Republic of the Philippines

Southern Leyte State University

Main Campus, Sogod Southern Leyte

MACHINE
DESIGN 1

By: BSME 4-A

Table of Contents Page

Chapter 3 Stresses 1
Simple Stress 1
Compressive Stress 1
Tensile Stress 1
Shearing Stress 1
Bearing Stress 2
Torsional Stress 2
Bending or Flexural Stress 2
Thermal Stress 3
Design Dress 3
Problems 6

Chapter 4 Shafting 7
Problems 12

Chapter 5 Keys and Splines 15

Key 15
Keyway 15
Types of Key 15
Formula 16
Splines 16
Safe Dimensions of Splines 17
Problems 18

Chapter 12 Threaded Members 20

Bolt 20
Screw 20
Types of Bolts 22
Standard Form of Threads 22
Bolts Formula 25
Power Screw 28
 Power Screw Formula 28
Problems 32

Chapter 15 Springs 34
Types of Springs 34
Coil Spring Formula 36
Leaf Spring Formula 38
Problems 40
 Chapter 3 – Stresses
I. Simple Stress is the unit strength of a material or the force per unit area.

A. Compressive Stress is the force per unit area directed so as to produce a change in density
in the region where it is applied.

B. Tensile Stress is the force per unit area directed perpendicular to the surface.

C. Shearing Stress is the force per unit area directed tangentially to a set of parallel planes so as
to produce relative motion of the planes parallel to themselves.
D. Bearing Stress is the internal stress caused by a compressive force.

E. Torsional Stress is the shearing stress which occurs at any point in a body when a torque o
torsional load is applied.

F. Bending or Flexural Stress tends to deflect a member when the force is applied.
G. Thermal Stress is the mechanical stress induced in a body when some or all of its parts are
not free to expand or contract in response to changes in temperature.

H. Design Stress is the stress value which is used in the mathematical determination of the
required size of the machine member.

I. Residual Stress are those internal, inherent trapped, locked-up body stresses that exist
within a material as the result of things other than external loading.
J. Elongation is the fractional increase in a material’s length due to stress in tension or to
thermal expansion.

K. Modulus of Elasticity is the ratio of the increment of some specified form of stress to the
increment of some specified form of strain.

Classification of Load

1. Static Load refers to load that is gradually applied and equilibrium is reached in a
relatively short time. The structure experiences no dynamic effects.
2. Sustained Load refers to load such as the weight of a structure, is constant over a long
time.
3. Impact Load refers to load that is rapidly applied. It is usually attributed to an energy
imparted to a system
4. Cyclic Load refers to load can vary and even reverse itself in sign and has a characteristic
period with respect to time.
5. Concentrated Load refers to load that is applied to an area much smaller than the
loaded member. It is applied to small nonconformal area.
6. Distributed Load refers to load spread along the entire area.
7. Normal Load refers to load passes through the centroid of the resisting section.
8. Shear Load refers to the force that is assumed to be collinear with the transverse shear
force.
9. Bending Load refers to load that is applied transversely to the longitudinal axis of the
member.
10. Torsion Load refers to load subject a member to twisting motion.
11. Combined Load refers to combination of any classified type of loads.
Problems with solution

1. A shell with an outside diameter of 406 mm and a wall thickness of 2.54 mm is

subjected to 280 MPa tensile load and a 45 KN.m. What is the maximum shear stress?

2. A taper pin with a minimum mean diameter of 6.2 mm will be applied to fix a lever to a
2-in. shaft with an allowable design stress of 15 ksi. Compute for the transmitted torque
in lbs-in. Use a factor of safety of 2.

3. Compute the drop/stretch of an underground mine elevator steel cable (in mm) if it has
a load of 56,000 N (equivalent to 80 persons) and it measures 60mm in diameter and
30m in length.

4. Calculate the elongation of a solid steel shaft of SAE 1030 carbon steel 2 7/8 inches in
diameter by 5 feet in length supporting a direct tension load of 60,000 lbs. The factor of
safety is set at 4, stress concentration factor K=1 and yield strength of 40,000 psi.
5. Compute for induced compressive stress in KPa of a steel solid shafting of 50mm in
diameter and 80mm in length that is subjected to an increase of temperature by 80°C.
Use α= 6.6 X10-6 ,E= 30 X 106 psi.
 Chapter 4 – Shaft Design
Shaft is a rotating or stationary member having a circular cross section much smaller in
diameter than the shaft length and having mounted on it such power-transmitting elements as
pulleys, gears, belts, chains, cams, flywheels, cranks, sprockets, and rolling element bearings.

Main Shaft is the shaft receiving its power from the engine or motor and transmitting power to
other parts.

Line Shaft is a shaft used to transmit power from a central source to individual machines.

