PROBLEMS ON THE DESIGN OF MACHINE ELEMENTS Prof.Dr. |. Hiiseyin Filiz Department of Mechanical Engineering Faculty of Engineering University of GaziantepCONTENTS PREFACE LIST OF SYMBOLS = semsof énte sr CHAPTER 1 INTRODUCTION 9 irs 2 STRESS AND DEFLECTION ANALYSIS 3 DESIGN OF SHAFTS _ 4 TOLERANCES AND FITS 245 DESIGNOFPOWERSCREWS->6c¢ wetler dest 246 DESIGN OF BOLTED JOINTS ~ Beslers cfc belony 237 DESIGN OF RIVETED JOINTS >Fercn bes/erlles X 8 DESIGN OF WELDED JOINTS 7 %9704 beglerdilans 2&9 DESIGNOF MECHANICAL SPRINGS. > %/- @fi0 SELECTION OF ANTI-FRICTION BEARINGS > sé gf DESIGN OF JOURNAL BEARINGS- sett sodas los 13 DESIGN OF SPUR GEARS 14 DESIGN OF HELICAL GEARS, > Helse! dish Sereevras 15 DESIGNOFWORMGEARS = Sensex oles” 16 DESIGNOF BEVEL GEARS ? Konrh drs i7 foserms 17 DESIGNOF BRAKES ~ fren dese! 18 SELECTION OF FLEXIBLE ELEMENTS: APPENDIX » £h sso REFERENCES 1 3 59 103 121 137 167 181 205 pelmodes 275 316 408 450 peehit, 12 GEARING AND KINEMATIC ANALYSIS-9 Ah deer ve068 cnele,LIST OF SYMBOLS Area; constant constant; dimension; addendum constant constant; fatigue strength exponent coefficient; spring index; column-end condition constant; center distance clearance; distance Diameter Modulus of elasticity Eccentricity; efficiency; strain value; constant for bearings Force; face width Frequency; coefficient of friction Shear modulus of elasticity Gravitational constant Hardness nurrber; power Bearing film thickness; nut height Moment of inertia Polar moment of inertia; geometry factor Stress concentration factor; Wahf correction factor; constant Spring scale; endurance limit modifying factor; radius of gyration; stiffness Length; life; lead MomentWs oLs DN nk AM eet aa gn Mass; margin of safoty; module; speed ratio Teeth number Rotational speed; number of start; load factor of safety Force; unit load Pressure; circular pitch Notch sensitivity factor Reaction forces; radius Radius Strength; bearing characteristic number Torque Thickness Energy Unit energy Shear force; velocity Weight; width; load; force Radiat load factor Distance Axial load factor; Lewis form factor Distance; Lewis form factor Angle; axial fatigue stress concentration factor Bearing angle shear strain; pitch angle Deformation; deflection Unit strain; eccentricity ratio Efficiency Wrap angle Lead angle Poisson's ratio; coefficient of friction Radius of curvature Normal stress Shear stress Pressure angle Helix angle INTRODU: Mechanical element design is generally consi interdisciptinary study on material mechanism, manufacturing, specified objectives. ‘A design process is usually not 2 process of CHAPTER fluid mechanics, hy pneumatics, etc.. In other words, a design study usual all or the combination of the some of the above disc} obtain a useful element which will function proper iON lered as ichanics, Jraulies, involves: iplines to ly along inserting numbers into certain formulas and obtaining @ sound design the méchanical Almost all of the mechanical systems ame ha or2 PROBLEMS ON THE DESIGN OF MAGHINE ELEMENTS. dgsigner's job to find a compromise between these requirements by} adjusting certain parameters of. the systems or the oloments. Hence, dosign process is an iterative process which will yield Soon solutions to the problem. That is the designer may end uy with different designs that all satisty customer requirements. Affong these alternatives, the most suitable one can be found by oFfimization techniques which is out of the scope of this book i A designer does not necessarily know or memorise design ffmice but he must know the way he proceeds at different stages of design. As everytiody accepts this Is not easy but it is at] experience to be gained after solving many dliferent problems | Reading and understanding is the first but the moot crucial sipp in solving the problems after which a decizion must be made atjout the procedure’ or the method to be followed. Then, the rest off the design work is just the selection of the formulae and Inperting the numerical values of the known parameters into the fofmulas to obtain the values of the parameters of concern. Another important point in the design study is the valuation of the results. Any result which has no practical value is mec That is, the designer is always expected to value ie order of magnitude of the’ results. After all the Pfoductibility, the availability and the cost must be taken into noun in finalising the design process and/or sblection of all mechanical elements. CHAPTER When a load or loads is/are applied on an element resist for any deformation. This internal resietanc load Is dofined as stress. Being as an intemal Jebistance to external loads, stress differs trom the pressure altholidn thoy aro defined with the same standard