NOTES

SUBJECT: MACHINE DESIGN-1

SUBJECT CODE: EME-501
BRANCH: MECHANICAL ENGINEERING
SEM: 5th
SESSION: 2014-15
Evaluation scheme:
Subject Name of Periods Evaluation Scheme Subject Credit
Code Subject L T P CT TA TOTAL ESC Total
EME- MACHINE 2 1 0 15 10 25 50 75 3
501 DESIGN-1

ASSO. PROF. DEVENDRA SINGH

ME DEPARTMENT

AKGEC, GZB.
 INDEX

Unit Page No.

I 3-35

II 36-68

III 69-99

IV 100-128

UNIT- I
Introduction to Engineering Design:
Engineering design may be defined as the iterative decision making activity to create a
plan or plans by which the available resources are converted, preferably optimally, into
systems, processes or devices to perform the desired functions and to meet human needs.
In fact engineering design has been defined in many ways but the simplest ways to define
engineering design as
An iterative decision making process to conceive and implement optimum systems to
solve societys problems and needs.
Engineering design is practical in nature and must be concerned with physical realizability,
or economic and financial feasibility.

Mechanical Engineering Design:

If the end product of the engineering design can be termed as mechanical then this may be
termed as Mechanical Engineering Design. Mechanical Engineering Design may be
defined as:
Mechanical Engineering Design is defined as iterative decision making process to
describe a machine or mechanical system to perform specific function with maximum
economy and efficiency by using scientific principles, technical information, and
imagination of the designer.
A designer uses principles of basic engineering sciences, such as Physics, Mathematics,
Statics, Dynamics, Thermal Sciences, Heat Transfer, Vibration etc.
For example:
Newtons Laws of Motion;
D Alemberts Principle;
Boyles and Charles Laws of Gases;
Carnot Cycle;
Bernoullis Principle;

The designer has technical information of basic elements of machines, like fastening
devices, chain, belt and gear drives, bearings, oil seals etc. The designer knows or having
the information about the relative advantages and disadvantages of these basic elements
and their suitability in different applications.

MACHINE DESIGN:
Machine Design or mechanical design is primarily concerned with the systems by which
the energy is converted into useful mechanical forms and of mechanisms required to
convert the output of the machine to the desired form. The design may lead to an entirely
new machine or an improvement on an existing one.
Thus machine design is the production or creation of the right combination of correctly
proportioned moving and stationary components so constructed and joined as to enable the
liberation, transformation, and utilization of energy.
The basic procedure of machine design (Mechanical Engineering Design) consists of a step
by step approach from given specifications of functional requirement of a product to the
complete description in the form of blue prints of the final product. The following steps are
involved:

First Step:
In the very first step a complete list of specifications for the functional requirement of the
product is to be prepared. The requirement may include, for example:
Output capacity;
Service life;
Cost;
Reliability; etc.
In consumer products, in addition appearance, noiseless operation, and simplicity in
control are important requirements.
Depending upon the type of product, various requirements are given weightage and a
priority list of specifications is prepared.

Second Step:
After a careful study of the requirements the designer prepares rough sketches of different
possible mechanisms of machine and depending upon the cost competitiveness, availability
of raw material, and manufacturing facilities, the possible mechanisms are compared with
each other and the designer selects the best possible mechanism for the product. For
example for designing the Blanking and Piercing Press the following mechanisms may be
thinking of:
1. Mechanism involving the CRANK AND CONNECTING ROD converting the
rotary motion of the electric motor into reciprocating motion of the punch.
2. Mechanism involving NUT AND SCREW which results in simple and cheap
configuration but having poor efficiency.
3. Mechanism involving HYDRAULIC CYLINDER, PISTON AND VALVES,
which is a costly configuration but highly efficient.

Figure 1.1

Third Step:
In the third step of the design procedure a block diagram is to be prepared which showing
the general layout of the selected configuration.
In this step designer specifies the joining methods, such as riveting, bolting, and welding to
connect the individual components. Rough sketches of shapes of individual parts are
prepared.
For example: the layout of an E.O.T (Electrically Operated Overhead Crane) will consist
following components.
Electric motor for supply of the power;
Flexible coupling to connect the motor shaft to the clutch shaft
Clutch to connect or disconnect the electric motor at the will of the operator.
Gear box to reduce the speed from 1440 rpm to 15 rpm
Rotary drum to convert the rotary motion of the shaft to the translator motion of the
wire rope
Wire rope and pulley with the crane hook to attach the load
Brake to stop the motion.

Fourth Step: After selecting the required or deciding the configuration of mechanism /
machine in third step above. The design of individual components of the selected
configuration is to be done in this step. It consists of the following stages:
Determine the forces acting on each component;
Selecting the proper material for the component depending upon the functional
requirement, such as strength, wear, rigidity, hardness and bearing properties etc.
Determine the likely mode of failure & select the criterion of failure like, yield
strength, ultimate strength, deflection etc.
Determine the geometric dimensions of the components using suitable factor of
safety and modify the dimensions from manufacturing considerations.
This stage involves the detailed stress analysis.

Fifth Step: The last stage in design process is to prepare the blue prints of assembly and
individual component.
On these drawings, the material of the components, dimensions and tolerances, surface
finish and machining methods are specified.
The designer prepare two separate lists of components
Standard components to be purchased directly from the market;
Special components to be machined in the factory;
Thus the machine design or mechanical design process is a systematic step-by-step
approach from known specification to unknown solution.

Definition Related to Machine Design:

1. Empirical Design: The design based on previous experience and existing practice
is known as empirical design. In empirical design various dimensions are set out as
a proportion of certain main dimension. For example the various dimensions of
rigid coupling are given as a proportion of shaft diameter.
2. Rational Design: It is purely a mathematical design based on principles of engg.
mechanics, mechanics of solids, or simply of engineering science etc. In this design
mechanics of solids is used to decide the different dimensions of a product. i.e By
solving the basic design equations and using optimization techniques. For example
the design of shaft diameter

3. Combined & Rational Design: In this design the components is designed on the
basis of mechanics of solids but in no case the individual dimensions to be less than
the existing or past practice. For example the design of hub diameter of protective
type rigid flange coupling by using the combined and rational design.

4. Design by Innovation: Innovation is the creative act where by an idea is

conceived and brought into successful practice. These days the competition has
widened. There is no lace for slow pace technological changes. Present
circumstances need faster, and bolder improvement or design. To achieve the
faster and bolder design utilizes new innovations like CAD, CATIA, ANSYS
etc. in the field of design. This is known as design by innovation, In this the
technical risks are great.

5. New Design: If the design is created from a scratch through the application of
scientific principles, technical ability and creative thinking of the designer known
as New Design or Inventive or Creative Design. If a problem arises that
suggests a machine for the solution and no suitable machine exists, a designer will
have to create it then the machine will be termed as NEW DESIGN.For example
the locomotives, airplane, steam engine were considered as New Design when they
had come in shape first time for use.

6. Adaptive Design & Redesign: There are many fields where the development has
practically cased e.g. bicycles, I.C. engines etc. So there is hardly anything left for
the designer to do except make minor modifications usually in the dimensions of
the product. This work is concerned with adaptation of existing design. The final
outcome does not differ much from the initial product. Thus much of designer work
consists of redesign.
For example: A press is to be designed for more capacity, a turret lathe is to be
designed to accommodate large stock, an automobile engine is to be designed to
produce more power. For all these examples the mechanisms are already designed
and the designer does not devise different mechanism. The designer only need to
decide which part is to be changed and what part is to remain same to achieve the
aim. But in making these changes the designer always keep in mind that the
changes are costly hence the redesign must produce desired result with minimum
alteration.
The mechanical design or machine design procedure may be shown schematically as
follows:

Figure 1.2

MORPHOLOGY OF DESIGN: Morphology of design is the chronological vertical

structure of the various phases or steps together from the engineering analysis to the
retirement of the product. Thus morphology of design includes the following steps:
(i) Feasibility Study: The aim is to produce a number of feasible and useful solutions.
Here the alternatives are assessed in stages. The first stage is made on the basis of
common sense. Many of the broad solutions may not be worth consideration.
Considering technical feasibility some of the solutions can be eliminated. The last
stage is the economic assessment. Systematic technical, economic, social and legal
considerations provide a rapid convergence towards the useful solutions.
(ii) Preliminary Design: Feasibility study yields a set of useful solutions. The aim in
this phase is to choose the optimal solution. To do this, criterion of optimization
must be explicitly delineated. The chosen alternative is then tested and predictions
are made concerning its performance.
(iii) Detailed Design: The purpose of the detailed design is to produce a complete
engineering description of a tested and producible design for manufacture. A
detailed design includes manufacturing drawings with tolerances.
 (iv) Planning for Manufacturing: A procedure sheet is to be made which contains a
sequence of manufacturing operations that must be performed on the component.
It specifies clearly the tooling, fixtures and production machines. This phase may
include planning, and inventory control, quality control system, the fixing of
standard time and labor cost for each operation.
(v) Planning for Distribution, Use and Retirement of the Product: The success of
a design depends on the skill exercised in marketing the product. Also the user-
oriented concern such as reliability, ease of maintenance, product safety,
convenience in use, aesthetic appeal, economy and durability must met. The
product life considering actual wear or deterioration, and technological
obsolescence must be planned.

Figure 1.3

Factors to be Considered in Machine Design:

There are many factors to be considered while attacking a design problem. In many cases
these are a common sense approach to solving a problem. Some of these factors are as
follows:
(a) What device or mechanism to be used? This would decide the relative
arrangement of the constituent elements.
(b) Material
(c) Forces on the elements
(d) Size, shape and space requirements. The final weight of the product is also a
major concern.
(e) The method of manufacturing the components and their assembly.
(f) How will it operate?
(g) Reliability and safety aspects
(h) Inspectibility
(i) Maintenance, cost and aesthetics of the designed product.
What device or mechanism to be used
This is best judged by understanding the problem thoroughly. Sometimes a
particular function can be achieved by a number of means or by using different
mechanisms and the designer has to decide which one is most effective under the
circumstances. A rough design or layout diagram may be made to crystallize the thoughts
regarding the relative arrangement of the elements.

Material
This is a very important aspect of any design. A wrong choice of material may lead
to failure, over or undersized product or expensive items. The choice of materials is thus
dependent on suitable properties of the material for each component, their suitability of
fabrication or manufacture and the cost.

Load
The external loads cause internal stresses in the elements and these stresses must be
determined accurately since these will be used in determining the component size. Loading
may be due to:
i) Energy transmission by a machine member.
ii) Dead weight.
iii) Inertial forces.
iv) Thermal effects.
v) Frictional forces.

In other ways loads may be classified as:

i) Static load- Does not change in magnitude and direction and normally increases
gradually to a steady value.

ii) Dynamic load-

a) changes in magnitude- for e.g. traffic of varying weight passing a bridge.
b) changes in direction- for e.g. load on piston rod of a double acting cylinder.
Vibration and shock loading are types of dynamic loading. The nature of these loads are
shown in figure-1.4

Figure 1.4, Types of Load

Size, shape, space requirements and weight
 Preliminary analysis would give an approximate size but if a standard element is to
be chosen, the next larger size must be taken. Shapes of standard elements are known but
for non-standard element, shapes and space requirements must depend on available space
in a particular machine assembly. A scale layout drawing is often useful to arrive at an
initial shape and size. Weight is important depending on application. For example, an
aircraft must always be made light. This means that the material chosen must have the
required strength yet it must be light. Similar arguments apply to choice of material for
ships and there too light materials are to be chosen. Portable equipment must be made
light.

Manufacture
Care must always be taken to ensure that the designed elements may be
manufactured with ease, within the available facilities and at low cost.

How will it operate?

In the final stage of the design a designer must ensure that the machine may be
operated with ease. In many power operated machines it is simply a matter of pressing a
knob or switch to start the machine. However in many other cases, a sequence of
operations is to be specified. This sequence must not be complicated and the operations
should not require excessive force. Consider the starting, accelerating and stopping a
scooter or a car. With time tested design considerations, the sequences have been made
user-friendly and as in any other product, these products too go through continuous
innovation and development.

Reliability and safety

Reliability is an important factor in any design. A designed machine should work
effectively and reliably. The probability that an element or a machine will not fail in use is
called reliability. Reliability lies between 0 R< 1. To ensure this, every detail should be
examined. Possible overloading, wear of elements, excessive heat generation and other
such detrimental factors must be avoided. There is no single answer for this but an overall
safe design approach and care at every stage of design would result in a reliable machine.
Safety has become a matter of paramount importance these days in design.
Machines must be designed to serve mankind, not to harm it. Industrial regulations ensure
that the manufacturer is liable for any damage or harm arising out of a defective product.
Use of a factor of safety only in design does not ensure its overall reliability.

Maintenance, cost and aesthetics

Maintenance and safety are often interlinked. Good maintenance ensures good
running condition of machinery. Often a regular maintenance schedule is maintained and a
thorough check up of moving and loaded parts is carried out to avoid catastrophic failures.
Low friction and wear is maintained by proper lubrication. This is a major aspect of design
since wherever there are moving parts, friction and wear are inevitable. High friction leads
to increased loss of energy. Wear of machine parts leads to loss of material and premature
failure. Cost and aesthetics are essential considerations for product design. Cost is
essentially related to the choice of materials which in turn depends on the stresses
developed in a given condition. Although in many cases aesthetic considerations are not
essential aspects of machine design, ergonomic aspects must be taken into considerations.

Standards and Standardization:

Standards In Design:
Standard is a set of specifications, defined by a certain body or an organization, to
which various characteristics of a component, a system, or a product should conform. The
characteristics may include: dimensions, shapes, tolerances, surface finish etc.

Types Of Standrads Used In Machine Design:

Based on the defining bodies or organization, the standards used in the machine
design can be divided into following three categories:
(i) Company Standards: These standards are defined or set by a company or
a group of companies for their use.
(ii) National Standards: These standards are defined or set by a national apex
body and are normally followed throughout the country. Like BIS, AWS.
(iii) International Standards: These standards are defined or set by
international apex body and are normally followed throughout the world.
Like ISO, IBWM.
Advantages:
Reducing duplication of effort or overlap and combining resources
Bridging of technology gaps and transferring technology
Reducing conflict in regulations
Facilitating commerce
Stabilizing existing markets and allowing development of new markets
Protecting from litigation
Selection of Preferred Sizes

French balloonist and Engineer Charles Renard suggested the method to specify the
sizes of the product to satisfy the needs of the customers with the minimum number of
sizes in the given range by using the G.P. He gave the five basic series having their
specific series factor as follows:
SERIES SERIES FACTOR

R-5 5
10

R-10 10
10

R-20 20
10

R-40 40
10

R-80 80
10
 The second size is obtained by multiplying the series factor to the first size. The
third size is obtained by multiplying the series factor to the second size. And this procedure
is repeated until the whole range is covered. Thus the sizes are specified in the given range
and this is known as the selection of preferred sizes.

For the number of R-10 series the series factor will be 10 10 .

ADVANTAGES OF SELECTION OF PREFERRED SERIES: The advantages of

preferred series are as follows:
1. The differences in two successive terms have a fixed percentage.
2. Provides small steps for small quantities and large steps for the large quantities.
It is in conformance with the mode of variation found in nature.
3. The product range is covered with minimum number of sizes without restricting
the choices of the customers.
4. It helps the designer to avoid the selection of sizes arbitrarily.

Q. It is required to standardize load carrying capacities of dumpers in a

manufacturing unit. The maximum and minimum capacities of such dumpers
are 630 and 40 kN respectively. The company is interested in developing
seven models in this range. Specify their load carrying capacities.
Sol.: Let the first Model capacity =40 kN;
Using the R - 5 serieshavingseriesfactor1.58,
First Model= 40 kN;
SecondModel= 40 1.58 = 63.2 63 kN; Third Model= 63.2 1.58 = 99.856 100kN;
FourthModel= 99.856 1.58 = 157.77248 158kN; Fifth Model= 157.77248 1.58 = 249.2805 = 249kN;
Sixth Model= 249.2805 1.58 = 393.86 394kN; SeventhModel= 393.86 1.58 = 622.3038 622kN;

B.I.S DESIGNATIONS OF THE PLAIN CARBON STEEL: Plain carbon steel is

designated according to BIS as follows:
1. The first one or two digits indicate the 100 times of the average percentage
content of carbon.
2. Followed by letter C
3. Followed by digits indicates 10 times the average percentage content of
Manganese Mn.

B.I.S DESIGNATIONS OF ALLOY STEEL: Alloy carbon steel is designated

according to BIS as follows:
1. The first one or two digits indicate the 100 times of the average percentage
content of carbon.
2. Followed by the chemical symbol of chief alloying element.
3. Followed by the rounded off the average percentage content of alloying
element as per international standards.
 4. Followed by the chemical symbol of alloying elements followed by their
average percentage content rounded off as per international standards in the
descending order.
5. If the average percentage content of any alloying element is less than 1%, it
should be written with the digits up to two decimal places and underlined.

(i) 45C8 = Plain carbon steel having average %age of carbon of 0.45% and 0.8% Mn.
(ii) Fe250 = Grey cast iron having minimum tensile strength of 250 N?mm2;
(iii) XT30Ni4Cr2V65 = High speed tool steel having
Average %age content of C = 0.30%;
Average %age content of Ni = 4.0%;
Average %age content of Cr = 2.0%;
Average %age content of V = 0.65%;
(iv) 37Mn2 = Alloy Steel having
Average %age content of C = 0.37%;
Average %age content of Mn = 2.0%;

BASIC CRITERION FOR SELECTION OF MATERIAL:

The basic criterions considered by a designer for the selection of a material for a particular
application are:
Availability of material;
Cost of material;
Manufacturing Considerations;
Material Properties.

Availability of Material:
The material which is available readily and in abundance in the market should be
selected.

Cost of Material:
The material should be selected such that the total cost should be minimum and
within the specified limits. The total cost includes the cost of material and cost of
processing of the material.

Manufacturing Considerations:
The material should be suitable for the required manufacturing processes to make
the product or component.

Material Properties:
 The material posses the required mechanical, physical and chemical properties
required for the application.

CLASSIFICATION OF ENGINEERING MATERIALS:

Figure 1.5 Classification of Materials

Ferrous Materials:

Cast iron:
It is an alloy of iron, carbon and silicon and it is hard and brittle. Carbon content
may be within 1.7% to 3% and carbon may be present as free carbon or iron carbide Fe3C.
In general the types of cast iron are (a) grey cast iron and (b) white cast iron (c) malleable
cast iron (d) spheroidal or nodular cast iron (e) austenitic cast iron (f) abrasion resistant
cast iron.

(a) Grey cast iron: Carbon here is mainly in the form of graphite. This type of cast iron is
inexpensive and has high compressive strength. Graphite is an excellent solid lubricant and
this makes it easily machinable but brittle. Some examples of this type of cast iron are
FG20, FG35 or FG35Si15.

(b) White cast iron: In these cast irons carbon is present in the form of iron carbide (Fe3C)
which is hard and brittle. The presence of iron carbide increases hardness and makes it
difficult to machine. Consequently these cast irons are abrasion resistant.

(c) Malleable cast iron: These are white cast irons rendered malleable by annealing.
These are tougher than grey cast iron and they can be twisted or bent without fracture.
They have excellent machining properties and are inexpensive. Malleable cast iron are
used for making parts where forging is expensive such as hubs for wagon wheels, brake
supports.
(d) Spheroidal or nodular graphite cast iron: In these cast irons graphite is present in the
form of spheres or nodules. They have high tensile strength and good elongation
properties.

