Machine Design 1: BASAEN, RV

MACHINE DESIGN 1 2. Enable students to acquire knowledge in the

determination of suitable design factors, design
Textbook: stresses, and the application of simple, variable,
Design of Machine Elements by V. M. Faires and combined stresses to machine components.
References: 3. Develop students’ ability in the analysis of
different theories of failure brought about by static
Books in MD with the following authors: and cyclic loading of the machine member.
- Mott
- Shigley
- Black and Adams COURSE OUTCOMES
- Doughtie and Vallance
- Spotts At the end of the course, the students will be able to:
- Hamrock 1. Identify the sources of loads on machine part.
- Norton 2. Compare the different types of stresses.
- Juvinal 3. Solve problems in every topic of the course using
- Bhandari prescribed concepts.
- Gupta 4. Design machine components by considering
- Creamer suitable material properties, the appropriate
- Ugural assumptions for the loads and the acceptable
theory of failure required in the calculation.
Handbook for Mechanical Engineers 5. Develop a technical skill in presenting design
- Kent’s (Design Volume) works through standard specifications.
- Machinery Handbook
- PSME Code (2004 edition and earlier)
- Mark’s ME Handbook Important Definition of Terms
- Magazines and www for latest info
Mechanical Engineering – branch of engineering that
Topics for Machine Design 1 deals with energy conversion and design of machines.
1. Stresses, Materials & Properties
2. Pressure Vessels Design – a process of devising a component, a process
3. Impact Loading or a system to satisfy a desired need.
4. Stress Raisers and Stress Concentration
5. Variable Stresses Engineering design – a process in which scientific
6. Screw Fastenings principles and the tools in engineering -- math, graphics,
7. Springs computer, English, etc. – are used to produce a plan, which
8. Columns when carried out, will satisfy a human need.
9. Combined Stresses, Power Screws
10. Shafting Machine – a combination of several mechanical
components that are properly arranged or assembled to
cause the forces of nature to produce a desired work with
COURSE DESCRIPTION constrained motion.

The course deals with designing simple machine

components by using various significant properties of Some Considerations in Engineering Design
materials and appropriate design factors on the basis of 1. Strength
strength, rigidity and other criteria. 2. Rigidity
It includes analyzes of simple, variable and combined 3. Cost
stresses applied to different mechanical elements such as 4. Safety
bolts, springs, columns, shafts, keys and couplings. 5. Reliability
6. Weight
7. Volume, space
COURSE OBJECTIVE 8. Aesthetics
9. Manufacturability
The course aims to 10. Legal requirement, etc.
1. Provide students with in-depth knowledge on the
different concepts in designing machine Note:
components. The first two considerations, stress and rigidity,
are usually the prime considerations in Mechanics of
1
 Machine Design 1: BASAEN, RV

Materials since they are treated with the use of stress

and deformation formulas.
Other considerations may include functionality,
utility, life, noise, control, surface, marketability,
maintenance, liability, etc.
__________________________________________

2
 Machine Design 1: BASAEN, RV

Note:
1. DESIGN FOR SIMPLE STRESSES Above formulas apply to a uniform cross-sectional
area A only. The stress magnitude computed is also
constant at any section along the length of the member
Two General Types of Stresses under the axial load F.
There are different stresses that may apply to loaded
members, but these can be generally classified into two: 3. Bearing Stress, 𝑺𝑺𝒃𝒃 𝒐𝒐𝒐𝒐 𝝈𝝈𝒃𝒃
normal and shear stresses. - Also a contact or a crushing stress
- Shown below is bearing stress in
1. Normal Stress, 𝝈𝝈 𝒐𝒐𝒐𝒐 𝑺𝑺 the plate in a riveted joint
- Stress in which the direction of the applied
load is perpendicular to the resisting area of F
F
the member.
- This includes the following stresses: tensile
stress, compressive stress, bearing stress, t
d
and bending stress. (𝒅𝒅𝒅𝒅 ⊥ 𝒅𝒅𝒅𝒅)
𝑭𝑭
2. Shear Stress, 𝝉𝝉 𝒐𝒐𝒐𝒐 𝑺𝑺𝒔𝒔 𝝈𝝈𝒃𝒃 = 𝑺𝑺𝒃𝒃 =
𝑨𝑨𝒃𝒃
- Stress in which the direction of the applied
load is parallel or tangent to the resisting area
of the member. Bearing area
- This includes the following stresses: direct (projected area of the
shear, induced or indirect shear, punching contact surface );
shear, and torsional shear stress. (𝒅𝒅𝒅𝒅 ∥ 𝒅𝒅𝒅𝒅) (Ab = dt)

4. Bending stress, 𝑺𝑺𝒇𝒇 𝒐𝒐𝒐𝒐 𝝈𝝈𝒇𝒇

NORMAL STRESSES, (𝝈𝝈 𝒐𝒐𝒐𝒐 𝑺𝑺) From the normal stresses, bending stress is the
1. Tensile stress, 𝑺𝑺𝒕𝒕 most complicated. Its magnitude differs at any section
in the beam. Most calculations are focused on the
𝐿𝐿 section of the beam having the greatest magnitude of
stress, or the section having the greatest deflection.
𝐴𝐴
𝑴𝑴𝑴𝑴
𝝈𝝈 =
𝑰𝑰
M
M ρ
𝐹𝐹 𝐹𝐹 𝑬𝑬𝑬𝑬
𝛿𝛿 𝑴𝑴 =
𝝆𝝆
𝛿𝛿𝑡𝑡

