Machine Design -1 (EME-501)

UNIT 2

Dr. Suvandan Saraswat

1
Cyclic Stresses
 Fatigue Failure – Type of Fluctuating Stresses
a = max
max = - min

Alternating stress
max min
a = 2
min = 0
Mean stress
a = m = max / 2 max + min
m = 2

3
 Fatigue Failure
It has been recognized that a metal subjected to a
repetitive or fluctuating stress will fail at a stress
much lower than that required to cause failure on
a single application of load. Failures occurring
under conditions of dynamic loading are called
fatigue failures.
Fatigue failure is characterized by three stages
 Crack Initiation
 Crack Propagation
 Final Fracture

4
Endurance Limit
S-N Curve
 Endurance Limit Approximation

• e=1/2to 5/8 u for ductile material

• e= 0.4 u for cast iron
• E= ABC e/Kf

Where
A= size factor
B= surface finish factor
C= reliability factor
Kf= fatigue stress concentration factor
Stress Concentration
Concept of Stress Concentration
Theoretical stress
concentration factor, Kt

Maximum stress at the discontinuity

Nominal stress, max stress

with no discontinuity

Kt is used for normal

stresses and Kts for shear
stresses.
Fatigue stress concentration factor
 Notch Sensitivity

In the case of fatigue /fluctuating load

 Design for infinite life
Goodman and soderberg criteria
 y

Syt
 Design for Finite Life

Sn = a (N)b equation of the fatigue line

A A

S B S B
Se Sf

103 106 N 103 5x108 N

Sn = .9Sut Sn = .9Sut
Point A Point A
N = 10 3
N = 103

Sn = Se Sn = Sf
Point B Point B
N = 10 6
N = 5x108
22
 Design for Finite Life
Sn = a (N)b log Sn = log a + b log N

Apply boundary conditions for point A and B to

find the two constants “a” and “b”
2
(.9Sut)
a=
log .9Sut = log a + b log 103 Se
log Se = log a + b log 106 1 .9Sut
b= log
3 Se

S
e
⅓ log ( )
N .9Sut
Sn = Se ( 10 ) 6

Calculate Sn and replace Se in the design equation

Sn
K f a = Design equation
n
23
Riveted Joints
Riveting
 Methods of riveting
Hand Riveting
Machine Riveting
• Drilling v/s Punching • Hot v/s Cold
- Reaming required for - heating of 1000 to 1100 deg C
punching till bright red condition for Hot
riveting
- Punching is not accurate
- Shank has tensile stress and
- Punching injures the plate has compressive stress in
metals plates
- Punching is feasible up - Hot riveting is only for upto 10
to 25 mm of thinness mm diameter of rivet where as
- Drilling is costly cold is for more than 10 mm
diameter of rivet
 Application
• For non ferrous metals
• To avoid thermal stresses
• For heterogeneous material
• Good Resistance to vibration and shock load
• Good for thin plates specially for aircrafts
Examples
Boiler, Pressure vessels and Tanks
Bridges, Trusses, cranes
Hull of Ship, Aircraft
 Advantages
• More reliable for shock and vibration load
• Good for non ferrous metal
• No thermal stresses
• Quality checked is visually possible
• Less damage in dismentalling
 Caulking and Fullering

Caulking: Operation of
burring down the edges of
the plates and heads of the
rivets to form a metal to
metal joint
Fullering is a better option
Types of rivets
3/4 7/8

1
 TYPES OF RIVETED JOINTS
The classification of riveted joints is based on following :
(a) According to purpose,
(b) According to position of plates connected, and
(c) According to arrangement of rivets.

According to purpose the riveted joints are classified as :

Strong Joints
In these joints strength is the only criterion. Joints in engineering structure
such as beams, trusses and machine frames are strong joints.
Tight Joints
These joints provide strength as well as are leak proof against low
pressures. Joints in reservoirs, containers and tanks fall under this group.
Strong Tight Joints
These are joints applied in boilers and pressure vessels and ensure both
strength and leak proofness.
Terminology
Eccentrically loaded riveted joint
Thank You