Machine design: Machine design is the creation of new and better machines which are more economical in the

overall cost of production and operation.In designing a component , it is necessary to have knowledge in mathematics , engg.mechanics , theory of machines , engg.drawing . There are three types in machine design 1.Adaptive machine design, 2.Development design, 3.New design. General considerations in design : 1.Type of load and stresses caused by the load, 2.Motion of the parts, 3.Selection of materials, 4.Form and size of the parts, 5.Frictional resistance and lubrication, 6.Use of standard parts, 7.Safety, 8.Workshop facilities, 9.No.of machines to be manufacture, 10.Cost of production,

11.Assembling Load: Load is defined as any external force acting upon a machine part. Types of load: 1.Dead or steady load, 2.Live or variable load, 3.Suddenly applied or shock load, 4.Impact load. Stress: The internal resistance which are setup at various sections of the body to resist externally applied forces per unit area is known as stress. = P/A where P = Force or load acting on a body, and A = Cross-sectional area of the body.

Strain When a system of forces or loads act on a body, it undergoes some deformation. This deformation per unit length is known as unit strain or simply a strain. It is denoted by a Greek letter epsilon (). Mathematically, Strain, = l / l or l = .l

where l = Change in length of the body, and l = Original length of the body. 1.A cast iron link, as shown in Fig. 4.4, is required to transmit a steady tensile load of 45 kN. Find the tensile stress induced in the link material at sections A-A and B-B.

Solution. Given : P = 45 kN = 45 103 N Tensile stress induced at section A-A We know that the cross-sectional area of link at section A-A, A1 = 45 20 = 900 mm2 Tensile stress induced at section A-A, t1=p/a t1=45000/900 = 50 N/mm2 = 50 MPa Ans. Tensile stress induced at section B-B We know that the cross-sectional area of link at section B-B, A2 = 20 (75 40) = 700 mm2 Tensile stress induced at section B-B, t2=45000/700
=75Mpa

2.A hydraulic press exerts a total load of 3.5 MN. This load is carried by two steel rods, supporting the upper head of the press. If the safe stress is 85 MPa and E = 210 kN/mm2, find : 1. diameter of the rods, and 2. extension in each rod in a length of 2.5 m. Solution. Given : P = 3.5 MN = 3.5 106 N ; t = 85 MPa = 85 N/mm2 ; E = 210 kN/mm2 = 210 103 N/mm2 ; l = 2.5 m = 2.5 103 mm 1. Diameter of the rods Let d = Diameter of the rods in mm. Area, A =4d^2/4 = 0.7854d^2 Since the load P is carried by two rods, therefore load carried by each rod, P1 =3.5 10^6 P = = 1.75 106 N We know that load carried by each rod (P1),

1.75 106 = t . A = 85 0.7854 d 2 = 66.76 d2 2 = 1.75 106/66.76 = 26 213 or d = 162 mm Ans. d 2. Extension in each rod Let l = Extension in each rod. We know that Young's modulus (E), E=(P*l)/(A*l) = 212.5 103/(210 103) = 1.012 mm l

3.A pull of 80 kN is transmitted from a bar X to the bar Y through a pin as shown
in Fig. 4.8. If the maximum permissible tensile stress in the bars is 100 N/mm2 and the permissible shear stress in the pin is 80 N/mm2, find the diameter of bars and of the pin.
Fig. 4.8

Solution. Given : P = 80 kN = 80 103 N; t = 100 N/mm2 ; = 80 N/mm2 Diameter of the bars Let Db = Diameter of the bars in mm. Area, Ab =D2/4 We know that permissible tensile stress in the bar Ab=D2/4 t=P/Ab 100=(80*103)/(D2/4) or Db = 32 mm Ans. Diameter of the pin Let Dp = Diameter of the pin in mm. Since the tensile load P tends to shear off the pin at two sections i.e. at AB and CD, therefore the pin is in double shear. Resisting area, Ap = ((2 )/4)Dp2 = 1.571 (Dp )2 We know that permissible shear stress in the pin (), =(Tangential load)/(Resisting area) 80=80000/1.571 (Dp )2 p)2 = 50.9 103/80 = 636.5 (D or Dp = 25.2 mm

Bearing Stress
A localised compressive stress at the surface of contact between two members of a machine part, that are relatively at rest is known as bearing stress or crushing stress. The bearing stress is taken into account in the design of riveted joints, cotter joints, knuckle joints, etc. Let us consider a riveted joint subjected to a load P In such a case, the bearing stress or crushing stress (stress at the surface of contact between the rivet and a plate), b (or c)=P/dtn where d = Diameter of the rivet, t = Thickness of the plate, d.t = Projected area of the rivet, and n = Number of rivets per pitch length in bearing or crushing.