𝑭𝑭 𝑭𝑭𝑭𝑭 M = bending moment

𝑺𝑺𝒕𝒕 = : 𝜹𝜹𝒕𝒕 = c = distance of the stressed fiber from the
𝑨𝑨 𝑨𝑨𝑨𝑨
neutral axis
I = rectangular moment of inertia of the
2. Compressive Stress, 𝑺𝑺𝒄𝒄 beam’s cross section from the neutral
axis
𝐿𝐿 E = modulus of elasticity of the beam’s
𝐴𝐴 material
𝜌𝜌 = radius of curvature of the beam

N.A.
𝐹𝐹 𝐹𝐹 y
c

𝛿𝛿𝑐𝑐 Note:
Treatment of the useful equations in bending involves
𝑭𝑭 𝑭𝑭𝑭𝑭 the calculations of the shearing force V and bending
𝑺𝑺𝒄𝒄 = ∶ 𝜹𝜹𝒄𝒄 =
𝑨𝑨 𝑨𝑨𝑨𝑨

3
 Machine Design 1: BASAEN, RV

moment M (shear and moment values) acting at desired Note:

sections of the beam. - 𝑀𝑀 is usually solved with the aid of shear &
• Shear and moment values moment equations & diagrams, or by some
- use the area method established formulas.
- 𝑐𝑐 is the distance of the outermost fiber from
𝑉𝑉2 = 𝑉𝑉1 + 𝐴𝐴𝐴𝐴𝐴𝐴𝑎𝑎𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙 ; ↑ (+) ; ↓ (−)
the neutral axis or centroidal axis.
𝑀𝑀2 = 𝑀𝑀1 + 𝐴𝐴𝐴𝐴𝐴𝐴𝑎𝑎𝑠𝑠ℎ𝑒𝑒𝑒𝑒𝑒𝑒
- Bending is the most complicated of all
loadings. Tension and compression
load: simultaneously occur, and beam’s normal
𝒅𝒅𝒅𝒅 stress is also accompanied by a shear stress.
𝒘𝒘 =
𝒅𝒅𝒅𝒅
(slope of the shear diagram )
SHEAR STRESSES, (𝝉𝝉 𝒐𝒐𝒐𝒐 𝑺𝑺𝒔𝒔 )
shear:
𝒅𝒅𝒅𝒅 1. Direct shear stress, 𝑺𝑺𝒔𝒔
𝑽𝑽 =
𝒅𝒅𝒅𝒅 a) Single Shear
(slope of the moment diagram ) - If the stress distribution is uniform or constant
then,
Beam Deflection, 𝜹𝜹:
- For some special bending cases, formulas for
maximum beam deflections are shown in tables or charts 𝑃𝑃 𝑃𝑃
from MDB.
- In general, beam deflection at a section of the beam
is expressed as
𝐸𝐸𝐸𝐸𝐸𝐸 = ∫ ∫ 𝑀𝑀𝑀𝑀𝑀𝑀. 𝑑𝑑𝑑𝑑 + 𝐶𝐶1 𝑥𝑥 + 𝐶𝐶2 𝑃𝑃
𝑃𝑃
… where 𝛿𝛿 is determined by double integration.
𝑃𝑃
Note:
- Bending is no longer a uniformly 𝑑𝑑
distributed stress.
- In bending, tension & compression occur 𝑃𝑃
simultaneously.
- The maximum stress happens at a fiber 𝑷𝑷 𝑷𝑷
farthest from the neutral axis. 𝝉𝝉 𝒐𝒐𝒐𝒐 𝑺𝑺𝒔𝒔 = = 𝝅𝝅
𝑨𝑨𝑨𝑨 𝒅𝒅𝟐𝟐
𝟒𝟒
In general,
𝑴𝑴𝑴𝑴 b) Double Shear
𝑺𝑺𝒇𝒇 = - two identical areas resist the load
𝑰𝑰
𝑃𝑃/2
where 𝑃𝑃
y = distance of the stressed fiber from the 𝑃𝑃/2
N.A.

For the maximum stress magnitude, 𝑷𝑷 𝑷𝑷

𝛕𝛕 𝐨𝐨𝐨𝐨 𝐒𝐒𝐬𝐬 = = 𝝅𝝅
𝑨𝑨𝑨𝑨 𝟐𝟐 � 𝒅𝒅𝟐𝟐 �
𝑴𝑴𝑴𝑴 𝟒𝟒
𝑺𝑺𝒎𝒎𝒎𝒎𝒎𝒎 = (double shear)
𝑰𝑰
use ct for tension and cc for compression)
𝑃𝑃/2
where
I = moment of inertia of the beam's cross 𝑃𝑃/2
section 𝑃𝑃
M = bending moment acting on the beam.
𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎

4
 Machine Design 1: BASAEN, RV

c) Punching Shear 3. Torsional shear stress, 𝑺𝑺𝒔𝒔

𝑷𝑷
𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃ℎ

𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃
Shaft with no
load
𝑡𝑡
𝑑𝑑
Reference point

𝑻𝑻 Displaced point
after torque T is
𝑷𝑷 𝑷𝑷 applied
𝛕𝛕 𝐨𝐨𝐨𝐨 𝐒𝐒𝐬𝐬 = =
𝑨𝑨𝑨𝑨 𝝅𝝅𝝅𝝅𝝅𝝅
Shaft loaded with
𝜃𝜃 a torque T
where
𝐴𝐴𝑆𝑆 = circumference of hole multiplied by the 𝑻𝑻
plate thickness
Reference point

