M.A.M.

COLLEGE OF ENGINEERING AND TECHNOLOGY

Siruganur, Tiruchirappalli – 621 105.

COURSE NAME

ME8593 DESIGN OF MACHINE ELEMENTS

Year & Sem. : III Year (MECH)– V Semester
Faculty Name : Mr. R. Manikandan
Department : Mechanical Engineering
Regulation : R2017
Course Code : ME8593
Unit : I

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Version: MAMCET_VP-1.1 1
Syllabus

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TEXT BOOK AND REFERENCE BOOK

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OTHER REFERENCE BOOK
• 1.Machine design By RS Khurmi (Design of machine elements and
Design of transmission system)

Dr. B. Muruganantham., Professor, Department of Electrical and Electronics Engineering, M.A.M. College of 5
10/14/2020
Engineering and Technology, Siruganur, Tiruchirappalli – 621 105.
UNIT I STEADY STRESSES AND VARIABLE
STRESSES IN MACHINE MEMBERS
Design process and Factors influencing machine design
Selection of materials
Fits and tolerance
Torsional and bending stress
Theories of failures
Principal Stress
Curved beams
Eccentric loading
Stress concentration
Variable stress
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 UNIT – I

Variable stress Combined stress

M.A.M. COLLEGE OF ENGINEERING AND TECHNOLOGY ::

TRICHY
Introduction of Machine elements
Machine element refers to an elementary component of a machine.
These elements consist of three basic types:
 Structural components such as frame members, bearings, axles,
splines, fasteners, seals, and lubricants,
 Mechanisms that control movement in various ways such as gear
trains, belt or chain drives, linkages, cam and follower systems,
including brakes and clutches, and
 Control components such as buttons, switches, indicators, sensors,
actuators and computer controllers..
Machine element
• Machine Elements is a structure or rigid body which can be designed
based on the the following
1.Applications
2. Function of component
3.Load acting on the element,
4.Stress acting on the element
5.Mechanism
 Introduction design process

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MACHINE COMPONENT(FLANGE
COUPLING)
ELEMENTS
1.Shaft
2.Key
3.Flange Hub
4.Bolt and nut
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THERMAL ANALYSIS
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Factors Influencing machine design

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Factors Influencing machine design

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FITS AND TOLERANCE
• Tolerance
• It is the difference between the upper limit and lower limit of a
dimension.
• In other words, it is the maximum permissible variation in a
dimension.
• The tolerance may be unilateral or bilateral.

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• Tolerance
1.Bilateral tolerance
2.Unilateral Tolerance

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 1.Bilateral tolerance

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 2.Unilateral tolerance

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• Fits
• The degree of tightness or looseness between the two mating parts is
known as a fit of the parts.

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Clearance fit
• The clearance is the amount by which the actual size of the shaft is
less than the actual size of the mating hole in an assembly
• Examples of clearance fits
• Bike clutch handle pivot point, from where it move.
• If you put mobile charger in electric plug, Fit between charger pin and
electric plug is clearance fit.

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Interference fit
• The interference is the amount by which the actual size of a shaft is
larger than the actual finished size of the mating hole in an assembly.
• Examples :Coupling of shaft ends, bearing bushing in hubs

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Transition fit
• It may be noted that in a transition fit, the tolerance zones of hole and
shaft overlap.
• The transition fits may be force fit, tight fit and push fit

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Leaf spring with shackle pin

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Direct stress (PSG DB P.NO :7.1)

Dr. B. Muruganantham., Professor, Department of Electrical and Electronics Engineering, M.A.M. College of 32
10/14/2020
Engineering and Technology, Siruganur, Tiruchirappalli – 621 105.
Torsional Stress
• When a machine member is subjected to the action of two equal and
opposite couples acting in parallel planes (or torque or twisting
moment), then the machine member is said to be subjected to
torsion.

• The stress set up by torsion is known as torsional shear stress. It is

zero at the centroidal axis and maximum at the outer surface.

