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Failure Theories: Stress in Machine Components Should Be Accurately Computed
Failure Theories: Stress in Machine Components Should Be Accurately Computed
Expected Stress
N
Stress at Component Failure
sut
• N for parts in tension
suc
• N for parts in compression
1 1 2
• for parts with general stress
N sut suc
Example
The Gray Cast Iron (Grade 40) cylinder carries
an axial compressive load of 75,000 lbs and a
torque of 20,000 in lbs. Compute the resulting
design factor.
Ø4.00”
R0.25”
Ø5.00”
R0.25”
Static Stresses - Ductile Materials
Percent elongation > 5%
Distortion Energy Theory
Define von Mises Stress
' 12 22 1 2
sy
• For nominal stress N
'
s ys sy
• For nominal stress N
max 2 max
sus
• For localized stress N
max
Example
Specify a diameter for the middle portion of
the rod, if it is to be made from AISI 1040-hot
rolled steel.
450
5000 lbs
Example
For the seat support shown, specify a standard
structural tube to resist static loads shown.
The tube has properties similar to AISI 1020
hot-rolled steel. Use a design factor of 3.
400 lb
alt
Stress
mean
Time
Example
The notched bar is machined from AISI 1020
steel. This bar is subjected to a load that varies
from 2000 lb to 3000 lb. Determine the mean
and alternating nominal stresses.
1.25”
0.1” R
1” .75”
Fatigue Strength
R.R. Moore Test
Motor
Alternating Stress, a
Endurance Strength, sn
– CR = Reliability Factor
• 50% CR = 1.0
• 90% CR = 0.90
• 99% CR = 0.81
• 99.9% CR = 0.75
Example
The notched bar is machined from AISI 1020
steel. This bar is subjected to a load that varies
from 2000 lb to 3000 lb. Determine the
endurance limit of the material.
1.25”
0.1” R
1” .75”
Repeated Stresses - Ductile Materials
Distortion Energy Theory
Define repeated von Mises Stress
'm 12m 22m 1m 2m
• Solderberg criterion
1 'm K t 'a
N sy s 'n
Repeated Stresses - Ductile Materials
Maximum Shear Stress Theory
1 ( m ) max Kt ( a ) max
N ssy s'sn
• ssy = 0.5 sy
• s’sn = 0.5 sn
Example
The notched bar is machined from AISI 1020
steel. This bar is subjected to a load that varies
from 2000 lb to 3000 lb. Comment on the
robustness of the design.
1.25”
0.1” R
1” .75”
Example
Comment on the robustness of a 1-1/4” round
bar made from AISI 1213 C-D steel. It carries
a constant tensile load of 1500 lbs, a bending
load that varies from 0 to 800 lbs at the senter
of the 48” length and a constant torque of
1200 in lbs.
48”
Shafts
Connect power transmission components.
Wr
T
Shaft Forces
Chains
Ftight
2T
Ftight
D
D
Fslack = 0
Shaft Forces
V-belts
Ftight
2.5T
Ftight
D
D
T T
Fslack
2D
Fslack
Shaft Forces
Flat belts
Ftight
3T
Ftight
D
D
T T
Fslack
D
Fslack
Material Properties
For steady load (torsion)
sys=.5sy
– Profile Kt = 2.0
– Woodruff Kt = 1.5
Stress Concentrations
Shoulders
– Sharp, Bearing (r/d .03) Kt = 2.5
– Round, Gear Bore (r/d .17) Kt = 1.5
Grooves
– Retaining Rings Kt = 1.5
Torsion stress Tr T
J 2S
J I
For round sections 2
r c
Strength Analysis
Mohr’s circle and Solderberg
K t M / sn ' T / s y
2 3 2
1 4
N S
Suggested Design Factors:
• N=2 smooth operation
32 N 2
D K t M / sn ' T / s y
2 3
4
Example
Determine a suitable diameter for a shaft
made from AISI 1144 OQT 1000. It is
subjected to a reversing bending moment of
3000 ft lbs and a steady torque of 1800 ft lbs.
The shaft has a profile keyway.
Example
The shaft shown is part of a grain drying system
At A, a 34 lb. propeller-type fan requires 12 hp
when rotating at 475 rpm.
A flat belt pulley at D delivers 3.5 hp to a screw
conveyor handling the grain.
