Formelsammlung Hamburg - De.en

Electrical engineer learning
group Mechatronics main

course
Formula collection
Machine elements and basic operations
of manufacturing technology 1 & 2
Hamburg, January 19, 2006

Author: Florian Cordes
Andreas Janssen
Pascal Stupperrich
Hannes Otto
Table of Contents
1 screws
1.1 Screw connections according to VDI 2230 (simplified) 1
1
1.1.1 Rough dimensioning 1
1.1.2 Attraction factor 2
1.1.3 Minimum clamping force 2
1.1.4 Balance of forces 2
1.1.5 Compliance screw 3
1.1.6 Compliance plates 4th
1.1.7 Preload change by setting 4th
1.1.8 Minimum assembly preload 5
1.1.9 Maximum assembly preload 5
1.1.10 ¨Verification 5
1.1.11 Operational stress (with GEH) 6th
1.1.12 Vibration stress 6th
1.1.13 surface pressure 7th
1.1.14 tightening torque 8th
1.2 Screw nominal values according to VDI-R 2230 8th
1.3 Screw tension diagrams 9
1.4 Table of abbreviations for screw calculation 10
2 springs 13
2.1 General law of force-displacement 13th
2.2 Switching of springs 13th
2.3 Rigidity and dimensioning of springs 14th
2.4 work of the spring 14th
2.5 Overview of spring types 15th
3 shaft hub 16
3.1 Form-fitting connections 16
3.1.1 General 16
3.1.2 Adjusting spring 16
3.1.3 Spline connection 17th
3.1.4 Splined shaft connection 17th
3.1.5 Polygon wave connection 17th
3.2 Non-positive connections 18th
3.2.1 Frictional forces required for external loads 18th
3.2.2 Required surface pressure for external loading 18th
3.2.3 Clamp connections 19th
3.2.4 Permissible surface pressures 19th
3.2.5 Choose a suitable fit 21st
3.3 Price connection 22nd
I.
4th Axis shaft 24
4.1 Shaft dimensioning procedure.................................................................................. 24
4.2 Rough dimensioning of the axis / shaft ..................................................................... 24
4.2.1 Determination of the maximum stress: ........................................................ 24
4.2.2 Determination of the fatigue strength........................................................... 25th
4.2.3 Calculation of the allowable stress .............................................................. 25th
4.2.4 Calculation of the minimum diameter .................................................... 26th
4.3 Recalculation of the loads at critical points (GEH) ..................................................... 27
4.3.1 Determination of existing stresses............................................................... 27
4.3.2 Summarize to the equivalent stress σ, ........................................................ 27
4.3.3 Determination of the allowable voltage .................................................... 27
4.3.4 Stress analysis........................................................................................... 28
4.4 Fatigue strength values in N/mm2 for standard materials .................................... 28
4.5 Forces and moments ........................................................................... 29
5 camp 31
5.1 Functions and types ................................................................................................ 31
5.2 Lifetime static load ........................................................................ 31
5.3 Service life dynamic load ......................................................................................... 31
5.4 Typical values for bearings ...................................................................................... 32
6th Weld 33
6.1 calculation ............................................................................................................... 33
6.1.1 Load sizes ................................................................................................. 33
6.1.2 Geometric sizes ............................................................................. 33
6.1.3 Nominal voltages ....................................................................................... 34
6.1.4 Allowable voltages ..................................................................................... 34
6.2 Weld seam shapes ................................................................................................. 35
6.3 Joint coefficients for loads ........................................................................................ 36
7th attachment 38
7.1 Forces and Moments .............................................................................................. 38
7.2 Energies ................................................................................................................. 39
7.3 Mass moments of inertia ................................................................................... 39
7.4 Conversion of units ................................................................................................. 41
II
~ c Electrical Formula collection: machine elements Mechatronics
engineer learning and basic operations in manufacturing technology 1/2 TUHH19. January
group 2006
1 screws
1.1 Screw connections according to VDI 2230
(simplified) 1.1.1 R0 determination of the nominal diameter (rough
dimensioning)
Axial force of the screw results in the reference force in table The occurring
axial force
per screw has been determined, then the next largest value in the table is used as Referenzkraft
chosen.
Type of load results in additional steps Depending on the type of load on the
screw, the next higher values in the table must be used for the reference force.
Just the Belas-
Case with the largest number of steps is considered!
· 4 steps for static and dynamic transverse forces FQ
FQ________________ FQ
· 2 steps for dynamic and eccentric attacking axesal forces
FA
· 1st step for dynamic and centric or static and eccentric F
axial forces A
· 0 steps for statically and centrally acting axial forces F

A
F F
Tightening type results in additional steps A A
· 2 steps for tightening with a simple screwdriver with F F

Tightening torque A A
F
A
· 1st step for tightening with a torque screwdriver or
precision screwdriver F
· 0 steps for tightening with angle control or yield point
control
Table for determining the nominal diameter

Force in N Nominal diameter in mm
Strength class
12.9 10.9 8.8
1000 3 3 3
1600 3 3 3
2500 3 3 4th
4000 4th 4th 5
6300 4th 5 6th
10,000 5 6th 8th
16000 6th 8th 10
25,000 8th 10 12th
40000 10 12th 14th
63000 12th 14th 16
100,000 16 18th 20th
160000 20th 22nd 24
250000 24 37 30th
400,000 30th 33 36
630000 36 39
1
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1.1.2 R1 tightening factor

The tightening factor αA takes into account the spread of the achievable assembly preload
betweenFM min and FM max.A determination is made taking into account the tightening and
setting procedures and, if applicable, the coefficient of friction classes (Table A5) according to
Table A8.
αA =FM max
FM min often aA. = 1.6 for torque wrenches
1.1.3 R2 Required minimum clamping force

The required minimum clamping force FK erf is determined taking the following requirements
into account.
Frictional connection to ¨Transfer of a transverse force FQ ( different from VDI)

S.R. : Security against slipping through (= 1 unless otherwise stated) i:
FQ total_______________ number of parting lines / cuts
FKQ = · SR n: number of screws
µ·i·n
F.Q total : Total shear force, often n = 1 and FQ already shared
Absorption of an axial force or sealing against a medium with pressure Pimax
Faxial AD · Pimax A.D. : Area of the lid

The FKA =
relationship = FK P
follows =
from the Pi maw : Maximum internal
requirements:
pressure n: number of screws
FKerf ≥ max (FKQ, FKA)
1.1.4 R3a balance of forces

The force ratio φK is the quotient of the additional screw force FSA and the axial operating
force component FA
FSA
φK = FA
This further relieves the load on the plates (or braced parts), in special cases (FA <0) burdening
force
FPA = (1 -φ K ) * FA = FA -FS A
To determine φ, the elastic flexibility of the screw oS and the elastic flexibility of the plate oP
are required, see next section
n: force application factor
oP
φK = n · n = 1: introduction to the support surface
oP + oSn = 0: introduction at the parting line
2
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1.1.5 R3b Determination of compliance (of the screw)
General (compliance / spring constant)
1 f rmm i
6 = =
F. l
c = EA 6 in N
Screw total compliance
8 th
SK : Head
6S = 6SK + 61 + 62 + 6h + 6W + 6G + 6M 8th
Weight : free thread
+ ... 8th
GM : screwed in thread
S .. {e.g. }
Shank, sleeve, expansion areas
π
A.1 = AN = 4 d2Nominal cross-section A3 = Ad3 = π 4 d2 3 core cross section
Head yield
SK :
Height of screw head
l
(Hexagon: lSK = 0.5 d, hexagon socket: lSK = 0.4 d)

lSK E.S. : Modulus of elasticity screw (205000 Nmm2)
6 S K = E S O N A.N: Screw with nominal cross-section
Shank compliance
li_____
6thi = Shaft screw: Ai = AN
IT Ai
Stretch ulse compliance

¨
lH π 4 (i.e.2 )
6thh =___________________________ A.H=w - d2 h
ES Ah
free thread indulgence
lWeight
6Gew = ES Ad3
Threaded in compliance
lG lm DSV: lm = 0.4d; E.
M = ES
6thG =_________ lG = 0.5d 6M =
E.S ad3 E.M AN ESV: l m = 0.33d; E. M. = E P
Plates compliance
lk
6P = EP Aers
3
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1.1.6 Resilience of the plates

Determination of the maximum diameter of the deformation cone
Depending on the plate geometry, the plates deform as a cone or as a sleeve with a cone,
therefore it is determined in advance which deformation case is present.
ESV: w = 2
DA, Gr = dw + w. lKtan ϕ DSV: w = 1
1. DA: Double the smallest edge distance in the parting line, largest circle in the holecan be
laid
D.0 A: largest circle in the basic field
2. Cone angle βL = dlKW . ; ' y = D 0
d W. lk: grip length
A.
ESV: tan ϕE = 1.295− 0.246lnβL + 0.194 ln'y DSV: tanϕ D

