MEE 3001 Design of Machine Element

(Module 1 Introduction to Design Process)

Dr. Deepak Kumar Biswal

Department of Design and Automation
School of Mechanical Engineering
VIT Vellore
Design
• to formulate a plan for the satisfaction of a specified need
• to solve a specific problem.
Design: innovative and highly iterative process
(decision-making process)
o with too little information,
o with just the right amount of information,
o with an excess of partially contradictory information

The engineering designer: personally comfortable with a decision-making,

problem-solving role

Aim: To have a product that is functional, safe, reliable, competitive,

usable, manufacturable, and marketable, regardless of who builds it
or who uses it.
How: knowledge of technology and first principles
Engineering tools (mathematics, statistics, computers, graphics, and
languages)
 Mechanical Engineering Design

Deals: (1) with the production and processing of energy

(2) with providing the means of production, the tools of
transportation, and the techniques of automation.

Disciplinary bases are mechanics of solids and fluids, mass and momentum
transport, manufacturing processes, and electrical and information theory.

Design Process
 What is the design process?
 How does it begin?
 Does the engineer simply sit down at a desk with a blank sheet of
paper and jot down some ideas?
 What happens next?
 What factors influence or control the decisions that have to be made?
 Finally, how does the design process end?
Identification of need
Recognition of the need and
phrasing the need

Definition of problem
Include all the specifications for the
object that is to be designed.
• the input and output quantities,
the characteristics
• dimensions of the space the
object must occupy
• all the limitations on these
quantities.
• implied specifications

The synthesis of a scheme connecting

possible system elements is sometimes Fig: Design process.
called the invention of the concept or
concept design.
Synthesis and Analysis and
optimization are intimately and
iteratively related.

analysis and optimization

Mmathematical models that will
simulate the real physical system
very well.

Evaluation is the final proof

of a successful design and usually
involves the testing of a prototype
in the laboratory.
If the design really satisfies the
needs.
Is it reliable? Will it compete
Fig: Design process.
successfully with similar products?
Is it economical to manufacture and to use? Is it easily maintained and
adjusted? Can a profit be made from its sale or use?
 Stress and Strength
Stress is a state property at a specific point within a body, which is a
function of load, geometry, temperature, and manufacturing processing.

Strengths are the magnitudes of stresses at which something of interest

occurs, such as the proportional limit, 0.2 percent-offset yielding, or
fracture.
Strength is a property of a material or of a mechanical element.
It depends on the choice, the treatment, and the processing of the material.
Factor of safety

Allowable stress: used to determine the dimensions of the component.

It is a stress, which the designer expects will not be exceeded under normal
operating conditions.
 Direct stress
Normal stress
The internal resisting force per unit area of the component is called stress.

Many times, the unit for stress or strength is taken as MPa.

Shear stress
Bending stress
Parallel axis theorem
Torsional (Shear) stress

Angle of twist
 Eccentric axial loading
According to the principle of statics, the eccentric force P can be replaced by a
parallel force P passing through the centroidal axis along with a couple (P *e)
 THEORIES OF ELASTIC FAILURE

1. Maximum principal stress theory (Rankine’s theory)

2. Maximum shear stress theory (Coulomb, Tresca and
Guest’s theory)
3. Distortion energy theory (Huber von Mises and
Hencky’s theory)
4. Maximum strain theory (St. Venant’s theory)
5. Maximum total strain energy theory (Haigh’s theory)
 MAXIMUM PRINCIPAL STRESS THEORY
The failure of the mechanical component subjected to bi-axial or
tri-axial stresses occurs when the maximum principal stress
reaches the yield or ultimate strength of the material .

The dimensions
of the component
are determined
by using a factor
of safety
Region of Safety
If a point with co-ordinates (𝜎1 , 𝜎2 ) falls outside this square then it
indicates the failure condition. On the other hand, if the point falls
inside the square, the design is safe and the failure may not occur.

 Experimental investigations
suggest that the maximum
principal stress theory gives
good predictions for brittle
materials.
 However, it is not
recommended for ductile
materials.
 MAXIMUM SHEAR STRESS THEORY
The failure of a mechanical component subjected to bi-axial
or tri-axial stresses occurs when the maximum shear stress at any
point in the component becomes equal to the maximum shear stress
in the standard specimen of the tension test, when yielding starts.