(e) Austenitic cast iron: Depending on the form of graphite present these cast iron can be
classified broadly under two headings:
Austenitic flake graphite iron; and
Austenitic spheroidal or nodular graphite iron
These are alloy cast irons and they contain small percentages of silicon, manganese,
sulphur, phosphorus etc. They may be produced by adding alloying elements viz. nickel,
chromium, molybdenum, copper and manganese in sufficient quantities. These elements
give more strength and improved properties. They are used for making automobile parts
such as cylinders, pistons, piston rings, brake drums etc.

(f) Abrasion resistant cast iron- These are alloy cast iron and the alloying elements
render abrasion resistance.

Wrought iron- This is a very pure iron where the iron content is of the order of 99.5%. It
is produced by re-melting pig iron and some small amount of silicon, sulphur, or
phosphorus may be present. It is tough, malleable and ductile and can easily be forged or
welded. It cannot however take sudden shock. Chains, crane hooks, railway couplings and
such other components may be made of this iron.

Steel- This is by far the most important engineering material and there is an enormous
variety of steel to meet the wide variety of engineering requirements. Steel is basically an
alloy of iron and carbon in which the carbon content can be less than 1.7% and carbon is
present in the form of iron carbide to impart hardness and strength. Two main categories of
steel are (a) Plain carbon steel and (b) alloy steel.

(a) Plain carbon steel- The properties of plain carbon steel depend mainly on the carbon
percentages and other alloying elements are not usually present in more than 0.5 to 1%
such as 0.5% Si or 1% Mn etc. The plain carbon steel further may be classified in the
following categories:
Dead mild steel- upto 0.15% C
Low carbon steel or mild steel- 0.15 to 0.46% C
Medium carbon steel- 0.45 to 0.8% C.
High carbon steel- 0.8 to 1.5% C
Usually in these steels in general higher carbon percentage indicates higher strength.

(b) Alloy steel- these are steels in which elements other than carbon are added in sufficient
quantities to impart desired properties, such as wear resistance, corrosion resistance,
electric or magnetic properties. Chief alloying elements added are usually nickel for
strength and toughness, chromium for hardness and strength, tungsten for hardness at
elevated temperature, vanadium for tensile strength, manganese for high strength in hot
rolled and heat treated condition, silicon for high elastic limit, cobalt for hardness and
molybdenum for extra tensile strength.

Non-Ferrous Metals:
Metals containing elements other than iron as their chief constituents are usually
referred to as on-ferrous metals. There is a wide variety of non-metals in practice.
However, only a few exemplary ones are discussed below:

Aluminium- This is the white metal produced from Alumina. In its pure state it is weak
and soft but addition of small amounts of Cu, Mn, Si and Magnesium makes it hard and
strong. It is also corrosion resistant, low weight and non-toxic.

Duralumin- This is an alloy of 4% Cu, 0.5% Mn, 0.5% Mg and aluminium. It is widely
used in automobile and aircraft components.

Y-alloy- This is an alloy of 4% Cu, 1.5% Mn, 2% Ni, 6% Si, Mg, Fe and the rest is Al. It
gives large strength at high temperature. It is used for aircraft engine parts such as cylinder
heads, piston etc.

Magnalium- This is an aluminium alloy with 2 to 10 % magnesium. It also contains

1.75% Cu. Due to its light weight and good strength it is used for aircraft and automobile
components.

Copper alloys:
Copper is one of the most widely used non-ferrous metals in industry. It is soft,
malleable and ductile and is a good conductor of heat and electricity. The following two
important copper alloys are widely used in practice:

Brass (Cu-Zn alloy):

It is fundamentally a binary alloy with Zn upto 50% . As Zn percentage increases,
ductility increases upto ~37% of Zn beyond which the ductility falls. This is shown in
figure-1.6. Small amount of other elements viz. lead or tin imparts other properties to
brass. Lead gives good machining quality and tin imparts strength. Brass is highly
corrosion resistant, easily machinable and therefore a good bearing material.

Figure 1.6, Variation of ductility of brass with percentage of zinc.

Non-Metals
Non-metallic materials are also used in engineering practice due to principally their
low cost, flexibility and resistance to heat and electricity. Though there are many suitable
non-metals, the following are important few from design point of view:

Timber- This is a relatively low cost material and a bad conductor of heat and electricity.
It has also good elastic and frictional properties and is widely used in foundry
patterns and as water lubricated bearings.

Leather- This is widely used in engineering for its flexibility and wear resistance. It is
widely used for belt drives, washers and such other applications.

Rubber- It has high bulk modulus and is used for drive elements, sealing, vibration
isolation and similar applications.

Plastics: These are synthetic materials which can be moulded into desired shapes under
pressure with or without application of heat. These are now extensively used in
various industrial applications for their corrosion resistance, dimensional
stability and relatively low cost. There are two main types of plastics:

(a) Thermosetting plastics-

Thermosetting plastics are formed under heat and pressure. It initially softens and
with increasing heat and pressure, polymerisation takes place. This results in
hardening of the material. These plastics cannot be deformed or remoulded again
under heat and pressure. Some examples of thermosetting plastics are phenol
formaldehyde (Bakelite), phenol-furfural (Durite), epoxy resins, phenolic resins etc.

(b) Thermoplastics-
Thermoplastics do not become hard with the application of heat and pressure and
no chemical change takes place. They remain soft at elevated temperatures until they
are hardened by cooling. These can be re-melted and remoulded by application of heat
and pressure. Some examples of thermoplastics are cellulose nitrate (celluloid),
polythene, polyvinyl acetate, polyvinyl chloride ( PVC) etc.

Mechanical Properties of Common Engineering Materials:

The important properties from design point of view are:

(a) Elasticity-
This is the property of a material to regain its original shape after deformation
when the external forces are removed. All materials are plastic to some extent but
the degree varies, for example, both mild steel and rubber are elastic materials but
steel is more elastic than rubber.
(b) Plasticity-
This is associated with the permanent deformation of material when the stress
level exceeds the yield point. Under plastic conditions materials ideally deform
without any increase in stress. A typical stress-strain diagram for an elastic-
perfectly plastic material is shown in the figure-1.7. A typical example of plastic
flow is the indentation test where a spherical ball is pressed in a semi-infinite body.

Figure 1.7, Stress-strain diagram of an elastic-perfectly plastic

material and the plastic indentation.

(c) Hardness-
Property of the material that enables it to resist permanent deformation,
penetration, indentation etc. Size of indentations by various types of indenters are the
measure of hardness e.g. Brinnel hardness test, Rockwell hardness test, Vickers
hardness (diamond pyramid) test. These tests give hardness numbers which are
related to yield pressure (MPa).

(d) Ductility-
This is the property of the material that enables it to be drawn out or elongated to
an appreciable extent before rupture occurs. The percentage elongation or percentage
reduction in area before rupture of a test specimen is the measure of ductility.
Normally if percentage elongation exceeds 15% the material is ductile and if it is
less than 5% the material is brittle. Lead, copper, aluminium, mild steel are typical
ductile materials.

(e) Malleability-
It is a special case of ductility where it can be rolled into thin sheets but it is not
necessary to be so strong. Lead, soft steel, wrought iron, copper and aluminium are
some materials in order of diminishing malleability.

(f) Brittleness-
This is opposite to ductility. Brittle materials show little deformation before
fracture and failure occur suddenly without any warning. Normally if the elongation is
less than 5% the material is considered to be brittle. e.g. cast iron, glass, ceramics are
typical brittle materials.
(g) Resilience-
This is the property of the material that enables it to resist shock and impact by
storing energy. The measure of resilience is the strain energy absorbed per unit volume.
For a rod of length L subjected to tensile load P, a linear load-deflection plot is shown
in figure-1.8.

Figure 1.8, A linear load-deflection curve

1 1 P dL 1
Strain energy stored = P dL = A L = s e V
2 2 A L 2
1
Strain energy stored per unit volume = s e
2
(h) Toughness-
This is the property which enables a material to be twisted, bent or stretched under
impact load or high stress before rupture. It may be considered to be the ability of
the material to absorb energy in the plastic zone. The measure of toughness is the
amount of energy absorbed after being stressed upto the point of fracture.

(i) Creep-
When a member is subjected to a constant load over a long period of time it
undergoes a slow permanent deformation and this is termed as creep. This is
dependent on temperature. Usually at elevated temperatures creep is high.
 Design Against Static Load:

Modes Of Failure Of Materials Subjected to Static Load: A mechanical component

may fail, that is, it may be unable to perform its function satisfactorily, as a result of any
one of three modes of failure:
i. Failure by elastic deflection;
ii. Failure by general yielding
iii. Failure by fracture;
(i) Failure by Elastic Deflection: In applications like transmission shafts supporting
gears, the maximum force acting on the shaft without affecting its performance is
limited by the permissible elastic deflection. Lateral or torsionla rigidity is
considered as the criterion of design in such cases. Sometimes the elastic deflection
results in unstable conditions, such as buckling of columns or vibrations and may
cause deterioration in performance of the mechanical system and it is considered
the case of failure of the design due to the elastic deflection. The moduli of
elasticity and rigidity are the important properties and the dimensions of the
component are determined by the load deflection equation.

(ii) Failure by General Yielding: A mechanical component made of ductile material

loses its engineering usefulness due to a large amount of plastic deformation after
the yield point stress is reached. Considerable portion of the component is
subjected to plastic deformation called general yielding. The yield strength of the
material is an important property when a component is designed against general
yielding.

(iii) Failure by Fracture: Components made of brittle material ceases to function

satisfactorily because of the sudden fracture without any plastic deformation. The
failure in this case is sudden and total. In such cases, ultimate tensile strength of the
material is an important property for determining the dimensions of these
components.

Factor of Safety:
Determination of stresses in structural or machine components would be meaningless
unless they are compared with the material strength. If the induced stress is less than or
equal to the limiting material strength then the designed component may be considered to
be safe and an indication about the size of the component is obtained. The strength of
various materials for engineering applications is determined in the laboratory with standard
specimens. For example, for tension and compression tests a round rod of specified
dimension is used in a tensile test machine where load is applied until fracture occurs. This
test is usually carried out in a Universal testing machine. Similar tests are carried out for
bending, shear and torsion and the results for different materials are available in
handbooks. For design purpose an allowable stress is used in place of the critical stress to
take into account the uncertainties including the following:
 1) Uncertainty in loading.
2) Inhomogeneity of materials.
3) Various material behaviours, e.g. corrosion, plastic flow, creep.
4) Residual stresses due to different manufacturing process.
5) Fluctuating load (fatigue loading): Experimental results and plot- ultimate strength
depends on number of cycles.
6) Safety and reliability.
7) Consequences of failure human safety and economy
8) Cost of providing a larger factor of safety.

For ductile materials, the yield strength and for brittle materials the ultimate strengths
are taken as the critical stress. An allowable stress is set considerably lower than the
ultimate strength. The ratio of ultimate to allowable load or stress is known as factor of
safety i.e. The factor of safety can be defined as the ratio of the material strength or failure
stress to the allowable or working stress. Mathematically it may be expressed as
failure stress
f.o.s =
working or allowable stress
S yt
f.o.s = ; for ductile materials,
working or allowable stress
S ut
f.o.s = ; for brittle materials,
working or allowable stress
Se
f.o.s = ; for fatigue loading of materials,
working or allowable stress
symbols are having the usual meanings.
The factor of safety must be always greater than unity. It is easier to refer to the
ratio of stresses since this applies to material properties.
Principal Stresses:

(a) (b)
Figure1.9(a) Transformation of stresses from x-y to x-y co-ordinate system
Figure1.9(b) Stresses on an isolated triangular element
 Consider a state of general plane stress in x-y co-ordinate system. Transforming it
to another stress system in, say, x- y co-ordinates, that is inclined at an angle , as shown
in figure 1.9(a). A two dimensional stress field acting on the faces of a cubic element is
shown in figure 1.9(b). In plane stress assumptions, the non-zero stresses are x, y and
xy= yx. The stresses x and xy are induced on the plane AC is inclined at an angle in
the isolated element ABC as shown in figure 1.9(b).
Considering the force equilibrium in x-direction we may write
x ' = x cos + y sin + xy sin cos
This may be reduced to
s x +s y s x -s y
s x' = + cos2 q + t xy sin 2q - - - - - - - - - - - - - (1.1)
2 2
Similarly, force equilibrium in y-direction gives
sy - s x
t x' y' = sin2 q + t xy cos 2q - - - - - - - - - - - - - (1.2)
2
Since plane AC can assume any arbitrary inclination, a stationary value of x is given by

ds x
=0
dq
This gives
2 t xy
tan 2q = - - - - - - - - - - - - - - - - - - - - - -(1.3)
s x -s y
This equation has two roots and let the two values of be 1 and (1+90o). Therefore these
two planes are the planes of maximum and minimum normal stresses. Now if we set
t x ' y ' = 0 we get the values of corresponding to planes of zero shear stress. This also
gives

2 t xy
tan 2q = - - - - - - - - - - - - - - - - - - - - - -(1.4)
s x -s y
And equation (1.3) and (1.4) are same, indicating that at the planes of maximum and
minimum stresses no shearing stress occurs. These planes are known as Principal planes
and stresses acting on these planes are known as Principal stresses. From equation (1.1)
and (1.3) the principal stresses are given as

2
s x +s y s x -s y 2
s 1,2 = + t xy
- - - - - - - - - - - - - (1.5)
2 2
In the same way, condition for maximum shear stress is obtained from
dt x y
=0
dq
This gives
 s x -s y
tan 2q = - - - - - - - - - - - - - - - - - - - - - -(1.6)
2 t xy
This also gives two values of say 2 and (2+90o), at which shear stress is maximum or
minimum. Combining equations (1.2) and (1.6) the two values of maximum shear stresses
are given by

2
s x -s y 2
t max = + t xy
- - - - - - - - - - - - - - - - - - - - - - - - (1.7)
2
One important thing to note here is that values of tan22 is negative reciprocal of tan21
and thus 1 and 2 are 45o apart. This means that principal planes and planes of maximum
shear stresses are 45o apart. It also follows that although no shear stress exists at the
principal planes, normal stresses may act at the planes of maximum shear stresses.

Q.Consider an element with the

following stress system shown in figure
1.10, x=-10 MPa, y = +20 MPa, = -20
MPa. Find the principal stresses and
show their senses on a properly
oriented element.

Solution:
The principal stresses areFigure 1.10, A 2-D element with normal and shear stresses.
2
s x +s y s x -s y 2
s 1,2 = + t xy

2 2
2
- 10 + 20 - 10 - 20
+ (- 20 )
2
s 1,2 =
2 2
s 1,2 = 5 25;
s 1 = +30 MPa;
s 1,2 = -20 MPa
This gives -20MPa and 30 MPa, the principal planes are given by
2 (- 20 )
tan 2q = = 1.33
- 10 - 20
2q = tan - 1 (1.33 ) = 53.130 0 ;
q = 26.56 0
\q 1 = 26.56 0 &
q 2 = 26.56 0 + 90 0 = 116.56 0
Thus the oriented element to show the principal stresses is shown in figure 1.11.
 Figure 1.11, Orientation of the loaded element in the left to show the principal stresses.

Stresses in Bending and Torsion:

Bending stresses: Consider two sections ab and cd in a beam subjected to a pure bending.
Due to bending the top layer is under compression and the bottom layer is under tension.
This is shown in figure-1.12. This means that in between the two extreme layers there must
be a layer which remains un-stretched and this layer is known as neutral layer. Let this be
denoted by NN.

Figure 1.12, Pure bending of beams

We consider that a plane section remains plane after bending- a basic assumption in pure
bending theory. If the rotation of cd with respect to ab is d the contraction of a layer y
distance
away from the neutral axis is given by ds = y d and original length of the layer is x = R
d, R being the radius of curvature of the beam. This gives the strain in the layer as
 y
e= - - - - - - - - - - - ( 1.8 )
R
We also consider that the material obeys Hookes law = E. This is another basic
assumption in pure bending theory and substituting the expression for we have
s y
= - - - - - - - - - - - - - - - - (1.9)
E R
Consider now a small element dA y distance away from the neutral axis. This is shown in
the figure 1.13.

Figure 1.13, Bending stress developed at any cross-section

Axial force on the element

dFx = s x dA - - - - - - - - - - - - - - - - - - - -(1.10)

And considering the linearity in stress variation across the section

sx y
= - - - - - - - - - - - - - - - - (1.11)
s max d
we have where x and max are the stresses at distances y and d respectively from the
neutral axis.
The axial force on the element is thus given by equation (1.10) and (1.11)

y s max
dFx = dA - - - - - - - - - - - - - - - - (1.12)
d
For static equilibrium total force at any cross-section
y s max
F = dFx = dA = 0 - - - - - - - - - - - - - - - - (1.13)
A A d
This gives
ydA = y A = 0 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - (1.14)
and since A 0.This means that the neutral axis passes through the centroid. Again for
static equilibrium total moment about NA must the applied moment M. This is given by
 y s max
y dA = M - - - - - - - - - - - - - - - - (1.15)
d
It gives
M d
s max = - - - - - - - - - - - - - - - - - - - - - - - ( 1.16 )
I
For any fibre at a distance of y from the centre line we may therefore write
My
s max = - - - - - - - - - - - - - - - - - - - - - - - ( 1.17 )
I

Torsion of Circular Members Torsion of Circular Members:

A torque applied to a member causes shear stress. In order to establish a relation between
the torque and shear stress developed in a circular member, the following assumptions are
needed:
1. Material is homogeneous and isotropic
2. A plane section perpendicular to the axis of the circular member remains plane even
after twisting i.e. no warping.
3. Materials obey Hookes law.
If the member is subjected to torque T, the maximum shear stress induced in the circular
member of the radius r may be given as
T r
t = ;
J
J= polar moment of inertia.
Thus the shear stress may be given as
16 T
t = ;
p d3
p d4 d
J= ; and r =
32 2

Theories of Failure

Necessity Of Having More Than One Theories Of Failure: When a machine

component is subjected to a uniaxial stress. It is easy to predict the failure because the
stress and the strength can be compared directly. There is only one value of stress and one
value of strength, be it yield strength, ultimate strength or shear strength and the method
becomes simple. But the problem of predicting the failure of a component subjected to
biaxial or triaxial stresses is more complicated.
This is because there are multiple stresses, but still only one significant strength. The
different theories of failure have been proposed to predict the failure of the components
subjected to biaxial or triaxial stresses and a shear stress.
When a machine element is subjected to a system of complex stress system, it is important
to predict the mode of failure so that the design methodology may be based on a particular
failure criterion. Theories of failure are essentially a set of failure criteria developed for the
ease of design. In machine design an element is said to have failed if it ceases to perform
its function. There are basically two types of mechanical failure:
(a) Yielding- This is due to excessive inelastic deformation rendering the machine part
unsuitable to perform its function. This mostly occurs in ductile materials.
(b) Fracture- In this case the component tears apart in two or more parts. This mostly
occurs in brittle materials. There is no sharp line of demarcation between
ductile and brittle materials. However a rough guideline is that if percentage
elongation is less than 5% then the material may be treated as brittle and if it
is more than 15% then the material is ductile. However, there are many
instances when a ductile material may fail by fracture. This may occur if a
material is subjected to
(a) Cyclic loading.
(b) Long term static loading at elevated temperature.
(c) Impact loading.
(d) Work hardening.
(e) Severe quenching.