units i.e. pascal. With| the clascical methods, it is not possible to measure stresses byt may be caleulcted by using the strain values. Howaver, | dressure is Measured with pressure gages, etc,4 ee | Type of load acting on an element may be of pure axial, pure berding or pure torsion type, It may as well be combination of axiil, bending and torsional loads or combination of any two of th a= and/or shear stresses (clockwise or i | 3. These loads generate normal stresses (tensile or cot ber sh terclockwise). Normal stresses may be due to axial loads or Ising loads. Shear stresses may be direct shear stress, torsional stress or flexural shear stress. Normal stress due to axial load is considered to be uniformly distributed on the cross-section of an element assuming that the art is straight and axial load is acting centrally. Normal stress due to bending is maximum (tensile or compressive) at the elements on the surface (upper or lower surface) and zero at the neutral axis. Neutral axis coincides with the} axis of symmetry of the parts which are initially straight with wa section that is constant throughout the part length. Stress varips linearly from the neutral axis. Tensile and compressive sidds ato determined from the direction of the moment, In the caso of Gurved members such as orene hooks and punch press frames, is ghifted toward the center of curvature of the beam and also the stroge does not vary linearly from the neutral axis | shear stresses may be due to shear loads, The oheat sos i the |component of the sires on a plane section that is parallel to tho section. An example of a member that has undergone permanent deformation in direct shear is a rivet in a riveted joint which is subjected to a shear load. Average shear stress is found dividing shear load by the cross sectional area of the member. i , Torsional shear stress is’ zero at tha neutrel axis end maximum at the surface. The direction of the shear stress is etermined by the direction of the torque. ‘In addition to normal stresses induced by bending of a beam, eect tele ate aa ‘STRESS AND DEFLECTION ANALYSIS “5 fibres providing that bending moment varies along the length of the beam. This flexural shear stress is zero at the lourface and maximum at the neutral axis. It's formulation is depchdent on the type of cross-sections. It is also assumed that the shear stresses are uniformly distributed across the beam width 4nd that the direction of shear stresses throughout the cross s¢ction is the same as the ditection of the shear force. As easily understood from above discussions,| for a given loading condition, different type of stresses fn different magnitudes are developed within the body of the mechanical element. That is, stresses on the surface element may be differont from stresses on an element within the body and lat a ceitain distance from the surface. Likewise, magnitude of the btresses may be different on the elements at different distances from the applied loads. Stress analysis is considered as the first stop thjthe design Process of mechanical elements. In the stress analys{s| by taking loading concition into account, stress elements are chosen from different places of the body of the mechanical elemeht and the worst stressed element is to be decided. All design| ¢alculations fare to be based on these elements. After deciding of] the worsily stressed element, stress components are combined {o| determine principal stresses. Principal .stresses are to be used in the determination of the safeness of the elements gckording 10 diferent failure criteria which are to be mentioned jh the next Chapter. There may be three stress stales which are namely |; + uniaxial stress state + biaxiat stress state - three axial stress state A bar loaded in simple tension or compression is on uniaxial stress state. Stresses developed on a shal In example Inaded he88 PROBLEMS ON THE DESIGN OF MACHINE ELEMENTS { stafe, Stresses developed in @ pressure cylinder is an example of a thrge axial siress state. The more usual case in mechanical design is biaxial(plane) stress state. And the problems given in thie book are mostly of this type. Deflection is an important consideration in the design of methanical elements. And in some cases, it is the deflection which governs the design. For instance, in some mechanical elements like spiadles of machine tools, the deflection at the tip point can not be grépter than tolerable limits since the accuracy of the work piece is Birectly affected with the deflection of the tip point, Therefore, in Bddition to the strength calculations, deflection at the specitiod Poipt must also be determined to finalise the design process. The mejhods used in deflection analysis are : 1) Double