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MACHINE DESIGN BASICS AND FORMULAE – VIJAY SIR

STATIC DESIGN
𝑷
1. 𝝈 =
𝑨

2. It is uniform throughout the cross-section, hence each

AXIAL STRESS (𝝈) point on the cross-section is critical.
3. It is either tensile or compressive
4. Examples: Uniaxial tension or compression, Thermal
Stresses, Initial Tightening in the bolts etc.
5. The direction of axial stress is collinear with the
direction of the corresponding axial force.

𝝈 𝑴 𝑬
1. = =
𝒚 𝑰 𝑹
y = Distance of layer from Neutral Axis ( NA)
M = Bending Moment about NA
I = Area Moment of Inertia about NA
R = Radius of Curvature of NA
2. Variation of bending stress is Linear; It is zero at NA
and maximum at the layer farthest from NA.
Hence the farthest layer is the critical.
BENDING STRESS(𝝈)
3. The direction of axial stress is along the length of the
beam hence it is also called as Longitudinal Stress.
4. Neutral axis lies between the layers experiencing
tension and compression.
𝑀∗ 𝑦𝑚𝑎𝑥 𝑀
5. 𝜎𝑚𝑎𝑥 = =
𝐼 𝑍
Z = section Modulus
Bending stress is inversely proportional to section
modulus.
𝟑𝟐𝑴
6. For circular Shaft, 𝝈𝒎𝒂𝒙 =
𝝅𝒅𝟑

Vijay Sir
 Page 2 of 26

SPECIAL BEAM CASES:

MAXIMUM
SR. TYPE OF BEAM WITH MAXIMUM
BENDING
NO. LOADING SHEAR
MOMENT
FORCE
Simply supported beam with 𝑃 𝑃𝐿
1 𝑆𝐹𝑚𝑎𝑥 = 𝐵𝑀𝑚𝑎𝑥 =
point load P at the center 2 4
Simply supported beam with ωL ω L2
2 𝑆𝐹𝑚𝑎𝑥 = 𝐵𝑀𝑚𝑎𝑥 =
UDL ω throughout its length 2 8
Cantilever beam with point
3 𝑆𝐹𝑚𝑎𝑥 = 𝑃 𝐵𝑀𝑚𝑎𝑥 = 𝑃𝐿
load P at the free end
Cantilever beam with UDL ω ω L2
4 𝑆𝐹𝑚𝑎𝑥 = ω L 𝐵𝑀𝑚𝑎𝑥 =
throughout its length 2

𝑭.𝑨.𝒀
1. 𝝉 =
𝒃.𝑰
2. The variation of transverse shear stress is parabolic:
it is maximum at NA6 and zero at the extreme fibres
3. It is neglected in the design because,
i. Its value is very small
ii. At the extreme layers,where bending stress is
TRANSVERSE SHEAR maximum while transverse shear stress is
STRESS (τ )
zero.
iii. In many cases, at the section where bending
moment is maximum, shear force is zero.
𝜏𝑚𝑎𝑥 3
4. Rectangular Section; =
𝜏𝑎𝑣𝑔 2

𝜏𝑚𝑎𝑥 4
Circular Section; =
𝜏𝑎𝑣𝑔 3

𝝉 𝑻 𝑮𝜽
TORSIONAL SHEAR 1. = =
𝒓 𝑱 𝑳
STRESS ( τ ) J = Polar Moment of Inertia
Vijay Sir
 Page 3 of 26

2. Variation of Torsional Shear stress is Linear; It is zero

at the center and maximum at circumference.
𝟏𝟔𝑴
3. For circular Shaft, 𝝉𝒎𝒂𝒙 = 𝟑 𝝅𝒅

𝑃
1. 𝜏 =
DIRECT SHEAR STRESS 𝐴
(τ ) P = Shear Force
2. Examples: Bolts/Rivets under shear

1. It is also called as compressive stress or crushing

stress.
Examples: Crushing of Rivets, Crushing of Key,
Bearing Pressure in hydrodynamic bearing
BEARING STRESS ( σ )
2. If the load is axial,
Axial Compressice Load
σ =
Cross − Sectional Area
3. If the load is Radial,
Radial Compressice Load
σ =
Projected Area

PRINCIPAL STRESSES
1. 𝜎𝑥 𝑎𝑛𝑑 𝜎𝑦 𝑎𝑟𝑒 𝑡ℎ𝑒 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑛𝑜𝑟𝑚𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠𝑒𝑠 ,

𝑒. 𝑔. 𝐴𝑥𝑖𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠, 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑆𝑡𝑟𝑒𝑠𝑠 𝑜𝑟 𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝑆𝑡𝑟𝑒𝑠𝑠.

2. 𝜏𝑥𝑦 𝑖𝑠 𝑡ℎ𝑒 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠,

𝑒. 𝑔. 𝑡𝑜𝑟𝑠𝑖𝑜𝑛𝑎𝑙 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠, 𝑡𝑟𝑎𝑛𝑠𝑣𝑒𝑟𝑠𝑒 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑟 𝑑𝑖𝑟𝑒𝑐𝑡 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠

3. 𝜃 𝑖𝑠 𝑡ℎ𝑒 𝑎𝑛𝑔𝑙𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑖𝑛𝑐𝑙𝑖𝑛𝑒𝑑 𝑝𝑙𝑎𝑛𝑒 𝑎𝑛𝑑 𝑝𝑙𝑎𝑛𝑒 𝑜𝑛 𝑤ℎ𝑖𝑐ℎ 𝜎𝑥 𝑖𝑠 𝑎𝑐𝑡𝑖𝑛𝑔

𝝈𝒙 + 𝝈𝒚 𝝈𝒙 − 𝝈𝒚
𝝈𝜽 = + ∗ 𝒄𝒐𝒔𝟐𝜽 + 𝝉𝒙𝒚 ∗ 𝒔𝒊𝒏𝟐𝜽
𝟐 𝟐
𝜎𝑥 − 𝜎𝑦
𝜏𝜃 = − ∗ 𝑠𝑖𝑛2𝜃 + 𝜏𝑥𝑦 ∗ 𝑐𝑜𝑠2𝜃
2

Vijay Sir
 Page 4 of 26

4. Principal Stresses

𝝈𝒙 + 𝝈𝒚 𝝈𝒙 − 𝝈𝒚
𝝈𝟏/𝟐 = ± √{ }𝟐 + 𝝉𝒙𝒚 𝟐
𝟐 𝟐

𝝈𝒙 −𝝈𝒚 𝟐
𝝉𝟏/𝟐 = ±√{ } + 𝝉𝒙𝒚 𝟐
𝟐

𝝈𝒙 + 𝝈𝒚 +𝝈𝒛 = 𝝈𝟏 + 𝝈𝟐 + 𝝈𝟑

𝝈𝟏 −𝝈𝟐 𝝈𝟏 −𝝈𝟑 𝝈𝟐 −𝝈𝟑

𝝉𝟏𝟐 = | | & 𝝉𝟏𝟑 = | | & 𝝉𝟐𝟑 = | |
𝟐 𝟐 𝟐

𝜎1 −𝜎2
5. Maximum In-plane Shear Stress = 𝜏12 = | |
2

6. Absolute maximum shear stress, τmax = max{𝜏12 , 𝜏13 , 𝜏23 }

7. The Eigen values of stress matrix are the principal stresses.

8. Mohr’s Circle :
𝝈𝒙 +𝝈𝒚
i. Center ( , 𝟎)
𝟐

𝝈𝒙 −𝝈𝒚 𝟐
ii. Radius = √{ } + 𝝉𝒙𝒚 𝟐
𝟐

Radius of Mohr’s circle is the maximum inplane shear stress.

iii. Angle on the circle is the twice of the actual angle.

