DESIGN OF MACHINE

MEMBERS
INTRODUCTION

1
 Unit I Syllabus
UNIT I: Introduction:
Basic design process and requirements of machine design, use of
standards in design, design synthesis; Engineering materials,
stress-strain diagrams, mechanical properties of engineering
materials; Materials selection in mechanical design.
Design against static loading:
Stresses due to axial loads, bending moment, torsional moment
and eccentric axial loading, factor of safety, principal stresses,
theories of elastic failure; Design of shafts under combined
loading, design for strength and rigidity, concept of stiffness in
tension / compression, bending and torsion
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 Henry Dreyfuss
(March 2, 1904 – October 5, 1972) was an American
industrial designer. Dreyfuss and his firm received world-
wide recognition for numerous designs for a wide
spectrum of consumer and commercial products,
including their long-time association with the Western
Electric company and the Bell System for designing
telephones from the 1930s through the 1960s. His
design philosophy was based on applied common sense
and scientific principles and resulted in significant
contributions to human factor analysis and consumer
research.
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 Design
Design is creation of some thing having a
physical reality the PRODUCT
The product must be
Functional
Safe
Reliable
Competitive
Usable
Manufacturable and Marketable
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Phases of Design:
Design is a iterative process

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 Design of machine members-I
Design: is fixing dimensions
Machine: Converts energy from one form to
another
Member: part of a mechanism (link)
Mechanism: Completely constrained chain
Chain: Contains links
DMM = design of links of mechanism
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 PREFERED NUMBERS:
These are numbers used for stanrdisation of sizes, capacities within a given set
of constraints. These are based on the geometric series.

ai  a i 1

a : is starting number and

i : th term in the series
 :Series factor or common ratio

Most of standardization is made based on Renard Number series and

it is geometric series with series factor

  n 10 , then  it  is  Rn  series

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Basic Preferred series:

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 Basic preeries
R5 Series 10 (1/5) = 1.58
R10 Series 10 (1/10) = 1.26
R20 Series 10 (1/20) = 1.12
R40 Series 10 (1/40) = 1.06
R80 Series 10 (1/80) = 1.03
Example: Find the numbers of R10 series from 1 to 5.

1, 1.258, 1.584,1.995, 2.511, 3.15,

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Example: Obtain R20 series up to 10 terms.

22
 R20 series factor = 1.12
1.00
1.12
1.25
1.40
1.60
1.80
2.00
2.24
2.50
2.80
3.15
3.55
4.00
Derived Series:
Based on the range and not utilising Renard
number series

a i 1
 ap
p : last  term
i : th  term
 : series  factor

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Example: Standardize ten widths of belt from 40 mm to 152 mm.

Series factor:
40  i 1  40 (1 . 16 ) 2 1  46
a i 1 i 1  a i 10 40  i 1
 40 (1 . 16 ) 3 1
 54
40 101  152 40  i 1  40 (1 . 16 ) 4 1  62
  1.16 40  i 1
 40 (1 . 16 ) 5 1
 72
40  i 1  40 (1 . 16 ) 6 1  84
40  i 1
 40 (1 . 16 ) 7 1
 98
40  i 1  40 (1 . 16 ) 8 1  113
40  i 1
 40 (1 . 16 ) 9 1
 131

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Problem

26
A geometric series in which the terms are doubled in every three terms if
common ratio is
 2 3

A geometric series in which the terms are tripled in every 5 terms if common
ratio is
 3 5

Etc…

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 Derived series based on Basic Series:
It is a series comprising of every q th term of Rn series. Its series factor is
given by

  10  
n
q

It is represented as: R n/q

Find out the numbers of R 20/4 from 100 to 1000

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STANDARDIZATION AGENCIES:

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 Standards
DIN: Deutsches Institut für Normung
AISI: American Iron and Steel Institute
SAE: Society of Automotive Engineers
ASM: American Society for Metals
Organizations established for Standards and safety/design
Aluminium Association (AA)
American Gear Manufacturers association (AGMA)
American Institute of Steel Construction (AISC)
American Iron and Steel Institute (AISI)
American National Standards Institute (ANSI)
ASM International
American Society of Mechanical Engineers (ASME)
American welding Society (AWS)
American Bearing Manufacturers Association (ABMA)
British Standards Institute (BSI)
Industrial Fasteners Institute (IFI)
Institution of Mechanical Engineers (I Mech E)
International Bureau of Weights and Measures (BIPM)
International Standards Organization (ISO)s and
National Institute for Standards and Technology
Society of Automotive Engineers (SAE)
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Another Classification:
1.Ductile Materials
2.Brittle Material