integration method 2) Numerical integration method 3) Graphical integration method 4) Moment-area method 5) Strain energy method (Cestigliano's theorem) |! this book, the emphasis is given to the application of strain engray method. The energy stored after deforming an elastic member is called as strain energy or potential energy. Castigliano's theorem stajes that deflection of a member at the point of application and in the direction of a force can be found by taking partial derivative of |the total strain energy with respect to that force. For this thebram to be applied in order to galeulate deflection at any point onj, 2 member, there must oxist a concentrated load. If the deflection of a member is required at a point where no cojjcentrated load is acting, an imaginary force Q is placed at that Polnt and in the resulting deflection’ expression Q is set to zero. | Buckling is another consideration in the dasign of eloments Subjected to a compression, load. If a bar is subjected to a Sc coe Ce OH STRESS AND FEFLECTION ANALYSIS. 7 it will shorten according to Hooke's law, if the magnitude of the force is increased to a value at which the stress is greater than the yield strength of the material, then the material is equoczed into a flat disk or fractures. I the bar is long ar length to diameter ratio is largo, as the compression load increases, a aitical value will be reached corresponding to an unstable condition. At this stage, any slight increase or movement in the load will result a suddon and total collapse of the bar. This failure is known as bucklig tallure and the load at this condition is called as the eritical load. in tho determination of the critical load or the factor of safoty, end conditions (end fixity) must always be taken into account. One can mention about four types of end conditions; 1) Both ends are rounded-simply supported 2) one end fixed, one end rounded and guided 2) both ends ara fixed 4) one end fixed one end free. Depending upon value of the slenderness ratio (length to radius of gyration ratio ) the columns are classified| as Euler or Johnson's columns as shown in Figure below. j Johnson's Column (fk) < CK){8 PROBLEMSON THE DESIGN OF MACHINE ELEMENTS ie ‘STRESS AND DEFLECTION ANALYSIS. 9 Example 2.1 A round shaft of diameter d and length L is supported by the bearings as shown in figure below. Bearing’ are arranged such that axial load is to be carried by the bearing at the eft end, Two stress elements identified in the section shown are 1 7 Jon top and: in xy plane; 2 is on the'front side and in xz plane. Draw i % <— ey each of the stress elements properly oriented with respect to xyz, show the stresses which act upon them, ; ©) Torsional toad actin; a) Axial load is acting, Stresses at any cross section ) oe throughout the length of the shaft will be uniform, : y Za. = Jet 1 mI : oN 28 } \ i xy | If the right bearing were to cary axial toad, then there will be no stress on the elements between the boarings. | b) Benging moment eoung only; i @) Bending load acting only; | Case 1: | Lin 7 i F /a Se a 2a. f A 2 8 : See eee 28 x 2.NO PROBLEMS ON THE DESIGN CF MACHINE ELEMENTS, } > stmess awa oertecrify anaursis 11 { i y i : yy , z | | + : i nex eee —— i Sy ey i % %@—]| 1 |—ey— 2 x : ze] ot j~-— 2 #b b % % i —— eat | yx yx case 2: 7 : ©) Bendind plus torsional leads i y 1 i Y i ait oa oy Say x Case 3: y 1 i y \ bem a|t = = x2 f“ A “4 a ce r c r r r r. s 7 - m r © i r ci12. PROBLENS ON THE DESIGN OF MACHINE ELEMENTS ') Bending plus torsional plus axiat loads; Example 2.2 The hand brace shown in the ‘igure Is used to apply a torque of 3 Nm and a thrust of 225 N to the bit In boring a hole in a wood. ) Make a three dimensional abstract drawing of the brace and calculate and show all the reactions. b) Tho drill used has @ shank diameter of 6 mm where it Projects from the chuck at section B-B. If the distance from B-B to the surtace of the wood is 80 mm, find the largest of the normal strasses at this section when the plane of the brace is horizontal, Calculate the shear stress at the same point, ening a STRESS AND DEFLECTION ANALYSIS. 13 Dimonsiens are in mm a ae abe Solution :a) The forces and teactions at typical points of tho hand brace is shown below. Axial load, Fx and torque, T are specified. Load Fz and reactions are calculated as follows, i F 222514 PROOLEMS OW THE DESIGN OF MACHINE ELEMENTS b) At section B-B 4 y oe z My=Fiy, AB=(7.62)(80}=609.6 Nmm Maximum sjfess at 8 occurs In the ‘element facing the negative Z-axis. XY plane on a stress 82M, By 3k 2008, 8) (8225) 567 Npa Oy x6)" 48T _ (163000). 76.75 shag xd (6)? Example 2.3 below, Consider the disk sander shown in figure : ts seuss STRESS AND DEFLECTIGN ANALYSIS. 