Machine Design - Lecture 1: Design Process, Materials, and Simple Stress

Machine Design - Lecture 1
Design Process, Materials, and Simple Stress
1
Machine Design Lecture 1: Design Process, Materials, and Simple Stress
Machine Design Flowchart :
Note: This flowchart shows

how tedious it is to design
a functional machine or a
machine element. A sound
knowledge of design
principles will always
prevent waste of time,
money, and effort.
2
Materials:
Material Classification:
• Brittle
• Ductile
1. Ductile Materials – materials which can be easily drawn into wires

- basically soft
- has a defined yield point
- has high resistance to impact loads
- fails by “yielding”
Examples of ductile materials:
- wrought iron, cast steel, copper alloys, 2000 series aluminium alloys,
alloy steel (AISI/SAE/ASTM standard), alloy steels such as stainless steels and
chromium molybdenum steels, magnesium alloys, etc.
2. Brittle Materials – materials with low resistance to deformation
- basically hard
- has no defined yield point
- can not absorb impact loads
- fails by “fracture”
Examples of brittle materials:
- cast iron (used in engine cylinder blocks, brake drums etc.), gray iron, white
iron, tool steel, high carbon steels, plastics, etc.
3
Materials:
Material Properties:
1. Strength = The ability of a materials to resist deformation when external
forces are applied.
Yield strength (Sy, Sys)= The upper limit of the elastic range (beyond this point,
the material is permanently deformed and becomes plastic) . It is the maximum
stress that can be applied to a material without permanent deformation.
(subscript s is for shear).
Ultimate strength (Su, Sus, Suc)= The maximum stress that the material
can withstand. Also called tensile strength(subscript c is for compression).
Endurance strength (Sn, Sns)= The resistance of material to fatigue.
Note: Strength and stress values are in psi, ksi, Mpa, Pa.
2. Modulus of Elasticity (E) (Stiffness) - The stress to strain ratio
within the elastic range (the linear section of the stress-strain graph); material
in tension (Unit in ksi, psi, MPa, Pa).
3. Shear Modulus of Elasticity (G) (transverse modulus or modulus of rigidity)=
The stress to strain ratio within the elastic range when material is subjected to
shear (Unit in ksi, psi, MPa, Pa).
4. Hardness (Rockwell A to E, BHN, Vickers, Shore) - measure of material

resistance to indentation; in some cases, and may be used as indication of the
material tensile strength. 4
Materials:
Stress - Strain Diagram ONLY for a DUCTILE MATERIAL

Note: Stress -Strain diagrams from material testing on Universal Testing
Machines (UTM) 5
Materials:
Sy = stress
value lowered
by a selected
factor of safety
as the
allowable
stress for
ductile
materials, used
in machine
design!
Part of Stress - Strain Diagram ONLY for a DUCTILE MATERIAL

6
Materials:
Note that
there is no
yield point!
Stress - Strain Diagram ONLY for a BRITTLE MATERIAL
7
Materials:
Necking
No necking on phenomenon
brittle on ductile
material 8
material
Materials:
USEFUL TABLES FOR MATERIAL PROPERTIES CAN BE TAKEN FROM:
1. Machine Design Text Books, e.g., DESIGN OF MACHINE ELEMENTS, by Faires 4th ed.
TABLE AT 3 - Non ferrous Metals

TABLE AT 4 – Stainless Steel
TABLE AT 5 – Plastics
TABLE AT 6 – Cast Iron and Cast Steel (sample for BRITTLE materials)
TABLE AT 7 – Wrought Ferrous Metals/Alloy Steel (sample for DUCTILE materials)
TABLE AT 8 – Alloy Steel at Various Sizes and Conditions
TABLE AT 9 – Heat Treated Steels
TABLE AT 10 – Endurance Limit and Endurance Strength of Various Materials
TABLE AT 11 – Carburized Steel
2. Mechanical Engineer’s Handbooks, which may use other symbol or letters to designate
material properties.
9
Materials:
Material Properties SAMPLE TABLES: Ductile
E
Sys
G
Su and Sy
Mild steels
10
Materials:
Material Properties SAMPLE TABLES: Brittle
Su, Suc and