Procedure to draw Mohr’s Circle

1. Draw X- Y axes, normal stresses on X axis while shear on Y axis.

2. Obtain Two points coordinates as, A (σx , τxy ) and B (σy , − τxy )

3. Locate these two points on X-Y graph.

4. Join A to B, take AB as diameter and draw circle.

𝜎𝑥 +𝜎𝑦
9. The normal stress on the plane of maximum shear stress =
2

𝟏+𝝁 𝟏 𝝉𝟏𝟐
10.𝝐𝟏 − 𝝐𝟐 = (𝝈𝟏 − 𝝈𝟐 ) ∗ = 𝟐 ∗ 𝝉𝟏𝟐 ∗ = = ∅𝟏𝟐
𝑬 𝟐 ∗𝑮 𝑮

Vijay Sir
 Page 5 of 26

Special Cases:

Applied Stresses Principal Stresses in- Center of

Sr.
Name 𝝈𝒎𝒂𝒙 plane 𝝉𝒎𝒂𝒙 Mohr’s
NO. 𝝈𝒙 𝝈𝒚 𝝈𝒛 𝝉𝒙𝒚 𝝈𝟏 𝝈𝟐 𝝈𝟑
𝝉𝒎𝒂𝒙 Circle

Uniaxial 𝜎𝑥 𝜎𝑥 𝜎
01 +𝜎𝑥 0 0 0 𝜎𝑥 0 0 𝜎𝑥 ( 2𝑥 , 0)
Tension 2 2

Uniaxial 𝜎𝑥 𝜎𝑥 𝜎𝑥
02 -𝜎𝑥 0 0 0 0 −𝜎𝑥 0 −𝜎𝑥 (− , 0)
2 2 2
Compression

03 Pure Shear 0 0 0 𝜏𝑥𝑦 𝜏𝑥𝑦 -𝜏𝑥𝑦 0 𝜏𝑥𝑦 𝜏𝑥𝑦 𝜏𝑥𝑦 (0,0)

Hydrostatic
04 σ σ σ 0 σ σ σ σ 0 0 (σ,0)
Stress

Thin
05 Pd/2t Pd/4t 0 0 Pd/2t Pd/4t 0 Pd/2t Pd/8t Pd/4t (3Pd/8t,0)
Cylinder

06 Thin Sphere Pd/4t Pd/4t 0 0 Pd/4t Pd/4t 0 Pd/4t 0 Pd/8t (Pd/4t,0)

SPECIAL CASE: A SHAFT SUBJECTED TO BENDING MOMENT AND TWISTING MOMENT :

32∗𝑀 16∗𝑇
 Applied Stresses: 𝜎𝑥 = & 𝜏𝑥𝑦 =
𝜋∗ 𝑑3 𝜋∗ 𝑑3

𝜎𝑥 𝜎 16
 𝜎1 = + √(( 2𝑥 )2 + 𝜏𝑥𝑦 2 ) = ∗ {𝑀 + √𝑀2 + 𝑇 2 }
2 𝜋∗ 𝑑3

𝜎𝑥 −𝜎𝑦 2 16
 12 = ±√( 2
+ 𝜏𝑥𝑦 2 ) = 𝜋∗ 𝑑3 ∗ { √𝑀2 + 𝑇 2 }

16
 𝑎𝑏𝑠 𝜏𝑚𝑎𝑥 = 𝑖𝑛 − 𝑝𝑙𝑎𝑛𝑒 𝜏𝑚𝑎𝑥 = 𝜋∗ 𝑑3 ∗ { √𝑀2 + 𝑇 2 }

Vijay Sir
 Page 6 of 26

SPECIAL CASE: A BOLT SUBJECTED TO AXIAL FORCE P AND SHEAR FORCE F:

4∗𝑃 4∗𝐹
 𝜎𝑥 = & 𝜏𝑥𝑦 =
𝜋∗ 𝑑2 𝜋∗ 𝑑2

𝜎𝑥 𝜎
 𝜎1 = + √(( 2𝑥 )2 + 𝜏𝑥𝑦 2 )
2

𝜎𝑥 −𝜎𝑦 2
 12 = ±√( 2
+ 𝜏𝑥𝑦 2 )

𝜎𝑥 −𝜎𝑦 2
 𝑎𝑏𝑠 𝜏𝑚𝑎𝑥 = 𝑖𝑛 − 𝑝𝑙𝑎𝑛𝑒 𝜏𝑚𝑎𝑥 = √( + 𝜏𝑥𝑦 2 )
2

 Equivalent Bending Moment Me

1
𝑀𝑒 = ∗ {𝑀 + √𝑀2 + 𝑇 2 }
2
 Equivalent Twisting Moment Te
𝑇𝑒 = √𝑀2 + 𝑇 2
 Te is always greater than Me.
 The maximum bending moment a shaft can sustain is equal to Me and The maximum
twisting moment a shaft can sustain is equal to Te.

FAILURE OF THE MATERIALS UNDER STATIC LOADING

𝑴𝒂𝒙𝒊𝒎𝒖𝒎 𝑺𝒕𝒓𝒆𝒔𝒔 𝒂𝒕
MATERIAL LOADING 𝜽𝒇𝒂𝒊𝒍𝒖𝒓𝒆
𝜽𝒇𝒂𝒊𝒍𝒖𝒓𝒆 Plane

Ductile Uniaxial Tension 450 Shear Stress

Brittle Uniaxial Tension 000 Normal Stress
Ductile Torsion 000 Shear Stress
Brittle Torsion 450 Normal Stress

Vijay Sir
 Page 7 of 26

THEORIES OF STATIC FAILURE

1. PRINCIPAL STRESS THEORY OR MAXIMUM NORMAL STRESS THEORY
 Rankine’s Theory;
𝑆𝑦𝑡
𝜎1 = → 𝐷𝑢𝑐𝑡𝑖𝑙𝑒 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙
𝐹𝑂𝑆
𝑆𝑢𝑡
𝜎1 = → 𝐵𝑟𝑖𝑡𝑡𝑙𝑒 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙
𝐹𝑂𝑆
 Useful for Brittle Materials
 Safe region is a Rectangle
2. MAXIMUM SHEAR STRESS THEORY
 Tresca, Coulomb, Guest Theory
𝑆𝑠𝑦 𝑆𝑦𝑡
 𝜏𝑚𝑎𝑥 = =
𝐹𝑂𝑆 2∗𝐹𝑂𝑆
 𝑺𝒔𝒚 = 𝟎. 𝟓 ∗ 𝑺𝒚𝒕
𝜎1− 𝜎2 𝜎1− 𝜎3 𝜎3− 𝜎2
 𝜏𝑚𝑎𝑥 𝑖𝑠 𝑡ℎ𝑒 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑜𝑓{ 𝜏12 = | | , 𝜏13 = | | , 𝜏23 = | |}
2 2 2
 Useful for Ductile Materials
 Safe region is a Hexagon. 3-D region is a hexagonal pipe.
 This theory is preferred for simple calculations.
 This is the most conservative theory → 𝑅𝑒𝑠𝑢𝑙𝑡𝑠 𝑖𝑛𝑡𝑜 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑑𝑖𝑚𝑒𝑛𝑠𝑖𝑜𝑛𝑠
 Disadvantage – Hydrostatic Stress State
3. SHEAR STRAIN ENERGY THEORY OR DISTORTION ENERGY THEORY
 von-mises, Huber, Hencky
𝑆𝑦𝑡
 𝜎𝑣𝑜𝑛 =
𝐹𝑂𝑆
 𝑣𝑜𝑛 − 𝑚𝑖𝑠𝑒𝑠 𝑠𝑡𝑟𝑒𝑠𝑠𝜎𝑣𝑜𝑛 = 2 ∗ √{(𝜎1 − 𝜎2)2 + (𝜎1 − 𝜎3)2 + (𝜎3 − 𝜎2)2 }
1

 𝜎𝑣𝑜𝑛 2 =
1
2
∗ { (𝜎𝑥 − 𝜎𝑦)2 + (𝜎𝑥 − 𝜎𝑧)2 + (𝜎𝑦 − 𝜎𝑧)2 + 6 ∗ (𝜏𝑥𝑦 2 + 𝜏𝑥𝑧 2 + 𝜏𝑧𝑦 2 )}
 𝑺𝒔𝒚 = 𝟎. 𝟓𝟕𝟕 ∗ 𝑺𝒚𝒕
 The safe region is an ellipse.
√2
𝑆𝑒𝑚𝑖 𝑚𝑖𝑛𝑜𝑟 𝑎𝑥𝑖𝑠 = ∗ 𝑆𝑦𝑡
3
𝑆𝑒𝑚𝑖 𝑚𝑎𝑗𝑜𝑟 𝑎𝑥𝑖𝑠 = √2 ∗ 𝑆𝑦𝑡
 This is the best or most accurate theory for ductile materials.

Vijay Sir
 Page 8 of 26

 Calculations of this theory are complicated.

