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Lecture 1

The document discusses machine design and failure analysis. It provides an introduction and overview of strength of materials and failure from static loading. The syllabus outlines topics like design of shafts, gears, bearings and more. Designation systems for metals are explained. Failure theories like maximum normal stress and distortion energy are also covered.

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79 views54 pages

Lecture 1

The document discusses machine design and failure analysis. It provides an introduction and overview of strength of materials and failure from static loading. The syllabus outlines topics like design of shafts, gears, bearings and more. Designation systems for metals are explained. Failure theories like maximum normal stress and distortion energy are also covered.

Uploaded by

nofal Adrees
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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University of Zakho Mechanical Department

College of Engineering Fourth Stage

2021-2022

Machine Design
Prepared by : Mr. Majeed Ali
[email protected]
Lectures 1, 2, 3, &4
Introduction, Fast Review on Strength of Materials, and
Failure Resulting From Static Loading
Textbook:
- Robert L. Moot , "Machine Elements in Mechanical
Design", Pearson, 4 Edition, 2004.

Refrences:
- Shigley's ,"Mechanical Engineering Design", Mc Graw
Hill,. 9 Edition, 2011.

Assessment scheme:
quiz 10 deg.
Homework 5 deg.
Mid. Exam. 20 deg.
Report & Seminar 15 deg.
Final Exam 50 deg.
Syllabus:
1- introduction & fast review on strength of materials.
2- failure resulting from static loading.
3- failure resulting from variable loading.
4-design of shafts.
5-design of keys and couplings.
6-design and selection of bearings
7- design of belts.
8- design of chain.
9- design of spur gear.
introduction

Figure:
Hand-held power drill
 the designation systems for steels are managed by either SAE International or
ASTM International.
 The wrought or rolled steels typically used for machine elements are most likely
to be selected from SAE grades.
 Structural steels and many cast metals carry ASTM grade designations.
 both SAE and AISI issued wrought or rolled steel designations that were
substantially identical. The system starts with the familiar four-digit designation
system that has been used for several decades under both the SAE and AISI
systems, as shown in below table.
Aluminuim Designation System
The standard designations for aluminum alloys listed by the Aluminum Association
use a four-digit system. The first digit indicates the alloy type according to the major
alloying element. The second digit, if it is other than zero, indicates modifications of
another alloy or limits placed on impurities in the alloy. The presence of impurities is
particularly important for electrical conductors. Within each group are several
specific alloys, indicated by the last two digits in the designation.
Fast Review on Strength of Materials

P=
ϴ
y
Consider loaded beam made from three boards As shown below, if the
top and bottom beams are glued or bonded together along the contact
surface, so that they become a single solid beam. When this beam is
loaded, horizontal shear stresses must develop along glued surface in
order to prevent the sliding shown.

Vertical Shear stress distribution


Where:
I = rectangular moment of inertia of the cross section of the beam.
t = thickness of the section at the place where the shearing stress is to be
computed.
Q = first moment, with respect to the overall centroidal axis, of the area
of that part of the cross section that lies away from the axis where the
shearing stress is to be computed.
Example:
When the stress element oriented atφσ ,the shear stress
on the element is zero.
𝜎1 − 𝜎2
𝜏𝑚𝑎𝑥 =
2

When the stress element oriented atφτ ,the


normal stress on the element will be average of
the acting stresses.
Example
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.
Factor of safety ( design factor) N
The term design factor, N, is a measure of the relative safety of a load-carrying
component . In most cases, the strength of the material from which the component is to
be made is divided by the design factor to determine a design stress, 𝝈d, sometimes
called the allowable stress. Then the actual stress to which the component is subjected
should be less than the design stress.
Failure Resulting From Static Loading

When a part is subjected to a load that is applied slowly, without shock, and is held
at a constant value, the resulting stress in the part is called static stress. An example is
the load on a structure due to the dead weight of the building materials .

Dynamic stress

Static stress
Permanent Separation
Deformation

Example for the failure


The maximum normal stress theory states that a material will fracture
when the maximum normal stress (either tension or compression) exceeds
the ultimate strength of the material as obtained from a standard tensile or
compressive test. Its use is limited, namely for brittle materials under pure
uniaxial static tension or compression. When applying this theory, any stress
concentration factor at the region of interest should be applied to the
computed stress because brittle materials do not yield and therefore cannot
redistribute the increased stress.
The following equations apply the maximum normal stress theory to design.
When stresses are applied in more that one direction or when normal
stress and shear stress are applied simultaneously, it is necessary to compute
the principal stresses, σ1 & σ2 using Mohr's circle or the equations in previous
lecture. Stress concentrations should be included in the applied stresses before
preparing Mohr's circle for brittle materials.
For safety, the combination of the two principal stresses must lie within the
area shown in Figure 5-12 that graphically depicts the modified Mohr theory.
The graph is a plot of the maximum principal stress σ1 on the horizontal axis
(abscissa) and the minimum principal stress, σ2 on the vertical axis (ordinate).