= 0.362 + 0.032 lnβ L. 2 + 0.153 ln'y
Cone deformation
Condition: DA ≥ DA, Gr
OP = h (dw + dh) (dw + w lk tan ϕ -

ie: diameter of the sleeve
i.e.) ] 2. ln (dw - d H ) (d w + w · l k · tan
ϕ+ d H ) dw: outside diameter of the flat screw head support DA:
w .EP. it. ie. tanϕ Double the smallest edge distance in the parting line
Cone and sleeve deformation
Condition: dw <DA <DA, Gr
Op
h (dw + dh) (DA — dh) ] H ]
=
w·d H·tanϕ ln _____________
Ep. it
OS + OP
Bracing body (c = 0) z
dw
Deformation cone
dH
DK /
2 DA
IV
/2D lH
'A / 2
The guide values for the setting amounts fZ for screws, nuts and compact, clamped parts made
of steel can be found in the table setting amounts on page 5.
4th
1.1.7 R4 preload reduction due to settlement

The following applies to the loss of pretensioning force
FZ of a screw:
fZ
FZ =
group 2006
Surface burden Corrective amounts for amounts to be

roughness RZ in the thread sethead
per in pm
or each inner
nut support parting line
<10pm Pull / push 3 2.5 1.5
push 3 3 2
10pm to Pull / push 3 3 2
<40pm push 3 4.5 2.5
40pm to Pull / push 3 4th 3
<160pm push 3 6.5 3.5
1.1.8 R5 minimum assembly preload
The required minimum assembly pre-tensioning force is obtained by observing the pre-tensioning
forceChanges taking into account the greatest possible relief of the connection.
FMmin = FKerf + (1_φK) FA + FZ
1.1.9 R6 Maximum assembly preload
Taking into account αA, the maximum assembly preload is calculated as FMmax = αA
FMmin
1.1.10 R7 review
The aim is to make the greatest possible use of the screw strength. In the event that for the
equivalent stress in the assembly state σred M only a partial use of the minimum yield strength Rp
0.2 min of the screw (usually 90%) standardized according to ISO 898-1 is permittedthe following
applies with degree of utilization v:
Permissible assembly stress ??
ii 0.9
σred, Mzul = v
RP0.2min R.P 0.2 = 640 (8.8) = 940 (10.9) = 1100 (12.9)

N
[ mm2]
Permissible assembly preload

~ i2
A.0 = smallest cross-section on the
shaft also A3, from table
v RP 0. 2 min d0 = smallest diameter also d3,
see table
d2 = Pitch diameter
FMzu l = A 0 r [3 ~ P d3
d2 German =
with expansion
1+3 π · d2+ 1, 155µg min screw pG 0 . 1 2
2 d0
If the screw size roughly determined in R0 can still be used, the following must apply: FMzul ~
FMmax
If the requirement is not met, a larger screw diameter must be selected and the calculation from R2
must be repeated. If an increase in the nominal diameter is not possible,other constructive changes
must be made.
5
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1.1.11 R8 operational stress (with GEH)

For connections in which the yield point of the screw is not exceeded under load should be, the
following applies:
Total screw force
F.S. Max = F Mmax + φ K F. Amax = F Mmax + F SA
Maximum tensile stress
[N ~
F.S. Max or [MPa] A.0: Smallest cross-sectional area on the

shaft
σz Max = in
A.0 mm2A.0 or A3 see table on page 8
Maximum torsional stress
M.G M.G : Moment of thread
τMax = WP W.P : Section modulus of the plate
/ P
d2 )P : F o r t h r e a d p i t c h s e e t a b l e o n
M.G = FMmax p a g e 8
+1, 155 µGmin
2 π d2 µG : Coefficient of friction on the thread
π d0 = d3 see table on page 8
W.P = 12 d3 0 The following applies to expansion screws:
d0 = dt
Equivalent stress according to GEH

\ /σred, B =σ2zmax + 3 (kτ τMax)2 with Kτ = 0.5
The following must apply:

1
σred, B < R.p0,2min S.F. ~ 1: safety factor
S.F.
or alternatively a security against Ëxceeding the yield point:
R.P0,2mi
n SF =
σred, B ≥1
at fullÄny loss of
torsional stress or for torsion-free tightening applies:
R.p 0.2min A. 0
F.S . M a x < ( d i f f e r e n t f r o m V D I )
S.F.
F.S. Max < R. P 0 , 2 min A0
R.P0,2min
≥1 Security against flow
S.F. = σz, max
1.1.12 R9 vibration
stress
<σAS F.
SAO : Upper additional axial screw force F SAU : Lower
2 AS. axial additional screw force σAS : Resistance to
F.S A O = F. A . O φK
F.S A U = deflection (see below)
F.A.U φK
σa = F.SAO - F.SAU
6
t
group 2006
For Schlui3-quenched and tempered (SV) screws, the stress amplitude of the durability is in the
range of 0.3 < F.M.
F. 0.2 mi <0.7 specified. (Σ [ N 1 ; d [mm])
mm2
σASV= 0.85 ( 150
d +45)
For close-rolled (SG) screws, the validity range is 0.3 <FM
F. o, 2 mi a
higher fatigue strength than with heat-treated screws: (~
2— FMmax
σASG σASV
=.
alternatively: σa <σAS
F.0.2
The following must apply to both types of screws:
S.D. = σAS ~ 1 Safety in the event of vibration
σa
thread Deflection strength

σAS in N / at strength class
mm2 slug- schlul3rollt 10.9 and
4.6 and 5.6 hardened8.8 12.9
under M8 50 to 12.9
60 100
M8 to M12 40 50 90
M14 to M20 35 40 70
via M20 35 35 60
1.1.13 R10 surface contact
In the support areaäche between the screw head and nut on the one hand and the clamped part on
the otheron the other hand, neither the assembly preload nor the maximum force in operation
FlÄchenpressungen become effective, the creepänge (time-dependentüsual plastic flow), combined
with a loss of pretensioning force. Taking into account Anmounts calculated FlÄchenpressung should
therefore the limitÄchenpressung the tense Do not exceed the material.
Assembly condition
Max =
✔ N mm2✕(from tab.)
p
F M m a x <p G
Operating condition
A. S. for St37: 490
p
Max =
FMmax+ FSAmax<pG π 4. (d2)
A= w - d2 n
alternatively: (Pmax can also be determined from the table)
FMmax + FSAO <pG

A. S.
p
Max =
S = pG . A. ~ 1 Security at Fl¨pinch pressure
F.M. Max
7th
~ c electrical engineer Formula collection: machine elements Mechatronics TUHH
Study group and basic operations in manufacturing technology 1/2 January 19, 2006
1.1.14 R13 tightening torque
The tightening torque is required for torque-controlled tightening. Tables A1 to A4, based on the
maximum possible frictional force and the maximumFriction coefficients can be taken from or
calculated as follows.
[ ~
0.16P + 0.58 d2 µGmin + DKm with: DKm= dw+ie
MA = FMmax 2
2 µKminµGm% n, µKm% n ≈ 0.12
In the case of flat circular ring supports, the following applies approximately for the friction
diameter under the head:
DKm = 2
dw + DKl
1.2
Screw nominal values according to VDI-R 2230

dimension Flanks Tension Tension Core cross- Force at minimum elongation
diam. cross cut diam. section F. 0 , 2 = R P 0 , 2 m% n · A S .
Slope P. Strength class
A.
d2 A.S. dS. d3 8.8 10.9 12.9
mm mm mm2 mm mm2 N N N
M4 0.7 3.545 8.78 3,344 7.749 5600 830 9700
M5 0.8 4,480 14.2 4,252 12.69 9100 13300 15600
M6 1 5.350 20.1 5.059 17.89 12900 18900 22100
M7 1 6.350 28.9 6,066 26.18 18500 27000 32000
M8 1.25 7.188 36.6 6.826 32.84 23400 34500 40500
M10 1.5 9.026 58.0 8,593 52.30 37000 55000 64000
M12 1.75 10,863 84.3 10,360 76.25 54000 79000 93000
M14 2 12,701 115 12.101 104.7 74000 108000 127000
M16 2 14,701 157 14,139 144.1 100,000 148000 173000
M18 2.5 16.376 193 15.676 175.1 127000 181000 212000
M20 2.5 18.376 245 17.662 225.2 162000 230000 270000
M22 2.5 20.376 303 19.642 281.5 200,000 285000 335000
M24 3 22.051 353 21,200 324.3 233000 330000 390000
M27 3 25.051 459 24.175 427.1 305000 430000 500000
M30 3.5 27.727 561 26.726 519.0 370000 530000 620000
M33 3.5 30.727 694 29.726 647.2 460000 650000 760000
M36 4th 33,402 817 32.253 759.3 540000 770000 900000
M39 4th 39,402 976 35.252 913.0 640000 920000 1070000
8th
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1.3 Screw tension diagrams