4. MAXIMUM PRINCIPAL STRAIN THEORY
 St. Venant Theory
𝜎𝑦
 𝜀𝑚𝑎𝑥 =
𝐸
 Safe Region is a parallelogram.
5. Maximum Strain Energy Theory
 Beltrami, Haigh Theory
𝑆𝑦𝑡 2
 𝜎1 2 + 𝜎2 2 + 𝜎3 2 − 2 ∗ 𝜇 ∗ (𝜎1 ∗ 𝜎2 + 𝜎1 ∗ 𝜎3 + 𝜎3 ∗ 𝜎2) = { }
𝐹𝑜𝑠
 Used in design of thick cylinders
 Safe Region is an ellipse.
SCIENTISTS
THEORY OF FAILURE SAFE ZONE APPLICATION
NAME

Maximum Principal Stress Theory Rankine Rectangle Brittle Materials

Tresca, Coulomb,
Maximum Shear Stress Theory Hexagon Ductile Materials
Guest

von Mises,
Maximum Shear Strain Energy Or
Hencky Ellipse Ductile Materials
Distortion Energy Theory
,Huber

Ductile Materials
Maximum Strain Energy Theory Beltrami, Haigh Ellipse
(Thick Cylinders)

Maximum Principal Strain Theory St. Venant Parallelogram Ductile Materials

1
Maximum Principal Stress Theory
Maximum Distortion Energy Theory
Maximum Shear Stress Theory

2 Vijay Sir
 Page 9 of 26

FATIGUE FAILURE

 Theoretical Stress Concentration Factor or Stress Concentration Factor ( Kt),

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑆𝑡𝑟𝑒𝑠𝑠 𝑎𝑡 𝑡ℎ𝑒 𝑑𝑖𝑠𝑐𝑜𝑛𝑡𝑖𝑛𝑢𝑖𝑡𝑦 𝜎𝑚𝑎𝑥

𝐾𝑡 = =
𝑁𝑜𝑚𝑖𝑛𝑎𝑙 𝑆𝑡𝑟𝑒𝑠𝑠 𝑎𝑡 𝑡ℎ𝑒 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝜎0

 Plate with a Hole – Axial Load; Maximum value of 𝐾𝑡 is 3.

 Plate with Elliptical Hole subjected to Axial Load

𝒂
𝑲𝒕 = 𝟏 + 𝟐 ∗ ; a and b are major and minor axes respectively
𝒃

 The Methods to Improve Endurance Strength or Fatigue Life

1. Shot Peening: It induces residual compressive stress on the surface.
2. Auto-Frettage – High Pressure Cylinder, Gun Barrels{Thick Cylinders}
I. A compound cylinder is made to shrunk
II. A wire under tension is wound over cylinder
It increases the pressure capacity as well endurance strength.

3. Burnishing Process

MOORE’S TEST OR ROTATING BEAM METHOD

1. Reversed Bending Stress is applied.
2. Steel, N < 103 - Low Cycle Life
N > 103 - High Cycle Life
N > 106 - Infinite Cycle Life

3. SN Curve Asymptotic after 106 cycles.

4. Amplitude Stress is on Y axis.
𝐼𝑛𝑐𝑟𝑒𝑎𝑠𝑒 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑣𝑒𝑟 𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝐾𝑓 ∗𝜎0 − 𝜎0
5. 𝑁𝑜𝑡𝑐ℎ 𝑆𝑒𝑛𝑠𝑖𝑡𝑖𝑣𝑖𝑡𝑦 𝑞 = =
𝐼𝑛𝑐𝑟𝑒𝑎𝑠𝑒 𝑜𝑓 𝑡ℎ𝑒𝑜𝑟𝑜𝑡𝑖𝑐𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑣𝑒𝑟 𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 𝐾𝑡 ∗𝜎0 −𝜎0
𝑲𝒇 = 𝟏 + 𝒒 ∗ (𝑲𝒕 − 𝟏)

1
𝑀𝑜𝑑𝑖𝑓𝑦𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑠𝑡𝑟𝑒𝑠𝑠 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛, 𝐾𝑑 =
𝐾𝑓

 𝑆 ′ 𝑒 = 𝐸𝑛𝑑𝑢𝑟𝑎𝑛𝑐𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡𝑒𝑠𝑡 𝑠𝑝𝑒𝑐𝑖𝑚𝑒𝑛

𝑆𝑒 = 𝐸𝑛𝑑𝑢𝑟𝑎𝑛𝑐𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑠𝑝𝑒𝑐𝑖𝑚𝑒𝑛

 𝑺𝒕𝒆𝒆𝒍 𝑺′ 𝒆 = 𝟎. 𝟓 ∗ 𝑺𝒖𝒕 if 𝑆𝑢𝑡 ≤1400 MPa

Vijay Sir
 Page 10 of 26

𝑆 ′ 𝑒 = 700 𝑀𝑃𝑎 if 𝑆𝑢𝑡 >1400 MPa

 𝐶𝑎𝑠𝑡 𝐼𝑟𝑜𝑛 𝑎𝑑 𝐶𝑎𝑠𝑡 𝑆𝑡𝑒𝑒𝑙 𝑆 ′ 𝑒 = 0.4 ∗ 𝑆𝑢𝑡

𝑆𝑒 = 𝐾𝑎 ∗ 𝐾𝑏 ∗ 𝐾𝑐 ∗ 𝐾𝑑 ∗ 𝐾𝑒 ∗ 𝑆 ′ 𝑒
𝜎𝑚𝑎𝑥 + 𝜎𝑚𝑖𝑛
 𝑀𝑒𝑎𝑛 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑟 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑆𝑡𝑟𝑒𝑠𝑠 𝜎𝑚 = 2

𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛
 𝑉𝑎𝑟𝑖𝑎𝑏𝑙𝑒 𝑜𝑟 𝐴𝑚𝑝𝑙𝑖𝑡𝑢𝑑𝑒 𝑠𝑡𝑟𝑒𝑠𝑠, 𝜎𝑎 = | |
2

𝜎𝑚𝑖𝑛
 𝑆𝑡𝑟𝑒𝑠𝑠𝑅𝑎𝑡𝑖𝑜 = 𝜎𝑚𝑎𝑥

𝜎𝑎 1 − ( 𝑠𝑡𝑟𝑒𝑠𝑠 𝑟𝑎𝑡𝑖𝑜)
 𝐴𝑚𝑝𝑙𝑖𝑡𝑢𝑑𝑒 𝑅𝑎𝑡𝑖𝑜 = =
𝜎𝑚 1 + ( 𝑠𝑡𝑟𝑒𝑠𝑠 𝑟𝑎𝑡𝑖𝑜)

𝜎𝑚𝑎𝑥
 Repeated Loading: Either 𝜎𝑚𝑎𝑥 𝑜𝑟 𝜎𝑚𝑖𝑛 𝑖𝑠 𝑧𝑒𝑟𝑜; ℎ𝑒𝑛𝑐𝑒 𝜎𝑚 = 𝜎𝑎 = 2
 Reversed or Alternating Loading or Cyclic Stress:

𝜎𝑚𝑖𝑛 = − 𝜎𝑚𝑎𝑥 : 𝜎𝑚 = 0: 𝜎𝑎 = |𝜎𝑚𝑎𝑥 |

a
YIELD LINE
Syt
GERBER’S PARABOLA
C
Se ASME ELLIPTICAL CURVE
B SODERBERG LINE
GOODMAN LINE

Sut m
Syt
 Area  O-A-B-C-O  Modified Goodman line.

 Soderberg line is the most conservative. It results into higher dimensions.

