"))o::o.~. g~ P'>'" ~Ie-m No. @ tU- I~a Nb·
~ 2.50MPA
rr>
v.Y ~
T~·ile ~~c:;.y, 6;c. ~~ ':. Q<?.x'{)~

® . (SI·~1cAA. ~blem)
A ~d'2-
J,...a.r. d. :: Mirl.(Tr ~e~ eJ bolt·
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DoME / II! YEAR/ V SEMESTER/ DESIGN OF MACHINE ELEMENTS/ ANNA UI\IIVERSITY QUESTIONS.
27. Determine the diameter of a steel bar, which is 28. A cantilever of span 800 mm carries uniformly
of ductile nature subjected to an axial tensile distributed load of 12 kN/m. The yield value of
load of 60 kN and torsional moment of 1600 N- material of cantilev(~r is 400 MPa. Factor of
m. Use the factor of safety of 2.5, E = 200 GPa. safey is 2.5. Find the economical section of
Pe -; 60 x 10" N HI:; -;. 'bll'D j\! ~t'If) cantilever among (i) circular cross section of
::: I bvo)(..Ij)~ N~mi'VJ' diruueter 'd' (ii) rectangular cross section of
n ~ '2.,? 56 depth 'd' and width 'w' with dlw = 2.5 (iii) '1'
t -= 2vox 10? Nt mar . section of total depth 7t and width 5t where 't' is
thickness. Find the dimension and cross
4 t- \IV) be-leer ~ miJ'-~ srce1. bdIA sectional area of the economic section.
at:) C4S ~"1h 63 0-;: ~bf) MfA' [~J~ 4vvMPOl. ~12~/rf)
D~J}-t? 5 ~ r ()~ ~ 5-. ~ ~
L 2·~
n -:;.2·t;. ~
m
1'1
r 0]::' I b D M PA . /
= 144- Nt mrf'?' 1..-'
R>CUlo\.:,.- m!l'm~ ~ Q:\I!M' ev€.\
'\ I..
yGet/M joo.I\
',.., UDL
~ O· t? [rJ :;-::t2 Meet
$6 ["['J
-::: 'f2J uri 2» Mb:= W. ~2. t p.~ 6· It-)
.co
, IV.
Tt!Nlhl Ie I.> \"y~ cb.tc 1-0 Pt. ~ 'I('liz- ::: J2;;<.
2-
l()
$2
)( (0.212.. -:= 3 &It 0
N- f1) •
PI:; _ -:: -box.!!)· _ -:--o-_ _~2-... ~

A Z
""4')(. d '
II IHb -:: 31140)(I,03;:~
~ : : 6; .;: 7'63'14 .1: Ptl. t:{) G:-r~ (/yomh-e..(~
ol2- tas ----~ 3
hie k::..o(li1lN ~ ~ _M~ _ 38;oXI~
t:7'7A
VLJ
S~l $~ oiM~ to Mt· '3 b - z' - -1C)(d~
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L::~"~
1Td3 - 1T tl3>
/61> ~ 32)( 3~4-o XI03. ""'? ch· 6 ~~~
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g }4~.1-~ . P~. ~14-!~T3
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h!)( ('2.. ? p..Ii ;-;. :;Of'll~ :::. '1 t -14 t'06'f) .
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L__________________________________~
~---------------