(As =𝜋𝜋𝜋𝜋𝜋𝜋)

2. Indirect Shear of Induced Shear Stress Deformation in the Cross Section of Shaft
𝑏𝑏’
glued joint of area, As 𝛿𝛿𝑠𝑠
𝑃𝑃 𝛳𝛳
𝑏𝑏

𝜃𝜃
where
𝛳𝛳 = angular deformation or angle of twist
𝛿𝛿𝑆𝑆 = shear deformation (circular arc b-b’)
𝜃𝜃 = inclination of joint
from the axis of block
𝑃𝑃 = axial load of D = shaft diameter
block L = shaft length

𝜃𝜃 Note:
𝑃𝑃𝑠𝑠 𝑷𝑷 Torque 𝑇𝑇 produces a shear stress and a shear
𝑷𝑷
deformation, but no change in dimension, only a change of
position (point 𝑏𝑏 𝑡𝑡𝑡𝑡 𝑏𝑏’).
𝑃𝑃𝑛𝑛
Stress Distribution of 𝝉𝝉 across the Shaft’s Cross-Section
𝑃𝑃𝑆𝑆 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑃𝑃(𝑠𝑠𝑠𝑠𝑠𝑠2𝜃𝜃) 𝑅𝑅
τ𝑗𝑗𝑗𝑗𝑗𝑗𝑗𝑗𝑗𝑗 = = = :
𝐴𝐴𝑆𝑆 𝐴𝐴 2𝐴𝐴 𝜌𝜌
𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠
𝜏𝜏𝑚𝑚𝑚𝑚𝑚𝑚
𝑷𝑷(𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔𝒔)
𝛕𝛕𝒋𝒋𝒋𝒋𝒋𝒋𝒋𝒋𝒋𝒋 𝒐𝒐𝒐𝒐 𝑺𝑺𝒔𝒔 𝒋𝒋𝒋𝒋𝒋𝒋𝒋𝒋𝒋𝒋 =
𝟐𝟐𝟐𝟐
𝜏𝜏@ 𝑎𝑎𝑎𝑎𝑎𝑎 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝
The block is under compression but shearing
(sliding) may happen at the joint as shown.

Thus, if the maximum stress of the shaft is desired use,

𝑻𝑻𝑻𝑻
𝝉𝝉𝒎𝒎𝒎𝒎𝒎𝒎 =
𝑱𝑱
Note:
The maximum torsional stress in the shaft is located at
its outermost layer.

5
 Machine Design 1: BASAEN, RV

Commonly Used Formulas for 𝝉𝝉𝒎𝒎𝒎𝒎𝒎𝒎 Shear deformation

For Solid Shaft
V δs
γ
L
𝜏𝜏𝑚𝑚𝑚𝑚𝑚𝑚
V
𝑽𝑽𝑽𝑽
𝐷𝐷 𝜹𝜹 =
δs = shear deformation 𝒔𝒔
𝑨𝑨𝒔𝒔 𝑮𝑮
G = shear modulus of elasticity or modulus
of rigidity

Relationship between G and E:

𝑇𝑇𝑇𝑇
𝜏𝜏𝑚𝑚𝑚𝑚𝑚𝑚 = � �
𝐽𝐽 𝑬𝑬
𝟏𝟏𝟏𝟏𝟏𝟏 𝑮𝑮 =
𝝉𝝉𝒎𝒎𝒎𝒎𝒎𝒎 𝒐𝒐𝒐𝒐 𝑺𝑺𝒔𝒔 = ∶ (solid shaft) 𝟐𝟐(𝟏𝟏 + 𝝂𝝂)
𝝅𝝅𝑫𝑫𝟑𝟑
ν = Poisson’s ratio of the material
𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏 (typically, 0.25 to 0.3 for metals)
𝝉𝝉𝒎𝒎𝒎𝒎𝒎𝒎 𝒐𝒐𝒐𝒐 𝑺𝑺𝒔𝒔 = ∶ (hollow shaft)
𝝅𝝅(𝑫𝑫𝟒𝟒 − 𝒅𝒅𝟒𝟒 )

Thermal deformation and thermal stress

Torsional Deformation or Angle of Twist, 𝜽𝜽
𝜹𝜹𝑻𝑻 = 𝜶𝜶𝜶𝜶𝜶𝜶𝜶𝜶
𝑻𝑻𝑻𝑻
𝜭𝜭 = ; (𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓) (+) or expansion for heating
𝑱𝑱𝑱𝑱 (-) or contraction for cooling
Note:
Cross sections other than round require correction
α = coefficient of thermal expansion
factors for their stress and deflection formulas. Refer to
handbooks or other sources if these sections are desired. (mm/mm-°C)
Other shear stresses may come out from the L = dimension of the member
combination of the above shear stresses. ∆t = change in temperature

Note:
4. Shear Stress in Beams If the above deformation is prevented to occur due to
𝑽𝑽𝑽𝑽 some restriction or constraint, said deformation is
𝝉𝝉 𝒐𝒐𝒐𝒐 𝑺𝑺𝒔𝒔 = converted to a load deformation. The member is then under
𝑰𝑰𝑰𝑰
a thermal stress, σT.
V = vertical shearing force
Q = moment of area [δT = αL(∆t)] = [δP = (PL/AE)], where σ = P/A= σT;
I = rectangular moment of inertia
b = width of beam at the section considered Thus, the resulting thermal stress equation is

