ME 321 MACHINE DESIGN 1

Machine Design – is a broad of simple and combined stress analysis and their application to the
design of shafts, keys, coupling, gears, screws, springs, and columns.

Mechanical Design – is the process of designing and/or selecting mechanical components and
putting them together to accomplish a desired function. The ultimate objective of mechanical
design is to produce a useful device that is safe, efficient, economical, and practical to
manufacture. As beginners, before designing you must define the functions and the design
requirements for the device clearly and completely (Mott, Vavrek & Wang, 2018).

Design Problem
A machine is usually designed to perform its function for a special length of time
(operating life) members must be able to resist external forces, called applied loads and in
addition they must satisfy rigidity requirements.

General Criteria for Machine Design

1. Safety
2. Performance (the degree to which the design meets or exceeds the design objectives)
3. Reliability (a high probability that the device will reach or exceed its design life)
4. Ease of manufacture
5. Ease of service or replacement of components
6. Ease of Operation
7. Low initial cost
8. Low operating and maintenance costs
9. Small size and low weight
10. Low noise and vibration; smooth operation
11. Use of readily available materials and purchased components.
12. Prudent use of both uniquely designed parts and commercially available components
13. Appearance that is attractive and appropriate to the application

Standards and Codes

Standard is a set of specifications for parts, materials, or processes intended to achieve
uniformity, efficiency, and a specified quality.
- It is to limit the multitude of variations that can arise from the random creation of a
part, material, or process.
Code is a set of specifications for the analysis, design, manufacture, and construction of
something.
Ex. Society of Automotive Engineers (SAE)
International Standards Organization (ISO)
 American Iron and Steel Institute (AISI)
American Society of Mechanical Engineers (ASME)
American Society of Testing and Materials (ASTM)

Factor of Safety (N)

In designing a component, it is very necessary to ensure sufficient reserve strength in
case of an accident. It is ensured by taking suitable factor of safety.
loading that would cause failure
N=
actual loading on part
σ
N= f
σ al
Where:
σ f can be yield stress or ultimate stress.
σ alallowable stress also known as design stress, working stress or safe stress.

Example: Using the material AISI –C1020 as rolled, and a factor of safety of 2 based on yield strength and
4 based on ultimate stress, compute the following:

a. The allowable stress in tension or compression base on yield stress.

b. The allowable stress in tension or compression base on ultimate stress.
c. The allowable stress in shear (torsion) based on yield stress.
d. The allowable stress in shear (torsion) based on ultimate stress.

AISI – C1020 as rolled material.

σ y =48 ksi; σ u=65 ksi ; τ y =24 ksi ; τ u=49 ksi
Solution:
σy 48
(a) σ = ; σ= =24 ksi
N 2
σ 65
(b) σ = u ; σ= =16.2 ksi
N 4
τy 24
(c) τ = ; τ= =12 ksi
N 2
τ 24
(d) τ = y ; τ= =12 ksi
N 2
τu 49
(e) τ = ;τ = =12.25 ksi
N 4

Analysis of Simple Stresses

Stress (σ) – is the unit strength of a material or the force per unit area.
 Force lb kg
σ= , 2, , KN /m2
Area i n c m 2

Ultimate Stress (σu) – is the stress that would cause failure.

Yield Stress (σy) – maximum stress without causing deformation.
Allowable Stress (σall) – Ultimate stress/Factor of Safety
Design Stress (σd) – stress used in determining the size of a member.
σu σy
Based on ultimate stress: σ d= ; Based on yield stress: σ d=
FS FS
Where: FS = Factor of Safety

Types of Simple Stresses:

1. Axial Stress – is the stress developed under the action of the force acting axially (or
passing the centroid) of the resisting area. It can be directed away for tensile stress or
toward for compressive stress.

Tensile stress (σt) F D F

Compressive stress (σc)

F F

π 2
For solid circular cross-section: A= D
4
π
A= ( D o −D i )
2 2
For hollow circular-section:
4
For rectangular cross-section: A = base x height

2. Shearing stress is the stress developed when the force is applied parallel to the resisting
area. It is produced when the applied loads cause one section of a body to tend to slide
past its adjacent section.

