MECHANICAL MACHINE DESIGN

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MECHANICAL MACHINE DESIGN

CONTENTS
Introduction 6
Factor of safety 6
Stress concentration 7
Stress concentration factors 8
Reduction of stress concentration 8
Fluctuating stresses 9
Fatigue failure 9
Endurance limit 10
Fatigue life 10

1 Low- cycle and high – cycle fatigue

Notch sensitivity
Endurance limit approximate estimation
10
10
11
DESIGN AGAINST
STATIC AND Reversed stresses – design for finite and infinite life 12
FLUCTUATING Soderberg and goodman lines 13
LOADS Modified gooman diagram 13
Gerber equation 14
Fatigue design under combined stresses 14
Impact stresses 15
Cotter joint & knuckle joint 16

Transmission shafts 24
Shaft design on strength basis 24
Shaft design on torsional rigidity basis 26
ASME code for shaft design 26
Design of hollow shaft on strength basis 27
Design of hollow shaft on rigidity basis 28
Keys 29
Saddle keys 29
Sunk keys 29

2 Feature key
Woodruff key
Design of square and flat keys
31
31
31
SHAFT, KEYS
AND COUPLINGS Design of kennedy key 33
Splines 33
Couplings 34
Muff coupling 34
Design procedure for muff coupling 35
Clamp coupling 35
Design procedure for clamp coupling 35
Rigid flange couplings 36

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Design procedure for rigid flange coupling 37

Bushed pin flexible coupling 38
Design procedure 39

Introduction 41
Stress relieving of welded joints 41
Classification of weld joints 41
Butt joints 41
Fillet joints 41
Other types of weld joint 42
Strength of butt welds 42
Strength of parallel fillet welds 42
Strength of transverse fillet welds 43

3 Maximum shear stress in parallel fillet weld

Maximum shear stress in transverse fillet weld
Axially loaded unsymmetrical welded joints
43
44
44
WELDED JOINTS
Eccentric load in the plane of welds 44
Welded joint subjected to bending moment 45
Welded joint subjected to torsional moment 45
Welded joint subjected to fluctuating forces 46

Riveted joints 48
Types of riveted joints 48
Types of failure 49
Strength equations 49
4 Efficiency of joint
Caulking
50
50
RIVETED JOINTS Longitudinal butt joint for boiler shell 50
Circumferential lap joint for boiler shell 52
Eccenrtically loaded riveted joint 54

Classification of clutches 57
Torque transmitting capacity 57
5 Multi-disk clutches
Friction materials
58
59
CLUTCHES Centrifugal clutches 61
Energy equation 62
Thermal considerations 63

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MECHANICAL MACHINE DESIGN

Introduction 66
Classification of brakes 66
6 Energy equations
Block brake with short shoe
66
67
BRAKES Block brake with long shoe 68
Band brakes 70
Disk brakes 71

Geometrical relationships 74
Condition of maximum power 77
Selection of flat belts from manufacturer catalogue 78
Pulleys for flat belts 78
7 Arms of cast iron pulley
V – belts
80
80
BELT & CHAIN Selection of belts 81
DRIVES V – grooved pulley 82
Chain drives 83
Geometric relationships 83

Basic types of screw fastening 86

Cap screws 86
8 Setscrews
Terminology of screw threads
87
87
THREADED Bolt joint-simple analysis 88
JOINTS Eccenrtically loaded riveted joint 89
Eccentricload perpendicular to axis of bolt 90

Types of rolling contact bearings 93

Static load carrying capacity 94
Stribeck equation 94
Dynamic load carrying capacity 94
Equivalent bearing load 94
Load life relationship 95
Selecton of bearing from manufacture catalogue 95
Selection of taper roller bearings 96
Design for cyclic loads and speeds 97
Bearing with a probability of survival other than 90% 97
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MECHANICAL MACHINE DESIGN

Sliding contact bearings 98

9 Modes of lubrication
Viscosity measurement
98
98
BEARINGS Viscosity index 99
Petroff’s equation 99
Mckee’s investigation 99
Viscous flow through rectangular slot 99
Hydrostatic step bearing 100
Load carrying capacity of bearing 101
Energy losses 101
Raimondi and boyd method 102
Temperature rise 103

Introduction 107
Gear drives 107
Classification of gears 107
Backlash 108
Gear blank design 109
Number of teeth 109
Beam strength of gear 109
Effective load on gear tooth 110
Estimation of module based on beam strength 111
Wear strenght of gear tooth 111
Estimation of module based on wear strenght 113
Helical gears 113