18) ‘The force that should be applied to the wood block is 10 N and the coefficient of friction between disk and wood is assumed to be 2 Draw the stress elements at points 1 and 2], show the stresses acting on them and calculate the principal os Solution : The element at point 1 is subjected fo torque due to friction force , axial force, and bending force simultaneously. Each load will create their respective stresses a3 shown below. tyx aed ee) "ky; Txy oy a tog << —> 5 o a = ya where Bending moment M and Torque T are calculated as follows Mz F(150-5) = (10)(145)=1450 Nmm TF, (150-5) « (10)(2)(145) = 2800 Nm Substituting Mand T into stress expressions normal and shear stresses are obtained as |16 PROBLEMS OVTHE DESIGN OF MACHINE ELEMENTS ~ O89). 9.127 Noa (19) (3234450) tio)? 4612900) x10 = 09 op= 177 0.127 = 14.77 Mpa = 14.77 Mpa 4.64 Mpa Principal stresses then aro : Sey 2 (2) see ral (7.20)°4(44.77)" p= 9.165 Mpa ‘The element at point 2 is subjected to the same type of stresses but this time bending strass Is due to the moment effect of the friction force. That is : = 0.127 Mpa yy 14.77 Mpa 82M 2\20)(100) 59 37 tga ad nto)” ea" ‘The principal stresses at element 2 are : 0,220.97 ~ 0.127 = 20.45 MPa 20.245 4 q ‘STRESS AND DEFLECTION ANALYSIS._17 Example 2.4 The figure shows a gear driven powar scrow which Is used to pull-up an eccentric load of 63 kN. The screw is supported in bearings which take out the radial and thrust load components. The load is suspended from a nut as shown, guided to provent rotation with the screw. The friction in the throads and between the nut and guide requires a torque of 450 Nm to be applied to the gear to raise the load. a) Compute the stress components that act at A and B. b) Find the principal stresses that act at A. €) Sketch a stress clement correctly oriented to show the maximum shear stress and the corresponding normal stress ata | Solution For the given loading condition, stress elements tA and 8 cen be shown as oon # ]| 18 Prowtens on THE DESIGN OF MACHINE ELEMENTS xy| Ope — (ays3000) =27 MPa (50) 32'53000)(400) (50) 116)(450000) x(60)" 727.5 MPa 18.9 MPa b) Principal stresses at A ste found as follows : Og2 27 +1727.5 = 1784.5 MPa og 3 : san (2X) ste 1754. 1754.8) 15 9? 0, p= WEEE a / (2285 ) 18.99 6,=1754.7 MPa o,=~0.2 MPa ©) Maximum sheer stress is calculated from a STRESS AND DEFLECTfON ANALYSIS. 19 7 axcey ( 2 ) a" 177.44 MPa 2 (zs 3) (18.9)? The two normal strosses corresponding 10 thi shear stress ate each 877.25 MPa, The otiontation is : tan 1754.5 Dyer ayy 0-999 | xy (@)(877.44) ! =-225" counterclockwise Example 2.5 Using Castigliano's theorem, develop an expression for the doftection of end A of the beli crank in terms of Fiolada,tila, and E. Dye re La FI Ly, —————. Solution : From the geometry of the figure20 PROOLEMS ON THE DESIGN OF MAGHENE ELEMENTS ala oor Fy % Strain energy duo to forces F1 nad F2 can be wrtton as : 1 Max “C noe fo 2El, “Jy BEI, Detection at point A can be found as follows where My=F x, My, then tte teed f” ef Fy toat aoa tae | FG Filly 36,” SEL Example 2.6 The rectangular shaped C frame shown in the figure is welded of three beams of rectangular cross section. Find an expression for the deflection of the frame at the point of force F and in the direction of F. sea welt eitemintiimtneedineemeeniha ‘STRESS AND DEFLECTION ANALYSIS 21 acl In order to find deflection of the frame at the force point, we are going to use Castigliano’s theorem. A schematic representation of deflection is shown below, Solution : Ld Total strain energy of the trama duo to force F is written ae uae [ Mee, pon rn ‘bei, "1, Ber, * aAE Deflection at the force point is found by taking Herivative of strain energy with respect to force F. That is« | | 22 PRomens OvTHEDESION OF MACHINE ELEMENTS “AE Example 2.7 A simple truss composed of two bars each of length L carries a vertical load P at joint D. Find the horizontal and vertical components of the total deflection 8 of point D. The bars fare made of same jnaterial, OB having @ cross sectional area of A and DC @ cross sectional area of 2A. Use theoram of Castigliano, Solution : Vertical deftection will be in the direction of the external load P. As shown in the following figure, forces diagram will yisld that the force acting on bar DB is equal to P and it is of stoner emrenenerfenineeineetow nici chalte ncaa STRESS AND DEFLECTICh ANALYSIS 23 tensile type and the force on bar DG is equal to P| but it is of compressive type Considering their cross sectional areas, strain energies stored in these bars can be written as; Upge Poe 2" AAG By applying Castigliano's theorem, we obtain deflection in vertical direction ac 2gt Yn) 2(r%t), of) amu oP op\ za)” aplane/"2 Ae 'n otder to determine detlection in ho¥izental direction, we must apply an imaginary force Q at point D as shown in. the following figure.24 PROBLEMS ON THE DESIGN OF MACHINE EL EVENTS STRESS AND DERLEGTION NALYSIS. 