NOTES IN MACHINE DESIGN

INSERT THE TITLE

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THE DESIGN PROCESS CAN BE SUMMARIZED
INTO DIFFERENT PHASES:

RECOGNITION OF NEED

This refers to the reasoning why the new product has

to be designed. In other words, it refers to the condition that
has made us to go for a new design.

DEFINITION OF THE PROBLEM

In this stage, the problem is clearly defined by it’s

specifications. Specifications are input and output quantities,
characteristics and dimensions of the space required, feed
and speed to be given etc.
SYNTHESIS
A creative process present in every design. Once all
the elements are defined for a particular problem, the
relationship between them has to be established. Synthesis is
the process of taking the elements of the concept and
arranging them in proper, size and dimension in a proper way.

ANALYSIS AND OPTIMIZATION

Analysis refers to find out whether the system

satisfies the requirements. By optimization, we see that the
system performs in the best possible way. If the present
system is not giving optimized performance, the synthesis
part has to be again carried out till the optimum performance
is achieved.
EVALUATION AND PRESENTATION

Evaluation is the final proof that the system is

successfully designed. This usually involves testing in
laboratory cells or real conditions. Presentation refers to
communicating the design to others. This should be done in
such way that the system’s components are clearly
understood by all.
FACTORS INFLUENCING MACHINE DESIGN

Machine design ultimately aims at designing a

component or element which will work satisfactorily under the
imposed conditions.

STRENGTH AND STIFFNESS

Strength of a component depends on the material

and the size or dimensions of it. Stiffness represents how
less a given element can deform under the application of
load. Stiffness is an important parameter in shafts and
machine tool spindles. If the spindle deforms too much, it will
adversely affect the cutting conditions. By employing correct
material and size, the strength and stiffness can be ensured.
SURFACE FINISH AND TOLERANCES

For the smooth running of mating parts, (e.g.

bearings, bushes) a good surface finish is required. So, on
the basis of the required running conditions, suitable surface
finish is decided.
Depending on how close the fitting between the mating parts
is needed, tolerances are decided. Incorrect tolerances will
lead to either seizing of the parts or a very loose and
ineffective running, both being undesirable.
MANUFACTURABILITY

A design should be easy to be worked on in the

production stage. So, before designing it is to be ensured
that sufficient capabilities are there to make the design as
product.
ERGONOMICS AND AESTHETICS
Ergonomics refers to the ease of handling a part.
Different handling or inconvenient access to a particular
component in a machine will not do. The more the operator of
a machine has to strain to work, the less ergonomic aspects it
has. Aesthetics means making a product appealing. This may
include modern styling, glossy finish, etc. These factors are to
be given due weighing while designing.

WORKING ATMOSPHERE
Some special parameters may also have to be
considered. For example, a drilling shaft in an offshore oil rig
is to be designed keeping in view the corroding nature of sea
water. Some special alloys or coating may be necessary in
such cases. These aspects should be considered while
designing.
WEAR AND HARDNESS REQUIREMENT

Though hardness improves wear resistance, it cannot

be increased beyond a limit. For example, in the case of high
speed gear, the teeth are only case hardened. Thorough
hardening will make the teeth more brittle. Such details are to
be look into.

COOLING AND LUBRICATION

Like in the case of worm-wheel set or a journal bearing

. Heat developed inside should be dissipated. So, the bearing
surface should be designed that cooling is proper. In case
artificial cooling is required provisions of the same should be
given a thought.
SAFETY AND RELIABILITY

This represents how far the component will serve its

intended function. It again depends on how serious or critical
the components are, for example, the turbine blades of an
air plane or some medical instruments. To ensure sufficient
reliability, factors of safety to be employed is higher or lower
depending on the critic ability.

For example, the FOS in the drilling machine spindles

may be 4 or 5. But in the case of an airplane component, it
may be as high as 100.
NOISE REQUIREMENT

The design is to be such that it creates less or no

noise. Using soft materials capable of absorbing vibrations
designing so as to operate at safe frequency range are some
ways of achieving this.

COST

The design process should aim at a cost effective way

of production. Unwanted strictness in terms of tolerances,
unwise approaches for reliability calculation (with a result of
unduly big sizes) all will increase the cost of the product. Use
of interchangeable manufacture and correct reliability
calculation are part of a good design procedure.
SELECTION OF MATERIALS BASED ON
MECHANICAL PROPERTIES:

Some important mechanical properties of materials:

1. STRENGTH
– this is the ability of the material to bear the
applied load without failure.

Examples:

Plain carbon steel ----- machine tool spindle shafts,

bolts
Steel with alloying elements:

Nickel steel ----- turbine blades, nuts screws

Nickel chromium steel or stainless steel ----

aircraft component, gear with heavy
loads

Chromium-molybdenum steel ---- gear box shafts, gears

Silicon-manganese steel -----------axles, shafts

2. HARDNESS
– this refers to the ability of a material to resist
abrasion and indentation on its surface.

Alloy steel -------- gears, chain sprockets,

bearings, bushes cutting tools

Stellite ------------- cutting tool

Ceramics (oxides, carbides and nitrates or materials

and non-metals) ----- cutting tools, refracting
linings
3. DUCTILITY
– property of material which enables it to be drawn
into thin wires.

Steel, copper, aluminum, silver ------ thin wires, rods

4. MALLEABILITY
– the property by which a material can be rolled
into thin sheets.

Aluminum, GI ----- sheets used for various purposes

5. TOUGHNESS – ability of material to resist shock loads

Titanium ---- aircraft parts, machine tools, connecting rod

valves

6. MACHINABILITY, VIBRATION DAMPING

Cast iron ---- bed ways of machine cutting tools,

frames, piston rings, brake drums, fly
wheels, gears
STRESS
*A force or load per unit area.*
TYPES OF STRESSES
• TENSILE STRESS
– if the stress tends to stretch or lengthen the material.
where :

St = normal stress of tension, MPa

F = axial load, N (tensile)

A = cross- sectional area, mm2

TYPES OF STRESSES
• COMPRESSIVE STRESS

– if the stress tends to compress or shorten the material.

c
A
where :

Sc = normal stress of compressive, MPa

F = axial compressive load, N

A = cross- sectional area, mm2

TYPES OF STRESSES
• SHEARING STRESS
– if to tear the material
TYPES OF STRESSES
• BENDING STRESS
TYPES OF STRESSES
• BEARING STRESS
TYPES OF STRESSES
• TORSIONAL STRESS
PROBLEM NO. 1:

It is desired to fabricate a simple structural

connection composed of 2 steel straps held together
by a bolt 20mm in diameter. The upper strap is 8mm
thick and the lower strap is 12mm thick. Both straps
are 50mm wide. Calculate the maximum unit
stresses in shear, bearing and tension caused by a
pull of 35 kN.
PROBLEM NO. 1:

Given:
Dia. of bolt ---------------------20mm
Thickness of strap(upper) ----- 8mm
Thickness of strap(lower) ----- 12mm
Width of both straps ----------- 50mm
PROBLEM NO. 1:
Required:
Maximum stresses in Shear, Bearing, Tension
Solution:
a) Shear Stress maximum :
P
S smax 
A
d 2
where : A
4
 (0.02m) 2
A
4
A  3.1416 x10  4 m 2
PROBLEM NO. 1:
Solution: (Continuation)

P
S smax 
A
35kN
S smax 
3.1416 x10  4 m 2
S smax  111408 kN 2  kPa
m
S smax  111.408MPa
PROBLEM NO. 1:
Solution: (Continuation)
b) Bearing Stress maximum :
P
Sbmax 
P Sbmax Upper 
AbU
Ab
Ab  bearing area 35kN
where : Sbmax Upper 
(8 x10 3 )(0.02)m 2
Ab  thickness  diameter
Sbmax Upper  218750 kN 2  kPa
m
Sbmax Upper  218.75MPa
PROBLEM NO. 1:
Solution: (Continuation)

P
Sbmax Lower 
AbL
35kN
Sbmax Lower 
(0.012)(0.02)m 2
Sbmax Lower  145833 kN 2  kPa
m
Sbmax Lower  145.83MPa
PROBLEM NO. 1:
Solution: (Continuation)
c) Tensile Stress maximum :

P
Stmax 
At

where : St  Tensile stress

Atmax  ( w  d )t
PROBLEM NO. 1:
Solution: (Continuation)
Atmax Upper  ( w  d )tU
Atmax Upper  (0.05m  0.02m)(0.008m)
Atmax Upper  2.4 x10  4 m 2

Atmax Lower  ( w  d )t L
Atmax Lower  (0.05m  0.02m)(0.012m)
Atmax Lower  3.6 x10  4 m 2
PROBLEM NO. 1:
Solution: (Continuation)
Therefore:
P
Stmax Upper 
AtU
35kN
Stmax Upper 
2.4 x10  4 m 2
Stmax Upper  145833.33 kN  kPa
m2
Stmax Upper  145.83MPa
PROBLEM NO. 1:
Solution: (Continuation)

P
Stmax Lower 
At L
35kN
Stmax Lower 
3.6 x10  4 m 2
Stmax Lower  97222.22 kN 2  kPa
m
Stmax Lower  97.22 MPa
PROBLEM NO. 2:

A flange coupling has an outside diameter of

200mm and connects two 40mm shafts. There are
four 16mm bolts on a 140mm bolt circle. The radial
flange thickness is 20mm. If the torsional stress in
the shaft is not to exceed 26 MPa, determine the
shear stress in the bolts if uniformly distributed.
PROBLEM NO. 2:

Given:
do ------------------------- 20mm
d of two shafts (ds) ---- 40mm
d of bolt (db) ----------- 16mm
d of bolt circle (dbc) ---- 140mm
Flange thickness (tf) --- 20mm
St max ----------------------- 26 MPa
PROBLEM NO. 2:
Required:
Ss of each bolt
Solution:

Fbolts
S sbolts  d 2
Ab where : Ab  b
4
PROBLEM NO. 2:
Solution: (Continuation)
Therefore,
T (0.02m)
26 MPa 
 (0.04m) 4
32
4
T  3.2673x10 MN  m
T  326.73 N  m
PROBLEM NO. 2:
Solution: (Continuation)
T  Ftotal  r
T
 Ftotal  Ftotal
r F of each bolt 
no. of bolts
d bc
where : r 
4667.51 N
Fbolt 
2 4
326.76 N  m Fbolt  1166.88 N
Ftotal 
(0.07 m)
Ftotal  4667.51N
PROBLEM NO. 2:
Solution: (Continuation)
Fbolt
 Ssb o lt 
Ab
db 2
 0.016 
2
where : Ab    2.0110  4 m 2
4 4
1166.8 N
Ssb o lt 
2.0110  4 m 2
Sbolt  5805.37 kPa
PROBLEM NO. 3:

It is desired to check the design of a

2-inch medium steel shaft subjected to a
turning moment of 40,000 in.-lb. Determine
the factor of safety used in the design of
ultimate stress is 50,000 psi.
PROBLEM NO. 3:

Given:

diameter of the shaft ds   2 in.