29. A hole and shaft have a basic size of 30 mm and 30. Give the dimensions for the hole and shaft for
to have a clearance fit with maximum clearance the following: Also find the minimum and
of 0.02 mm and a minimum clearance of 0.01 maximum clearance in each case. (i) A 12 mm
mm. The hole tolerance is to 1.6 times the shaft electric motor sleeve bearing, (ii) A medium
tolerance. Determine the limits for both hole force fit on a 200 mm shaft.
and shaft using (i) hole basis system (ii) Shaft
basis system. Rede.t P'YlJ J, Iem N'tJ. ( [ ) ~
dl:'30mm. P~e N'o '@ .
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DoME /111 YEAR/ V SEMESTER/ DESIGN OF MACHINE ElEMENTS/ ANNA UNIVERSITY QUESTIONS.
31. AnVisit : www.Civildatas.com
j
overhang crank as shown in figure carries a tangential 32. A Shaft; transmits 20 kW power and rotates at
load of 10 kN at the centre of the crankpin. Find the 500 rpm. The material of shaft is 50C4 and the
maximum principle stress and the maximum shear stress
at the centre of the crankshaft bearing. factor of safety is 2. (1) Determine the diameter
of shaft on the basis of its shear strength. (2)
Determine the diameter of shaft on the basis of
-its torsional rigidity, if the permissible angle of
0
twist is 3 per meter length and modulus of
I rigidity of shaft material is 79300 N/mm2 •
p -; 20 Jit\O~ N N -:: 5vv ~ -
.AD .r. - .,'" /~ -:: O. 0';2,.11.
SOC4 n::az 0""/'" I
'2.. ~'VrI1
G7 -0;:. '1-9311"0 N/rom
fi,r 5'oC4 -Tn.e. ~le\'~ ~~I? 0, q)
om
(/0(' eso ~ :~ S8D rJ/ mm 2.-
d. :; '1 f5 Irf)m • 'X ~ 40 +2 '? +2-'7 ~~'t6'J -=- ~ -=- 3?fc~::: Iq D rJ / rf) ('() 1-
:: qom(t) n ~ ~
'"i. a <::! I'J/fY) M •
'd -::. 1'2.1:3 1"Ilrfl • J:! [-z::] ":. 0-'3 (6.J:; 7?
s.c
TN""WLe. ~~~ '?)(.60
~ pxbo .... E...f))c'1D -
,--/ t ~J - gx.1r)( '3 I/O
:;;: 3-'8Z N ·-tIY)