F
ϑ s=
As

Where:
F F
F = shearing force
A = cross-sectional area
 = area parallel to the direction of force
σs = shear stress

Forms of Shear
(1) Single Shear Cross-sectional Area
π
A= d 2
4

Rivet of diameter d

F F
Shearing Stress
F F
σ s=
F A

F
σ s=
π 2
d
This rivet resist shear across its 4
cross sectional area

Effect of Load on Rivet

Single Shear

F F

(2) Double Shear

π
A= d 2
4

P
2 P
σ s= ; σ s=
A 2A

P
σ s=
π 2
2( d )
4

Note: If double shear always multiply

Bolt w/ diameter d twice the cross sectional area
 two- sectional areas.

Effect of Load

Double Shear

(3) Direct Shear or shearing due to punching of hole

F
h
F e
σ s=
A a Shear area
r
Where: a
A = πDt (for punching a hole) t r
A = 4St (for square hole) h e
d
Where: e a
h
a t
S = length of side of square e
r h
T = plate thickness a
e
r
a a
a
Shear Strain r
r r
τ e a
γ= where: γ=Shearing strain e
G a r
a
τ =shearing stress e
G=modulus of rigidity a
E=modulus of elasticity
 Relationship between E, G, and μ (poisson’s ratio)

E=2G(1+ μ)

3. Bearing stress

Bearing stress is the stress developed when the force is applied to a projected area. It is
the contact pressure between two bodies.

Pb
σ b= Where: Pb = bearing force
A
A = area of projection of body in contact
σb = bearing stress

Rivet hole, diameter (d)

F F

Bearing deformation due to

force P
F

Original plates condition w/out

load New plates condition w/ load P

The bearing stress on the plate will be:

Pb
σ b= where:
A
d = diameter
P❑
σ b= t = thickness
dt

4. Bending/Flexural Stress – is the stress developed due to the applied bending load or the load
applied perpendicular to the neutral axis.
F

M M
Flexural stress is stress caused by bending moment.

Flexural Formula
c dy
y

My c
σ=
I

For Maximum Stress, y = c

N.A. (Neutral Axis) or centroidal axis
Mc M
σ max= ∨¿
I S

Where:

I
S=
C

Where:

σ = flexure stress c = distance from N.A. to remotest element

M = maximum moment I = moment of inertia at N.A.
y = distance of an element from N.A. S = section modulus

Common Moment of Inertia:

3
bh
(a) I = for rectangular section
12
π 4
(b) I = (D ) for solid circular section
64
π 4 4
(c) I = (D o −D i ) for hollow circular section
64

Note:
1. When the bending moment is (+), the beam is concave upward.
compression
N.A.
Meaning:
*The upper fiber (above the N.A.) is compression
*The lower fiber (below the N.A.) is tension

Tension
 2. When bending moment is (-), the beam is concave downward.

Meaning:
*upper fiber – tension
*lower fiber – compression
N.A.

Note: No stress in neutral axis

5. Torsional Stress (τ) – is the stress developed when the material is subjected to twisting load.

If a torque T is applied at the end of the bar or shaft, a bar which was originally straight will be
twisted by a torque or twisting moment T equivalent to F x d.

For a solid or hollow circular shaft subject to a twisting moment T, the torsional shearing stress
τ at a distance ρ from the center of the shaft is

Tρ Tr
τ= ∧τ max =
J J

TL
θ=
JG

Where: τ = torsional shearing stress

T = Torque, twisting moment
ᵨ = radius (any radius)
J = polar moment of inertia
Ɵ = angular deformation or twist (in radian)

For Solid Cylindrical Shaft:

 π 4
J= D
32
D 16 T
τ max= 3
πD

For Hollow Cylinder Shaft:

π 4 4
J= (D −d )
32
D
16 TD 2 TR
τ max= 4 4
; τ max= 4 4
d π ( D −d ) π (R −r )

Power (torque due to power)

From dynamics, it is known that power P is transmitted by a constant torque T rotating at

constant angular speed Ѡ.

P = TѠ

Where: Ѡ = 2πn or 2πf, radian/time

n = frequency/or no. of revolution per unit of time
T = torque, N.m
P = Power, Hp, ft-lb/min, watts

P = 2πTn

Strain Analysis:

Strain - is a unit deformation that will take place when sufficient load is applied to a machine
member. It is the ratio of the change in dimension to the original dimension.

L ΔL
∆L
∈=
L
Strain Stress Ft
δ ∨∆ L P
∈= σ=
L A
Where:

ΔL or δ = deformation (elongation); in, ft, m, cm, mm

P = applied load or total load; lb, N, kip, KN
L = longitudinal length; m, in, ft
A = cross-sectional area; m2, in2, ft2,mm2

P δ PL σL
=E δ= ∨
A L AE E