Maximum principal stress theory ( Rankine theory)

According to this, if one of the principal stresses 1 (maximum principal stress), 2
(minimum principal stress) or 3 exceeds the yield stress, yielding would occur. In a two
dimensional loading situation for a ductile material where tensile and compressive yield
stress are nearly of same magnitude
1 = y
2 = y
Using this, a yield surface may be drawn, as shown in figure-1.14. Yielding occurs when
the state of stress is at the boundary of the rectangle. Consider, for example, the state of
stress of a thin walled pressure vessel. Here 1= 22, 1 being the circumferential or hoop
stress and 2 the axial stress. As the pressure in the vessel increases the stress follows the
dotted line. At a point (say) a, the stresses are still within the elastic limit but at b, 1
reaches y although 2 is still less than y. Yielding will then begin at point b. This theory
of yielding has very poor agreement with experiment. However, the theory has been used
successfully for brittle materials.

Figure 1.14, Yield surface corresponding to maximum principal stress

Maximum principal strain theory (St. Venants theory):
According to this theory, yielding will occur when the maximum principal strain just
exceeds the strain at the tensile yield point in either simple tension or compression. If 1
and 2 are maximum and minimum principal strains corresponding to 1 and 2, in the
limiting case

This gives

The boundary of a yield surface in this case is thus

given as shown in figure 1.15

Figure 1.15, Yield surface corresponding to maximum principal strain theory

Maximum shear stress theory ( Tresca theory):
According to this theory, yielding would occur when the maximum shear stress just
exceeds the shear stress at the tensile yield point. At the tensile yield point 2= 3 = 0 and
thus maximum shear stress is y/2. This gives us six conditions for a three-dimensional
stress situation:
In a biaxial stress situation ( figure-1.14) case, 3 = 0 and this gives

This criterion agrees well with experiment. In the case of pure shear, 1 = - 2 = k (say), 3
=0
and this gives 1- 2 = 2k= y This indicates that yield stress in pure shear is half the
tensile yield stress and this is also seen in the Mohrs circle ( figure- 1.17) for pure shear.

Figure 1.17, Mohrs circle for pure shear

Maximum strain energy theory ( Beltramis theory):

According to this theory failure would occur when the total strain energy absorbed at a
point per unit volume exceeds the strain energy absorbed per unit volume at the tensile
yield point. This may be given

Substituting, 1, 2 , 3 and y in terms of stresses we have

This may be written as

This is the equation of an ellipse and the yield surface is shown in figure-1.18

Figure 1.18, Yield surface corresponding to Maximum strain energy theory

It has been shown earlier that only distortion energy can cause yielding but in the above
expression at sufficiently high hydrostatic pressure 1 = 2 = 3 = (say), yielding may
also occur. From the above we may write

And if ~ 0.3, at stress level lower than yield stress, yielding would occur. This is in
contrast to the experimental as well as analytical conclusion and the theory is not
appropriate.

Distortion energy theory (Von Mises yield criterion):

According to this theory yielding would occur when total distortion energy absorbed per
unit volume due to applied loads exceeds the distortion energy absorbed per unit volume at
the tensile yield point. Total strain energy ET and strain energy for volume change EV can
be given as

Substituting strains in terms of stresses the distortion energy can be given as

At the tensile yield point, 1 = y , 2 = 3 = 0 which gives

The failure criterion is thus obtained by equating Ed and Edy , which gives

In a 2-D situation if 3 = 0, the criterion reduces to

This is an equation of ellipse and the yield surface is shown in figure-1.19.This theory
agrees very well with experimental results and is widely used for ductile materials.

Figure 1.19, Yield surface corresponding to von Mises yield criterion

Superposition of Yield Surface:

A comparison among the different failure theories can be made by superposing the yield
surfaces as shown in figure- 1.20

Figure 1.20, Comparison of different failure theories

It is clear that an immediate assessment of failure probability can be made just by plotting
any experimental in the combined yield surface. Failure of ductile materials is most
accurately governed by the distortion energy theory where as the maximum principal strain
theory is used for brittle materials.

Q. A beam of uniform cross section is fixed

at one end and carries an electric motor
weighing 400 N at a distance of 300 mm
from the fixed end. The maximum
bending stress in the beam is 40 MPa.
Find the width and depth of the beam if
the depth is twice that of the width.

SOLUTION:

Referring the figure given in the problem

b = Width of the beam in mm;
h = Depth of the beam in mm
bh 2 b(2b )2 2b 3
\ Z (section modulus) = = = mm 3 ;
6 6 3
At the fixed end, the maximum bending moment will be,
M = WL = 400 300 = 120000 N - mm;
Bending moment s b is given as 40 MPa;
M 120000 3
\ 40 = =
Z 2b 3
b = 16.5 mm;
h = 2b = 2 16.5 = 33 mm;

Q. A bolt is subjected to an axial pull of 10 kN and transverse shear force of 5

kN. The yield strength of the bolt material is 300 MPa. Considering the factor
of safety of 2. Determine the diameter of the shaft using (i) maximum shear stress
theory and (ii) distortion energy theory.

Solution: Assuming the problem for designing the bolt diameter as this problem started
with the data for bolt but asked to find the diameter of the shaft.

Given: Transverse load Pt = 10 kN = 1000 N; Shear Load Ps = 5 kN =5000 N; The

yield strength of the material Syt = 300 MPa; Factor of safety f.o.s. = 2.0;

S yt 300
The permissible stress: sd = = = 150 MPa; -------------(1)
f .o.s 2.0
 Pt 4 10000 12732.395
The axial stress: sa = = = MPa; ----------(2)
(pd 4)2
p d2 d2

The transverse shear stress:

Ps 4 5000 6366.1977
t= = = MPa; ------------(3)
(pd 4)
2
p d2 d2

The principal stresses and maximum shear stress:

s s
2
s 1,2 = a a + t 2 =
12732.395
2
12732.395 6366.1977

(6366.1975 9003.163) ;
2

2 2 + 2 =
2 2 2d 2d d d2
15369.3605 - 2636.9655
s1 = + MPa; s 2 = MPa; - - - - - - - - - - - - - -(4)
d2 d2
s - s 2 1 15369.3605 2636.9655 9003.163
t max = 1 = + = - - - - - -(5)
2 2 d2 d2 d2

(i) According to maximum shear stress theory:

S yt
t max
2 f .o.s
9003.163 300

d2 2 2
4 9003.163
d = 10.9564 mm;
300

(ii) According to distortion energy theory:

2
S yt
s 12 + s 22 - 2s 1 s 2 ;

f .o.s.
2 2 2
15369.3605 - 2636.9655 15369.3605 - 2636.9655 300
2
+ 2
- 2
d d d2 d2 2.0
18006.326
150;
d2
18006.326
d ;
150
d 10.9564 mm;

Q. A wall bracket, as shown in following figure, is subjected to a pull of P = 5 kN,

at 60 to the vertical. The cross-section of bracket is rectangular having b = 3t.
Determine the dimensions b and t if the stress in the material of the bracket is limited
to 28 MPa.
Solution: Given : P = 6000 N ; q = 45
; = 60 MPa = 60 N/mm2
Let t = Thickness of the section in mm, and
b = Depth or width of the section = 3 t
Aarea of cross-section,
A = b t = 3 t t = 3 t2 mm2
and section modulus,
tb 2 3t 3
Z= =
6 2
Horizontal component of the load,
PH = 5000 sin 60
= 5000 0.866=4330.13 n
Bending moment due to horizontal component of the load,
MH = PH 60 = 4330.13 60 = 259807.62 N-mm
Maximum bending stress on the upper surface due to horizontal component,
MH 259807.62 2 173205.81
s bh = = 2
= 2
N/mm2
z 3t t
Vertical component of the load,
PV = 5000 cos60 = 6000 0.5 = 2500 N
Direct Shear;
PV 2500 833.33
t = = 2
= 2
N/mm2
A 3t t
Bending moment due to vertical component of the load,
MV = PV 60 = 2500 120 = 300000 N-mm
Maximum bending stress on the upper surface due to horizontal component,
MV 300000 2 200000
s bV = = = N/mm2
z 3t 2 t2
Direct tensile stress due to horizontal component
PH 4330.13 1443.38
sd = = 2
= 2
N/mm2
A 3t t
Net normal stress
173205.81 200000 1443.38 374649.1867
s = 2
+ 2
+ 2
= 2
N/mm2
t t t t
Now applying the maximum shear stress theory
1
2
( )
s 2 + 4t 2 28

putting the values and solving the above equation for " t"
t = 25mm and b = 3t = 75 mm
 Unit-II

In this chapter we will be discussing on design aspects related to fatigue failure, an

important mode of failure in engineering components. Fatigue failure results mainly due to
variable loading or more precisely due to cyclic variations in the applied loading or
induced stresses So starting from the basic concepts of variable (non-static) loading, we
will be discussing in detail how it leads to fatigue failure in components, what factors
influence them, how to account them and finally how to design parts or components to
resist failure by fatigue.

FATIGUE:
Fatigue is a phenomenon associated with variable loading or more precisely to
cyclic stressing or straining of a material. Just as we human beings get fatigue when a
specific task is repeatedly performed, in a similar manner metallic components subjected to
variable loading get fatigue, which leads to their premature failure under specific
conditions.

WHAT IS FATIGUE LOADING?

Fatigue loading is primarily the type of loading which causes cyclic variations in the
applied stress or strain on a component. Thus any variable loading is basically a fatigue
loading.
In reality most mechanical components experience variable loading due to:
-Change in the magnitude of applied load Example: punching or shearing operations-
-Change in direction of load application Example: a connecting rod
-Change in point of load application Example: a rotating shaft

There are different types of fatigue/variable loading. The worst case of fatigue loading is
the case known as fully-reversible load. One cycle of this type of loading occurs when a
tensile stress of some value is applied to an unloaded part and then released, then a
compressive stress of the same value is applied and released.

Variable Loading
Variable loading results when the applied load or the induced stress on a component is not
constant but changes with time i.e load or stress varies with time in some pattern. Most
mechanical systems and devices consists moving or rotating components. When they are
subjected to external loadings, the induced stresses are not constant even if the magnitude
of the applied load remains invariant.
In reality most mechanical components experience variable loading due to
-Change in the magnitude of applied load Example: punching or shearing operations-
-Change in direction of load application Example: a connecting rod
-Change in point of load application Example: a rotating shaft
There are different types of fatigue/variable loading. The worst case of fatigue loading is
the case known as fully-reversible load. One cycle of this type of loading occurs when a
tensile stress of some value is applied to an unloaded part and then released, then a
compressive stress of the same value is applied and released.

A rotating shaft with a bending load applied to it is a good example of fully reversible
load. In order to visualize the fully-reversing nature of the load, picture the shaft in a fixed
position (not rotating) but subjected to an applied bending load (as shown here). The
outermost fibers on the shaft surface lying on the convex side of the deflection (upper
surface in the picture) will be loaded in tension (upper green arrows), and the fibers on the
opposite side will be loaded in compression (lower green arrows). Now, rotate the shaft
180 in its bearings, with the loads remaining the same. The shaft stress level is the same,
but now the fibers which were loaded in compression before you rotated it are now loaded
in tension, and vice-versa. Thus if the shaft is rotated let us say at 900 revolutions per
minute then the shaft is cyclically stressed 900 times a minute.
To illustrate how damaging such type load is, take a paper clip, bend it out straight, then
pick a spot in the middle, and bend the clip 90 back and forth at that spot (from straight to
"L" shaped and back). When you bend it the other way, you reverse the stresses (fully
reversing fatigue). You can notice that the clip will break in a few to about a maximum of
10 cycles.
When you are bending it you are plastically-deforming the metal, you are, by definition,
exceeding its yield stress. When you bend it in one direction, you are applying a high
tensile stress to the fibers on one side of the OD, and a high compressive stress on the
fibers on the opposite side. In the next cycle the phenomena is repeated, the tensile stress
fibers are now compressed and vice versa, thus the material is cyclically strained which
ultimately results in their premature failure.

Fatigue Failure
Often machine members subjected to such repeated or cyclic stressing are found to have
failed even when the actual maximum stresses were below the ultimate strength of the
material, and quite frequently at stress values even below the yield strength. The most
distinguishing characteristics is that the failure had occurred only after the stresses have
been repeated a very large number of times. Hence the failure is called fatigue failure.

Fatigue Failure- Mechanism

A fatigue failure begins with a small crack; the initial crack may be so minute and can not
be detected. The crack usually develops at a point of localized stress concentration like
discontinuity in the material, such as a change in cross section, a keyway or a hole. Once a
crack is initiated, the stress concentration effect become greater and the crack propagates.
Consequently the stressed area decreases in size, the stress increase in magnitude and the
crack propagates more rapidly. Until finally, the remaining area is unable to sustain the
load and the component fails suddenly. Thus fatigue loading results in sudden, unwarned
failure.
Fatigue Failure Stages
Thus three stages are involved in fatigue failure namely
-Crack initiation
-Crack propagation
-Fracture
The macro mechanism of fatigue failure is briefly presented now.
Crack initiation
Areas of localized stress concentrations such as fillets, notches, key ways, bolt holes and
even scratches or tool marks are potential zones for crack initiation.
Crack also generally originate from a geometrical discontinuity or metallurgical stress
raiser like sites of inclusions
As a result of the local stress concentrations at these locations, the induced stress goes
above the yield strength (in normal ductile materials) and cyclic plastic straining results
due to cyclic variations in the stresses.
On a macro scale the average value of the induced stress might still be below the yield
strength of the material.
During plastic straining slip occurs and (dislocation movements) results in gliding of
planes one over the other. During the cyclic stressing, slip saturation results which make
further plastic deformation difficult.
As a consequence, intrusion and extrusion occurs creating a notch like discontinuity in
the material.
Crack propagation
This further increases the stress levels and the process continues, propagating the cracks
across the grains or along the grain boundaries, slowly increasing the crack size.
As the size of the crack increases the cross sectional area resisting the applied stress
decreases and reaches a thresh hold level at which it is insufficient to resist the applied
stress.
Final fracture
As the area becomes too insufficient to resist the induced stresses any further a sudden
fracture results in the component.

How is the fatigue strength of a metal determined?

The fatigue behavior of a specific material, heat-treated to a specific strength level, is
determined by a series of laboratory tests on a large number of apparently identical
samples of that specific material.
These laboratory samples are optimized for fatigue life. These laboratory samples are now
standardized in geometry and configuration such that no extraneous factors other than the
applied stress influence the fatigue life. They are machined with shape characteristics
which maximize the fatigue life of a metal, and are highly polished to provide the surface
characteristics which enable the best fatigue life. A single test consists of applying a
known, constant bending stress to a round sample of the material, and rotating the sample
around the bending stress axis until it fails. As the sample rotates, the stress applied to any
fiber on the outside surface of the sample varies from maximum-tensile to zero to
maximum-compressive and back. The test mechanism counts the number of rotations
(cycles) until the specimen fails. A large number of tests is run at each stress level of
interest, and the results are statistically massaged to determine the expected number of
cycles to failure at that stress level. The most widely used fatigue-testing device is the R.R
Moore high-speed rotating beam machine. This machine subjects the specimen to pure
bending (no transverse shear).

Figure 2.1

The S-N Diagram

Tests on several specimens are conducted under identical conditions with varying levels of
stress amplitude. The cyclic stress level of the first set of tests is some large percentage of
the Ultimate Tensile Stress (UTS), which produces failure in a relatively small number of
cycles. Subsequent tests are run at lower cyclic stress values until a level is found at which
the samples will survive 10 million cycles without failure.

The results are plotted as an S-N diagram (see the figure) usually on semi-log or on log-log
paper, depicting the life in number of cycles tested as a function of the stress amplitude. A
typical plot is shown in the figure below for two class of materials.

Figure 2.2
Endurance or Fatigue Limit
In the case of the steels, a knee (flattening or saturation) occurs in the graph, and beyond
this knee failure will not occur, no matter how large the numbers of cycles are. The
strength (stress amplitude value) corresponding to the knee is called the endurance limit
(Se) or the fatigue limit. However the graph never does become horizontal for non-ferrous
metals and alloys, hence these materials do not have an endurance limit.

Endurance or Fatigue limit - definition

Endurance or fatigue limit can be defined as the magnitude of stress amplitude value at or
below which no fatigue failure will occur, no matter how large the number of stress
reversals are, in other words leading to an infinite life to the component or part being
stressed. For most ferrous materials Endurance limit (Se) is set as the cyclic stress level
that the material can sustain for 10 million cycles.
In general, steel alloys which are subjected to a cyclic stress level below the EL (properly
adjusted for the specifics of the application) will not fail in fatigue. That property is
commonly known as "infinite life". Most steel alloys exhibit the infinite life property, but
it is interesting to note that most aluminum alloys as well as steels which have been
casehardened by carburizing, do not exhibit an infinite-life cyclic stress level (Endurance
Limit).

S-N Diagram

Figure 2.3
To find the fatigue strength and the endurance limit of a material, quite a large number of
tests are necessary because of the statistical nature of fatigue. For the first test in the high
speed rotating beam test, the bending moment is kept slightly less than the ultimate tensile
strength of the material. Then the stress is slightly reduced and a second test is carried out.
This process is continued and the results are plotted as fatigue strength Sf versus stress
cycles N popularly known as S-N Diagram as shown above, on log log paper. For the
ferrous materials, like steels the graph becomes horizontal at 106 cycles indicating the
fatigue failure will not occur beyond this whatever great may be the number of the cycles.
The corresponding fatigue strength is known as endurance limit of the material.
Low Cycle Fatigue
The body of knowledge available on fatigue failure from N=1 to N=1000 cycles is
generally classified as low-cycle fatigue.

High Cycle Fatigue

High-cycle fatigue, then, is concerned with failure corresponding to stress cycles greater
than 103 cycles.(Note that a stress cycle (N=1) constitutes a single application and removal
of a load and then another application and removal of load in the opposite direction.
Thus N= means that the load is applied once and then removed, which is the case with
the simple tensile test.)

Finite and Infinite Life

We also distinguish a finite-life and an infinite-life region. Finite life region covers life in
terms of number of stress reversals upto the knee point.(in case of steels) beyond which is
the infinite-life region. The boundary between these regions cannot be clearly defined
except for specific materials; but it lies somewhere between 106 and 107 cycles, for
materials exhibiting fatigue limit.