25 PL ! AO tesa Example 2.8 The figure shows a welded steel bracket loaded by @ bending force F. Bearing at A carries both axial and radial loads and Force on DB:P + we roe on bo: P- & Force on DG: P= | i : i i } ; Energies stored in these bars due to the addition of the fictitious force Q can be witten as : bearing at B carries radial load only. Dedive the expression for the We substitute Q=0 into above equation and obtain 3h as; | : |} daltection in the dlrection of F at point C. Use Castigiano’s Method | Gran } Ube iB : Solution ; Force and deflection diagram of the bracket is | | chown below, Deflection in horizontal direction is calculated from ; i ov ae i Pee Sy L | ee ne ( ag ‘Yea * Yoo AE AE i t : The reactions Rx and fy are determined as (ro) det (eB) | | sadist (Prvadlys, i AE AE i | |Potential energy stored in part DC is only due to bending load, ‘As it is seen from the above figure, potential energy stored in parts AD and DB ate also due to bending. Addlionslly part AD is subjected to compression load and therefore there is another component of strain energy due to axial load, Hence, total strain energy is considered to be the sum of all these components. That is: Us Uae Uno + Uostrentng t (Uanbarin where, 4 Ry)? WeDeeadre™(Ysa)oendea™ Jy Zi, 2 xo) bt Aoiarial” 2A, E 2A, E (Fx? oor |.” 21, Substituting the expressions for each of the above 4 components, we obtain; 2 2 MH (Ry) 2 Fu ext I ce aire Me (Ex yt t 2Ely E Yor O° oF By taking partial derivative of U with respect to F, yo Is i Deflection in the direction of F is then calculated from | expressed as; I seins STRESS ANO DEFLEGTIRN ANALYSIS._27 od IRE Example 2.9 Determine the rotation @ in the plkine of torque To of the free end of the’ tube shown in the followind figure. Sath portions of the tube lie in the same plane. Solution ; To will be acting as torque on sortion Ly and as the moment on portion Lz. Strain energies stored in these portions are: el G a TE : =] = ax 1" o 2EI Hence the total strain energy U will be the sum of above,228 PROBLEMS ON THE DESIGN OF MAGHENE ELEMENTS Sy ft u, J wot ie ‘The rotation © will be obtairied from partial derivative of the above expression with respect to To. Example 2.10 Each of the two cantilever beams shown in ihe figure has cross section 25x6mm, Both beams are made of steel. A spring having a free length of 125 mm is to be assembled between the beams along lino AB, | | gist : 4 | If the original distance between beams is 100 mm and the scale of the spring is 80 kNim, determine the deflection of each beam. Solution : When the spring is placed between two cantilever plates, the system will come to equilidrium after plate A is defiected with ya and plate 8 is deflected with yp, The net eflection of the spring will be 25-(ya+ys). ee Mel Ss at 7 OE ‘The potential energy stored in the spring by deflecting it at an amount of 25 mm initially is equal to the sum of strain energies in the final condition, That i L u=f Max ana 712.5 mm* and and k=80 N/mm. and F,=k8=80 (25) = 2000 N80. PROBLEMS ON THE DESIGN OF MACHINE ELENENTS Writing the ‘gompatibiiy of. deflections, we obtain; fine ty | __Substtuting jhe expressions of each term above, wo solve ; for Fas, 25 300° ( 3 (207000) ea ate ars k 7812.5" 450)" 86 Fe2ian Dellections ya and ye are calculated from 3 Yq 218 B00" on anen *° SEI, (207000) (7812.5) 7 3 ee 218 200" 94.06 mm ” BEI, ~ 3(207000) (450) Example 2.11 The figure below’ shows a welded steel bracket loaded by @ force F, Derive an expression for the deflection of point B. : fri rot Equilibrium of force and moment give us: FeO A,+Ay=F ZM_=0 9M,~Fa+Ryl-My=0 'STESS ANO DEFLECTICW ANALYSIS. 31 Moments acting on AB and on BC can be written Myg=—M, +, x for oxxsa Mac=—My +R, X-Fo-a) for asxsl We have the following partial derivatives; he Mes a, + WR, | Mg Meo mM, : My The total strain energy is written and exgressions for ya and dyaidx (slope of deflection curve at point A) are’ obtained as follows : ‘These equations are rewritten as;82. PROBLEMS ONTHE DESIGN OF MACHINE ELEMENTS -3M,U242 RL2=F(2 U8 4a%-3 al?) The above together with equilibrium equations are solved for Fi. Ra. Mt and Me. _Fo*@a+b) lta’ @bsa) e Fath 2 and My Example 2.12 Two cantilever beams are arranged as shown in the figure. They have rectangular cross sections 75x100 mm and 100x150 mm. Find the magnitude of the force transmitted through the roller at C. Use Castigliano’s theorem. a Solution: Moment of inertias of upper and tower beams are calculated first. 