Sus
Cast Iron
No Sy
values
11
SIMPLE STRESS:
Induced Stress (σ , sigma, or S; and, Ss or τ ) = applied force per unit area (lb/sq inch,
N/sqm, or Pascal)
Strength = ability of the material to resist stress (kips/sq inch, lb/sq inch, N/sqm, or Pascal)
from Material Property Tables
Allowable Stress = Design Stress (Sd or σd)
For good design :
Strength_______
Allowable Stress Sd =
Factor of Safety or N
Factor of Safety (N) = may be taken from a handbook or textbook, e.g., Table 1.1 page
20, MD by Faires, 4th ed., and as follows:
Note: The recommended factor of

safety in Table 1.1 are for land
machine elements. However, for
aircraft, the usual factor of safety used
is N= 1.5, so as parts will not become
heavy. As a result, aircraft structures
are regularly inspected for damage or
failure.
12
SIMPLE STRESS:
For good design:
FOR DUCTILE MATERIALS,
Design Stress = Allowable Stress Sd or σ d = Sy___, Sys___

N N
FOR BRITTLE MATERIALS,
Design Stress = Allowable Stress Sd or σ d = Su___, Sus___

N N
13
SIMPLE STRESSES:
TYPES
1. TENSION or TENSILE STRESS
Area A
F___
Tensile Stress St or σ t =
A
14
SIMPLE STRESSES:
TYPES
2. DIRECT COMPRESSION or COMPRESSIVE STRESS
Type of Loading Illustration Stress Distribution
Area A
F___
Compressive Stress Sc or σ c =
A
15
SIMPLE STRESSES:
TYPES
2. COMPRESSION or COMPRESSIVE STRESS (Other forms)
2. a. Bearing stress
F
F
F___
Bearing Stress Sb or σ b = = F___
Ab d (t)
16
SIMPLE STRESSES:
TYPES
3. DIRECT SHEAR
Shear
Area A
F
F___
Direct Shear Stress Ss or σ s =
A
17
SIMPLE STRESSES:
TYPES
3. SHEAR (other forms)
3.a. Single Shear
1 Stress
Area A
F___
Single Shear Stress Ss or σ s =
A
18
SIMPLE STRESSES:
TYPES
3.b. Double Shear

F/2
F
F/2
2 Stress D
Areas A
F___
Single Shear Stress Ss or σ s =
2A
19
SIMPLE STRESSES:
TYPES
3.c. Tear out
20
SIMPLE STRESSES:
TYPES
4. BENDING or FLEXURAL STRESS
-M = compression
Z
+M = tension
Mc___ , or, M___ Z
Flexural Stress Sf or Ơf = Z
I
Important notes on Flexural/Bending stress:
1. This type of stress is a combination of tension and compression .
2. Z = I/c; also called section modulus; with formulas that can be taken from Tables.
3. Very important! I (moment of inertia) can be Ixx or Iyy. Use Ixx if direction of force is perpendicular to
neutral axis or plane of the material (Vertical bending) , and Iyy if parallel to the neutral axis of the
material (Lateral bending). If I values are not available from the Tables, calculate I using the parallel
axes theorem. 21
SIMPLE STRESSES:
TYPES
4. BENDING or FLEXURAL STRESS
22
SIMPLE STRESSES:
TYPES
4. BENDING or FLEXURAL STRESS (Cont.)
Note: 1. Ʈ is induced shear.

23
SIMPLE STRESSES:
TYPES
5. TORSION = also classified as shearing stress but it as a result of a twisting effect of the torque as
load.
Torsional Stress Ss or τ = Tc__ or T__

J Z’
Note: Z’ = J/c; also called polar section modulus; with formulas that can be taken from Tables.
24
SIMPLE STRESSES:
Additional formulas
1. ELONGATION ( δ, inches, mm ): elements subjected to tension will expand in its length and
if stress applied is within the proportional limit, the material will return to its original length.
It is quantified mathematically by :
Stress Area A
Change in Length δ= FL_

AE
25
SIMPLE STRESSES:
Additional formulas
2. ANGLE OF TWIST (θ, radians): elements subjected to torsion will experience twisting to
some degree and if stress applied is within the proportional limit, the material will return to its
original configuration. It is quantified mathematically by :
Torque T
Angle of twist θ
Angle of twist θ= TL_