This shear stress τ is generally maximum at the 𝝈𝝈𝑻𝑻 = 𝑬𝑬𝑬𝑬(𝜟𝜟𝜟𝜟)

neutral axis, while the bending stress σ is zero at the said
axis. For a beam of rectangular section. If the constraint is partial the above thermal stress
formula should also be correspondingly adjusted.
𝟑𝟑𝟑𝟑
𝝉𝝉𝒎𝒎𝒎𝒎𝒎𝒎 =
𝟐𝟐𝑨𝑨 Stress-Strain Diagrams:
a) For ductile materials (e.g. mild steel)
For a beam of circular section of dia D 𝜎𝜎

𝟒𝟒𝟒𝟒 𝑈𝑈𝑈𝑈
𝝉𝝉𝒎𝒎𝒎𝒎𝒎𝒎 =
𝟑𝟑𝟑𝟑 𝑌𝑌𝑌𝑌
𝐸𝐸𝐸𝐸 𝑅𝑅𝑅𝑅
𝑃𝑃𝑃𝑃

6
𝜖𝜖
 Machine Design 1: BASAEN, RV

where - 𝑨𝑨𝑨𝑨𝑨𝑨 𝒐𝒐𝒐𝒐𝒐𝒐𝒐𝒐𝒐𝒐𝒐𝒐𝒐𝒐 of DME by Faires, give the

PL = Proportional limit values of 𝑆𝑆𝑦𝑦 & 𝑆𝑆𝑢𝑢 .
EL = Elastic Limit
YP = Yield Point
UP = Ultimate Point Design Stresses, 𝑺𝑺𝒅𝒅 𝒂𝒂𝒂𝒂𝒂𝒂 𝑺𝑺𝒔𝒔𝒔𝒔
RP = Rupture Point - Design stresses is analogous to the stress
used in MDB which could be any of the
following,
𝑆𝑆𝑆𝑆

𝑆𝑆𝑆𝑆
Normal Design Stress, Working Stress, Allowable
Stress, 𝑺𝑺𝒅𝒅
𝑺𝑺𝒚𝒚 𝑺𝑺𝒖𝒖
𝑺𝑺𝒅𝒅 = 𝒐𝒐𝒐𝒐
𝑵𝑵𝒚𝒚 𝑵𝑵𝒖𝒖
where
𝑁𝑁 = factor of safety, safety factor or design
factor
Note:
b) For brittle materials (e.g. cast iron, concrete, - 𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻 𝟏𝟏. 𝟏𝟏, 𝒑𝒑𝒑𝒑𝒑𝒑𝒑𝒑 𝟐𝟐𝟐𝟐 of Faires gives the
glass, etc.) recommended values of 𝑁𝑁.
- In general, ductile materials are designed
𝑆𝑆𝑆𝑆 based on the yield point (𝑆𝑆𝑦𝑦 ) unless
otherwise specified.
- Brittle materials are designed based on the
ultimate point (𝑆𝑆𝑢𝑢 ), since there are no well-
designed 𝑆𝑆𝑦𝑦 values.

Shear Design Stress, 𝑺𝑺𝒔𝒔𝒔𝒔

𝑺𝑺𝒚𝒚𝒚𝒚 𝑺𝑺𝒖𝒖𝒖𝒖
𝑺𝑺𝒔𝒔𝒔𝒔 = 𝒐𝒐𝒐𝒐
𝑵𝑵𝒚𝒚 𝑵𝑵𝒖𝒖
Note: where
- The allowable stress or working stress is 𝑆𝑆𝑦𝑦𝑦𝑦 = yield strength in shear
computed from the yield strength 𝑆𝑆𝑦𝑦 or ultimate 𝑆𝑆𝑢𝑢𝑢𝑢 = ultimate strength in shear
strength 𝑆𝑆𝑢𝑢 of the material as tested. These
stresses are often referred to as the stress at failure
𝜎𝜎𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 . Typically for steels,
𝑺𝑺𝒚𝒚 𝒐𝒐𝒐𝒐 𝑺𝑺𝒖𝒖 𝑺𝑺𝒚𝒚𝒚𝒚 ≈ (𝟎𝟎. 𝟓𝟓 𝒕𝒕𝒕𝒕 𝟎𝟎. 𝟔𝟔)𝑺𝑺𝒚𝒚
𝝈𝝈𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂 𝒐𝒐𝒐𝒐 𝝈𝝈𝒘𝒘 = 𝑺𝑺𝒖𝒖𝒖𝒖 ≈ 𝟎𝟎. 𝟕𝟕𝟕𝟕𝟕𝟕𝒖𝒖
𝑭𝑭. 𝑺𝑺. 𝒐𝒐𝒐𝒐 𝑵𝑵

where - Use 0.6 for torsion.

𝐹𝐹. S. or N = factor of safety - Use 0.5 for other shear stress application.

- As much as possible the allowable stress should • Designing Based on Strength

not exceed the proportional limit (i.e. where the
stress is still proportional to strain) since most 𝑺𝑺𝒊𝒊𝒊𝒊𝒊𝒊𝒊𝒊𝒊𝒊𝒊𝒊𝒊𝒊 ≤ 𝑺𝑺𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅 𝒐𝒐𝒐𝒐 𝑺𝑺𝒅𝒅 𝒐𝒐𝒐𝒐 𝑺𝑺𝒔𝒔𝒔𝒔
assumptions in Engineering estimates are based
on Hooke’s law (i.e. 𝜎𝜎 ∝ 𝜖𝜖). where
𝑆𝑆𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = design stress
Note: 𝑆𝑆𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 = induced stress (stress due to the
- Strength of materials are described generally applied load)
in terms of the yield strength (𝑆𝑆𝑦𝑦 ) & the
ultimate strength (𝑆𝑆𝑢𝑢 ). These are the highest • Design Based on Rigidity
points on the diagram and are easily
estimated. 𝜹𝜹 𝒅𝒅𝒅𝒅𝒅𝒅 𝒕𝒕𝒕𝒕 𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍 < 𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂 𝜹𝜹

