ALCORCON ENGINEERING REVIEW CENTER Cebu Main: 4 floor Coast Pacific Downtown Center, Sanciangko St, Cebu City Tel #(032) 254-33-84 Manila: 3 floor JPD Bldg 1955, C M Recto comer N. Reyes St, Sampaloc, Manila Tel # (02) 736-4438 MACHINE DESIGN - DAY 3 | FLYWHEEL Flywheel - 2 rotating energy reservoir which absorbs energy from 2 power source during a portion of the operating cycle and delivers that stored energy as useful work during the other portion of the cycle. Flywheel Applications: 7 Punch press: Shears Internal combustion engines Compressors Reciprocating pumps Steam engines FORMULAS: 1, Kinetic energy released by the flywheel (KE) = Mey ey aye GoW? KE = Zev a Tg wher: vs = maximum speed = =D Ni vz = minimum speed = xDINz W = total weight ofthe flywheel 4g = acceleration due to gravity = 9.81 misec* v= average velocity cf = coefficient of fluctuation 2. Total weight of Flywheel(W) Ws We + Wan where: W, = weight ofthe flywheel rim Won = weight of arm of the hub 3. Weight ofthe flywheel rim (WW) W. = Vw W, = (xD btw) where: b = width of the flywheel rim thickness of fywheel rim Ww = density of flywheel material For cast iron: w = 7200 kgim?4. Energy required to punch a metal (E) E=12Fh B= 12(SuxAle For circular hole: E = E = 112(Sa.X Ally where: A = shearing area A= xd (lorcicular hole) r F = average force needed to punch a hole Sa = ulate shear stress {p= thickness ofthe plate 4 = hole diameter Dp, = mean diameter of fywhee! +E 5, Power needed to punch a hole (P) Energy Time needed to punch a hole 6. Kinetic energy released by the flywheel = Energy needed to punch a hole Wy 2_y,2 12(Sux Alte = Wiy,2—v, 251") 7. Coefficient of fluctuation (C1) eee where: y= M1=¥2, 2 2vs=V2) _21N,-Ne) vitveNNe Ml. BOLTS AND SCREWS Bolts and Screws are threaded fasteners which are used to hold together machine members which require easy dismanting, Pitch (p) - isthe axial distance betwoen adjacent threads, Lead isthe axial distance a thread advances in one revolution Minor diameter - is the smallest diameter ofthe threads. Pitch diameter -is the mean of major and minor diameters. Major diameter -is the outside diameter of the threads and is the nominal diameter Stress area -is the area of an imaginary circle whose diameter is the mean of the pitch and minor diameter Stress area = 1/16 (Dr. +OTYPES OF THREAD! 4, UNG (Ur Imaginary circle Where: inor diameter ajor diameter . j= mean diameter T Dea z= 4 0 imaginary diameter L | puDmtd 1d National Course) - for general use, except where other types are recommended. 2, UNF (Unified National fine) - frequently used in automotive and aircraft work and where a fine adjustment is required 3. UNEF (Unified National Extra Fine) - used in aeronautical equipment and where very fine adjustment is required. Common forms of threads: 41, Acme thread 2. Sellers square thread THREAD SPECIFICATIONS: 1 2. Bolt Stress Area: (English Unit) Ae = ‘American and UNC thread Example: 1—8UNC-XY-Z 4 stands for nominal diameter in inches 8 stands for TPI(Thread/nch) X stands for value (1 for widest tolerance, 2 for normal fi, 3 for closest fi) Y stands for (A for extemal thread, B for internal thread) Z stands for (RH — right hand thread, LH-eft hand thread) F(0-o97409F. wf jominal diameter, in pitch in Where: Metric Thread: Example: M-16 x2-6A Mstands for metric series 416 stands for nominal diameter, mm 2 stands for pitch, mm 6 stands for tolerance ‘A stands for (q for external thread, h for intemal thread) Bolt Suess Are: (SI Uni) As = 2(0-0.938pF, mm? Where: D = nominal diameter, mm pitety, mmCOMMON THREAD FORMS: 1. Sellers Square thread 2. Trapezoidal Thread 3. Buttress Thread pall y—tP 9 = 145° for ACME threads #918 or Trapezoidl Metric threads “he (0569) Wi jnor diameter major diameter D=d+2h a= mean diameter Du=dth Dy =D-h hh= height of thread BOLTS 4. Formulas from Vallance: A. Sy = CAs B. Fy = Clay's ©. Depth of tap D. Initial torque 4.5 D (for castiron) = 1.25 D (for steel) 02F,0 where: Sy = permissible working stress, psi F plied load, Ib ‘Ac= stress area, in? = 5,000 (for carbon sto) = 15,000 (fer alloy ste!) 0 = nominal dameter 2, Formulas from Faires: Sy(Agy? a sy = SA? = 6 2 3, r= SA 6 ©. Depth of tap = 1.5 (for cast ron) D. Intial Torque = CO Fi D (for steel of wrought iron) where: Ss c D design tensile stress Fe = tensile load A; = stress area S, = yield stress 0.20 for as received = 0.15 for lubricated nominal diameter F; = intial tensionPOWER SCREWS Wetood collar X= lead angle vl [p= pitch major diameter d= minor diameter mean diameter a d+D i 2 ne 1. Pitch (p) -is the axial distance between two adjacent threads. 