MACHINE DESIGN EXCEL SPREAD SHEETS

Copy write, © Machine Design Spreadsheet Calculations by John R Andrew, 6 July 2006

* Machine components are designed to withstand: applied direct forces, moments and torsion.
* These loads may be applied gradually, suddenly, and repeatedly.
* The design load is equal to the applied load multiplied by a combined shock and fatigue factor, Ks.
* The average applied design stress must be multiplied by a stress concentration factor K.
* Calculated deflections are compared with required stiffness.
* The material strength is compared with the maximum stress due to combinations of anticipated loads.

Math Symbols
A x B = A*B A / B =A / B
Spread Sheet Method: 2x3= 2*3 3/ 2=3/ 2
1. Type in values for the input data. =6 = 1.5
2. Enter.
3. Answer: X = will be calculated. A+B= A+B Xn = X^n
4. Automatic calculations are bold type. 2+3= 2+3 23 = 2^3
=5 =8
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When Excel's Goal Seek is not needed, restore protection with:
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TENSION AND COMPRESSION

As shown below, + P = Tension
- P = Compression

Reference: Design of
Machine Elements, by V.M.
Faires, published by: The
Macmillan Company, New
York/Collier-Macmillan
Limited, London, England.

Two machine components, shown above, are subjected to loads P at each end.
The force P is resisted by internal stress S which is not uniform.
At the hole diameter D and the fillet radius R stress is 3 times the average value.
This is true for tension +P and compression -P.
Machine Component Maximum Stress Calculation Use if: D/H > 0.5 or R/H > 0.5
Refer to the diagram above: Input
External force, ± P = 2000 lbf
Section height, H = 3.5 in
Section width, B = 0.5 in
Original length, L = 5 in
Stress concentration factor, K = 3.0 -
Combined shock and fatigue factor, Ks = 3.0 -
Calculations
Section area, A = H*B
= 1.75 in^2
Maximum direct stress, Smax = K*Ks*P / A
= 10286 lbf/in^2
Safety factor, SF = Sa / Smax
= 2.14 -

Material E x 10^6 lbf/in^2 G x 10^6

Brass 15.0 5.80
Bronze 16.0 6.50
ASTM A47-52 Malleable Cast Iron 25.0 10.70
Duralumin 10.5 4.00
Monel Metal 26.0 10.00
ASTM A-36 (Mild Steel) 29.0 11.50
Nickel-Chrome Steel 28.0 11.80

Input
Tension ( + ) Compression ( - ), P = 22000 lbf/in^2
Section Area, A = 2.00 in^2
Original length, L = 10 in
Original height, H = 3 in
Material modulus of elasticity, E = 29000000 lbf/in^2 See table above.
Calculation
Stress (tension +) (compression -), S = P/A
= 11000 lbf/in^2
Strain, e = S/E
= 0.00038 -
Extension (+), Compression ( - ), X = L*e
= 0.0038 in
Poisson's Ratio, Rp = 0.3 = ((H - Ho) / H) / e For most metals
Transverse (contraction +) (expansion -) = (H - Ho)
= 0.3*e*H
= 0.00034 in
Shear Stress Distribution
A stress element at the center of the
beam reacts to the vertical load P with
a vertical up shear stress vector at the
right end and down at the other. This
is balanced by horizontal right acting
top and left acting bottom shear stress
vectors. A stress element at the top or
bottom surface of the beam cannot
have a vertical stress vector. The
shear stress distribution is parabolic.

Reference: Mechanical Engineering

Reference Manual (for the PE exam),
by M.R. Lindeburg, Published by,
Professional Publications, Inc.
Belmont, CA.

Input
External shear force, P= 2200 lbf
Section height, H= 3.500 in
Section width, B= 1.250 in
Shear modulus, G= 1150000 lbf/in^2
Length, L= 12 in
Calculation
Section area, A = H*B
A= 4.375 in^2
Shear stress concentration factor, k = 1.5 -
Maximum shear stress, Sxy = k*P / A
= 754 lbf/in^2
Shear strain, e = Fs / G -
= 0.00066 -
Shear deflection, v = e*L
= 0.0079 in
SHEAR STRESS IN ROUND SECTION BEAM
Refer to the diagram above:
Solid shafts: K = 1.5 & d = 0.
Thin wall tubes: K = 2.0 & d is not zero. Input
External shear force, P = 4000 lbf
Section outside diameter, D = 1.500 in
Section inside diameter, d = 0.000 in
Shear stress concentration factor, k = 1.33 -
Shear modulus, G = 1.15E+06 lbf/in^2
Length, L = 5 in
Calculation
Section area, A = π*( D^2 - d^2 )/ 4
A= 1.7674 in^2
Maximum shear stress, Fs = k*P / A
Fs = 3010 lbf/in^2
Shear strain, e = Fs / G -
e= 0.00262 -
Shear deflection, v = e*L
v= 0.0131 in

COMPOUND STRESS

Stress Element
The stress element right is at the point of interest in
the machine part subjected to operating: forces,
moments, and torques.

