Professional Documents
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Machine Design
A Compilation
Simple Stress
Stress – is defined as the internal resistance of a material
to the action of external forces.
1. Tension
2. Compression
3. Shear
Illustrations:
1. Tension
2.
Compression
3. Shear
1. Tension: st =
2. Compression: sC =
3. Shear: sS =
Where: st = tensile stress; psi or kip per sq. inch; Pa
1kip = 1000lbs
sc = called the compressive stress, psi or
kip; Pa
ss = shearing stress; psi; Pa
therefore, sS =
By definition: E= =
Since the strain Є is dimensionless (in/in) the units of E
are the same as those of s. in terms of total
deformation, δ, where δ = ЄL, the normal stress in
simple tension or compression is,
st = ;
sC =
Where: sf = flexure in psi or ksi, Pa
M = bending moment in in-lb or in-kips; N-m
c = distance from the neutral plane in inch; meter
I = is the centroidal moment of inertia in in4, m4
st = bending stress due to tension in psi or ksi; Pa
sc = bending stress due to compression; psi or ksi, Pa
z = I/c, is called the Section Modulus.
Note: expression for I and E for some sections commonly
met in machine design are given in table AT1: Properties of
Sections (p.563, DME by Faires).
Torsional Stress – s or Shear stress
for Solid Circular Member: for Hallow Circular Member:
sS = sS =
Where:
T = applied torque or twisting moment in in-lb or in-
kips
Ss = is a shearing (tensional) stress.
D = nominal diameter, in.
Do = outside diameter for hallow circular member in
inch.
Di = inside diameter for hallow circular member in
inch.
Modulus of Rigidity, G
Modulus of Elasticity in Shear. The angle of twist of shaft
between two sections is given by, θ = in radians.
Where:
θ = angle of twist; rad.
T = torque in in-lb or in-kips
J = polar moment of inertia in in4
G = modulus of rigidity and transverse modulus in
psi.
For steel: G = 12 x 106 psi
Torque, T
Assume a force, F, is acting at the circumference of a circle
of radius, r, inch. The size of pulleys, gears, etc. is always
given as the diameter in inches. The work, W, done by the
force F moving once around a circle is
W=
where: n = represent the number of RPM.
Using 33,000 = 1HP,
hence
HP = = =
Given:
F= 5500 lbs
N= 4
Su= 65ksi = 65000psi
[Problem 1] Solution
Since the steel rod is subjected to
tension, we use tensile stress formula:
, based on ultimate
strength
= 65000psi
Then,
F= 5500lbs
d = 0.66 in
[Problem 2]
Given:
= 43 ksi = 43000 psi
d = 0.625 in
h = 0.672 in
F=?
[Problem 3]
Solution
Given:
d = 12.7mm
h = 9.55 mm
= 298380 kPa = 289380 kN/m2
[Problem 4]
Solution
F = 110.26 kN
[Problem 5]
Given:
ε = 0.0000105 m/m
s = 3.03 x 108 Pa = 3.03 x 108 N/m2
E = =
E =
Where:
– is called the yield stress in tension.
C.2. Variable Stress:
½ h a rd 2 0 .7 0 % 3 7 .1 0 % E x t ra h a rd 50% 75%
½ h a rd 2 9 .4 0 % 50% S p ri n g H a rd 6 0 .5 0 % 8 4 .4 0 %
E x t ra sp ri n g h a rd 6 8 .7 0 % 9 0 .2 0 %
Admiralty metal: condenser and other heat exchanger tubes and
plates.
Aluminum bronze: corrosion resistant parts, marine pumps,
shafts, valves, parts of high strength, toughness, wearbility, low
coefficient of friction and damping are important.
Berrylium copper: parts where high formability
Cartridge brass: electrical parts, automotive radiator cores, pins,
lock washers, bushings, spring.
Manganese bronze: clutch disk, pump rods, shafts, valve stems,
welding rod.
Naval brass: condenser plates, piston rods, valve stems, welding
rod, balls, nuts, and bolts.
Phosphorus bronze: bellows, diaphragms, cluthch disk, cotter
pins, lock washers , bushing, spring, wire, welding rod, chemical
hardware, and wire brushes
Silicon bronze: hydraulic pressure lines, hardware,
bolts, nuts, rivets, screws and electrical conduits
Yellow brass: electrical, plumbing, wire, pins, rivets,
screw, springs, architectural grillwork, radiator cores.
ALUMINUM ALLOYS.