14= 6250000 mm* and Iz= 26125000 mm* and they are related as Iz = 4.5 It. The elemant at G is replaced by an equivalent farce Q as STRESS AND DEFLECTIGN ANALYSIS. 33 {Al dimensions are ia ram This problem is another example on statically indeterminate structure. By using the compatibility condition, the reaction Q at point © can be determined. Compatibility requires that, Yor= Yoo The energy stored in beam 1 is oxpressed as, Uy=Uje+ Ugg 1000,9 2 Fx! Yer f Fea ye", en, ™ 000 LFx- Q0x-1000)* Ung=[__ EFE=Geet000VF 0 Nog Ei, ‘The energy stored in beam 2 is as well written as, Deflections of these beams are obtained by taking partial Gerivatives of the above energy expressions with respect to @‘34 PROBLEMS ON THE DESIGN OF MAGHNEELEMENTS sane J cFe-a0-1000)3¢) 1000) dx coo 28F 8Q),9_ 10)" +22 \ro8. 0 yess oer ser| ser, _ 2000 2 o ox? 800° El SEI, By equating yor and ycz, we obtain Q as, 1.492 Fe 14 920 N Example 2.13 As shown in figure below, two cantilever beams AD and BE having the samo flexural rigidity El= 2.58 (10)12 ate connected by @ steal rod having E=207 GPa, This rod OC is 750 mm long and has a crossection of 320 mm. Find the deflections of the cantilever AD BC at points D and C respectively. {Al dimonsions are in mo Festa kN Solution + In order to calculate deflections at points D and C, the force exerted by rod DC on tho cantilevers AD and BE must be ‘STRESS AND DEFLECT Known. This can not simply be done by staties alone, fompatiblity Concition must be considered. Compatibiity condition cbquires that deflection at point is the sum of deflection of cantilever AD at point D and the stretch of the rad, itself. Free body diagram of this configuration is illustrated below. Deflection et poin{ D of the cantilever AD can be found trom Castigliano's theorem a 3 3 Yom Se = 180" a. 5.48 (1070 min SEI 3 2.58) (10)" ‘The stretch in the bar Is easily found as; 750 Dyes = 11.92 (roy 320 (207600) ° ee Deflection at point © of the cantilever BE is foupdl by taking the derivative of the strain energy in the cantilever with respect to force Q. Wag Ye" aq‘36 PROBLEMS ON THEDESIGN OF MACHINE ELEMENTS STRESS AND DEFLECTIONNALYSIS. 37 i Vo 881862500 F+ 140625000 @ ay : : “ip Ie on fp I | | Yo and yp are related with the following expression, i net = | Yo=Yo* boo Peale sare By considering the direction ‘of the deflections, we write; Moment expressions between A and B and between and C are 6.45 (oy? as41.92 (oya written as_ follows. Q is solved and dotlecti in the bar are calculated as; ns at points D and C and the stretch for Osx=0, the column is an Euler column. (71000) 280 70.744, PROBLEMS ON THE DESIGN OF MAGHINE ELEMENTS So, thie column is indeed an Euler column and our assumption Is. correct. Example 2.18 The figure below illustrates a part of a hydraulic floor crane. We are interested in the design of the rod of its hydraulic cylinder, ‘| ‘The hydraulic pressure of 25 MPa is applied at the maximum. Cylinder bore diameter is 75 mm. A medium carbon steel rod having |. a yield strength of 490 MPa is used. Find the diameter of the rod for a factor of safety of 4. Solution : The force on the rod is : BUEY as00)= 110846 N ‘Then, the critical column load: is found as’: (4) (110446) =441786 N STRESS AND DEFLECTION ANALYSIS. 45 Examining the figure, it can easily be seen that ehd con tion of the rod is : one end fixed and one end pinned and guid4d(C=2). The critical load can then be expressed as 2 p. -20El ome Moment of inertia and diameter of the rod arp calculated from Pu (441786\(1270 ax'E — 2n*(207000) Jo) 3.4mm We have to check whether the rod is an Euler column pr not (5) a aEC (2(2)@m"(207000) 29) Ol Bee Bere (}e4-eacaro Wa” 434 (A, This shows that the rod is a Johnson column pnd therefore tho diameter found is incorrect. Using Johnson's fornula diameter of the rod is recalculated Re 1 74389 mm* 117 | 490 1 490) (_—_4_). o oraz (2) (azarae) tf and from which diameter d is solved as46 PROBLEMS ON THE DESIGN OF MACHINE ELEMENTS PEAT roy0.0147u12709 —— = 43.84 mm 400 As the proferred size we choose d = 44 mm, It this problem were solved by using strength requirement, the diameter of the rod would be approximately 18 mm. This shows why buckling is ‘so’ important consideration in the design of machine elements subjected to compressive loads. Example 2.19: A steel strut shown below Is rectangular in cross-section and. is the part of the operating mechanism of a bascule bridge. The compressive load to be carried is 150 KN. Determine the required dimensions w and t, assumning @ factor of safely of 4. The material has Sy=430 Mpa and Sut=570 MPa. Solution : Critical load on the strut is calculated as Poy | P=4 (150) =600 kN=600 000 KN End condition is both end rounded, that is C=1. Assuming that the column is an Euler Column, we can calculate moment of inertia | from : 2 2 Po" _ g00000 (1500) WE 207000 = 660790 mnm* As may easily be visualised, buckling will take place about the weakest section. STRESS ANO CEFLECTION ANALYSIS. 