Design of Machine Elements-I Semester V- Mechaical Engineering (Gavitribai Phule Pune University) (SPPU) R. B. Patil ME. (Mech) (Design Engg.) Professor, Department of Mechanical Engineering, \ Amy Institute of Technology, Pune. Mabiarashtra. ® & MI | Innovation Throughout Engineering Division JDesign of Machine Elements -I RB, Patil Semester V ~ Mechanical Engineering (Savitribai Phule Pune University) (SPPU) |Copyright © by Tech-Max Publications. All ights reserved. No part of this publication may be reproduced, copied, or stored in a retrieval system, distributed or transmitted in any form or by any means, including photocopy, recording, or oth electronic or mechanical methods, without the prior written permission ofthe publisher. 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E-mail: rahulshahimage@ gmail.com ISBN. 978-93-5224-593.2 Published by Tech-Max Publications [Head Office: B/S, First floor, Maniratna Complex, Taware Colony, Aranyeshwar Corner, Pune - 411 009, Maharashtra State, India Ph: 91-20-24225065, 91-20-24217965. Fax 020-24228978, mail :info@techmaxbooks.com, Website : www.techmaxbooks.com [302041] (FID : TP491) (Book Code : PO279A)Preface Ie gives a great pleasure to present this book on ‘Design of Machine Elements « P. This book has been written for the first course in ‘Machine Design’, especially for the pre-final year students of mechanical engineering. This is the first book of the series on ‘Machine Design’ which comprehensively covers the design concepts and the design of various machine elements. ‘The main objective of this book is to bridge the gap between the reference books written by the renowned intemational authors and the requirements of undergraduate students ‘The book has been presented in a simple language without compromising the quality of text. The concepts have been developed from the fundamentals. The main emphasis has been given on explaining the concepts rather than merely providing the information. Every concept is illustrated With the help of number of solved examples which are aranged in the orer of increasing degree of 4ifficulty. The list of formulae has been given at the end of each chapter for the ready reference. This book is an outcome of the years of classroom interaction with the students, I would like to express my thanks to the Publishers, Shri. Sachin Shah and Shri. Pradeep Lunawat of “Tech-Max Publications’ for their efforts in publishing this book. My thanks are also due to Mr. Prashant Patel and the staff of “Tech-Max Publications’ for their untiring efforts in bringing this book. Last, but not least, my special thanks go to all my students whose continuous feedback while teaching this subject isthe source of inspiration behind this book. A feedback, inthe form of suggestions and comments, from the readers for further improvement of this book will be highly appreciated wert ancaaiasnannnomienSyllabus Savitribai Phule Pune University, Pune ‘Third Year of Mechanical (2015 course) Course Code: 302041 Course Name : Design of Machine Elements ~I ‘Teaching Scheme : Credits Examination Scheme : ‘TH: - 04 Hrs/week ‘TH: ~04 TH In-Sem:~30 End-Sem:--70 PR :- 02 Birs/week TW:-01 TW:--50 Course Objectives : |. Student shall gain appreciation and understanding of the design function in Mechanical Engineering, different steps involved in designing and the relation of design