Threshold load
Pressure load Tensile load

f
SA = f PA
f
SA = fPA
F.
F. PA
F. F.
F. KR A. SA SA
F. M. F.
M.
F.
PA F F
F.S. A S
F.
KR
fS fP Change in length f fS fP Change in length f

. .
Train threshold load Alternating load
F.
A.U 2. F. SAA F.
AU
F.
SAO
F. M. FS AU SAO F. 2. F. SAA.
F. M.
F. SAU
F.A. F. M F.
A
O S. O
F. F. F.
S.M
KRmax KRmin
.
Change in length f Change in length f

fS. fP f S. fP
FM: assembly preload

FA: axial force / operating force
f = f
PA
FS: screw force
SA
F.SA F.SA : additional axial screw force
A. F.PA : Additional plate force
F. M. 2. F.SA =A.F F. KR : Residual clamping force
= SA
F.
fS: extension of the screw

=
FA f P : Shortening of the plates
F. = PA
F.
PA F.
KR
F.
SM
fSA : additional extension of the screw fPA : additional
shortening of the plates
Change in length f
f S. fP
Formulas for the stress diagrams
f S = δS • FS f P = δP • FP here: FS = FP = FM
F . SA = φK • FA FPA = (1-φK) • FA
9
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1.4 Table of abbr shortfalls in the screw calculation

¨
Formula symbols and terms for screw connections (according to VDI 2230)
FZ description FZ description
AD D A , G R Limit outside diameter, Max. By-
Separation area less the area of the
through hole for the screw; Sealing surface knife of the deformation cone
A.0 applicable smallest Cross sectional DK Max. Outside diameter of Verfor-

area cone at the parting line
D.
AT Nominal cross-section Km
effective diameter for the reitorque in the
screw head or nut support
D.
AP Ki
Surface of the screw head or nut edition Inner diameter of the flat head supportge
AS Stress cross-section of the screw wind There Inner diameter of the flat nutsurface area
according to DIN 13-28 (bevel diameter)
A. D.
SG Shear cross section of the thread Ha Inner diameter of the nut or aFlat support on
the screw thread sidearea of the clamped
parts
A.
SGM
Shear cross section of Thread the Dl Nut thread pitch diameter
screw
A.
SGMS Shear cross section of Thread the DSV Push-through screw connection
screw
AT Waist cross section E. modulus of elasticity
A.
d3 Core cross-section of the thread according EP Modulus of elasticity of the clamped parts
to DIN 13-28
A.5 Elongation at break at 5% permanent Modulus of elasticity of the clamped
E P R T
change parts at room temperature
D. Nut thread outside diameter EPT Modulus of elasticity of the clamped
parts at a temperature unequal to the
roomtemperature
THERE IT Modulus of elasticity of the screw material-
Replacement outside diameter of the base
body in the parting line; for joint areas fes
deviating from a circular shape empif DA is
the diameter of the Insert inside circle
THERE Replacement outer diameter of the main
bodypers
FA Axial force; one oriented in the screw axis FM Assembly preload
and proportionally related to a screwgene
component of an arbitrarily directed
Operating force FB
F.
FB arbitrarily directed operating force on one Mm medium assembly preload
connection
FK Clamping force FM max. assembly preload for the eggne
maw screw must be laid out, therewith despite
the inaccuracy of the tighteningdriving
and expected setting amount during
operation the required clamping force is
generated in the connection and hehold
remains.
F. F.
KA Minimum clamping force at the lift limit Mzul permissible assembly preload
F. F.
Cab Clamping force at the lift limit mGM Stripping force of nut or internal thread
F. F.
Kerf PA Part of the axial force that changes the
Clamping force required for the sealing
functions, friction fit and prevention of load on the clamped parts, plates-
one-sided lifting at the parting line. is lich additional force
Continued on next page
10
group 2006
F. KP Minimum clamping force to secure a F.Q Shear force; an operating force directed
Sealing function perpendicular to the screw axis or its
component with arbitrarily directed loading-
drivingforceFB.
F.
KR Residual clamping force in the parting line F.S. Bolt force (total force applied to the Screw
when relieved or loaded by FP A and put in works)
business
F.
F.SA additional axial screw force SAab
additional axial screw force on the liftlimit
F.
SAO upper (max.) additional axial screw force F S A U lower (min.) additional screw force
F. F.
SR Residual clamping force in the screw Sl
Screw force is over-elastictightened screw at
support the first Belastion
F.
F.V General preload Vab Pre-tensioning force at the lift-off limit
F. F.
VRT Pre-tension force at room temperature VT Preload force at a temperature unequal
to room temperature
¨
F.V l Pretensioning force of an over-elastic Δ F V t h Change in the preload force as a result of a
tightened screw after the first load temperature unequal to the room
temperaturedoor; additional thermal
ΔF 0 Vth ¨
Change in the preload force due to a F.Z force
Loss of prestressing force as a result of
temperature not equal to the room setting in business
temperature (simplified); approximated
thermalAdditional force
F.0,2 Screw force at the minimum elongation-
ze or 0.2% proof stress
M.A. Tightening torque during assembly tighten d Screw diameter = outer threaddiameter
a screw on FM. (nominal diameter)
M.G effective part of the indicator in the thread dS.
Diameter to the stress cross-section A.S.
torque (thread torque)
M.K Frictional moment in the head support dT Shank diameter for waist screws
M.T Torsional moment da Inner diameter of the flat head supportflat (at
the inlet of the radius transitionges from the
shaft)
P Pitch of the screw thread dH Bore diameter the tense
Parts
R. radius dw Outside diameter of the flat headposition of
the screw (at the inlet of the radius transition
from the head); generalOuter support
diameter
R.m Tensile strength of the screw; minimum dwa Outside diameter of the flat support surface-
valueaccording to DIN ISO 898-1 surface of a disc in contact with the ver-
clamped parts
R.
mM Tensile strength of the nut d0 Diameter to the smallest cross section of
the screw shaft
R.S. Strength ratio d2 Pitch diameter of Screw
thread-
R.p0,2 0.2% proof stress of the screw according to d3 Core diameter of the screw thread
DIN ISO 898-1
S.G Security against sliding S.L. Security against embedment
S.P Protection against surface pressure SW Key-width
W.p polar Moment of resistance one
Screw cross-section
l
fM. SK Substitute stretching length for the
Sum of the deformations of the screw and
deformation of the Screw head
clamped parts in the assembly state
fPA elastic change in length of the ten parts by lV Length of the deformation cone
FM.
Continued on next page
11
group 2006
m
fPM Shortening of the clamped parts FM eff
effective nut height or screw-in tiefe
(covering of outside and insidethread)
m
fSA Extension of the screw by FSA kr
critical nut height or screw-in tiefe
fSM Extension of the screw by FM ni Force introduction factor of the green body
˙
fZ ni reduced Force transmission factor of
plastic deformation by setting, setting amount
Basic body
hk Force introduction height nS Number of screws
lA Long between the main body and the p Surface pressure
point of application of force K in the
connecting body
left Substitute stretching length for the pB Surface pressure in the operating state
deformation of the screwed in thread
l
i n t h e Replacement length, sum of li and lM pi Boundary surface pressure, max.permissible
pressure under the screw head, nut or
washer
l
iew Length of the free loaded thread pM Surface pressure in the assembled state
lH Length of the deformation sleeve lK Clamping length
lM Substitute stretching length for the
deformation of the Nut or screw-in
α thread
Flank angle of the screw thread αA Display factor
8i elastic indulgence of in- 8S elastic compliance of the screw
screwed thread
elastic resilience of the screwed-in ϑ
8th
in Angle of rotation when tightening a screw
the thread and the nutorscrew-inthreadarea
8M elastic indulgence of Mother- µi Friction coefficient in the thread
or screw-in thread area
8SK µ'i increased coefficient of friction
elastic compliance of the screw head
compared to µi in pointed threads
8P µK Friction coefficient in the head support
elastic resilience of the braced parts with
central bracing and centric loading
8H P elastic indulgence a de- µT Friction coefficient in the parting line
mungshulse
8V P elastic indulgence one ii Utilization of the yield strength chiption
Procedural when tightening
8z P elastic compliance centric verclamped
parts
σn ρ' Angle of friction to µ 'i
Continuous vibration stress on the screw be
σAS Stress amplitude of the durability related σM
Tensile stress in the screw due to FM
to AS
σ
red reduced stress, equivalent stress σred, B Equivalent stress in the operating state
σ
red, M Equivalent stress in the assembled state σz Tensile stress in the screw in the
operating state
T Torsional stress in the thread in the TM Torsional stress in the thread in the
assembly state assemblystate
Φ Power ratio, relative Compliant ΦK
Power ratio with centric clampingtion and
relationship centric force introduction in Levels through
the screw head and nut support
ϕ Pitch angle of the screw thread; Equivalent
deformation cone angle
12th
group 2006
2 springs
2.1 General law of force-displacement
F (x) = cx c: stiffness constant of the spring [N / m]
2.2 Switching of springs
Series connection Parallel connection