Vijay Sir
 Page 11 of 26

𝝈𝒎 𝝈𝒂 𝟏
 Soderberg Equation: + =
𝑺𝒚𝒕 𝑺𝒆 𝑭𝑶𝑺

𝝈𝒎 𝝈𝒂 𝟏
 Goodman Line Equation : + =
𝑺𝒖𝒕 𝑺𝒆 𝑭𝑶𝑺

𝝈𝒎 ∗𝑭𝑶𝑺 𝟐 𝝈𝒂 ∗ 𝑭𝑶𝑺
 Gerber’s Parabola: ( ) + = 𝟏
𝑺𝒖𝒕 𝑺𝒆

FATIGUE DESIGN UNDER COMBINED LOADING

 Using the distortion theory,
𝟏 𝟐 𝟐
𝝈𝟐 = ∗ { (𝝈𝒙 − 𝝈𝒚 ) + (𝝈𝒙 − 𝝈𝒛 )𝟐 + (𝝈𝒛 − 𝝈𝒚 ) + 𝟔 ∗ ( 𝝉𝒙𝒚 𝟐 + 𝝉𝒙𝒛 𝟐 + 𝝉𝒛𝒚 𝟐 )}
𝟐

 Case I: 𝜎𝑥 𝑎𝑛𝑑 𝜎𝑦 𝑜𝑛𝑙𝑦 𝑎𝑐𝑡𝑖𝑛𝑔

𝜎 = √(𝜎𝑥 2 − 𝜎𝑥 ∗ 𝜎𝑦 + 𝜎𝑦 2 )
𝜎𝑥𝑚𝑎𝑥 +𝜎𝑥𝑚𝑖𝑛 𝜎𝑥𝑚𝑎𝑥 −𝜎𝑥𝑚𝑖𝑛
𝜎𝑥𝑚 = ; 𝜎𝑥𝑎 = 2
and so on
2

𝜎𝑚 = √(𝜎𝑥𝑚 2 − 𝜎𝑥𝑚 ∗ 𝜎𝑦𝑚 + 𝜎𝑦𝑚 2 )

𝜎𝑎 = √(𝜎𝑥𝑎 2 − 𝜎𝑥𝑎 ∗ 𝜎𝑦𝑎 + 𝜎𝑦𝑎 2 )

 Case II: 𝜎𝑥 𝑎𝑛𝑑 𝜏𝑥𝑦 𝑜𝑛𝑙𝑦 𝑎𝑐𝑡𝑖𝑛𝑔

𝜎 = √(𝜎𝑥 2 + 3 ∗ 𝜏𝑥𝑦 2 )

𝜎𝑚 = √(𝜎𝑥𝑚 2 + 3 ∗ 𝜏𝑥𝑦𝑚 2 )

𝜎𝑎 = √(𝜎𝑥𝑎 2 + 3 ∗ 𝜏𝑥𝑦𝑎 2 )

CUMULATIVE DAMAGE
 Miner’s Equation- Linear Damage Rule
𝜶𝟏 𝜶𝟐 𝜶 𝟏
 + + 𝑵𝟑 + ⋯ = 𝑵
𝑵𝟏 𝑵𝟐 𝟑
N = life of the component under combined loading
α1 = fraction of period for which σ1 is applied
N1 = fatigue life for stress σ1 alone

Vijay Sir
 Page 12 of 26

ROLLING CONTACT BEARING

 It involves least friction and least wear too, hence they are called as anti-friction bearings.
RCB life is limited by fatigue failure.
STRIBECK’S EQUATION
STATIC LOAD CARRYING CAPACITY = C0

𝑘 ∗ 𝑑2 ∗ 𝑧
𝐶0 = → 𝐵𝑎𝑙𝑙 𝐵𝑒𝑎𝑟𝑖𝑛𝑔
5
𝑘∗ 𝑑∗𝐿∗𝑧
𝐶0 = → 𝑅𝑜𝑙𝑙𝑒𝑟 𝐵𝑒𝑎𝑟𝑖𝑛𝑔
5
𝑧 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓𝑏𝑎𝑙𝑙𝑠 &
𝑘 𝑑𝑒𝑝𝑒𝑛𝑑𝑠 𝑢𝑝𝑜𝑛 𝑟𝑎𝑑𝑖𝑠 𝑜𝑓 𝑐𝑢𝑟𝑣𝑎𝑡𝑢𝑟𝑒 𝑎𝑡 𝑡ℎ𝑒 𝑝𝑜𝑖𝑛𝑡 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡
𝑎𝑛𝑑 𝑚𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝑒𝑙𝑎𝑠𝑡𝑖𝑐𝑖𝑡𝑦.

EQUIVALENT DYNAMIC BEARING LOAD P

𝑃 = 𝐶𝑠 ∗ (𝑋 ∗ 𝑉 ∗ 𝐹𝑅 + 𝑌 ∗ 𝐹𝑎 )
𝑋 𝑎𝑛𝑑 𝑌 𝑎𝑟𝑒 𝑟𝑎𝑑𝑖𝑎𝑙 𝑎𝑛𝑑 𝑡ℎ𝑟𝑢𝑠𝑡 𝑓𝑎𝑐𝑡𝑜𝑟𝑠 respectively

 𝑅𝑎𝑐𝑒 𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑉 = 1 → 𝑤ℎ𝑒𝑛 𝑖𝑛𝑛𝑒𝑟 𝑟𝑎𝑐𝑒 𝑟𝑜𝑡𝑎𝑡𝑒𝑠 𝑎𝑛𝑑 𝑛𝑜𝑡 𝑜𝑢𝑡𝑒𝑟
𝑉 = 1.2 → 𝑤ℎ𝑒𝑛 𝑜𝑢𝑡𝑒𝑟 𝑟𝑎𝑐𝑒 𝑟𝑜𝑡𝑎𝑡𝑒𝑠 𝑎𝑛𝑑 𝑛𝑜𝑡 𝑖𝑛𝑛𝑒𝑟
 𝐶𝑠 = 𝐿𝑜𝑎𝑑 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑟 𝑆𝑒𝑟𝑣𝑖𝑐𝑒 𝐹𝑎𝑐𝑡𝑜𝑟

LOAD-LIFE RELATIONSHIP
𝐶 60 ∗ 𝑁 ∗ 𝐿ℎ
𝐿10 = ( )𝑛 = 𝑖𝑛 𝑚𝑖𝑙𝑙𝑖𝑜𝑛𝑠 𝑜𝑓 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠
𝑃 106
 C is the Dynamic Load Carrying Capacity Or Load Rating
 The above formula is valid only for 𝐿10 .
 𝑛 = 3 → 𝑓𝑜𝑟 𝐵𝑎𝑙𝑙 𝐵𝑒𝑎𝑟𝑖𝑛𝑔𝑠
10
 𝑛= → 𝑓𝑜𝑟 𝑅𝑜𝑙𝑙𝑒𝑟 𝐵𝑒𝑎𝑟𝑖𝑛𝑔𝑠
3

Vijay Sir
 Page 13 of 26

DESIGNATION

𝐴𝐵𝐶𝐷
 𝐴 𝐵 𝐶 𝐷 are the digits
 𝐶𝐷 ∗ 5 = 𝐵𝑜𝑟𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟
 𝐵 = 1 → 𝐸𝑥𝑡𝑟𝑎 𝐿𝑖𝑔ℎ𝑡 𝑆𝑒𝑟𝑖𝑒𝑠
= 2 → 𝐿𝑖𝑔ℎ𝑡 𝑆𝑒𝑟𝑖𝑒𝑠
= 3 → 𝑀𝑒𝑑𝑖𝑢𝑚 𝑆𝑒𝑟𝑖𝑒𝑠
= 4 → ℎ𝑒𝑎𝑣𝑦 𝑆𝑒𝑟𝑖𝑒𝑠
 𝐷 → 𝑇𝑦𝑝𝑒 𝑜𝑓 𝐵𝑒𝑎𝑟𝑖𝑛𝑔
𝐷 = 6 → 𝐷𝑒𝑒𝑝 𝐵𝑎𝑙𝑙 𝐺𝑟𝑜𝑜𝑣𝑒
𝐷 = 7 → 𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝐶𝑜𝑛𝑡𝑎𝑐𝑡

EQUIVALENT LOAD 𝑃𝑒

𝑁1 ∗ 𝑃1 𝑛 + 𝑁2 ∗ 𝑃2 𝑛 + 𝑁3 ∗ 𝑃3 𝑛 + ⋯
𝑛 𝑛 1
𝑃𝑒 = √ = √ ∗ ∫ 𝑃𝑛 ∗ 𝑑𝑁
𝑁1 + 𝑁2 + 𝑁3 + ⋯ 𝑁
𝟏
𝟏 𝟏.𝟏𝟕
𝑳 𝒍𝒐𝒈𝒆 ( )
RELIABILITY R 𝑳𝟏𝟎
= { 𝑹
𝟏 }
𝒍𝒐𝒈𝒆 ( )
𝑹𝟗𝟎

Applications:
1. Deep groove Ball bearings can take both axial and radial loads.
2. Cylindrical roller bearings can’t take axial loads.
3. Needle bearing are suitable in vibrations and jerk applications.
4. Taper roller bearing can take high radial and axial loads.
5. Spherical bearing is a self-aligning bearing.