In the tension test, uni-axial stress (𝜎1 ) &

(𝜎2 = 0). The stress in the specimen of
tension test and the corresponding Mohr’s
circle diagram
𝜎1
𝜏𝑚𝑎𝑥 =
2

When the specimen starts yielding (𝜎1 = 𝑆𝑦𝑡 )

𝑆𝑦𝑡
𝜏𝑚𝑎𝑥 =
2
 Therefore, the maximum shear stress theory predicts that the yield
strength in shear is half of the yield strength in tension
𝑆𝑦𝑠 = 0.5 𝑆𝑦𝑡

Suppose 𝜎1 , 𝜎2 and 𝜎3 are the three principal stresses at a point on the

component, the shear stresses on three different planes are given by,
𝜎1 − 𝜎2 𝜎2 − 𝜎3 𝜎3 − 𝜎1
𝜏12 = 𝜏23 = 𝜏31 =
2 2 2

The largest of these stresses is equated to 𝜏𝑚𝑎𝑥 or 𝑆𝑦𝑡 /2

Considering factor of safety

𝜎1 − 𝜎2 𝑆𝑦𝑡
=
2 2(𝑓𝑠)
Region of Safety For bi-axial stresses 𝜎3 = 0

𝜎1 − 𝜎2 = ±𝑆𝑦𝑡
𝜎2 = ±𝑆𝑦𝑡
𝜎1 = ±𝑆𝑦𝑡

pure shear stress

𝜎1 = −𝜎2 = 𝜏12

𝜎1
= −1 = −tan 45°
𝜎2

Shear Diagonal Shear diagonal or line of pure shear is the locus

of all points, corresponding to pure shear stress.
 The maximum shear stress theory of failure is widely used by
designers for predicting the failure of components, which are
made of ductile materials, like transmission shaft.
 DISTORTION-ENERGY THEORY
The failure of the mechanical component subjected to bi-axial or tri-axial
stresses occurs when the strain energy of distortion per unit volume at any
point in the component, becomes equal to the strain energy of distortion
per unit volume in the standard specimen of tension-test, when yielding
starts.
The total strain energy U of a unit cube subjected to the three principal
stresses 𝜎1 , 𝜎2 and 𝜎3 is given by,

1
𝑈= 𝜎1 2 + 𝜎2 2 + 𝜎3 2 − 2𝜇 𝜎1 𝜎2 + 𝜎2 𝜎3 + 𝜎3 𝜎1
2𝐸
 The total strain energy
U is resolved into two
components

𝑈 = 𝑈𝑣 + 𝑈𝑑
𝑼𝒗 corresponds to the change of volume with no distortion of the element
𝑼𝒅 corresponds to the distortion of the element with no change of volume

𝜎1 = 𝜎1𝑑 + 𝜎𝑣 𝜎2 = 𝜎2𝑑 + 𝜎𝑣 𝜎3 = 𝜎3𝑑 + 𝜎𝑣

Since the components 𝜎1𝑑 , 𝜎2𝑑 and 𝜎3𝑑 do not change the volume of the cube
The strain energy 𝑈𝑣 corresponding to the
change of volume for the cube is given by

𝑈𝑑 = 𝑈 − 𝑈𝑣

1+𝜇 2 2 2
𝑈𝑑 = 𝜎1 − 𝜎2 + 𝜎2 − 𝜎3 + 𝜎3 − 𝜎1
6𝐸
 In simple tension test, when the specimen starts yielding,

The criterion of failure for the distortion energy theory is expressed as

2𝑆𝑦𝑡 2 = 𝜎1 − 𝜎2 2
+ 𝜎2 − 𝜎3 2
+ 𝜎3 − 𝜎1 2

1 2 2 2
𝑆𝑦𝑡 = 2 𝜎1 − 𝜎2 + 𝜎2 − 𝜎3 + 𝜎3 − 𝜎1

𝑆𝑦𝑡 1 2 2 2
= 2
𝜎1 − 𝜎2 + 𝜎2 − 𝜎3 + 𝜎3 − 𝜎1
𝑓𝑠
𝑆𝑦𝑡
For bi-axial stresses (𝜎3 = 0) = 𝜎12 − 𝜎1 𝜎2 + 𝜎22
𝑓𝑠
A component subjected to
pure shear stresses and the
corresponding Mohr’s circle
diagram is shown.
From the figure,

Therefore, according to the distortion-energy theory, the yield strength

in shear is 0.577 times the yield strength in tension.
 Region of Safety

Experiments have shown that the distortion energy theory is in better

agreement for predicting the failure of a ductile component than any other
theory of failure.
 Ductile materials have an
identifiable yield strength
that is often the same in
compression as in tension
(𝑆𝑦𝑡 = 𝑆𝑦𝑐 = 𝑆𝑦 ).