SeriesF .connection of two springs
tot = F1 = F2 sges Parallel connection of two springs
= s1 + s2
F . tot = F1 + F2 sges
= s1 = s2 cges = c1 +
1 c2
1 = 1
c +
cg c
es 1
c1 c1
13th
group 2006
2.3 Rigidity and dimensioning of springs

Coil spring
T 8th . F. D.m τt : Torsional stress Dm :

E- τt = G.d4= c module: E = 205,000 Spring diameter
N / mm
2 d: wire
Wt π. d 3 diameter 2
= 8th D. 3m. Shear modulus: 2 G = 80,000 N / mm (hot-formed) G =
78,000 N / mm (cold formed)
numberif of i f = i - 1.5 (thermoformed)
Spring coils i f = i - 2 (cold formed)
Gas / air spring

Rod spring ( 1
n = polytropic exponent
E: modulus of elasticity s = path
A: F = Ap 0 .EA(1 - s / h) n )1area l: h = piston height
cross-sectional
Long
c = l
c = fl. p0 .A.2 p0 : Pressure of the medium in the
piston A: area of the piston
V Bending beamV: volume of the cylinder
b: width h:
E. .b. H3
height l:
c = 4. l 3
Long
Estimating a coil spring

Dm
w = d ≈ 5 ... 13
s
G. d4th d : w i r e d i a m e t e r (useful value: d 2mm)
D. m = if : Number of turns, estimate so that turns never touch!
3 _________________________
8.ci f G: Shear modulus, c: stiff ness
2.4 work of the spring

Translation
11 Max
W = 2 . F. Max .s Max = 2. c. s 2 Max = F2
2. c [J] or [Nm]
rotation
1 1 Max
W = 2 . T M a x . ϕ M a x = 2 . c O .ϕ 2 Max = T2 [ J ] or [Nm]
2. cO
_______________________________________ 14th _____________________________________

group 2006
2.5 Overview of spring types

Feather types
Günnikar: progressive
Coil spring: linear
Gas spring: strongly progressive
Disc spring: degressive
Metal springs (Roloff / Matek 10.2.1 types of springs)

Pull & push: Tension & compression bar springs
Ring spring
Bend: Leaf spring
Spiral spring, torsion spring,
disc spring, diaphragm
spring
Twist: Torsion bar
cylindrical Coil spring non-
cyl. Coil spring
15
th
group 2006
3 shaft hub
3.1 Form lock outside connections
¨
3.1.1 General
Circumferential force
F.U = resulting circumferential force
2. T
F.U = ______ T = torque to be transmitted
dm dm = effective diameter
Typical values for all form-fitting connections

Outer hub diameter permissible surface pressure Security values
Steel hubs Steel (gul3) hubs static load and tight fit
1.8 ... 2. d Gray hubs R.0
p
allow4 S = 2 ... 3
S.
2 ... 2.2. d Gray hubs dynamic load and tight fit
R.m
p
allow4
S = 3 ... 4
S. dynamic load and sliding fit
S = 4 ... 6
3.1.2 Key
Fl axle pressure of the feather key connection
¨
p: surface pressure
p of
z: number ≈psprings 2 . T ≤ l: load-bearing T:length,
torsional
withmoment
round-ended tongue groove: l = l '- b
p e r m d (h - t1). l.
.
z.ϕ
h: height of the key d: shaft diameter
go: contact ratio (see typical values)
t1 : Deep shaft groove p
perm : permissible surface pressure
Typical values of the parallel key connection

ht = h - t1 (Hub) h t = t1 (Wave)
1 z = 1
z = 1 ... 3, mostly z = 1 ϕ
0.75 z
Standard lengths for feather keys: 6, 8, 10, 12, 14, 16, 18, 20, 22, 25, 28, 32, 36, 40, 45, 50, 56, 63, 70, 80, 90, 100,
= = 2
110, 125, 140, 160, 180, 200, 220, 250, 280, 320, 360, 400
0.66 z
Permissible pressings Empirical values for dimensioning
16Hub
p
wave hub perm N Hub Outlets-
mm2
in Torque materi length l diameter
proud constant al
group 2006
3.1.3 Spline connection Surface

pressure of the spline connection
dm: average profile diameter (see typical values)
2 . T
< p p e r m Ht: Wedge height (see typical
p = values) l: load-bearing length z:
dm. ht. l. z. number of wedges go: load-
bearing ratio (see typical values)
Typical values of the spline connection

d1 + d2 d2—D1
dm = 2 Ht = - 2. e
2 e = bevel width
{
z = 4 ... 20 = 0.75 body t
centered 0 . 9
flank centered
3.1.4 Splined shaft connection
dm : average profile diameter (see typical values) Ht :

Wedge height (see typical values)
p =< p p 2e .r Tm dm. Ht. lz. l: load-bearing length z: number of teeth
cosα. go: contact ratio (see typical values)
cos a: pressure angle a = 30
Typical values of the serration connection
d1 + d 3 d3—D1
dm = 2 Ht = 2
i = 28 ... 81 = 0.75
Typical values of the involute tooth connection

0.7.k k:
d3 - d2
dm = d0 Ht = 2
i = 6 ... 61 = 0. 75
3.1.5 Polygon shaft connection
· P3G (3-cornered):
2T
.
d1 : Constant diameter c = 0.75
p = l (c. π .d 1 . e 1 + 0.05.d2 1) <p perm e 1 : 2 · d3
d
4th
d2 : Inner circle diameter d3 : Outer
circle diameter
· P4G (square):
d1 = d2 + 2er c=1 er: d1·d2
4th
p= 2 .
T d2 : Inner circle diameter d1 :
l (c. π. dr .er +0.05. d2r) <pperm Outer circle diameter
17th
group 2006
. Secondary wall thickness
µ dry oiled
/______________________________
F.R.: Friction force ST-ST k = 1.44
0.07 for P0.05
3 <35mm
T σ : σzzul hub ST-GG
material 0.13 0.02
F.
skR.• =________________________________
p. • FN perm
F.N : Normal force GG-GG k ,=70
0.13
forfor
1.20 0.02
P4th
P 3>
µ: coefficient of friction
3.2 frictional
F.N= p • A =outside
¨
p • p. • DF.connections
•b p: surface pressure in the joint
Forces in the joint A: peripheral surface
Surface pressure in the joint

F.N F.N F.R.
D.F. : Diameter of the joining
p = A = ii- • D F . • b = p. • ii- • D F.
surface b: width of the joining
• b surface
µ: coefficient of friction
3.2.1 Frictional forces required for external loads

Torque transmission
T: torsional moment to be transmitted
2•T 2 • FU • r D.F. : Diameter of the joint surface
F.R.= _________ = F.U : circumferential force to be
D.F. D.F. transferred r: lever arm of the
circumferential force
Axial force transmission
F.R. = Faxial F.
a x i al : Axial force to be transmitted
3.2.2 Necessary surface pressure to external load torque

transmission
T: torque to be transmitted
p
min = p. • ii- • D2F. • b D.F. : Diameter of joining surface
2•T µ: coefficient of sliding friction
b: length of the press fit
Axial force transmission
p
min = F.
axial : Axial force
to be transmitted
F.axial µ: coefficient of sliding
friction
p. • ii- • DF. •b D.F. : Diameter of
the joint surface
b: length of the press fit
Press connections must meet the following condition:

min : required surface pressure for torque transmission pmin <p <
p
pzulp
perm : permissible surface pressure
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group 2006
3.2.3 Clamp connections Clamp
connection with slotted hub
Tl 2
D.
. F.
F = n. Ii .DF. l1 F: screw force T: torsional
moment
l2
F.axial .l2
F = 2.n. Ii. l1 l1
T D.
F = n .Ii. D.F. F.
F = Faxial
2.n.Ii
n: total number of screws DF. :

Diameter Füg area
F.
a x % a l : Axial force
2: two friction surfaces

p .: coefficient of friction
l1, l2 : Long see sketch
Clamp connection with split hub
F: screw force T: torsional moment
n: total number of screws

p. : Coefficient of friction
D.F. : Diameter Füfflat
F.
a x % a l : Axial force
2: two friction surfaces
Tilting force clamp connections