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ta hie leAl (jW T W"'fIIA.E: e:::w.e1V'h~
t..-f t 'Z' - 61 &-
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da
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'iT;. ~.1>'
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Page 16 of 70
33. A bolt is subjected to a direct load of 25 kN and 34. Define the terms : Fit and tolerance .. A hole and
shear load of 15 kN. Considering variows shaft have basic size of 32mm and to have a
theories of failure, determine a suitable size of clearance fit with maximum clearance.of 0.022
the bolt, if the material of the bolt is C 15 having mm and a minimum clearanee of 0.011 mm. The
2
200 N/mm yield strength. hole tolerance is to be 1.5 times the shaft
tolerance. Determine the limits for both hole and
ReJet P?'Vbl~ No· ® G() pttye shaft using (1) Hole basis system (2) Shaft;
NO.@) basis system.
S f ~1aA. problem...
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DoME / II! YEAR! V SEMESTER/ DESiGN OF MACHINE ELEMENTS/ ANNA UNIVERSITY QUESTIONS.
35. C.L pulley of 600 mm diameter transmits 30 kW 36. A mild ateel bracket as shownin Fig. is
at 3001Pm. The pulley is secured to the shaft by subjected to a pull of 6000 N acting at 45° to its
means of key. The material for shaft and key is horizontal axis. The bracket has a rectangular
30ers steel. Find diameter d of shaft and section whose depth is twice the thickness. Find
dimensions of key, assuming width of key = d/4. the cross sectional. dimensions of the bracket, if
For 30C8 steel cry(Yield strength of material)= the permissible stress in the material of the
330 MPa, cruc(Crushing strength of material) = bracket IS limited to 60 MPa.
630MPa.
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Page 18 of 70
37. A shaft, as shown in fig. is subjected to a 38. The C-frame of 100 kN capacity press is shown
bending load of 3 kN, pure torque of 1000 N-m in fig. The material of the, frame is grey cast
and an axial pulling force of 15 kN. Calculate iron and the factor of safety is 3 Determine the
the stresses at A and B. dimensions of the frame.
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bolt is subjected to a tensile load of25 kN and 40. A medium force fit on a 50 mm shaft requires a
to a shear load of 10 kN. Suggest a suitable size hole tolerance of 0.025 mrn and a shaft
of a bolt according to various theories of failure. tolerance of 0.016 mm, The maxImum
Take allowable yield stress is 300 N/mm2, interference is to be 0.042 mm. How will you
Poisson's ratio is 0.25. dimension the hole and the shaft. if hole
deviation is H?
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41. A hollow shaft is required to transmit 600 k"W at 42. A wall bracket with a rectangular cross section
110 rpm, the maximum torque being 20% is shown'in fig. The depth of the cross section is
greater than the mean. The shear stress is not to twice the width. The force P acting on the
exceed 63 Mpa and twist in a length of 3 meter bracket at 60° to the vertical is 5 kN. The
not to exceed 1.4 degrees. Find the external material of the bracket is grey cast iron FG 200
diameter of the shaft, if the internal diameter to and the factor of safety is 3.5. Determine the
the external diameter is 3/8. Take modulusof dimensions of the cross section of the bracket.
rigidity as 84 Gpa. Assume maximum principal stress theory of
'P~ brro ~ 10'2> N N ~ 1/0 ~ . failure.
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143. A compound bar of 3 m length made of copper 44. A C- clamp is subjected to a maximum load of
having E =105 GN/m2 and the other of steel W, as shown in figure. If the maximum tensile
having = 210 GN/m2 • Each bar is 25 mm broad stress in the clamp is Hmited to 140 MPa. Find
and 12.5 mm thick. This compound bar is the value ofload W.
stretched by a load of 50 kN. Find the increase
in length of the compound bar and the stress
produced in the steel and copper. The length of
copper as well as' of steel bar is 3 m each.
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45. A hollow shaft is required to transmit 600 kW at VARIABLE STRESSES UNIVERSITY
110 r.p.m., the maximum torque being 20% QUESTION PAPERS
greater than the mean. The shear stress is not to TCoAb~
exceed 63 MPa and twist in a length of 3 meters 1. A bar of circular cross section is subjected to
not to exceed 1.4 degrees. Find the external alternating tensile forces varying from a
diameter of the shaft, if the ratio internal minimum of 200 kN to maximum of 500 kN It
diameter to the external diameter is 3/8. Take is to be manufactured from a material with an
modulus of rigidity as 84 GPa. ultimate tensile strength of 900MPa and an
endurance limit ofroOMPa. Determine the
~ PyVble.-m ~o.@ (ii) PAfe.. diameter of the bar using safety factors of 3.5 in
f'lo .® ultimate l;e,Mj/e. strength and 4- k.endurance
limit strength and stress concentration factor of
m
1.65 for fatigued load. Use Goodman relation
for the basis of design.
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2. A shaft IS subjected to a bending moment 3. A rod of a linkage mechanism made of steel
varying from -200 Nm to 500 Nm and a twisting 40C4- (Sut = 550 MPa) is subjected to AI
moment varying from 60 Nm to 175 Nm. The completely reversed axial load of 100 kN. The
material used has Su = 600 MPa, Se = 300 MPa, rod IS machined on lathe and the expected
Ka = 0.76, Kb = 0.85, Kc = 0.897, Kt = 1.85 and reliability IS 95%. There is no stress
q = 0.95 Find the diameter of the shaft by Von concentration. Determine the diameter of the
Mises Hencky theory. Factor of safety is 1.5 'rod using a factor of safety of 2 for an infinite
Mbmto'l "'- -2/IV N-ffJ
life condition.
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~
~ A pulley is keyed to a shaft midway between ICV A: cantilever rodvof circular section is subjected
two anti-friction bearings. The bending moment to a cyclic transverse load; varying from -100 N
at the pulley varies from - 170 Nm to 510 Nm as to + 300 N as shown in Fig. Detennine the
the torsional moment in the shaft varies from 55 diameter d of the rod by (i) Goodman method
Nm to 165 Nm. The frequency of the variation and (ii) Soderberg method using the following
of the loads is the same as the shaft speed. The data. Factor of safety = 2, Theoretical stress
shaft is made of cold drawn steel having an concentration factor =1.4, Notch sensitivity
ultimate strength of 538 MPa and yield strength factor =0.9, Ultimate strength = 550 MPa, Yield
of 400 MPa. Detennine the required diameter strength =320 MPa, Endurance strength=275
for an indefinite life. The stress concentration MPa, Size correction factor=0.85, Surface
factor for the keyway in bending and torsion correction factor = 0.9. Pn-u:.fl '=' -I vv oJ
may betaken as 1.6. and 1.3 respectively,
-lCCN fj",H- ~ StDN'
m
Correction factors A =1 (tor bending), A =0.6
(for torsion), B = 0.85, C = 0.88. Use a design n ... 2..
factor N=1.5. J. _--'I- ·Klt~ ,-:,-