Vijay Sir
 Page 14 of 26

SLIDING CONTACT BEARING

VISCOSITY (µ)

 1
𝑁∗𝑠𝑒𝑐 𝑘𝑔
= 1 𝑃𝑎 ∗ 𝑠𝑒𝑐 = 10 𝑃𝑜𝑖𝑠𝑒 = 103 𝑐𝑒𝑛𝑡𝑖 − 𝑝𝑜𝑖𝑠𝑒 = 1
𝑚2 𝑚−𝑠𝑒𝑐

PETROFF’S EQUATION
 It neglects the leakage. It is applicable for the light loads only. It is based on
a journal concentric with the bearing.
𝑟 µ ∗ 𝑁𝑠
𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛, 𝑓 = 2 ∗ 𝜋 2 ∗ ∗
𝑐 𝑝
𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑇𝑜𝑟𝑞𝑢𝑒 𝑇 = 𝑓 ∗ 𝑊 ∗ 𝑟
2∗𝜋∗𝑁
𝑃𝑜𝑤𝑒𝑟 𝐿𝑜𝑠𝑡 𝑖𝑛 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 = 𝑇 ∗ 𝜔 = 𝑓 ∗ 𝑊 ∗ 𝑟 ∗
60
Heat Dissipation = 𝐶𝑑 ∗ 𝐿 ∗ 𝐷 ∗ ( 𝑇𝑏𝑒𝑎𝑟𝑖𝑛𝑔 − 𝑇𝑎𝑚𝑏𝑖𝑒𝑛𝑡 )

r =journal radius; L= journal length; W=radial load;

Bearing Pressure, p =W/(2*r*L); N = speed rpm

Mckee’s Equation
𝑟 𝜋∗ 𝑁
𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛, 𝑓 = 0.002 + 0.326 ∗ ∗
𝑐 𝑝

 0.002 → 𝐿𝑒𝑎𝑘𝑎𝑔𝑒 𝐹𝑎𝑐𝑡𝑜𝑟 ;𝑁 → 𝑠𝑝𝑒𝑒𝑑 𝑖𝑛 𝑅𝑃𝑀; 𝑐 → 𝑅𝑎𝑑𝑖𝑎𝑙 𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒

Vijay Sir
 Page 15 of 26

 Bearing Characteristic Number (BCN) corresponding to minimum coefficient

of friction is called as Bearing Modulus (K).
𝑆𝑡𝑎𝑡𝑖𝑐 𝐿𝑜𝑎𝑑 → 𝐵𝐶𝑁 ≈ 𝟑𝑲 − 5𝐾
𝐷𝑦𝑛𝑎𝑚𝑖𝑐 𝐿𝑜𝑎𝑑 → 𝐵𝐶𝑁 > 15𝐾
 𝐵𝐶𝑁 > 𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝑀𝑜𝑑𝑢𝑙𝑢𝑠 → 𝑇ℎ𝑖𝑐𝑘 𝐹𝑖𝑙𝑚 → 𝑆𝑡𝑎𝑏𝑙𝑒 𝐿𝑢𝑏𝑟𝑖𝑐𝑎𝑡𝑖𝑜𝑛
 𝐵𝐶𝑁 < 𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝑀𝑜𝑑𝑢𝑙𝑢𝑠 → 𝑇ℎ𝑖𝑛 𝐹𝑖𝑙𝑚 → 𝑈𝑛𝑠𝑡𝑎𝑏𝑙𝑒 𝐿𝑢𝑏𝑟𝑖𝑐𝑎𝑡𝑖𝑜𝑛
 𝐵𝐶𝑁 = 𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝑀𝑜𝑑𝑢𝑙𝑢𝑠 → 𝐶𝑂𝐹 𝑖𝑠 𝑚𝑖𝑛𝑖𝑚𝑢𝑚
𝑅𝑎𝑑𝑖𝑎𝑙 𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑐 = 𝑅 − 𝑟
𝑅 = 𝑒 + 𝑟 + ℎ0
𝑒 → 𝑒𝑐𝑐𝑒𝑛𝑡𝑟𝑖𝑐𝑖𝑡𝑦 ∶ ℎ0 → 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝐹𝑖𝑙𝑚 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠; 𝑅 − 𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝑅𝑎𝑑𝑖𝑢𝑠

 𝐴𝑡𝑡𝑖𝑡𝑢𝑑𝑒 𝑜𝑟 𝐸𝑐𝑐𝑒𝑛𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝑅𝑎𝑡𝑖𝑜 𝜀 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑒𝑐𝑐𝑒𝑛𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝑤ℎ𝑒𝑛 𝑗𝑜𝑢𝑟𝑛𝑎𝑙 𝑖𝑠 𝑎𝑡 𝑟𝑒𝑠𝑡

𝐴𝑐𝑡𝑢𝑎𝑙 𝑒𝑐𝑐𝑒𝑛𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝑢𝑛𝑑𝑒𝑟 𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛𝑠

𝑒 ℎ0
𝜀= =1−
𝑐 𝑐
𝑟 2 𝜇 ∗ 𝑁𝑠
 𝑆𝑜𝑚𝑚𝑒𝑟𝑓𝑒𝑙𝑑 𝑁𝑢𝑚𝑏𝑒𝑟 𝑆=( ) ∗ = (𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑅𝑎𝑡𝑖𝑜)2 ∗ 𝐵𝐶𝑁
𝑐 𝑝
 Friction radius = f  Rjournal
COMPARISON OF BEARINGS

HYDRO DYNAMIC BEARING

ROLLING CONTACT BEARING

LOAD
HYDROSTATIC BEARING
CARRYING

CAPACITY SPEED

CLUTCH
POSITIVE CONTACT CLUTCHES
Spiral Jaw, Square Jaw, toothed clutches. Power is transmitted due to interlocking of jaws. No
slip → positive contact type. It can transmit large torque. It is difficult to engage at high speeds.
No heat generation. Jaws can be engaged at small speeds only. Power presses and rolling mills.
Jaw clutch is not a friction clutch. Dis-engagement can be done at high speeds.

Vijay Sir
 Page 16 of 26

FRICTION CLUTCHES
𝑒𝑙𝑒𝑚𝑒𝑛𝑡𝑎𝑙 𝑁𝑜𝑟𝑚𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑑𝐹 = 2 ∗ 𝜋 ∗ 𝑟 ∗ 𝑑𝑟 ∗ 𝑝

𝑒𝑙𝑒𝑚𝑒𝑛𝑡𝑎𝑙 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑡𝑜𝑟𝑞𝑢𝑒 𝑑𝑇 = 2 ∗ 𝜋 ∗ 𝑟 ∗ 𝑑𝑟 ∗ 𝑝 ∗ 𝜇 ∗ 𝑟

Uniform Uniform

Pressure Theory Wear Theory

𝜋 𝑑
Axial Force 𝐹= ∗ 𝑝 ∗ (𝐷2 − 𝑑 2 ) 𝐹 = 𝜋 ∗ 𝑝𝑚𝑎𝑥 ∗ ∗ (𝐷 − 𝑑)
4 2

𝜋 𝜋 ∗ 𝜇 ∗ 𝑝𝑚𝑎𝑥 ∗ 𝑑
𝑇= ∗ 𝜇 ∗ 𝑝 ∗ (𝐷3 − 𝑑 3 ) 𝑇= ∗ (𝐷2 − 𝑑 2 )
Frictional 12 8

Torque 𝜇 ∗ 𝐹 (𝐷3 − 𝑑 3 ) 𝜇∗𝐹

𝑇= ∗ 𝑇= ∗ (𝐷 + 𝑑)
3 (𝐷2 − 𝑑 2 ) 4

Friction
1 (𝐷3 − 𝑑 3 ) (𝐷 + 𝑑)
𝑅𝑓 = ∗ 𝑅𝑓 =
Radius 3 (𝐷2 − 𝑑 2 ) 4

 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑇𝑜𝑟𝑞𝑢𝑒 = 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 ∗ 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑑𝑖𝑢𝑠 = 𝜇 ∗ 𝐹 ∗ 𝑅𝑓

 Uniform Wear, It is used for old clutch

𝑑 𝐷
𝑝 ∗ 𝑟 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = 𝑝𝑚𝑎𝑥 ∗ = 𝑝𝑚𝑖𝑛 ∗ = 𝑝𝑎𝑣𝑔 ∗ 𝑅𝑎𝑣𝑔
2 2
 Uniform Pressure – New clutch
 𝑇𝑜𝑟𝑞𝑢𝑒𝑊𝑒𝑎𝑟 < 𝑇𝑜𝑟𝑞𝑢𝑒𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
 (𝑅𝑓 )𝑤𝑒𝑎𝑟 < (𝑅𝑓 )𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
 Hence designing clutch based on wear theory is safer and conservative.
 If not mentioned, uniform wear theory should be used.
 For safe design, Uniform Wear theory should be used.
 𝐸𝑛𝑔𝑖𝑛𝑒 𝑠ℎ𝑎𝑓𝑡 → 𝑐𝑙𝑢𝑡𝑐ℎ → 𝐺𝑒𝑎𝑟𝑏𝑜𝑥 → 𝑜𝑢𝑡𝑝𝑢𝑡 𝑠ℎ𝑎𝑓𝑡

Vijay Sir
 Page 17 of 26

 The torque transmitting capacity of the clutch is maximum, when (d/D) is equal to 0.577,
according to Uniform Wear theory.