Dr. B. Muruganantham., Professor, Department of Electrical and Electronics Engineering, M.A.M. College of 33
10/14/2020
Engineering and Technology, Siruganur, Tiruchirappalli – 621 105.
Torsional Stress

Consider a shaft fixed at one end and subjected to a torque (T) at

the other end as shown in Fig. As a result of this torque, every
cross-section of the shaft is subjected to torsional shear stress

Dr. B. Muruganantham., Professor, Department of Electrical and Electronics Engineering, M.A.M. College of 34
10/14/2020
Engineering and Technology, Siruganur, Tiruchirappalli – 621 105.
Torsion Equation in Reference book

Dr. B. Muruganantham., Professor, Department of Electrical and Electronics Engineering, M.A.M. College of 35
10/14/2020
Engineering and Technology, Siruganur, Tiruchirappalli – 621 105.
TORSIONAL Equation (Design Data book)
(P NO7.1)

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Bending stress

when a beam is subjected to the bending moment, the fibres on the upper side of
the beam will be shortened due to compression and those on the lower side will
be elongated due to tension.

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BENDING STRESS (P.NO -7.1)

Dr. B. Muruganantham., Professor, Department of Electrical and Electronics Engineering, M.A.M. College of 38
10/14/2020
Engineering and Technology, Siruganur, Tiruchirappalli – 621 105.
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PRINCIPAL STRESS
• At any point in a strained material, there are three planes, mutually
perpendicular to each other which carry direct stresses only and no
shear stress.
It may be noted that out of these
three direct stresses, one will be
maximum and the other
will be minimum.

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• These perpendicular planes which have no shear stress are known as
principal planes and the direct stresses along these planes are known
as principal stresses

Dr. B. Muruganantham., Professor, Department of Electrical and Electronics Engineering, M.A.M. College of 43
10/14/2020
Engineering and Technology, Siruganur, Tiruchirappalli – 621 105.
• The planes on which the maximum shear stress act are known as
planes of maximum shear

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Applications of principal stress
• There are many cases in practice, in which machine members are
subjected to combined stresses due to simultaneous action of either
tensile or compressive stresses combined with shear stresses.

• In many shafts such as propeller shafts, C-frames and crank shaft

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Formulae for Principal stress (PSG DB P.NO7.2)

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PROBLEMS ON PRINCIPAL STRESS
1.A shaft, as shown in Fig. , is subjected to a bending load of 3 kN, pure
torque of 1000 N-m and an axial pulling force of 15 kN. Calculate the
stresses at A and B

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Bending Stress in Curved Beams

• In straight beams, the neutral axis of the section coincides with its
centroidal axis and the stress distribution in the beam is linear.

• But in case of curved beams, the neutral axis of the cross-section is

shifted towards the centre of curvature of the beam causing a non-
linear (hyperbolic) distribution of stress, as shown in Fig.

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Bending Stress in straight Beams

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Applications of curved beams
• The application of curved beam principle is used in
• Crane hooks,
• Chain links and
• Frames of punches,
• Presses,
• Planers

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Applications of curved beams

Punch press • Crane hook

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Terminology of curved beam

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Stress acting on curved beam

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Formulae for curved beam problem (P.NO 6.2)

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PSG DATA BOOK P.NO 6.3

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UNIT-I STEADY STRESS AND
VARIABLE STRESS
• Class notes work
• Design process and factors influencing machine design
• Fits and tolerance
• Write the formulae for torsional stress and bending stress with
diagram
• Principal stress with problems
• Curved beam with problems
• Theories of failure with problems
• Submission date : 6.7.2020
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Assignment-I
• Curved beam
• Theories of failure

• Submission date : 9.7.2020

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• Distortion Energy Theory: The distortion energy theory says that
failure occurs due to distortion of a part, not due to volumetric
changes in the part (distortion causes shearing, but volumetric
changes due not).

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Stress concentration
• Whenever a machine component of uniform cross section is
subjected to a static tensile or compressive load ,the stress
distribution throughout the cross section is uniform.

• If the machine component is having different cross section or any

irregularity in the shape of a machine part such as a shoulder ,V-
groove or hole etc, some extra amount of stress is accumulated in the
component of v groove or shoulder , change of section as shown in
fig. this accumulation stress in the place of notch or fillet is called
stress concentration, and a factor called as stress concentration factor
How to reduced stress concentration factor

• The stress concentration of the stress will cause failure more quickly.