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A spherical pressure vessel, with a 500 mm
inner diameter, is welded from steel plates. The
welded joints are sufficiently strong and do not
weaken the vessel. The plates are made from
cold drawn stee 1 20C8 (SuF440 MPa and Syt =
242 MPa). The vessel is subjected to internal
pressure which varies from zero to 6 MPa. The
expected reliability is 50% and the factor of
safety is 3.5. The vessel is expected to withstand
infinite number of stress cycles. Calculate the
thickness of the plates.
6: =- 0.5 OtA '; o· C; )C.. 4+0 :: 220 /VI ~ •
-I ~ dw 7-·I~
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DoME /111 YEAR/ V SEMESTER/ DESIGN OF MACHINE ELEMENTSj ANNA UNIVERSITY QUESTIONS.
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10. A can ilever beam made of steel Fe 540 (Sut 11. A shaft of760 mm length is simply supported at
=540 N/mm2 and Syt =320 N/mm2) is subjected its ends. It is subjected to a central concentrated
to a completely reversed load (P) of 5 kN is cyclic load that varies from 12 to 36 kN.
shown in Fig. The shaft is machined and the Determine the diameter of the shaft assuming a
reliability is 50%.The factor of safety is 2 and factor of safety of 2, size correction factor of
the notch sensitivity factor is 0.9. Calculate (i) 0.8, and surface correction factor oill.85. The
endurance strength at the fillet section and (ii) material properties are ultimate strength =500
diameter'd' for infinite life. MPa; yield strength :=280 MPa; and endurance
limit = 250 MPa. Fatigue stress concentration
factor =1.5. f--=:=::=:fll '" iZ-h:>36 ~
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12. Determine the thickness of' 120 mm wide a
r---~~~~~~~~--------------~
13. Determine the diameter of a steel bar, which is
uniform plate for safe continuous operation if of ductile nature subjected to an ~~tensile
the plate is to be subjected to a tensile load that load of 80 kN and torsional moment of 1800
has a maXImum value of 250 kN and a N.m. Use the factor of safety of 2.5. E =200
minimum value of 100 kN. The properties of the Gpa. 3
plate material are as follows. Endurance limit 'P~Bf»(IO?ltJ Nt 0;. 18w t-J-M ~ I~VV)(.ID tJ-t1I~
stress is 225 MPa and Yield point stress is 300 n : 2. r;;;. E ~ 2l1O ~ fO 3 tv7 P(l\ .
MPa. The factor of safety based on yield point
maybe taken as 1.5. ............t: A"-:>WfYle C4'S 5~ C,.<f)
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14. A shaft of700 mm length/is simply supported at 15. A pulley is keyed to a shaft /midway between
its ends. It is subjected to a central concentrated two anti-friction bearings. The bending moment
eyc1ic load that varies from 10 to 30 kN. at the pulley varies from-170 N-m to 510 Nm
Determine the diameter of the shaft assuming a and the torsional moment in the shaft varies
factor of safety of 2, size correction factor of from 55 N-m to 165 N-m. The frequency of the
0.8, and surface correction factor of 0.85. The variation of the loads is the same as the shaft
material properties are: ultimate strength =550 speed. The shaft is made of cold drawn steel
MPa; yield strength = 300 MPa and endurance having an ultimate strength of 540 MPa, and
limit = 275 MPa. Fatigue stress concentration yield strength Of 400MPa. Determine the
factor =1.5. required diameter for indefinite life. The stress
concentration factor for the keyway in bending
R~ ~hl€'lffl 6\1'\5.@ G) p~~ and torsion may be taken as 1.6 and 1.3
respectively. The factor of safety is 1.5. Take
m
rJo. 2.'3 size factor = 0.85 and surface finish factor =
&,'01il~ /»ohle-rvt. 0.88.
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f!!J A cold drawn steel rod of circular cross section 17. A bar of circular cross-sectIon is subjected to
is subjected to a variable bending moment of alternating tensile forces varymg from a
565 N-m to 1130 N-m as the axial load varies minimum of 200 kN to a maximum of 500 kN.
from 4500 N to 13500 N. The maximum It is to be manufactured of a material with an
bending moment occurs at the same instant that ultimate tensile strength of 900 MPa and an
the axial load is maximum. Determine the endurance limit of 700 MPa. Determine the
required diameter of the rod for a factor' of diameter of bar using, safety factors of 3.5
safety.2.Neglect any stress concentration and related to ultimate tensile strength and 4 related
column effect. Assume the following values. to endurance limit and a stress concentration
Ultimate strength = 550 MPa, Yield strength = factor of 1.65 for fatigue load. Use Goodman