MULTIPLATE CLUTCH
 𝑀1 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒𝑠 𝑜𝑛 𝑑𝑟𝑖𝑣𝑖𝑛𝑔 𝑠ℎ𝑎𝑓𝑡
𝑀2 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒𝑠 𝑜𝑛 𝑑𝑟𝑖𝑣𝑒𝑛 𝑠ℎ𝑎𝑓𝑡
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒂𝒄𝒕𝒊𝒗𝒆 𝒔𝒖𝒓𝒇𝒂𝒄𝒆𝒔, 𝒛 = 𝑴𝟏 + 𝑴𝟐 − 𝟏
 If N is the total number of plates, then the number of active surfaces are equal to N-1.
 𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑎𝑡𝑒 𝑐𝑙𝑢𝑡𝑐ℎ → 𝑚𝑜𝑟𝑒 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 → 𝑚𝑜𝑟𝑒 ℎ𝑒𝑎𝑡 → 𝑛𝑒𝑒𝑑 𝑙𝑢𝑏𝑟𝑖𝑐𝑎𝑡𝑖𝑜𝑛 →

ℎ𝑒𝑛𝑐𝑒 𝑚𝑢𝑙𝑡𝑖𝑝𝑙𝑎𝑡𝑒 𝑐𝑙𝑢𝑡𝑐ℎ 𝑖𝑠 𝑤𝑒𝑡 𝑤ℎ𝑖𝑙𝑒 𝑠𝑖𝑛𝑔𝑙𝑒 𝑝𝑙𝑎𝑡𝑒 𝑖𝑠 𝑑𝑟𝑦.

 𝑚𝑢𝑙𝑡𝑖𝑝𝑙𝑎𝑡𝑒 → 𝑐𝑜𝑚𝑝𝑎𝑐𝑡 → 𝑠𝑐𝑜𝑜𝑡𝑒𝑟 𝑎𝑛𝑑 𝑚𝑜𝑡𝑜𝑟𝑐𝑦𝑐𝑙𝑒𝑠

 𝑠𝑖𝑛𝑔𝑙𝑒 𝑝𝑙𝑎𝑡𝑒 → 𝐶𝑎𝑟𝑠 𝑎𝑛𝑑 𝑇𝑟𝑢𝑐𝑘𝑠

CONE CLUCTCH

 𝛼 − 𝑠𝑒𝑚𝑖 𝑐𝑜𝑛𝑒 𝑎𝑛𝑔𝑙𝑒 or pitch angle

( 𝐷−𝑑)
 𝐹𝑎𝑐𝑒𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑙𝑖𝑛𝑖𝑛𝑔 𝑏 = 2∗𝑠𝑖𝑛𝛼
 𝛼 < 𝜑 → 𝑠𝑒𝑙𝑓 𝐺𝑟𝑎𝑏𝑏𝑖𝑛𝑔
 Engagement Force, 𝑃𝑎𝑥𝑖𝑎𝑙 = 𝜇 ∗ 𝐹 ∗ 𝑐𝑜𝑠𝛼 + 𝐹 ∗ 𝑠𝑖𝑛

 Dis-engagement Force, 𝑃𝑎𝑥𝑖𝑎𝑙 = 𝜇 ∗ 𝐹 ∗ 𝑐𝑜𝑠𝛼 − 𝐹 ∗ 𝑠𝑖𝑛

CENTRIFUGAL CLUCTCH

 Whenever load is required to engage after driving member attains a particular speed.
 It allows motor or engine to start, warm up and accelerate without load.
 This clutch is preferred on the motors with low starting torque.
 It is also called as an automatic clutch.
 Engagement force is perpendicular to the shaft axis.
 Applications – Mopeds, Battle Tanks
𝑆𝑝𝑟𝑖𝑛𝑔 𝐹𝑜𝑟𝑐𝑒 = 𝑚 ∗ 𝑟𝑔 ∗ 𝜔1 2

𝑻𝒐𝒓𝒒𝒖𝒆 = 𝒏 ∗ 𝒎 ∗ 𝒓𝒅 ∗ 𝒓𝒈 ∗ (𝝎𝟐 𝟐 − 𝝎𝟏 𝟐 ) ∗ 𝝁

{ Be careful, with the units here; Better use all dimensions in SI units}

Vijay Sir
 Page 18 of 26

m = mass of each shoe; rd = inner radius of drum; rg = radial distance of C.G. of

shoe; ω2 = working speed and ω1 = engagement speed; n = number of shoes;

µ = coefficient of friction

 Friction Lining, 𝐿 = 𝑟𝑑 ∗ 𝜃

𝑃𝑐𝑓2 − 𝑃𝑠 𝒎 ∗ 𝒓𝒈 ∗ (𝝎𝟐 𝟐 − 𝝎𝟏 𝟐 )
𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = =
𝐵∗𝐿 𝐵∗𝐿

BRAKES

 𝐸𝑛𝑒𝑟𝑔𝑦 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑 𝑏𝑦 𝐵𝑟𝑎𝑘𝑒 = (𝐵𝑟𝑎𝑘𝑖𝑛𝑔 𝑇𝑜𝑟𝑞𝑢𝑒) ∗ (𝐴𝑛𝑔𝑙𝑒 𝑇𝑢𝑟𝑛𝑒𝑑)

 𝐻𝑒𝑎𝑡 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 = 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝐹𝑜𝑟𝑐𝑒 ∗ 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

 For Uniform Torque or Uniform Acceleration;

𝜔2 = 𝜔1 + 𝛼 ∗ 𝑡

𝜔22 = 𝜔12 + 2 ∗ 𝛼 ∗ 𝜃
1
𝜃 = 𝜔1∗ 𝑡 + 2 ∗ 𝛼 ∗ 𝑡 2

1
𝜃= ∗ (𝜔1 + 𝜔2 ) ∗ 𝑡
2

 𝑀𝑎𝑠𝑠 𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎, 𝐼 = 𝑚 ∗ 𝑘 2 {𝑘 = 𝑅𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝐺𝑦𝑟𝑎𝑡𝑖𝑜𝑛}

MASS MOMENT OF
RADIUS OF GYRATION
SR. NO. COMPONENT INERTIA ABOUT
(k)
CENTROIDAL AXIS

2 2
01 Sphere m R2 𝑅∗√
5
5

02 Hollow Cylinder
𝑚
∗ (𝑅𝑜2 + 𝑅𝑖2 ) (𝑅𝑜2 + 𝑅𝑖2 )
2
√
2

Vijay Sir
 Page 19 of 26

BLOCK BRAKE WITH SHORT SHOES

 Shoe brakes are used in locomotive Bogies.
 𝜃 = 𝐴𝑛𝑔𝑙𝑒 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑏𝑙𝑜𝑐𝑘 𝑎𝑛𝑑 𝑑𝑟𝑢𝑚
 𝑆ℎ𝑜𝑟𝑡 𝑆ℎ𝑜𝑒 → 𝜃 < 400 → 𝐼𝑛𝑡𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑖𝑠 𝑢𝑛𝑖𝑓𝑜𝑟𝑚.
 𝐵𝑟𝑎𝑘𝑖𝑛𝑔 𝑇𝑜𝑟𝑞𝑢𝑒 𝑇 = 𝜇 ∗ 𝑁 ∗ 𝑅
𝑁
 𝑃𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑝 = 𝑙∗𝑤

 If the moment of frictional force and moment of force P, are in the same directions, then the
brake is called as SELF-ENERGIZING.
 If the external force required is zero or negative, the brake is called as SELF-LOCKING brake.
Application – Hoisting, Material Handling equipment, Bucket Elevators.
 In automobiles, internally expanding brake is commonly used.
 Direction of rotation does not change braking torque capacity in internal expanding brakes.
BLOCK BRAKE WITH LONG SHOES

