Mechanical Eng. Dept.

Machine Design I (Lecture 3&4&5) Third Class-All Branches

1- Direct stresses, tension and compression:

Tensile and compressive stresses, called normal stresses, are shown acting
perpendicular to opposite faces of the stress element. Tensile stresses tend to
pull on the element, whereas compressive stresses tend to crush it.

Where: = Design tensile or compression stress

F= direct axial load
A= cross sectional area
= total deformation
L=original total length
E= Modulus of elasticity

( )( )

For ductile material:

N = 1.25 2 (for static loads)

N = 2 2.5 (for dynamic loads with average confidence)
N = 2.5 4 (for dynamic loads with uncertainly about load)
N = 4 or higher (for shock load or to desire extra safety)

For brittle material:

N = 3 4 (for static load with high level of confidence)
N = 4 8 (for dynamic loading with uncertainly about load)

(For tensile stress) Based on Ultimate tensile

strength
(For compression stress)

OR

(For tensile stress) Based on Ultimate yield

strength
(For compression stress)

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

Example:
A large electrical transformer is to be suspended from a roof truss of a building.
The total weight of transformer is 142.33 KN. Design the means of support.
Selection:
Choose N=3
Choose material AISI 1040 cold-drawn steel
Choose two straight cylindrical rod to support the transformer
Sol:
From APPENDIX 3, SY = 489.54 MPa

Key:
A key is a machinery component placed at the interface between a shaft and the
hub of a power-transmitting element for the purpose of transmitting torque (see
figure 11-1). It is installed in an axial groove machined into the shaft, called a
keyseat. Keyseat in shafts are usually machined with either an end mill or
circular milling cutter, producing the profile or sled runner key seat.

Figure (11-1) parallel keys

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

2- Direct shear stress:

Direct shear stress occurs when the applied force tends to cut through the
member as scissors or shears do or when a punch and a die are used to punch a
slug of material from a sheet. Another important example of direct shear in
machine design is the tendency for a key to be sheared off at the section between
the shaft and the hub of a machine element when transmitting torque.
Figure (3-7) shows the action.

Where:

Example Problem (3-3), (page 93), [Ref. 1]:

Figure 3-7 shows a shaft carrying two sheaves that are keyed to the shaft.
Part (b) shows that a force F is transmitted from the shaft to the hub of the
sheave through a square key. The shaft is 57.15 mm in diameter and transmits a
torque of 1589.119 N. The key has a square cross section, 12.7 mm on a side, and
a length of 44.45 mm. compute the force on the key and the shear stress caused
by this force.

Sol:

Torque = F * R

Area in shear = b*L = 12.7*44.45 = 564.55

( )

Note: see table 11-1 (Page 495) to find key size vs. shaft diameter.

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

3- Bearing stress:
A localized compressive stress at the surface of contact between two
members of a machine part that is relatively at rest is known as bearing
stress or crushing stress or bearing pressure.

Example:

Find the bearing stress caused by force in last example for the key.

Sol:
( )

Note: For CI Hub

From Reference 2
For steel Hub

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

Splines: A spline can be described as a series of axial keys machined into a shaft,
with corresponding grooves machined into the bore of the mating part (gear,
sheave, sprocket, and so on: see Figure 11-6). The splines perform the same
function as a key in transmitting torque from the shaft to the mating element.

Figure (11-6) internal spline

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

Coupling:
The term coupling refers to a device used to connect two shafts together at their
ends for the purpose of transmitting power. There are two general types of
couplings: rigid and flexible.

Rigid Couplings:
Rigid couplings are designed to draw two shafts together tightly so that no
relative motion can occur between them. This design is desirable for certain
kinds of equipment in which precise alignment of two shafts is required and can
be provided. In such cases, the coupling must be designed to be capable of
transmitting the torque in the shafts.