Transmission Shaft is the shaft transmitting power between the source and the machines
absorbing the power

Machine Shaft is the shaft used as an integral part of the machine itself.

Axle is a stationary member of primarily loaded in bending with gears, pulleys and wheels
rotating on it.

Spindle is a shaft or short axles on machine

Countershaft is a secondary shaft that is driven by a main shaft and from which power is
supplied to a machine part.

Jackshaft is a countershaft, especially when used as an auxiliary shaft between two other
shafts.

Head Shaft is the shaft driven by a chain and mounted at the delivery end of a chain conveyor.
It serves as the mount for a sprocket which drives the drag chain.
Formulas:

1. For Main Power Transmitting Shafts

2. For Line Shafts Carrying Pulley

3. For Small, Short Shafts and Counter Shafts

4. Power Transmitted

5. Twisting moment for shafts of any cross section

6. Torque transmitted for solid circular shaft

7. Pure Torsional Shear Stress (Solid)

8. Pure Flexural or Bending Stress (Solid)

9. Pure Torsional Stress (Hollow)

10. Pure Flexural or Bending Stress (Hollow)

11. Combined Torsion and Bending Stress

12. Combined Torsion and Bending Considering Shock and Fatigue Factors

13. Vertical Shear

14. Angular Deformation (Solid Shaft)

15. Angular Deformation (Hollow Shaft)

Problems with solution

1. Determine the power transmitted by a main power transmitting steel shaft with 2 7/8
inches in outside diameter. SAE 1040 driving conveyor head pulleys at a shaft speed of
150 rpm.

2. Design the safe diameter for a power transmitting shaft to transmit 30 hp at a shaft
speed of 180 rpm

3. What would be the diameter in millimeters of a main power transmitting steel shaft SAE
1040 to transmit 100 KW at 600 rpm?
4. Determine the torsional deflection in degrees of a SAE 1040 steel shafting of 120 mm in
diameter and 1.4m long subjected to a twisting moment of 3,000 N.m. The torsional
modulus of elasticity is 80,000 MPa.

5. Compute for the diameter in inches of a SAE 1030 steel shaft to transmit 12 hp at 120
rpm with torsional deflection below 0.08 degree/foot length as required.
6. Determine the diameter of the chain driven power transmitting steel shaft to transmit
200hp at 400 rpm.

7. Find the diameter of a SAE 1040 line shaft to transmit 10 KW at 120 rpm with a torsional
deflection not exceeding 0.26 degree/meter ength of 0.08 degree/foot length. Shaft
allowable stress is 8000 psi.
 Chapter 5 – Keys and Splines
Key is a machine member employed at the interface of a pair of mating male and female
circular cross-sectioned members to prevent relative angular motion between these mating.
Keyway is a female mating member that forms a groove in the shaft to which the key fits.

Types of Key

1. Square key is a machine key of square, usually uniform but sometimes tapered, cross
section.
2. Flat key is used where the weakening of the shaft by the keyway is serious.
3. Round key is used for fastening cranks hand wheels and other parts that do not transmit
heavy torques.
4. Barth key is a square key with bottom two corners beveled.
5. Woodruff key is widely used in the automotive and machine tool industries
6. Gib-Head Taper key is a special gib-head to facilitate easy driving and removal of the
head
7. Saddle key is used without a keyway in the shaft usually flat
8. Feather key is one that allows the hub to move along the shaft but prevents rotation on
the shaft.
9. Kennedy key is a square key fitted into a keyway of square section and driven from
opposite ends of the hub.
10. Sunk key is provided half in the keyway of the shaft and half in the keyway of the hub of
the pulley.
11. Pin key is a cylindrical pin placed in a cylindrical groove in the shaft and hub.
12. Tangent key is fitted in pair at right angles. It is to withstand torsion in one direction
only.
Formulas:

1. Shearing Stress on the Key

2. Compressive Stress on the Key

3. Width for Square and Flat Key When They Are Made Of The Same Material

4. Length for Key and Shaft When They Are Made of The Same Material

5. Minimum Length of Key

Splines are permanent keys made integral with the shaft and fitting into keyways broached into
the mating hub. It is recommended when the power transmitted is too high that three keys are
not enough.
Calculations for the safe dimensions of the splines:

1. Based on shearing of the splines

2. Based on compression between the splines and the hub

3. Total Torque transmitted

4. The Mean Radius

5. The Depthness of Splines

6. Torque capacity of one spline

Problem with solution

A key is to be designed for a 12.7 cm shaft, which will transmit power of 150 KW at 360 rpm. If
the allowable shear stress for the key is 920 kg/cm2, the allowable compressive stress is 1200
kg/cm2, the width of the key is 3.175 cm and height is 2.22 cm.
1. Determine the torque in KN.m

2. Determine the force in KN

3. What is the length of key based on the allowable shearing stress?

4. What is the length of key based on the allowable compressive stress?

5. What axial force to remove the hub from the shaft if the coefficient of friction is 0.45?
 Chapter 12 - Threaded Members
Bolt is a threaded fastener designed to pass through holes in the mating members and to be
secured by tightening a nut from the end opposite the head of the bolt. It is provided with nut.