7
 Machine Design 1: BASAEN, RV

Conversion of Computed Size to Preferred Size, Significant difference between MDB and Simple
- The following guide (increment and size Machine Design Problems:
ranges) will be tentatively used to arrive at a
standard or preferred size or dimension of a 1. In MDB, the allowable stresses or limiting
machine member. This will be superseded by stresses are generally specified, and thus, the
other more specific tables later. material description (steel, wood, etc.) may not be
- Other sources are presented in Chapter 3.
in detail.
2. Problems in Machine Design may require the use
Increment Range of size Increment Range of size
1 1 1 1 1 3 of tables/charts for the needed material properties,
𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑡𝑡𝑡𝑡 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑡𝑡𝑡𝑡
64
1
64
3
32
7
32
1
32 16
7
and a factor of safety or design factor. From these
16
𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑡𝑡𝑡𝑡
16 8 8
𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑡𝑡𝑡𝑡 3
8 values, the allowable or design stresses are
1 1
𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 3 − 6 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 6
determined and thus, reverting the analysis to, as
4 2
Source: Design of Machine Elements by V.M Faires if, an MDB solution. A sound foundation in MDB
is then a must for Machine Design. Thorough
Other useful Tables and Charts from DME by Faires understanding about Machine Elements, Material
include the following: properties and Kinematics is also of utmost
AT1 - properties of sections importance.
AT2 - moments and deflections of beams 3. Most Machine Design problems in licensure
AT3 - properties of non-ferrous materials
examinations at present, if not all, are furnished
AT4 - properties of stainless steels
with enough data for their solution -- without the
AT5 - properties of plastics
AT6 - properties of cast ferrous metals need of opening important Tables, Charts, etc.
AT7 - properties of wrought ferrous metals
(steels) To avoid the cumbersome task of opening tables
AT8 - properties of various sizes of steels and charts while solving problems, most examples
AT9 - properties of heat-treated steels can be converted with additional data, already
AF1 - properties of AISI C1040 giving the required data from Tables and Charts.
AF2 - properties of AISI 4340 This has been the case of the previous board exam
AF4 - relation among hardness numbers questions, since nothing is allowed to be opened
during exams, except non-programmable
It is always recommended to convert all computed calculators. However, it should always be
sizes to preferred sizes. Most machine members are
emphasized that the student should at least know
described together with a Table about their standard sizes.
where and how to get material properties, etc.
This technique of consulting a table would be observed in
the succeeding presentation.
Example 1:
Numbering System for Steel The link loaded as shown is to be machined from
- AISI, SAE (example: AISI C1030, AISI AISI C1020, as rolled steel and is to have the given
3140) – Ductile Material proportions below. Recommend the cross-sectional
dimensions h and b if the maximum tensile load is 12 kips,
Numbering System for Cast Iron repeated but not reversed. Take ℎ = 4𝑏𝑏. Base the design
- ASTM (American Society for Testing and on:
Materials) – Brittle Material a. Yield Point
b. Ultimate Point
Materials are often described with numbering systems. c. Elongation not exceeding 0.005" in a length
From the numbers, the main components of the alloy are of 18 𝑖𝑖𝑖𝑖𝑖𝑖ℎ𝑒𝑒𝑒𝑒.
indicated. d. Solve part a) if the load is repeated and
For both the AISI and SAE steel numbering systems, reversed.
p. 48 of DME Faires serves as a guide in identifying the
main alloying elements: ` F F
More descriptions about material properties and + h +
numbering systems are shown in Chapter 2.
b

8
 Machine Design 1: BASAEN, RV

Solution:

The link is axially loaded with a maximum magnitude

of 12 kips, repeated, but not reversed.
F

Example 2:
The piston rod of a 12” 𝑥𝑥 18”, double acting air
compressor is to be made of steel,
𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 3140 𝑂𝑂𝑂𝑂𝑂𝑂 1000 °𝐹𝐹. The pressure inside the cylinder
F is to have a maximum value of 200 𝑝𝑝𝑝𝑝𝑝𝑝. Recommend the
piston diameter if the design is based on the yield strength.

For the useful material properties: (AT7 of DME Faires)

𝑆𝑆𝑦𝑦 = 48 𝑘𝑘𝑘𝑘𝑘𝑘 𝑎𝑎𝑎𝑎𝑎𝑎 𝑆𝑆𝑢𝑢 = 65 𝑘𝑘𝑘𝑘𝑘𝑘
And for the recommended factor of safety (Table 1.1)
𝑁𝑁𝑦𝑦 = 3 𝑎𝑎𝑎𝑎𝑎𝑎 𝑁𝑁𝑢𝑢 = 6; (repeated, one direction)

Solution:

Example 3:
A 10ℎ𝑝𝑝, 800 𝑟𝑟𝑟𝑟𝑟𝑟 electric motor drives a centrifugal
pump by means of a shaft that is made of 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝐶𝐶1040,
𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠. Recommend the shaft diameter
required if shaft only rotate clockwise motion.
T Power = 10hp
n=800rpm
D=? D =?