470 MPa, Size factor = 0.85, Surface finish straight line as basis for design.
factor = 0.89, Correction factors = 1.0 (for ~ .p~h)ert7 NO, (!) rev P~E' rJ» @)
m
bending) and 0.7 for axial loading. The
endurance limit in reversed bending may be Iq.€) A tcrn«leA~ Co It! .", \\e.cl C30 s~ (1w-tW-
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20. A simply support Q beam as concentrated load old drawn carbon
at the centre which fluctuates a value from P to steel of circular cross section as shown in figure
4P. The span of the beam is 500 mm and its is subjected to a load which varies from -? to
cross section is circular with a diameter of 60 3P. Determine the maximum load that this
mm. Beam material is cold drawn 0.2% carbon member can withstand for an indefinite life
steel. Calculate the maximum permissible value using a factor of safety as 2. The theoretical
ofP for a factor of safety of 1.3. Beam surface is stress concentration factor is 1.42 and the ndtch
ground. sensitivity is 0.9. Assume the following values:
?,n,Vi =- f P 4fmPI(.. ::. t ':
5'(/'0 rt'I tfJ Ultimate strength = 550 MPa, Yield strength =
a~6orn,. O·l.,..c.-, 11=.1·3. 470 MPa, endurance limit = 275 MPa, Size
factor = 0.85, Surface finish factor = 0.89,
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DoME fill YEARj V SEMESTERj DESIGN OF MACHINE ELEMENTSj ANNA UNIVERSITY QUESTIONS.
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22. A Visit
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rod of yield str~rigth 350 N/mrn2and 23. Determine the thickness 0 a 120 mrn wide
endurance limit of 265 N/mrn2 is subjected to an uniform plate for safe continuous operation if
axial load which varies from -300 kN minimum the plate is to be subjiected to a tensile load that
to 700kN maximum and has a stress has a maximum value of 250 kN and a
concentration factor 1;8. Assume factor of minimum value of 100 kN. The properties of the
safety 2. Calculate the diameter of the steel rod. plate are as follows. Endurance limit stress =225
cr.: ~ 3150 MPIll cr::! 0: 265 M f'~ . MPa, and Yield point stress = 300 MPa. The
3 '2. x I of} N Pm~ ~,.. I 0 ~ rJ • 0;: factor of safety based on yield point may be
P\l?"\it'l .,.. -,;;;;PfI'O taken as 1.5.
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24. A pulley is key\fd to a shaft midway between 25. A pulley is keyed to a shaft midway between
two anti-friction bearings. The bending moment two bearings. The shaft is made of cold drawn
at the pulley varies from - 160 N-m to + 500 N- steel for which the ultimate strength is 550 MPa
m and the torsional moment in the shaft varies and the yield strength is 400 MPa. The bending
from 60 N-m to 160 N-m. The frequency of the moment at the pulley varies from -150 N-m to +
variation of the loads in the same as the shaft 400 N-m as the torque on the shaft varies from -
speed. The shaft material- is having an ultimate 50 N-m to + 150 N-m. Obtain the diameter of
strength of 540 MPa and yield strength of 400 the shaft for an indefinite life. The stress
MPa. Determine the required, diameter for an concentration factors for the keyway at the
indefinite life. The stress concentration factor pulley in bending and in torsion are 1.6 and 1.3
for the keyway in bending and torsion maybe respectively. Take the following values: Factor
taken as 1.5 and 1.3 respectively. The factor of of safety = 1.5; Load correction factors = 1.0 in
m
safety is 1.5, size factor = 0.80 and surface bending, and 0.6 in torsion; Size effect factor
finish factor = 0.85. =0.85; Surface effect factor =0.88.
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26. A 50 mm diameter shaft is made from carbon 27. A machine component is subjected to
steel having ultimate tensile strength of 630 fluctuating stress that varies from 40 to 100
2
MPa. It is subjected to a torque which fluctuates N/mm . The corrected endurance limit stress for
between 2000 N-m to - 800 N-m. Using the machine components 270 N/mm2, The
Soderberg method, calculate the factor of safety. ultimate tensile strength and yield strength of
Assume suitable values for any other data material are 600 and 450 N/mm2 respectively.
needed. Find the factor of safety using: (1) Gerber theory
e ~(!;l PlrO bIervt f'JO . ®) Q p"'-'je NO • (2) Soderberg line (3) Goodman line and (4)
Also, find factor of safety against static failure.
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Page 36 of70
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Design of Machine Elements Page