10 Terminology of helical gears

Virtual number of teeth
Tooth proportions
113
114
115
GEARS
Force analysis 116
Beam strenght of helical gears 117
Effective load on gear tooth 117
Wearstrenght of helical gears 117
Bevel gears 118
Beam strenght of bevel gears 118

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MECHANICAL MACHINE DESIGN

Wear strenght of bevel gears 118

Effective load on gear tooth 118

Power screw 121

Forms of threads 121
Multiple threaded screws 121
11 Terminology of power screw
Torque requirement lifting load
122
122
POWER SCREWS Torque requirement lowering load 123
Self+locking screw 123
Efficiency of square threaded screw 124
Efficiency of trapezoidal and acme threaded screw 124
Collar friction torque 124
Ovrall efficiency 124
Design of screw anf nut 124
Design of screw jack 125

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MECHANICAL MACHINE DESIGN

CHAPTER 8 THREADED JOINTS

INTRODUCTION
Threaded joint is defined as a separable joint of two or more machine parts that are held together
by means of a threaded fastening such as a bolt and a nut. The salient features of this definition
are as follows:
Threaded joints are used to hold two or more machine parts together. These parts can be
dismantled, if required, without any damage to machine parts or fastening. Therefore, threaded
joints are detachable joints, unlike welded joints.

BASIC TYPES OF SCREW FASTENING

There are three parts of a threaded fastening,
viz., a bolt or screw, a nut and washer. There is a
basic difference between the bolt and the screw.
A bolt is a fastener with a head and
straight threaded shank and intended to
be used with a nut to clamp two or more
parts.
The same bolt can be called screw when
it is threaded into a tapped hole in one of
the parts and not into the nut.

Simple washers are thin annular shaped metallic disks. The functions of a washer are as follows:
-
1. It distributes the load over a large area on the surface of clamped parts.
2. It prevents marring of clamped parts during assembly.
3. It prevents marring of the bolt head and nut surface during assembly.
4. It provides bearing surface over large clearance holes.

Through Bolts: A through bolt is simply called a ‘bolt’ or a bolt and nut’. The bolt consists of a
cylindrical rod with head at one end and threads at the other. The cylindrical portion between the
head and the threads is called shank. Hexagonal head bolt and nut are popular in the machine
building industry. Square head and nut are used mostly with rough type of bolts in construction
work.

Tap Bolts and Cap Screws: There is basic difference between through bolt and tap bolt. The tap
bolt is turned into a threaded (tapped) hole in one of the parts being connected and not into a nut.
On the other hand, the through bolt is turned into the nut.
Studs: A stud is a cylindrical rod threaded at both end. One end of the stud is screwed into the
tapped hole in one of the connecting parts. The other end of the stud receives a nut. Stud joints
are used under the following conditions:

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CAP SCREWS
Cap screws belong to the category of tap bolts. A wide variety of shapes are available for the
head of cap screw. On the other hand, tap bolt has hexagonal or square head.Depending upon the
shape of the head, cap screws are divided into the following two groups:
1. Cap screws in which the head is engaged externally by a spanner; and
2. Cap screws in which the head is engaged internally and from the end face

SETSCREWS
Setscrew is used to prevent relative motion between two parts. The threaded portion of the
setscrew passes through a tapped hole in one of the parts and the end of the screw presses against
the other part. The end of the screw is called the point of the screw.

- Flat Point: Flat point is used when lateral force, which tens to displace one part with
respect to another, is randomly applied.
- Dog Point: Dog point is used when the lateral force, which tends to displace one part
with respect to other, is large.
- Cone Point: Cone point is used when the lateral force is small.
- Hanger Point: Hanger point has a smaller taper. It is used when the lateral force is large.
- Cut Point: Cut point is used when the part being held cannot be drilled or hardened.

TERMINOLOGY OF SCREW THREADS

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MECHANICAL MACHINE DESIGN

The right handed threads are always used unless there is special reason for requiring left hand
thread.

Various dimensions of external and internal threads. They are as follows:

Major Diameter
The major diameter is the diameter of an imaginary cylinder that bounds the crest of an external
thread (d) or the root of an internal thread (D). The major diameter is the largest diameter of the
screw thread. It is also called the nominal diameter of the thread.
Minor Diameter
The minor diameter is the diameter of an imaginary cylinder that bounds the roots of an external
thread (Dc) or the crest of an internal thread (Dc). The minor diameter is the smallest diameter of
the screws thread. It is also called core or root diameter of the thread.

Pitch Diameter
The pitch diameter is the diameter of an imaginary cylinder, the surface of which would pass
through the threads at such points as to make the width of the threads equal to the width of
spaces cut by the surface of the cylinder. It is also called the effective diameter of the thread.