T
9
 Machine Design 1: BASAEN, RV

Solution: For AISIC1040, normalized steel, 𝑆𝑆𝑢𝑢 ≈ 79000 𝑝𝑝𝑝𝑝𝑝𝑝

This is a simple torsion example. If there are no tested F

torsional strengths for steel, most books use 𝑆𝑆𝑦𝑦 𝑠𝑠 =
(0.5 𝑡𝑡𝑡𝑡 0.6)𝑆𝑆𝑦𝑦 ; 𝑎𝑎𝑎𝑎𝑎𝑎 𝑆𝑆𝑢𝑢 𝑠𝑠 = 0.75𝑆𝑆𝑢𝑢
where
𝑆𝑆𝑦𝑦 𝑠𝑠 = 𝑦𝑦𝑦𝑦𝑦𝑦𝑦𝑦𝑦𝑦 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠ℎ 𝑖𝑖𝑖𝑖 𝑠𝑠ℎ𝑒𝑒𝑒𝑒𝑒𝑒:
0.6Sy for torsion and 0.5Sy for other shear
𝑆𝑆𝑢𝑢 𝑠𝑠 = 𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠ℎ 𝑖𝑖𝑖𝑖 𝑠𝑠ℎ𝑒𝑒𝑒𝑒𝑒𝑒:
0.75Su for shear in general

Example 5:
A cast iron beam, 𝐴𝐴𝑆𝑆𝑇𝑇𝑀𝑀 25 is loaded as shown with
F1 = 4000 lb & F2 = 2000 lb. The loads are in phase
and are repeated, but not reversed.
a. Recommend the cross-sectional
dimensions of the beam (𝐻𝐻 𝑥𝑥 𝐵𝐵) if it is
arranged as a T-section as shown.
b. The same as 𝑎𝑎), except that the cross-
section is arranged as an inverted 𝑇𝑇-
section.

𝐅𝐅𝟏𝟏 𝐅𝐅𝟐𝟐
B = 4a
𝐴𝐴 𝐵𝐵 𝐶𝐶 𝐷𝐷
𝑎𝑎
1.5𝑎𝑎
H = 4a
16" 16" 16"
𝐑𝐑 𝟐𝟐 𝑎𝑎
𝐑𝐑 𝟏𝟏

Example 4: Solution:
Determine the number of ¾” diameter holes that can AT6 of Faires shows the following properties of cast
be punched in one stroke from a steel plate, ¼” thick, if the iron ASTM 25:
plate is made of an annealed AISI C1040. The maximum Sut = 25 ksi
applied load is to be 90 tons. Suc = 97 ksi
Sus = 35 ksi
Solution:
This is a basic punching stress problem, but ‘n’
simultaneous punches are to be engaged in just one stroke.

Since the plate is to be punched, the applied stress

should be at least equal to the ultimate shear strength of the
plate, and there should be no factor of safety.

Unless specified, the ultimate shear strength of steel

is 𝑆𝑆𝑢𝑢 𝑠𝑠 = 0.75𝑆𝑆𝑢𝑢 .

10
Machine Design 1: BASAEN, RV

11
 Machine Design 1: BASAEN, RV

Example 6:
A steel 2” diameter and 24" long is inserted
between rigid walls, preventing axial deformation. If the
rod is made of A 𝐶𝐶 1020,
, compute for its final
stress when heated by 150°𝐶𝐶 (302 𝐹𝐹 ), also determine
the elongation of this rod if the ends are free.

Solution:
Should a gap exist between the rigid wall and the
rod, partial conversion of stress takes place and the
analysis below applies. Once heated, thermal expansion
freely takes place until the rigid wall is reached. Then,
the remaining supposed thermal expansion is
converted to a load deformation. This is a more
generalized treatment of a thermal stress problem.

𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤

At a
temperature To
𝐿𝐿
gap, Δ
𝛿𝛿𝑇𝑇
At a
temperature
𝑷𝑷 𝑷𝑷 Tf > To
(expansion)
𝛿𝛿𝑃𝑃
Δ

12
 Machine Design 1: BASAEN, RV

PRESSURE VESSELS
𝒑𝒑𝒑𝒑
𝑺𝑺𝒕𝒕 =
1. THIN WALLED VESSELS 𝟒𝟒𝟒𝟒𝒏𝒏𝒋𝒋
- vessels whose ratio of the wall thickness t and
the inside diameter D does not exceed 0.1. Note:
𝑡𝑡 The stress at any section of the spherical vessel
≤ 0.1
𝐷𝐷 (cutting the vessel into two hemispheres) is constant
- stress analysis for this class of vessel is based and thus, in designing a cylindrical pressure vessel, use
on simple stresses (i.e. stress distribution is
uniform) 𝒑𝒑𝒑𝒑
𝑺𝑺𝒕𝒕 = ⇒ 𝑺𝑺𝒅𝒅
𝟒𝟒𝟒𝟒𝒏𝒏𝒋𝒋
A. Cylindrical Thin walled Vessels
Spherical vessels are the strongest vessels. They
t are twice stronger than cylindrical vessels!
B
D Example 1
A A A cylindrical thin-walled vessel with two
B hemispherical ends is made of stainless steel, AISI 301, ¼
hard (Sy = 75 ksi).
Tensile stress at section A-A: t=1/4”

𝒑𝒑𝒑𝒑 Transverse stress;

𝑺𝑺𝒕𝒕𝑨𝑨𝑨𝑨 = tangential stress; D=36”
𝟐𝟐𝟐𝟐𝒏𝒏𝒋𝒋 circumferential stress;
hoop stress; girth stress