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CAST IRON DESIGNATION

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CARBON STEEL DESIGNATION

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 Stress strain diagrams
a)Low carbon steel, b)Aluminium alloy
Stress Strain diagram for brittle materials
 Problem
The following results were obtained in a tensile test on a
mild steel specimen of original diameter 20mm and
gauge length 40mm.
Load at limit of proportionality = 80kN
Extension at at 80kN Load = 0.048mm
Load at yield point = 85kN
Maximum load = 150kN
When the two parts are fitted together after being broken
the length between the gauge points was 55.6mm and
the neck size was 15.8mm
Calculate Young’s Modulus, yield stress, Ultimate tensile
stress, percentage elongation, percentage area
reduction.
 Solution
Stress = load/area =
80000/(3.14*20*20/4)=254.777N/mm2
Strain = dL/L=0.048/40=0.0012
E = Stress/Strain=254.777/0.0012=213kN/mm2
Yield stress =85000/(3.14*20*20/4)=270.N/mm2
Ultimate tensile stress =
150000/(3.14*20*20/4)=478N/mm2
Percentage elongation=(55.6-40)/40=39%
Percentage reduction in area=
(202-15.82)/202=38%
 Material selection: weighted point method
It is required to select the material by the weighted point
method. There are 4 candidate materials, viz.,low alloy
steel, plain carbon steel, stainless steel, and chromium
steel, which have passed through screening test. For a
particular application the designer has given a 5 point
weightage for Ut , 3 point for Hardenability, 2 point for
cost-economy
Plain
Low alloy carbon stainless Chromium
Sr No Material property Steel steel steel steel

1 Ultimate strength 850 850 1200 950

2 Hardenability 60 80 30 100

3 Cost (Rs/unit) 40 50 100 80

Select the most suitable material
 Solution
Low Plain
Material alloy carbon stainless Chromium
Sr No property Steel steel steel steel Total

1 Ultimate strength 850 850 1200 950 3850

2 Hardenability 60 80 30 100 270

3 Cost (Rs/unit) 40 50 100 80

Units per Rs 0.0250 0.0200 0.0100 0.0125 0.0675

Ultimate tensile 850/385 850/3850 1200/3850 950/3850=

a) strength per cent 0=0.22 = 0.22 = 0.312 0.247 Answer
points(5) 1.1 1.1 1.56 1.235
Hardenability per
b) cent 0.222 0.296 0.111 0.37
points(3) 0.666 0.888 0.333 1.11

c) Cost per cent 0.37 0.296 0.148 0.185

points(2) 0.74 0.592 0.296 0.37
Select Cr
Total points 2.506 2.58 2.189 2.715 steel
 Uncertainty
concerning stress and strength are many. They include:
1) Composition of materials and the effect of variation of properties
2) Variation in properties from place to place in a bar of stock
3) Effect processing locally, or nearby, on properties
4) Effect of nearby assemblies such as weldments, shrink fits on stress condition
5) Effect of thermo-mechanical treatment on properties
6) Intensity and distribution of loading
7) Validity of mechanical models used to represent reality
8) Intensity of stress concentration
9) Influence of time on strength and geometry
10) Effect corrosion
11) Effect of wear
12) Uncertainty to the length of list of uncertainties
There are mathematical methods to address uncertainties (Stochastic methods)
fs=strength /stress

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 STRESSES DUE TO AXIAL LOADS:
(Direct Stresses)

Compressive load:

Strength based design

Rigidity based design

See page 7.1 in Design

Hand book

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Tensile loads:
Strength based design:

Rigidity based design:

See page 7.1 in Design

Hand book
57
 Problem
A short hallow , C.I.
cylinder with wall
thickness of 1cm is to Stress =load/area
carry a compressive load 80=100000/(πdt)
of 100kN. Design the
cylinder if the working d= 100000/(80*3.14*10)
stresses i.e., compressive mm
stress is 8kN/cm2. d= 39.8 say (40mm)
Load = 100000N
Stress = 8000N/cm2
=80N/mm2
Area = πdt
t=10mm
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 A cast iron link shown in figure is required to
transmit a steady tensile load of 45kN. Find the
tensile stresses induced in the link at sections A-A
and B-B ( All dimensions in mm)
Stress at A-A=45000/(45*20)=50N/mm2
Stress at B-B = 45000/(75*20-40*20)
=45000/(35*20)=64.3N/mm2
Concept of Projected area and cross section area:

Cross
section area

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 Bending
equation:
Mb b E
 
I y R

See page 6.4 for bending

moment and deflection 61
equations in Design Hand book
 Problem
A simply supported beam W
of cross section 15cm wide
W/2 L W/2
and 25cm deep is centrally l
loaded. If the allowable M/I = σ/y = E/R
working stress in tension is M = WL/4
7N/mm2 what is the safe I = bh3/12 Z=bh2/6
working load.
σ = 7N/mm2 =M/Z=σ
Given: in units in Std Units
Assume L=1m =1000mm
b= 15cm 150mm W =4σZ/L=4*7*150*2502/6000
h= 25cm 250mm =43750N=43.75kN
y= h/2=125mm
σ= 7N/mm2 7N/mm2
W= ?
 Problem
A shaft is supported in
bearings, the distance W
between their centres being WL/2 L WL/2
1m. It carries a pulley in the
centre, its weight being 1kN.
Find the diameter of the
shaft if the permissible
bending stress for the shaft Z = M/σ M = WL/4=250000
material is 40MPa. Πd3/32 = M/σ=250000/40
Given in Units In Std Units d3 = 32*250000/(40*3.14)
W 1KN 1000N d= 39.93 say 40mm
σ 40MPa 40N/mm2
L 1m 1000mm
d ?
 Problem
In steel rule of 25cm
length, 0.06cm thick,
and 2.5 cm width is bent
by a couple applied at
ends so that it subtends
a central angle 60°. The Given in Units Std Units
steel member has L 25cm 250mm
strength of 25kN/cm2 t 0.06cm 0.6mm
and E = 2*107 N/cm2 . b 2.5cm 25mm
Examine the failure. θ 60° π/3 rad
σ 25kN/cm2 250N/mm2
E 2*107N/cm2 2*105N/mm2
 Problem
M/I=σ/y=E/R
L = Rθ L
R= L/θ = 250*3/π R
=238.7mm θ
y=t/2 =0.3mm Given in Units Std Units
I =bt3/12=25*0.63/12 L 25cm 250mm
=0.45mm4 t 0.06cm 0.6mm
M=250*0.45/0.3 b 2.5cm 25mm
= 375Nmm θ 60° π/3 rad
σ= Ey/R=2*105*0.3/238.7 σ 25kN/cm2 250N/mm2
=251.4N/mm2 E 2*107N/cm2 2*105N/mm2
Material fails
 M t  G
 