47 Hence, the above calculated value is to be equated to the moment of inortia about the weakest section and a |relationship between w and tis obtained. ' we we 7 7 2 | = 12 (660790) 7929480 mm* In order to solve tor w and t, we must haye another Felationship between them. Consideration of yielding under compressive load may help the designer to have an idea about the cross section (wxt) of the element. If compressive stress is equated to yield strengi by taking factor of safety into account, we obtain another relationship between w and t. 8, P. Sy Pent 4 aA 41600000) 2 wt = 41800000) S564 4 430 mm wand{ are then solved as: w=148 mm ; 1=37,7 mm Now we have to check to see whether the colunfa is actually an Euler column or not. So, we must find (UK) and (LIK)‘48 PROBLEMS ON THE DESIGN OF MACHNEELENENTS. k=0.289 1 = 0.289 (97.7)= 10.89 mm (E)-1908 «1978 70.85 ty) fete _. [2n%207000) _ 97 4g ky Sy 430 (PC) ic), The column is an Euler column, ‘STRESS AND DEFLECTION ANALYSIS 49 | SELECTED PROBLEMS Problem 2.1 A machine bracket is loaded wifh an inclined force of 1000 N as shown in the figure a) Find the principal stresses at point A. b) Show the results on @ proporty oriented elemerft, ©) Considering that point A is critical, calculate {the factor of safety if the material has ‘the yield strongth By=600 Mpa. Use distortion energy theory. torque of T=1000 Nm and a repeated axial load Fz between 0 and 15 kN. Determine and show components on the elements at points A,B and ©. hich is varying II the stress Fs Ls -100—m] Dimensions[50 PROBLEMS ON THEDESIGN OF MAGHINE ELEMENTS Problem 2.3 A cantilever machine bracket Is loaded with ‘an inclined force of 1800 N as shown in the following figure. ) Find the principal stresses on an element at point A. b) Show the results on a property oriented element, 6) Determine whether there will be a buckling failure or not. A imoncione re i en Problem 2.4 A cantilever machine bracket is lodded with fan inclined force of 1100 N as shown in the fotlowing figure. a) Find the grincipal stresses on an element at-point A. : ) Show the results on a properly oriented element. y AN irs are In a +100N =) VZZIZTBA LLL STRESS ANDDETLECTION ANALYSIS 51 Problem 2.5 Consider the following toad raising system. i Tow kg @) Calculate the power of the motor if th raised at a constant speed of 2 mis. Problem 2,6 Consider the following helical ‘The motor delivers 5 hp at 1000 rpm’ of the pinion, jear_system. algulete the located on the surface. 1000 gm (= Transverse odd m=3 mm Hom angle Ya 16° Transverse pussure angle $, #20 We = tan oy| $2 PROaLEHES ON THE DESIGN OF MACHINE ELEMENTS Problem 2.7 On the shait shown in Figure below, @ bell runs over a pulley at A which is 800 mm diameter and rotates at 300 rpm, The belt tensions are Fy = 6 kN and F2= 4 KN. The pitch diameter of the gear at B is 100 mm. The forces acting on the gear are Fa, Fr, and Ft where Fr= 36 Ft and Fa= 0.5 Ft. Bearings are selected so that bearing at left end | support carries axial load. ; a) Determine all stress components at points C and D, b) Determine the principal stresses at point C. 200" w ww ¢50 nee ele ye Problem 2.8 Consider that a prossure cylinder closed at both ends is 5000 mm tong and 1200 mm in diameter. The pressure inside the cylinder is 5Mpa, The cylinder is made of steel with Find the thickness of the cylinder for a factor of safety of 2.2. Use maximum shear stress theory of failure. Assume thal the cylinder is thin walled. Problem 2.9 A cast steal rank having a hub whose outer diameter and length are 175mm and 150mm respectively, is to be press fitted on the end of a steel shaft. The bore in the crank is 100mm and the shatt is 100.1mm, Deter STRESS AND DEFLECHION ANALYSIS 59 2) the radial pressure that is acting between thd shaft and hub. b) the tangential siress that is induced in the ctank 100: mm EL | 500 am Problem 2.10 A gray cast iron crank having 4 hub whose outer diameter and length are 160mm and 150mm respectively, is to be press fitted on the end of a carbon steel shaft. The bore in the crank is 99.98mm and the shaft is 100.05mm. Determine the radial and the tangential stresses at the outer surface of the shaft. 7 is ae w ’‘54 PROBLEMS ON THE DESIGN OF NACHINE ELEMENTS Problem 2.11 Find the deflection at point B of the shaft shown below. Us@ theorem of Castigliano. uu ue. Problem 2.12 Find the doliection at point A and at the tip point of the stepped cantilever shaft shown below, Use tho theorem of Castigliano. Li2——P}e— 112 Problem 2.13 Find the dofloction at point C of the stepped shaft shown below. Use theorem of Castigliano, Problem 2.14 Find the deflection at point © of the stepped shaft shown below. Use theorem of Castigliano. shaft shown below. Use theorem of Castigliano. STRESS AND DEFLECTION ANALYSIS. 