activity with manufacturing activity .. The student shall lea to choose proper materials for different machine elements depending on their physical and ‘mechanical properties. They will leam to apply the knowledge of material science in real life situations. Student shall gain a thorough understanding of the different types of failure modes and criteria. They will be conversant with various failure theories and be able to judge which criterion isto be applied fora particular situation, Student shall gain design knowledge of the different types of elements used in the machine design process, for e.g. fasteners, shafts, couplings etc. and willbe able to design these elements for each application. Course Outcomes : 1, Ability to identify and understand failure modes for mechanical elements and design of machine elements based on strength, Ability to design Shafts, Keys and Coupling for industrial applications, Ability to design machine elements subjected to fluctuating loads. Ability to design Power Screws for various applications, Ability to design fasteners and welded joints subjected to different loading conditions. Ability to design various Springs for strength and stiffness. Course Contents Unit | : Design of Simple Machine Elements \ ‘Machine Design, Design cycle, Design considerations - Strength, Rigidity, Manufacture, Assembly and Cost, Standards and codes, Use of preferred series, Factor of safety, Service factor. Design of Cotter joint, Knuckle joint, Levers - hand / foot lever, lever for safety valve, bell crank lever, and components subjected to eccentric loading, (Refer chapter 1) [Unit I: Design of Shafts, Keys and Couplings Shaft design on the basis of strength, torsional rigidity and lateral rigidity, A.S.MLE. code for shaft design. Transmission shaft- Theoretical treatment only. Design of keys and splines. Design of Flange Coupling and Flexible Bushed Pin Coupling. (Refer chapter 2) Unit Ill: Design for Fluctuating Loads ‘Stress concentration - causes & remedies, fluctuating stresses, fatigue failures, S-N curve, endurance limit, notch sensitivity, endurance strength modifying factors, design for finite and infinite life, cumulative damage in fatigue failure, Soderberg, Gerber, Goodman, Modified Goodman diagrams, Fatigue design of components under combined stresses:- Theoretical treatment only. (Refer chapter 3)Unit IV: Power Screws Forms of theads, multiple start screws, Torque analysis and Design of power screws with square and trapezoidal threads, Self locking screw, Cola fiction torque, Stresses in power screws, design of a C-Clamp. Design of screw ‘ek, Differential and Compound Screw and Re-icultng Ball Screw (Theoretical reatment oni), (Refer chapter 4) Unit V : Threaded Joints and Welded Joints Basic types of serew fasteners, Bolts of uniform strength, LS.O. Metric screw threads, Bolts under tension, eccentrically. Tcaded bolted joint in shear, Eeentric load perpendicular nd prll to axis of bolt, Eccentric load on circular base ‘esign of Tun Buckle. Welding symbols, Suesses in ut and filet weld, Stength of but, parallel and ansvee fille welds, Axaly loaded unsymmetrical welded joins, Boonie load in plane of welds, Weled joints subjected to bending and torsional moments (Refer chapter 5) Unit VI : Mechanical Springs ‘Types, applications and materials for sping, Stress and deflection equations for helical compression