Where:
B. Relation of Power, Torque, and Speed.
P = 2πTN ; T=Fxr
Where: P = power transmitted; kW
T = torque or torsional moment; kN-m
N = speed; rev/sec.
F = transmitted load or tangential force; kN
r = radium; m
G = modulus of rigidity in shear
= 11,500,000psi – 12,000,000psi for steel
Ss = is a shearing (tensional) stress.
D = diameter of the shaft
L = length of shaft
θ = angular deformation in length L; radians
Di = inside diameter
Do = outside diameter
1. Stresses in Solid Circular shaft subject to Torsion and
Bending
A. For Maximum Shear stress,
P = 2 π TN
P = 2 π (2.18175363 kN-m)(490rpm)
P = 111.81 kW
Prob.2) The shaft varies from 2000N-m to 6000N-m
has 0.0381m in diameter and 6000kPa yield strength.
Determine the shaft average stress in Mpa. [ME Board
Prob.]
Given:
Tmin = 2000 N-m
Tmax = 6000 N-m
D = 0.0381
Prob.2) - Solution
Prob.3) A hollow shaft has an inner radius of 0.0175m
and an outer radius of 0.025m. Compute for the torque if the
shearing stress not to be exceed 125Mpa in N-m. [ME Board
Prob.]
Given:
Di = 0.035m
Do = 0.05 m
ss = 125 MPa
Prob.3) - Solution
T = 2331.334 N-m
Prob.4) A short 59mm shaft transmits 100HP.
Compute the linear speed of a pulley 53cm mounted on the
shaft. [ME Board Prob.]
Given:
D = 59mm x = 2.32in
Dp = 53cm x = 0.33m
P = 100hp
Prob.4) - Solution
= π DN
= π (0.33m)(304.31rpm)
= 8.44 m/s x x
= 1660.992 ft/min
CHAPTER 10:
KEYS, FASTENERS, and COUPLINGS
•KEY
- Gears, pulleys, etc., may be attached to shafts by
force or shrink fits, by one or more several kinds of
keys, by splined connections. Couplings are used to
connect shafts. Couplings that are readily disconnected
are called clutches.
Common types of keys:
1. Flat keys – are rectangular in section with the
smaller dimension placed in a radial direction.
2. Square keys – are square in section and they or
may not be tapered.
Keys – rigid connectors between a shaft and the
hub of another component such as pulley, gear or cam. Its
purpose is to prevent relative rotation between the two
points. If a key is to be used, a keyseat must be provided
in the shaft and a keyway in the hub of the other part.
Keyway – a groove in the shaft and mating member
to which the key fits.
Splines – permanent keys made integral with the
shaft and fitting into keyways broached into the mating
hub.
Equation used to obtain the Torque (T) Capacity of a splined
fitting in in-lb.: (p.287, by V.M. Faires)
T = 1000psi, h, L, n, rm; in-lb.
Where:
h = depth in inch. Refer to Table 6-8, p.240, M.
Design by Robert D. Creamer. Also see Table
10.2, Nominal Dimension of Splines, p.287,
M.D. by Faires.
L = active length; inch
N = number of splines
rm = mean radius; inch =
[Example] Determine the torque capacity of a splined
shaft that is 4 inches in diameter and has 16 splines. The
length of contact between the two connected components is
1.45.
Given:
D = 4 inches Required:
n = 16 splines Torque, T in inch-lb.
L = 1.45
Solution:
From Table 6-8, p.244, MD by Creamer at n =16 splines,
permanent fit, h = 0.045(D), then, h = 0.045(4inch) = 0.18
inch.
rm = = 6.19 inch
Thus,
T = 1000 h L n rm = (1000)(0.18)(16)(6.19)
T = 7976.16 in-lb.
TYPES OF KEYS
GIB-HEAD KEYS - are square or flat and tapered, with a
head. The head should not be left exposed so that there is
danger that it will catch on workmen’s clothing, possibly
resulting in serious injury. This key is useful when the
small end is inaccessible for tapping it out; the head
permits its easy removal.
PIN KEY - may be either straight or tapred (taper of ¼ to
1/16 in./ft.). It is usually a drive fit. Longitudinal assembly
at the end of a shaft, is easy to do, and in this position, it
can transmit heavy power; size, about one-fourth of the
shaft diameter. In the transverse position, it cannot
transmit nearly power; and in this configuration, it is
sometimes used as a shear pin. Stock sizes, large end, are
available from 0.625 to 0.7060 in. diameter.