F. R . : Frictional force p .:
k k Friction coefficient F K : Tilting
F.R.= Ii.FK. l FN =
FK. l force F N : Normal force
k: Distance pivot point - center of the axis
1 k: Long the F¨connection
2. Ii Self-locking condition
Diameter ratios (auxiliary values)

D.iI
Q I. = D : Inner diameter inner part (with solid shaft
% I
D.
% I = 0)
D. F.
___________D.F.
D. :
QA. = Outside diameter outside part
%I
D.aA
3.2.4 Permissible surface pressures
Outer part ppermissible:

1 - Q2 A.
tough material: pzulA = Re S. : Security against tiles 1.1 · · · 1.5
F.
√3.S.F.
1 - Q2 A.
brittle material: pzulA = Rm S.B . : Security against breakage 2 ··· 3
(1 + Q2 A). S.B.
19th
kl ≥
group 2006
R.e: R.m:
ST37-2 225 GG-15 150
Inner part pzulI: ST32-3 345 GG-20 200
ST60-2 325 GG-35 350
ST70-2 1 − Q2 355 I GG-40 400
H o l l o w s h a f t : pC35
z u l I = R365
mSF: 1.1 · · · 1.5
GGG-40 400
C45 √3 · SF
410 GGG-60 600
C60 2490 GTS-45 450
Solid wave: ppermI16MnCr5
= Rm 590 S.F.: 1, 1 ··· 1.5 GTS-65 650
20MnCr5√3 · SF 700 GS-38 380
Resulting maximum surface 17CrNiMo6
pressure785 of the connection: GS-45 450
18CrNi8 800 GS-60 600
pmax = min (pzulI, pzulA)
Relative
Zges Ztotal: Total deformation
adhesive measure
tot = DF D.F.: Diameter of the joint surface

Room
i = _Zi: deformation of the inner part
D.F.
Za
A =_Za: Deformation of the outer part
D.F.
Relative expansion of the outer part A and compression of the inner part I:
Pmin· (1 + Q2 A+ mA) Imin = Pmin · (1 + Q2 I.
Amine = + mI)
E.A1 − Q2 E.I 1 -QI.2
A.
Pmax· (1 + Q2 A+ mA) Imax = PMax·( 1 + Q2 I.
Amax = + mI)
E.A1 − Q2 E.I 1 -Q2
A. I.
Relative total adhesive strength with the same materials for solid shaft and hub:
tot min = imine + amine total min
p min
=
2
E. · 2
1 - Q2 A
tot max = Imax + Amax total max = pmax

E 1 - Q2 A
E. Cross
Steels 210000 number
0.3 m
GG 90000-150,000 0.24 ... 0.26
GS 200,000-215,000 0.3
20th
group 2006
Adhesion dimension Ztotal

Zgesmin = 'totmin · DF Ztotmax = 'totmax · DF
¨
Oversize Umin, Umax
Umin = Zges min + ΔU = 'tot min DF + 0.8 (RZA + RZI)
Umax = Zgesmax + ΔU =' totmax DF + 0.8 (RZA + RZI)
Reference value for Rz≈ (15 ... 110) May3tolerance
to water Rotate Reshaping Machinin grind Honking, lapping

R. Z≈ 100 fit 16-25 16 g
16 2.5 0.4
3.2.5 Select a suitable
· UK = Smallest oversize3 ~ Uges min UG = Largest oversize3 <Uges max
· choose standard bore H = lower dimension3 = 0
· Bore an ISO basic tolerance level worse than shaft
· Upper May 3
UMax -Umin
AoB> 2 = Hole tolerance
· Shaft tolerance term: (letter)
AuW ~ AoB + Umin

· Width of the tolerance field: (number)
Tw <Umax - AuW Tw
: Width of the tolerance field
AoW <Umax
Press-in force with a lings press fit

FLmax = µ · pmax · π · DF · b
Temperature difference for cross press fit

· Warming of the outer part:
S.K ≈ 0.001 .DF.
A.oW
D.F.: Diameter of the joint
_____________________________
+ SK surfaceϑ0 ≈ 20 ° C
'9A = + '90
αϑA · DF.
· Cooling down inner part: S.K ≈ 0.001 .DF.

D.F.: Diameter of the joint
A.oW surfaceϑ0 ≈ 20 ° C
a warming a hypothermia
ST, GS 11. 10-6 8.5. 10-6
GG, GT 10.10-6 8.10-6
Al-Leg 23.10-6 18. 10-6
Mg Leg 26. 10-6 21.10-6th
21st
group 2006
3.3 Press connection

Diameter ratios
Q N = Hub diameter ratio D.F. =
D. F. Joint diameter
QN = D.at = Outer diameter of the hub
D. at D.
in = Inner diameter of the hub
QW. = Shaft diameter ratio D.F. =

Joint diameter
D.iW D. D.
aW = Shaft outside diameter iW
QW. = DF. = Shaft inside diameter
Minimum compression at torque ¨transmission
T = torque to be transmitted µr =
2•T Coefficient of static friction
p
min = D.F. = Joint diameter
π • µr • D2 F. • lF. = Wing length
lF. S.R. = Safety factor
Expansion of the hub diameter

[1+__Q2 ] p = joint pressure
N E.N = E-module of the hub material
ΔD i n =______p
• Di n • + νN D.
in = Inner diameter of the hub
E. N 1 - Q2 N Q N = Hub diameter ratio
νN = Poisson's ratio of the hub material
Compression of the shaft diameter
[1 + Q2] p = joint pressure

E.W. = E-modulus of the shaft material
W.
ΔDaW = -p• DaW• + νW. D.
aW = Shaft outside diameter
E.W . 1 - Q 2 W . Q W. = Shaft diameter ratio
νW. = Poisson's ratio of the shaft material
Equivalent stress
s [1 + Q 2 ] 2 +1+ 1 + Q 2
a_v = p •
N N + 3 • µ 2r the hub
1 - Q 2
1 - Q 2
s [1 + Q 2 ] 2 +1+ 1 + Q 2
N N
W. W. +3• µ 2 r the wave
a_ v = p • 1— Q2
1-Q 2
W. W.
Effective Ëxcess
Z = | ΔD i n | + | ΔD a W | ΔDin = Expansion of the hub diameter
ΔD
aW = Compression of the shaft diameter
22nd
group 2006
Assembly temperature
t = t1 + t1 = Starting temperature
Umax UMax = Gröl3tübermal3
+ D.F. = Joint diameter
0.001. DF αN = Coefficient of thermal expansion of the hub
α N DF
R.
zW = Roughness of the shaft
Smoothing
R.
ΔUges = 0.8. (RzW + RzN) zN = Roughness of the hub
23
group 2006
4 axis shaft
4.1 Shaft dimensioning procedure

Procedure of the rough dimensioning
1. Determination of the maximum stress 3. Calculation of the allowable stress
2. Determination of the fatigue strength 4. Calculation of the minimum diameter
Recalculation procedure
1. Determination of existing stresses 1. Determination of the allowable stress0zuj
2. Summary of the existing VerDC voltage 2. Stress verification (safety S. ~ S.min or

0v tension 0v < 0zuj check)
Circumferential force F Ufrom performance

drive P
rotational F1
FU = n
d
F
2
Pulley on shaft P.11
P: engine power
Pη η: Belt drive efficiency
it d n
d: pulley diameter
n: speed of the pulley / shaft
F.U = F1 - F2 if direction of rotation as in figure
Torque from drive power
P: performance
P η T η: efficiency of torque transmission (= 1 with direct drive)
= 2 it n n: speed
4.2 Rough dimensioning of the axis / shaft
4.2.1 Determination of the maximum load: Fixed and
rotating axes
qMb (l) = M2 bx (l) + M2 by (l)
· If the forces acting on the axis lie in one plane, the calculation will be of the maximum
bending moment Mb max is made via the equilibrium of forces and moments. The maximum
bending moment occurs in the pulley.
· If the forces are in several planes, they are broken down into an orthogonal xyz system. The
bending moments are determined for the planes and the resulting bending moment Mb (l) (at
the corresponding point l) is calculated.
24
group 2006
waves
P
Mt max = 2 π n
q q_______________________________________________
Mvmax = M2 b max + 0.75 (α0 Mtmax) 2 = M2 b max + 0.37 M2tmaxwith: α0

0.7: effort ratio
· Pure torsional stress, then the torsional moment Mt max is considered.
· A shaft with a combined load is treated like a shaft with a pure bending loadtet, but the
bending moment is assumed to be higher, the comparison moment Mv max is considered.
4.2.2 Determination of the fatigue strength
· Smith chart, read the values for obw on the ordinate.
4.2.3 Calculation of the allowable stress