Springs, Style of nds, Design of helical compression and tension springs, Springs in series and parallel, Concentric helical springs, Suge in springs, Design of Mutleat springs. Helical torsion Spring (Theoretical teatment only). (Refer ‘chapter 6) goagw Design of Machine Elements! (SPPU) Chapter 1: Design of Simple Machine Elements 1-110 1-59 Factor. Design of Cotter Joint, Knuckle Joint, Lovers - Hand / Subjected to Eocentic Loacng _ Y Syllabus Tople : Machine Design 1.4 Introduction to Machine Design... ¥ Syllabus Topic : Design Cyl. 12 Phases (Step) In Design Process (GPU - May 11, Dec.11, May 12, May 13) ¥ Slabs Tople : Design Consitertions - Strength, Figity, Manufacture, Assembly and Cost. 13 Design Consideration nen ¥ Syllabus Topic: Standards and Codes. 4.4 Standards And Codes in Design (SPPU - May 15, ‘Aug, 18(1 Som), Aug 16h Sem), Dec. 16). 4.441 Advantages of Standardizaton (SPPU- Aug 16(hn Sem)... 142 Typo (Categories ol Standards (PPU-May 15) ¥ Syllabus Topic : Use of Prefered Series. 1.5 Proferred Series (SPPU- Dee. 10, Dec. 11, ‘Deo, 12, May 16, Dec. 16, May 17) : 15.1 Advantages of Prefered Series (SPPU - Dec. 10). Syllabus Topic: Factor of Satay. 118 Factor of Slety (SPPU-- Aug. 14(In Sem), Dec. 16, May 17)... 116.1 Factors tobe Considered in Selection of Factor of Safety (SPPU- Aug. 14(In Sem), Aug. 15(In Sem).. 1.82 Guideline Values of Factor of Say... ¥ Syllable Topic: Senice Factor. 1.7 Service Factor or Applicaton Factor (SPPU-- Dec. 16, May 17) 18 Types of Loa nn 1.9 Types of Stesses.. — 140 Design of Simple Machine Eloment. ¥ Syllabus Topic: Design of Cote Joint. 41.11 Cottor Joint (Socket and Spigot Joint) {(SPPU - Aug. 16(in Sem)Aug. 15 Sem), May 17) : 1.111 Design of Coter Joint (SPPU--Dec. 14, Aug. 15 in Ser), May 17). 1.11.2 Summary of Design of Colfer Jo 7 Syllabus Tople: Design of Knucie Jit. ‘Syllabus : Machine Design, Design Cycle, Design Considerations + Strength, Rigidity, Manufacture, Assombly and Cost, Standards ‘and Codes, Use of Preferred Series, Factor of Safety, Service Foot Lever, Lever for Safety Valve, Bll Crank Lever and Components 2 12 12 19 1 19 413 113 114 1418 1-24 Table of Contents 1.42 Knuclle Joint. 126 1421. Design of Knuckle Joint 1-24 1.422 — Summary of Design of Knuckle Joint. 1.28 ¥ Syllabus Topic : Levers, 98 1.43 Levers (SPPU - May 17) 136 AIBA Types of Leveson 96 1492 Design of Anguiar Lever {Rocker Arm for LC. Engine) 1-37 Syllabus Topic : Bel Crank Level 142 1.433 Design of Bali Crank Lever $42 ¥ Syllabus Topic: Lever or Satety Valve. 146 1.184. Design of Lover for Salty Valve ¥ "Syllabus Topic : Hands Foot Lovo. 4.485 Design of one Am Lever (Hand Lever and Foot Lever) 4 © Syllabus Tople Components Subjected o Eccentric Loading 1.14 Eecentte Loading 1.14.1 Eocenticity about One Axis 1.442 Enoenticity about Two Axes 145 Ustof Formulae, UNIT IT Chapter 2: Design of Shafts, Keys and Couplings 2-4 to 2-63, Syllabus : Shaft Design on Basis of Strength, Torsional /Pigaty ‘and Lateral Rigidity, A.S.M.E. Code for Shaft Design, Transmission shaft - Theoretical Treatment Only. Design of Keys and Splines, Design of Fange Couping and Flexible Bushes Pin Coupling ¥ Syllabus Topic: Transmission Shaft 22 21 Shale 244 Typesof Shats. 212 Axle. 21:9 Malerials for Shats.. 