Stresses in

machine parts
Introduction

In engineering practice, the machine parts are subjected to various

forces which may be due to either one or more of the following
 Energy transmitted,
 Weight of machine,
 Frictional resistances,
 Inertia of reciprocating parts,
 Change of temperature, and
 Lack of balance of moving parts.
Load

Load is “Any external force acting on machine part”

Following four types of loads are important by subject point of view
 Dead or steady load
 Live or variable load
 Suddenly applied or shock loads
 Impact load
Stress

When some external system of forces or loads act on a body, the internal
forces (equal and opposite) are set up at various sections of the body, which
resist the external forces. This internal force per unit area at any section of the
body is known as unit stress or simply a stress. It is denoted by a Greek
letter sigma (σ).
Stress, σ = P/A
where P = Force or load acting on a body, and
A = Cross-sectional area of the body.
In S.I. units, the stress is usually expressed in Pascal (Pa) such that 1 Pa = 1
N/m2. In actual practice, we use bigger units of stress i.e. mega pascal (MPa)
and giga pascal (GPa), such that
1 MPa = 1 × 106 N/m2 = 1 N/mm2
and 1 GPa = 1 × 109 N/m2 = 1 kN/mm2
Strain

When a system of forces or loads act on a body, it undergoes some

deformation. This deformation per unit length is known as unit
strain or simply a strain. It is denoted by a Greek letter epsilon (ε).
Strain, ε = δl / l or δl = ε.l
where δl = Change in length of the body, and
l = Original length of the body.
It is unit less quantity
Tensile stress and strain

 When a body is subjected to two equal and opposite axial pulls P

(also called tensile load) then the stress induced at any section of
the body is known as tensile stress.
 A little consideration will show that due to the tensile load, there
will be a decrease in cross-sectional area and an increase in
length of the body. The ratio of the increase in length to the
original length is known as tensile strain.
Tensile stress, σt = P/A
Tensile strain, ε t = δl / l
Compressive stress and strain

 When a body is subjected to two equal and opposite axial pushes

P (also called compressive load), then the stress induced at any
section of the body is known as compressive stress
 A little consideration will show that due to the compressive load,
there will be an increase in cross-sectional area and a decrease in
length of the body. The ratio of the decrease in length to the
original length is known as compressive strain.
Compressive stress, σc = P/A
Compressive strain, εc = δl /l
Young’s modulus or modulus of
elasticity
 Hooke's law* states that when a material is loaded within elastic
limit, the stress is directly proportional to strain, i.e.
σ ∝ε or σ = E.ε
E =P l/A δl
where E is a constant of proportionality known as Young's
modulus or modulus of elasticity. In S.I. units, it is usually
expressed in GPa i.e. GN/m2 or kN/mm2. It may be noted that
Hooke's law holds good for tension as well as compression.
Shear stress and strain

 When a body is subjected to two equal and opposite forces acting

tangentially across the resisting section, as a result of which the
body tends to shear off the section, then the stress induced is
called shear stress.
 The strain produced by shear stress is known as shear strain
and it is measured by the angular deformation accompanying the
shear stress
Shear stress = Tangential force/Resisting area
Single shear and double shear

 When shearing takes place at one cross-section of the rivet), then

the rivets are said to be in single shear.
 when the shearing takes place at two cross-sections of the rivet),
then the rivets are said to be in double shear.

 Modulus of rigidity
Modulus of rigidity (C) values for
different materials
Bearing stress

 A localised compressive stress at the surface of contact between

two members of a machine part, that are relatively at rest is
known as bearing stress or crushing stress. The bearing
stress is taken into account in the design of riveted joints, cotter
joints, knuckle joints, etc.
σb (or σc) =P/d t n
d = Diameter of the rivet,
t = Thickness of the plate,
d.t = Projected area of the rivet, and
n = Number of rivets per pitch length in bearing or crushing.
Stress strain diagram for mild
steel
 Proportional limit
 Elastic limit
 Yield point
 Ultimate stress
 Breaking stress

 Percentage reduction in area

 Percentage elongation
Working stress

 When designing machine parts, it is desirable to keep the stress

lower than the maximum or ultimate stress at which failure of the
material takes place. This stress is known as the working stress
or design stress. It is also known as safe or allowable stress.
Factor of safety

 The ratio of maximum stress to working stress.

Factor of safety =Maximum stress/Working or design stress
 In case of ductile materials e.g. mild steel, where the yield point
is clearly defined, the factor of safety is based upon the yield
point stress.
Factor of safety = Yield point stress/Working or design stress
 In case of brittle materials e.g. cast iron, the yield point is not
well defined as for ductile materials. Therefore, the factor of
safety for brittle materials is based on ultimate stress.
Factor of safety = Ultimate stress/ Working or design stress
Selection of factor of safety

 The reliability of the properties of the material and change of these

properties during service ;
 The reliability of test results and accuracy of application of these
results to actual machine parts ;
 The reliability of applied load ;
 The certainty as to exact mode of failure ;
 The extent of simplifying assumptions ;
 The extent of localised stresses ;
 The extent of initial stresses set up during manufacture ;
 The extent of loss of life if failure occurs ; and
 The extent of loss of property if failure occurs.
Values of factor of safety