1 ° © No of threa is per inch 2. Lead (L) L = p (for single thread) L = 2p (for double thread) L = 3p (for triple thread) 3. Linear velocity, v = (‘otational speed)(Lead) = NL Lead 4, Lead angle (x), tan x = For one revolution of the screw:5, Torque applied to turn the screw in raising the load, T For square threas: © T= WDm| tanx it 2 [t= ftanx For ACME thread = WOm {cos étanx-+f 2 [cos-ftanx where: Dn = mean diameter of screw W = weight or load 1 = coefficient of fiction of threads @ = 14.5" for ACME 6. Torque required to overcome collar frit qT, = Man) _ fe WD 2 2 where: (02+ DY2= ta +H ‘mean diameter of collar outside radius of collar inside radius of collar { = coefficient of friction of collar 7. Torque required to turn the screw in lowering the load: T On| weet) 2 | cos} +ftanx Note: For any thread (but for square thread, ¢=0) 8, Total torque to operate the screw, Ty Ty = T + Te 9. Output power of screw (P.) Py = Weight x linear velocity of screw = Wxv 40. Power input of screw (P)) 2nT:N 411, Efficiency of power screw(e) A Forsqure Woes: = Power OupuPowarinputs —_‘avat=fians) fans f+ (Xt ftanx) B. For ACME thread: e tan x(cos ¢—f sin x) tanxeos 9 fe0sx+ (Ecos pf 8inx)For one revolution of the screw: e= efficiency ofthe screw work output 1X = lead angle “work input e- Ww ®) F@nk) Where: — = pitch 7 force applied at end of the lever arm Dm in order to turn the screw beg Re length of lever arm 12. From Machineries Handbook: ‘A. W= working strength to screwed up tightly to packed joint W = S, (055d? - 0.254), bs Where: S; = working stress, psi bolt diameter, iné B. For Set Screws: T = 1250 4, nb Where:PROBLEMS: FLY WHEEL, 41. The energy required to punch a square hole from 20 mm thick plate is 10 KJ. Ifthe ultimate strength of plate is 420 Mpa, with factor of safety of 4, determine the maximum sides of square that can be punched. A. 45mm B. 30mm. ©. 60mm D. 55mm 2. A flywheel has a mean diameter of § ft and is required to handle 2450 fb of kinetic energy. The flywheel has a ‘width of Bin. Normal operating speed is 320 rpm and the coefficient of fluctuation isto be 0.08. Find the weight ofthe rim, Weight of arm and hub neglected ‘A. 204.37 Ios B. 236.18 lbs ©. 244.37 Ibs D. 284.37 Ibs 3. A flywheel has a mean diameter of 4 ft and is required to handle 2250 ft-lb of kinetic energy. It has a width of 8 inches, a normal operating speed of 300 rpm and the coefficient of fluctuation is to be 0.05. Find the thickness of the rim, assuming that the arms and hub are equivalent to 10% ofthe rim weight. The flywheel is made up of cast iron with a specitic weight of 0.26 Ib per cubic inch, 1.56 inches B. 1.12inches ©. 1.65inches D. 1.234 inches BOLTS 1. The cylinder head of a 10 x 16 in Freon compressor is altached by 10 stud bolts made of SAE grade 5. The cylinder pressure is 200 psi, What size of stud bolt should be used if SAE grade 5 (1/4" - 9’) has the following tresses: S,=85 ksi, Sy= 88 ksi? ‘A. 0.2255 in? B. 0.3256 in? ©. 0.4265 int D. 0.5255 in? 2. Determine the permissible working stress of a UNC bolt that has a stress area of 0.606 in? if material used is carbon steel ‘A. 4055.5 psi B. 5244.5 psi ©. 4675.5 psi D. 4186.5 psi POWER SCREW 1. Compute how many % in diameter set screws required to transmit 30 hp at a shaft speed of 1000 rpm. The shaft diameter is 1.0 in. AB Ba cs D6 2. What weight can be lifted by a screw that has an efficiency of 80% if itis operated by a 50 Ib force at the end of a 30 in lever? The pitch ofthe screw is % in ‘A. 12,079 Ios B. 13,000 Ibs ©. 14,000 Ios D. 15,079 Ibs 3, Asingle square thread power screw is to raised load of 70 KN, The screw has a major diameter of 96 mm and a pitch of 6 mm. The coefficient of thread friction and the collar friction are 0.13 and 0.10 respectively. Ifthe collar mean diameter is 90 mm and the screw tums al 60 rpm, find the combined efficiency of screw and collar. ‘A 13.438% BL 15.530% ©. 14.526% D. 12:526% 4. Asingle thread ACME thread has a pitch of 8 mm and a mean diameter of 36 mm. It has a collar mean radius of 45 mm. The coefficient of fiction of screw is 0.15 and for collar is 0.20. Find the efficiency of the screw. ‘A. 20.34% B. 26.45% C. 16.23% D. 9.82%