22 Design of Shaft. % —Sylabus Top: Stat Design on Bass of Seng 23 Design of Shaft Based on Stength 23.1 Design of Solid Shaft by Theories of Fallures (SPPU - May 15, May 16) o 232 Design of Hollow Shaft by Theotes of Failure {SPPU-May 18)... Y Syllabus Topic: ASME. Codo for Sha Design...2-5 233 ASME. Code for Design of Shaft (SPPU - May 11, May 15, May 16... 28 23.4 fect of Keyway on Shaft Strength (SPPU - Deo.18), 235 Summary ol Desig of Stat Basud on Seng ..26 ¥ Syllabus Topic: Shaft Design on Basis of “Torsional and Lateral gil...[4 Design of Machine Elements: (SPPU) Table of Contents 24 24d 242 243 25 26 ar ana an ara 28 20: 29 294 210 an aaa ama aya 212 2124 2.122 243 2131 2132 218 244 2ag2 245 Design of Shat Based On Figity Design of Shaft Based on Torsional Rigity (SPPU- Aug 14 (In Sem.) May16, May 17). Design of Shat Based on Lara Rigidity (GPPU- Aug. 14(In Sem), Difference between Torsional Rigity and Lateral Figity of Shats(SPPU Dec. 15) ‘Advantages, Limitations and Applications of Hollow Shas, Keys nn - “Types (Classification) of Koys (SPPU - May 17) Sunk Keys Splines (SPPU = May 16) on Ditference Between Keys and Splines (SPPU-Dec. 19) ‘Syflabus Topic: Design of Kes... Design of Sunk (Parallel and Tape) Keys, Procedure for Selection and Design of Sunk (Parle and Taper Keys. Design of Spine. — Procedure for Selection and Design of Splines, ‘Summary of Design of Keye.. Coupling, Purposes of Using Coupling (SPPU -Dec. 14) Classitcation of Goupings (SPPU May 11, ‘Aug. 14 (in Som), Aug. 16 In Sem), Dec. 1). Diterence (Comparison) between Rigid end Flexible Couplings (SPPU Aug. 14(In Sem). Mu (Soave) Coupling Design of Muff Coupling (SPPU - May 13) ‘Summary of Design of Mufi Coup... ‘Syllabus Topic: Designo Flange Coupling Figid Flange Coupling (SPPU - Dec. 16... Design of Protected Type Rigi Flange Coupling (SPPU -May 11), ‘Summary of Design of Figid Flange Couping ‘Syllabus Topi : Design of Fleble Bushes-Pin Coup ‘Bushed-Pin Type Flexible Flange Couping (SPPU~ DEC. 15) ‘Desig of Bushed - Pin Type Flexible Farige Coupling... ‘Summary of Design of Bushed-Fin Type Flexible Flange Coupling... st of Forbes 27 27 27 29 29 29 29 29 240 ant 2a 2a. 22 22 23 243 299 239 299 299 su 2.40 pat 241 242 244 254 54 255 287 261 UNIT Ir Chapter3: Design for Fluctuating Loads 3-1 to 3-96 Syllabus: Svoss Concentration - Causes & Remedies, Fluctuating Stresses, Fatigue Failures, S-N Curve, Endurance Limit, Notch Sensitivity, Endurance Strength Modtying Factors, Design for Fine and Inte Life, Cumulative Damage in Fatigue Failure, Soderberg, Gerber, Goodman, Modified Goodman cdagrams, Fatigue Design of Components Under Combined ‘Stresses (Theoretical Treatment ni). Y Syllabus Tope: Stross Concentration -Causos and Remotes. 32 3.41 Sess Concentration (SPPU Dec. 11, Aug. 14 (n Sem), 22 BAA Causes o tess Concentraton (SPPU- Aug. 14(In Ser, son 38.12 Methods (Remedies) of Reducing Stress CConcontaion (SPPU- May 11,Dee.11, May 12, Aig. 14 (9 SoM). on 2 Y "Syabus Topic: Stess Concentaon Factors and Notch Sensitivity. 33 32 Stess Concentration Facto 33 321 Theoretical (Geometric) Stess Concentration Factor (K) (SPU - Dee. 11, DOC. 19} ncn rnnnn 8S 322 Fatigue Sess Concentation Factor (Ki). 33 323 Notch Soni (q)(SPPU-Dec. 11, May 12, Dee. 13, Aug 15 (Sem). 