All power comes to the shaft through the v-belt at
C.
A B D E
C
12” 10” 10” 4”
150
Sheave C Sheave D
Shafts Accessories
Components used to securely mount power
transmitting elements on a shaft.
Axial
Rotational
Keys
Allow torque to be transferred from a shaft
to a power transmitting element (gear,
sprocket, sheave, etc.)
Key Design
Use a soft, low strength material
H (ie, low carbon steel)
L W
T S
D H D2 W 2
S
2
D H D2 W 2
T .005 in.
2
Key Design
T 2T
F
D/2 D
F 2T
Key Shear
A DLW
sy s y LW
Failure Theory N
2 4TD
4TN
Length L
DWs y
Example
Specify a key for a gear (grade 40, gray cast
iron) to be mounted on a shaft (AISI 1144, hot
rolled) with a 2.00 in. diameter. The gear
transmits 21000 lb-in of torque and has a hub
length of 4 in.
Retaining Rings
Also known as snap rings
Provides a removable shoulder to lock
components on shafts or in bores.
Made of spring steel, with a high shear
strength.
Stamped, bent-wire, and spiral-wound.
Retaining Ring Selection
Based on shaft diameter & thrust force
Set Screws
Setscrews are fasteners that hold collars,
pulleys, or gears on shafts.
They are categorized by drive type and
point style.
Standard Set Screw Sizes
Set Screw Holding
Pins
A pin is placed in double shear
Holds torsion and axial loads
8T N D
d
D sy
d
Fd m l fd m sec
TR ( )
2 d m fl sec
Wedging action, it
increases friction
Stresses in the power Screw
16T
Shear stress in the base
of the screw
d 3
F
Bearing stress B
d m nt p / 2
Bending stress at the root
6F
of the screw b
Shear stress in the thread
d r nt p
3V 3F
nt number of engaged
thread 2 A d r nt p
Loading to the fasteners and their
Failure considerations
Bolts are used to clamp two or more parts
d
l
t
l
ld
h
t2 lt=L’- ld
Used to:
Exert force
Store energy
Spring Rate
Effective springs have a linear deflection
curve.
Slope of the spring deflection curve is the
rate
F
Force k
L
k
1
Deflection
Example
A compression spring with a
rate of 20 lb/in is loaded with
6 lbs and has a length of 1.5
in. Determine the unloaded
spring length (free length)
Geometry
Di
Dw
Dw
Do
L
G = Shear modulus
Spring rate for helical springs
GDw
k
8C 3 N a
Example
A helical compression spring is formed from
35 gage music wire with 10-1/4 turns and an
O.D. if 0.850 in. It’s ends are squared. The
free length is 2 inches. Determine the force to
press the spring solid.
Stress Analysis
Spring wire is in torsion
V
T r 8K F C
J Dw 2
T
Wahl factor, K
Accounts for the
curvature of the wire
4C 1 .615
K F
4C 4 C
Example
A helical compression spring is formed from
35 gage music wire with 10-1/4 turns and an
O.D. if 0.850 in. It’s made from A228 and
the ends are squared. The free length is 2
inches.
If the spring is repeatedly compressed to 1.3
in, do you expect problems?
Design Procedure
Select a material
Compute required spring rate
Estimate Dm based on size constraints
Determine required Dw (use K=1.2)
Select standard wire
Verify actual stress is satisfactory.
Compute number of coils required.
Example
Design a helical compression spring to exert a
force of 22 lbs when compressed to a length
of 1.75 in. When its length is 3.0 in, it must
exert 5 lb. The spring will be cycled rapidly.
Use ASTM A401 steel wire.
Rolling Element Bearings
Provides support for machine elements,
while allowing smooth motion.
m=0.001 - 0.005
Types
Single-row Radial Roller
Radial Ball
Angular Angular
Contact Ball Roller
Types
Spherical Tapered Roller
Roller
Needle
Thrust
Ball Bearings
Stress Analysis
Contact Stress
c=300,000 is not unusual
Balls, rollers and races are made from
extremely high strength steel
ex. AISI 52100
sy = 260,000 psi
su=322,000 psi
Bearing Load/Life
Test (fatigue) data
Radial Load (lbs) Empirical relationship:
k
L2 P1
L1 P2
•k=3.0 (ball)
•k=3.33 (roller)