INTEGRATION

COURSE 2
 FLYWHEEL

 BRAKES AND CLUTCHES

 BEARINGS

 FLEXIBLE POWER
TRANSMISSION SUCH
AS BELTS, WIRE, ROPES,
AND CHAINS

 ANALYSIS AND
SYNTHESIS OF
MACHINERIES
Week 3
Stresses,
Shaft,
Machine
Shop
 Problem 1:
Compute the allowable load in kn on a
20mmx120cm long steel rod with a maximum
elongation must not exceed 1mm
 Problem 2:
How many 5/16inch holes can be punch in one
motion in a steel plate made of SAE1010
STEEL, 7/16 inch thick using a fprce of 55
toms. the ultimate strength for shear is 50 ksi
and use 2 factor of safety.
 Problem 3:
The shaft whose torque varies from 2,000 to
6,000 inlbs has 1½ inches in diamer and
60,,000 psi yield strength. Compute for
the shaft ,mean average stress .
 Problem 4:
A steel tie rod on bridge must be made
withstand a pull of 5,000 lbs. Find the diameter
of the rod assuming a factor of safety of 5 and
ultimate stress of 64,000 psi.
 Problem 5:
What is the modulus of elasticity if the stress is
44,000 psi and unit a strain of 0.00105?.
 Problem 6:
Compute the working strength of 1” bolt which
is screwed up tightly in packed joint when the
allowable working stress is 13,000 psi.
 Problem 7:
Compute the cutting speed in fpm of a
workpiece with 2 inches diameter and turning
at 100 rpm?
MACHINE SHOP (Formulas)
MILLING
V= πDN
 Cutting Speed, V:

Where: V= Cutting Speed

D= Diameter of workpiece
N= Speed

Time of Milling Time

 HACKSAW

Time

N O T E : F o r a h a c k s a w, t h e r e i s o n l y o n e c u t
stroke per revolution

Time
 WELDING
Time

 Vo l u m e c o n s u m p t i o n o f g a s , V

 Where:

V = total gas consumption of oxygen and acetylene

Vo = volume of oxygen consumed
Va = volume of acetylene needed
L = length of seam
CUTTING

Time of Cutting
 Problem 8:
Compute the manual cutting time in minutes of
a steel plate 4ft by 8ft by 2.5cm thick with a
hand cutting speed of 3.8 to 4 mm/sec. cutting
lengthwise.
 Problem 9:
How long will it take to mill a 3⁄4” by 2” long
keyway in a 3” diameter shafting with a
24tooth cutter turning at 100 rpm and 0.005
feed/tooth?
 Problem 10:
Using oxyacetylene welding method to weld a
3ft long seam in a 3/8inch thick plate at a
consumption rate of a 9ft ³/ft of weld for
oxygen and 7ft ³/ft for acetylene. What is the
total combined gas consumption in ft ³?
SHAFTING
SHAFT- Is a rotating member that is used to SHAFT POWER– A power formula in English unit
transmit power .

P=
SHAFT POWER– A power formula in SI unit

P= 2πTN
Where: P= power, Hp

where: P= power, kw T= torque, ft-lb

N= speed, rpm
T= torque, KN-m

N= speed, rps
TORQUE

T= F × r

A. For solid shaft

Where: Where:
F= applied force Do= outside diameter
Ss= =
Di= inside diameter
r= radius= P/2
J= polar moment of inertia
c= is the distance of the farthest fiber
Stresses in shaft B. For hallow shaft from neutral axis
when subjected to pure T= torque
torsion Ss= d= diameter of shaft
(Torsional shear stress)
Torsional deflection (Ø), rad

Ø=

A. For solid shaft

Where:
L= length of shaft J=
J=polar moment of
inertia
B. For hallow shaft
G= modulus of rigidity
in shear = J=
11.5 × 10 ^6 psi (steel)
  Stress in shaft when subjected
to torsion and bending loads:

A. For solid shaft B. For hallow shaft

Ss= + T ²) Ss= + T ²)

St = + T ²) Ss= + T ²)

Where:
T= torque
M= moment
Ss= maximum shear stress
St= maximum tensile or compressive stress
Power of shaft
A. For main shaft P=