39 Y — Sylabus Tope : Fatigue Fallues ey 33 Fatigue Loi And Fatigue Flu 34 Syllabus Tope : Fucuating Stosses 34 34 Fltuatng Stesses 34 34.1 Special Cases of Fluctuating Stesses nS 342. Summary of Fluctuating Stesses ¥ Syllabus Topic: Endurance init and SN Cure... 36 35 Endurance Strength, Endurance Limit and ‘SN Diagram (SPPU - Dec. 11, Dec. 12, May 12, Dec. 13, Aug. 15 (In Sem) 35:1 SN Diagram (SPPU - Dec. 13) 36 Relation Between Endurance Limit and Utimate Tensile Svength of Maer... a7 Syllabus Topic : Endurance Strength Modiying Factors... 37 37 Endurance Limit of Mecharical Component. 37 87.1 Endurance Limit (Endurance Strength) Modiying Factors {SPPU-- May 14, Aug. 15 (In Sem), DOC. 18) nn 9B[&FP besign of Machine Elements (SPPU) Table of Contents 828 Eran nn Stet 8 Gin | 38 Design of Components Subjected to = Fatigue Loading 39 | Chapter 4: Power Screws 41 104-39 ¥ Syllabus Topic: Design for infrite Lio, Frito Lite ‘and Cumulative Damage in Fatigue Faure 29 39 Design of Components Subjected To Completely Reversed Stresses (cn=0)) 39.1 Desig of Components Subjected to Completely Reversed tressos (aC) fr Infinit Litas 98 392 Design of Components Subjected to Completely Reversed Strossos (aq =0) fr Finite 3-10 393 Design of Camponents wth Cumulative Damage in Fatigue Falure-Mine's Equation... 3-10 ¥ —_Sylabus Topic: Sodetbers, Gerber and Goodman Diagrams = a8 3.40 Design of Components Subjected to Fuctuating Stesees (24 #0) Forni Un 918 3.101 Goodman Cfterion (Goodman Line) (GPPU- Dec, 2012, May 2013, Aug. 14(In Sem), ‘Aug. 15 (In Sem. 318 8.102 Soderberg Crteran Soderberg Line) (SPPU - Deo, 2012, May 2019, Aug, 14{In Sem), ‘Aug. 15 (In Sem). 319 3103 Gorbor Citron (Garber Parola) 319 3.104 Comparison of Goodman Lie, Soderberg Une and Gerber Paabola (SPPU-- Aug 16 (n Sem)... 319 ¥ ——Sylabus Topic : Modied Goodman Diagram.....-24 3:11 Motes Goodman Bagram oat 3.11.1 Mosiied Goodman Diagram for Fluctuating ‘ial o Bonding Srsses (SPPU-May 11, Dee. 19)... 321 3.11.2 Moslied Goodman Diagram for \ Fuctuatng Torsional Shear Stresses 32 3.12 Summary of Design of Components ‘Subjected to Fluctuating Stresses (0, #0) For nite Lit. 323 38.18. Design of Components Subjctod To Fluctuating Stresses (04.0) For Fite Life ou.332 ¥ Syllabus Topic: Faique Desig of Components Under Combined Stresses. 334 3:14 Fatigue Design of Components Under Combined Stresse.. sen A 318 LUistof Formulae... 395 Syllabus : Forms of Threads, Multiple Start Screws, Torque ‘Analysis and Design of Power Screws with Square and ‘Trapezoidal Threads, Self Locking Screw, Collar Friction Torque, Stresses in Power Screws, Design ofa C-Ciamp, Design of Screw Jack, Differential and Compound Sorew and Re-Cirulating Ball ‘Screw (Theoretical reatment ony). 4.1 Introduction (SPPU - Dec. 13) 42 42 Terminology of Power Scr... 42, ¥ Syllabus Topic: Forms of Treads. 43 43° Fos ofThreads (SPPU- Deo. 11, May 13, Dec. 15, May 18) 43 ¥.— Syllabus Tople : Torque Analysis... 45. 44 Torque Analysis of Square Threads... 45 44.1 Torque Required o Raise the Load Against ‘Tivead Friction (SPPU - Dec. 10, Dec. 12). 46 442 Torque Required to Lower the Load Against ‘Thread Friction (SPU - Dec. 10, Dec. 12)... 47 ¥ Syllabus Topic: Sat-Locking Screws. 47 443 Sel-Locking and Over-Hauling Screws (SPPU- May 11, May 12, Dec. 12, May 16, Dee, 18, MaY 17) en a7 444 Screw Efciency of Square Threads (SPPU- May 11, May 13, May 16) vn 445 Parameters Affecting Screw Efficiency (SPPU- Dec. 14, May 15).. 