Direct Stresses:
Horizontal, +Fx = tension, -Fx = compression.
Vertical, +Fy = tension, -Fy = compression.

Shear stress:
Shear stress, Sxy = normal to x and y planes.

Principal Stress Plane:

The vector sum of the direct and shear stresses,
called the principal stress F1, acts on the principal
plane angle A degrees, see right. There is zero
shear force on a principal plane. Angle A may be
calculated from the equation:
Tan 2A = 2 x Sxy / ( Fy - Fx)
 Principal Stresses:
Two principal stresses, F1 and F2 are required to
balance the horizontal and vertical applied
stresses, Fx, Fy, and Sxy.

The maximum shear stress acts at 45 degrees to

the principal stresses, shown right. The maximum
shear stress is given by:

Smax = ( F2 - F1 ) / 2

The principal stress equations are given below.

PRINCIPAL STRESSES
Principal stress, F1 = (Fx+Fy)/2 + [ ((Fx-Fy)/2)^2 + Sxy^2 )^0.5 ]

Principal stress, F2 = (Fx+Fy)/2 - [ ((Fx-Fy)/2)^2 + Sxy^2 )^0.5 ]

Max shear stress, Sxy = [Fn(max) - Fn(min)] / 2

Principal plane angle, A = ( ATAN(2*Sxy / (Fy - Fx) ) / 2

See Math Tab below for

Excel's Goal Seek.

Use Excel's, "Goal Seek"

to optimize shaft diameter.

Power Shaft with: Torque T, Vertical Load V, & Horizontal Load H

Input
Horizontal force, H= 3000 lbf
Vertical force, V= 600 lbf
Torsion, T= 2000 in-lbf
Cantilever length, L= 10 in
Diameter, D= 2 in

Properties at section A-B Calculation

 π= 3.1416 -
Area, A = π*D^2 / 4
A= 3.142 in^2
Section moment of inertia, I = π*D^4 / 64
I= 0.7854 in^4
Polar moment of inertia, J = π*D^4 / 32
J= 1.5708 in^4
AT POINT "A"
Horizontal direct stress, Fd = H/A
Fd = 955 lbf/in^2
Bending stress, Fb = M*c / I
Fb = 7639 lbf/in^2
Combined direct and bending, Fx = H/A + M*c / I
Fx = 8594 lbf/in^2
Direct stress due to, "V", Fy = 0 lbf/in^2
Torsional shear stress, Sxy = T*(D / 2) / J
Sxy = 1273 lbf/in^2

Max normal stress at point A, F1 = (Fx+Fy)/2 + [ ((Fx-Fy)/2)^2 + Sxy^2 )^0.5 ]

F1 = 8779 lbf/in^2
Min normal stress at point A, F2 = (Fx+Fy)/2 - [ ((Fx-Fy)/2)/2)^2 + Sxy^2 )^0.5 ]
F2 = -185 lbf/in^2
Max shear stress at point A, Sxy = [Fn(max) - Fn(min)] / 2
= 4482 lbf/in^2

AT POINT "B"
Horizontal direct stress, Fd = H/A
Fd = 955 lbf/in^2
Bending stress, Fb = -M*c / I
Fb = -7639 lbf/in^2
Combined direct and bending, Fx = H/A + M*c / I
Fx = -6684 lbf/in^2
Direct stress due to, "V", Fy = 0 lbf/in^2
Torsional shear stress, Sxy = T*D / (2*J)
Sxy = 1273 lbf/in^2

Max normal stress at B, F1 = (Fx+Fy)/2 + [ ((Fx-Fy)/2)^2 + Sxy^2 )^0.5 ]

F1 = 234 lbf/in^2
Min normal stress at B, F2 = (Fx+Fy)/2 - [ ((Fx-Fy)/2)^2 + Sxy^2 )^0.5 ]
F2 = -6919 lbf/in^2
Max shear stress at B, Sxy(max) = [Fn(max) - Fn(min)] / 2
3577 lbf/in^2
Curved Beam-Rectangular Section
Input
Outside radius, Ro = 8.500 in
Inside radius, Ri = 7.000 in
Section width, B = 1.500 in
Applied moment, M = 500 in-lbf
Calculation
Section height, H = Ro - Ri in
= 1.500 in
Section area, A = 2.250 in^2
Section neutral axis radius = Rna
Radius of neutral axis, Rna = H / Ln(Ro / Ri)
= 7.726 in
e= Ri + H/2 - Rna
= 0.024 in
Inside fiber bending stress, Si = M*(Rna-Ri) / (A*e*Ri)
= 950 lbf/in^2
Outside fiber bending stress, So = M*(Ro-Rna) / (A*e*Ri)
= 1013 lbf/in^2
Curved Beams-Circular Section
Curved Beam-Section diameter, D = Ro - Ri
= 1.500 in
Section radius of neutral axis, Rna = 0.25*(Ro^0.5 + Ri^0.5)^2
= 7.732 in
e= Ri + D/2 - Rna
= 0.018 in
Inside fiber bending stress, Si = M*(Rna-Ri) / (A*e*Ri)
= 1626 lbf/in^2
Outside fiber bending stress, So = M*(Ro-Rna) / (A*e*Ro)
= 1406 lbf/in^2
Curved Beam-2 Circular Section
Input
Outside radius, Ro = 6.000 in
Inside radius, Ri = 4.000 in
Applied moment, M = 175 in-lbf
Calculation
Curved Beam-Section diameter, D = Ro - Ri
D= 2 in
Section radius of neutral axis, Rna = 0.25*(Ro^0.5 + Ri^0.5)^2
Rna = 4.949 in
e= Ri + D/2 - Rna
e= 0.051 in
Inside fiber bending stress, Si = (P*(Rna+e))*(Rna-Ri) / (A*e*Ri)
= 1309 lbf/in^2
Outside fiber bending stress, Fo = M*(Ro-Rna) / (A*e*Ro)
= 193 lbf/in^2