Screw is a threaded fastener design to be inserted through a hole in one member to be joined
and into a threaded hole in the mating member.
Major Diameter is the largest diameter of the thread of the screw or nut.

Minor Diameter is the smallest diameter of the thread of the screw or nut.

Pitch Diameter is the mean of the major or minor diameters.

Stress Area is the area of an imaginary circle whose diameter is the mean of the pitch and
minor diameters. It is used for the purpose of computing the tensile strength

Lead is the axial distance a thread advances in one revolution.

Pitch is the axial distance between corresponding points on adjacent threads. It is also equal to
the reciprocal of the number of threads per inch.

Crest is the top surface joining the sides of two adjacent threads.

Root is the bottom surface joining the sides of two adjacent threads.

Angle of thread is the angle included between the sides of the thread measured in an axial
plane.

Depth of Thread is the distance between the crest and the base of the thread, measured
perpendicular to the axis.

Depth of Engagement is the depth of thread contact between two mating parts, measured
radially.

Length of Engagement is the length of contact between two mating parts, measured axially.
Types of Bolts
1. Machine Bolt (Through Bolt) is a heavy weight bolt with a square hexagonal or flat head
used in the automotive, aircraft and machinery fields.

2. Eye Bolt is a bolt with a loop at one end.

3. Stud Bolt is a type of bolt, which threaded at both ends without a head. It is used where
through bolt is undesirable.

4. Stove bolt is a coarsely threaded bolt with a slotted head, which with a square nut is used to
join metal parts. It is a cheap variety of bolt made in small sizes.

5. U-Bolt is a U shaped bolt with threads at the end of both arms to receive nuts.

6. Carriage Bolt is a round head type of bolt with a square neck, used with a nut as through
bolt.

7. Automotive Bolt is usually made of heat-treated steal frequently has a castle nut.

8. Plow Bolt is widely used on farm machinery.

9. Track Bolts are used in railway track construction.

10. Coupling Bolt is finished all over, usually have coarse threads.

Standard Forms of Threads

1. Acme Thread is modification of the square form of thread. It is preferred for many jobs
because it is fairly easy to machine. It has a 29° included angle and is largely used for feed and
lead screws on machine tools.
2. V thread is used by watchmakers and instrument makers for very small screws.

3. Square Thread is one in which the width of the thread, the depth of the thread and the space
between threads are approximately equal. This type of thread is very strong. It is difficult to
machine square threads accurately.

4. Brown and Sharpe Worm Thread are similar to the acme thread in shape but are cut deeper.
5. Buttress Thread is cut square on one side and slanting on the other side. It is used where a
thread requiring great strength in one direction is required as in certain types of vises, gun
breeches and ratchets.

6. Whitworth Thread a standard thread in England and Canada. It has a 55° angle with the crest
and root rounded.
Bolts Formulas:
A. Stresses Induced in Bolts
1. Torsional shear stress in the root.

2.Tensile stress at the root.

3. Compressive stress at the threads.

4. Shear stress at the root

5. Permissible Working Stress

6. Axial load (Tensile load)

7. Working strength of the bolt

8. Initial tension in tightening

9. Final load on the bolt.

10. Final Stress

11.Initial Torque

12. Bolt Spacing

13. Bolt Circle Diameter

14. Bolt Elongation

15. Depth of Tap

a. For Steel (Vallance)

b. For Steel / Wrought Iron (Faires)

c. For Brittle Materials

Power Screw is a device used to change ngular motion into linear motion and usually to
transmit power. It is commonly used to obtain greater mechanical advantage in order to lit
weight, as in a screw type of jack for cars; to exert large forces, as in home compactor or a
press; to obtain precise positioning of an axial movement, as in a micrometer screw or the lead
screw of a lathe.