Pitch
Pitch is the distance between two similar points on threads measured parallel to the axis of the
threads measured parallel to the axis of the thread. It is denoted by the letter p.

Lead
Lead is the distance that the nut moves parallel to the axis of the screw, when the nut is given
one turn.

Thread Angle
Thread angle is the angle included between the sides of the thread measured in an axial plane.
Thread angle is 600 for ISO metric threads.

Tensile Stress Area

It has been observed during testing of the threaded rods that an unthreaded rod, having a
diameter equal to the mean of the pitch diameter and the minor diameter [i.e. (d p+dc)/2] has the
same tensile strength as the threaded rod.

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MECHANICAL MACHINE DESIGN

BOLT JOINT-SIMPLE ANALYSIS

A bolted joint subjected to tensile force p. The cross section at the core diameter d c is the
weakest section. The maximum tensile stress in the bolt at this cross section is give by,

The height of the nut h can be determined by equating the strength of the bolt in tension with the
strength in shear.

Assumptions:
1. Each turn of the thread in contact with the nut supports an equal amount of load.
2. There is no stress concentration in the threads.
3. The yield strength in shear is equal to half of the yield
strength in tension (Ssy= 0.5Syt).
4. Failure occurs in the threads of the bolt and not in the
threads of the nut.

Since
σt =

The strength of the bolt in tension is given by:

P=
The threads of the bolt in contact with the nut are sheared at the core diameter d c. The shear area
is equal to (πdch), where h is the height of the nut. The strength of the bolt in shear is given by,
P = (πdch)

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= (πdch)
Equating
h = 0.5 dc
Assuming (dc=0.8d),
h = 0.4d
Therefore, for standard coarse threads, the threads are equally strong in failure by shear and
failure by tension, if the height of the nut is approximately 0.4 times of the nominal diameter of
the bolt. The height of the standard hexagonal nut is (0.8d). Hence, the threads of the bolt in the
standard nut will not fail by shear. Rewriting the height of the standard nut,
h = 0.8d

ECCENRTICALLY LOADED RIVETED JOINT

The primary shear forces are given by

The secondary shear forces are given by

Where C = constant of proportionality.

Hence

The primary and secondary shear forces are added vectorially added to get the resultant shear
stress.
The maximum resultant shear force is equated to shear strength of bolt to find out diameter of
rivet.

ECCENTRICLOAD PERPENDICULAR TO AXIS OF BOLT

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Assumption:
1. The bracket and the steel structure are rigid.
2. The bolts are fitted in reamed and ground holes.
3. The bolts are not pre-loaded and there is no tensile stress due to initial tightening.
4. The stress concentration in the threads is neglected.
5. All bolts are identical.

Direct shear stress in each bolt due to force P,

The moment ( P×e) tend to tilt the bracket about C. Each bolt is stretched by an amount (δ)
which is proportional to its vertical distance from the point C.

From stress-strain relationships, it can be concluded that

The secondary shear forces are given by

Where C = constant of proportionality.

Hence

The bolt which is located at the farthest distance from the tilting edge C, is subjected to
maximum force.
Shear stress is given by

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The tensile stress is given by

The principal stresses are given by

The principal shear stress is given by

ECCENTRIC LOAD ON CIRCULAR BASE

Assumption:
1. All bolts are identical.
2. The bearing and structure are rigid.
3. The bolts are not pre-loaded and there is no tensile stress due to initial tightening.
4. The stress concentration in the threads is neglected.
5. The bolts are relieved of shear stresses by dowel pins.

The resisting force acting on any due to tendency of the bearing to tilt, is proportional to its
distance from tilting edge.

Similarly

= constant of proportionality.

From both equations

Forces acting on bolt 1

If a = radius of flange, b = radius of pitch circle of bolts

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Hence

Hence general expression for ‘n’ bolts becomes

The maximum value will be when

EXAMPLE
A crane-runway bracket is fastened to the roof truss by means of two identical bolts as
shown in figure. Determine the size of the bolts, if permissible tensile stress in the bolts is
limited to 75 N/mm2.
SOLUTION
Given P = 20 kN, e = 550 mm,

STEP I: Direct tensile stress

STEP II: Tensile force due to the tendency of bracket to tilt.

and

Then
and

Moment of resisting forces

From two eq

Hence

Substituting values

STEP III: Resultant tensile force

Bolt 1 is at farthest point, hence it is subjected to maximum tensile force.

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Hence total force on bolt 1 is

= (10000+24146.34) = 34146.34 N

STEP IV: Size of bolts

Hence standard size of bolt is M30.

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