Bearing Pressure: A localised compression which exist at the surface of contact between two members of machine part that are in relative motion . It is used in the use of journal bearing. Pb=P/ld l=length of the journal d=diameter of journal P=radial load

Two plates 16 mm thick are joined by a double riveted lap joint . The rivets are 25 mm in diameter.Find the crushing stress induced between the plates and the rivet, if the maximum tensile load on the joint is 48 kN. Solution. Given : t = 16 mm ; d = 25 mm ; P = 48 kN = 48 103 N Since the joint is double riveted, therefore, strength of two rivets in bearing (or crushing) is taken. We know that crushing stress induced between the plates and the rivets, c = P/d t n = 48000/(25*16*2) = 60 N/mm2

A journal 25 mm in diameter supported in sliding bearings has a maximum end reaction of 2500 N. Assuming an allowable bearing pressure of 5 N/mm2, find the length of the sliding bearing. Solution. Given : d = 25 mm ; P = 2500 N ; pb = 5 N/mm2 Let l = Length of the sliding bearing in mm.

We know that the projected area of the bearing, A = l d = l 25 = 25 l mm2 Bearing pressure ( pb) = 5 = P/A = 2500/2l l= 20 mm

Torsional and bending stresses: Mt/J = /r = C/l

1.A shaft is transmitting 97.5 kW at 180 r.p.m. If the allowable shear stress in the material is 60 MPa, find the suitable diameter for the shaft. The shaft is not to twist more that 1 in a length of 3 metres. Take C = 80 GPa. Solution. Given : P = 97.5 kW = 97.5 103 W ; N = 180 r.p.m. ; = 60 MPa = 60 N/mm2 ; = 1 = / 180 = 0.0174 rad ; l = 3 m = 3000 mm ; C = 80 GPa = 80 109 N/m2 = 80 103 N/mm2 Let T = Torque transmitted by the shaft in N-m, and d = Diameter of the shaft in mm. 1. Considering strength of the shaft We know that the torque transmitted (T), Mt/J=/r P=2NMt/60 97.5 103=2*180*Mt/60 Mt=5172.53 103 Nmm J=d4/32 Mt/J=/r (5172.53 103 )/0.098d4 = 60/0.5 d d3=439840.98 d=76.04mm 2. Considering stiffness of the shaft Polar moment of inertia of the shaft, Mt/J=C/l (5172.53 103 )/(d4/32) = (80*103*0.0174)/3000 4 = 52.7 106/0.464 = 113.6 106 or d d = 103 mm ...(ii) Taking larger of the two values, we shall provide d = 103 say 105 mm

2.A hollow shaft is required to transmit 600 kW at 110 r.p.m., the maximum torque being 20% greater than the mean. The shear stress is not to exceed 63 MPa and twist in a length of 3 metres not to exceed 1.4 degrees. Find the external diameter of the shaft, if the internal diameter to the external diameter is 3/8. Take modulus of rigidity as 84 GPa. Solution. Given : P = 600 kW = 600 103 W ; N = 110 r.p.m. ; Tmax = 1.2 Tmean ; = 63 MPa = 63 N/mm2 ; l = 3 m = 3000 mm ; = 1.4 / 180 = 0.024 rad ; k = di / do = 3/8 ; C = 84 GPa = 84 109 N/m2 = 84 103 N/mm2 Let Tmean = Mean torque transmitted by the shaft, do = External diameter of the shaft, and

di = Internal diameter of the shaft. We know that power transmitted by the shaft P=2 NMt/60 600 103 = 2*110*Mt/60 Mt = 52087.07 Nm mean = 600 103/11.52 = 52 103 N-m = 52 106 N-mm T and maximum torque transmitted by the shaft, Tmax = 1.2 Tmean = 1.2 52 106 = 62.4 106 N-mm Now let us find the diameter of the shaft considering strength and stiffness. 1. Considering strength of the shaft Tmax =/16 (do)3 (1 k4)

(do)3 = 62.4 106/12.12 = 5.15 106 or do = 172.7 mm ...(i) 2. Considering stiffness of the shaft We know that polar moment of inertia of a hollow circular section,

Bending stress:

An axle 1 metre long supported in bearings at its ends carries a fly wheel weighing 30 kN at the centre. If the stress (bending) is not to exceed 60 MPa, find the diameter of the axle. Solution. Given : L = 1 m = 1000 mm ; W = 30 kN = 30 103 N ; b = 60 MPa = 60 N/mm2 Let d = Diameter of the axle in mm. Section modulus, Z =I/y = / 32 * d3 = 0.098d3 Mb = WL/4 = 30000*1000/4 = 7.5 106 Nmm b = M/Z 60= 7.5 106 / 0.098d3 3 = 76.4 106/60 = 1.27 106 or d = 108.3 say 110 mm d A beam of uniform rectangular cross-section is fixed at one end and carries an electric motor weighing 400 N at a distance of 300 mm from the fixed end. The maximum bending stress in the beam is 40 MPa. Find the width and depth of the beam, if depth is twice that of width. Solution. Given: W = 400 N ; L = 300 mm ; b = 40 MPa = 40 N/mm2 ; h = 2b Let b = Width of the beam in mm, and h = Depth of the beam in mm. Section modulus, Z = I/Y = (bd3/12)/(d/2)
= 4b3/6