Factors Considered While Designing Against Fatigue: Any material against fatigue
loading is designed in the two ways i.e design for finite life and design for infinite life. The
design for finite life is based on the fatigue strength whereas the design for infinite life is
based on the endurance limit. Hence in both the cases the following modifying factors
should be considered while designing against the fatigue:
Size factor;
Surface finish factor;
Temperature Factor;
Reliability factor
Modifying factor for stress concentration
Environmental factor
Application factor etc.
In addition to above factor the type of loading that is repeated, fluctuating or completely
reversed load.
Size Factor: A little consideration will show that if the size of the standard specimen is
increased, then the endurance limit of the material will decrease. This is due to the fact that
a longer specimen will have more defects than a smaller one.
Let Ksz = Size factor.
1. The value of size factor is taken as unity for the standard specimen having nominal
diameter of 7.657 mm.
2. When the nominal diameter of the specimen is more than 7.657 mm but less than
50 mm, the value of size factor may be taken as 0.85.
3. When the nominal diameter of the specimen is more than 50 mm, then the value of
size factor may be taken as 0.75.
Surface Finish Factor: When a machine member is subjected to variable loads, the
endurance limit of the material for that member depends upon the surface conditions,
shows in the following figure, the values of surface finish factor for the various surface
conditions and ultimate tensile strength. When the surface finish
factor is known, then the endurance limit for the material of the machine member may be
obtained by multiplying the endurance limit and the surface finish factor. We see that for a
mirror polished material, the surface finish factor is unity. In other words, the endurance
limit for and for non ferrous materials it can be taken as unity.
Let Ksur = Surface finish factor.

Figure 2.4

Stress Concentration Effect

Localization of high magnitude stresses in the vicinity of any irregularity or discontinuity
or abrupt change in the cross section of the mechanical component is known as stress
concentration effect.

Fatigue Stress Concentration

The existence of irregularities or discontinuities, such as holes, grooves, or notches, in a
part increase the magnitude of stresses significantly in the immediate vicinity of the
discontinuity. Fatigue failure mostly originates from such places. Hence its effect must be
accounted and normally a fatigue stress-concentration factor K is applied when designing
f
against fatigue, even if the materials behaviour is ductile.
Fatigue Stress Concentration Factor
Recall that a stress concentration factor need not be used with ductile materials when they
are subjected to only static loads, because (local) yielding will relieve the stress
concentration. However under fatigue loading, the response of material may not be
adequate to nullify the effect and hence has to be accounted. The factor K commonly
f
called a fatigue stress concentration factor is used for this. Normally, this factor is used to
indicate the increase in the stress; hence this factor is defined in the following manner.
Fatigue stress concentration factor can be defined as

Notch Sensitivity: It may be defined as the degree to which the theoretical effect of stress
concentration is actually reached.

Notch Sensitivity Factor q: Notch sensitivity factor is defined as the ratio of increase in
the actual stress to the increase in the nominal stress near the discontinuity in the specimen.

Where, Kf and Kt are the fatigue stress concentration factor and theoretical stress
concentration factor.

Figure 2.5
Methods of reducing the stress concentration are as follows:

The presence of stress concentration cannot be totally eliminated but it may be reduced to
some extent.

To reduce the stress

concentration, the stress lines
should maintain their spacing
as far as possible.

The change in the cross

section should be gradual to
the possible extent. The
following figures shows the
use of notches, drilled holes or
removing the extra material,
which may be adopted in the
design in order to reduce the
stress concentration effect.
The stress concentration effect
can also be reduced by
improving the surface finish. Figure 2.6

Relation Between Endurance Limit and Ultimate Tensile Strength

It has been found experimentally that endurance limit (e) of a material subjected to
fatigue loading is a function of ultimate tensile strength (u). The following figure shows
the endurance limit of steel corresponding to ultimate tensile strength for different surface
conditions. Following are some empirical relations commonly used in practice:

For steel, e = 0.5 u ;

For cast steel, e = 0.4 u ;
For cast iron, e = 0.35 u ;
For non-ferrous metals and alloys, e = 0.3 u

Figure 2.7
Goodman Method for Combination of Stresses:
A straight line connecting the endurance limit (e) and the ultimate strength (u), as shown
by line AB in figure given below follows the suggestion of Goodman. A Goodman line is
used when the design is based on ultimate strength and may be used for ductile or brittle
materials.

Figure 2.8

Now from similar triangles COD and PQD,

This expression does not include the effect of stress concentration. It may be noted that for
ductile materials, the stress concentration may be ignored under steady loads. Since many
machine and structural parts that are subjected to fatigue loads contain regions of high
stress concentration, therefore equation (i) must be altered to include this effect. In such
cases, the fatigue stress concentration factor (Kf) is used to multiply the variable stress
(v). The equation (i) may now be written as
Soderberg Method for Combination of Stresses
A straight line connecting the endurance limit (e) and the yield strength (y), as shown by
the line AB in following figure, follows the suggestion of Soderberg line. This line is used
when the design is based on yield strength. the line AB connecting e and y, as shown in
following figure, is called Soderberg's failure stress line. If a suitable factor of safety
(F.S.) is applied to the endurance limit and yield strength, a safe stress line CD may be
drawn parallel to the line AB. Let us consider a design point P on the line CD. Now from
similar triangles COD and PQD,

Figure 2.9
Modified Goodman Diagram:
In the design of components subjected to fluctuating stresses, the Goodman diagram is
slightly modified to account for the yielding failure of the components, especially, at
higher values of the mean stresses. The diagram known as modified Goodman diagram and
is most widely used in the design of the components subjected to fluctuating stresses.
There are two modified Goodman diagrams for the axial, normal or bending stresses and
shear or torsion shear stresses separately as shown below. In the following diagrams the
safe zones are ABCOA.

Figure 2.10
DESIGN APPROACH FOR FATIGUE LOADINGS
Design for Infinite Life
It has been noted that if a plot is made of the applied stress amplitude verses the number of
reversals to failure to (S-N curve) the following behaviour is typically observed.

Figure 2.11
Completely Reversible Loading
If the stress is below the (the endurance limit or fatigue limit), the component has
effectively infinite life. for the most steel and copper alloys. If the material does not have a
well defined e, Then, endurance limit is arbitrarily defined as Stress(0.35- 0.50) that
gives For a known load (Moment ) the section area/(modulus) will be designed such that
the resulting amplitude stress will be well below the endurance limit.
Design approach can be better learnt by solving a problem.

Q. A machine component is subjected to bending stress which fluctuates between

300 N/mm2 tensile and 150 N/mm2 compressive in cyclic manner. Using the
Goodman and Soderberg criterion, calculate the minimum required ultimate tensile
strength of the material. Take the factor of safety 1.5 and the endurance limit in
reversed bending as 50% of ultimate tensile strength.

Solution:

Assuming the yield strength S yt = 0.55 ultimate strength S ut

s + s min 300 + (- 150)
Mean stress " s m = max = = 75MPa;
2 2
s - s min 300 - (- 150)
Amplitude stress " s a = max = = 225MPa;
2 2
As per Goodman Relation :
1 s s
= m + a
f.o.s S ut S e
As given S e = 0.5S ut
1 75 225 1 525
= + = S ut = 787.5MPa;
1.5 S ut 0.5S ut 1.5 S ut
As per Soderberg Relation :
1 s s
= m + a
f.o.s S yt S e
As given S yt = 0.55S ut
1 75 225 1 586.36
= + = S ut = 879.545MPa;
1.5 0.55S ut 0.5S ut 1.5 S ut

Q. A circular bar is subjected to a completely reversed axial load of 150 kN. Determine
the size of the bar for infinite life, if it is made of plain carbon steel having ultimate
tensile strength of 800 N/mm2 and yield point in tension of 600 N/mm2. Assuming
the surface finish factor as 0.80, size factor 0.85, reliability as 90%, and modifying
factor for the stress concentration as 0.9.
Solution:
GIVEN:

Maximum Axial Load " Pmax " = +150 kN ; Minimum Axial Load " Pmin " = -150 kN ;
Ultimate tensile strength of the material of the bar " S ut " = 800 N/mm 2 ;
Yield point in tension of the material of the bar " S yt " = 600 N/mm 2 ;
Surface finish factor " k a " = 0.80 ; Size factor " k b " = 0.85; Reliability factor " k c " = 0.90 ; Modifying
the stress concentration
factor " k e " = 0.90.

ASSUMING:
The temperature factor k d = 1.0; & miscelleneous factor k g = 1.0;
Factor of safety = 1.0;
Endurance Limit of the material:
S e/ = 0.5 S ut = 0.5 800 = 400MPa
Modified Endurance Limit of the Material of the Bar:
S e = k a k b k c k d k e k g S e/ = 0.80 0.85 0.90 1.0 0.9 1.0 400 = 220.32 MPa;

Amplitude and Mean Normal Stresses:

P - Pmin 150 - (-150 )
Amplitude Load " Pa " = max = = 150 kN;
2 2
P + Pmin 150 + (- 150 )
Mean Load " Pm " = max = = 0 kN;
2 2
4 Pa 4 150 190.9859 190985.9
Amplitude Stress " s a " = = = kN / mm 2 = N/mm 2 ;
2 2 2 2
p d pd d d
Mean Stress " s m " = 0 N/mm 2 ;
Using Modified Goodman Diagram:
The Load Line becomes the amplitude axis.
Hence the design equation may be written for infinite life as:
190985.9
S e s a 220.32 = ;
d2
190985.9
d d 29.44
220.32
d = 30mm.

(b) A cantilever beam made of cold drawn

steel 20C8 (Sut =540 N/mm2) is subjected to
a completely reversed load of 1000 N as
shown in below figure. The corrected
endurance limit for the material of the
beam may be taken as 123.8 N/mm2.
Determine the diameter d of the beam
for a life of 10000 cycles.
Solution:
GIVEN:
Maximum Axial Load " Pmax " = +1000 N;
Minimum Axial Load " Pmin " = -1000 N;
Ultimate tensile strength of the material of the bar " S ut " = 540 N/mm 2 ;
Corrected Endurance Limit " S e " = 123.8 N / mm 2

USING THE S-N DIAGRAM:

The values of various points
0.9S ut = 0.9 540 = 486 N/mm 2 ;
log10 (0.9S ut ) = log10 (486) = 2.6866;
log10 (S e ) = log10 (123.8) = 2.0927;
log10 ( N ) = log10 (10000) = 4.0
From the S-N Diagram:
AE =
AD EF
=
(2.6866 - 2.0927 ) (4 - 3) = 0.198
DB (6 - 3)
Therefor
log10 S f = 2.6866 - AE = 2.6866 - 0.198 = 2.4886;
S f = 308.03 N/mm 2 ;
And
32M b 32 M b 32 (1000 150 )
Sf = s b = d3 = =
pd 3 p Sf p 308.3
d = 17.05 mm.

Q. A flat bar as shown in the figure 1

is subjected to an axial load F
equal to 500 N. Assuming that the
stress in the bar is limited to 200
MPa, determine the thickness of
the bar. All dimensions are in mm.
Solution: The stress concentration factor at circular hole kt =2.35

The stress concentration factor at circular hole kt =1.78

Hence the critical section is at the section of circular hole. The stress magnitude
induced at this location

F 500 7.143
s= = = N / mm 2 ;
t (100 - 30) t 70 t

For successful design

7.143
200;
t
t 0.036mm;

However the minimum cross section area A =62t mm2;

F 500 8.06452
s= = = N / mm 2 ;
62t t 62 t

For successful design

8.06452
200;
t
t 0.0403mm;

Hence the thickness of the plate = 0.0403 mm.

Q. A forged steel bar 50 mm in diameter is subjected to a reversed bending stress

of 300 MPa. The bar is made of 40C8. Calculate the life of the bar for a
reliability of 90%

Given: The material 40C8,

The diameter of the shaft = d=50mm;
Reversed bending stress = 300MPa.
Reliability = 90%
Assuming: ut= 600MPa ; yt=380 MPa Fatigue stress concentration factor=1.612
;
Assuming the size factor Ksz = 0.85 ;
Surface finish factor Ksur = 0.89
Reliability factor Kre=0.892
Endurance Limit:

S e = 0.5s ut Qs ut < 1400MPa;

S e = 0.5 600 = 300MPa;
Modified Endurance Limit:
 1
S e = K sz K sur K re S e
Kf
1
= 0.85 0.89 0.892 300 = 125.583 MPa
1.612

Using the S-N diagram

log10 (S ut ) = log10 (600) = 2.778;

0.9 log10 (S ut ) = 2.500
log10 (S e ) = log10 (125.583) = 2.099;
log10 (s a ) = log10 (300) = 2.477;
2.50 - 2.099 2.477 - 2.099
=
6-3 6 - log10 N
6 - log10 N = 2.82793
log10 N = 6 - 2.82793 = 3.17207
N = 1486.1752 reversals

Q. A shaft subjected to bending moment varying from -200 N m to +500 N m and a

varying torque from 50 N m to 175 N m. If material of the shaft is 30C8, stress
concentration factor is 1.85, notch sensitivity is 0.95 reliability 99.9% and
factor of safety is 1.5, find the diameter of the shaft.

Solution: Mean or average bending moment,

M max + M min 500 + (-200)

Mm = = = 150 N - m ;
2 2

Amplitude or variable bending moment

M max - M min 500 - (-200)

Ma = = == 350 N - m
2 2

Mean or average torque,

Tmax + Tmin 175 + (50)

Tm = = = 112.5 N - m ;
2 2

Amplitude or variable torque

Tmax - Tmin 175 - (50)

Ta = = == 62.5 N - m
2 2

Equivalent mean and amplitude bending moments

1 1
M em = M m + M m2 + Tm2 = 150 + 150 2 + 112.5 2 = 168.75N - m = 168750 N - mm;
2 2
1 1
M am = M a + M a2 + Ta2 = 350 + 350 2 + 62.5 2 = 352.77N - m = 352770 N - mm;
2 2
 Mean or average bending stress,

32Mem 32 168750 1718874

sm = 3
= 3
= ;;
p d p d d3

Amplitude or variable bending moment

32Ma 32 352.77 3593286

sa = 3
= 3
= ;
p d p d d3

Material properties: ut= 490MPa ; yt=270 MPa (assumed)

Given Notch sensitivity q = 0.95 ;

Assuming the size factor Ksz = 0.85 ;

Surface finish factor Ksur = 0.89

Reliability factor Kre=0.75 corresponding to 99.9% reliability (Assumed)

The fatigue stress concentration factor

K f = 1 + q( K t - 1) = 1 + 0.95(1.85 - 1) = 1.8075

Endurance Limit:
S e = 0.5s ut Qs ut < 1400MPa;
S e = 0.5 490 = 245MPa;
Modified Endurance Limit:
1 1
S e = K sz K sur K re Se = 0.85 0.89 0.75 245 = 76.91 MPa
Kf 1.8075
We know that according to Soderberg formula;

1 s s
= m + a;
f .o.s. s yt S e
1718874 3593286
1 d3 d3
= + ;
1 .5 270 76.91
d 3 1718874 3593286
= + ;
1 .5 270 76.91
d 3 = 1.5 [100519 + 6083178 ] = 79630.291
d = 43 .022 mm 45 mm;
We know that according to Goodman's formula
 1 s s
= m + a;
f .o.s. s ut S e
1718874 3593286
1 d3
d3
= + ;
1.5 490 76.91
d 3 1718874 3593286
= + ;
1.5 490 76.91
d 3 = 75342.85
d = 42.235mm 45 mm;

Hence the shaft diameter is 45 mm. Ans.

 REVITED JOINT
What is joint?
The means to keep the two things together is known as joint.
Components of any Joint:
There are two basic components of any joint:
1. The components to be joined
2. Fastener or joining elements
Types of Joints:
1. Permanent Joints;
2. Semi-Permanent Joints;
3. Temporary Joints.
Permanent Joint:

If the joined or fastened element joint can not open or separated without causing any
damage them, then joint is known as permanent joint. Like Welded Joints

Semi-Permanent Joint:

If the joined or fastened element joint can open or separated with a marginal damage
to any one of the joined parts, then joint is known as semi-permanent joint. Like
Riveted Joints

Temporary Joint:

If the joined or fastened element joint can open or separated without causing any
damage them, then joint is known as temporary joints. Like Bolted Joints

Components of Riveted Joints: There are two basic components of

riveted joints:
1. Rivets and;
2. Two or more plates.

Rivet: Rivet is a cylindrical bar having a head and tail portion as its
integral part.

Material Used for Rivets: The rivet head are made by the following
two methods:

Cold Heading and;

Hot forging;
Therefore the material of the rivets must possess the sufficient DUCTILITY and
TOUGHNESS.
The popular materials for the rivets are:
Steel, Brass, Aluminium & Copper.
as per the requirement of the application for fluid tight joints the steel rivets are used

AS per Indian standard IS: 2998-1982:

The material of rivet must have the following properties:
2
Minimum tensile strength = 40 N/mm ;And
Elongation capacity not less than 26%.

TYPES OF RIVET HEADS

Figure 2.12

Methods of Riveting
If the shank diameter of the rivet is more than 12 mm than machine riveting is preferred for
cold riveting and if the shank diameter of the rivet is more than 18 mm Hot machine
riveting is preferred.

Figure 2.13
Advantages of Riveted Joints

1. Production rates are high.

2. Initial and maintenance costs for equipment are low.

3. Either metallic or non- metallic materials can be joined.

4. Dissimilar metals and assemblies having a number of parts with non uniform
thickness can readily be fastened.

5. Unskilled labor can be used to operate equipment.

6. The rivets can be made of variety of material ranging from monel or inconel to lead
or zinc.

7. The rivets can be used not only as a fastener but as a pivot or other functional
component.

Limitations of Riveted Joints:

1. In riveted joints the parts once fastened can not be easily dissembled.
2. The riveted joints are not as fluid tight as welded joints.
3. The riveted joints weaken the parts to be connected.
4. The complicated components can not be riveted.
5. The riveted joints can not be produced as fast as welded joints.
6. As compared to welded joints the riveted joints lead to bulky construction.
7. The protruding rivet heads are inconvenient and undesirable in many applications.

TYPES OF RIVETED JOINTS:

Lap
Joint:

In a lap joint , the plates to be connected overlap each other and the rivet pass
through drilled coaxial holes in the overlapped plates.

Butt Joint:

In butt riveting or joint, the plates are kept in alignment and a butt strap or a cover
plate (either single or double) is placed over the joint and rivets are inserted through holes
in plates aligned over one another.
Figure 2.13

Figure 2.14
 Figure 2.15

Figure 2.16

Caulking and Fullering:

In order to make the joints leak proof or fluid tight in pressure vessels like steam
boilers, air receivers and tanks etc. a process known as caulking is employed. In this
process, a narrow blunt tool called caulking tool, about 5 mm thick and 38 mm in breadth,
is used. The edge of the tool is ground to an angle of 80. The tool is moved after each
blow along the edge of the plate, which is planed to a bevel of 75 to 80 to facilitate the
forcing down of edge. It is seen that the tool burrs down the plate at A in Fig. (a) forming a
metal to metal joint. In actual practice, both the edges at A and B are caulked. The head of
the rivets as shown at C are also turned down with a caulking tool to make a joint steam
tight. A great care is taken to prevent injury to the plate below the tool.
 A more satisfactory way of making the joints staunch is known as fullering which
has largely superseded caulking. In this case, a fullering tool with a thickness at the end
equal to that of the plate is used in such a way that the greatest pressure due to the blows
occur near the joint, giving a clean finish, with less risk of damaging the plate. A fullering
process is shown in Fig.(b).

Figure 2.14
Modes of Failure of Riveted Joint

Strength of the Riveted Joints: The strength of a riveted joint is defined as the maximum
force which the joint can take without failure per pitch length.
Strength of riveted joint =least among " Pt , Ps, and Pc "
Efficiency of the Riveted Joint:

Q. A bracket supported by means of four

rivets of the same size as shown in
below figure. Determine the diameter of
the rivets if the maximum permissible
shear stress for the material of the rivet is
as 150 N/mm2.