5S: ae & LOGAN ' > Ls Jeu Ce ql Problem 2.15 Find the defiection at point C pi the stepped shaft shown below. Use theorem of Castigliano. 7 fe Noe X Problem 2.16 Find the deflection at pont 8 ol the stepped _ op Ps a B c — 2156 PROBLEMS ON THE DESIGN OF MACHINE ELEMENTS Problem 2.17 A simply supported steel beam rectangular in cross section and 2400 mm long is to carry @ concentrated load of 20 KN at a point 900 mm from one end, The depth of section is twice the width. Determine the detlection at the midpoint by using the theorem of Castigliano. Problem 2.18 The capacity of the jib crane, shown below, Js to be 2 tons. Determine the size of AB for a factor of safety of 2.5, Neglect the weight of the construction. AB has circular cross- section and is made of steel with Sy=400 MPa and Syt=550 MPa. SS Problem 2.19 A steal bar as shown in Figure below is used to seperate the cables. if cables and connections aro properly designed, what pull may be applied to the assembly for a factor of safety of 3. Material properties of the bar are Sy=560 Mpa and 50 MPa. 2-41 fe | os, Dimensions are in ram 500 600 ‘STRESS AND DEFLEGTION ANALYSIS. S7 Problem 2.20 The figure shows a schemblic drawing of a Portion of @ latching mechanism. When the mechanism is in use, an ‘operating force Fo is appliod. ‘This load ie resisted by a spring force acting ailsider B and a pin roaction at point ©. When the ink OA is pushod! tnfough the deed Poston, it comes to rest against a bumper et © and ib held there by the spring force. The link AB is to be manufactured from sheat motal having yiold strongth of 450 MPa, The maximum spring force ie 100 N. Find @ suitable thickness ¢ for the link AB.PROBLEMS ON THE DESIGN OF MACHINE ELEMENTS. Problem 2.21 A steel strut 150 mm long shown below is cular in otoss-section is subjected to 2 compressive load of 10 Determine the dimensions of the strut, assuming a factor of fely of 1.5. The material has Sy=560 Mpa and Sut=750 MPa. © 150 mm @ DESIGN OF SHAFTS Shafts ate mechanical olements which ere usully cylindricat in shape. They carry forces, bending moments and torques produced by the members such as gears, pulleys, flywheels, crayks and the like which are mounted upon thom. | A shaft may be rojating or stationary. According to the nature of the loads, a single shaft may be subjectdd to static stresses, reversed stresses, and repeated stresses ot fll of these acting at the same time. if a shaft or a beam is stationary and the load is of static type, only static type of stresses are developed ‘and the design is to be based on static strength and the procedure is dependent on the type of material ,2¢.ilustiated in the following figure.PROBLEMS ON THE DESIGN OF MACHINE ELEMENTS. DESIGN FOR STATIC STRENGTH OUCTILE MATERIALS BRITTLE MATERIALS Failure Theories t Failure Theories ‘Maximum Normal Stress Maximum Normal Stress Maximum Shear Stress Coulomb Mohr | Distortion Energy ‘Modified Mohr Failure theories used for the elements made of ductile materials, are represented in the following figure. Distortion energy Moximum-shear theory Stress thoory Sy Syo Syr . Peer Stress theory Sye According to maximum normal stress theory, failure will occur when the maximum normal stress in the element is equal to the normal stress in a tensile test specimen at the Yield point or at fracture point. Maximum shear stress theory statts’ that failure will occur when the maximum shear stress in the elpment is equal to the maximum shear stress in a tensile test specimen at the Yield point. Distortion energy theory states that ah element will fail if tho distortion energy in that element is |equat to the distortion energy in tensile test spesimen at the yield point. Since Yielding Is considered as the failure criterion, mpximum shear stress and distortion eriergy theories are applied bnly to ductile materials, Among the above theories, maximum normal stress theory of fellure is ot recommended. Because it does no} give correct results for the elements subjected to pure torsional fonds. IF the shaft material is of britte type and the loading is of static type, the following theories of fallures are appicable, @) Maximum Normal Stress theory of failure b) The Coulomb Mohr theory of failure : ©} The Modified Mohr theory of failure. ‘The Coulomb Mohr theory states that failure will occur when the stress situation on an element results in a mohr's|circie which is tangent to the common tangent of mohr's circle} when that element is loaded by a tensile and compression load seperately,