ALCORCON ENGINEERING REVIEW CENTER

Cebu Main: 4th floor Coast Pacific Downtown Center, Sanciangko St, Cebu City Tel #(032) 254-33-84
Manila: 3rd floor JPD Bldg 1955, C M Recto corner N. Reyes St, Sampaloc, Manila Tel # (02) 736-4438

MACHINE DESIGN – DAY 3

I. FLYWHEEL
Flywheel - a rotating energy reservoir which absorbs energy from
a 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:

1. Punch press
2. Shears
3. Internal combustion engines
4. Compressors
5. Reciprocating pumps
6. Steam engines

FORMULAS:

1. Kinetic energy released by the flywheel (KE)

b
C W v2
KE = W ( v12 - v 22 )= f t
2g g

where:
v1 = maximum speed = p D N1
v2 = minimum speed = p D N2
W = total weight of the flywheel
g = acceleration due to gravity = 9.81 m/sec2 t
v = average velocity
Cf = coefficient of fluctuation
d D D
2. Total weight of Flywheel(W) m

W = Wr + Wah t

where:
Wr = weight of the flywheel rim
Wah = weight of arm of the hub

3. Weight of the flywheel rim (Wr)

Wr = V x w
Wr = (p D b t)(w)

where: b = width of the flywheel rim

t = thickness of flywheel rim
w = density of flywheel material
For cast iron: w = 7200 kg/m3

This file is only for viewing and printing.

Page 1 Contents are not allowed to be edited.
4. Energy required to punch a metal (E)

E = 1/2 F tp E = 1/2(Ssu x A)tp

For circular hole: E = E = 1/2(Ssu x A)tp

where:
A = shearing area
A = p d tp (for circular hole)
F = average force needed to punch a hole
Ssu = ultimate shear stress
tp = thickness of the plate
d = hole diameter
Dm = mean diameter of flywheel

5. Power needed to punch a hole (P)

P =
Energy
Time needed to punch a hole

6. Kinetic energy released by the flywheel = Energy needed to punch a hole

1/2(Ssu x A)tp = W ( v12 - v 22 )

2g

7. Coefficient of fluctuation (Cf)

v1 - v 2
Cf =
v

v1 + v 2
where: v=
2

2( v1 - v 2 ) 2(N1 - N2 )
Cf = =
v1 + v 2 N1 + N2

II. BOLTS AND SCREWS

Bolts and Screws are threaded fasteners which are used to hold together machine members which require easy
dismantling.
Pitch (p) - is the axial distance between adjacent threads.
Lead - is the axial distance a thread advances in one revolution.
Minor diameter - is the smallest diameter of the 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 = π/16 (Dm + Di)2

This file is only for viewing and printing.

Page 2 Contents are not allowed to be edited.
TYPES OF THREADS:
1. UNC (Unified 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:

1. Acme thread
2. Sellers square thread

THREAD SPECIFICATIONS:

1. American and UNC thread:

Example: 1 – 8UNC – XY – Z

1 stands for nominal diameter in inches

8 stands for TPI(Thread/inch)
X stands for value (1 for widest tolerance, 2 for normal fit, 3 for closest fit)
Y stands for (A for external thread, B for internal thread)
Z stands for (RH – right hand thread, LH-left hand thread)

Bolt Stress Area: (English Unit) As = p (D - 0.9743p)2, in2

4
Where: D = nominal diameter, in
p = pitch, in

2. Metric Thread:
Example: M-16 x 2-6A

M stands for metric series

16 stands for nominal diameter, mm
2 stands for pitch, mm
6 stands for tolerance
A stands for (g for external thread, h for internal thread)

Bolt Stress Area: (SI Unit) As = p (D - 0.938p)2, mm2

4
Where: D = nominal diameter, mm
p = pitch, mm

This file is only for viewing and printing.

Page 3 Contents are not allowed to be edited.
COMMON THREAD FORMS:
1. Sellers Square thread 2. Trapezoidal Thread 3. Buttress Thread

f = 7o

BOLTS
1. Formulas from Vallance:
A. Sw = C(Ar)0.418
B. Fa = C(Ar)1.418
C. Depth of tap = 1.5 D (for cast iron) = 1.25 D (for steel)
D. Initial torque = 0.2 Fa D

where: Sw = permissible working stress, psi

Fa = applied load, lb
Ar = stress area, in2
C = 5,000 (for carbon steel)
C = 15,000 (for alloy steel)
D = nominal diameter

2. Formulas from Faires:

S y ( A s )1 / 2
A. Sd =
6

S y ( A s )3 / 2
B. Fe =
6
C. Depth of tap = 1.5 D (for cast iron) = D (for steel of wrought iron)
D. Initial Torque = C D Fi

where: Sd = design tensile stress Fe = tensile load As = stress area Sy = yield stress
C = 0.20 for as received = 0.15 for lubricated
D = nominal diameter Fi = initial tension

This file is only for viewing and printing.