1- Draw the modified Mohr diagram as shown in Figure 5-12.


2- Plot point A at (15 , -80).
3- Draw the load line from the origin through point A until it intersects the
failure line on the diagram at the point labeled Af .
4- Determine the distances OA = 81.4 ksi and OAf = 112 ksi by scaling the
diagram.
5- Compute the design factor from N= OAf/OA = 112/81.4 = 1.38.
This is a simple application of the principle of yielding in which a
component is carrying a direct tensile or compressive load in the manner
similar to the conditions of the standard tensile or compressive test for the
material. Failure is predicted when the actual applied stress exceeds the yield
strength. Stress concentrations can normally be neglected for static stresses on
ductile materials because the higher stresses near the stress concentrations
are highly localized. When the local stress on a small part of the component
reaches the yield strength of the material, it does in fact yield. In the process,
the stress is redistributed to other areas and the component is still safe.
The following equations apply the yield strength principle to design
(Tresca)
The maximum shear stress method of failure prediction states that a
ductile material begins to yield when the maximum shear stress in a load-
carrying component exceeds that in a tensile-test specimen when yielding
begins. A Mohr's circle analysis for the uniaxial tension test, shows that the
maximum shear stress is one-half of the applied tensile stress.

The maximum shear stress method of failure prediction has been


shown by experimentation to be somewhat conservative for ductile
materials subjected to a combination of normal and shear stresses. It is
relatively easy to use and is often chosen by designers. For more precise
analysis, the distortion energy method is preferred.
The distortion energy method has been shown to be the best predictor of failure
for ductile materials under static loads or completely reversed normal, shear, or
combined stresses. It requires the definition of the new term, von Mises stress,
indicated by the symbol, σ', that can be calculated for biaxial stresses, given the
maximum and minimum principal stresses, σ1 and σ2 from:

Failure is Predicated When Von-Mises Stress Exceeds The Yield Strength.


Triaxial Distortion Energy Method. A more general expression of the von
Mises (distortion energy) stress is required when principal stresses occur in all
three directions σ1,σ2 &σ3. We normally order these stresses such that σ1> σ2 >
σ3 Then

safe
Example:
A bracket is made by welding a rectangular bar to a circular rod, as shown in
Figure 5–20. Design the bar and the rod to carry a static load of 250 lb.
Rectangular Bar:
The bracket design is shown in Figure 5–20. The rectangular bar carries a load of
250 lb vertically downward at its end. An effectively fixed support is provided by the
weld at its left end where the loads are transferred to the circular rod. The bar acts
as a cantilever beam, 12 in long. The design task is to specify the material for the
bar and the dimensions of its cross section
We will use steel for both parts of the bracket because of its relatively high stiffness,
the ease of welding, and the wide range of strengths available. Let’s specify AISI
1340 annealed steel having sy = 63 ksi and su = 102 ksi (Appendix). The steel
is highly ductile, with a 26% elongation.
The objective of the design analysis that follows is to determine the size of the cross
section of the rectangular bar. Assuming that the bar acts as a cantilever and the
loading and processing conditions are well known, we will use a design factor of
N = 2 because of the static load.
The relationship for S is

As a design decision, let’s specify the approximate proportion for the


cross-sectional dimensions to be h = 3t. Then

The required minimum thickness is then

The nominal height of the cross section should be, approximately,


Circular rod:
The bracket design is shown in Figure 5–20. The design task is to specify
the material for the rod and the diameter of its cross section.
Let’s specify AISI 1340 annealed steel, the same as that used for the
rectangular bar. Its properties are sy = 63 ksi and su = 102 ksi .
𝑀 𝑇
𝜎𝐵 = 𝜎𝑋 = 𝜏𝐵 = 𝜏𝑥𝑦 = For circular section Zp=2S
𝑆 𝑍𝑃
2000 3000
𝜎𝐵 = tension
𝑆
𝜏𝐵 =
2𝑆
Using Maximum Shear Stress Theory:

0.5𝑆𝑦 𝜎𝑥 −𝜎𝑦 2 2 0.5𝑆𝑦


𝜏𝑚𝑎𝑥 = −−−→ + 𝜏𝑥𝑦 =
𝑁 2 𝑁

𝑀/𝑆 2 𝑇 2 1 3606
𝜏𝑚𝑎𝑥 = + = 𝑀2 + 𝑇2 𝜏𝑚𝑎𝑥 = psi
2 2𝑆 2𝑆 2𝑆

0.5 ∗ 63000 3606


= 𝑠 = 0.1144 in3 D=1.053 in Ans.
2 2𝑆
Example:

Shaft diameter is 1.5 in.

Note : Cast iron Grade 40 ,(Brittle material) having a tensile ultimate strength of 40 ksi
and a compressive ultimate strength of 140 ksi.
σ2

Sut
Sut= 40 Ksi
Suc= 140Ksi
Suc 45 Sut σ1
o σ1 = 25Ksi
A σ2 = -25Ksi
Af
N= OAf/OA

Suc
Question:

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