T  40,000 in.  lb.
Su  50,000 psi
PROBLEM NO. 3:
Required:
Design Factor (d f )

Solution:

loading that causes failure (ultimate stress; Su )

design factor (d f ) 
actual loading on the part ( S d ) or design stress
PROBLEM NO. 3:
Solution: (Continuation)
Su
df 
Ss
16T
where : S s 
d s3
16(40000lb  in.)
Ss 
 (2in)3
Ss  25,464.79 lb 2  psi
in
PROBLEM NO. 3:
Solution: (Continuation)

50000 psi
df 
25464.79 psi
d f  1.96
PROBLEM NO. 4:

A 1.5mm MTon hoist is to be installed in an

I-beam mounted on a truck platform to lift loads.
The I-beam is framed horizontally, cantilever with
overhang of 1.5m beyond the cantilever fulcrum.
Determine the section modulus in m3 of the I-beam
if allowable stress is 100MPa.
( Sd = Sallow = 100Mpa )
PROBLEM NO. 4:
Figure:
PROBLEM NO. 4:
Given:
L = 1.5m
Sd = 100 MPa
F = 1.5 MT
Required:

a.) Z’ ( section modulus ) in m3

PROBLEM NO. 4:
Solution:
PROBLEM NO. 5:
A punch press punches a 1 inch diameter
hole in a steel plate ¾ in thick every 10 seconds.
The actual punching takes 1 second. The
ultimate shear strength of the plate is 60,000 psi.
The flywheel of the punch press has a moment of
inertia of 500 in-lbs-sec2 and rotates at a mean
speed of 150 rpm. What is the Hp required for the
punch operation?
PROBLEM NO. 5:
Given:
PROBLEM NO. 5:
Given:
PROBLEM NO. 5:
Required:

Solution:
PROBLEM NO. 5:

Solution:
PROBLEM NO. 5:
Solution:

1
Work = 𝐹 𝑇
2
1 3
= 45000𝜋 𝑙𝑏 𝑖𝑛
2 4
=18685𝜋 𝑙𝑏 − 𝑖𝑛
=44170865 ft.-lb.
𝑊 4417.865 𝑓𝑡−𝑙𝑏
P= =
𝑇 1 𝑠𝑒𝑐
PROBLEM NO. 5:
=(4417.865 ft.-lb/sec)(1 hp/530 ft.-lb/sec)
P =8.03 hp
PROBLEM NO. 6:

A rectangular key was used in a pulley connected

to a line shaft with a power of 7.46 kw at a
speed of 1200 rpm. If the shearing stress of the
shaft and key are 30 𝑁/𝑚𝑚2 , respectively. What
is the diameter of the shaft?
PROBLEM NO. 6:
Given:
P=7.46 kw
n=1200 rpm
Ss(shaft)=30 𝑁/𝑚𝑚2
Ss(key)=240 𝑁/𝑚𝑚2
Required:
Diameter of shaft
PROBLEM NO. 6:
Solution:

𝑃 = 2𝜋𝑇𝑛
𝑃 7.46 𝑘𝑤 7.46 × 103 𝐽/𝑠𝑒𝑐
𝑇= = =
2𝜋𝑛 2𝜋(120 𝑟𝑝𝑚) 2𝜋𝑟𝑎𝑑 𝑟𝑒𝑣
1200 (1min/60sec)
𝑟𝑒𝑣 𝑚𝑖𝑛
𝑇 = 59.365 𝐽
PROBLEM NO. 6:
Consider the shearing stress on shaft:
16𝑇
𝑆𝑠 =
𝜋𝑑3
16𝑇
𝑑3 =
𝜋𝑆𝑠
1000𝑚𝑚
16(59.365𝑁−𝑚)( )
𝑑=[ 𝑁
1𝑚
]
𝜋(30 )
𝑚𝑚2
𝑑 = 21.6 𝑚𝑚
PROBLEM NO. 6:
Consider the shearing stress in the key:

16𝑇
𝑆𝑠 =
𝜋𝑑3
16𝑇
𝑑 =
3
𝜋𝑆𝑠
1000𝑚𝑚
16(59.365𝑁−𝑚)( )
𝑑=[ 𝑁
1𝑚
]
𝜋(240 )
𝑚𝑚2
𝑑 = 10.80 𝑚𝑚
Thick Walled Pressure Vessels
*Faires, p.256

1/2
1
𝑡 = 𝑟𝑖 − 1 in.
𝑃
1− 3
𝑆

where: S=circumferential stress, a safe normal

stress in design
Thick Walled Pressure Vessels
*Doughtie & Vallance

𝑆𝑡 + 𝑃
𝑡 = 𝑟𝑖 − 1 in.
𝑆𝑡 − 𝑃

where: P=inside/internal pressure

St=allowable tensile strength
t=wall thickness=ro-ri
ri=internal radius of cylinder
Thin Walled Pressure Vessels
-is one whose plate thickness is small compared to the
diameter of the vessel.
𝑡
=< 0.07 𝐷𝑂𝑀𝐸 𝑏𝑦 𝐹𝑎𝑖𝑟𝑒𝑠
𝑑
𝑡
=< 0.10 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝐷𝑒𝑠𝑖𝑔𝑛 𝑏𝑦 𝐵𝑙𝑎𝑐𝑘 & 𝐴𝑑𝑎𝑚𝑠
𝑑
where: t=plate thickness
d=inside diameter

𝑃𝐷𝑖
(𝐿𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙 𝑠𝑒𝑐𝑡𝑖𝑜𝑛)
2𝑡
where: P=pressure
t=thickness
Di=diameter
Thin Walled Pressure Vessels
If the vessels are welded:

𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑗𝑜𝑖𝑛𝑡

𝜇 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑝𝑙𝑎𝑡𝑒
St=PD/2t

If welded: St=PD/2t𝜇

Therefore: St=PD/2(St)𝜇 (thickness if welded)

Thin Walled Pressure Vessels
Stress on a transverse section:

S=PD/4t

The nominal stress a transverse section is half

that of a longitudinal section.
(S transverse=1/2 S longitudinal)
The one on the longitudinal section is the maximum
principal stress & is the basis of design.
PROBLEM NO. 7:
A steel cylinder air receiver w/ 5ft. diameter and a pressure
load of 175 psi, design stress of 9000 psi maximum. The
pressure vessel is to be provided with 1 ½” diameter drain
valve installed at the bottom of the vessel and safety pressure
relief valve installed either at the top most or at the side with
pop out rating of 195 psi. Assume a 100% efficiency. The lap
welding tensile strength is 60000 psi. Determine the bursting
pressure of this air receiver.
where: 𝜇 = 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑜𝑓 𝑤𝑒𝑙𝑑 𝑗𝑜𝑖𝑛𝑡
PROBLEM NO. 7:
Given:

d1=diameter if air receiver

operating pressure=175 psi
St=Sd=9000 psi=PD/2t𝜋
d2=diameter of drain valve
𝜇 = 100%
St weld joint=60000 psi
Required:
bursting pressure
tp (thickness of plate)
PROBLEM NO. 7:
Solution:

St=PD/2tp𝜇

*where P=bursting pressure

Using operating pressure,

St=PD/2tp𝜇
9000=(157)(5*12in)/*2)(tp)(100%)
∴ 𝑡𝑝 = 0.58 𝑖𝑛
PROBLEM NO. 7:
Using the pop-out pressure,
St=PD/2tp𝜇
9000=(195)(5*12in)/*2)(tp)(100%)
∴ 𝑡𝑝 = 0.65 𝑖𝑛

*refer to p.32 Faires, text foe preferred sizes,

tp=5/8=0.625 in

0.65−0.625
Test %= × 100% = 3.8%
0.65
<4% to 5%
PROBLEM NO. 7:
t/d=0.625/5*12in=0.01 thin walled

St=60000=P(5*12in)/2(0.625in)(100%)
∴ 𝑃 = 1250 𝑝𝑠𝑖
PROBLEM NO. 8:
Helium is used to provide pressure on the fuel and liquid
oxygen in rocket motors. Helium is stored in the
cylindrical vessel 22 × 24𝑖𝑛 at 3800 psi. The welded joints
are assumed to have an efficiency of 85% and for the
purposes of saving weight, the vessel is to be made of
annealed titanium alloy TiGAl4V. For normal temperature,
what thickness of plate is needed with a design factor of
1.4 on the yield strength?
PROBLEM NO. 8:
Given:

Cylinder size= 22 × 24𝑖𝑛

Pressure=3000 psi
Material= annealed titanium alloy TiGAl4V
𝜇 = 85%
d.f.=1.4

Required:
Thickness of plate
PROBLEM NO. 8:
Solution:
Sd=St=PD/2tp𝜇
*From table AT-3, Sy=130 ksi=130000 psi
F.S=D.F=Sy/Sd
Sd=Sy/D.F.
130000 𝑝𝑠𝑖 (3800 𝑝𝑠𝑖)(22𝑖𝑛)
=
1.4 2(𝑡𝑝)(85%)
∴ 𝑡𝑝 = 0.53 𝑖𝑛

0.53−0.5
Test %= × 100% = 5.6%
0.53
PROBLEM NO. 8:

Preferred size=8/16=1/2

tp=9/16 (recommended)
*must be <4-5%
PROBLEM NO. 9:

The work cylinder of a hydrostatic system is

acted by a hydraulic pressure of 365 psi while
the maximum load of the piston is 5750 lbs.
If the allowable tensile stress is 2000 psi, what is
the required wall thickness of the cylinder?
PROBLEM NO. 9:
Given:

Hydraulic pressure=365 psi

Load=5750lbs
St=2000psi

Required:
t (thickness of cylinder)
PROBLEM NO. 9:
Solution:

*Assume thick-walled pressure vessel

>0.1
>0.07

Force=PA

A=5750lbs/365psi=15.75𝑖𝑛2
PROBLEM NO. 9:
𝜋𝑑 2
= 15.75𝑖𝑛2
4
d=4.48 in

Test:
1
4.48 1 2
𝑡= − 1 = 0.468in
2 365
1− 3
2000
1
2
4.48 2000 + 365
𝑡= −1 = 0.454in
2 2000 − 365
PROBLEM NO. 9:

Faires,
𝑡 0.468
= = 0.10446 >0.07
𝑑 4.48

Black and Adams,

𝑡 0.468
= = 0.10446 >0.10
𝑑 4.48
PROBLEM NO. 10:
With the present interruption prevailing in
Metro Manila you are asked to design an
upright cylindrical water tank 6.5m in diameter &
6.5m high, vented, and to be filled completely
with water. Determine the minimum thickness of
the tank plate if the stress is limited to 40 Mpa.
PROBLEM NO. 10:

Given:
Fluid=water
Height of tank=6.5m
Diameter of tank=6.5m

Required:
Minimum thickness of tank
PROBLEM NO. 10:
Solution:

St=PD/2t𝜇
*Assume thin walled cylinder
𝜇 = 100%
P=𝜔ℎ
where: 𝜔 = 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑
ℎ = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑
P=(9.80665kN/cu.m)(6.5m)
P=63.74 kN/sq.m
PROBLEM NO. 10:
St=PD/2t
𝑘𝑁
(63.74 2)(6.5𝑚)
40000 kn/sq.m= 𝑚
2(𝑡)
∴ 𝑡 = 5.18 𝑚
PROBLEM NO. 11:

If the water tank had to be elevated 12 meters fr

om its bottom and has to be filled up in 2
hours, determine the motor power to drive
the pump, if velocity and head loss is 5 meters.
Consider the pump efficiency = 75%.
PROBLEM NO. 11:
Given:
t=2 hrs
Velocity and head loss=5m
Pump efficiency=75%

Required:
Motor power (BHP)-Break hp
PROBLEM NO. 11:
Solution:

Pump efficiency=WHp/BHp
(Q)(d)(H)
where: WHp (water horsepower)= 𝐻𝑝
4500000
TDH=total dynamic head loss
EE=elevation energy loss
PE=pressure energy loss
VE=velocity energy loss
FE=friction energy loss
PROBLEM NO. 11:
𝑊𝐻𝑝
Pump efficiency=
𝐵𝐻𝑝
WHp=QWH
where: H=TDH
Q=volume flow rate=volume of liquid/time
For volume:
V=Ah
𝜋 6.5𝑚 2
V= (6.5𝑚)
4
V=215.69 cu.m
PROBLEM NO. 11:
𝑉 215.69𝑐𝑢.𝑚
Therefore, Q= = = 1.80𝑐𝑢. 𝑚/𝑚𝑖𝑛
𝑡𝑖𝑚𝑒 2ℎ𝑟𝑠∗60𝑚𝑖𝑛

And, H=12.0+6.5+5.0
H=23.5m

WHp=Q𝜔𝐻 where: 𝜔 = 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑤𝑒𝑖𝑔ℎ𝑡

WHp=(1.80cu.m/min)(9.80kN/cu.m)(23.5m)(1min/60sec)
WHp=6.91 kW
PROBLEM NO. 11:
Therefore,
WHp
BHp=
0.75

6.91kW
BHp=
0.75

BHp=9.22 kW
PROBLEM NO. 12:

A simply supported shafts 30mm diameter, 20m

m long is acted upon by a sudden load of 1000
N at its midspan. This load falls freely from a hei
ght of 2mm. find the impact stress produced in t
he shaft. Assume Young’s modulus of the shaft
material as 2𝑥105 MPa.
PROBLEM NO. 12:
Given:

shaft dia. = 30mm

Length of shaft = L= 200mm
F = 1000n at its midspan
h = 2mm ; E = 2𝑥105 𝑀𝑃𝑎
Required:

impact stress
PROBLEM NO. 12:
Solution:
𝑆𝑖𝑚𝑝𝑎𝑐𝑡 = 𝑆𝑏𝑜𝑛𝑑𝑖𝑛𝑔 ∙ 𝑆ℎ𝑜𝑐𝑘 𝐹𝑎𝑐𝑡𝑜𝑟
𝑤ℎ𝑒𝑟𝑒: 𝑆𝑖𝑚𝑝𝑎𝑐𝑡 = 𝑙𝑜𝑎𝑑 𝑑𝑟𝑜𝑝𝑝𝑒𝑑 𝑠𝑢𝑑𝑑𝑒𝑛𝑙𝑦 @ 2𝑚𝑚
𝑆𝑏𝑜𝑛𝑑𝑖𝑛𝑔 = 𝑙𝑜𝑎𝑑 𝑔𝑟𝑎𝑑𝑢𝑎𝑙 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑡𝑖𝑜𝑛
𝑀𝑏 𝑚𝑎𝑥 𝐶
𝑆𝑏 =
𝐼
𝜋𝑑 4 𝜋 30𝑚𝑚 4
𝑤ℎ𝑒𝑟𝑒: 𝐼 = = = 39760.782 𝑚𝑚4
64 64
𝐹𝐿 1000𝑁 200𝑚𝑚
𝑀𝑏 𝑚𝑎𝑥 = = = 50000 𝑁 ∙ 𝑚𝑚
4 4
30𝑚𝑚
𝑐= = 15 𝑚𝑚
2
PROBLEM NO. 12:
(50000𝑁∙𝑚𝑚)(15𝑚𝑚)
𝑇ℎ𝑢𝑠, 𝑆𝑏 =
39760.782𝑚𝑚4
𝑁
𝑆𝑏 = 18.86
𝑚𝑚
𝑺𝒃 = 𝟏𝟖. 𝟖𝟔 𝑴𝑷𝒂

𝐹𝐿3
𝑚𝑎𝑥. 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 = 𝑦 =
48𝐸𝐼
1000𝑁 200𝑚𝑚 3
𝑦= 2𝑥105 𝑁
48 39760.782𝑚𝑚4
𝑚𝑚2
𝑦 = 0.02096𝑚𝑚 → 𝑆𝑚𝑎𝑥
PROBLEM NO. 12:
For shock factor:
𝑃 2𝑐ℎ 𝑃
=1+ 1+ 𝑤ℎ𝑒𝑟𝑒: 𝑐 =
𝑊 𝑊 𝛿

𝑃 ℎ
= 1+ 1+2
𝛿𝑊
ℎ
𝑆. 𝐹. = 1 + 1 + 2
𝛿

2𝑚𝑚
𝑆. 𝐹. = 1 + 1 + 2
0.02096𝑚𝑚
𝑺. 𝑭. = 𝟏𝟒. 𝟖𝟓
PROBLEM NO. 12:

𝑆𝑖𝑚𝑝𝑎𝑐𝑡 = 𝑆𝑏 ∙ 𝑆. 𝐹.
𝑆𝑖𝑚𝑝𝑎𝑐𝑡 = (18.86𝑀𝑃𝑎)(14.85)
𝑺𝒊𝒎𝒑𝒂𝒄𝒕 = 𝟐𝟖𝟎. 𝟎𝟕 𝑴𝑷𝒂
PROBLEM NO. 13:
A shaft in torsion only is to transmit 1678.5 KW
at 585 rpm with medium shock. Its material is
AISI 1137 steel annealed. A) what should be the
diameter of a solid shaft. B) if the shaft is hollow,
if 𝐷𝑜 = 2𝐷𝑖 , what size is required? C) what is the
weight per meter length for each of these shaft?
Which is lighter? By percentage? D) which shaft
is more rigid? Compute the torsional deflection
of each for a length of 3.0m?
PROBLEM NO. 13:
Given:
p = 1678.5 KW
n = 585
material: AISI 1137 steel annealed
Required:

dia. of shaft (solid)

size, 𝐷𝑜 , 𝐷𝑖 (hollow)
weight per meter of length for (a), (b)
torsional dedflection 𝜃𝑠 , 𝜃, for L=3m
PROBLEM NO. 13:
Solution:
For AISI 1137 steel annealed, Table AT-8
6.8948𝑀𝑃𝑎
𝑆𝑦 = 50𝑘𝑠𝑖 = 50𝑘𝑠𝑖
1𝑘𝑠𝑖
𝑺𝒚 = 𝟑𝟒𝟒. 𝟕𝟒𝑵/𝒎𝒎𝟐 = 𝟑𝟒𝟒. 𝟕𝟒 𝑴𝑷𝒂
From table 1.1 for medium shock, N=3
*Solve for the torsional stress, 𝑆𝑡 :
0.6𝑆𝑦 → 𝑆𝑦𝜃
𝑆𝑡 =
𝑁
0.6(344.74 𝑁/𝑚𝑚2
𝑆𝑡 =
3
𝑆𝑡 = 68.948 𝑁/𝑚𝑚2
PROBLEM NO. 13:
*for solid shaft, solve for d,
16𝑇
𝑆𝑡 =
𝜋𝑑 3
16𝑇
𝑑3 =
𝜋𝑆𝑡
1
16𝑇 3
𝑑3 =
𝜋𝑆𝑡
where:
𝑃 1678.5 𝑘𝑊
𝑇= = 𝑟𝑒𝑣
2𝜋𝑛 2𝜋(585 )
min
𝑚
1678.5𝑥103 𝑁∙
sec
𝑇= 2𝜋 𝑟𝑒𝑣 𝑚𝑖𝑛
585
𝑟𝑒𝑣 𝑚𝑖𝑛 60𝑠𝑒𝑐

𝑇 = 27399.14 𝑁 ∙ 𝑚
𝑻 = 𝟐𝟕𝟑𝟗𝟗𝟏𝟒𝟎 𝑵 ∙ 𝒎𝒎
PROBLEM NO. 13:

Thus,
1
16(27399140 𝑁∙𝑚𝑚 3
𝑑= 𝑁
𝜋(68.448 )
𝑚𝑚2

𝒅 = 𝟏𝟐𝟔. 𝟒𝟗 𝒎𝒎 = 𝟏𝟐𝟔. 𝟓𝟎 𝒄𝒎
PROBLEM NO. 13:
*For hollow shaft, if 𝐷𝑜 = 2𝐷𝑖
16𝑇𝐷𝑜
𝑆𝑡 =
𝜋(𝐷𝑜4 −𝐷𝑖4 )
16𝑇(2𝐷𝑖 )
𝑆𝑡 = *weight per meter of length,
𝜋 2𝐷𝑖4 −𝐷𝑖4
𝜌𝑠𝑡𝑒𝑒𝑙 = 0.284 𝑙𝑏/𝑖𝑛3
32𝑇𝐷𝑖 𝜌𝑠𝑡𝑒𝑒𝑙 = (0.284 𝑙𝑏/
𝑆𝑡 = 𝜋 15𝐷𝑖4 3
3 4.4482 𝑁 𝑖𝑛
32 𝑇 𝑖𝑛 )( 1 𝑙𝑏 ) 25.4 𝑚𝑚
𝑆𝑡 = 15 𝜋𝐷3
𝑖 𝜌𝑠𝑡𝑒𝑒𝑙 = 7.709𝑥10−5 𝑁/𝑚𝑚3
1
32𝑇 3
𝐷𝑖 = 15𝜋𝑆𝑡
𝐷𝑖 = 64.45 𝑚𝑚
𝑫𝒐 = 𝟐𝑫𝒊 = 𝟏𝟐𝟖. 𝟗 𝒎𝒎
PROBLEM NO. 13:

for solid:
𝑊𝑠𝑜𝑙𝑖𝑑 = 𝑉𝑠𝑜𝑙𝑖𝑑 ∙ 𝜌𝑠𝑡𝑒𝑒𝑙
𝜋 2
𝑊𝑠𝑜𝑙𝑖𝑑 = 𝑑 𝐿 𝜌𝑠𝑡𝑒𝑒𝑙
4
𝑊𝑠𝑜𝑙𝑖𝑑 𝜋 2
= 126.50𝑚𝑚 7.709𝑥10−5 𝑁/𝑚𝑚3
𝐿 4
𝑾𝒔𝒐𝒍𝒊𝒅
= 𝟎. 𝟗𝟔𝟖𝟗 𝑵/𝒎𝒎
𝑳
𝑾𝒔𝒐𝒍𝒊𝒅
= 𝟗𝟔𝟖. 𝟗 𝑵/𝒎
𝑳
PROBLEM NO. 13:

for hollow:
𝜋
𝑊ℎ𝑜𝑙𝑙𝑜𝑤 = 𝐷𝑜2 − 𝐷𝑖2 𝐿 𝜌𝑠𝑡𝑒𝑒𝑙
4
𝑊ℎ𝑜𝑙𝑙𝑜𝑤 𝜋 7.709𝑥10−5 𝑁
= 128.9𝑚𝑚 2 − 64.45𝑚𝑚 2
( )
𝐿 4 𝑚𝑚3
𝑾𝒉𝒐𝒍𝒍𝒐𝒘 𝑵
= 𝟎. 𝟕𝟓𝟒𝟒𝟗
𝑳 𝒎𝒎
𝑾𝒉𝒐𝒍𝒍𝒐𝒘
= 𝟕𝟓𝟒. 𝟒𝟗 𝑵/𝒎
𝑳
PROBLEM NO. 13:
*torsional deflection, L=3.0m
For solid:
𝑇𝐿
𝜃𝑠 =
𝐺𝐽
𝜋 4 𝜋
where: 𝐽 = 𝑑 = (126.50𝑚𝑚)4
32 32
𝐽 = 25139810.31𝑚𝑚 = 25.14𝑥106 𝑚𝑚4
4

𝐺 = 11.5𝑥106 𝑝𝑠𝑖
6.8948𝑘𝑃𝑎 𝑀𝑃𝑎
𝐺 = (11.5𝑥106 𝑝𝑠𝑖)( )( )
1 𝑝𝑠𝑖 1000𝑘𝑃𝑎
2
𝐺 = 79290.2 𝑀𝑃𝑎 → 𝑁/𝑚𝑚
Thus,
(27399140 𝑁∙𝑚𝑚)(3000𝑚𝑚)
𝜃𝑠 =
(25.14𝑥106 𝑚𝑚4 )(79290.2𝑁/𝑚𝑚2 )
𝜃𝑠 = 0.0412 𝑟𝑎𝑑
𝜃𝑠 = 7.42°
PROBLEM NO. 13:
For hollow:
𝑇𝐿
𝜃ℎ = 𝐺𝐽
where:
𝜋 𝜋
𝐽 = 32 𝐷𝑜4 − 𝐷𝑖4 = 32 [(128.9𝑚𝑚)4 − 64.45𝑚𝑚 4 ]
𝐽 = 25.41𝑥106 𝑚𝑚4
Thus,
27399140 𝑁∙𝑚𝑚 3000𝑚𝑚
𝜃𝑠 = 79290.2𝑁2
(25.14𝑥106 𝑚𝑚4 )( 𝑚𝑚
)

𝜃𝑠 = 0.0408 𝑟𝑎𝑑
𝜃𝑠 = 7.34°
Solid shaft is more rigid than the hollow shaft.
PROBLEM NO. 13:
What would be the diameter of a steel rod 7-in
long if it is to re resist the impact of a weight of
W=600lbs dropped through a distance of 2-in?
Maximum computed stress is to be 25ksi. Use
𝐸 = 30𝑥106 𝑝𝑠𝑖.
PROBLEM NO. 13:
Given:

Length=7 in
Impact weight=600 lbs
Distance=2 in
Smax=25 ksi
E=30𝑥106 𝑝𝑠𝑖.

Required:
Diameter of steel rod
PROBLEM NO. 13:
Solution:

1
𝑊 ℎ + 𝑆𝑚𝑎𝑥 = 2 𝐹𝑆𝑚𝑎𝑥
1
𝑊 ℎ + 𝑆𝑚𝑎𝑥 = 2 (𝑆𝐴)𝑆𝑚𝑎𝑥
2𝑊(ℎ+𝛿)
𝐴= 𝑆𝛿
Solve for the 𝛿𝑚𝑎𝑥 :
𝑙𝑏 2
𝑠𝐿 25𝑥103 𝑖𝑛 7𝑖𝑛
𝛿𝑚𝑎𝑥 = = 𝑙𝑏 2
𝐸 30𝑥106 𝑖𝑛
𝑠𝐿
= 𝑜. 𝑜𝑜583 𝑖𝑛.
𝐸
PROBLEM NO. 13:
Solve for d:
2𝑊(ℎ+𝛿) 𝜋𝑑 2
𝐴= 𝑤ℎ𝑒𝑟𝑒 𝐴 =
𝑆𝛿 4
𝜋𝑑 2 2𝑊(ℎ+𝛿)
=
4 𝑆𝛿
1
8𝑊(ℎ+𝛿) 2
𝑑= 25𝑥1𝑜3 𝑙𝑏
𝜋( )(0.00583𝑖𝑛)
𝑖𝑛2

𝑑 = 4.59 𝑖𝑛.
PROBLEM NO. 13:
1
Refer on the preferred sizes p.32 D.O.M.E take 𝑑 = 4 𝑖𝑛.
2
4.59𝑖𝑛−4.5𝑖𝑛
%= 𝑥100%
4.59𝑖𝑛
% = 1.96 𝑖𝑛.
1
then, preferred size is 𝑑 = 4 𝑖𝑛.
2
Ordinary bending load (static stress)
𝑀𝑚𝑎𝑥 𝑀𝑚𝑎𝑥
𝑆𝑏 = =
𝐼 𝑍′

Impact load
→shock factor or magnification of load due to the impact.
𝑆𝑖𝑚𝑝𝑎𝑐𝑡 = 𝑆𝑡 × 𝑠ℎ𝑜𝑐𝑘 𝑓𝑎𝑐𝑡𝑜𝑟
𝜌 2𝑐ℎ
=1+ 1+
𝑊 𝑊

where:
c = spring scale or constant
𝐴𝐸
=P/𝛿𝑚𝑎𝑥 = 𝐿
PROBLEM NO. 14:
A rigidly built-in steel cantilever has a cross-section of
½ “ deep, 3/8” wide and is loaded 10-in. from the
support. Determine the maximum bending stress in the
beam, assuming that
a. a load of 10 lbs is gradually applied; and
b. a load of 10 lbs weight is dropped on the beam
through a distance of 3/16 in.

Use E=30 × 106 𝑃𝑠𝑖

PROBLEM NO. 14:
Given:
1 3
Cross section= 2 𝑖𝑛 × 8 𝑖𝑛
L=10 in
F=10 lbs
E=30 × 106 𝑃𝑠𝑖

Required:
a. Mmax
b. Mmax if load is dropped 3/16 in. above the beam
PROBLEM NO. 14:
Solution:
𝐹𝐿3 (10 𝑙𝑏𝑠)(10 𝑖𝑛)3
a. 𝛿=𝑦= 3𝐸𝐼
= 3 1 3
3 30×106 𝑝𝑠𝑖 8∗2 /12

𝛿 =0.00196 in

Mmax=FL=(10)(10)=100 in-lb

1
b. w(h+𝛿) = 2 𝑆𝐴𝛿

2𝑊(h+𝛿)
3
2(10)(16+0.00196)
S= 𝐴𝛿 = 3 1
∗ ∗0.00196
8 2

S=100030.75 lb/sq.in
PROBLEM NO. 14:
Solve for Mmax:
S=Mc/I
M=SI/c
[10310.75][(3/8∗1/2)/12)]
M= 1
2𝑖𝑛
2

M=161.11 in-lb
Columns (Design of Machine Members by Vallance) p. 57
𝐹𝑐𝑟 = critical load , is the load on the column at which bu
ckling occurs. This load is not a direct function of stress, t
hus designers normally base their column calculations up
on critical load rather than upon direct stress.
a. Euler’s Long Column Equation
𝜇𝜋2 𝐸𝐼 𝜇𝜋2 𝐸𝐴
𝐹𝑐𝑟 = 𝐿2
= 𝐿
( )2
𝐾

where: A = constant cross-sectional area column, 𝑖𝑛2

E = Young’s modulus of the material of the
column, psi
I = area moment of inertia of the cross-section of
the column. Calculated about the axis through the
cross- section about which buckling occurs, 𝑖𝑛2
 𝐼
𝑘= , radius of gyration of the cross-section, in
𝐴

L = effective length of the column, in

y = end-fixity factor, the square of the

member of 180° of approximate sine-curve
deflection exhibited by the deflected neutral
axis of the column

𝐿
= slenderness ratio
𝐾
𝐹𝑐𝑟 = critical load, axial concentric load
*Euler’s Formula (D.O.M.E, Faires p.211)
𝐿𝑒
(𝑓𝑜𝑟 > 120)
𝑘
𝜋2 𝐸𝐴
𝐹𝑐 = 𝐿 2
𝑘

where:
𝐹𝑐 = critical load or axial concentric load that c
auses the column to be on the point of buckling
E = modulus of elasticity
𝐹𝑐
𝑁 = 𝐹. 𝑆. = design factor =
𝐹
where: F = actual load on the column
𝐹𝑐 = critical load
𝜋2 𝐸𝐴 𝜋2 𝐸𝐴
𝐹𝑐 = 𝑁𝐹 = 𝐿𝑒 2
;𝐹 = 𝐿𝑒 2
;
𝑘 𝑘

𝜋2 𝐸𝐼
𝐹=
𝑁𝐿2𝑒

F = safe central load

Use for the structural steel when

𝐿𝑒
> 𝑎𝑏𝑜𝑢𝑡 120
𝑘
Types of columns and effective length
b.) J.B Johnson Equation – for shorter columns
𝐿 2
𝑆𝑦 𝑘𝑒
𝐹𝑐 = 𝑆𝑦 𝐴 1 − (critical load)
4𝜋2 𝐸

𝐿 2
𝐹 𝑆𝑦 𝑘𝑒
Or = 𝑆𝑒 1 − (actual load)
𝐴 4𝜋2 𝐸
𝐿
(approximate for 30 < 𝑒 > 120 , for structural steel)
𝑘
where: 𝑆𝑒 = equivalent stress that indicates the degree
of safety for the load, F
𝐹𝑐 𝑆𝑦 𝐹
𝑁= = = actual nominal stress
𝐹 𝑆𝑒 𝐴
*Straight line Formula for shorter columns (Faires p.213)
Structural steel:
𝐹 𝐿 𝐿
= 16000 − 70 (Eng) 30 < 𝑒 > 120
𝐴 𝑘 𝑘
𝐹 𝐿
= 110.3 − 0.483 (SI)
𝐴 𝑘

Cast Iron:
𝐹 𝐿 𝐿𝑒
= 9000 − 40 30 < > 120
𝐴 𝑘 𝑘
𝐹 𝐿
= 62.07 − 0.276
𝐴 𝑘

These formulas are not applied to free-end column.