The permissible stress is calculated from the fatigue strength ob and a safety factor Snet. The
safety factor takes the following influences into account:
· Överload in operation (S)

· Notch effects (notch factor βk, surface coefficient bO)
· Deviations in the material parameters as a result of component sizes (size factor bG)
Calculation of the allowable stress
bG bO ob S: safety factor S 1.3 I-3k :

o zu l = x Notch factor σ
bx
σb sch : with fixed axes σb w : with
βk S bO : Surface coefficient rotating axes τt sch : with waves
bG : Size factor
simplified calculation of the allowable stresses

fixed axes rotating axes waves
σb sch σbw τt sch
σbzul = 3 ... 5 σbzul = 4 ... 6 τt perm = 10 ... 15
Size factor bG Surface coefficient bO Notch factor I-3k

25th
group 2006
4.2.4 Calculation of the minimum diameter
The minimum diameter dmin is the smallest design diameter that can be used.
Minimum diameter bolt (bolt is the axis with pure shear stress), calculation using
shear stress τs.
Fq F.q : Shear
force
Shear stress: τs =/ A = π. d2 <τs perm A: cross-sectional
τ
area zzul = 0, 8.σzzul
1, 6 . F.q
Ozsch Oz w
Circular cross-section: dmin ~ O z p e r m
Stress trap: Oz perm = 3 ... 5 or. Oz perm = 3 ... 5
Minimum diameter axes Calculation of the minimum diameter using the bending chip-
voltage obmax. V_________________________ /________
4th___. F.q 1.6. Fq with circular cross-section
M b m a d = ≈
obma = <if allow:
x Wb d3
= π .d 3 ≈
Wb 32 10
a - d4 π. d3 (1 -
≈ d3 a . (1 -
i
Wb = π. (d4) = k4) a with circular cross-section
32 k4)
10
32. there
k = di Diameter ratio for hollow axles
there
Obsch Obw
Stress trap: Ob perm = 3 ... 5 or whether perm = 4 ... 6
Circular cross-section: dmin ~

/
10th M.bmax
V
10. M.b Max

Annular cross section: damine ~ 3 obzul (1 - k4)
dimax <k. then
Minimum shaft diameter Works in addition to the mostly circumferential bending load -
Lich a torsional moment is a wave. The rough interpretation can be found under Verreduction of the
bending moment.
τt sch
M.tmax 10 ... 15
τt max = <τt perm____τt perm =
Wt
26th
group 2006
π d3
≈d3
W.t = 16 5 with circular cross-section
Wt = π ( d 4 ) π d3k4th (1)a- d3 a (1 - with circular cross-

a - d4th i
= ≈ section
Circular cross-section: d m i n16~ r5 Mtmax k4th)
16 da 5
3
τtzul
5 Mt M a x
s
Annular cross section: da min ~ 3 τt perm (1 - k4th)

di Max ≤ kda min k: diameter ratio, so
4.3 Recalculation of the loads at critical points (GEH)

4.3.1 Determination of existing stresses
Normal stress: F.A. : Normal force, perpendicular to the cut

✕
[ N
F.A. surface
mm2
σz = A
Bending stress:
M.b
σb W.b
= ✕
[mm2
N
M.b : Bending moment [Nm]
W.b : Section modulus against bending
[ N
Torsional stress:
T
τt = Wt
✕
mm 2
T: torsion [Nm]
W.t : Section modulus against torsion
Shear stress: F.Q : Shear force, parallel to the cut surface

F.Q
τs = A
[Nmm ✕ 2
Solid Hollow shaft Form fit

shaft πD4th
W.t π D.3 A . -d 4 t h D = D - t1
16 16 D.A.
π D4th
W.b π D.3 A - d4th D = D - 2 h
32 32 D.A.
π π A. - d2 i
A. D.2
4th (D2 )
4.3.2 Summarizing the equivalent stress σv

qσv = (σz+ σb) 2 + 3 (α0 (τt + τs))2
σb w
α0 = Effort ratio α0 0.7
1, 73 τtsch
4.3.3 Determination of the permissible
stress as under 4.2.3 on page 25
27
~ c electrical engineer Formula collection: machine elements Mechatronics TUHH
Study group and basic operations in manufacturing technology 1/2 January 19, 2006
4.3.4 Stress analysis
Either check the existing security p

bG bO ab w
S= 13k av
bG bO ab w
= a0 0.7
13k (a z + ab) 2 +3 (α0 (τt+ τs)) 2
Or check the existing voltage a v
(az + ab) 2 + 3 (α0 (τt + τs)) 2 ≤aperm = bG bO

from w
a v = 1 3 k S
4.4 Fatigue strength values in N / mm2 for standard materials

Q Q
material zsc betwe Qb sch Qb w Tt sch Tt w
en
General structural steels:
St 37 240 175 340 200 170 140
St 42 260 190 360 220 180 150
St 50 300 230 420 260 210 180
St 60 340 270 470 300 230 210
St 70 370 320 520 340 260 240
Tempering steels:
C22, Ck22 360 250 480 280 250 190
C45, Ck45 490 340 625 370 340 260
40Mn4, 25CrMo4, 34Cr4, 34CrMo4 650 400 750 440 450 300
41Cr4, 34CrMo4 780 450 830 480 550 330
50CrMo4, 34CrNiMo6, 36CrNiMo4 860 500 940 540 630 370
30CrNiMo8, 30CrMoV4, 32CrMo12 980 570 1040 600 730 420
Case hardening steels:
Ck15 300 270 420 300 210 180
15Cr3 400 320 560 350 280 210
16MnCr5, 25MoCr4 600 400 780 450 430 270
15CrNi6 650 500 900 550 450 300
20MnCr5 700 540 980 600 490 340
18CrNi8, 17CrNiMo8 800 580 1060 650 550 410
Cast steel:
GS 38 190 150 250 150 110 85
GS 45 230 180 300 180 130 100
GS 52 260 210 350 210 160 120
GS 60 300 230 400 240 180 140
Cast iron with spheroidal graphite:
GGG 38 180 110 260 150 140 95
GGG 42 220 130 310 180 160 100
GGG 50 250 150 360 210 200 130
GGG 60 300 180 440 250 250 150
GGG 70 360 220 530 300 290 170
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group 2006
4.5 Force and moment curves (recipe) Free body

diagram with loads
x = {0, a, b, c}, p (x) = {1,2,3,4}
Axial force Tension / compression (normal stress): σz = FA
A.
All forces that act in the axial direction.
F. a (x) = FX (x)
F. a (x): 1. F. a (0) = - ( F. AX)
2. F.a (a) = - ( F.AX + F1X ) = Fa(0) - F.1X
F.
3. F.a (b) = - ( F.AX + F1X + 0) = Fa(a) -0 Bx = 0 (floating
bearing)
F. 2rad Principle course: forces and

F. 2X torsional moment abruptly
F. 2u
F. 1rad F, T
F.
iu F.
iX
F. Ay F. B y X
y r2
F. Az
F. AX r1 F. F. BX
z Bz
X
1
M.
1 2 3 4
a X
b
Bending moment as a section-wise
c function f (X) = mX + b
4. F.a(c) = - (FAX+ F1X+ 0 + F2X) = F a (b) - F. 2 X = 0

!
Shear forcesShear stress: τ = F.Q
A.
All forces acting orthogonally to the axis / shaft. Qy(x)
= Fy(x), Q z (x) = F z (x)
Q y (x): 1st Q y (0) = - ( F. Ay)
2. Qy(a) = - (F.Ay + F1wheel) = Q y (0) - F. 1 wheel
3. Qy(b) = - (F.Ay + F1wheel + FBy) = Qy(a) - F.By
4. Qy(c) = - (F.Ay + F1wheel + FBy + F2wheel) = Qy(b) -
F.2wheel = 0 !
Q z (x): 1st Q z (0) = - ( F. Az)

2. Qz (a) = - ( F.Az + F1u ) = Q z (0) - F. 1 u
3. Qz (b) = - ( F.Az + F1u + FBz) = Qz(a) - F.Bz
!
4. Qz(c) = - (F.Az + F1u + FBz + F2u) = Qz(b) -F2u= 0
29
group 2006
Torsional moment Torsional stress: τ t = T

W.t
¨
Changes only in places in which a moment is introduced or removed. ⇔ Forces
acting eccentrically in the direction of rotation at the point p (x)
T = Tx (x) = Mx (x)
Tx (x): 1st Tx (0) = 0
2. Tx (a) = 0 + F1u r1 = Tx (0) + F1u r1
3.Tx (b) = 0 + F1u r1 + 0 = Tx (a) +0
!
4.Tx (c) = 0 + F1u r1 + 0 + F2u r2 = Tx (b) + F2u r2 = 0
P P transmitted power n
Tmax = 2πn speed
Bending moments Bending stress: O s M. b