Figure (11-15) Unprotected type flange coupling

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

The usual proportions for an unprotected type cast iron flange couplings, as shown in
figure (11-15) are as follows:

If (d) is the diameter of the shaft or inner diameter of the hub, then

Outside diameter of hub, D=2 d

Length of hub, L=1.5 d

Pitch circle diameter of bolts, D1=3 d

Outside diameter of flange, D2=D1+ (D1-D) =2 D1-D=4 d

Thickness of flange, tf =0.5 d

Number of bolts = 3, for (d) up to 40mm

= 4, for (d) up to 100mm

= 6, for (d) up to 180mm

4- Torsional shear stress:

When a torque, or twisting moment, is applied to a member, it tends to
deform by twisting, causing a rotation of one part of the member relative
to another. Such twisting causes a shear stress in the member. For a small
element of the member, the nature of the stress is the same as that
experienced under direct shear stress.

Where: C = radius of the shaft to outside surface

J = Polar moment of inertia
Zp = Section modulus (J/C)

Note: see APPENDIX 1 [Ref. 1] for formulas for J

( )

L = Length of shaft
G = Modulus of elasticity in shear (Modulus of Rigidity)

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

Example problem 3-6 (Page 96), [Ref. 1]:

Compute the maximum torsional shear stress in a shaft having a diameter
of 10 mm when it carries a torque of 4.10 N.m.
Sol:

J= =

( )( )

Example problem (3-7), (Page 97), [Ref.1]:

Compute the angle of twist of a 10 mm-diameter shaft carrying 4.10 N.m of
torque if it is 250 mm long and made of steel with G = 80 GPa. Express the result
in both radians and degrees.

5- Vertical shearing stress:

A beam carrying loads transverse to its axis will experience shearing
forces denoted by V. In the analysis of beams, it is usual to draw the
shearing force diagram. Then the resulting vertical shearing stress can be
completed from:
( )

( )

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

Example problem (3-11), (Page 104), [Ref. 1]:

Compute the maximum shearing stress in the beam described below:

( )

6- Stress due to Bending:

Where: M= magnitude of the bending moment at the section

I = moment of inertia of the C.S. with respect to its neutral axis
C= distance from the neutral axis to the outer most fiber of the beam C.S.
S = section modulus = I/C

Example Problem (3-12), (Page 107) [Ref.1]

For the beam shown in Figure 3-16, the load F due to the pipe is 53376 N.
The distances are a = 1.2192 m and b = 1.8288 m. Determine the required
section modulus for the beam to limit the stress due to bending to 206850 kPa,
the recommended design stress for a typical structural steel in static bending.

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

Sol:
( )

Now from table A16-3 & A16-4 choose (W203*22.1) wide-flange shape with
S = 19.3 * 104 mm3
7- Stresses due to combined bending moment with axial load:

Example problem (3-17), (Page 117), [Ref.1]:

The cantilever beam in Figure 3-24 is a steel American Standard beam.
S6x12.5. The force F is 44480 N. and it acts at an angle of 30 below the
horizontal, as shown. Use a = 609.6 mm and e = 152.4 mm. Draw the free-body
diagram and the shearing force and bending moment diagrams for the beam.
Then compute the maximum tensile and maximum compressive stresses in the
beam and show where they occur.

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

Sol:

From table A16-4 (S = 12.079*104 mm4 & A=2367.884 mm2)

FX = F cos30 = 44480 cos30 = 38520 N
FY = F sin30 = 44480 sin30 = 22240 N
M1 = FX (0.152 m) = 5871.5 N.m
Mmax = 7688.5 N.m occurs at left end of beam

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

8- Stress Concentrations:

The above simple stresses are applicable for the geometry of a member is
uniform throughout the section of interest. But if there is a fillet, holes, key seals,
grooves, etc, will cause the actual max. stress, so defining stress concentration
factors by which the actual max. stress exceeds the nominal stress.

Where K can be found from APPENDIX 15 [Ref.1]

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Mechanical Eng. Dept. Machine Design I (Lecture 3&4&5) Third Class-All Branches

Example Problem (3-18), (Page 121), [Ref.1]:

Compute the maximum stress in a round bar subjected to an axial tensile force of
9800 N. The geometry is shown in Figure 3-26.

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