Page 4 Contents are not allowed to be edited.
POWER SCREWS

1. Pitch (p) - is the axial distance between two adjacent threads.

1
p =
No. of threads per inch

2. Lead (L)
L = p (for single thread)
L = 2p (for double thread)
L = 3p (for triple thread)

3. Linear velocity,
v = (rotational speed)(Lead) = N L

Lead
4. Lead angle (x), tan x =
pD m

This file is only for viewing and printing.

Page 5 Contents are not allowed to be edited.
5. Torque applied to turn the screw in raising the load, T
For square thread: T = WDm éê tan x + f ùú
2 ë 1 - f tan x û
WDm é cos f tan x + f ù
For ACME thread: T = ê ú
2 ë cos f - f tan x û

where: Dm = mean diameter of screw

W = weight or load
f = coefficient of friction of threads
f = 14.5° for ACME

6. Torque required to overcome collar friction, Tc

Tc = fc W(ro + ri ) = fc W Dc
2 2

where: Dc = (Do + Di)/2 = ro + ri

Dc = mean diameter of collar
ro = outside radius of collar
ri = inside radius of collar
fc = coefficient of friction of collar

WDm é cos f tan x - f ù

7. Torque required to turn the screw in lowering the load: T = ê ú
2 ë cos f + f tan x û

Note: For any thread (but for square thread, f = 0 )

8. Total torque to operate the screw, TT TT = T + Tc

9. Output power of screw (Po) Po = Weight x linear velocity of screw = W x v

10. Power input of screw (Pi) Pi = 2 p TT N

11. Efficiency of power screw(e)

A. For square thread: = Power Output/Power input = tan x(1 - f tan x )

f D
tan x + f + ( c c )(1 - f tan x )
Dm

B. For ACME thread: e= tan x(cos f - f sin x )

fD
tan x cos f + f cos x + ( c c )(cos f - f sin x )
Dm

This file is only for viewing and printing.

Page 6 Contents are not allowed to be edited.
12. From Machineries Handbook:

A. W = working strength to screwed up tightly to packed joint

W = St (0.55d2 - 0.25d), lbs

Where: St = working stress, psi

d = bolt diameter, in2

B. For Set Screws: T = 1250 D d2.3, in-lb D N d2.3

HP = , hp / set screw
50

Where: D = shaft diameter, in

d = set screw diameter, in
N = speed, rpm

This file is only for viewing and printing.

Page 7 Contents are not allowed to be edited.
PROBLEMS:

FLY WHEEL

1. The energy required to punch a square hole from 20 mm thick plate is 10 KJ. If the ultimate strength of plate is
420 Mpa, with factor of safety of 4, determine the maximum sides of square that can be punched.
A. 45 mm B. 30 mm C. 60 mm D. 55 mm

2. A flywheel has a mean diameter of 5 ft and is required to handle 2450 ft-lb of kinetic energy. The flywheel has a
width of 8 in. Normal operating speed is 320 rpm and the coefficient of fluctuation is to be 0.05. Find the weight
of the rim. Weight of arm and hub neglected
A. 204.37 lbs B. 236.19 lbs C. 244.37 lbs D. 264.37 lbs

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% of the rim weight. The flywheel is made up of
cast iron with a specific weight of 0.26 lb per cubic inch.
A. 1.56 inches B. 1.12 inches C. 1.65 inches D. 1.234 inches

BOLTS

1. The cylinder head of a 10 x 16 in Freon compressor is attached 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” – ¾”) has the following
tresses: Su = 85 ksi, Sy = 88 ksi?
A. 0.2255 in2 B. 0.3255 in2 C. 0.4255 in2 D. 0.5255 in2

2. Determine the permissible working stress of a UNC bolt that has a stress area of 0.606 in2 if material used is
carbon steel.
A. 4055.5 psi B. 5244.5 psi C. 4675.5 psi D. 4186.5 psi

POWER SCREW

1. Compute how many ½ in diameter set screws required to transmit 30 hp at a shaft speed of 1000 rpm. The shaft
diameter is 1.0 in.
A. 3 B. 4 C. 8 D. 6

2. What weight can be lifted by a screw that has an efficiency of 80% if it is operated by a 50 lb force at the end of a
30 in lever? The pitch of the screw is ½ in.
A. 12,079 lbs B. 13,000 lbs C. 14,000 lbs D. 15,079 lbs

3. A single square thread power screw is to raised load of 70 KN. The screw has a major diameter of 36 mm and a
pitch of 6 mm. The coefficient of thread friction and the collar friction are 0.13 and 0.10 respectively. If the collar
mean diameter is 90 mm and the screw turns at 60 rpm, find the combined efficiency of screw and collar.
A. 13.438% B. 15.530% C. 14.526% D. 12.526%

4. A single 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 friction 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%

This file is only for viewing and printing.

Page 8 Contents are not allowed to be edited.