JG
26
SIMPLE STRESS:
Sample Problems:
1. A cylindrical rod is to carry a load of 2 tons and space requirements limit the
maximum elongation to 0.0305 inch. If the material is AISI 1020 cold drawn steel
and applied with a dead load and the rod is to have a length of 10 inches,
determine the required minimum diameter of the rod in inches.
Diameter D
δ= 0.0305” max
SEE APPENDIX FOR SOLUTIONS AND ANSWERS!
27
SIMPLE STRESS:
Sample Problems:
2. A cast iron beam made of ASTM 50 is 30 inches long and supports 2 gradually
applied in one direction repeated loads (in phase). One is 2000 lb at a distance 10
inches from the free end, and one of 1000 lb at the free end.
Determine the dimensions of the beam cross section if b = c = 3a. Refer to the
Figure below.
28
SIMPLE STRESS:
Sample Problems:
3. A shaft in torsion only is to transmit 1865 KW (2500 HP) at 570 rpm with
medium shock. Its material is AISI1137 annealed steel. ( a ) What should be the
diameter of the solid shaft to sustain the load (mm)? ( b ) If the shaft is hollow
and Do= 2Di, what size is required (mm) ?
( c) What is the weight in Newtons per meter of each of the shafts and compute
the percent difference? (d ) Which is more rigid ? Compute torsional deflection
for a length of 3 meters.
29
HOMEWORK:
1. Review your knowledge on Strength of Materials.
2. Familiarize yourselves with textbooks, handbooks and other references which
can be used to determine properties of sections and material properties.
3. Make further readings on materials used for machine elements including the
latest ones, such as composite materials.
4. Solve the following problems:
4.a
30
SIMPLE STRESS:
HOMEWORK
4.b
31
SIMPLE STRESS:
HOMEWORK
4.c. A hollow shaft must carry a torque of 3 ,400, 000 N-.mm (30,050 in-lb) at an
allowable shearing stress of 55 Mpa (7,970 psi). The inside diameter is to be 65 % of
the outside diameter. Determine:
a. choose a possible material (ductile, steel alloy) for the shaft. Provide
specifications.
b. the required outside diameter in mm.
c. the required inside diameter in inches.
32
APPENDIX
USEFUL DATA– Tables taken from Design of
Machine Elements by Faires 4th ed.
33
34
35
36
37
38
39
Solution to Sample Problem 1.
Notes: 1. The factor of

safety N= 2 is from Table 1.1
DOME by Faires, for dead
load
2. It is always safer to select
factor of safety based on
yield strength due allowable
stress will always be within
the proportional limit.
40
Solution to Sample Problem 2
Notes: 1. The Ixx values

were calculated using the
section property formula in
Table AT 1. The I values are
available from tables for
regular sections , in
handbooks. If Ixx or Iyy
values are not available for
complex figures, calculate
these values using the Solving for tension:
Parallel Axis Theorem,
which I have included an
example in the Appendix in
this Lecture 1.
2. There is a need to draw
the force, shear and
moment diagrams for
flexural stress problems.
41

(continued)
Solving for tension
Solve for compression with

Suc = 164,000 psi. since very
large value, dimensions will
be a lot lower. Then chose
answers from calculations on
tension.
42
43

(continued)
44
Solution to Sample Problem 3(continued)
45

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Machine Design - Lecture 1

Design Process, Materials, and Simple Stress

Note: This flowchart shows

1. Ductile Materials – materials which can be easily drawn into wires

4. Hardness (Rockwell A to E, BHN, Vickers, Shore) - measure of material

Stress - Strain Diagram ONLY for a DUCTILE MATERIAL

Part of Stress - Strain Diagram ONLY for a DUCTILE MATERIAL

Stress - Strain Diagram ONLY for a BRITTLE MATERIAL

USEFUL TABLES FOR MATERIAL PROPERTIES CAN BE TAKEN FROM:

TABLE AT 3 - Non ferrous Metals

Su, Suc and

Note: The recommended factor of

For good design:

FOR DUCTILE MATERIALS,

Design Stress = Allowable Stress Sd or σ d = Sy___, Sys___

FOR BRITTLE MATERIALS,

Design Stress = Allowable Stress Sd or σ d = Su___, Sus___

Type of Loading Illustration Stress Distribution

3.a. Single Shear

3.b. Double Shear

3.c. Tear out

Note: 1. Ʈ is induced shear.

Torsional Stress Ss or τ = Tc__ or T__

Change in Length δ= FL_

Angle of twist θ= TL_

SEE APPENDIX FOR SOLUTIONS AND ANSWERS!

SEE APPENDIX FOR SOLUTIONS AND ANSWERS!

SEE APPENDIX FOR SOLUTIONS AND ANSWERS!

Solution to Sample Problem 1.

Notes: 1. The factor of

Solution to Sample Problem 2

Notes: 1. The Ixx values

Solution to Sample Problem 2

Solving for tension

Solve for compression with

Solution to Sample Problem 3

Solution to Sample Problem 3

Solution to Sample Problem 3(continued)

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Design Stress = Allowable Stress Sd or σ d = Sy_, Sys_

Design Stress = Allowable Stress Sd or σ d = Su_, Sus_

Torsional Stress Ss or τ = Tc or T