48 45 Torque Analysis of Trapezoidal And ‘Acme Threads. ns 49 ‘45:1 Torque Required to Raise and Lower the Load Against Thread Friction, 49 452, Screw Efcioncy of Trapezoldal and ‘Acme Threads. es 49 Sylabss Tope: Cola Fron Torque. 410 48 Collar Friction Torque (SPU - May 16). 440 AT Total Torque. vs 410 48 Overall Efcieney of Power Screw.. 410 49 Coofcient of Fiction... c= ¥—Syllabus Topic : Multiple Start Screws 41 440 Mult-Start Soros... ant ¥ Syllabus Topic: Stresses in Power Sorews ‘and Design of Power Scrows. a7 4.11 Stresses in Power Screws “17 4.11.1 Stresses in Sorow Body... 47 4.112 Swosses in Sorow Throats... 418(7 vesion of Machine Elements (SPU) Tablet Contents 432 Samar of Stescer in Poe Sos 419 | 851 Fags Ang on Each Bot v ‘Syllabus Topic : Design of Screw Jack.. 4-28 (SPPU-May 11, May 14). 5-6 coh en 42 | 852 "sitar Tens Foes on ae bot Y ——Sylabus Tope: Das of -Oamp se (SPU-May 1, 58 oy a dese | 559. Coon Ac ant Sepatin De eae coors . (SPPU-Dee. 1 on a ee aes EF | 54 sunset tan Comet Nantes 57 v ‘Syllabus Topic : Compound Screw. 437 8s SeEReannueenenenees 510 5:7 xen Loaded Bate Joints 510 aaa aces eae, ‘Syllabus Topic : Eccentrically Loaded Bolted 4 Syabue Tepe: Rect Bo Som 438 cee _ 417 rita Swe SUD 16,86y15. | 54 tommetantnpanoatoon eecwean Dec. 15 a 16, ee. 18). 401 |. tpuedote sur nan so 418 List of Formulae... 439 | 5.8.1 fect of Load at Ofset From Centre of Gravity. univ. Bot Syetom : aT] 582. Pree for Desi of Bote th Chapter 5: Threaded and Welded onts 5110550 Lodi Pane fo (SPPU- Mey 16, Dee. 16.51 1 sytaus Topi: Eee ond Peper Sylibus: Threaded Js: Bos Types of Soon Faster, eee ee Een ste Bots of Unio Stent, 0. Mais Scow Thess, Sots Under Tension, Eccentrically Loaded Bolted Joint in Shear, ee conic Load Perpendziar To Ars Of BO aan 6-18 Eocentric Load Perpendicular and Parallel to Axis of Bot, Eccentric || 5°71 _Elfect of Load Perpendicular to Axes of Bolts au) ee 582° Proce Designo Sede wih Lod Welded Joints : Welding Symbols, Stresses in Butt and Fillet stoner cay ee nee eieeat te ‘Welds, Strength of Butt, Parallel and Transverse Fillet Welds, “ SSyleius Topic: Eocene cad Paral fo ‘Aéally Loaded Unsymmetical Welded Joints, Eocentic Load in eee ae mo a Pane of Welds, Welded Joins Subjected to Bending and Torsional || 510 Esvontio Load Parallel To Axes of Bots. oa omens 5.1011 Elect Lond Parl aso Bots $23 are Sa | 8102 Peder es teed Jit Lond 5.11 Purposes of Using Threaded Joints perememnccent aed se | % —Slabus Top actions on Crain asa, $.28 512 jomtona monde te | 811 een oad On ical Base 1828 5.1.3 Limtatlons of Threaded Joints 52 | Silsbus Topi: Desk and Tum But. Ser Y—Sylabus Tepe :180. Mee Scow Tieas...52 | 512 TunBite SPPU-Des 1 $a es fa | 8124 DesqnotTun Baie (SPPU-De. 16)... $28 524 Type of LS.0. Metic Screw Threads 52 | 5122 Summary of Design of Tum Buckle oa ¥ Syllabus Topic: Basic Types of Seow Fasteners....5.4_ | 518 Advantages And Limitations of Welded Joint....5:94 $a ome nyertoontenn 5.01 Arias of Wald Jot (PPU- ay 1, (SPPU- Dec 1, ay 1, ee 8 May 1). 54 May 4, Dec 1a. 18 May 17 504 een 5.82 Unions of Wet dts aretina a (SPPU-May 11, May 14) 534 ¥ Syllabus Topic: Bots of Unitom Stength. Bo |e eee oa) 54 Boltof Uniform Strength (SPPU-Dec. 10, May 12, cece need Sh May 18, DOC. 15, May 18)-ceonwmnmninnnn &§ | S142 Flot or Lap Weld on. sae ¥ Syllabus Topic: Bots Under Tension. 56 | 5148 Ober Types of Wold : aa 55 Boted Joints Under Tension. 56 | Silabus Tope: Wacng Symbos cael 5.18 Weng Sb SPPU- Dee 1) 55