 𝜃 > 400
𝜃
4 ∗ 𝑠𝑖𝑛
 2
𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡, 𝜇𝑒 = 𝜇 ∗ 𝜃 + 𝑠𝑖𝑛𝜃
BAND BRAKE

 If one end of the band is attached to the fulcrum or hinge, it is called as Simple Band
brake.
 Self -Locking is not possible in Simple Band Brake.
 If no end is connected to hinge, it’s called as differential band brake.
𝑻𝟏
𝑩𝒓𝒂𝒌𝒊𝒏𝒈 𝑻𝒐𝒓𝒒𝒖𝒆 = ( 𝑻𝟏 − 𝑻𝟐) ∗ 𝒓 & 𝑻𝟐 = 𝒆𝝁∗𝜽

DESIGN OF WELDED JOINTS

 Parallel or Longitudinal Fillet Weld

1. ℎ → 𝑝𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, 𝑤𝑒𝑙𝑑 𝑠𝑖𝑧𝑒, 𝑙𝑒𝑔 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑙𝑒𝑔 𝑠𝑖𝑧𝑒, 𝑓𝑖𝑙𝑙𝑒𝑡 𝑠𝑖𝑧𝑒
2. 𝑝𝑙𝑎𝑛𝑒 𝑜𝑓 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠, 𝜃 = 450
ℎ
3. 𝑡ℎ𝑟𝑜𝑎𝑡 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, 𝑡 = = 0.707 ∗ ℎ
√2

Throat thickness is the thickness of maximum shear stress plane.

Vijay Sir
 Page 20 of 26

√𝟐 ∗𝑷
4. 𝝉𝒎𝒂𝒙 = 𝒉 ∗𝑳

5. 𝑷 = 𝟎. 𝟕𝟎𝟕 ∗ 𝒉 ∗ 𝑳 ∗ 𝝉𝒎𝒂𝒙 { L is the total weld length}

 Transverse Fillet Weld

1. Load is perpendicular to the line of the weld.
2. 𝑝𝑙𝑎𝑛𝑒 𝑜𝑓 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠, 𝜃 = 67.50
1.21 ∗𝑃
3. 𝜏𝑚𝑎𝑥 =
ℎ ∗𝐿

4. 𝑃 = 0.8284 ∗ ℎ ∗ 𝐿 ∗ 𝜏𝑚𝑎𝑥
 Circumferential Weld
𝐴𝑟𝑒𝑎 𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎 𝐼𝑥𝑥 = 𝐼𝑦𝑦 = 𝜋 ∗ 𝑡 ∗ 𝑟 3
𝑃𝑜𝑙𝑎𝑟 𝑀. 𝐼. ; 𝐼𝑧𝑧 = 𝐼𝑥𝑥 + 𝐼𝑦𝑦 = 2 ∗ 𝜋 ∗ 𝑡 ∗ 𝑟 3
 If Circumferential weld is subjected to a bending moment M, Bending Stress
𝑀∗𝑦 𝑀∗𝑟
𝜎= =
𝐼 𝜋 ∗ 𝑡 ∗ 𝑟3
 If Circumferential weld is subjected to a bending moment T, torsional shear
stress,
𝑇∗𝑟 𝑇∗𝑟
𝜏= =
𝐽 2 ∗ 𝜋 ∗ 𝑡 ∗ 𝑟3
 Unsymmetrical Parallel Welds
𝑃 = 0.707 ∗ ℎ ∗ 𝜏𝑎𝑙𝑙𝑜𝑤 ∗ ( 𝐿1 + 𝐿2 )
𝐿1 ∗ 𝑎 = 𝐿2 ∗ 𝑏
{ L1 and L2 are the lengths of weld parts; a and b are weld
distances from load line}

Vijay Sir
 Page 21 of 26

DESIGN OF THREADED JOINTS

PRELOADING OF BOLTS

 It secures the parts tightly

 If the preload is low, the joint may separate in service and subject the bolt to
an excessive alternating stress.
 It increases fatigue loading.
 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑡𝑖𝑔ℎ𝑡𝑒𝑛𝑖𝑛𝑔 𝑙𝑜𝑎𝑑, 𝐹𝑖 = 2840 ∗ 𝑑 ( 𝑑 − 𝑚𝑎𝑗𝑜𝑟 𝑜𝑟 𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟)
 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑡𝑖𝑔ℎ𝑡𝑒𝑛𝑖𝑛𝑔 𝑡𝑜𝑟𝑞𝑢𝑒 𝑇𝑖 = 𝑘 ∗ 𝐹𝑖 ∗ 𝑑 = 0.2 ∗ 𝐹𝑖 ∗ 𝑑
 Due to Initial tightening the bolt is elongated and the connecting members are compressed.
When the external load P is applied, the bolt deformation increases and the compression of the
compressed members decreases.
𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙 𝐹𝑜𝑟𝑐𝑒 𝑝𝑒𝑟 𝑏𝑜𝑙𝑡, 𝑷 = 𝑷𝒃 + 𝑷𝒄𝒎

𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑏𝑜𝑙𝑡, 𝑹𝒃 = 𝑷𝒃 + 𝑭𝒊

𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑐𝑜𝑛𝑛𝑒𝑐𝑡𝑖𝑛𝑔 𝑚𝑒𝑚𝑏𝑒𝑟𝑠 , 𝑹𝒄𝒎 = 𝑷𝒃 − 𝑭𝒊

𝑐𝑜𝑚𝑏𝑖𝑛𝑒𝑑 𝑠𝑡𝑖𝑓𝑓𝑛𝑒𝑠𝑠 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑟 𝑠𝑡𝑖𝑓𝑓𝑛𝑒𝑠𝑠 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑜𝑓 𝑗𝑜𝑖𝑛𝑡 ( 𝐶),

𝒌𝒃
𝑪=
𝒌𝒃 + 𝒌𝒄𝒎

𝑹 𝒃 = 𝑪 ∗ 𝑷 + 𝑭𝒊

𝑹𝒄𝒎 = ( 𝟏 − 𝑪) ∗ 𝑷 − 𝑭𝒊

 For leak-proof joint, 𝑅𝑐𝑚 ≤ 0 𝑖. 𝑒. ( 1 − 𝐶) ∗ 𝑃 ≤ 𝐹𝑖

𝐴∗𝐸
 As the load is axial, 𝑘 =
𝐿

Vijay Sir
 Page 22 of 26

 If clamped members consist many members, they represent members in series.

1 1 1 1
= + + …
𝑘𝑐𝑚 𝑘1 𝑘2 𝑘3

𝑃
01 Tensile stress 𝜎= 𝜋
∗ 𝑑𝑐 2
4
16 ∗ 𝑇
02 Torsional Shear Stress 𝜏=
𝜋 ∗ 𝑑𝑐 3
𝑃
𝜏=
𝜋 ∗ 𝑑𝑐 ∗ 𝐵 ∗ 𝑁

Shear Stress B – Base Width of the thread root

03
across the threads N=Number of Threads sharing the load.
Height or length of nut = 𝑁 ∗ 𝐵 ∗ 2

𝑃
Bearing or Crushing 𝜎𝑐 = 𝜋
04 ∗ (𝑑 2 − 𝑑𝑐 2 ) ∗ 𝑁
4
stress on Threads
The d and dc are major and core diameters

 SQUARE THREADS
1. Efficiency of square threads is more than trapezoidal threads.
2. No side thrust – more life of nut
3. Difficult to manufacture – single point tool is used
4. Lower thickness at root - this reduces load carrying capacity
5. More wear – wear cannot be compensated
Vijay Sir
 Page 23 of 26

6. Screw Jack
 TRAPEZOIDAL or ACME THREADS
1. Multi point tool is used manufacture – economical
2. More root thickness – more load carrying capacity
3. Axial wear can be compensated by split type nut.
4. Efficiency is less than square
5. Side thrust is present
6. Lead Screw
 Buttress Threads
1. Used in heavy axial loading in one direction only
2. Used in vices, anti- aircraft guns
 The buttress can transmit power and motion in one direction only. While
square and trapezoidal can transmit power and motion in both directions.
 The bolts are never subjected to compression.

RIVETED JOINT

 Rivet is specified by its shank diameter ( d ) . It is also called as rivet diameter.

 Single Rivet Joint means one row of rivets; Double Rivet Joint means two rows of rivets and
so on….