Tensile stress at section B-B: L=48” 𝜂𝜂𝑗𝑗 = 75%

𝒑𝒑𝒑𝒑 a) Determine the maximum permissible mass of oxygen
𝑺𝑺𝒕𝒕𝑩𝑩𝑩𝑩 = Longitudinal stress
𝟒𝟒𝟒𝟒𝒏𝒏𝒋𝒋 gas that can be safely contained by the vessel at 80oC.
Use a factor of safety of 4, based on Sy.
where b) If the above vessel is to be replaced by a hypothetical
p = internal pressure ellipsoidal vessel containing equal volume of gas with
D = inside diameter same material and operating conditions, determine the
t = wall thickness dimensions of the vessel: 𝐷𝐷𝑒𝑒 , 𝑑𝑑𝑒𝑒 and 𝑡𝑡𝑒𝑒 if 𝐷𝐷𝑒𝑒 = 2𝑑𝑑𝑒𝑒 .
nj = joint efficiency or relative strength c) The same as b), but the replacement is spherical vessel.
of joint Determine 𝐷𝐷𝑠𝑠 and 𝑡𝑡𝑠𝑠 .

Note: Solution:
The stress at section A-A is greater and thus, a) m = ? (mass of 𝑂𝑂2 in kgm)
in designing a cylindrical pressure vessel, use

𝒑𝒑𝒑𝒑
𝑺𝑺𝒕𝒕𝑨𝑨𝑨𝑨 = ⇒ 𝑺𝑺𝒅𝒅
𝟐𝟐𝟐𝟐𝒏𝒏𝒋𝒋

B. Spherical Thin walled Vessels

t
C
A B
D
B A
C

Tensile stress at any section AA, BB, CC:

13
 Machine Design 1: BASAEN, RV

2. THICK WALLED PRESSURE CYLINDERS

- vessels whose ratio of the wall thickness t and

the inside diameter D exceeds 0.1.
𝑡𝑡
> 0.1
b) Dimensions of ellipsoidal vessel if 𝐷𝐷𝑒𝑒 = 2𝑀𝑀𝑒𝑒 : 𝐷𝐷
- stress distribution (particularly at its weak
𝑡𝑡𝑒𝑒 section) is not uniform.
𝑑𝑑𝑒𝑒 - Lame’s equations are generally used
Sa
St
Sr

St Sr
Sa pi

po
ri t
ro

where
Sa = axial stress
Sr = radial stress
St = tangential stress
pi = internal pressure
po = external pressure
ro = outer radius
ri = inner radius
c) Dimensions of spherical vessel: 𝐷𝐷 , 𝜋𝜋 =? t = wall thickness = ro - ri
𝑠𝑠

LAME’S EQUATIONS:
𝑡𝑡𝑠𝑠 𝒑𝒑𝒊𝒊 𝒓𝒓𝟐𝟐𝒊𝒊 − 𝒑𝒑𝒐𝒐 𝒓𝒓𝒐𝒐 𝟐𝟐
𝑺𝑺𝒂𝒂 =
𝒓𝒓𝒐𝒐 𝟐𝟐 − 𝒓𝒓𝒊𝒊 𝟐𝟐
𝐷𝐷𝑠𝑠
(axial stress)

𝒑𝒑𝒊𝒊 𝒓𝒓𝟐𝟐𝒊𝒊 − 𝒑𝒑𝒐𝒐 𝒓𝒓𝒐𝒐 𝟐𝟐 (𝒑𝒑𝒊𝒊 − 𝒑𝒑𝒐𝒐 )𝒓𝒓𝒐𝒐 𝟐𝟐 𝒓𝒓𝒊𝒊 𝟐𝟐 𝟏𝟏

𝐷𝐷𝑠𝑠 𝑺𝑺𝒕𝒕 = + � 𝟐𝟐 �
𝒓𝒓𝒐𝒐 𝟐𝟐 − 𝒓𝒓𝒊𝒊 𝟐𝟐 𝒓𝒓𝒐𝒐 𝟐𝟐 − 𝒓𝒓𝒊𝒊 𝟐𝟐 𝒓𝒓
For equal volume: (tangential stress)
14
 Machine Design 1: BASAEN, RV

𝒑𝒑𝒊𝒊 𝒓𝒓𝟐𝟐𝒊𝒊 − 𝒑𝒑𝒐𝒐 𝒓𝒓𝒐𝒐 𝟐𝟐 (𝒑𝒑𝒊𝒊 − 𝒑𝒑𝒐𝒐 )𝒓𝒓𝒐𝒐 𝟐𝟐 𝒓𝒓𝒊𝒊 𝟐𝟐 𝟏𝟏

𝑺𝑺𝒓𝒓 = − � 𝟐𝟐 �
𝒓𝒓𝒐𝒐 𝟐𝟐 − 𝒓𝒓𝒊𝒊 𝟐𝟐 𝒓𝒓𝒐𝒐 𝟐𝟐 − 𝒓𝒓𝒊𝒊 𝟐𝟐 𝒓𝒓
(radial stress)
where
r = ri if inner surface of the cylinder is considered
r = ro if outer surface of the cylinder is considered

Note:
From the above stress equations, the greatest
magnitude of stress is the tangential or transverse stress 𝑆𝑆𝑡𝑡 ,
particularly at the inner surface of the vessel.
𝑆𝑆𝑚𝑚𝑚𝑚𝑚𝑚 = 𝑆𝑆𝑡𝑡 𝑖𝑖 : 𝑇𝑇ℎ𝑢𝑢𝑢𝑢, 𝑢𝑢𝑢𝑢𝑢𝑢 𝑆𝑆𝑡𝑡 𝑖𝑖 ⇒ 𝑆𝑆𝑑𝑑