 𝑃
𝑃 = 𝑐𝛿 → 𝑐 =
𝛿

where: w = falling weight, lbs

h = height of free fall, in
𝛿 = displacement of point of load application, in
P = impact load
𝑃 𝑙𝑏𝑠
Spring constant = 𝑐 = = of deflection
𝛿 𝑖𝑛
1
𝑃𝛿 =𝑊 ℎ+𝛿
2
𝑃
𝛿=
𝑐
 2𝑐ℎ
𝑃 = 𝑊(1 + 1 +
𝑊

2𝑐ℎ
Shock factor: 𝑃 = 𝑊(1 + 1 +
𝑊

For a bar in tension:

𝑃𝐿
𝛿=
𝐴𝐸

Spring scale or constant:

𝑃 𝐴𝐸
𝑐= =
𝛿 𝐿
 2𝑐ℎ
𝑃 = 𝑊(1 + 1 +
𝑊

2𝑐ℎ
Shock factor: 𝑃 = 𝑊(1 + 1 +
𝑊

For a bar in tension:

𝑃𝐿
𝛿=
𝐴𝐸

Spring scale or constant:

𝑃 𝐴𝐸
𝑐= =
𝛿 𝐿
1
𝑃𝛿 = 𝑊 ℎ + 𝛿
2
𝑃
𝛿=
𝐶

2𝑐ℎ
P=W(1+ 1 + )
𝑤

2𝑐ℎ
Shock factor: P/W=1+ 1 +
𝑤

For a bar in tension:

𝑃𝐿
𝛿=
𝐸𝐴
𝑃 𝐴𝐸
Spring scale or constant = C= =
𝛿 𝐿
PROBLEM NO. 15:

A certain piston rod is subjected to a maximum

compressive load of 30,000 lbs and is 18-in. long
. The material is AISI C1040 OQT 1000℉ in order
to obtain a desired hardness. What would be the
diameter for N=3?
PROBLEM NO. 15:
Given:

Material: C1040 OQT 1000℉

F=30,000 lbs
L=18-in.
N=3

Required:
D=?
PROBLEM NO. 15:
Solution:
For C1040 OQT 1000℉ from Fig. AF-1
Sy=71 ksi
L/k for columns (Euler’s/Johnsons Eq.)

𝐼
For k= round bar shaft
𝐴

Where Ix=𝜋𝑑4 /64 A=𝜋𝑑 2 /4

𝜋𝑑 4 /64 𝑑
K= =
𝜋𝑑 2 /4 4
18
Thus, L/k= = 72/𝑑 *30<L/k<120 (Johnson) *L/k>120 (Euler)
𝑑/4
PROBLEM NO. 15:
Assume 30<L/k<120, use Johnson’s Eqn.
𝐿
𝐹 𝑆𝑦( )2
𝑘
=𝐴 1− 2
𝑆𝑒 𝜋 4𝐸

Sy=71 ksi=7100 psi

Se=design or allowable stress

N=Sy/Se

Se=Sy/N=71/3=23.67 ksi
PROBLEM NO. 15:
Thus,
30000 𝑙𝑏𝑠 𝜋𝑑 2 7100𝑙𝑏/𝑖𝑛2
= 1− 30000000𝑙𝑏 = 1.387 𝑖𝑛
23670𝑙𝑏/𝑖𝑛2 4 4𝜋2 ( )(𝑑 2 )
𝑖𝑛2

3
Preferred size=1 𝑖𝑛 = 1.375𝑖𝑛
8

L/k=72/1.375=52.36

Thus, it satisfies the condition 30<L/k<120.

PROBLEM NO. 16:

A shaft is loaded by a torque of 40,000 in. lbs. The material has a

yield point of 50,000 psi. N=2

a. Find the diameter by the maximum shear theory

b. Find the diameter by Mises-Hencky theory or Distortion Energy

theory
PROBLEM NO. 16:
Given:

T=40,000 in.lbs
N=2
Syp=50,000 psi

Required:

Ds using max. shear theory and distortion energy theory

PROBLEM NO. 16:
Solution:

Design stress=Sshear=Syp/N=5000/2=2500 psi

S1=16T/𝜋𝑑 3 = 16(40000 𝑖𝑛. 𝑙𝑏)/𝜋𝑑 3

S2=-16T/ 𝜋𝑑 3 = −64000 𝑖𝑛. 𝑙𝑏/𝜋𝑑 3

PROBLEM NO. 16:
Maximum Shear Theory
Smax=1/2(S1-S2)=1/2(640000/ 𝜋𝑑3 - 640000/ 𝜋𝑑3 )
Smax=640000 in.lbs/ 𝜋𝑑3

Sys=? N=Sys/Smax

On p. 240 (DOME Faires)

Sys=0.5Syp=0.5(50000 psi)=25000 psi (Shear stress / Ss)

Thus, on Eqn. 1
25000 𝑙𝑏/𝑖𝑛2
2= 640000 𝑖𝑛.𝑙𝑏 = 2.535 𝑖𝑛
𝜋𝑑3

Preferred size, d=2 ½ in.

PROBLEM NO. 16:
Distortion Energy Theory

𝑆𝑠 2 = 𝑆12 + 𝑆22 − 𝑆1𝑆2

2 2
640000𝑖𝑛. 𝑙𝑏 2 −640000𝑖𝑛. 𝑙𝑏 2 640000𝑖𝑛. 𝑙𝑏 −640000𝑖𝑛. 𝑙𝑏
(25000lb/𝑖𝑛2 )2 = ( ) +( ) −[ ]
𝜋𝑑 3 𝜋𝑑 3 𝜋𝑑 3 𝜋𝑑 3

1 640000 1
(25000lb/𝑖𝑛2 )2 = {3 }2
𝜋𝑑 3

25000lb 640000
= 3
𝑖𝑛2 𝜋𝑑 3

d=2.42 in

Preferred size: d=2 ½ in.

DESIGN CRITERIA
*p.81 Machine Design by Black and Adams*
Common Modes of Failures of Machine or
Structural Member
A. Yielding
a. Maximum stress exceeding the yield strength of t
he material
causing it to deform plastically
b. Deep deformation whereby the member deforms
under a
constant load, usually at an elevated temperature

B. Fracture
a. Due to static load
b. Due to fatigue loads
c. Due to impact loads
C. Excessive Elastic Deflection
D. Wear
E. Buckling
F. Corrosion fatigue and caustic
embrittlement
Theories of Failure
Maximum Normal/Principal Stress Theory

Failure (yielding or fracture) occurs at a point in a body when

one of the principal stresses at that point equals a critical str
ess for the material (yield stress or ultimate strength). If S1 is
numerically greatest principal stress S1 > S2 > S3 failure for
combined stresses occurs when,

S1=∓𝑆𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙
𝑆𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙
S1 allowable = ∓ 𝑁
where:

𝑆𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙 − 𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 (yield stress or ultimate stress)

assuming that the critical stress is equal in tension or
compression.
Theories of Failure
Maximum Shear Stress Theory

this theory assumes that failure (yielding or failure) occurs

for a combined stress condition when the maximum shear
stress equals the value of a critical shear stress ( yield shear
stress or ultimate shear stress) produced in an element
subjected to simple tension.

𝑆𝑦𝑝
𝑆𝑠 𝑦𝑝 = , element subjected to simple tension at the yield
2
condition.
For three-dimensional stress state, the maximum shear
stresses are given by:

𝑆1 −𝑆2 𝑆2− 𝑆3 𝑆3− 𝑆1

𝑆𝑚𝑎𝑥 = = 𝑜𝑟
2 2 2

𝑆𝑥 −𝑆𝑦 2
𝑆𝑚𝑎𝑥 = + 𝑆𝑥𝑦 2
2
𝑆1 − 𝑆2 = ±𝑆𝑦𝑝 if it is assumed that the shear
𝑆2 − 𝑆3 = ±𝑆𝑦𝑝 stress at yield for simple tension
𝑆3 − 𝑆1 = ±𝑆𝑦𝑝 is equal to that for simple compression
Theories of Failure
Distortion-energy Theory

This theory is concerned with the predicting the

beginning of yielding and seldom is used in
connection with fracture. Yielding will occur when the
strain energy of distortion per unit volume for a
specimen in an uniaxial tension or compression
(strained to the yield stresses).
(S1−S2) 2 +(S2−S3) 2 +(S3−S1) 2 = 2𝑆𝑦𝑝2

For biaxial state, S3=0

𝑆12 − 𝑆1𝑆2 + 𝑆22 = 𝑆𝑦𝑝2

𝑆𝑦𝑝
S1= 0.577𝑆𝑦𝑝
3
𝑆𝑦
Or Sys= = 0.577𝑆𝑦
3

In terms of maximum allowable stress,

𝑆𝑦𝑝2
𝑆12 − 𝑆1𝑆2 + 𝑆22 = or
𝑁
𝑆𝑠 2 = 𝑆12 +𝑆22 −𝑆1𝑆2
=𝑆𝑥 2 + 𝑆𝑦 2 − 𝑆𝑥𝑆𝑦 − 3𝑆𝑥𝑦 2

S allowable=Syp/N
Fatigue Failures
A fatigue failure may be described as a
progressive fracture leading from a
point of stress concentration such as
may occur in some machine and
structural members.
PROBLEM NO. 17:
A link shown is to be made of AISI 2330 WQT 1000℉. The load F=5
kips is repeated & reversed.
For the time being, ignore all stress concentration:

a. If its surface is machined, what would be its diameter for N=1.4?

b. The same as in a. except that the surface is mirror polished. What
would be the percentage
of saving weight?
c. The same as in a. except that the surface is forged.
PROBLEM NO. 17:
Given:

Material: AISI 2330 WQT 1000℉

Load=5000 lbs
Type of load: repeated and reversed

Required:

Diameter of link
PROBLEM NO. 17:
Solution:

From p.579, Table AT-9

MATERIAL TEMPERATURE SIZES

AISI 2330 600 1/2 in
1000 1/2 in
1300 1/2 in
1000 4 in

Su at ½ “ dia. and 1000℉=135 ksi

Su at 4” dia. and 1000℉=105 ksi

*Use 135 ksi

PROBLEM NO. 17:
Sn=(factors)(Su)

If surface is machined, p.583 Fig. AF-5

F axial loading=use 0.8 due to axial loading

F size=use 0.85 due to size

F endurance ratio=0.50

F surface=0.8
PROBLEM NO. 17:

Thus,
Sn=[F size F al F surf F er][Su]=(0.85)(0.8)(0.8)(0.5)(135000 psi)
Sn=36720 psi

N=Sn/Sd

Sd=Sn/N=F/A
PROBLEM NO. 17:
𝜋
*where: A= 𝑑 2
4
𝜋
Sn/N=F/ 𝑑 2
4
d=[4NF/𝜋𝑆𝑛]
1
d= [4(1.4)(500lb)/𝜋(36720 𝑝𝑠𝑖)] 2

d=0.49 in

Preferred size: d=0.50 in.=1/2”

PROBLEM NO. 17:
If surface is mirror polished,

p.583 Fig. AF-5

F axial loading=use 0.8 due to axial loading

F size=use 0.85 due to size
F endurance ratio=0.50
F surface=0.1

Su=13500 psi
PROBLEM NO. 17:
Thus,
Sn=[F size F al F surf F er][Su]=(0.85)(0.8)(0.1)(0.5)(135000 psi)
Sn=45900 psi
N=Sn/Sd
Sd=Sn/N=F/A
𝜋
*where: A= 4 𝑑 2
𝜋
Sn/N=F/ 4 𝑑 2
d=[4NF/𝜋𝑆𝑛]
1
d= [4(1.4)(500lb)/𝜋(45900 𝑝𝑠𝑖)] 2

d=0.44 in
Preferred size: d=0.50 in.=1/2”
PROBLEM NO. 17:
𝑊𝑎−𝑊𝑏
% weight= × 100%
𝑊𝑎

𝑉𝑎𝜌−𝑉𝑏𝜌
= × 100%
𝑉𝑎𝜌

𝜋 2 𝐿𝜌−𝜋𝑑𝑏 2 𝐿𝜌
𝑑𝑎
=( 4
𝜋 2
4
) × 100%
𝑑𝑎 𝐿𝜌
4

𝑑𝑎2 −𝑑𝑏2
= 𝑑𝑎2 × 100%

0.492 −0.442
= × 100%
0.492

%weight=19.37%
PROBLEM NO. 17:

If surface is forged,
p.583 Fig. AF-5

Thus,
Sn=[F size F al F surf F er][Su]
Sn=(0.85)(0.8)(0.33)(0.5)(135000 psi)
Sn=15147psi

N=Sn/Sd
Sd=Sn/N=F/A
PROBLEM NO. 17:
𝜋
*where: A= 𝑑 2
4
𝜋
Sn/N=F/ 𝑑 2
4
d=[4NF/𝜋𝑆𝑛]
1
d= [4(1.4)(500lb)/𝜋(15147 𝑝𝑠𝑖)] 2

d=0.767 in

Preferred size: d=7/8”

VARIABLE LOADS AND STRESS CONCENTRATIONS

Instead of using the yield stress or ultimate stress as a

basis of finding a design stress for a part subjected to a
varying load, we should use endurance strength.

Sn’ = Endurance limit or fatigue limit, is the maximum

reversed stress that may be repeated an indefinite
member of times on a polished, standard (nominal 0.2 to
0.4 in diameter) specimen in rotating bending without
causing failure.

Sn = endurance strength or fatigue strength

(Table AT-10 for Sn of various materials, p. 150)
𝑆𝑚𝑎𝑥+𝑆𝑚𝑖𝑛
Sm = average or mean stress =
2
𝑆𝑚𝑎𝑥−𝑆𝑚𝑖𝑛
Sa = alternating component =
2
(range stress)
where:
A compressive stress is a negative stress.
For complete reversal,

Smin=0
Sa=Smax

Smax=Sm+Sa --- in ideal case

R=stress ratio=Smin/Smax
R=-1 for completely reversed stress
Other possible criteria for design

a. Sodergberg equation/line (for ductile materials)

1/N=Sm/Sy+Sa/Sn

b. Goodman equation/line (for brittle materials)

1/N=Sm/Su+Sa/Sn

c. Gerber equation/line
𝑆𝑚 2 𝑆𝑎𝑠
1=( ) +
𝑆𝑢 𝑆𝑛𝑠
For Varying Shear (Torsional Stress)

1/N=Sms/Sys+Sas/Sns

where:

Sns = shearing endurance strength

Sys = yield strength in shear
Sms = mean stress in shear
Sas = alternating or variable stress in shear
For wrought steel, BHN<400, good ductility

𝑆𝑢
𝑆𝑛′ ≅ 0.5𝑆𝑢 =
2
𝑆𝑛′ ≅250(BHN) Psi
𝑆𝑛′ ≅0.25(BHN) Ksi

(Table AT-3, AT-4, AT-6, AT-10) for endurance, limit and

strength
Stress Concentration Factors

• degree of stress concentration

• is design factor that is used to take into account the
concentration of stress

Kt = theoretical stress concentration factor

= theoretical max. local stress
nominal computed stress, So

Smax=KtSo *where, So=F/A

So=Mc/I
So=Tc/J
 𝐾𝑓−1
Notch Sensitivity q = (fatigue notch factor)
𝐾𝑡−1

*where, Kf=1+q(Kt-1)

𝑎𝑐𝑡𝑢𝑎𝑙 𝑆𝑚𝑎𝑥
Kf= 𝑆𝑜

(Table AT-13) Values of Kf for keyways

Variable Stress Equation with Kf :

1/N=Sm/Sy+(Kf)(Su)/(Sn) (normal)
1/N=Sms/Sys+(Kf)(Sus)/Sns (shear)
Endurance Strength is affected by size: (p.15 Faires)

Sn=0.85Sn’ and Sns=0.85Sns’ (between ½ - 2 in size)

(Bending and Torsion)

Surface Factor – reduction of endurance strength

(Fig, AF-5/Faires p.583)
Endurance Ratio

Varies from 0.23 to 0.65 for steel lowest values

for untampered martensite. 0.4 or less for pearlite or
austenite. 0.6 or greater for ferrite (pure carbon). 0.5 for
wrought steel in its more commonly wet commercial
forms.

Sns=0.6Sn’=0.6 (endurance strength, rotating beam)

Sn max=0.8Sn (from standard specimen, rotating beam)

For endurance strength (axial loading only)

Sn=(Fsurf)(Fsize)(Fa.l.)(Fe.r.)(Su)

Where:

Fsurf = surface factor Fig. AF-5 (Faires)

Fsize = size factor taken as 0.85
Fa.l =strength reduction factor used only in case of axial
loading (reversed). Varies from 0.6 to 1.0 for steels and 0.82
to 1.06 for aluminum alloys. In the absence of test values,
use 0.8.
Fe.r. =endurance ratio, varies from 0.23 to 0.65 for steels depe
nding on the microstructure
For ductile materials, and when design is based upon
Syp rather than Sult, the stress concentration factor is
used to multiply the alternating stress, Sr.

KtSr=Se/f.s.-Se/Syp×Sm (p.94 Black&Adams)

(Se=endurance strength)

If calculation is based on ultimate strength, Sult is

substituted for Syp.
PROBLEM NO. 18:

The diameter of the figure below is 1” thick.

The load varies from 50,000 to 30,000 lbs.
Factor of safety is 2, Syp=40200 psi and Se=
28500 psi.
PROBLEM NO. 18:
Given:
Thickness=1”
Load max=50000 lbs
Load min=30000 lbs
FS=2
Syp=40200 psi
Se=28500 psi
Required:
D=?
D if minimum load is 20000 lbs
PROBLEM NO. 18:
Solution:
Refer to figure AF-9 p.585 (Find the stress concentration factor)

Refer to p.94 (Black&Adams)

KtSr=Se/FS-Se/Syp(Sm)
where:
Syp=yield point stress
Se=endurance strength=28500 psi
Tension=40200 psi
PROBLEM NO. 18:
Pave=1/2 (50000+30000)=40000 lbs
Prange=1/2 (50000-30000)=10000 lbs
KtSr=Se/FS-Se/Syp(Sm) eqn.1

𝐾𝑆𝑦𝑝𝑆𝑟 𝑆𝑦𝑝
Sd=Save+ = Soderberg eqn eqn.2
𝑆𝑒 𝐹𝑆

Divide both sides by Syp

𝑆𝑎𝑣𝑒 𝐾𝑆𝑟 1
+ = eqn.3
𝑆𝑦𝑝 𝑆𝑒 𝐹𝑆

Using eqn. 3 and Save & Sr

40000 10000
Save= or Sr=
𝐴 𝐴
40000 10000 1
+ =
𝐴(40200) 𝐴(28500) 2
PROBLEM NO. 18:
For K,
3
𝑑 3
h/d= 2
= = 1.5
𝑑 2
K=1.62
𝑑/4 1
r/d= = = 0.25
4 4

Thus, (40000)(28500)(1.62)(1000)(40000)=(0.5)(28500)(40000)(4)
A=3.13 sq.m
A=dt
d=A/t=3.13/1.0=3.13 in
PROBLEM NO. 19:

A wall bracket as shown in the figure is loaded so that the two top
bolts that fasten it to the wall are each subjected to a tension load
of 710 lbs. The bolts are to be cold forged from AISI C1020
steel with UNC threads. Neglecting the effect of shearing stresses,
determine the diameter of these bolts if they are well tightened.