𝑡𝑜 𝑎𝑣𝑜𝑖𝑑 𝑡𝑒𝑎𝑟𝑖𝑛𝑔 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒 𝑎𝑡 𝑒𝑑𝑔𝑒, 𝑚 ≥ 1.5 ∗ 𝑑

Design Equations:
 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑃𝑡 = (𝑝 − 𝑑) ∗ 𝑡 ∗ 𝜎𝑡
𝜋
 𝑆ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑃𝑠 = 𝑛 ∗ ∗ 𝑑2 ∗ 𝜏
4

 𝐶𝑟𝑢𝑠ℎ𝑖𝑛𝑔 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑃𝑐 = 𝑛 ∗ 𝑑 ∗ 𝑡 ∗ 𝜎𝑐
 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒 𝑃 = 𝑝 ∗ 𝑡 ∗ 𝜎𝑡
𝑃𝑡
 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝜂𝑡 =
𝑃
𝑃𝑠
 𝑠ℎ𝑒𝑎𝑟 𝑒𝑓𝑓𝑐𝑖𝑒𝑛𝑐𝑦, 𝜂𝑠 =
𝑃

Vijay Sir
 Page 24 of 26

𝑃𝑐
 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦, 𝜂𝑐 =
𝑃

 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑜𝑓 𝑗𝑜𝑖𝑛𝑡 𝑖𝑠 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑜𝑓 𝜂𝑡 , 𝜂𝑠 𝑎𝑛𝑑 𝜂𝑐 .

 𝑅𝑖𝑣𝑒𝑡 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑖𝑠 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑜𝑓 𝑃𝑠 𝑎𝑛𝑑 𝑃𝑐.
 𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑖𝑣𝑒𝑡𝑠 𝑢𝑛𝑑𝑒𝑟 𝑠ℎ𝑒𝑎𝑟 𝑜𝑟 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 𝑝𝑒𝑟 𝑝𝑖𝑡𝑐ℎ
 Shearing and Crushing failure occur in Rivet but tearing failure occurs with plate.
 Caulking and Fullering are used to obtain leak-proof riveted joints.

 Unwin’s Formula, 𝑑 = 6.04 ∗ √𝑡 𝑤ℎ𝑒𝑛 𝑡 ≥ 8 𝑚𝑚

DESIGN OF GEARS

SR. NO. MECHANICAL DEVICE USE OR APPLICATION

1 Spur Gear Parallel shafts

2. Helical Gear Parallel shafts

3. Herringbone Gears Parallel shafts

4. Crossed Helical Gears Neither parallel Nor Intersecting shafts

Intersecting shafts
5. Bevel Gears
i.e. shafts at right angle to each other

Non parallel, Non Intersecting shafts.

6. Hypoid Bevel Gears
Little offset is also tolerated

7. Skew Bevel Gears Non parallel, Non-Intersecting shafts.

8. Worm Gears Non parallel, Non- Intersecting.

9. Spiral Gears Neither parallel, Non Intersecting

Shafts neither co-axial nor parallel but intersect at a

10. Hooke’s Joint/Universal Joint point. It is also used for shafts with angular
misalignment.

11. Oldham Coupling Parallel shafts with small offset.

Vijay Sir
 Page 25 of 26

𝜋 ∗𝑑
𝐶𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑃𝑖𝑡𝑐ℎ, 𝑃𝑐 =
𝑧
𝑧 1
𝐷𝑖𝑎𝑚𝑒𝑡𝑟𝑎𝑙 𝑃𝑖𝑡𝑐ℎ, 𝑃𝑑 = =𝑚
𝑑

𝑑
𝑚𝑜𝑑𝑢𝑙𝑒, 𝑚 =
𝑧
𝑁𝑝 𝑧𝑔 1
 𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜, 𝑇𝑟𝑎𝑛𝑠𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑖𝑜, 𝑖 = = = 𝑆𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜
𝑁𝑔 𝑧𝑝
𝑚 ∗ (𝑧𝑝 +𝑧𝑔 )
 𝐶𝑒𝑛𝑡𝑒𝑟 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 2

SPUR GEAR DESIGN

 FORCE ANALYSIS
𝑃𝑡 = 𝑃𝑁 ∗ 𝑐𝑜𝑠∅
𝑃𝑟 = 𝑃𝑁 ∗ 𝑠𝑖𝑛∅
𝑃𝑟 = 𝑃𝑡 ∗ 𝑡𝑎𝑛∅
𝑃𝑁 𝑎𝑐𝑡𝑠 𝑎𝑙𝑜𝑛𝑔 𝑡ℎ𝑒 𝑙𝑖𝑛𝑒 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 𝑐𝑜𝑚𝑚𝑜𝑛 𝑛𝑜𝑟𝑚𝑎𝑙 𝑎𝑡 𝑡ℎ𝑒 𝑃𝑖𝑡𝑐ℎ 𝑝𝑜𝑖𝑛𝑡.
𝑃𝑡 𝑎𝑐𝑡𝑠 𝑎𝑙𝑜𝑛𝑔 𝑡ℎ𝑒 𝑙𝑖𝑛𝑒 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 𝑐𝑜𝑚𝑚𝑜𝑛 𝑡𝑎𝑛𝑔𝑒𝑛𝑡 𝑎𝑡 𝑡ℎ𝑒 𝑃𝑖𝑡𝑐ℎ 𝑝𝑜𝑖𝑛𝑡.

Beam Strength of Gear

Assumptions at Lewis Beam strength equation.

1. The tangential load Pt is acts at the tip of the tooth.

2. The effect of radial load Pr is neglected and only tangential load is considered in
design.

3. Stress concentration effect is neglected.

4. It is assumed that the total load is acting on one pair of gear teeth which means
contact ratio considered as one.

5. The load acting is considered as static.

6.The tooth is considered as a cantilever beam of uniform strength.

𝑃𝑡 = 𝑏 ∗ 𝜎𝑏 ∗ 𝑚 ∗ 𝑌

𝑡2
𝑤ℎ𝑒𝑟𝑒, 𝑌 = = 𝜋 ∗ 𝑦; is called as Lewis form factor
6∗ℎ∗𝑚

b = face width; 𝜎𝑏 = 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠; 𝑚 = 𝑚𝑜𝑑𝑢𝑙𝑒

Vijay Sir
 Page 26 of 26

 The beam strength (Sb) is the maximum value of the tangential force that the tooth can
transmit without bending failure,

𝑺𝒃 = 𝒃 ∗ 𝝈𝒃 ∗ 𝒎 ∗ 𝒀

 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝐹𝑎𝑐𝑡𝑜𝑟 = 𝜎𝑏 ∗ 𝑌
When the same material is used for gear and pinion, the pinion is always weaker. In gear
design, design should be made for that gear whose strength factor is smaller.
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑇𝑜𝑟𝑞𝑢𝑒 𝑃𝑡 𝑚𝑎𝑥
 𝑇ℎ𝑒 𝑆𝑒𝑟𝑣𝑖𝑐𝑒 𝑓𝑎𝑐𝑡𝑜𝑟, 𝐶𝑠 = =
𝑅𝑎𝑡𝑒𝑑 𝑇𝑜𝑟𝑞𝑢𝑒 𝑃𝑡

 The dynamic force is induced due to, Inertia of rotating parts; Elasticity of parts;Errors in
tooth spacing; Inaccuracies of the tooth profile; Misalignment between bearings
3
 Buckingham Equation: 𝐶𝑣 = 𝑤ℎ𝑒𝑛 𝑣 < 10 𝑚/𝑠𝑒𝑐
3+𝑣

𝜋∗𝑑∗𝑁 𝑚
𝑣=
60 𝑠𝑒𝑐
𝐶𝑠 ∗ 𝑃𝑡
𝑃𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 =
𝐶𝑣

WEAR STRENGTH
𝑺𝒘 = 𝒃 ∗ 𝑸 ∗ 𝒅𝒑 ∗ 𝑲
 The ratio Factor Q
2 ∗ 𝑧𝑔
𝑄= 𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙 𝐺𝑒𝑎𝑟𝑠
𝑧𝑔 + 𝑧𝑝
2 ∗ 𝑧𝑔
𝑄= 𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝐺𝑒𝑎𝑟𝑠
𝑧𝑔 − 𝑧𝑝
 The Load-Stress factor K
𝑆𝑒 2 ∗ 𝑠𝑖𝑛∅ 1 1
𝐾= ∗( + )
1.4 𝐸𝑝 𝐸𝑔
𝐵𝐻𝑁 2
𝐾 = 0.16 ∗ ( ) for Ø = 200
100

Vijay Sir