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Mee 334 (A)

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Taiwo Subair
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© © All Rights Reserved
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MEE 334

MACHINE DESIGN
1. Application of mechanical Engineering Theories
to Machine Design
2. Analysis, Synthesis and Evaluation Procedures
in Creative Design
3. Use of Codes, Charts, Tables, Standards and
Empirical Data.
4. Presentation of Design Portfolio.

RECOMMENDED TEXTBOOK
MACHINE DESIGN
By

R.S. Khurmi and J.K. Gupta


TOPIC 1: INTRODUCTION
DEFINITION: Machine design is the theoretical analysis that precedes the
creation of a new machine.
The analysis involves evaluation of stresses in the machine components
and choice of parts specification that guarantees non-failure under operations
In designing machine components, good Knowledge of many subjects
such as (1) Mathematics (2) Engineering Mechanics (3) Strength of Materials
(4) Theory of Machines (5) Metallurgy (6) Engineering drawing, are required.
All designs can be placed under any of the listed classifications
a. Rational design: Entails detailed stress analysis due to applied Load.
b. Empirical design: Machine component specifications are based on
empirical formulae arising from practice and experiences.
c. Industrial design: Cognizance is taken of the production method in the
design process.
d. Optimum design: It a procedure of obtaining the best specification of
machine parts under specified constraints.
e. System design: It entails the design of any complex mechanical system
(example: aeroplane, train, cars etc.)
f. Element design: Machines comprises of an assembly of several elements
(Parts). The design of each element is carried out in details.
g. Computer Aided Design: Computer systems (programs and softwares) are
applied extensively in the creation, analysis optimization and presentation
of the design concept.
MAJOR CONSIDEDRATONS IN ANY DESIGN OF A MACHINE
COMPONENT
(i) Type of applied load and stresses developed due to these load
Load(s). Loads normally cause internal stresses in machine parts. The
stresses must not exceed certain pre-determined safe values.
(ii) Motion (or kinematics) of machine parts
(iii) Choice of appropriate material. knowledge of material properties and
their behavior are essential towards successful designs Typical
properties are: * strength *castability * machinability *weight *heat
and corrosion resistance properties
(iv) Shape and size of part whatever size used must be safe in term of
induced stresses. Impact loads must also be factored.
(v) Frictional resistance and Lubrication.
(vi) Convenience of operator and Economy
(vii) Use of standard parts
Using standard parts are much cheaper. Typical standard parts are
Gears, pulleys, bearings, Bolts & Nuts etc.
(viii) Safety in Operation
(ix) Cost of machine building.
This is very important, a design need to evolve designs with minimal
cost through optimum parts sizes and material selection.
Over designing is the use of an excessively large size where a
smaller size will equally perform safely
(x) Assembling:
This factors transportation constraints and limitations of the structure
in final location.
TOPIC NO12

SIMPLE STRESSES IN MACHNE DESIGN

In operation, machine parts are subjected to various external forces (loads),


which consequently results in internal stresses at the respective components.
Applied loads are in various forms which might be
i. Steady
ii. Variable
iii. Shock Load
iv. Impact load
Students are required to revise their CVE 254 (Engineering Mechanics II). The
following is to be noted.
 Stress, strain
 Tensile and compressive stresses
Young’s Modulus or modulus of Elasticity.
Example:
A load of 5KN is to be raised by means of a steel wire. Find the minimum
diameter required, if the stress in the wire is not to exceed 100 N/mm2
SOLUTION
Fig: 1.

5 X 1000
F
σ= A = πd
2

4
2
π d 5 x 1000
=
4 100
2 50.4
d= =63.7
3.14
d = 8mm
Extensive revision of MEE 311 should also be carried out by all students.
Take special note of Theories of failure; stress concentration factor.