Hence this stress concentration must be reduced to some extent by

making some modification in their structures like by changing the

sharp corners into curved corners, notch into semi circular notch and

so on as shown in fig.
Nominal stress (psg data book p.no 7.8 to 7.16)
ASSIGNMENT PROBLEM (CURVED
BEAM)
1.The frame of a punch press is shown in Fig. . Find the stresses at
the inner and outer surface at section X-X of the frame, if W = 5000
N.
ASSIGNMENT PROBLEM (THEORIES OF FAILURE)

Take Yield stress

refer data book p.no 1.9
ECCENTRIC LOADING
• An external load, whose line of action is parallel but does not coincide
with the centroidal axis of the machine component, is known as an
eccentric load.

• The distance between the centroidal axis of the machine component

and the eccentric load is called eccentricity and is generally denoted
by e.

• The examples of eccentric loading, from the subject point of view, are
C-clamps, punching machines, brackets, offset connecting links etc
Bending moment Mb=P × e
Note

• 1. When the direct stress σ o is greater than or equal to bending

• stress σ b, then the compressive stress shall be present all over the

• cross-section.
• When the direct stress σ o is less than the bending stress σb, then the

tensile stress will occur in the left hand portion of the crosssection

and compressive stress on the right hand portion of the crosssection.

Problems on Eccentric loading
• A hollow circular column of external diameter 250 mm and internal
diameter 200 mm, carries a projecting bracket on which a load of 20
kN rests, as shown in Fig.
• The centre of
• the load from the centre
• of the column is 500 mm.
• Find the stresses at the
• sides of the column.
VARIABLE STRESS
• We have discussed, in the previous chapter, the stresses due to static
loading only. But only a few machine parts are subjected to static
loading.
• Since many of the machine parts (such as axles, shafts, crankshafts,
connecting rods, springs, pinion teeth etc.) are subjected to variable
or alternating loads (also known as fluctuating or fatigue loads),
therefore we shall discuss, in this chapter, the variable or alternating
stresses.
Completely Reversed or Cyclic Stresses
• Consider a rotating beam of circular cross-section and carrying a load
W, as shown in Fig.
• This load induces stresses in the beam which are cyclic in nature.
• A little consideration will show that the upper fibres of the beam (i.e.
at point A) are under compressive stress and the lower fibres (i.e. at
point B) are under tensile stress.
Reversed stress
A steel rod is subjected to a reversed axial load of 180 kN
Maximum load =180kN Minimum load = -180KN
• After half a revolution, the point B occupies the position of point A
and the point A occupies the position of point B. Thus the point B is
now under compressive stress and the point A under tensile stress.

• The speed of variation of these stresses depends upon the speed of

the beam
• From above we see that for each revolution of the beam, the stresses
are reversed from compressive to tensile.

• The stresses which vary from one value of compressive to the same
value of tensile or vice versa, are known as completely reversed or
cyclic stresses.
Fluctuating stresses.
• The stresses which vary from a minimum value to a maximum value
of the same nature, (i.e. tensile or compressive) are called fluctuating
stresses.
A 50 mm diameter shaft is made from carbon steel having ultimate
tensile strength of 630 MPa. It is subjected to a torque which fluctuates
between 2000 N-m to – 800 N-m.
• 2. 3. The stresses which vary from a minimum value to a maximum
value of the opposite nature (i.e. from a
• certain minimum compressive to a certain maximum tensile or from a
minimum tensile to a maximum compressive) are called alternating
stresses
REPEATED STRESS
• The stresses which vary from zero to a certain maximum value are
called repeated stresses. The spherical vessel is subjected to
internal pressure which varies from 0 to 6N/mm2
Variable stress
• Variable load
• Axial load variation
• Bending load variation
• Torque variation

• Combined variation load problem

• Axial +Bending load
• Bending +Torque
• Axial +torque load
Variable stress formulae
UNIT-II Design of shaft, keys and
couplings
• Shaft
• A shaft is a rotating machine element which is used to transmit power
from one place to another.
• The power is delivered to the shaft by
• some tangential force and the
resultant torque (or twisting moment)
set up within the shaft permits the
power to be transferred to various
machines linked up to the shaft.
• In order to transfer the power from
• one shaft to another, the various members such as pulleys,
• gears etc., are mounted on it. These members along with
• the forces exerted upon them causes the shaft to bending.
• In other words, we may say that a shaft is used for the
• transmission of torque and bending moment. The various
• members are mounted on the shaft by means of keys or
• splines.
 Thank you

Dr. B. Muruganantham., Professor, Department of Electrical and Electronics Engineering,

10/14/2020 M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 11
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