M = W.L = 400 300 = 120 103 N-mm b = M/Z 4b3=18000 3 = 180 103/40 = 4.5 103 or b = 16.5 mm b and h = 2b = 2 16.5 = 33 mm

Thermal stress: th = c.E = .t.E =Co.efficient of thermal expansion t= Rise in temperature E=Young's Modulus

Impact Stress
Sometimes, machine members are subjected to the load with impact. The stress produced in the member due to the falling load is known as impact stress. Consider a bar carrying a load W at a height h and falling on the collar provided at the lower end Let A = Cross-sectional area of the bar, E = Young's modulus of the material of the bar, l = Length of the bar, l = Deformation of the bar, P = Force at which the deflection l is produced, i = Stress induced in the bar due to the application of impact load, and h = Height through which the load falls.

1.An unknown weight falls through 10 mm on a collar rigidly attached to the lower end of a vertical bar 3 m long and 600 mm2 in section. If the maximum instantaneous extension is known to be 2 mm, what is the corresponding stress and the value of unknown weight? Take E = 200 kN/mm2. Solution. Given : h = 10 mm ; l = 3 m = 3000 mm ; A = 600 mm2 ; l = 2 mm ; E = 200 kN/mm2 = 200 103 N/mm2 Stress in the bar Let = Stress in the bar. We know that Young's modulus, E = Stress/Strain =l/l =133.3 N/mm2

Resilience
When a body is loaded within elastic limit, it changes its dimensions and on the removal of the load, it regains its original dimensions. So long as it remains loaded, it has stored energy in itself. On removing the load, the energy stored is given off as in the case of a spring. This energy, which is absorbed in a body when strained within elastic limit, is known as strain energy. The strain energy is always capable of doing some work. The strain energy stored in a body due to external loading, within elastic limit, is known as resilience and the maximum energy which can be stored in a body up to the elastic limit is called proof resilience. The proof resilience per unit volume of a material is known as modulus of resilience. It is an important property of a material and gives capacity of the material to bear impact or shocks. Mathematically, strain energy stored in a body due to tensile or compressive load or resilience U=2V/2E

Principal stresses:

A hollow shaft of 40 mm outer diameter and 25 mm inner diameter is subjected to a twisting moment of 120 N-m, simultaneously, it is subjected to an axial thrust of 10 kN and a bending moment of 80 N-m. Calculate the maximum compressive and shear stresses. Solution. Given: do = 40 mm ; di = 25 mm ; T = 120 N-m = 120 103 N-mm ; P = 10 kN = 10 103 N ; M = 80 N-m = 80 103 N-mm We know that cross-sectional area of the shaft,

= 32.038Mpa

Theories of Failure:
1. Maximum principal (or normal) stress theory (also known as Rankines theory). 2. Maximum shear stress theory (also known as Guests or Trescas theory). 3. Maximum principal (or normal) strain theory (also known as Saint Venant theory). 4. Maximum strain energy theory (also known as Haighs theory). 5. Maximum distortion energy theory (also known as Hencky and Von Mises theory). 1.Rankine's theory: According to this theory, the failure or yielding occurs at a point in a member when the maximum principal or normal stress in a bi-axial stress system reaches the limiting strength of the material in a simple tension test.

2.Guest theory:
According to this theory, the failure or yielding occurs at a point in a member when the maximum shear stress in a bi-axial stress system reaches a value equal to the shear stress at yield point in a simple tension test. Mathematically,

3.St.Venant's theory: According to this theory, the failure or yielding occurs at a point in a member when the maximum principal (or normal) strain in a bi-axial stress system reaches the limiting value of strain (i.e. strain at yield point) as determined from a simple tensile test. The maximum principal (or normal) strain in a bi-axial stress system is given by

4.Haigh's theory: According to this theory, the failure or yielding occurs at a point in a member when the strain energy per unit volume in a bi-axial stress system reaches the limiting strain energy (i.e. strain energy at the yield point ) per unit volume as determined from simple tension test.

5.Hancky Theory: According to this theory, the 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. Mathematically, the maximum distortion energy theory for yielding is expressed as

1.The load on a bolt consists of an axial pull of 10 kN together with a transverse shear force of 5 kN. Find the diameter of bolt required according to 1. Maximum principal stress theory; 2. Maximum shear stress theory; 3. Maximum principal strain theory; 4. Maximum strain energy theory; and 5. Maximum distortion energy theory. Take permissible tensile stress at elastic limit = 100 MPa and poissons ratio = 0.3. Given : Pt1 = 10 kN ; Ps = 5 kN ; t(el) = 100 MPa = 100 N/mm2 ; 1/m = 0.3 Let d = Diameter of the bolt in mm.