SHEAR STRESS AND STRAIN


Shear stresses act tangentially across the resisting section of a bar. Typical
example is in a riveted thick plate acted upon by parallel forces transverse to
bar section

Fig:2.
Tangential Force(P)
Shear stress, τ =
Resisting Area
For a single section (AB) as shown above, it is called single shear. Area
πd ²
resisting the shear ¿ A= 4
P 4P
Shear stress, γ = A = πd ²

There exists also 2-plates connected by 2-cover plates as shown below. It is a


double shear case
Fig:3.
From above figure area resisting the shear is double indicated as AB and CD
(for one rivet only)
πd ²
A=2×
4
P 2P
γ= =
A πd ²
It’s observed that shear stress reduced by half when resisting area is doubled.
NOTE:
(i) Example of single shear presented is referred to as Lap joint while the second
example with double shearing surface is called Butt – joint

SHEAR MODULUS OR MODULUS OF RIGIDITY


γ =⊂ . ⏀

γ =Shear stress

⏀= shear strain
⊂=modulus of rigidity

EXAMPLE
A pull of 80KN is transmitted from a bar X to the bar Y through a pin as shown
in fig ‘X’. if the maximum permissible tensile stress in the bars is 100N/mm 2
and the permissible shear stress in the PIN is 80N/mm 2. find the diameter of
bars and of the pin.

Fig:4.
SOLUTION
P= 80 X 1000 N
σᵗ=100 N/mm2, τ =80 N /mm ²

Diameter of the bars


Let Db = Dia of the bar (mm)
π 2
Area, Ab = 4 Db=0.785 D 2
b

Permissible tensile stress, σt = 100


P 80× 1000
100¿ A = 0.785 D2
b b

Db = 32mm.
Diameter of the Pin.
Let Dp be diameter of pin (mm). The tensile load, P tends to shear the Pin across
sections AB and CD .This is double shear.
π 2
Shear area, Ap ¿ 2 × 4 DP =1.57 D 2
P

Permissible shear stress in the pin (τ)


3
P 80 ×10
80 = A = 2
P 1.571 DP

DP = 25.2mm

BEARING STRESS
A localized compressive stress at the point of contact between two machine
parts (without relative motion) is called Bearing Stress. Typical components
that experience bearing stress are
- Riveted joint
- Cotter joint
- Knuckle joint
To analyses for riveted joint

Fig:5.
P
Bearing stress: σb = d .t .n

d =diameter of the rivet


t =thickness of the plate
n =number of the rivets per pitch length in bearing
Shaft rotating in bearing also exerts bearing pressure of none-uniform
distribution on the bearing. (Contact area of the shaft in bearing is called
journal)
Example: A journal 25mm in diameter (d) supported in sliding bearings has a
maximum end reaction of 2500N.
If allowable bearing pressure is 5N/mm2, find the length (L) of the sliding
bearing.

Fig:6.
d =25mm, p = 2500N, Pb =5N/mm2
L = length of the sliding bearing
Projected area, A, of the bearing = L x d = Lx 25 = 25L mm2
P 2500
Bearing pressure, Pb = A = 25 L

L = 20mm

STRESS –STAIN DIAGRAM


Machine parts are designed such that the developed stress under load does not
exceed the ELASTIC LIMIT for mild steel material. The stress- strain diagram
is as follows
Fig:7.
A =Elastic limit
C =Upper yield point
D = Lower yield point
E =Ultimate tensile stress
F =Breaking stress

WORKING STRESS
When designing a machine part, it is essential to keep stress lower than the
maximum or ultimate stress at which failure occurs [i.e. below E]
This stress is known as the working stress [ or Design stress]. It is also referred
to as safe or allowable stress.
FACTOR OF SAFETY
Maximum Stress
Factor of safety = Working Stress

For mild steel


Yield Point (c )
Factor of Safety =
Working Stress
For Brittle Materials
Example: Cast Iron
Ultimate Stress( E)
Factor of Safety =
Working Stress
CHOICE OF FACTOR OF SAFETY

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