Where:
P= Power, Hp
B. For line shaft
P= N= speed, rpm
D= diameter, inch

P=
C. For short shaft
 Problem 11:
Compute for the twisting moment in
in-lb developed when the shaft delivers 20 hp
at 1200 rpm.
 Problem 12:
What power would a spindle 55mm in
diameter transmit at 480 rpm stress allowed for
the short shaft is 59 N/m ² ?
 Problem 13:
The shaft is subjected to a steady load of
36,000 lbs at a shear of 10,,000 psi. Compute
the diameter of the said shaft in inches.
 Problem 14:
Compute the linear shaft diameter to transmit
12 Hp at 180 rpm with torsional deflection of
0.08 degree per foot length.
 Problem 15:
A 3 in solid shaft is desired to replace a hallow
shaft having 4 in outside diameter. Consider
the strength to be the same, determine the
inside diameter of hallow shaft. .
 Week 5
Keys and
Couplings
 Key

Key: a machine member employed at the interface of a pair of mating

male and female circular cross-sectional members to prevent relative
angular motion between these mating members.
Keyway: a groove in the shaft and mating member to which the key fits.
 Types of Key
 Square
 Flat
 Round
 Barth
 Woodruff
 Gib-head
 Saddle
 Kennedy
 Feather
 Power of key  Shearing stress of key (Ss)
Where:
P= 2πTN, kw
A. Ss= L= length of key
W= width of key
H= height of key
B. P=
Relation of key and shaft for the same
 Force Transmitted, material
F W= L=1.2D
F=
 Compressive stress
of key (Sc)  Force tangent to pulley rim
T= T³ Where:
F= Force tangent to the key
Sc= F.r=F’R F’= force tangent to the pulley rim-outer part
R= radius of pulley
 Problem 1:
A flat key is to be designed to be designed for
75mm diameter shaft which will transmit 150
kw at 400 rpm. If allowable shearing stress is
200 mpa and key width is 15mm, determine
the length of key.
 Problem 2:
A square key is to be used in a 40mm diameter
shaft and that will developed a 2KN-m torque.
If bearing stress of the key is 400 Mpa,
determine the cross-sectional dimension of
square key to be used if the key length is
30mm.
 Coupling
*Is a mechanical device
which is used to connect Purposes
length of shafts  To provide for misalignment of the
permanently. shaft
 To reduce the transmission of shock
Types of couplings loads from one shaft to another
*Rigid  To introduce protection against
overloads
*Flange
*Sleeve or collar
*Flexible
 Power transmitted  Shearing stress of bolts (Ss)
P= 2πTN, kN
A. Ss=
B. P=
Compressive stress on bolts and flange (Sc)
 Total Force Transmitted, F

F= Sc= Where:
t= thickness of flange
d= bolt diameter
 Total force transmitted
per bolt (Fb)

Where: Fb=
n= no. of bolts
Dc= bolts circle diameter
 Problem 3:
A flanged bolt coupling has ten(10) steel
25.4mm diameter bolts evenly tighten around a
415 bolt circle. Determine the torque capacity
of the connection if the allowable shearing
stress in the bolt is 50 MN/m².
 Problem 4:
A flange coupling with bolt circle diameter of
250mm uses 8 bolts, 25mm diameter, the
torque transmitted is
15KN-m and compressive stress of bolt is 15
Mpa. Determine the required flange thickness.
 Week 8
PRESSURE VESSEL,
BOLTS & POWER
SCREW, FLYWHEEL
 Pressure Vessel

Cylindrical or spherical vessels are commonly used in industry to serve as

boilers or tanks. When under pressure, the material of which of which
they are made is subjected to a loading from all directions.
Ex: Boilers, storage tanks, heat exchangers, oil & gas chemicals,
petrochemicals.
Storing liquefied gas in a safe, used in storing and disposing of unstable
substances and chemicals like LPG, ammonia, and propane, balloon.
 Thin wall Pressure Vessel

If the ratio of wall thickness t the inside diameter (t/Di) is less than 0.07
then the cylinder is considered as a thin wall.
FOR CYLINDRICAL PRESSURE VESSEL
 If efficiency of joint is not considered
St= tangential stress or hoop stress; SL= longitudinal stress

St= = SL= =
 If efficiency of joint is not considered

St= = SL= =

Where: e= joint efficiency

Di= inside diameter
S= tangential stress
t= thickness of the wall

Di= Do – 2 t

Where: t= wall thickness Do= outside diameter

 For a cylindrical vessel filled with fluid:
P= maximum pressure at the bottom

P= (pf )(h) = [(S.G.)(Pw )](h)

FOR SPHERICAL PRESSURE VESSEL

 If efficiency of joint is not considered:
St= =
 If efficiency of joint is considered
St= =
 Thick wall Pressure Vessel

 If the ratio of (t/Di) is greater than 0.07, then the vessel is considered as a thick
wall.
 Using Lame’s equation for internal pressure
Where:
t= [√
t=wall thickness
D=inside diameter
St= tangential stress
Pi=internal pressure
 When the vessel is subjected to an internal and external pressures:
FOR MAXIMUM INTERNAL STRESS