Brittle materials do not exhibit an identifiable

yield strength, and are typically classified by
ultimate tensile and compressive strengths, 𝑆𝑢𝑡
and 𝑆𝑢𝑐 , respectively (where 𝑆𝑢𝑐 is given as a
positive quantity).
 SELECTION AND USE OF FAILURE THEORIES
1. Ductile materials typically have the same tensile strength and compressive
strength. Also, yielding is the criterion of failure in ductile materials. In
maximum shear stress theory and distortion energy theory, it is assumed
that the yield strength in tension (𝑆𝑦𝑡 ) is equal to the yield strength in
compression (𝑆𝑦𝑐 ).

Also, the criterion of

failure is yielding.
Therefore, maximum shear
stress theory and distortion
energy theory are used for
ductile materials.

Comparison of Theories of Failure

2. Distortion energy theory predicts yielding with precise accuracy in all
four quadrants. The design calculations involved in this theory are
slightly complicated as compared with those of maximum shear stress
theory.

3. The hexagonal diagram of

maximum shear stress
theory is inside the ellipse
of distortion energy theory.
Therefore, maximum shear
stress theory gives results
on the conservative side.
On the other hand,
distortion energy theory is
slightly liberal.

Comparison of Theories of Failure

4. The graph of maximum principal stress theory is the same as that of
maximum shear stress theory in the first and third quadrants. However, the
graph of maximum principal stress theory is outside the ellipse of
distortion energy theory in the second and fourth quadrants. Thus, it would
be dangerous to apply maximum principal stress theory in these regions,
since it might predict safety, when in fact no safety exists.

5. Maximum shear stress

theory is used for ductile
materials, if dimensions
need not be held too close
and a generous factor of
safety is used. The
calculations involved in
this theory are easier than
those of distortion energy
theory.

Comparison of Theories of Failure

6. Distortion energy theory is used when the factor of safety is to be held
in close limits and the cause of failure of the component is being
investigated. This theory predicts the failure most accurately.

7. The compressive strength

of brittle materials is much
higher than their tensile
strength. Therefore, the
failure criterion should
show a difference in
tensile and compressive
strength. On this account,
maximum principal stress
theory is used for brittle
materials. Also, brittle
materials do not yield and
they fail by fracture.
Comparison of Theories of Failure
To summarize,
• The maximum principal stress theory is the proper choice for brittle
materials.
• For ductile materials, the choice of theory depends on the level of
accuracy required and the degree of computational difficulty the
designer is ready to face.
• For ductile materials, the most accurate way to design is to use
distortion energy theory of failure and the easiest way to design is to
apply maximum shear stress theory
 Impact and Shock loading
• Impact refers to the collision of two masses with initial relative velocity.
• Shock is a more general term that is used to describe any suddenly applied
force or disturbance. Thus the study of shock includes impact as a special
case.

Impact is desirable: Coining, stamping, and forming presses,

Driving a nail with a hammer or breaking a coconut

Impact to be minimized: rattling of mating gear teeth in their tooth spaces,

clearance space between a cam and follower
between a journal and its bearing

Definition: Impact is as a collision of one component in motion with a

second component, which may be either in motion or at rest.
 IMPACT STRESSES

The potential energy released by the falling

weight is absorbed by the bar and stored in
the form of strain energy.
Now Also

Root of the
quadratic equation

Substituting the above expression for impact stress

 Or,

𝑷
The quantity is called shock factor, which indicates the magnification
𝑾
of the load W into the impact force P during impact

When the weight is applied instantaneously without any initial velocity

Means Putting it in, We get,

This means that the stress in the bar is double when the load is suddenly
applied compared with a gradually applied load.