Stress distribution across the wall:

𝑺𝑺𝒕𝒕 𝒊𝒊 𝑺𝑺𝒕𝒕 𝒊𝒊
𝑺𝑺𝒕𝒕 𝒐𝒐 𝑺𝑺𝒕𝒕 𝒐𝒐

Note:
If the vessel has no external pressure, the above
equation for tangential stress can be expressed as (taking r
= ri):

𝑫𝑫 𝑺𝑺𝒕𝒕 + 𝒑𝒑𝒊𝒊
𝒕𝒕 = �� − 𝟏𝟏�
𝟐𝟐 𝑺𝑺𝒕𝒕 − 𝒑𝒑𝒊𝒊
where
t = wall thickness
D = inside diameter of the cylinder
St = tangential stress
pi = internal pressure

Example 1:
Boiler tubes with 50 mm inside diameter are used in
handling steam at a maximum pressure of 20 MPa. If the
allowable tensile stress of the tubes is only 80 MPa, what Example 2:
minimum tube thickness is required? A pressure cylinder has an inside diameter of 26” and
an outside diameter of 32”. If it is applied with an internal
Solution: pressure is 8 ksi and an external pressure of 2 ksi,
• If the tubes are treated to be thin-walled, the result calculate the hoop stress at its (a) inner surface, and (b)
may not be satisfactory. outer surface
From
Solution:

pi Di=26” Do=32”

po=2 ksi

15
 Machine Design 1: BASAEN, RV

Example 3:
A spherical vessel has an inside diameter of 24” and a
uniform wall thickness of 2.5”. If it is loaded with an
internal pressure of 3 ksi, determine the maximum tensile
stress induced in the vessel.

Solution:
From the given dimensions,
𝑡𝑡 2.5
= = 0.1041 > 0.1: thick − walled!
𝐷𝐷 24
t

16
 Machine Design 1: BASAEN, RV

FACTOR OF SAFETY OR
DESIGN FACTOR, N Note:
Above values are based on the material’s yield
 Table 1.1. Factors of Safety for Different Material strength. For brittle materials, the factors should be
Type and Loading Conditions approximately doubled.
Cast Timber For repeated loads, the factors must be applied to
Steel, Ductile Metals Iron, the endurance limit rather than to the yield strength
Brittle of the material.
Kind of Load metals
Based on Based on Based on Ultimate
For impact forces, an impact or shock factor
Ultimate Yield Strength should be included.
Strength Strength More thorough analysis is should be undertaken
Dead load 3-4 1.5-2 5-6 7 before considering the use of a higher safety factor.
Repeated, one 6 3 7-8 10
direction, Other recommendations are available from other
gradual (mild sources. However, they involve a lot of considerations
shock) and oftentimes the listed values are in terms of range of
Repeated, 8 4 10-12 15
factors. In actual designing, a thorough investigation
reversed, about the use of an appropriate safety factor is a must.
gradual (mild
shock) For a more straightforward value of safety factor or a
Shock 10-15 5-7 15-20 20
design factor, an older source may be used as the
Source: Design of Machine Elements, V. M. Faires, 4th ed. reference. Table 2 shows conservative values of safety
factor, typically used when only the material’s yield
strength or ultimate strength is the basis. Most
Factors in the Selection of a Safety Factor calculations involve in the succeeding examples, in which
Selection of an appropriate value of safety factor is safety factors are required, involve assumptions based on
based primarily on the following factors: Table 2.
1. Degree of uncertainty about loading. Some problems give directly the safety factor to be
2. Degree of uncertainty about material strength. used in the computation to come up with a result that is
3. Degree of uncertainty in stress analysis. not too far from the expected range of answers.
4. Human safety and economics.
 Table 1.3. Factors used to determine a safety factor
 Table 1.2. Recommended Values for a Safety for ductile materials
Factor Information Quality of Information Factor
Factor of Conditions E1
Safety The actual material used was 1.3
1.25 to 1.5 exceptionally reliable materials Material- tested
under controllable conditions; loads property data Representative materials test data 2
and stresses can be determined with available from are available
test Fairly representative materials 3
certainty
test data are available
1.5 to 2 well-known materials, under
Poorly representative materials 5+
reasonably constant environmental test data are available
conditions, loads and stresses can be E2
determined readily. Are identical to material test 1.3
2 to 2.5 average materials in ordinary condition
environments; loads and stresses can Environmental Essentially room-ambient 2
be determined. condition in environment
2.5 to 3 less tried materials; or materials are which it will Moderately challenging 3
brittle under average conditions of be used environment
environment, load, and stress Extremely challenging 5+
environment
3 to 4 untried materials under average
E3
conditions of environment, load, and Models have been tested against 1.3
stress experiments
3 to 4 better known materials in uncertain Analytical Models accurately represent 2
environments or subjected to models for system
uncertain stresses. loading and Models approximately represent 3
Source: Fundamentals of Machine Component Design stress system
by R. C. Juvinall, 5th ed. Models are crude approximation 5+

17
 Machine Design 1: BASAEN, RV

Source: Machine Design: An Integrated Approach; Norton

Then, the factor of safety N is the product of the three

factors above
𝑵𝑵 = 𝑬𝑬𝟏𝟏 (𝑬𝑬𝟐𝟐 )(𝑬𝑬𝟑𝟑 )

Again, for brittle materials the above factor of safety is

usually doubled.

18