Solution:
Given :
W = 20000 N; n = 4; t all = 150 N / mm 2 ; e = 80 mm;
1. C.G. of the rivet system is at the gemetric center of the rivet system.
2. Primary Shear :
The primary shear force on each rivet is
W 20000
Fp = = = 5000 N ;
n 4
3. Secondary Shear Force :
W.e = Fs1 .l1 + Fs2 .l 2 + Fs3 .l 3 + Fs4 .l 4
W.e = wl12 + wl 22 + wl 32 + wl 42
W.e
w= = 355.55 N/mm;
l12 + l 22 + l 32 + l42
From the figure it is seen that load is maximum on rivets 1 and 4. The secondary shear force on rivet 1 and 4
is
Fs1 = Fs 4 = wl1 = 355.55 45 = 16000 N ;
4. Resultant Shear Force :

FR1 = F p2 + Fs21 + 2 F p Fs1 cos q

FR1 = F p2 + Fs21 + 2 F p Fs1 cos 90 = FR1 = F p2 + Fs21 = FR1 = 5000 2 + 16000 2 = 16763.055 N;
5. Rivet Size :
t all = 150 N / mm 2
The shear stress induced in rivet 1 is,
F 16763.055
t = R1 150 =
A pd 2 4( )
d = 11.93 mm;

From design data book the standard diameter of rivet is 12 mm;

i.e d = 12 mm

Design of Boiler Joints

The boiler has a longitudinal joint as well as circumferential joint. The longitudinal
joint is used to join the ends of the plate to get the required diameter of a boiler. For this
purpose, a butt joint with two cover plates is used. The circumferential joint is used to get
the required length of the boiler. For this purpose, a lap joint with one ring overlapping the
other alternately is used. Since a boiler is made up of number of rings, therefore the
longitudinal joints are staggered for convenience of connecting rings at places where both
longitudinal and circumferential joints occur.

Assumptions in Designing Boiler Joints

The following assumptions are made while designing a joint for boilers :
1. The load on the joint is equally shared by all the rivets. The assumption implies that the
shell and plate are rigid and that all the deformation of the joint takes place in the rivets
themselves.
2. The tensile stress is equally distributed over the section of metal between the rivets.
3. The shearing stress in all the rivets is uniform.
4. The crushing stress is uniform.
5. There is no bending stress in the rivets.
6. The holes into which the rivets are driven do not weaken the member.
7. The rivet fills the hole after it is driven.
8. The friction between the surfaces of the plate is neglected.

Design of Longitudinal Butt Joint for a Boiler

According to Indian Boiler Regulations (I.B.R), the following procedure should be adopted
for the design of longitudinal butt joint for a boiler.
1. Thickness of boiler shell. First of all, the thickness of the boiler shell is determined by
using the thin cylindrical formula, i.e.

2. Diameter of rivets. After finding out the thickness of the boiler shell (t), the diameter of
the rivet hole (d) may be determined by using Unwin's empirical formula, i.e.

But if the thickness of plate is less than 8 mm, then the diameter of the rivet hole may be
calculated by equating the shearing resistance of the rivets to crushing resistance. In no
case, the diameter of rivet hole should not be less than the thickness of the plate, because
there will be danger of punch crushing
3. Pitch of rivets. The pitch of the rivets is obtained by equating the tearing resistance of
the plate to the shearing resistance of the rivets. It may noted that
(a) The pitch of the rivets should not be less than 2d, which is necessary for the formation
of head.
(b) The maximum value of the pitch of rivets for a longitudinal joint of a boiler as per
I.B.R. is

4. Distance between the rows of rivets. The distance between the rows of rivets as
specified by
Indian Boiler Regulations is as follows :
(a) For equal number of rivets in more than one row for lap joint or butt joint, the distance
between the rows of rivets ( pb) should not be less than
0.33 p + 0.67 d, for zig-zig riveting, and
2 d, for chain riveting.
(b) For joints in which the number of rivets in outer rows is half the number of rivets in
inner rows and if the inner rows are chain riveted, the distance between the outer rows and
the next rows should not be less than
0.33 p + 0.67 or 2 d, whichever is greater.
The distance between the rows in which there are full number of rivets shall not be less
than 2d.
(c) For joints in which the number of rivets in outer rows is half the number of rivets in
inner rows and if the inner rows are zig-zig riveted, the distance between the outer rows
and the Next rows shall not be less than 0.2 p + 1.15 d.
The distance between the rows in which there are full number of rivets (zig-zag) shall not
be less than 0.165 p + 0.67 d.
Note : In the above discussion, p is the pitch of the rivets in the outer rows.

5. Thickness of butt strap. According to I.B.R., the thicknesses for butt strap (t1) are as
given below :
(a) The thickness of butt strap, in no case, shall be less than 10 mm.

(c) For unequal width of butt straps, the thicknesses of butt strap are
t1 = 0.75 t, for wide strap on the inside, and
t2 = 0.625 t, for narrow strap on the outside.
6. Margin. The margin (m) is taken as 1.5 d.

Design of Circumferential Lap Joint for a Boiler

The following procedure is adopted for the design of circumferential lap joint for a boiler.
1. Thickness of the shell and diameter of rivets. The thickness of the boiler shell and the
diameter of the rivet will be same as for longitudinal joint.
2. Number of rivets. Since it is a lap joint, therefore the rivets will be in single shear.
Shearing resistance of the rivets,

where n = Total number of rivets.

Knowing the inner diameter of the boiler shell (D), and the pressure of steam (P), the total
shearing load acting on the circumferential joint,
 Figure 2.16
3. Pitch of rivets. If the efficiency of the longitudinal joint is known, then the efficiency of
the circumferential joint may be obtained. It is generally taken as 50% of tearing efficiency
in longitudinal joint, but if more than one circumferential joints is used, then it is 62% for
the intermediate joints.
Knowing the efficiency of the circumferential lap joint (c), the pitch of the rivets for the
lap joint ( p1) may be obtained by using the relation :

5. After finding out the number of rows, the type of the joint (i.e. single riveted or double
riveted etc.) may be decided. Then the number of rivets in a row and pitch may be re-
adjusted. In order to have a leak-proof joint, the pitch for the joint should be checked from
Indian Boiler Regulations.

6. The distance between the rows of rivets (i.e. back pitch) is calculated by using the
relations as discussed in the previous article.
7. After knowing the distance between the rows of rivets (pb), the overlap of the plate may
be fixed by using the relation,
Overlap = (No. of rows of rivets 1) pb + m
where m = Margin.
There are several ways of joining the longitudinal joint and the circumferential joint

Q. A longitudinal joint for a boiler is to be designed for a steam pressure of 2.5

N/mm2 with an efficiency of 85%.The inside diameter of the largest course of
the drum is 1.35 meter. The allowable stresses may be taken as in tension =
78.0 N/mm2, in shear 62.5 N/mm2, in crushing = 135.0 N/mm2

Solution: Given:

The internal presure " P" = 2.5 N/mm 2 ; Efficiency of the joint "h " = 0.85;
The inside diameter of the drum " D" = 1.35 meter;
The allowable stresses may be taken as in tension "s t " = 78.0 N/mm2,

The allowable shear stress "t " = 62.5 N/mm 2 ;

The allowable crushing stress "s c " = 135.0 N/mm 2 ;
PD 2.5 1350
The thickness of the plate t= + 1.0 = + 1.0 = 26.5 mm;
2s th 2 78.0 0.85
THE RIVET HOLE AND RIVET DIAMTER:

d = 6.05 t = 6..05 26.5 = 31.1 mm;

Assuming the clearance of 1.5 mm, then the rivet diamter corresponding to the calculated diamter of rivet hole diameter
d r = 31.1 - 1.5 = 29.6mm;
S tan dard rivet diameter " d r " = 30mm; {Ref. : Table # 5.3b Page #68A}
The rivet hole diamter " d" = 30 + 1.5 = 31.5mm;

THE PITCH:
Equating the shear and tearing resistance of the joint that is
p p
(p - d ) t s t
= 1.875 5 d 2 t + d 2 t
4 4
Assuming the joint is tripple riveted double butt strap zig - zag riveted joint in which the pitch in the inner rows
are hlf that o f the outer row.
p
(p - 31.5) 26.5 78.0 = 1.875 5 31.5 2 62.5
4
p = 252.4132 mm;
The permissible maximum pitch as per I.B.R
p max = k 1 t + 41mm {Ref. : Equation # 5.23b Page #65}
p max = 6 26.5 + 41 = 200mm
Hence the pitch for the joint is 200 mm.
 BACK PITCH:

The back pitch between the outer row and the inner row
p b = 0.2p + 1.15d = 0.2 200 + 1.15 31.5 = 76.225 76mm; {Ref. : Equation # 5.33a, page #66}
The back pitch between the succesive inner rows
p b = 0.165p + 0.67d = 0.165 200 + 0.67 31.5 = 54.105 54mm; {Ref. : Equation # 5.33b, page #66}
THE BUTT STRAP THICKNESS: Assuming the unequal width of the
straps

Inner strap thickness " t i " = 0.750t = 0.750 26.5 = 19.875 20 mm; {Ref. : Equation # 5.8b, page #63}
Outer strap thickness " t o " = 0.625t = 0.625 31.5 = 16.5625 17 mm; {Ref. : Equation # 5.8a, page #63}

LENGTH OF THE RIVET:

L = t + (1.5 to 1.7 ) d {Ref. : Equation # 5.9, page #63}
L = t + (1.6 ) d = (17 + 26.5 + 20) + 1.6 31.5 = 113.9 114mm;
MARGIN:
m 1.5 d (Ref. : Equation # 2.34, page# 66}
m 1.5 31.5 = 47.25 mm
Taking m = 48 mm;
EFFICIENCY OF THE DESIGNED EFFICIENCY:
Strength of the unpunched plate = s t p t = 78.0 200 26.5 = 413400 N;
Tearing resis tan ce of the plate = (p - d ) t s t = (200 - 31.5) 26.5 78 = 348289.5 N;

p p
Shearing resistance of the joint = 1.875 5 d 2 t = 1.875 5 31.5 2 62.5 = 456627.731N;
4 4
Crushing resistance of the joint = 5 d t s c = 5 31.5 26.5 135 = 563456.25 N
Hence the design efficiency of the joint
348289.5
h= 100 = 84.25%
413400
Even the design efficiency is less than the desired efficiency but this lack in the
efficiency is very small as compared to the factor of safety usually taken for the design of
longitudinal joint is high i.e. 4 to 5. There for the joint may be assumed to successful.
 Unit-III
Keys: Key is a mechanical element used on shafts to secure rotating elements like gears,
pulleys, or sprockets and prevent relative motion between the two. A key way is a slot or
recess in a shaft and a hub of the rotating element to accommodate a key, and the keys
used in this way are known as sunk keys. The key transmits torque from the shaft to the
shaft supported element or vice versa. It is always inserted parallel to the axis of the shaft.

Rectangular Key: It is s sunk key having the rectangular section as shown in below
figure. It is used where higher stability is desired in connection. A rectangular key may be
tapered, whose width is kept constant while the height is tapered by 1:100. The keyway in
hub has the same taper as that in the key while the keyway in the shaft has uniform depth.
This key is used for light and medium duty industrial use.

Figure 3.1
Square Keys: A sunk key having square cross-section as shown in below figure is called
square key. The key is sunk half in the shaft and half in the hub, This type of the key is
used in light industrial machinery.

Figure 2.10

Figure 3.2
Splined shafts are the shaft on which the keys are made integral to it. They are used when
there is a relative axial motion between the shaft and the hub. The gear shifting mechanism
in automobile gear boxes requires such type of construction. Splines are cut on the shaft by
milling and on the hub by broaching. There are the following three types of the splined
shafts;
1. Straight splinted shaft;
2. Involute splinted shaft
3. Serrations;
In case of the straight splinted shaft the keys made integral to it are straight. In the involute
splined shafts the splines are in the form of concentric external and internal gear teeth
having the involute profile. And the serrations are straight splinted shafts but are used in
the applications where it is important to keep the overall size of the assembly as small as
possible.

Figure 3.3

INTRODUCTION TO SHAFTS-

A shaft is a rotating machine element which is used to transmit power from one place to
another. The power is delivered to the shaft by some tangential force and the resultant
torque (or twisting moment) set up within the shaft permits the power to be transferred to
various machines linked up to the shaft. In order to transfer the power from one shaft to
another, the various members such as pulleys, gears etc., are mounted on it. These
members along with the forces exerted upon them causes the shaft to bending. In other
words, we may say that a shaft is used for the transmission of torque and bending moment.
The various members are mounted on the shaft by means of keys or splines.
Notes: 1. The shafts are usually cylindrical, but may be square or cross-shaped in section.
They are solid in cross-section but sometimes hollow shafts are also used.

2. An axle, though similar in shape to the shaft, is a stationary machine element and is used
for the transmission of bending moment only. It simply acts as a support for some rotating
body such as hoisting drum, a car wheel or a rope sheave.

3. A spindle is a short shaft that imparts motion either to a cutting tool (e.g. drill press
spindles) or to a work piece (e.g. lathe spindles).

Material Used for Shafts

The material used for shafts should have the following properties :
1. It should have high strength.
2. It should have good machinability.
3. It should have low notch sensitivity factor.
4. It should have good heat treatment properties.
5. It should have high wear resistant properties.
The material used for ordinary shafts is carbon steel of grades 40 C 8, 45 C 8, 50 C 4 and
50 C 12.

The mechanical properties of these grades of carbon steel are given in the following table.

Mechanical properties of steels used for shafts

When a shaft of high strength is required, then an alloy steel such as nickel, nickel-
chromium or chrome-vanadium steel is used.

Types of Shafts
The following two types of shafts are important from the subject point of view :
1. Transmission shafts. These shafts transmit power between the source and the machines
absorbing power. The counter shafts, line shafts, over head shafts and all factory shafts are
transmission shafts. Since these shafts carry machine parts such as pulleys, gears etc.,
therefore they are subjected to bending in addition to twisting.
2. Machine shafts. These shafts form an integral part of the machine itself. The crank shaft
is an example of machine shaft.

Standard Sizes of Transmission Shafts

The standard sizes of transmission shafts are :
25 mm to 60 mm with 5 mm steps; 60 mm to 110 mm with 10 mm steps; 110 mm to 140
mm with 15 mm steps ; and 140 mm to 500 mm with 20 mm steps.
The standard length of the shafts are 5 m, 6 m and 7 m.
Stresses in Shafts
The following stresses are induced in the shafts :
1. Shear stresses due to the transmission of torque (i.e. due to torsional load).
2. Bending stresses (tensile or compressive) due to the forces acting upon machine
elements like gears, pulleys etc. as well as due to the weight of the shaft itself.
3. Stresses due to combined torsional and bending loads.
Design of Shafts
The shafts may be designed on the basis of
1. Strength, and
2. Rigidity and stiffness.

In designing shafts on the basis of strength, the following cases may be considered:
(a) Shafts subjected to twisting moment or torque only,
(b) Shafts subjected to bending moment only,
(c) Shafts subjected to combined twisting and bending moments, and
(d) Shafts subjected to axial loads in addition to combined torsional and bending loads.

Shafts Subjected to Twisting Moment Only

When the shaft is subjected to a twisting moment (or torque) only, then the diameter of the
shaft
may be obtained by using the torsion equation. We know that

where T = Twisting moment (or torque) acting upon the shaft,

J = Polar moment of inertia of the shaft about the axis of rotation,
= Torsional shear stress, and
r = Distance from neutral axis to the outer most fibre
= d / 2; where d is the diameter of the shaft.
We know that for round solid shaft, polar moment of inertia,

The equation (i) may now be written as

From this equation, we may determine the diameter of round solid shaft ( d ).
We also know that for hollow shaft, polar moment of inertia,
where do and di = Outside and inside diameter of the shaft,
and r = do / 2.
Substituting these values in equation (i), we have

Let k = Ratio of inside diameter and outside diameter of the shaft

= di / do
Now the equation (iii) may be written as

From the equations (iii) or (iv), the outside and inside diameter of a hollow shaft may be
determined.
It may be noted that
1. The hollow shafts are usually used in marine work. These shafts are stronger per kg of
material and they may be forged on a mandrel, thus making the material more
homogeneous than would be possible for a solid shaft.
When a hollow shaft is to be made equal in strength to a solid shaft, the twisting moment
of both the shafts must be same. In other words, for the same material of both the shafts,

2. The twisting moment (T) may be obtained by using the following relation:
We know that the power transmitted (in watts) by the shaft,

where T = Twisting moment in N-m, and

N = Speed of the shaft in r.p.m.
3. In case of belt drives, the twisting moment ( T ) is given by
T = (T1 T2 ) R
where T1 and T2 = Tensions in the tight side and slack side of the belt respectively, and
R = Radius of the pulley.

Shafts Subjected to Bending Moment Only

When the shaft is subjected to a bending moment only, then the maximum stress (tensile or
compressive) is given by the bending equation. We know that

where M = Bending moment,

I = Moment of inertia of cross-sectional area of the shaft about the axis of rotation.
b = Bending stress, and
y = Distance from neutral axis to the outer-most fibre.
We know that for a round solid shaft, moment of inertia,

Substituting these values in equation (i), we have

From this equation, diameter of the solid shaft (d) may be obtained.
We also know that for a hollow shaft, moment of inertia,

Again substituting these values in equation (i), we have

From this equation, the outside diameter of the shaft (do) may be obtained.

Shafts Subjected to Combined Twisting Moment and Bending Moment

When the shaft is subjected to combined twisting moment and bending moment, then the
shaft must be designed on the basis of the two moments simultaneously. Various theories
have been suggested to account for the elastic failure of the materials when they are
subjected to various types of combined stresses. The following two theories are important
from the subject point of view:
1. Maximum shear stress theory or Guest's theory. It is used for ductile materials such as
mild steel.
2. Maximum normal stress theory or Rankines theory. It is used for brittle materials such
as cast iron.
Let = Shear stress induced due to twisting moment, and
b = Bending stress (tensile or compressive) induced due to bending moment.
According to maximum shear stress theory, the maximum shear stress in the shaft,

Substituting the values of and b

The expression

is known as equivalent twisting moment and is denoted by Te. The

equivalent twisting moment may be defined as that twisting moment, which when acting
alone, produces the same shear stress () as the actual twisting moment. By limiting the
maximum shear stress (max) equal to the allowable shear stress () for the material, the
equation (i) may be written as

From this expression, diameter of the shaft ( d ) may be evaluated.

Now according to maximum normal stress theory, the maximum normal stress in the shaft,

The expression

is known as equivalent bending moment and is denoted by Me. The equivalent bending
moment may be defined as that moment which when acting alone produces the same
tensile or compressive stress (b) as the actual bending moment. By limiting the
maximum normal stress [b(max)] equal to the allowable bending stress (b), then the
equation (iv) may be written as

From this expression, diameter of the shaft ( d ) may be evaluated.