What size set screw is necessary to fasten a pulley shaft 2” diameter

which transmits 3hp and rotates at 150 rpm?
PROBLEM NO. 19:
Given:

Material: AISI C1020 cold forged

From table AT-7, Sy=66 ksi

Required:
Diameter of bolt
PROBLEM NO. 19:
Solution:

Tensile load=710 lbs

Fe=safe external load
3
𝑆𝑦𝐴𝑠 2
=
6
2 2
6𝐹𝑒 3 6(710) 3
As= = =0.161 sq.in
𝑆𝑦 66000

For UNC bolts (refer to Table AT-14)

diameter
Ashaft
of bolt
1/2" 0.1419
9/16" 0.182
PROBLEM NO. 19:
use: d=9/16”

Solve for Torque,

P=3hp
2𝜋𝑇𝑛
P=
𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝑃 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
T=
2𝜋𝑇𝑛
3ℎ𝑝(33000)
T=
2𝜋(150)
T=1260.507 in.lbs
PROBLEM NO. 19:
Table 5-3 p. 177
SCREW SIZE TIGHTENING TORQUE HOLDING FORCE
9/16" 620 in-lbs 3500
5/8" 1225 in-lbs 4000

T=Fr
F=T/r --- ds/2=2in/2=1in
F=1260.507in-lbs/1in
F=1260.507 lbs. (force in set screw)

𝐻𝑜𝑙𝑑𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒 𝐹𝑜𝑟𝑐𝑒 𝑓𝑎𝑖𝑙𝑢𝑟𝑒

= 𝑓. 𝑠 = 𝑁 =
𝐹𝑜𝑟𝑐𝑒 𝑖𝑛 𝑠𝑒𝑡 𝑠𝑐𝑟𝑒𝑤 𝐴𝑐𝑡𝑢𝑎𝑙 𝑙𝑜𝑎𝑑𝑖𝑛𝑔
PROBLEM NO. 19:
Table 1.1 p.20
for gradual load, repeated, one direction based on yield strength,
N=3
Thus, Holding force=N( Force set screw)
=(3)(1260.507)
Holding force=3781.52
Based in Table 5-3
take the next higher value for Holding force=4000lbs
Therefore, d of set screw=5/8”

Based on p.177
size of set screw=1/4d=1/4(2in)=0.50 in
Bolts and Screws (Threaded Members)
Threaded bolts and screws are used to hold
the removable heads of cylinder, machine
members that must be readily disassembled,
and parts of large machines that must be
built in small units for ease in manufacturing,
assembling or shipping. Screws are also used
for the transmission of power. Screws are
sometimes used for adjusting or obtaining ac
curate movement in measuring instruments
such as micrometers.
Designation:
1in. - 8UNC - 2A → a 1-in. Unified Course Thread
Series right have thread with
eight threads per inch
and class 2A fit
1in. -8UNC -2A -LH → same description except that, it is left
hand thread
Pitch P → is the axial distance between corresponding points
on adjacent threads and is equal to the reciprocal of t
he member of threads per inch.

1
𝑃= = 𝑖𝑛𝑐ℎ
𝑁𝑜.𝑜𝑓 𝑡ℎ𝑟𝑒𝑎𝑑𝑠 𝑝𝑒𝑟 𝑖𝑛𝑐ℎ
Lead, L → is the axial distance a thread advances in one revolution.
A single thread is one on which the load equals the pitch,
a double thread is one on which the lead equals twice the
pitch, and so on.

Major diameter, 𝐷𝑜 → is the outside, or largest, diameter of the

threads and is the nominal diameter

Minor diameter, 𝐷𝑖 → is the smallest diameter of the thread and is

commonly called the root diameter

Pitch diameter, 𝐷𝑚 → is the mean of the major and minor diameters

Stress area → is the area of an imaginary circle whose diameter is

the mean of the pitch and minor diameter. This area is
used for the purpose of computing the tensile strength
 𝜋 𝐷𝑚+ 𝐷𝑖 2
𝑆𝑡𝑟𝑒𝑠𝑠 𝐴𝑟𝑒𝑎 = Table AT-14 Faires p. 588 Table 6-1 Vallance p.13
4 2
0

Types of Threads:
1.UNC -Unified National Course, for general use except where other types
are recommended
2.UNF -Unified National Fine, frequently used in automotive, compressor,
pumps and aircraft work where a fine adjustment is required
3.UNEF -Unified National Extra Fine, used in aeronautical equipment and w
here very fine adjustment is required.

Working Strength of Bolt (Machineries Handbook)

𝑊 = 𝑆𝑡 0.55𝑑2 − 0.25𝑑 𝑖𝑛 𝑙𝑏𝑠
where: W = working strength in lbs
𝑆𝑡 = allowable working stress, psi
d = nominal diameter, in
Screws -is an externally threaded fastener capable of being inserted into holes is
assembled parts, of mating with a performed internal thread or forming its
own thread and of being tightened or released by torqueing a nut.

Power Screws -are used to move weights and machine parts and uses square,
acme or buttress threads.

P = pitch → distance b/w adjacent threads, in

L = lead → distance the screw advance in one turn
L=P (for single threaded screw)
L = 2P (for double threaded screw)
Linear Velocity = (rotational speed)(lead) or V = N x lead

x = lead angle
𝐷𝑚 = mean diameter of threads
𝑙𝑒𝑎𝑑
tan 𝑥 =
𝜋𝐷𝑚
Torque applied to turn the screw:
𝑊𝐷𝑚 (tan 𝑥+𝑓)
𝑇= , for square thread
2(1−𝑓 tan 𝑥)
𝑊𝐷𝑚 (cos 𝜃 tan 𝑥+𝑓)
𝑇= , for the acme thread
2(cos 𝜃−𝑓 tan 𝑥)
Where: w = load
𝜃 = 14.5° for acme (15° for trapezoidal)
f = coefficient of friction
f = tan 𝛽 (𝛽, frictional angle)

Torque required to overcome collar friction

𝑓𝑐 𝑊 (𝑟𝑜 +𝑟𝑖 )
𝑇𝑐 = 2
Where: 𝑓𝑐 = coefficient of friction of collar
𝑟𝑜 = outside radius of collar
𝑟𝑖 = inside radius of collar
Total torque required to operate the screw = 𝑇𝑡 = 𝑇 + 𝑇𝑐
Power = 2𝜋𝑇𝑡 𝑁
Torque required to lower the load:
𝑊 𝐷𝑚 (tan 𝑥−𝑓)
𝑇𝐿 =
2(1+𝑓 tan 𝑥)
Efficiency of Power screw:
𝑢𝑠𝑒𝑓𝑢𝑙 𝑤𝑜𝑟𝑘
𝐸𝑓𝑓 =
𝑤𝑜𝑟𝑘 𝑜𝑢𝑡𝑝𝑢𝑡
tan 𝑥(1−𝑓 tan 𝑥)
𝐸𝑓𝑓 = 𝑓 𝐷 , for square thread
tan 𝑥+( 𝐷𝑐 𝑐 )(1−𝑓 tan 𝑥)
𝑚
tan 𝑥(cos 𝜃−𝑓 sin 𝑥)
𝐸𝑓𝑓 = 𝑓 𝐷 , for acme thread
tan 𝑥 cos 𝜃+𝑓 cos 𝑥+( 𝐷𝑐 𝑐 )(cos 𝜃−𝑓 sin 𝑥)
𝑚

where: 𝜃 = 14.5°
𝐷𝑜 +𝐷𝑖
Where: 𝐷𝑐 =
2
Design of bolts: (tensile stress in bolts)
𝑆𝑦 1
𝑆𝑑 = (𝐴𝑠 ) Τ2
6
𝑆𝑦 𝑆𝑦
𝐹𝑒 = safe external load = 𝑆𝐴 =
1 3
(𝐴𝑠 ) Τ2 𝐴 = (𝐴𝑠 ) Τ4
6 6
Where: 𝐴𝑠 = stress area

𝑇 = 𝑐𝐷𝐹𝑖 As received c = 0.20

As lubricated c = 0.15
Where: 𝑇 = 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑡𝑜𝑟𝑞𝑢𝑒, 𝑖𝑛 − 𝑙𝑏𝑠
D = nominal bolt size, in
c = Torque coefficient
𝐹𝑖 = initial tension, lbs
Torque producing shear in bolt = 0.4 (Total)
Net Compressive force on the connected parts
𝐹
𝛿=𝑘 & ∆𝐹𝑐 = 𝐹𝑒 − ∆𝐹𝑏
Where: ∆𝐹𝑏 = change of force corresponding to an increase of
deformation ∆𝛿
∆𝐹𝑐 = change of load on connected parts
𝐹𝑒 = external load applied to joint
∆𝐹𝑐 𝐹𝑒 −∆𝐹𝑏 ∆𝐹𝑏
∆𝛿 = = =
𝑘𝑐 𝑘𝑐 𝑘𝑏
Solving for ∆𝐹𝑏
𝐹𝑒 −∆𝐹𝑏 ∆𝐹𝑏
=
𝑘𝑐 𝑘𝑏
𝑘𝑏
∆𝐹𝑏 = 𝐹𝑒 (𝑘 )
𝑏 +𝑘𝑏
Total load on the bolt:
𝑘𝑏
𝐹𝑡 = 𝐹𝑖 − ∆𝐹𝑏 = 𝐹𝑖 + ( )𝐹𝑒
𝑘𝑏 +𝑘𝑐
Net Compressive load on the connected parts
𝑘𝑏
𝐹𝑐 = 𝐹𝑖 − ( )𝐹𝑒
𝑘𝑏 +𝑘𝑐
𝐴𝑐 = equivalent area of the connected parts
𝐴𝑐 𝐸𝑐
𝑘𝑐 =
𝐿𝑐
𝜋𝐷𝑒 2 𝜋𝐷2
𝐴𝑐 = −
4 4
Where: D = nominal diameter of the bolt
𝐷𝑒 = equivalent diameter of the plate area considered to be in compression
ℎ
𝐷𝑒 = (nut or head width across flats) +
2
ℎ
𝐷𝑒 = (dimension A, for example, Table AT-14) +
2
h = grip of the bolt, w/c is the total thickness of the plates being champed
If there is use of gasket:

1 1 1 1
= 𝑘 + 𝑘 + 𝑘 ∙∙∙
𝑘𝑐 1 2 3

Where 𝑘1 , 𝑘2 , 𝑘3 → are the spring constants for the individua

l components being champed.

𝐴1 𝐸1
𝑘1 = 𝑒𝑡𝑐.
𝐿1
PROBLEM NO. 20:
A 63.5 mm diameter shaft has a key
16mm×16mm. The shaft material tests 400 Mpa
at yield point. Let Sys=0.5Sy. The factor of safety
equals 2. The shaft fits into a cast iron hub for
which the working stress in compression is 125
mPa. What length of key in the hub material will
be required to carry the torque of the solid
shaft?
PROBLEM NO. 20:
Given:
D shaft=63.5mm
Key=16x16mm
Sy shaft=400 mPa ; Sys=0.5Sy
S bearing=125 mPa
N=2

Required:
Length of key
PROBLEM NO. 20:
Solution:
16𝑇
Solve for torque, Ss=
𝜋𝑑 3
Ss=Sys/N=0.5(400 mPa)/2=100mPa
𝜋𝑆𝑠𝑑 3
T=
16
𝜋 100 (63.5)3
T=
16
T=5027.49 kN-mm
Bearing/Compression on Key=125 mPa
Sb=4T/tDL
L=4T/tDSb
L=4(5027488.27)/(16)(63.5mm)(125 N/mm^2)
L=158.35 mm
Keys and Couplings
Keys
The most common function of a key is to prevent relative

rotation of a shaft and the member to which it is connected,

such as the hub of a gear, pulley or crank.