Sti=

FOR MAXIMUM EXTERNAL STRESS

Sto=

Where:
Sti= maximum internal tangential stress ro= outside radius
Sto= maximum external tangential stress ri= inside radius
Pi=internal pressure
Po= external pressure
 Problem 1:
A cylindrical tank with 10 inches diameter
contains oxygen gas at 2500 psi. Calculate the
required wall thickness in millimeters under
stress of 28,000 psi.
 Problem 2:
A cylinder having an internal diameter of 16
inches and external diameter of 26 inches is
subjected to 1500 psi external pressure and
internal pressure of 9000 psi. Determine the
hoop stress on outer surface of cylinder.
 BOLTS & POWER SCREW

Power Screw- move machine parts against resisting forces, for instance,
on a screw-operated tensile testing machine, jack, press or lead screw of a
lathe. (conventional power screw: 30-70%) (Ball screw 90%)
Forms of threads for power screw
 Seller square
 Acme thread
 Buttress thread
Pitch- Is the axial distance a thread advances in one revolution.

P=

 Lead (L)
L= P (for single thread)
L=2P (for double thread)
L=3P (for triple thread)
 Efficiency of Power Screw
Where:
w= weight that screw is lifting
e= = = V= speed/velocity it was turning
øf= friction angle
 Linear Velocity  Torque required to overcome collar
V= N x L friction
Tc= =
 Lead Angle
X= tan ^-1()
Torque (Tf) applied to turn the screw
• Raising the load
Do=Di+
Tf=
Do=Di+ • Lowering the load

Tf=
 Remember:
b=1 Square cos (0˚)
b=0.968 Acme cos (14.5˚)
b=0.966 Trapezoidal cos(15˚)
Metric cos (30˚)
b=0.866 American
Std. course
 General  Thread Torque
Pi= 2πTₜ ₒ ₜ ₐ ₗ N
Tₜ =
Tₜ ₒ ₜ ₐ ₗ = Tc + Tf
Tc=overcome collar friction
Tₜ =
Tf=thread friction
Where:
 Uniform pressure(NEW) T ₜ = tread torque
Pm= Screw mean diameter
rmc= W= weight (load)
Ø= thread angle
 Uniform pressure(OLD) ⅄= lead angle
rmc=
 Working strength

Ws=Sₜ(0.55d ²-0.25d)

 Force

Fₜ = )

Feach=C A ₛ ¹⁴¹⁸

 For Thread angle Ø

• S= square
• A= acme
• T= trapezoidal
• A= American
 Stress induced in Bolts

VALLANCE FAIRES
S= C(Aₛ) S=(A) ½
F=C(Aₛ)
Tensile stress
in volt Where: F=(A) ^3/2
C=500(carbon steel)
=10,000(bronze steel)
=15,000(alby steel)

Depth of tap
 Problem 1:
What is the frictional hp acting on a collar
loaded with 100 kg weight? The collar has an
outside diameter of 100mm and an internal
diameter of 40mm. The collar rotates at 1000
rpm and the coefficient of friction between the
collar and the pivot surface is 0.15.
 Problem 2:
A single square thread power screw is to raise
a load of 70 Kn, the screw has a major
diameter of 36mm and a pitch of 6mm. The
coefficient of thread friction are 0.13 and 0.10
respectively. If the collar mean diameter is
90mm and the screw turns at 60 rpm, find the
power input to the screw.
 Problem 1:
A plate 200mm wide and 25mm thick with
strength of 410mPa is to be shear along its
width. During shearing process an 800mm
mean diameter flywheel changes its speed
from 200 rpm to 180 rpm. Determine the
weight of flywheel to be use.
 Problem 2:
A 1m mean diameter flywheel, 500kg weight
changes its speed from 220 rpm to 200 rpm
during shearing process. What average force is
needed to shear a 30mm thick plate.
 Problem 3:
The energy required to punch a hole is 3kJ
from a flywheel mean diameter of 800mm that
slows down from 3.3 rps to 3ps during
punching. If weight of arm and the hub
account 10% of rim weight,, determine the rim
weight in kg.
 Problem 1:
Compute the maximum deflection of a 20 coils
helical spring having a load of 75kgs. The
spring is a square / ground ends with modulus
of elasticity in shear if 79.84 Pa outside
diameter of 101.6 mm wire diameter of 9.525
mm
Problem :
 Thank you

Brita Tamm

502-555-0152

brita@firstupconsultants.com

www.firstupconsultants.com