J r L
Mt=60*106kW/(2πn) Nmm
n in rpmN in rpm

See page 7.1 in Design

66
Hand book
 Problem
A shaft is transmitting 100kW
Mt/J = τ/r =Gθ/L
at 180 rpm. If the allowable
Mt=60*106kW/(2πn)
stress in the material is
60MPa, find the suitable =60*106*100/(2*3.14*180)
diameter of the shaft. The =5307856 Nmm
shaft is not to twist more than Design based on strength:
1° in a length of 3m. Take C J/r=Zp=πd3/16 = Mt/τ
= 80 Gpa. =5307856/60=88464.2
Given: in Units: Std Units d= [8846.2*16/3.14](1/3)
Power 100kW 100kW =76.68mm
Design based on rigidity (twist)
n 180rpm 180rpm
J = MtL/(Gθ)=πd4/32
τmax 60MPa 60N/mm2
= 5307856*3000/(80000*π/180)
θ 1° π/180 =11404751
L 3m 3000mm d=[11404751*32/3.14](1/4)=103.8 ~105
C(G) 80GPa 80000N/mm2 Select d=105mm
 Problem
Design a hollow cylinder to
transmit 11.2 MW at a
Mt /J = τ/r =Gθ/L
speed of 300rpm. The Mt=60*106kW/(2πn)
maximum shear stress =60*106*11200/(2*3.14*300)
allowed in the shaft is =356687898.1 Nmm
80MPa and the ratio of inner
J/r=(π/32)(do4-di4)/(d0/2)
to outer diameter is ¾
=(π/16)do3(1-0.754)
Given: in units: Std units
=0.134do3 =
Power:11.2MW 11200kW
Mt/τ=356687898.1/80
n 300rpm 300rpm
do= [356687898.1/(80*0.134)]1/3
τ 80MPa 80N/mm2
= 320mm
di/do ¾ ¾
di= 0.75*320=240mm
 Problem
Compare the weights of Given solid-sh hollow-sh
hollow shaft and solid Dia ds di/do=2/3
shaft to transmit a given
torque for the same Mt Mt = Mt
maximum shear stress. Stress τs = τh
The material for both Weight Ws Wh
the shafts is same. To find Wh/Ws
Inside diameter is 2/3 of
outside diameter for τ = Mt rs /Js = Mt ro/Jh
hollow shaft. ds= do (65/81)1/3
Wh/Ws = (do2-di2)/ds2
=(do/ds)2{1-(di/do)2}
=(81/65)2/3*{1-4/9}=0.64
Stresses due to Eccentric loading:

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See page 7.1 in Design
Hand book
71
 Problem

An offset link subjected

to a force 0f 25kN is
shown in Figure. It is
made of grey Cast Iron
FG300, and factor of
safety 3. Determine the
dimensions of the cross
section of the link.
Given in Units Std units
P 25kN
25000N
e 10+t 10+t
M Pe
25000(10+t)
A 2t2
fs 3
σmax 300N/mm2
σallow 300/fs=100N/mm2
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t3-500t-3750=0
Say t=10
1000-5000-3750= -8750
Say t=20
8000-10000-3750= -5750
Say t=30
27000-15000-3750= +8250
Say t=25
15625-15000-3750= -3125
Say t=27
19783-15000-3750= +1033 say t=26 or select t=27
 Problem
The frame of a hydraulic
press consisting of two
identical plates as
shown in figure. The
maximum force P acting
on the frame is 20kN.
The plates are made of
steel 45C8 with tensile
yield strength 380
N/mm2 The factor of
safety is 2.5 Determine
plate thickness.
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 Problem
A hollow circular column carries a
projecting bracket, which supports a
load of 25kN as in Figure. The
distance between the axis of the
column and the load is 500mm. The
inner diameter of the column is 0.8
times of the outer diameter. The
column is made of steel FeE200 (Syt
=200N/mm2) and the factor of safety
is 4. Determine the dimensions of the
cross section of the column.
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 Problem
A wall bracket with rectangular
cross section is shown in Figure.
The depth of the cross section is
twice the width. The force P
(5kN) acting on the bracket is at
60° to the vertical. The material of
the bracket is FG200. Factor
safety is 3.5 Determine the
dimensions of the cross section.
Assume maximum principal
theory of facilure.
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Principal Stresses :
For combined Loading

85
Principal stresses:

Shear stresses:

86
A machine member 50mm diameter by 250mm long and supported at
one end as a cantilever. Demonstrate how numerical tensile,
compressive, shear stresses and combined stresses are
determined for various types of loading.

87
Theories of Failures :

88
 σ1 = σ y / fs
or
σ2 = σy/fs
or
σ3 = σy/fs which ever is maximum
See Page Number 7.3 of design Hand Book
89
1   2   y / fs
σ2-σ3 =σy/fs
σ3-σ1 =σy/fs 90
Maximum Strain Theory:

 1   y   1  2   y / fs 

91
Maximum Strain Energy Theory:

σ12+ σ22-2μσ1σ2=(σy/n)2
σ12+ σ22 + σ32-2μ(σ1σ2 + σ2σ3 + σ3σ1) =(σy/n)2

92
Maximum distortion Energy theory:
(Shear Strain Energy Theory:

σ + σ  σ1σ 2 = σ y / fs 
2 2 2
1 2
σ12+ σ22 + σ32-(σ1σ2 + σ2σ3 + σ3σ1) =(σy/fs)2

93
Derive expression for maximum distortion energy theory:

1 2 1 2 1 2 1 2 1 2 1 2
 12   23   31   xy   xy   xy
2G 2G 2G 2G 2G 2G
 122   232   312   xy2   xy2   xy2