Notes: 1. In case of a hollow shaft, the equations (ii) and (v) may be written as

2. It is suggested that diameter of the shaft may be obtained by using both the theories and
the larger of the two values is adopted.
Shafts Subjected to Axial Load in addition to Combined Torsion and
Bending Loads
When the shaft is subjected to an axial load (F) in addition to torsion and bending loads as
in propeller shafts of ships and shafts for driving worm gears, then the stress due to axial
load must be added to the bending stress (b). We know that bending equation is

and stress due to axial load

Resultant stress (tensile or compressive) for solid shaft,

I
n case of a hollow shaft, the resultant stress,

I
n case of long shafts (slender shafts) subjected to compressive loads, a factor known as
column factor () must be introduced to take the column effect into account.
Stress due to the compressive load,

The value of column factor () for compressive loads* may be obtained from the following
relation :

This expression is used when the slenderness ratio (L / K) is less than 115. When the
slenderness ratio (L / K) is more than 115, then the value of column factor may be obtained
from the following relation:

where L = Length of shaft between the bearings,

K = Least radius of gyration,
y = Compressive yield point stress of shaft material, and
C = Coefficient in Euler's formula depending upon the end conditions.
The following are the different values of C depending upon the end conditions.
C =1, for hinged ends,
= 2.25, for fixed ends,
= 1.6, for ends that are partly restrained as in bearings.

Note: In general, for a hollow shaft subjected to fluctuating torsional and bending load,
along with an axial load,
the equations for equivalent twisting moment (Te) and equivalent bending moment (Me)
may be written as

I
t may be noted that for a solid shaft, k = 0 and d0 = d. When the shaft carries no axial load,
then F = 0 and when the shaft carries axial tensile load, then = 1.
Design of Shafts on the basis of Rigidity
Sometimes the shafts are to be designed on the basis of rigidity. We shall consider the
following two types of rigidity.
1. Torsional rigidity. The torsional rigidity is important in the case of camshaft of an I.C.
engine where the timing of the valves would be effected. The permissible amount of twist
should not exceed 0.25 per metre length of such shafts. For line shafts or transmission
shafts, deflections 2.5 to
3 degree per metre length may be used as limiting value. The widely used deflection for
the shafts is limited to 1 degree in a length equal to twenty times the diameter of the shaft.
The torsional deflection may be obtained by using the torsion equation,

where = Torsional deflection or angle of twist in radians,

T = Twisting moment or torque on the shaft,
J = Polar moment of inertia of the cross-sectional area about the axis
of rotation,

G = Modulus of rigidity for the shaft material, and

L = Length of the shaft.

2. Lateral rigidity. It is important in case of transmission shafting and shafts running at

high speed, where small lateral deflection would cause huge out-of-balance forces. The
lateral rigidity is also important for maintaining proper bearing clearances and for correct
gear teeth alignment. If the shaft is of uniform cross-section, then the lateral deflection of a
shaft may be obtained by using the deflection formulae as in Strength of Materials. But
when the shaft is of variable cross-section, then the lateral deflection may be determined
from the fundamental equation for the elastic curve of a beam, i.e.
 COUPLINGS

Couplings are used to connect two shafts for torque transmission in varied applications. It
may be to connect two units such as a motor and a generator or it may be to form a long
line shaft by connecting shafts of standard lengths say 6-8m by couplings. Coupling may
be rigid or they may provide flexibility and compensate for misalignment. They may also
reduce shock loading and vibration. A wide variety of commercial shaft couplings are
available ranging from a simple keyed coupling to one which requires a complex design
procedure using gears or fluid drives etc. However there are two main types of couplings:
Rigid couplings
Flexible couplings
Rigid couplings are used for shafts having no misalignment while the flexible couplings
can absorb some amount of misalignment in the shafts to be connected. In the next section
we shall discuss different types of couplings and their uses under these two broad
headings.

ADVANTAGES OF COUPLINGS:

1. It provides the connection of shafts of two different units such as an

electric motor and a machine.
2. It makes the provision for disconnection of two units for repair or
alteration.
3. It introduces the mechanical flexibility between two connected units.
4. It reduces the transmission of vibrations and shocks between two
connected units.
5. It makes the maintenance easy.

REQUIREMENTS OF A GOOD COUPLING:

1. It should transmit full power from one shaft to another.

2. It should keep the shaft in perfect alignment.
3. It should absorb the slight misalignment that may present between the
driver and driven shaft.
4. It should be easy to connect and disconnect.
5. It should have no projecting parts.

Rigid Flange Coupling

A typical rigid flange coupling is shown in following figure.

 Figure 3.4
It essentially consists of two cast iron flanges which are keyed to the shafts to be joined.
The flanges are brought together and are bolted in the annular space between the hub and
the protecting flange. The protective flange is provided to guard the projecting bolt heads
and nuts. The bolts are placed equi-spaced on a bolt circle diameter and the number of bolt
depends on the shaft diameter d. A spigot A on one flange and a recess on the opposing
face is provided for ease of assembly.
The design procedure is generally based on determining the shaft diameter d for a given
torque transmission and then following empirical relations different dimensions of the
coupling are obtained. Check for different failure modes can then be carried out.
Design details of such couplings will be discussed in the next lesson. The main features of
the design are essentially
(a) Design of bolts
(b) Design of hub
(c) Overall design and dimensions.
Design procedure is given in the following steps:

(1) diameterd based on torque transmission is given by

Where T is the torque and y is the yield stress in shear.

(2) Hub diameter d1 =1.75d +6.5mm

(3) Hub length L = 1.5d

But the hub length also depends on the length of the key. Therefore this length L must be
checked while finding the key dimension based on shear and crushing failure modes.
(4) Key dimensions:
If a square key of sides b is used then b is commonly taken as d/4. case, for shear failure
we have

where Lk is the length of the key and is the shear stress

If Lk determined here is less than hub length L we may assume the key length to be the
same as hub length.
For Crushing

and if c < cy , the bearing strength of the key material , the key dimensions chosen are in
order.

(5) Bolt dimensions :

The bolts are subjected to shear and bearing stresses while transmitting torque.
Considering the shear failure mode we have

where n is the number of bolts, db the nominal bolt diameter, T is the torque transmitted,
yb is the shear yield strength of the bolt material and dc is the bolt circle diameter. The bolt
diameter may now be obtained if n is known.

The number of bolts n is often given by the following empirical relation:

Where d is the shaft diameter in mm. The bolt circle diameter must be such that it should
provide clearance for socket wrench to be used for the bolts. The empirical relation takes
care of this.
Considering crushing failure we have

where t2 is the flange width over which the bolts make contact and cyb is the yield
crushing strength of the bolt material. This gives t2. Clearly the bolt length must be more
than 2t2 and a suitable standard length for the bolt diameter may be chosen from hand
book.
 (6) A protecting flange is provided as a guard for bolt heads and nuts. The thickness t3 is
less than t 2 2 . The corners of the flanges should be rounded.

(7) The spigot depth is usually taken between 2-3mm.

(8) Another check for the shear failure of the hub is to be carried out. For this failure
mode we may write

where d1 is the hub diameter and yf is the shear yield strength of the flange material.
Knowing yf we may check if the chosen value of t2 is satisfactory or not.
Finally, knowing hub diameter d1, bolt diameter and protective thickness t2 we may decide
the overall diameter d3.

Flexible rubber bushed couplings

This is simplest type of flexible coupling and a typical coupling of this type is shown in
Figure.

Figure: 3.4 A typical flexible coupling with rubber bushings.

In a rigid coupling the torque is transmitted from one half of the coupling to the other
through the bolts and in this arrangement shafts need be aligned very well.
However in the bushed coupling the rubber bushings over the pins (bolts) (as shown
in Figure) provide flexibility and these coupling can accommodate some
misalignment.
Because of the rubber bushing the design for pins should be considered carefully.
(1) Bearing stress
Rubber bushings are available for different inside and out side diameters. However rubber
bushes are mostly available in thickness between 6 mm to 7.5mm for bores upto 25mm
and 9mm thickness for larger bores. Brass sleeves are made to suit the requirements.
However, brass sleeve thickness may be taken to be 1.5mm. The outside diameter of
rubber bushing dr is given by

dr= db +2 tbr +2 tr

where db is the diameter of the bolt or pin , tbr is the thickness of the brass sleeve and tr
is the thickness of rubber bushing. We may now write

where dc is the bolt circle diameter and t2 the flange thickness over the bush contact
area. A suitable bearing pressure for rubber is 0.035 N/mm2

the number of pin is given by

The dc here is different from what we had for rigid flange bearings. This must be
judged considering the hub diameters, out side diameter of the bush and a suitable
clearance. A rough drawing is often useful in this regard.
t2 c

d
br

Loading on a pin supporting the bushings.

Clearly the bearing pressure that acts as distributed load on rubber bush would produce
bending of the pin. Considering an equivalent concentrated load F= pt2d the bending
stress is

Knowing the shear and bending stresses we may check the pin diameter for principal
stresses using appropriate theories of failure.
 We may also assume the following empirical relations:

Hub diameter = 2d
Hub length = 1.5d

Pin diameter at the neck =

Compare The Rigid Flange Coupling And Bush Pin Type Flexible Coupling.

Rigid Flange Coupling Bush Pin Type Flexible Coupling

1. Rigid flange coupling can not 1. Bush pin type flexible coupling can bear angular
bear any kind of misalignment. misalignment up to 0.50 and the lateral
misalignment up to maximum 5 mm.
2. Rigid flange coupling has smaller 2. Bush pin type flexible coupling has larger axial
axial dimensions. dimensions as compared to rigid flange coupling.
3. Both flanges are of equal 3. Input flange is of larger thickness as compared to
thickness the output flange.
4. Bolts are used to connect the two 4. Pin bush assembly is used for connecting the
flanges of the rigid flange input and output flanges.
coupling
5. Torque can be transmitted from 5. Torque can be transmitted from input flange to
input flange to the output flange the output flange by shear strength of the pin and
by shear strength of the bolts as bearing stress of the rubber bush as well as
well as through the friction through the friction between the flanges
between the flanges.
6. Two flanges touches each other 6. There is always a gap of up to 5 mm between the
except in the recess provided in two flanges to bear the angular misalignment
the hub portion to assure the
perfect alignment of both the
shafts.
7. Rigid flange coupling is cheaper 7. Bush pin type flexible coupling is costlier as
compared to rigid flange coupling
8. Rigid flange coupling Can not 8. Bush pin type flexible coupling Can absorb the
absorb the shocks and vibrations shocks and vibrations

Q. It is required to design a square key for fixing a pulley on the shaft, which is 50 mm
in diameter. The pulley transmits 10 kW power at 200 rpm to the shaft. The key is
made of steel 45C8 (yt= yc=380 MPa) and the factor of safety is 3. Determine the
dimensions of the key. Assume (sy=0.577 yt).
Solution: The torque is to be transmitted
kW 60 10 6
T=
2p N
10 60 10 6
T= = 477464.83 N - mm;
2p N
Permissible Stresses:
Permissible crushing stress
s yc 380
s cp = = = 126.66 MPa;
f .o.s 3
Permissible shear stress
s sy 0.577s yt 0.577 380
tp = = = = 73.08 MPa;
f .o.s 3 3

Cross section dimensions of the keys:

Refer table no. 4.1 page no. 60, Design data handbook for mechanical engineers by K.
Mahadevan and K. Balveera Reddy;

The cross section dimensions corresponding to the shaft diameter 50 mm are as follows
Width of the key b = 16 mm
Height of the key h = 10 mm
Taking the dimension for sqaure key b = 16mm and h=16 mm
Now determining the length of the key l:
Against crushing:
4T
s cp ;
d hl
4 477464.83
126.66 ;
50 16 l
4 477464.83
l
50 16 126.66
l 18.85 mm;

Against Shearing:
2T
tp ;
d bl
2 477464.83
73.08 ;
50 16 l
2 477464.83
l
50 16 73.08
l 16.33mm
The minimum length of the key should be 18.85 mm. Taking it as 20 mm.Hence
the dimensions of the key are
b= 16 mm;
h=16mm;
l=20mm
Q. A mild steel shaft transmits 20 kW at 200 rpm. It is subjected to a
bending moment of 562.5 N-m. Determine the size of the shaft, if the allowable
shear stress is 42 MPa, and the maximum tensile or compressive stress is not to
exceed 58 MPa. What size of the shaft will be required if it is subjected to
gradually applied load.
Solution:

Given :
Power " P = 20 kW" , Rotational speed N = 200 rpm; Bending moment M = 562.5 N - m;
Alloable shear stress t all = 42 MPa; Normal stress s all = 58 MPa
Torque :
kW 10 6 60 20 10 6 60
T= = = 954929.6585 N - mm;
2pN 2 p 200
Equivalent Bending Moment :
1
( 1
) (
M e = M + M 2 + T 2 = 562500 + 562500 2 + 954929.6585 2 =
2
2
)
1
M e = [562500 + 1108285.569 ] = 835392.7845 N - mm
2
Equivalent Twisting Moment :

Te = (M 2 + T 2 ) = (562500 2 + 954929.6585 2 ) = 1108285.569 N - mm;

The maximum shear stress induced in the material of the shaft
16Te 16 1108285.569 5644452.053
t max = = =
pd 3 pd 3 d3
Hence using the maximum shear stress theory
5644452.053 5644452.053
42 d3
3 42
d
d 3 134391.7156
d 51.22 mm;
The maximum normal (tensile or compressive) stress induced in the material of the shaft
32 M e 32 835392.7845 8509241.029
s max = = =
3 3
pd pd d3
Hence using the maximum normal stress theory
8509241.029 8509241.029
58 d3
3 58
d
d 3 146711.0522
d 52.74 mm;
Considering the gradual application of the load :
Assu min g :
shock and fatigue factor for bending and torsion K t = 1.0
Then shock and fatigue factor for bending K b = 1.5
Equivalent Bending Moment :
1
2
( 1
)
M e = K b M + (K b M )2 + (K t T )2 = 1.5 562500 +
2
(1.5 562500 2 + (1 954929.6585
M e = 1059016.483 N - mm
Equivalent Twisting Moment :

Te = ((K b M )2 + (K t T )2 ) = (1.5 562500 2 + (1 954929.6585)2 )

Te = 1274285.963 N - mm
The maximum shear stress induced in the material of the shaft
16 Te 16 1274285.963 6489885.117
t max = = =
pd 3 pd 3 d3
Hence using the maximum shear stress theory
6489885.117 6489885.117
42 d3
3 42
d
d 3 154521.0742
d 53.66 mm;
The maximum normal (tensile or compressive) stress induced in the material of the shaft
32 M e 32 1059016.483 10787053.32
s max = = =
pd 3 pd 3 d3
Hence using the maximum normal stress theory
10787053.32 10787053.32
58 d3
3 58
d
d 3 185983.6779
d 57.08 mm;

Hence the diameter of the shaft is 57.08 mm or 58 mm.

Q. A rigid flange coupling is used to transmit a torque of 215 N-m

from a shaft of 35 mm diameter to another shaft of the same
diameter. Design the hub, flange thickness and the bolt diameter
on the basis of shear strength of the bolt material. Assuming the
permissible stresses as follows: Shear stress for the material of the
bolt = 40 MPa; Crushing stress for the material of the bolt = 80
MPa; Shear stress for the cast iron = 8 MPa.

Solution:

Given : Torque " T" = 215 N - m;

Shaft diameter " d" = 35 mm; Bending moment M = 562.5 N - m; Alloable shear stress
cast iron t ci = 8 MPa; Alloable shear stress for the bolt material t ba = 40 MPa; Alloable
stress for the bolt materia s ba = 80 MPa;

Design of the HUB:

 The dimensions of the hub of the rigid flange coupling emperically may be given as :
Inner diamer of hub " Dhi " = d = 35 mm;
Outer diameter of hub " Dho " = 2 d = 70 mm
length of the hub " l h = 1.5d = 52.5 mm;
Dhi d
k= = = 0.5
Dho 2d
The induced torsional shear stress in the material of the hub may be given as
16 T 16 215 10 3
= 3.405 N/mm 2 ;
th =
p 3
Dho (
1- k 4
) =
3
(
p 70 1 - 0.5 4
)
Since t h < 8 N/mm 2 (i.e permissible shear stress of the cast iron) hence the dimensions taken for
the hub are safe .

Design of Flange Thickness:

The flange thickness of the rigid flange coupling emperically may be given as :
t f = 0.5 d = 17.5 mm;
The induced torsional shear stress in the material of the flange at the junction with hub may be
given as
2T 2 215 10 3
tf = = = 1.596 1.6 N/mm 2 ;
2 2
p Dho t f p 70 17.5
Since t h < 8 N/mm 2 (i.e permissible shear stress of the cast iron) hence the dimensions taken for
theflange are safe .

Design of Bolt:

Assuming that the bolts are fitted in the reamed holes, hence power is to be transmitted
by the shear strength of the bolt material.

Number of the bolts used in the coupling n = 4 {Assumed}

p D
T = db2 t b n b ;
4 2

Where
d b = nominal diameter of the bolt in mm;
Db = Bolt Circle Diameter = 3d = 3 35 = 105 mm; &
t b = permissible shear stress of the bolt material.
 8T 8 215000
\d b = = = 5.708mm
p t b n Db p 40 4 105
Check for crushingstressin the bolt material:

[ ]
T = (d b t f ) s cb n b
D
2
2T 2 215000
s cb = = = 10.249 N/mm2 ;
[ ]
(d b t f ) n Db [(5.708 17.5) 4] 105
Sinces cb < 80 N/mm2
(i.e permissible crushingstress of the bolt material)hencedesignednominaldiameter
of the bolt is safe and successful.
Standardise the Bolt Refer thetable no. 9.8 page no.113,
Design Data Handbookfor ?Mechanical Engineers
by K Mahadevan& K. Balveeareddy .
\ d b = 6.0 or
bolt M6.0is to be used for thegiven application.
Q.1:Design a typical rigid flange coupling for connecting a motor and a centrifugal
pump shafts. The coupling needs to transmit 15 KW at 1000 rpm. The allowable
shear stresses of the shaft, key and bolt materials are 60 MPa,50 MPa and 25 MPa
respectively. The shear modulus of the shaft material may be taken as 84GPa. The
angle of twist of the shaft should be limited to 1 degree in 20 times the shaft diameter.
 We now consider a typical rigid flange coupling as shown in Figure

Hub-
Using empirical relations

Hub diameter d1 = 1.75d + 6.5 mm. This gives

Key

Now to avoid the shear failure of the key

Assuming an allowable crushing stress for the key material to be

100MPa, the key design is safe. Therefore the key size may be taken as: a
square key of 6.25 mm size and 37.5 mm long. However keeping in mind that
for a shaft of diameter between 22mm and 30 mm a rectangular key of 8mm
width, 7mm depth and length between 18mm and 90mm is recommended. We
choose a standard key of 8mm width, 7mm depth and 38mm length which is
safe for the present purpose.
Q. It is required to design square key for fixing a gear to transmit a
torque of 198943.68 N-mm. The key is made of plain carbon steel having
the yield pointy in tension and in compression as 460 MPa and factor of
safety 3. Determine the dimensions of the key.

Solution: Given S yt = S yc = 460MPa, f.o.s = 3.0; Torque " T" = 198943.68N - mm

Diameter of the shaft d:
Applying the maximum shear stress theory
16T S yt 16 198943.68 460
d 23.64
pd 3 2 f .o.s pd 3 23
Taking the shaft diameter as
d = 25 mm.
The proportion of the square key :
d 25
w=h= = = 6.25 mm 6.0 mm
4 4
Considering the shearing of the key the length of the key may be given as :
2 T 2 198943.68
l= = = 34.60 mm;
t d w 460
25 6
23

Considering the crushing of the key the length of the key may be given as :
4 T 2 198943.68
l= = = 34.60 mm;
s c d w 460
25 6
3
Hence the length of the key is 35 mm;

The key is 6X6X35mm.