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Design of Machine Elements Page

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CLASSIFICATION OF MACHINE DESIGN

GENERAL CONSIDERATION IN MACHINE DESIGN

BENDING STRESS IN STRAIGHT BEAMS

(ii) The material of the beam obeys Hooks law.

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Fig. Bending Stress in Straight Beams

BENDING STRESS IN CURVED BEAMS

 Consider a curved beam subjected to a bending moment M as shown in figure.

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 Kt depends upon material and geometry of the part.

PRINCIPLE STRESSES AND PRINCIPLE PLANES

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(σ1- σ2) or (σ2- σ3) or (σ3- σ1) (which is maximum) = σy/n.

(iii) Maximum strain theory (or) Venant’s theory

(iv) Maximum strain energy theory

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(v) Distortion energy theory (Von-Mises Henky theory)

DESIGN OF VARIABLE LOADING

is called fluctuating stresses.

nature is called alternative stresses (from a certain minimum compressive to a

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NOTCH SENSITIVITY (q)

Gerbers Formula for variable stresses:

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Sodererg Equation with stress concentration:

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2. Shaft subjected to bending moment only

1. SHAFTS SUBJECTED TO TWISTING MOMENT ONLY

For Solid shaft

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T1- Tension in the tight side

2. SHAFT SUBJECTED TO BENDING MOMENT ONLY

4. SHAFT SUBJECTED TO COMBINED TWISTING MOMENT, BENDING MOMENT AND

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, column action factor

the hub or boss of the pulley.

TYPES OF SUNK KEYS

2. Square sunk key

3. Parallel sunk key

4. Gib head key

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TYPES SADDLE KEYS

FORCES ACTING ON A SUNK KEY

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1. To provide for connection of shaft of units those are manufactured

3. To reduce the transmission of shock loads from one shaft to another.

REQUIREMENT OF A GOOD SHAFT COUPLING

1. It should be easy to connect or disconnect.

4. It should have no projecting parts.

TYPES OF SHAFT COUPLINGS

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 Bushed pin type coupling

SLEEVE (or) MUFF COUPLING:

2. Design for key

CLAMP (or) COMPRESSION COUPLING:

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DESIGN OF CLAMP (or) COMPRESSION COUPILNG

5. Design of clamping bolts

 Force exerted by each side of the shaft

 Torque transmitted by the coupling

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3. Design for flange