ROLL PIN- one of several patented methods of keying, is
driven or pressed into a hole that is small enough to close the
slit, assembled in a radial direction. The chamfered end makes
it easy to drive-in, and the pressure it exerts holds it in place.
Observe that the roll pin will be effective in a hole made with
loose tolerances, a circumstance that is conductive to cost
reduction. Made of heat-treated C 1095 (other materials: 420
stainless, beryllium copper), its shear strength is as a solid,
mild-steel taper pin.
SADDLE KEYS - are tapered, suitable for light power, and
are either hollow with a radius or curvature slightly smaller
than the shaft radius, or flat, in which case they are
assembled on a flat on the shaft. They depend entirely on
friction to transmit the load; in this type, the hub can be
located in any angular position relative to the shaft. Airtight
fit and the consequent friction also improve the load capacity
of the flat saddle key.
KENNEDY KEYS - are tapered square keys, with or
without gib heads. These keys are also said to be tangential
keys. Rectangular keys with the diagonal dimension
virtually in a circumferential direction are also called
tangential key, and there are other ways of assembly. The
advantage of this configuration is a significant increase in
capacity.
WOODRUFF KEY - which fits into a semi-cylindrical seat in
the shaft is widely used in the automotive and machine toll
industries. Since it goes deeper into the shaft, it has less
tendency to tip when the load load is applied. Note that the
construction is such that key must first be placed in its seat
and the hub pressed on. Two grades of material are readily
available; SAE 1035 and heat treated alloy steel. For extra
strength, two or more keys may be used—usually in a tandem
arrangement.
FEATHER KEY - is one that allows the hub to move along
the shaft but prevents rotation on the shaft. It is used, for
example, to permit moving a gear into or out of engagement
with its mate, or to engage and disengage a jaw clutch. The
feather key may be attached to the shaft or to the hub. A
force analysis based on certain assumptions shows that two
feather keys 180 degrees apart are preferable to a single key.
The axial force required to move a member along a shaft is
about half as much when there are two or more feather keys
as when there is one.
PRATT AND WHITNEY KEY - The Pratt & Whitney key is
rectangular in cross section and has rounded ends. It is
placed two-thirds in the shaft (2/3*H) one-third in the hub
(H/3). Key numbers are assigned to specify these keys.
Stress Analysis for Flat and Square Key
A. For shear stress of key:
Let A = resisting Area; = bL
b = width of key
L = length of key
The Corresponding Force, , with moment
arm of , the torque T is ; in-lb or in-
kips, D = shaft diameter.
B. For Compression of key:
Let A be the bearing resisting area,
4. Shearing stress, Ss
; where b = width of key; in; mm
t = thickness of key; in; mm
Fn = corresponding force; lbf; N
Problem: A SAE1045 as rolled shaft having a diameter
of 76mm and yield point in shear with ¾ x ¾ x 5 in key.
Find the minimum yield point in the key in order to
transmit the torque of the shaft. Use factor of safety
equals to 3 and yield stress; SYS= 0.60sY.
Given:
D = 76mm x = 2.99in N =3
L = 5 in SYS = 0.60SY
b = ¾ in
t = 36 in
From Table AT7, p. 576 Faires,
using SAE 1045, as rolled
SY= 59ksi
Su = 46ksi
; T = 185000.43 in-lb
Fn = 124,291.22lb
The shearing stress on key,
1. Elevators
2. Hoists
3. Cranes
4. Drilling
5. Conveyors
6. Trainways
7. Suspension Cables
8. Guy-Wire
Various Rope Sizes and their Application:
1. 6 x 7 – for haulage, guy wires.
2. 6 x 19 – general-purpose rope, hoists, cranes,
drilling, elevators.
3. 6 x 37 – high-speed elevators, cranes, hoists.
4. 8 x 19 – extra flexible hoisting rope applications.
c. Factor of Safety, N
Where:
E = modulus of elasticity; 30 x 106psi for steel
Am = Cross sectional Area of metal
DW = wire diameter
FU = breaking strength of rope
Ft = Tensile Force due to the load including
acceleration forces.
d. Recommended Factor of Safety, N
Types:
1. Flat Belt
2. V-Belt
3. Toothed Belt
4. Serpentine Belt
5. Quarter Turn Belt
(a) For Open Belt:
(D2 – D1)2
L = 2C + 1.57 (D2 – D1) + 4C
R–r
-1 D2 – D 1
θ = π ± 2sin = π± ; in radians
C C