=
W.b
Always look at the left edge of the cut!
Do not forget eccentric forces acting in the direction of rotation! (Jump in the course)
Beginning and end must always be zero!
Find M y (x) moments around y at significant places:
1. My (0)! = 0
2. My (a) = FAz a
3. My (a) = FAz b + F1u (ba)
4. My (b) = FAz c + F1u (ca) + FBz (cb)! =
0 Mz (x) determine moments around z at
significant places: 1. Mz (0)! = 0
2.1 Mz (a) = -FAy a

2.2 Mz (a) = -FAy a - F1x r1 DANGER! Jump by F1xr1
3 . M z ( b ) = - F A y b - F 1 x r 1 - F1 r a d ( b - a )
4.1 Mz (c) = -FAy c - F1x r1 - F1rad (c - a) - FBy (c - b )
4.2 Mz (c) = -FAy c - F1x r1 - F1rad (c - a) - FBy (c - b) - F2x r2 = 0 Leap
!
/ Mb (x) = (My (x)) 2 + (Mz (x)) 2Mb max
30th
group 2006
5 bearings
5.1 Functions and types
· Functions: guiding movement, transferring forces
· Types: radial bearings, thrust bearings, guide bearings
5.2 Lifetime static load Ëquivalent static

bearing load
X0, Y0 : Values from the roller
P0 = X0 Fr + Y0 Fa bearing catalog F.r : Radial force on
the bearing
F.a : Axial force on the bearing
Static safety factor
I .
⎨ > 1.5 ... 2.5 high appüche
C.0
S.0= fs= static key figure fs > 1.0 ... 1.5 normal appüche
P0 ⎩ > 0.7 ... 1.0 low contüche
Lifetime static load Service life in [106
revolutions]:
~ C0 )6thp Ball bearing: p = 3
L.10 = L = [10 Revolutions] Roller bearing: p = 10/3
P0
Lifetime in [h]: C.0 : static load rating from storage table
C: dynamic load rating

1 ~ C 0 ) p 106
L.
1 0 H = P : d 6y0n [ aH ]m=i Lc [ 1e0 q6 U
u ] i v106
. B e a r i n g l o a d n [Rpm]
nP0 60 n : s p e e d [ m i n −1]
5.3 Service life dynamic load Ëquivalent

dynamic bearing load
X, Y: values from rolling bearing
P = XF r + YF a catalog Fr : Radial force on the
bearing F.a: Axial force on the
bearing
values X and Y determine
1. Storage type LLBB  LL: bearing row and BB: number of holes
2. Values f 0 , C and C 0 take from table
3. Calculate ratio f0 and select the next larger value in table e C0
4. in case Fa F or>
≤e . a e read the values X and Y
F.r F.r
31
Formula collection: machine elements Mechatronics
and basic operations in manufacturing technology 1/2 TUHH19. January
2006
Service life dynamic load Service life in

[106 revolutions]:
L.10 = L =
~ C ~ p Ball bearing: p = 3
[ 1 0 6 Revolutions] Roller bearing: p =
Lifetime in [h]:
~ C ~ p C : d y n a m i c l o a d r a t i n g
1 106
60 [ H ] = L [106 U ]
L . 10H = P: dynamic ëquiv. Bearing load
n [ Rpm] 106
n P60 n : s p e e d [ m i n −1]
Extended service life: a23 = 1 normal dirt load
L . n / A = a 1 a23 f t
L10 a 2 3 = 0 . 1 he av y po ll ut io n
a1: Failure-
5.4 Typical values for bearings Bore Shaft
probabilities identificat throughknife
10% 1 ion 00 [mm] 10
5% 0.62 01 12th
4% 0.53 02 15th
ft temperature 3% 0.44 03 17th
ft C.° 2% 0.33 04 20th
1% 0.21 05 25th
06 30th
07 35
08 40
32
10,73
0,420.
22
150
200
250
300
group 2006
6 weld seam 6.1

Calculation
Procedure for proof of strength
1. Load magnitudes in the weld seam
2. Geometric sizes
3. Nominal stresses in the weld seam and connection cross-section
4. Allowable stresses
5. Comparison of the nominal stresses with the permissible stresses
6.1.1 Load quantities

·Bending moment Mb = Fq r (in connection level) • Tensile force F x = FN
·Shear force F y = FQ • Torsional moment T
2 T
·Circumferential force F U = D
6.1.2 Geometric quantities

Tail seam thickness a (calculated size)
· Butt weld: minimum sheet thickness
· Fillet weld: Height of the largest inscribable right-angled, isosceles triangle
a i : T h i c k n e s s o f w e l d s e a m o f s e c t i o n a i left
li : Length of the SN section
Tail seam shear surface Aw8
Aw8 = Xn ai li For all lik FQ

Flat momenti=of1 inertia against bending due to shear force
for rectangle h I z
(F × r) ind
I.
b H3
q, z =. . . 12th
Steiner share:
⑤④③⑥ ba
Area of the seam
·
⑤④③⑥
d2
Distance I z-axis
Moment of resistance against bending due to transverse force
I.q, e.g.
Wq, z = lmax: Largest edge fiber distance Iz axisl max
Circular ring
32 there
Flat fillet weld Fillet weld Fillet weld

a a a
s s
s
s s s
Tail seam surface (tensile force fläche)
Aw
Aw = Xn
i= 1
π ( d 4 )
Wb = a- d4 i
3
3
~ c Electrical Formula collection: machine elements Mechatronics TUHH19.
engineer learning and basic operations in manufacturing technology 1/2 January 2006
group
6.1.3 Nominal voltages
Tensile stress = ˆ normal stress

a
wx(m / a), z = in X direction
F.
x (m / a) (m / a): mean voltage or amplitude with
Aw dynamic load
F.x I weld seam area
Shear stress F.
Q (m /
τ
w(m / a) = a)
F.q II weld seam
Maximum bending stress
a
w ( m / a ) , b = M.b (m / a)
π a(- dd4i4 ) W.t :
Torsional moment of inertia

Wt
Wt = 2 Wb = Circular ring
16 there
Maximum tensile stress

Maximum tangential stress (shear stress) τ = τwm
awx = awxm + awxa
+ τwa
= awxm, z + + awxa, z +
Equivalent stressawxm, b|
according
{e.g.
to }GEH
awxa, b |
}
{e.g.
r
static dynamic ~ ) II: Shear stress in the welding plane
av = a ⊥ + a2 k + a⊥ ak + 3 τ2 ⊥ + τ2 k
2
I: perpendicular to the welding plane
6.1.4 Permëdgy tensions

re
azul m R.e : Yield strength from the fatigue limit diagram
SF
= azulb
ape rm
= σperm : from fatigue limit diagram with σvm
SD
τaF : from Smith chart
τ aF v1 : Seam coefficient (type of seam, stress)
τzulm
τzula = v1=v2
v1 v2
SF v2 : Quality factor (normal good: v2 = 0.8)
τaD
τ
aD : from Smith diagram with τwm as the mean portion
SD
static dynamic
S F = 1 ,2 . .2= 1 .6
SD = . ˆ 2, 5
2 .. . =
3
4
group 2006
6.2 Weld seam shapes 1.

Butt sutures
a) I-seam (without weld seam preparation c) X seam (with weld preparation
by chamfering the parts on both sides)
s = 1..3mm 60
b) V-seam (with weld seam preparation by d) U-seam (with weld seam preparation
chamfering the parts on one side) s = 12. 40mm
s = 3..20mm
s> 30mm
2mm
2mm
α = 60 ° for steel
in d type of letter U; au tulip seamcalled
2. Fillet welds
a) Vaulted fillet weld c) fillet weld
b) EFackhkeehnaah ( d) EEkkenah (outer seam)
3. Stitched tea (withoutSundSititShcheienßntvtvbebeieunung a)

ForeheadFlachnnah b) Forehead flue seam
35
a
a = t6 °
ftirsteelh
~ c Electrical Formula collection: machine elements and basic Mechatronics
engineer learning operations in manufacturing technology 1/2 TUHH19. January
group 2006
Other weld seam types are:
· K-weld (double fillet weld with · HV seam (double fillet weld, root-
SNV) welded, with SNV)
· Triple sheet seam (with SNV) 6