 1   2    2   3    3  1    x   y    y   z    z   x 
2 2 2 2 2 2

              
 2   2   2   2   2   2 
For bi-axial state For uni axial state
 1   2    2    1    x   0     x 
2 2 2 2 2 2

            
 2    
2 2      
2 2 2 
2 2 2 2 2 2
 1   2    2    1    x   0     x 
                
           
2 12  2 12  2 1 2  2 x2
 12   12   1 2   y2
With factor of safety
 
2

 12   22   1 2   y 
 fs  94
Develop an expressions for maximum principal stress and
maximum shear stress for a shaft subjected to a a twisting
moment T and bending moment M.

95
A circular shaft made up of a steel of yield strength 700 Mpa
is subjected to bending moment 10 kN-m and twisting
moment 30kN.m Find diameter of shaft using maximum
shear stress theory, maximum strain theory and strain
energy theory.

96
 Problem
The shaft of an overhang
crank subjected to a force P
of 1kN is shown in Fig. The
shaft is made of plain Carbon
steel 45C8 with yield strength
380N/mm2 . The factor of
safety is 2. Determine the
diameter of the shaft using
maximum shear stress
theory.
 Solution
Given:
P = 1kN=1000N
Syt=380N/mm2
Ssy=0.5*380=190N/mm2
τmax= Ssy/fs=190/2
=95 N/mm2 ------(1)
Calculation of torsional
and shear stresses:
Solution
101
 Problem
The dimensions of an
overhang crank are
given in Figure. The
force P acting at the
crank pin is 1kN. The
crank is made of steel
30C8 (Syt=400N/mm2)
and Factor of safety is
2. Using maximum
shear stress theory .find
d
 Solution
Given
P=1kN = 1000N
Syt=400N/mm2
fs=2
Ssy=0.5 Syt=200N/mm2
τmax= Ssy/fs = 100N/mm2
Mb=1000(50+25+100)
=175x103 Nmm
Mt=1000(500) =
500x103 Nmm
 Solution
σx= σb= Mb/Z=175x103/(πd3/32)
=1782.5x103/d3
σy= 0
τxy = Mt/Zp =500x103/(πd3/16)

100=2697950/d3
D=29.99 say 30mm
105
Obtain the relation between shear strength
and yield strength for ductile materials using
theories of failures. Take poission ratio:1/4

106
 Theories of failure
Syt= (σ12- σ1σ2+σ22)1/2
σ1= -σ2= τxy
Syt =(3τxy)1/2

0.577 Syt =τxy

Concept of stiffness:

P AE
Axial stiffness ka  
 L
P 3 EI
k
Bending stiffness b   3
 L
T GJ
Torsion stiffness k  

t
L
108
Parallel stiffness: In which members so connected that the
overall member deflection is sum of individual deflection and
individual member carries same load of overall member.

1 1 1
 
ke k1 k2

109
Series stiffness: In which members so connected that the load
acting on overall member is shared by individual members
deflection and individual member deforms equal to deformation
of overall member.

ke  k1  k 2

110
A stepped shaft has lengths L1 and L2 and diameters d1 and
d2. It is made up of steel of shear modulus G. Stepped ends
are fixed and a torque TO is at L1. Find the angle of TWIST
and stresses developed.

111
k e  k1  k 2
J1G J 2G
ke  
L1 L2
T0 T0  L1 L2 
   
k e G  L2 J1  L1 J 2 

112
A stepped shaft has lengths L1 and L2 and diameters d1 and
d2. It is made up of steel of shear modulus G. One of the
ends of Stepped shaft is fixed and a torque TO is at L1. Find
the angle of TWIST and stresses developed.