Shear failure:

Ss=induced shear stress

Ss=Force transmitted/Shear area

Ss=F/bL
In terms of transmitted torque
T=Fr=F(D/2)
F=2T/D
Ss=2T/bDL

For length of key

L=2T/bDSs

For compressive/bearing failure

Sc=induced compressive stress
Sc=force transmitted/bearing area

Sc=F/(t/2)(L)=2F/tL and F=2T/D

Sc=2(2T)/tDL=4T/tDL

For length of key:

L=4T/tDSc
Design of key considerations
1. Select whether to use a flat or square key. Shear design stress due to the
compressive design stress ratios. Sds/Sdc=0.5, square key. If otherwise, u
se flat key.
2. Determine the key dimension (Table AT-19)
3. Determine the length of key, Sc=4T/tDL (for induced compressive stress)
4. Choose the longer length of key

where: T=torque that can be transmitted through the key, in in-kips or N-m
m
Ss=shear stress in key (yield strength in shear divided by the design f
actor)
Sc=compressive stress in key (yield strength in compression divided b
y the design factor)
b=width of key
t=thickness of key
d=diameter of shaft
L=length of key
Note:

Length of hub and length of key are about the same. Typical hub length fall b
etween 1.250 to 2.40 where d=shaft diameter (Faires, p.283)
If the needed key length is greater than about 20, consider using two keys
180° apart, or kennedy keys.

Splined shafts (p.287 Faires)

Design torque capacity of splined shaft with axial loading

T=(SA)rm=100(hL)(rm)(Nt) in-lbs
T=6.895(hL)(rm)(Nt) N-mm
Based on side pressure of 100 psi=6.895 mPa
where: h=height of spline, mm
L=contact length, mm
rm=mean redius, (D=d)/4, mm
Nt=total number of splines
Keys and Couplings
Couplings
Shaft Couplings are used in machinery for several purposes:
1. To provide for the connection of shafts of units that are
manufactured separately, such as a motor and a generator and to
provide for disconnections for repairs or alterations.
2. To provide for misalignment of the shafts or to introduce
mechanical flexibility.
3. To reduce the transmission of shock loads from one shaft to
another.
4. To introduce protection against overloads.
5. To alter the vibration characteristics of rotating units.
Hub will shear the flange or hub bores through the flange punching shear stre
𝐹
ss 𝑆𝑓 = 𝐻 .
𝐴𝑠

𝐹𝐻
𝑆𝑓 =
𝜋𝐻𝑡
In terms of torque:
𝐻
𝑇 = 𝐹𝐻 ( )
2
2𝑇
𝐹𝐻 =
𝐻
2𝑇
𝑆𝑓 =
𝜋𝐻2 𝑡

Factor of safety against shear in the flange:

𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑓𝑙𝑎𝑛𝑔𝑒 𝑖𝑛 𝑠ℎ𝑒𝑎𝑟
𝐹. 𝑆. =
𝑖𝑛𝑑𝑢𝑐𝑒𝑑 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠
𝑆𝑦 𝐹𝑙𝑎𝑛𝑔𝑒
𝐹. 𝑆. =
𝑆𝑓
Shaft Design:
Shaft – is a rotating member supported by bearings and
transmitting power. An axle is a stationary member, primary loaded
in bending, gears, pulleys and wheels rotating on it.
Spindle – short axles and shafts.

Two General Classes of Shafts:

Transmission shafts – are those used to transmit power between the
source and the machines absorbing the power and include
counter-shafts, line shafts, head shafts and all factory shafting.
Machine shafts – are those forming an integral part of the machine
itself.

Maximum Shear Theory – commonly used for shafts made of ductile

materials
Maximum Normal Stress Theory – for shafts of brittle materials.
Commercial sizes of Shafts: (Faires: p. 269)
Shaft subject to torsion only:
𝑇𝑐 𝑇𝐿 16𝑇
𝑆𝑠 = and 𝛳 = 𝑆𝑠 = for solid circular shaft
𝐽 𝐽𝐺 𝜋𝐷3
16𝑇𝐷𝑜
𝑆𝑠 = for hollow circular shafts
𝜋(𝐷𝑜 4 −𝐷𝑖 4 )

Where:
𝑆𝑠 = 𝑡𝑜𝑟𝑠𝑖𝑜𝑛𝑎𝑙 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠
𝑇 = 𝑇𝑜𝑟𝑞𝑢𝑒 𝑜𝑟 𝑇𝑜𝑟𝑠𝑖𝑜𝑛𝑎𝑙 𝑚𝑜𝑚𝑒𝑛𝑡
C= 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑓𝑟𝑜𝑚 𝑛𝑒𝑢𝑡𝑟𝑎𝑙 𝑎𝑥𝑖𝑠 𝑡𝑜 𝑡ℎ𝑒 𝑜𝑢𝑡𝑒𝑟𝑚𝑜𝑠𝑡 𝑓𝑖𝑏𝑒𝑟 𝑜𝑟 𝑟𝑎𝑑𝑖𝑢𝑠 𝑓𝑜𝑟 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑟
𝑠ℎ𝑎𝑓𝑡
𝐽 = 𝑃𝑜𝑙𝑎𝑟 𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎
𝜋𝐷4
= for solid circular shaft
32
𝜋(𝐷𝑜 4 − 𝐷𝑖 4 )
=
32
𝐷 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑠ℎ𝑎𝑓𝑡
𝐿 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠ℎ𝑎𝑓𝑡
𝛳 = 𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑑𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 𝑖𝑛 𝑙𝑒𝑛𝑔𝑡ℎ 𝐿, 𝑟𝑎𝑑𝑖𝑎𝑛𝑠

G= 𝑚𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝑟𝑖𝑔𝑖𝑑𝑖𝑡𝑦 𝑖𝑛 𝑠ℎ𝑒𝑎𝑟 (11.5 𝑡𝑜 12 𝑥 106 𝑓𝑜𝑟

𝑝𝑠𝑖 𝑓𝑜𝑟 𝑠𝑡𝑒𝑒𝑙)
𝐷𝑜 = 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝐷𝑖 = 𝑖𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
Stresses in solid circular shafts subject to torsion and

bending.

16𝑇 2 + 𝑇2
𝑆𝑠 𝑚𝑎𝑥 = 𝑀
𝜋𝐷 3
16𝑇
𝑆𝑡 𝑚𝑎𝑥 = 3
(𝑀 + 𝑀2 + 𝑇 2 )
𝜋𝐷
Where:
𝑆𝑠 𝑚𝑎𝑥 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠
𝑆𝑡 𝑚𝑎𝑥 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑜𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
𝑀 = 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡
𝑇 = 𝑡𝑜𝑟𝑠𝑖𝑜𝑛𝑎𝑙 𝑚𝑜𝑚𝑒𝑛𝑡
Shaft subjected to pure axial stress.

𝐹𝑡 𝛼𝐹𝑡
𝑆𝑡 = 𝑆𝑐 =
𝐴 𝐴

Where:
𝑆𝑡 = 𝑖𝑛𝑑𝑢𝑐𝑒𝑠 𝑜𝑟 𝑑𝑒𝑠𝑖𝑔𝑛 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ, 𝑝𝑠𝑖
𝑆𝑐 = 𝑖𝑛𝑑𝑢𝑐𝑒𝑠 𝑜𝑟 𝑑𝑒𝑠𝑖𝑔𝑛 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
𝐹𝑡 = 𝑎𝑥𝑖𝑎𝑙 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑙𝑜𝑎𝑑
𝐹𝑐 = 𝑎𝑥𝑖𝑎𝑙 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑙𝑜𝑎𝑑
𝐴 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
Shaft subjective to pure bending stress:

𝑘𝑡 𝑀
𝑆=
𝑍
Where:
𝑆 = 𝑖𝑛𝑑𝑢𝑐𝑒𝑑 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
𝑘𝑚
= 𝑛𝑢𝑚𝑒𝑟𝑖𝑐𝑎𝑙 𝑐𝑜𝑚𝑏𝑖𝑛𝑒𝑑 𝑠ℎ𝑜𝑐𝑘 𝑎𝑛𝑑 𝑓𝑎𝑡𝑖𝑔𝑢𝑒 𝑓𝑎𝑐𝑡𝑢𝑟𝑒 𝑡𝑜 𝑏𝑒
𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑖𝑛 𝑒𝑣𝑒𝑟𝑦
𝑐𝑎𝑠𝑒 𝑡𝑜 𝑡ℎ𝑒 𝑐𝑜𝑚𝑝𝑢𝑡𝑒𝑑 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡
𝑀 = 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡
𝑍 = 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑚𝑜𝑑𝑢𝑙𝑢𝑠 𝑖𝑛 𝑏𝑒𝑛𝑑𝑖𝑛𝑔
Shaft design subjecting to torsion and bending stress.

1
𝑆𝑠 𝑚𝑎𝑥 = (𝑘𝑚 𝑀)2 + (𝑘𝑠 𝑇)2 1/2
𝑍
Or

𝑆
𝑆𝑠 𝑚𝑎𝑥 = (𝑆𝑠 )2 + ( )2
2

Km & Ks : p. 279 Faires

Where:
𝑆𝑠 = 𝑑𝑒𝑠𝑖𝑔𝑛 𝑠ℎ𝑒𝑎𝑟𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
𝑆 = 𝑑𝑒𝑠𝑖𝑔𝑛 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
Shaft subjected to torsion, bending & axial stress

2 2 1/2
1 2
𝛼𝐹𝐷(1 + 𝛽 )
𝑆𝑠 𝑚𝑎𝑥 = (𝑘𝑚 𝑇) + 𝑘𝑚 𝑀 +
𝑍(1 + 𝛽 4 ) 8

Use Z’ in torsion
𝐹 = 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑜𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑓𝑜𝑟𝑐𝑒
𝛽 = 𝑜 𝑓𝑜𝑟 𝑠𝑜𝑙𝑖𝑑 𝑠ℎ𝑎𝑓𝑡

𝑑 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝛽= 𝑓𝑜𝑟 ℎ𝑜𝑙𝑙𝑜𝑤 𝑠ℎ𝑎𝑓𝑡 =
𝐷 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
Shaft design by ASME Code

Design of transmission shaft (without keyway)

𝑆𝑠𝑑 = 𝑆𝑠 = 0.3 𝑥 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑦𝑒𝑖𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
𝑆𝑠𝑑 = 𝑆𝑠 = 0.18 𝑥 𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ

Whichever is smaller.

For a shaft in bending only:

𝑆𝑑 = 𝑛𝑜𝑟𝑚𝑎𝑙 𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠
𝑆𝑑 = 0.6 𝑥 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑦𝑖𝑒𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
𝑆𝑑 = 0.36 𝑥 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ

Whichever is smaller.

For a keyway:
𝑆𝑑 = (0.75)(𝑎𝑑𝑎𝑝𝑡𝑒𝑑 𝑠𝑡𝑟𝑒𝑠𝑠)