.
3
J
o
i
n
t
c
o
e
f
f
i
c
i
e
n
t
s
f
o
r
l
o
a
d l
s o
a
J d
o
Seam shape T y p e o f Coefficient
i stress v1 static
n Butt sutures train 1.0
print 1.0
t Bend 1.0
thrust 0.8
Fillet welds every stress 0.8
c
Seam coefficient V1with dynamic
o load
e
Stump 3
f V-seam X seam V-bevel-
V-seam root- processed seam
f welded 3
a = s a = s a = s a = s
i
c
i 0.92
0.70,840.56 1.1 0.70,840.56 0.80,980.65
e 0.73
T-Stol3
n Flat- K-seam X seam
seam HV seam
with double-
t seam root welded
fillet weld
2a a a s s
a a S. S. S.
V
1
0.22 0.63 0.56
0.70,840.
w 0.11 0.8 0.8
56
0.22 0.5 0.45
i Eckstol3
Corner-
t Corner butt Corner butt
X seam
joint
h
s 2a
s
a
s a
0.6 0.35
t 0.75 0.7
0.5 0.35
a
t
36
i
c
group 2006
Permissible weld seam stresses σw, perm and rw, perm

Permissible weld seam stresses σw, zulundrw, zulinN / mm2 for the load cases H (main-
loads) and HZ (main and additional loads) for different seam types according to DIN 18800.
Seam type Seam quality Voltage type Steel grade
St37 St52
H HZ H HZ
Butt weld, all seam quality Pressure and bending
K-weld with double fillet pressure 160 180 240 270
weld (penetrated root), K-
web seam with Freedom from Train and bend
Double fillet weld, cracks, joint and root across the 160 180 240 270
HV seam with fillet weld defects proven Seam direction
(counter-welded cap layer) Not good
seamsproven 135 150 170 190
HV web weld with fillet weld, all seam quality Pressure and bending
Fillet weld pressure Tensile and 135 150 170 190
flexural tension
all seams comparison
thrust value 135 150 170 190
37
group 2006
7 Appendix
7.1 Forces and moments
Powers
· force F in general
F = m · X¨ m = mass
x ¨ = acceleration
· Spring force FF of a longitudinal spring
c = spring constant
FF = c * X x = length change of the spring
· Damper force FD of a long steamer

FD = d X˙ d = steam constant
x ˙ = rate of change in length of the damper
· Frictional force FR on one surface
FR = FN · F.N = Normal force on the surface
µ0 µ0 = Coefficient of friction
· Centrifugal force FZ on a circular path

m = mass
v2 (w R) 2 v = speed on the circular path
FZ = m r = m r r = radius of the circular path ω = angular velocity
Moments
· Moment of inertia MD of a rotary steering
MD = Θ ·ϕ¨ Θ = I = mass moment of inertia

go ¨ = angular acceleration
· Spring moment M. ϕ a torsion spring
M.ϕ = c ϕ ·ϕ c ϕ = Sp rin g co n st a nt
go = change in angle of the spring
· Frictional moment Mθ on a circular path

Mθ = µ0 · θ˙ µ0 = Coefficient of friction
θ ˙ = angular velocity
38
group 2006
7.2 energies
· Kinetic energy (translational)
2 m v2 m = mass
1
TT = v = speed
· Kinetic energy (rotary)
1 '· ˙ϕ2 '= Mass moment of inertia

TR = 2 ϕ˙ = angular velocity
· Potential energy (Positional energy)
UL = mg · hm = mass, g = acceleration due to

gravityh = height
· Potential energy of the spring (Longitudinal spring)
2 c x2 c = stiffness of the spring
1
UF = x = change in length of the spring
· Potential energy of the spring (Torsion spring)
2 c ϕ2 c = stiffness of the spring
1
Uϕ = x = length change of the spring
· Frictional energy
p = coefficient of friction, m = mass
EReib = µ · mg · x g = acceleration due to gravity, x = friction distance
7.3 moments of inertia

· Moment of inertiaa circular disk
2 mr2 m = mass of the circular disk
1
'=
r = radius of the circular disk
· Moment of inertia a thin rectangular slice 12 m (b2
+ h2) m = mass of the rectangular disk
1
'=
b, h = width and height of the pane
· Moment of inertiaof a non-rotating bodyat the end

of a massless rod
'=' K + ml2 'K = Moment of inertia of the body
m = mass of the body, l = length of the rod
· Steiner's moment of inertia

'=' S + md2 'K = Moment of inertia around the center of gravity
m = mass of the body, d = distance SP axis of rotation
39
~ c Electrical Formula collection: machine elements and basic Mechatronics
engineer learning operations in manufacturing technology 1/2 TUHH19. January
group 2006
· Moment of inertiaa rotatable bodyat the end of

a massless rod
I = ml2m = mass of the rod

l = length of the rod
· Moment of inertiaof a rod around the center of gravity of the rod

1
I =
12 ml2 m = mass of the rod
· Moment of inertiaof a rod around an end point of the 3ml2 rod m
= mass of the rod
1
I =
4
0
group 2006
7.4 Conversion of units
Area Unit name character Base unit

force Kilopond 1 kp 9, 80665N ≈ 10N
Newton 1N kg m
1
s2
print 1 N = 1 kg
m2 m. s2
1
PascalMegapascalBarTech 1 Pa1
mm2
nical atmosphere MPa1bar 1,105Pa = 0.1MPa =
1 at 1,105N
Physical atmosphere m 2
1 atm
98066, 5Pa
101 325Pa
Lengths millime t e r 1 mm
1.
10−3m
centimeter 1 cm
1.
Surfaces Square millimeters 1 mm2 1 . 10−6m2
job 1 kWh 3.6. 103kJ
Kilowatt hours joule
1Y 1. Nm
1 W 1
power 1 hp
0.7355 kW
Horsepower watts J Nm kg. m2
. = 1. = 1.
s s s3
time Minute hour day 60. s3600. s

1 min1
year 86.4.103.s
h1d
31.54. 106. s
1a
Intent Abbreviation importance Intent Abbreviation importance

Exa E. 10'8 times Atto a 10 − '8
Peta P 10'5 times Femto f times
10-5 times
Tera T 10'2 times Pico p 10 − '2
Giga C. 109 times Nano n times
10-9 times
Mega M. 106 times Micro µ 10-6 times
41

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Electrical engineer learning

group Mechatronics main

Hamburg, January 19, 2006

· 0 steps for statically and centrally acting axial forces F

· 2 steps for tightening with a simple screwdriver with F F

Table for determining the nominal diameter

1.1.2 R1 tightening factor

1.1.3 R2 Required minimum clamping force

Frictional connection to ¨Transfer of a transverse force FQ ( different from VDI)

Absorption of an axial force or sealing against a medium with pressure Pimax

Faxial AD · Pimax A.D. : Area of the lid

1.1.4 R3a balance of forces

1.1.5 R3b Determination of compliance (of the screw)

General (compliance / spring constant)

(Hexagon: lSK = 0.5 d, hexagon socket: lSK = 0.4 d)

Stretch ulse compliance

free thread indulgence

1.1.6 Resilience of the plates

ESV: tan ϕE = 1.295− 0.246lnβL + 0.194 ln'y DSV: tanϕ D

OP = h (dw + dh) (dw + w lk tan ϕ -

Cone and sleeve deformation

Condition: dw <DA <DA, Gr

1.1.7 R4 preload reduction due to settlement

Surface burden Corrective amounts for amounts to be

1.1.8 R5 minimum assembly preload

FMmin = FKerf + (1_φK) FA + FZ

1.1.9 R6 Maximum assembly preload

Permissible assembly stress ??

RP0.2min R.P 0.2 = 640 (8.8) = 940 (10.9) = 1100 (12.9)

Permissible assembly preload

1.1.11 R8 operational stress (with GEH)

F.S. Max or [MPa] A.0: Smallest cross-sectional area on the

Equivalent stress according to GEH

The following must apply:

thread Deflection strength

1.1.13 R10 surface contact

alternatively: (Pmax can also be determined from the table)

FMmax + FSAO <pG

Screw nominal values according to VDI-R 2230

1.3 Screw tension diagrams

Pressure load Tensile load

fS fP Change in length f fS fP Change in length f

Train threshold load Alternating load

Change in length f Change in length f

FM: assembly preload

fS: extension of the screw

1.4 Table of abbr shortfalls in the screw calculation

A.0 applicable smallest Cross sectional DK Max. Outside diameter of Verfor-

Continued on next page

F (x) = cx c: stiffness constant of the spring [N / m]

2.2 Switching of springs

Series connection Parallel connection

2.3 Rigidity and dimensioning of springs

T 8th . F. D.m τt : Torsional stress Dm :

Gas / air spring

Estimating a coil spring

2.4 work of the spring

_______________________________________ 14th _____________________________________

2.5 Overview of spring types

Metal springs (Roloff / Matek 10.2.1 types of springs)

Typical values for all form-fitting connections

Typical values of the parallel key connection

___ 14th _