1 1 1
 
ke k1 k2
113
1 L L
 1  2
k e GJ 1 GJ 2

GJ 1 J 2
ke 
L1 J 2  L2 J 1

T0 T0  L1 J 2  L2 J 1 
   
ke G  J1 J 2 

114
Consideration of shear
stress due to direct loading:

115
Consideration of Shear stress due
to bending:

116
SHAFT DESIGN WHEN BELT DRIVE IS MOUNTED ON SHAFT:

Total pull

117
Electric motor
L
Vertical Belt
Drive(T1+T2)

L1
Horizontal
Belt
Drive(T1+T2)

16
d 3 max  M 2
T 2

M  T1  T2 L1
118
 ASME code for shaft design
According to ASME code
permissible shear stress for
shafts without keyways is 30% of
yield strength in tension or 18%
of ultimate strength which ever is
minimum.
τmax= 0.30 Syt or 0.18Sut
if keyways are present the above
are reduced by 25%
To account for shock and fatigue
factors kb and kt are used
τmax= [16/(πd3)][(kbMb)2+(ktMt)2]1/2
 Equivalent moments
Equivalent torsional Moment
= [(kbMb)2+(ktMt)2]1/2
It is defined as torsional moment,
which when acting alone will
produce the same torsional shear
stress in the shaft under the action
of Mb and Mt
Equivalent bending Moment
kbMb+ [(kbMb)2+(ktMt)2]1/2
121
 Problem
A line shaft supporting two
pulleys A and B is shown in
Figure. Power is supplied to the
shaft by means of a vertical belt
on the pulley A, which is then
transmitted to the pulley B
carrying a horizontal belt. The
ratio of belt tension on tight and
loose sides is 3:1. The limiting
value of tension in the belts is
2.7kN. The shaft is 40C8
(Sut=650N/mm2 Syt=380N/mm2)
The pulleys are keyed to the
shaft. kb=1.5, kt=1.0. find shaft
dia d.
 Solution
3600 Given
Sut=650 N/mm2 Syt=380 n/mm2
1800 1800 kb=1.5, kt=1.0
810000
P1/P2=3=P3/P4
Max belt tension = 2.7kN
Permissible shear stresses
0.3Syt=0.30*380=114N/mm2
556 2000 0.18Sut=0.18*650=117N/mm2
(P1-P2)*250/2=(P3-P4)*450/2
2556
P1=2700N and P2=900N
250000
P3=1500N, P4=500N
500000 Mt=(2700-900)*(250/2)=225000Nm
 Solution
3600 τmax=114N/mm2
M t=
1800 1800
810000 (2700-900)*(250/2)=225000Nmm
Mb= [8100002+2500002]1/2
τmax= [16/(πd3)][(kbMb)2+(ktMt)2]1/2

d=42.53mm
556 2000 Say d = 45mm
2556

250000
500000
SHAFT DESIGN WHEN A SPUR GEAR DRIVE MOUNTED ON IT:

Gear of 400mm PCD is to transmit 10kW power at 1000

r.p.m.It is mounted centrally on shaft as shown figure. If the
yield strength of shaft material is 480N/mm2, find diameter of
shaft
125
 3
16
d  max  M 2
T2 
Mt=T= 60*106(kW)/(2πn)
2T
Pt 
D
Pr  Ft Tan 
R Pt
2
 Pr
2

M   R L / 4

126
Take tooth load F= 580N and drum weight
400N.L1=0.25m,L=1.5m . Design shaft by taking
shear strength 350Mpa and factor of safety 1.5.

DRUM

L1 Gear
127
 3
16
d  max  M 2
T 2


2T Ft=F cos(20)=548.24~=550N
Ft 
D Fr=F sin(20)=198.39~=200N
F r  F t Tan  Vertical Ra+Rb=600
Ra=166, Rb=434
M v   F r  L 1  or  W
L
Horizontal, RA+550=RB
2
M h   F t L 1
RA=92, RB=642
M1v=166*0.75=125
M  M 2
v M 2
h  M1h=92*0.75=69
M1=[1252+692]`1/2=142.8Nm
M2v=200*0.25=50
M2h=550*0.25=137.5
M2=[137.52+502]=146.3~=150Nm 128

T = F *D/2= 550*D/2 assume D=100mm

129
Permissible stresses
0.3*Syt=
0.18Sut=
Because of Key =0.75*
=N/mm2
132
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