POWER SCREW FORMULA

1. Torque required to overcome collar friction

2. Torque applied to turn the screw

2.1 For Square Threads (Raising Load)

2.2 For Square Threads (Lowering the Load)

2.3 For Acme Threads (Raising the Load)

2.4 For Acme Threads (Lowering the Load)

2.5 For Trapezoidal Metric Threads (Raising the Load)

 2.6 For Trapezoidal Metric Threads (Lowering the Load)

2.7 For American Standard Threads (Raising the Load)

2.8 For American Standard Threads (Lowering the Load)

3. Total torque required to operate the screw

4. Power input of the screw

5. Power output of the screw

6. Efficiency of the screw

7. Linear Velocity

8. Lead Angle

9. Lead

10. Outside Diameter

Problem with Solution

A square single thread jackscrew has 2 threads per inch. It is to lift 15 tons. The friction radius of
the collar is 1 inch. The coefficient of friction between the threads of the screw and base is 0.15
that between the screw and collar is 0.13

1. Determine the root diameter if the allowable stress in compression is 6,000 psi

2. Determine the pitch of the screw.

3. Find the major diameter.

4. Find the mean diameter.

5. Find the lead angle.

6. Determine the torque required to overcome friction in threads.

7. Determine the torque required to overcome friction in collar.

8. What is the expected total torque to operate in a jackscrew?

9. What is the expected total force required by the torque?

10. What is the expected efficiency of the screw?

 Chapter 15 – Springs

Spring is an elastic stored energy machine element that when released, will recover its basic
form or position. It is a device made of an elastic material that undergoes a significant change in
shape, or deformation, under an applied load.

Spring Materials
1. High carbon steel
2. Alloy steel
3. Stainless steel
4. Copper alloys
5. Nickel-base alloy

Uses of Spring
1. To absorb energy or shock loads as in automobile chassis springs and railroad bumper
springs.
2. To act as a source of energy as in clocks.
3. To produce pressure or force, as in maintaining pressure between the friction surfaces
of clutches and as in keeping a cam follower in contact with the cam.
4. To absorb vibration.
5. To act as load measuring devices as in spring balances power dynamometers and
instruments such as gages, meters and engine indicators.
Types of Springs
1. Helical Springs are made up of wire coiled in the form of helix and is primarily intended
for compressive or tensile loads. The advantages of helical springs are: easy to
manufacture, available in wide range, reliable, constant spring rate, the performance
can be predicted more accurately, and the characteristics can be varied by changing
dimensions.
2. Conical and Volute Springs are used in special applications were a telescoping spring or
spring with a spring rate that increases with the load is desired.
3. Torsion Springs maybe helical or spiral type. The helical type maybe used only in
applications where the load tends to wind up the spring and are used in various
electrical mechanisms. The spiral type is also used where the load tends to increase the
number of coils and when made of flat strip are used in watches and clocks.
4. Laminated of Leaf Springs consist of a number of flat plates of varying lengths held
together by means of clamps and bolts. The major stresses produced in leaf springs are
tensile and compressive stresses.

5. Disc or Belleville Springs consist of a number of conical discs held together against
slipping by a central bolt or tube. They are used in applications where high spring rates
and compact spring units are required. The major stresses produced in disc or Belleville
springs are tensile and compressive stresses.
Coil Spring Formula

1. Stress for Round Wire

2. Stress for Square Wire

3. Stress for Rectangular Wire

4. Wahl Factor

5. Spring Index

6. Spring Rate

7. Deflection for Round Wire

8. Deflection for Rectangular Wire

9. Deflection for Square Wire

10. Torsional Stress in Spring

11. Deflection for Helical Torsion Spring of Round Wire

12. Deflection for Helical Torsion Spring of Rectangular Wire

13. Deflection for Spiral torsion Spring of Round Wire

14. Deflection for Spiral torsion Spring of Rectangular Wire

15. Length of Wire

16. Free Length

17. Impact Load on Spring

18. Stresses in Leaf Spring (Single Leaf)

19. Stresses in Leaf Spring (Multiple Leaves)

20. Deflection of Leaf Spring (Single Leaf)

21. Deflection of Leaf Spring (Multiple Leaves)
Problems with Solution
The smaller of two concentric helical springs is made of 22mm diameter steel spring and has an
outside diameter of 100mm with 10 active coils. The outer spring is made of 32mm steel spring
and has an outer diameter of 250m with 8 active coils. Before the load is applied, the outer
spring is 25mm longer than the inner spring. If the load of 90 KN is applied to this nest of
springs:

1. Determine the spring index of the inner spring

2. Determine the spring index of the outer spring

3. Find the spring rate of the inner spring

4. Find the spring rate of the outer spring

5. What load of the inner spring in KN?

6. What load of the outer spring in KN?

7. Determine the portion of load carried by inner spring

8. Determine the portion of load carried by outer spring

A spring is designed to fire a 2 kg projectile. The outside diameter of the coil is 160mm with an
18mm wire and a total of 22 coils squared and ground. The spring has a free length of 650mm.
When set or loaded, the spring is compressed to a length of 450mm

1. Determine the spring index

2. Determine the active number of coils

3. Find the spring deflection

4. Find the Wahl’s factor