Rectangular Section Properties

Input
Breadth, B = 1.500 in
Height, H = 3.000 in
Calculation
Section moment of inertia, Ixx = B*H^3 / 12
= 3.375 in^4
Center of area, C1 = C2 = H/2
= 1.5 in

I and C Sections
Input Calculation
 Bn Hn A Yn
1 9 2 18 11
2 1.5 7 10.5 6.5
3 6 3 18 1.5
ΣA = 46.5

Calculation
Yn A*Yn A*Yn^2 Icg
1 11.000 198.00 2178.00 6.00
2 6.500 68.25 443.63 42.88
3 1.500 27.00 40.50 13.50
Σ = 293.25 2662.13 62.38

Calculation
Section modulus, Ixx = ΣA*Yn^2 + ΣIcg
= 2724.50 in^4
Center of area, C1 = ΣA*Yn/ΣA
= 6.306 in
C2 = Y1 + H1/2
= 12.000 in

Input
P= 2200 lbf
L= 6 in
a= 2 in
Calculation
b= L-a
4
Cantilever, MMAX at B = P*L
13200 in-lbs Ref: AISC Manual of
Fixed ends, MMAX, at C ( a < b ) = P * a * b^2 / L^2 Steel Construction.
1956 in-lbs
Pinned ends, MMAX, at C = P*a*b/L
2933 in-lbs

Enter value of applied moment MMAX from above:

Bending shock & fatigue factor, Kb = 3 Data
Bending stress will be calculated. Input
Applied moment from above, MMAX = 13200 in-lbf
 Larger of: C1 and C2 = C = 12.00 in
Section moment of inertia, Ixx = 4.66 in^4
Bending shock & fatigue factor, Kb = 1.50 -
Calculation
Max moment stress, Sm = Kb*M*C / I
= 50987 lb/in^2

Input Calculation
Bn Hn A Yn
1 2 9 18.00 1.00
2 7 1.5 10.50 3.50
3 3 6 18.00 1.50
ΣA = 46.5

Calculations
Yn A*Yn A*Yn^2 Icg
1.000 9.00 4.50 121.50
3.500 18.38 32.16 1.97
1.500 13.50 10.13 54.00
Σ= 40.88 46.78 177.47

Section modulus, Ixx = ΣA*h^2 + ΣIcg

= 224.25 in^4
Center of area, C1 = ΣA*Yn/ΣA
= 0.879 in
C2 = B1 - C1
= 1.121 in

Symmetrical H Section Properties

Input Calculation
Bn Hn A Icg
1 2 9 18.00 6
2 7 1.5 10.50 43
3 3 6 18.00 14
ΣA = 46.5 62

Center of gravity, Ycg = B1 / 2

= 1.000 in
Section modulus, Ixx = ΣIcg
= 62 in^4
Center of area, C1 = C2 = B1 / 2
= 1.000
Enter value of applied moment MMAX from above:
Input
P= 1800 lbf
L= 12 in
a= 3 in
Calculation
b= L-a
= 9
Cantilever, MMAX at B = P*L
= 21600 in-lbs
Ref: AISC Manual of
Fixed ends, MMAX, at C ( a < b ) = P * a * b^2 / L^2 Steel Construction.
= 3038 in-lbs
Pinned ends, MMAX, at C = P*a*b/L
4050 in-lbs

Enter values for applied moment at a beam section given: C, Ixx and Ycg.

Bending stress will be calculated. Input

Applied moment from above, MMAX = 13200 in-lbf
Larger of: C1 and C2 = C = 1.750 in
Section moment of inertia, Ixx = 4.466 in^4
Bending shock & fatigue factor, Kb = 1.5 -
Shaft material elastic modulus, E = 29000000 lb/in^2
Calculation
Beam length from above, L = 12 in
Beam load from above, P = 1800 lbf
Max moment stress, Sm = Kb*M*C / I
= 7759 lb/in^2
Cantilever deflection at A, Y = P*L^3 / (3*E*I)
0.0080 in
Fixed ends deflection at C, Y = P*a^3 * b^3 / (3*E*I*L^3)
0.000053 in
Pinned ends deflection at C, Y = P*a^2 * b^2 / (3*E*I*L)
0.000281 in

This is the end of this worksheet