Q. It is required to design square key for fixing a gear to transmit a torque of 198943.68
N-mm. The key is made of plain carbon steel having the yield pointy in tension and in
compression as 460 MPa and factor of safety 3. Determine the dimensions of the key.

Solution: Given S yt = S yc = 460MPa, f.o.s = 3.0; Torque " T" = 198943.68N - mm

Diameter of the shaft d:
Applying the maximum shear stress theory
16T S yt 16 198943.68 460
d 23.64
3
pd 2 f .o.s pd 3 23
Taking the shaft diameter as
d = 25 mm.
The proportion of the square key :
d 25
w=h= = = 6.25 mm 6.0 mm
4 4
Considering the shearing of the key the length of the key may be given as :
2 T 2 198943.68
l= = = 34.60 mm;
t d w 460
25 6
23
Considering the crushing of the key the length of the key may be given as :
4 T 2 198943.68
l= = = 34.60 mm;
s c d w 460
25 6
3
Hence the length of the key is 35 mm;
The key is 6X6X35mm.

Q. A machine shaft is to transmit 61.5 kW at a speed of 1150 rev./min. with mild

shocks. The shaft is subjected to a maximum bending moment of 900 N-m and an
axial thrust of 70 kN. The shaft is supported at intervals of 2.5 meter. What should
be its diameter when designed according to the ASME code and keyway effect is
considered in the design?
Solution: According to code, shaft is made of ductile material whose ultimate tensile strength is
twice the ultimate shear strength, and the shaft diameter is controlled by the maximum
shear theory regardless of the ratio of the twisting moment to the bending moment
 1
K 16 T
2
1 K b 32 M b Fa
22
t = s + 4 +a ;
p d 3 pd 3 pd 2

Let
t = 56 MPa; K s = 1 .5 ; K b = 1 .5 ;
9550 61.5
F a = 70 kN ; M b = 900 N - m ; & T = = 510 N - m ;
1150
Neglecting Fa ; the diameter of the shaft
3
d =
16
p t
[(K b M b ) + (K s T )
2 2
] = p 16 56 [(1 .5 900 )
2
+ (1 . 5 510 )2 ]
d = 52 mm ;
Let us try for d = 60 mm;
d 60
\ Radius of gyration, k = = = 15 mm ;
4 4
L 2500
and = = 166 . 7 > 115
k 15
S yp (L k )2
a = ;
cp 2 E
Assu min g
S yp = 300 MPa ; c = 1.6; for partially restrained ends;
2
300 166 . 7
a = = 2 . 51
1 . 6 p 2 210 10 9
Hence
1
1 . 5 16 510
2
1 1 . 5 32 900 70000 2
2
t = + 4 + 2 . 51 = 65 . 5 MPa ;
p 0 . 60 3 3 2
p 0 . 60 p 0 . 60

.
Since induced shear stress in the material of the shaft is more than the permissible shear
stress i. e. 56 MPa hence the assumed dimension is unsafe.
Second trial
Let
d = 64 mm;
d 64
\ Radius of gyration, k = = = 16 mm;
4 4
L 2500
and = = 156.25 > 115
k 16
S yp (L k )2
a= ;
cp 2 E
Assu min g
S yp = 300 MPa; c = 1.6; for partially restrained ends;

300 156.25 2
a= = 2.2086
1.6 p 2 210 10 9
Hence
1
1.5 16 510 2 1 1.5 32 900 70000 2
2
t = + + 2.2086 = 52.32 MPa;
p 0.60 3 4 p 0.60 3 p 0.60 2

Since induced shear stress in the material of the shaft is less than the permissible shear stress
i. e. 56 MPa with the diameter of 64 mm hence the assumed dimension is safe.

DIAMETER OF THE SHAFT = 64 mm.

Q. It is required to design a rigid type of flange coupling to connect two shafts. The
input shaft transmits 37.4 kW power at 175 rpm to the output shaft through the
coupling. The design torque is 1.5 times of the rated torque. Select suitable material for
various parts of the coupling,design the coupling and specify the dimensions of its
components.

Given : P = 37.4 kW; ; N = 175 r.p.m. ; Service factor = 1.5

The torque is to be transmitted
kW 60 10 6
T=
2p N
37.4 60 10 6
T= = 2040821.099 N - mm;
2 p 175

Assume: Protective type rigid flange coupling

Component Material Permissible stress

Shaft Mild steel shear stress = 40 MPa;
Key Mild steel shear stress = 40 MPa; Crushing stress c = 80 MPa
Bolt Mild steel shear stress = 40 MPa; Crushing stress c= 80 MPa
Flange Cast iron shear stress = 8 MPa

1. Design for hub

Determining the diameter of the shaft (d) for the torque transmitted by the shaft,Since the
service factor is 1.5, therefore the maximum torque transmitted by the shaft,

Tmax = 1.5 2040821.099 = 3061231.65 N-mm;

The torque transmitted by the shaft (T),

p p
T= d 3 t s = d 3 40 = 7.854d 3
16 16
\ 3061231.65 = 7.854d 3
3061231.65
d3 = = 389768.12
7.854
d = 73.05 75mm

We know that outer diameter of the hub,

D = 2d = 2 75 = 150 mm Ans.

and length of hub, L = 1.5 d = 1.5 75 = 112.5 mm Ans.

 Let us now check the induced shear stress for the hub material which is cast iron.
Considering the hub as a hollow shaft. We know that the maximum torque transmitted
(Tmax).

p D4 - d 4 p 150 4 - 75 4
3061231.65 = t c = t c
16 D 16 150
3061231.65 16 150
tc = = 4.93MPa;
(
p 150 4 - 75 4 )
Since the induced shear stress for the hub material (i.e. cast iron) is less than the
permissible value of 8 MPa, therefore the design of hub is safe.

2. Design for key

Assuming the square key is to be used and the crushing stress for the key material is
twice its shear stress (i.e. ck = 2k ),

square key may be used. From Table 4.1, pp#60, Design Data Handbook for Mechanical
Engineers by K. Mahadevan and K. Balveera Reddy, for a shaft of 75 mm diameter,

Width of key, w = 22 mm Ans.

and thickness of key, t = w = 22 mm Ans.

The length of key ( l ) is taken equal to the length of hub.

l = L = 112.5 mm Ans.

Let us now check the induced stresses in the key by considering it in shearing and
crushing. Considering the key in shearing. We know that the maximum torque
transmitted (Tmax),

d
3061231.65 = l w t k
2
3061231.65 2 3061231.65 2
tk = = = 32.983 MPa;
l w t k d 112.5 22 75

Considering the key in crushing. We know that the maximum torque transmitted (Tmax),

t d
3061231.65 = l s ck
2 2
3061231.65 4 3061231.65 4
s ck = = = 65.97 MPa;
l t d 112.5 22 75
 Since the induced shear and crushing stresses in the key are less than the permissible
stresses, therefore the design for key is safe.

3. Design for flange

The thickness of flange (tf) is taken as 0.5 d.

tf = 0.5 d = 0.5 75 = 37.5 mm Ans.

Check the induced shearing stress in the flange by considering the flange at the junction
of the hub in shear. We know that the maximum torque transmitted (Tmax),
p D2 p 150 2
3061231 . 65 = t c t f = t c 37 . 5
2 2
3061231 . 65 2
t c = = 2.31 MPa;
p 150 2 37 . 5

Since the induced shear stress in the flange is less than 8 MPa, therefore the design of
flange is safe.

4. Design for bolts

Let d1 = Nominal diameter of bolts.

Since the diameter of the shaft is 75 mm, therefore let us take the number of bolts,

n=4 (Assumed)

and pitch circle diameter of bolts,

D1 = 3d = 3 75 = 225 mm

The bolts are subjected to shear stress due to the torque transmitted. We know that the
maximum torque transmitted (Tmax),

p d12 D
3061231.65 = t b n 1
4 2
2
p d1 225
3061231.65 = 40 4
4 2
3061231 .65 8
d12 = = 216.54;
p 40 4 225
d 1 = 14.71mm

Assuming coarse threads, the nearest standard size of bolt is M 18. Ans.

(Ref. Table # 9.8, pp#114)

Other proportions of the flange are taken as follows :

Outer diameter of the flange,

D2 = 4 d = 4 75 = 300 mm Ans.

Thickness of the protective circumferential flange,

tp = 0.25 d = 0.25 75 =18.75 say 20 mm Ans.

 UNIT-IV

Mechanical Spring

Spring provide a flexible joint between two parts or bodies. Spring may be used to absorb the
energy and control the motion of two mating bodies.

Basic Functions of Spring

1. Cushioning, absorbing, or controlling of energy due to shock and vibration. e.g. Car
springs or railway buffers
2. To control energy, springs-supports and vibration dampers.
3. Control of motion, and maintaining contact between two elements (cam and its follower)
4. Creation of the necessary pressure in a friction device (a brake or a clutch)
5. Restoration of a machine part to its normal position when the applied force is withdrawn
(a governor or valve). A typical example is a governor for turbine speed control. A
governor system uses a spring controlled valve to regulate flow of fluid through the
turbine, thereby controlling the turbine speed.
6. Measuring forces, spring balances, gages
7. Storing of energy, in clocks or starters, the clock has spiral type of spring which is wound
to coil and then the stored energy helps gradual recoil of the spring when in operation.

Before considering the design aspects of springs we will have a quick look at the spring materials
and manufacturing methods.

Materials Used for Spring:

One of the important considerations in spring design is the choice of the spring material. Some of
the common spring materials are given below.

Hard-drawn wire:
This is cold drawn, cheapest spring steel. Normally used for low stress and static load. The
material is not suitable at subzero temperatures or at temperatures above 1200C.

Oil-tempered wire:
It is a cold drawn, quenched, tempered, and general purpose spring steel. However, it is not
suitable for fatigue or sudden loads, at subzero temperatures and at temperatures above 1800C.
When we go for highly stressed conditions then alloy steels are useful.

Chrome Vanadium:
This alloy spring steel is used for high stress conditions and at high temperature up to 2200C. It
is good for fatigue resistance and long endurance for shock and impact loads.
Chrome Silicon:
This material can be used for highly stressed springs. It offers excellent service for long life,
shock loading and for temperature up to 2500C.

Music wire:
This spring material is most widely used for small springs. It is the toughest and has highest
tensile strength and can withstand repeated loading at high stresses. However, it can not be used
at subzero temperatures or at temperatures above 1200C.
Normally when we talk about springs we will find that the music wire is a common choice for
springs.

Stainless steel:
Widely used alloy spring materials.
Phosphor Bronze / Spring Brass: It has good corrosion resistance and electrical conductivity.
Thats the reason it is commonly used for contacts in electrical switches. Spring brass can be
used at subzero temperatures.
Helical spring
The figures below show the schematic representation of a helical spring acted upon by a tensile
load F and compressive load F. The circles denote the cross section of the spring wire. The cut
section, i.e. from the entire coil somewhere we make a cut, is indicated as a circle with shade.

Figure 4.1
SOME DEFINITIONS RELATED TO HELICAL SPRING:

Solid Length; The axial length of the spring under loaded condition when the coils of the
spring touches each other is known as solid length of the spring as shown in below figure,

Free Length: The axial length of the spring under no loading condition is known as solid
length of the spring as shown in below figure,

Compressed Length: The compressed length is defined as the axial length of the spring,
that is subjected to maximum compressive force.

Figure 4.2

Compressed Length = Free Length - Maximum deflection

= Nt d + ( Nt - 1) gap between adjacent coils;
Spring Index: Spring index is defined as the ratio of the mean coil diameter to the wire
diameter of the spring and denoted as C.
D Mean coil diameter
C= =
d Wire diameter
The spring index indicates the relative sharpness of curvature of the coil.

Spring Rate: Spring rate may be defined as the force per unit deflection of the spring, it
is also known as stiffness constant

Types of Stresses Produced In The Wire of the Closed Coiled Helical Spring:

In addition to the torsional shear stress (1) induced in the wire,

The following stresses also act on the wire:
1. Direct shear stress due to the load W, and
2. Stress due to curvature of wire.

The Resultant Shear Stress

The positive sign is used for the inner edge of the wire and negative sign is used for the
outer edge of the wire. Since the stress is maximum at the inner edge of the wire,
therefore

Maximum shear stress induced in the wire= Torsional shear stress + Direct shear stress

In order to consider the effects of both direct shear as well as curvature of the wire, a
Wahls stress factor (K) introduced by A.M. Wahl may be used.
Distribution of Stresses:

Figure 4.3
Here the d and D represents the wire diameter and mean coil diameter of the spring.

Q. A helical compression spring is made of oil tempered carbon steel and is subjected
to a load varying from 600 N to 1000 N. The spring index is 6 and the factor of
safety is 1.5. If the yield stress & endurance stress of the material is 700 MPa, and
350 MPa respectively. Find the wire diameter of the spring.

Solution:
Given :
Fmax = 1000 N ; Fmin = 600 N; Spring index " C" = 6.0; Factor of safety :" N f " = 1.5
S sy = 700 MPa; = 350 MPa;
S se
1. Mean Force and Amplitude Force :
F + Fmin 1000 + 600
Fm = max = = 800 N;
2 2
F - Fmin 1000 - 600
Fa = max = = 200 N;
2 2
 2. Mean Shear Stress :
Shear stress multiplication factor
0.5 0.5
K s = 1 + = 1+ = 1.0833;
C 6.0
8F C 8 800 6 13241.69
t m = K s m = 1.0833 = N/mm 2
2 2 2
pd pd d
;
3 Amplitude Shear Stress :
Wahl' s Correction Factor
4C - 1 0.615 4 6 - 1 0.615
Kw = + = + = 1.2525;
4C - 4 C 46 - 4 6
8F C 8 200 6 3827.35
t a = K w a = 1.2525 = N/mm 2 ;
2 2 2
pd pd d
4. Spring Wire Diameter :
Sse 3827.35 350
ta d 2
= 2 = 2
Ssy Sse 700 13241.69 350
- t m S sy - - 700 -
Nf 2 1.5 d2 2
3827.35
d2 =
175
13241.69 700 - 175
466.6667 -
d2
3827.35 4413.8967
= 155.555 -
d2 d2
8241.2467
= 155.555
d2
d 2 = 52.98;
d = 7.28 mm or 7.30 mm
\ d = 7.30 mm

Q. A helical valve spring is to be designed for an operating load range of 90 N to 140 N.

The 90 N load acts when the valve is closed and 140 N force acts when the valve is
open. The deflection of the spring is limited to 8 mm. Take G=84 GPa.
Solution:

Given : W1 = 90 N ; W2 = 140 N ; = 8 mm ; G = 84 kN/mm2 = 84 103 N/mm2;

Assume: Spring index C = D/d = 6

Permissible shear stress intensity = 420MPa = 420 N/mm2

1. Mean Diameter of the Spring Coil

Let D = Mean diameter of the spring coil for a maximum load of W2 = 140 N, and

d = Diameter of the spring wire.

The twisting moment on the spring,

D 6d
T = W2 = 140 = 420d
2 2
p p
420d = t d 3 = 420 d 3 = 82.467d 3 D
16 16 (Q C = =6)
d
420
d2 = = 5.093mm;
82.467
d = 2.257mm;

Standard wire diameter d = 2.40 mm (Refer: Table# 11.3a, pp#150)

\Mean diameter of the spring coil,

D = 6d = 6 2.40 = 14.40 mm Ans.

The outer diameter of the spring coil,

Do = D + d = 14.40 + 2.40 = 16.80 mm Ans.

and inner diameter of the spring coil,

Di = D d = 14.40 2.40 = 12.0 mm Ans.

2. Number of Turns of the Spring Coil

Let n = Number of active turns.

It is given that the axial deflection ( for the load range from 90 N to 140 N (i.e. for W
= 50 N) is 8 mm.

The deflection of the spring (), may be given as

 8 W C 3 n 8 50 6 3 n
8= = = 0.4856 n
Gd 84 10 3 2.40
8
n= = 16.74 , say 17.
0.4856

For squared and ground ends, the total number of turns,

n' = 17 + 2 = 19 Ans.

3. Free Length of the Spring

Since the compression produced under 50 N is 8 mm, therefore maximum compression

produced under the maximum load of 140 N is

8
d max = 140 = 22.4mm;
50

The free length of the spring,

LF = n'.d + max + 0.15 max = 19 2.40 + 22.4 + 0.15 22.4

= 71.36 say 72 mm Ans.

4. Pitch of the Coil

The pitch of the coil

LF 72
p= = = 4 mm
n - 1 19 - 1
 POWER SCREW:

A power screw is a drive used in machinery to convert a rotary motion into a linear
motion for power transmission. It produces uniform motion and the design of the power
screw may be such that
a. Either the screw or the nut is held at rest and the other member rotates as it moves
axially. A typical example of this is a screw clamp.

b. Either the screw or the nut rotates but does not move axially. A typical example for this
is a press.
Other applications of power screws are jack screws, lead screws of a lathe, screws for
vices, presses etc.
Power screw normally uses square threads but ACME or Buttress threads may also be
used. Power screws should be designed for smooth and noiseless transmission of power
with an ability to carry heavy loads with high efficiency. We first consider the different
thread forms and their proportions:
Square Threads

Acme Threads

Trapezoidal Threads

Buttress Threads

1. Square Thread: A square thread is shown in below figure and it is used transmission of
power in both directions. It has maximum efficiency and minimum radial or bursting
pressure on the nut. These threads are usually used in screw jack, mechanical presses and
clamping devices

2. Acme Threads: In the following figure the acme threads are shown. Acme threads
permits the use of split nut which can compensate the wear. And these threads are
stronger than square threads, but having the efficiency lower than the square threads.
These threads are usually used in lead screws.
3. Trapezoidal Threads: In the following figure the trapezoidal threads are shown. These
threads are similar to the acme threads except the thread angle which is 300 in trapezoidal
threads.

4. Buttress Threads: In the

following figure the buttress threads are shown. it is used transmission of power in one
direction only. These threads are stronger in shear than any other power threads because
of the largest cross section at the root. Buttress threads combine the high efficiency of
square threads and high strength of V threads. These threads are used in vices and screw
jacks where force is to be applied only in one direction.

Efficiency Of A Power Screw:

A square thread power screw with a single start is shown in following figure. Here p is
the pitch, helix angle, d the mean diameter of thread and F is the axial load. A
m
developed single thread is shown in figure where L = n p for a multi-start drive, n being
the number of starts. In order to analyze the mechanics of the power screw we need to
consider two cases:
(a) Raising the load
(b) Lowering the load.
Raising the Load:
his requires an axial force P as shown in the following figure. Here N is the normal
reaction and N is the frictional force.

For equilibrium
P - N cos - N sin = 0
F + N sin - N cos = 0
This gives
Torque transmitted during raising the load is then given by

The force system at the thread during lowering the load is shown in following figure. For
equilibrium

P - N cos + N sin = 0
F - N cos - N sin = 0
This gives

Torque required to lower the load is given by

Self Locking and Overhauling of Power Screw;

The torque required to lower the load is given as follows
Wd m
Tt = [tan(f - l )]
2
 Self Locking:
n above equation if f > l , the torque required to lower the load " Tt " will be positive.. Such a screw is
known as self locking screw.

i.e. f >l
lead
tan f > tan l m > tan l or m>
p dm
Over Hauling:
In above equation if f < l, the torque required to lower the load " Tt " will be egative.. That is load]
will start to moving downward without the applicatioof any torque. Such a screw is known as over
hauling screw.

Efficiency of the power screw is given by

Q. An electric motor driven screw moves a nut in a horizontal plane against a force of
75 kN at a speed of 250 mm/min. The screw has a single square thread of 6 mm
pitch on a major diameter of 40 mm. The coefficient of friction at screw thread is
0.1. Estimate Power of the motor.
Soluion:
The mean diameter of the screw " d m " = d - 0.5 p = 40 - 0.5 6 = 37 mm;
L
The lead angle " l" = tan - 1 ; Where L = lead of the screw.
p dm
6
\ l = tan - 1 = 2.95
0
p 37
Angle of friction f = tan - 1 m = tan - 1 0.1 = 5.710 ;
The torque required to overcome the thread friction is given as

T=
W dm
2
tan(l + f ) =
75000 37
2
( )
tan 2.95 0 + 5.710 == 211326.1017 N - m
Hence the effort required
2 T 2 211326.1017
Ft = = = 11423.03252 N ;
dm dm
The tangential speed
0.250
v = 250 mm / min = m / s = 0.0042 m / s ;
60
Power of the motor required
P = Ft v = 11423.03252 0.0042 = 47.595 Watt 50 Watt.
 SCREW JACK

Screw jack is a portable device consisting of a screw mechanism used to raise or lower the load.
There are two types of jacks most commonly used,
(1) Hydraulic
(2) Mechanical

Merits of Screw jack

(1) Can be used to lift a heavy load against gravity.
(2) Load can be kept in lifted position.
(3) Due to leverage obtained by handle force required to raise load is very less & can be
applied manually also

Demerits of screw jack

1) Chances of dropping of load
2) Tipping or slipping of load.
3) This failure is not SAFE FAIL& can cause serious accidents.

Reasons of Accidents
1) Load is improperly secured on jack.
2) The screw jack is overloaded.
3) Center of gravity is off center with axis of jack.
4) Jack is not placed on hard & level surface.
5) Using for other purpose instead of using it for which it is designed.

Screw jack has following parts :-

1) Frame
2) Screw
3) Nut
4) Handle
5) Cup
6) Set Screw
7) Washer

(1) Frame
Frame Size - Most of the times frame is conical in shape and hollow internally to accommodate
a nut & screw assembly. The hollow conical shape insures a safe & complete resting of a jack on
ground. If it is provided with legs like structure , it quite possible that in case of uneven
distribution load may fail down because all legs will not touch ground.
Force Analysis The force by a load is directed by a cup to screw then is directed by cup to
screw then to threads of screw to nut then to frame so it is always compressive in nature.

Manufacturing Process The complex shape of frame leads us to use a Casting process for
manufacturing. For all this purpose We need to select a cast iron as material for frame. We
select a FG200 as material for frame such as it contains carbon precipitates as graphite flakes
as graphite is soft in nature it improves its ability to resist a compressive load.

(2) Screw
Screw size Screws is nothing but a member having Helical groove around periphery of
solid bar. It can be around 22 to 100mm diameter for square power screws & 24 to
100mm for trapezoidal power screws.
Thread profile The screw or power screw thread is always a square type because it has
more efficiency than trapezoidal threads and there is no radial thrust on screw i.e. no
Bursting Pressure, so motion is uniform.
Square threads usually turned on lathes using single point cutting tool. It leads us to use
free cutting steel.
Square threads are weak in roots. Wear of thread surface lead us to use Unalloyed free
cutting steel.

(3) Nut
As we know there always a relative motion between screw and nut, which cause a friction. The
friction causes wear if some material is used for screw & nut it will wears both components. So
one out of two has to be softer than other so as to ease of replacement. The size & shape of screw
is costlier than nut, so generally we use softer material for nut than screw. Phosphor bronze is
ideal material for nut which is a copper alloy having 0.2%phospher which increases tensile
strength. Ultimate tensile strength for this is 190mpa and coefficient of friction is 0.1
Bearing pressure is 10mpa.
Advantages of phosphor bronze are,
(1) Good corrosion resistance.
(2) Low coefficient of friction
(3) Higher tensile strength than copper brass.

4] Handle
Handle is subjected ti bending moments. So plain carbon steel with 0.3%carbon i.e. 30C8 can be
selected. Yield strength in tension is 400mpa

(5) Cup
Shape of cup is again complex and so economical to manufacture by Casting process, hence
material will be cast iron with grade FG200.
(6) Set Screw
Purpose of set screw is to resist motion of nut with screw. It can be of commercial steel.

(7) Washer
Washer is to provide uniform force of tightening nut over screw force by enlarging area under
actions of force. We can use commercial steel.
Procedure for the design of the screw having square threads: Threaded screw is
subjected to compressive loads when used in the power screws.

1. The core diameter of the threaded screw spindle determined by assuming the pure
direct compression as given below

4W
dc = ;
p sc
Where
d c = core diameter of the screwed spindle in mm;
W = load applied in N;
s c = permissible compressive stress of the threaded screw material in N/mm 2 ;

2. Calculating the torque required to overcome the thread friction and the total torque
required to raise the load as given
 Wd m
Tt = [tan(f + l )]
2
and
Tc = mc W R f
Where
mc = coefficient of friction between the head and cup;
pitch of thred
d m = mean diameter of the screw = root diameter +
2
f = angle of friction between the threads of nut and screw
l = lead angle of the screw thread
R f = radius of friction circle
Total torque
T = Tc + Tt

3. Then the diameter of the screw is checked against the induced torsional shear stress
and principal stress induced due to the combined effect of torsion and bending
moment

16 Tt
t=
p d c3
screw is subjected to the bending moment M
induced bending stress
32 M
sb =
p d c3
Net Direct stress " s d " = bending stress + direct compressive stress
Maximum shear stress :
s 2
t max = d + t 2
2
Maximum principal stress
s 2
s
s 1 = d + d + t 2
2 2

For sucessful design of the screw the maximum shear stress and maximum principal stresses must be
less than the permissibl e respective stresses.
and finally the design will be checked against buckling using J. B. Johnson formula

Crippling load " Wc" =

p d c2
.S yc 1 -
( )
S L 2
yc k
4 4Cp 2 E

Symbols are having the usual meaning.
For sucessful design of the screw the crippling load must begreater than the applied load.
 Design procedure of Nut : The following procedure is followed in designing of the nut of a
screw jack;;
1. Height of the Nut:
The height of the nut is decided as follows:
By considering the bearing failure of the nut threads the number of nut threads in mesh is
calculated. Once the number of nut threads in mesh is known then the height of the nut will
be determined as
Height of the nut = number of nut threads in mesh X pitch of thread;
In the next step these number of threads will be cheked against the direct shear stresses in
the nut threads and screw theads. If fails then number of threads will be further increased to
make it successful.
2. The body diameter of the nut is determined by considering the tensile failure of the
material of the nut.
3. The outside diameter of the collar of the nut is determined by considering the crushing
failure of the material of the nut.
4. The thickness of the collar may be determined by considering the direct shear failure of
the material of the nut.

Q. Name the various components of the screw jack and their usual materials. A single
start square threaded screw of mean diameter 24 mm and pitch of 5 is tightening
by screwing a nut whose mean diameter at bearing surface is 50 mm. If the
coefficient of friction between the nut and screw is 0.1 and for the nut and bearing
surface is 0.16. Find the force required at the end of a spanner 0.5 meter long
when the load on the screw is 10 kN.
Ans.: Name of the components of screw Jack Material
Frame FG200;
Screw Plain Carbon Steel or Alloy Steel;
Nut Phosphor Bronze;
Handle Plain Carbon Steel or Alloy Steel;

GIVEN: Single start threaded screw: mean diameter dm = 24 mm; Pitch P = 5 mm;
Mean Diameter of the bearing surface Df = 50 mm or Mean Radius of the bearing
surface Rf = 25 mm; Coefficient of friction between the nut and screw n = 0.1;
Coefficient of friction between the nut and bearing surface c = 0.16; Load W = 10
kN; Length of the spanner L=0.5 meter = 500 mm.
Sol.:

Lead 5
Lead angle l = tan -1 = tan -1 = 3.794 ;
0

p dm p 24
Beacuase for single start thread Lead = Pitch
Angle of friction between nut and thraed f = tan -1 (m n ) = tan -1 (0.1) = 5.7106 0 ;
Torque required to overcome the thread friction between the nut and screw to raise the load " W"
d 24
Tt = W m tan(l + f) = 10000 tan(3.794 + 5.7106) = 20091.00246 N - mm;
2 2
Torque required to overcome the bearing surface friction between the nut and bearing surface raise the load " W"
Tc = m c W R f = 0.16 10000 25 = 40000 N - mm;
Total torque required to raise the given load
T = Tt + Tc = 20091.00246 + 40000 = 60091.00246 N - mm;
The force " P" required at the end of the spanner to raise the given load
T = P L 60091.00246 = P 500
60091.00246
Hence P= = 120.182 N 121 N ANS.
500

Q. Design a screw jack for lifting a load of 20 kN through 200 mm.

Solution: Given : W = 20 kN = 20000N ; H1 = 200 mm = 0.2 m ;

Assuming: Elastic strength of screw material in tension and compression

et = ec = 200 MPa and in shear et = 120 MPa;

The material for the nut is phosphor bronze; for which the elastic limit in

Tension et(nut) = 100 MPa;

Compression ec (nut) = 90 MPa;

Shear e(nut) = 80 MPa;

Bearing pressure for nut pb= 18N/mm2 ;

1. Design of screw for spindle

Let dc = Core diameter of the screw.

Since the screw is under compression, therefore load (W),

 p s p 200
20 10 3 = d c2 ec = d c2
4 f .o.s. 4 2 .0
20000 8
d c2 = = 254.65 (Taking Factor of Safety = 2.0)
p 200
d c = 15.95mm;

For square threads of normal series, the following dimensions of the screw are selected
fromTable # 9.10, pp.#121.

Core diameter, dc = 17 mm Ans.

Nominal or outside diameter of spindle, do = 22 mm Ans.

Pitch of threads, p = 5 mm Ans.

Now let us check for principal stresses:

We know that the mean diameter of screw,

d o + d c 22 + 17
d= = = 19.5mm
2 2

The helix angle

p 5
tan a = =
p d p 19.5
a = 4.67 0

Assuming coefficient of friction between screw and nut is 0.14,

=tanf=0.14

\Torque required to rotate the screw in the nut,

d d tan a + tan f d
T1 = P = W tan(a + f ) = W
2 2 1 - tan a tan f 2
0.0817 + 0.14 19.5
= 20000 = 43729.31 N - mm;
1 - 0.0817 0.14 2

Now the compressive stress due to axial load

4 W 4 20000
sc = = = 88.1135MPa;
p d c2 p 17 2

And shear stress due to torque

 16 T1 16 43729.31
t= = = 45.3311MPa;
p d c3 p 17 3

\ Maximum principal stress (tensile or compressive),

1 1
s c max = s c + s c2 + 4t 2 = 88.1135 + 88.1135 2 + 4 45.33112 = 107.27MPa
2 2

The given value of c is equal to 200 /2=100 MPa, Hence the design is fail. Taking
dc=19mm; from Table # 9.10, pp.#121.

Core diameter, dc = 19 mm Ans.

Nominal or outside diameter of spindle, do = 24 mm Ans.

Pitch of threads, p = 5 mm Ans.

Now let us check for principal stresses:

We know that the mean diameter of screw,

d o + d c 24 + 19
d= = = 21.5mm
2 2

The helix angle

p 5
tan a = =
p d p 21.5
a = 4.234 0

Assuming coefficient of friction between screw and nut is 0.14,

=tanf=0.14

\Torque required to rotate the screw in the nut,

d d tan a + tan f d
T1 = P = W tan(a + f ) = W
2 2 1 - tan a tan f 2
0.0704 + 0.14 21.5
= 20000 2 = 46474.95 N - mm;
1 - 0.0704 0.14

Now the compressive stress due to axial load

4 W 4 20000
sc = = = 70.54 MPa;
p d c2 p 19 2

And shear stress due to torque

 16 T1 16 46474.95
t= = = 34.51MPa;
p d c3 p 19 3

\ Maximum principal stress (tensile or compressive),

1 1
s c max = s c + s c2 + 4t 2 = 70.54 + 70.54 2 + 4 34.512 = 84.615MPa
2 2

And Maximum shear stress

1 1
t c max = s c2 + 4t 2 = 70.54 2 + 4 34.512 = 49.345MPa
2 2

The given value of c is equal to 200 /2=100 MPa and c is equal to 120 /2=60 MPa

Since these maximum stresses are within limits, therefore design of screw for spindle is
safe. And the designed dimensions for the spindle are

Core diameter, dc = 19 mm Ans.

Nominal or outside diameter of spindle, do = 24 mm Ans.

Pitch of threads, p = 5 mm Ans.

2. Design for nut

Let n = Number of threads in contact with the screwed spindle,

h = Height of nut = n p, and

t = Thickness of screw = p / 2 = 5 / 2 = 2.5 mm

Assume that the load is distributed uniformly over the cross-sectional area of nut.

We know that the bearing pressure ( pb ),

4 W 4 20000
18 = =
p [d o2 - d c2 ] n [ ]
p 24 2 - 19 2 n
4 20000
n= = 6.58 7threads
p [24 2
]
- 19 2 18

Now theheight OF THE NUT

h = nxp =7x5 = 35 mm

Now check the stresses induced in the screw and nut

 W 20000
t screw = = = 19.15 MPa
p n d c t p 7 19 2.5

And the stress in the nut

W 20000
t nut = = = 15.16 MPa
p n d o t p 7 24 2.5

The permissible shear stress for the nut 80/2=40 MPa;

Since these stresses are within permissible limit, therefore design for nut is safe.

Let D1 = Outer diameter of nut,

D2 = Outside diameter for nut collar, and

t1 = Thickness of nut collar.

First of all considering the tearing strength of nut, we have

W=
p 2
4
[
D1 - d o2 s t ]
p
[
20000 = D12 - 24 2
4
]
100
2
[
= 39.27 D12 - 576 ]
20000
D12 - 576 = = 509.30
39.27
D1 = 32.94 33mm;

Now considering the crushing of the collar of the nut, we have

W=
p 2
4
[
D 2 - D12 s c]
p
[
20000 = D 22 - 33 2
4
90
2
] [
= 35.343 D 22 - 1089 ]
20000
D 22 - 1089 = = 565.883
35.343
D 2 = 40.68 41mm;

Considering the shearing of the collar of the nut, we have

W = p D1 t1 t
20000 = p 33 t1 40
20000
t1 = = 4.823mm 5.0mm
p 33 40

3. Design for handle and cup

The diameter of the head (D3) on the top of the screwed rod is usually taken as 1.75 times the
outside diameter of the screw (do).

\ D3 = 1.75 do = 1.75 24 = 42 say 45 mm Ans.

The head is provided with two holes at the right angles to receive the handle for rotating the
screw. The seat for the cup is made equal to the diameter of head, i.e. 45 mm and it is given
chamfer at the top. The cup prevents the load from rotating. The cup is fitted to the head with a
pin of diameter D4 = D3/4 =45/4=11.25 or 12 mm. The pin remains loose fit in the cup.Now let
us find out the torque required (T2) to overcome friction at the top of the screw.

Assuming uniform pressure conditions, we have

2 R 3 - R 43
T2 = m1W 32 2

3 R3 - R 4
2 (45 2 )3 - (12 2)3
T2 = 0.14 20000 = 44357.895 N - mm (Assuming m1 = m = 0.14)
(45 2) - (12 2)
3 2 2

Hence the total torque to which the handle is subjected,

T = T1 + T2 = 46474.95 + 44357.895 = 90832.845 N-mm

Assuming that a force of 300 N is applied by a person intermittently, therefore length of handle
required. Assuming the effort applied by an average person is 300 N

= 90832.845 / 300 =302.7762 mm say 305 mm.

Allowing some length for gripping, we shall take the length of handle as 305 mm. A little
consideration will show that an excessive force applied at the end of lever will cause bending.
Considering bending effect, the maximum bending moment on the handle,

M = Force applied Length of lever

= 300 305 = 91500 N-mm

Let D = Diameter of the handle.

Assuming that the material of the handle is same as that of screw, therefore taking bending stress
b = t = et / 2 = 100 N/mm2. The bending moment (M),.
p p
91500 = s b D 3 = 100 D 3 = 9.82 D 3
32 32
91500
D3 = = 9317.72
9.82
D = 21.043 22mm;
The height of head (H) is taken as 2D.
 \ H = 2 D = 2 22 = 44 mm Ans.
Now let us check the screw for buckling load. The effective length for the buckling of screw,

L = Lift of screw +0.5times of height of nut = H1 + h / 2

= 200 + 44 / 2 = 221 mm

When the screw reaches the maximum lift, it can be regarded as a strut whose lower end is
fixedand the load end is free. We know that critical load,

s y L 2
Wcr = Ac s y 1 -
4Cp 2 E k
For one end fixed and other end free C = 0.25;
Also k = 0.25d c = 0.25 19 = 4.75
p 200 221
2
\ Wcr = 19 2 200 1 -
4 4 0.25 p 2 210 10 3 4.75
p
Wcr = 19 2 200 [1 - 0.209] = 44854.25N;
4

Since the critical load is more than the load at which the screw is designed (i.e. 20 103
N), therefore there is no chance of the screw to buckle.

4. Design of body

The various dimensions of the body may be fixed as follows:

Diameter of the body at the top,

D5 = 1.5 D2 = 1.5 41 = 61.5 mm Ans.

Thickness of the body,

t3 = 0.25 do = 0.25 24 = 6 mm Ans.

Inside diameter at the bottom,

D6 = 2.25 D2 = 2.25 41 = 92.25 mm Ans.

Outer diameter at the bottom,

D7 = 1.75 D6 = 1.75 92.25 = 161.44 say 165 mm Ans.

Thickness of base, t2 = 2 t1 = 2 5 = 10 mm Ans.

Height of the body = Max. lift + Height of nut + 100 mm extra

=200 + 35 + 100 = 335 mm Ans.

The body is made tapered in order to achieve stability of jack.

Let us now find out the efficiency of the screw jack. We know that the torque required to
rotate the screw with no friction,

d 21.5
To = W tan a = 20000 tan 4.234 = 15916.8903 N - mm;
2 2

Hence efficiency of the screw jack,

T0 15916.8903
h= = = 0.175 = 17.5%
T 90832.845

Hence the designed screw jack offers self locking that is desirable.
 REFERENCES

1. A textbook of machine design by P.C.Sharma and D.K.Agarwal, S.K.Kataria and sons,

1998.
2. The elements of machine design by S.J.Berard and E.O.Waters, D.Van Nostrand
Company, 1927.
3. Design of machine elements by M.F.Spotts, Prentice hall of India, 1991.
4. Mechanical engineering design by Joseph E. Shigley, McGraw Hill, 1986.
5. A text book of machine drawing by R. K. Dhawan, S. Chand and Co. Ltd., 1996.
6. A Text Book Of Machine Design, R. S. Khurmi and J. K. Gupta, S. Chand and Co.
Ltd.,2005
7. Design Data Hand Book, K. Mahadevan and K. Balaveera Reddy, 3rd Edition.