MACHINE DESIGN 1

PREPARED AND PRESENTED BY: ENGR. REYVENCER T. REYES

MACHINE DESIGN 1
SHAFT DESIGN (DECEMBER 7, 2022)

KEYS AND COUPLING DESIGN (DECEMBER 7, 2022)

DESIGN OF SCREW FASTENING- (DECEMBER 9, 2022) (RIVET, WELDED, SCREW JOINTS)

QUIZ NO.1 (DEC 15-16)

DESIGN OF MECHANICAL SPRING (JANUARY 4)

QUIZ NO. 2 (JANUARY 9, 2022) BRING HOME

DESIGN OF POWER SCREWS (JANUARY 5-6)

QUIZ NO. 3 (JANUARY 12-13)

GEARS

PIT DEFENSE
CHAPTER 6
SHAFT DESIGN
EXPECTED LEARNING OUTCOMES:

Be able to classify various types of shaft based on its application

Be able to calculate size of shaft based on the load
Be able to select proper shaft size based on standards
6.0 INTRODUCTION
A shaft is a rotating machine element which is used to transmit
power from one place to another. Power is transmitted through
tangential force and transmitting torque that is permitted by
various machine members such as pulleys and gears.
 6.1 SHAFT CLASSIFICATION
1. Shaft- is a rotating member that is used to tansmit power
2. Axle- a stationary member carrying rotating wheels and
pulleys
3. Machine Shaft- shaft that is an integral part of the machine.
4. Line Shaft (Main Shaft)- transmission shaft driven by prime
mover
5. Counter Shaft- transmission shaft intermediate between the
line shaft and the driven machine.
6. Spindles- is a short axle and shaft
7. Transmission Shaft- is a shaft used to transmit power
between the source and the machines absorbing the power,
and include countershafts, line shafts, head shafts, and all
factory shafting.
-
6.2 MATERIAL USED FOR SHAFTS
The material used for shafts should have the following
properties :

1. It should have high strength.

2. It should have good machinability.
3. It should have low notch sensitivity factor.
4. It should have good heat treatment properties.
5. It should have high wear resistant properties.
-
6.3 STANDARD SIZES OF TRANSMISSION
SHAFTS
The standard sizes of transmission shafts are :
25 mm to 60 mm with 5 mm steps;
60 mm to 110 mm with 10 mm steps ;
110 mm to 140 mm with 15 mm steps ; and
140 mm to 500 mm with 20 mm steps.

The standard length of the shafts are 5 m, 6 m and 7 m.

6.4 STRESSES IN SHAFTS
The following stresses are induced in the shafts :
1. Shear stresses due to the transmission of torque (i.e. due to
torsional load).
2. Bending stresses (tensile or compressive) due to the forces
acting upon machine elements like gears, pulleys etc. as well as
due to the weight of the shaft itself.
3. Stresses due to combined torsional and bending loads.
6.4 MAXIMUM PERMISSIBLE WORKING
STRESSES FOR TRANSMISSION SHAFTS
According to American Society of Mechanical Engineers (ASME) code for the design of
transmission shafts, the maximum permissible working stresses in tension or
compression may be taken as

(a) 112 MPa for shafts without allowance for keyways.

(b) 84 MPa for shafts with allowance for keyways.

For shafts purchased under definite physical specifications, the permissible tensile
stress (σt) may be taken as 60 per cent of the elastic limit in tension (σel), but not more
than 36 per cent of the ultimate tensile strength (σu). In other words, the permissible
tensile stress, σt = 0.6 σel or 0.36 σu, whichever is less.
6.4 MAXIMUM PERMISSIBLE WORKING
STRESSES FOR TRANSMISSION SHAFTS
The maximum permissible shear stress may be taken as
(a) 56 MPa for shafts without allowance for key ways.
(b) 42 MPa for shafts with allowance for keyways.

For shafts purchased under definite physical specifications, the permissible shear
stress (τ) may be taken as 30 per cent of the elastic limit in tension (σel) but not more
than 18 per cent of the ultimate tensile strength (σu). In other words, the permissible
shear stress, τ = 0.3 σel or 0.18 σu, whichever is less.
6.5 DESIGN OF SHAFTS
The shafts may be designed on the basis of
1. Strength, and 2. Rigidity and stiffness.

In designing shafts on the basis of strength, the following cases may be

considered :
(a) Shafts subjected to twisting moment or torque only,
(b) Shafts subjected to bending moment only,
(c) Shafts subjected to combined twisting and bending moments, and
(d) Shafts subjected to axial loads in addition to combined torsional and bending
loads.
6.5 SHAFT POWER
A. Power Formula in SI Units
P= 2πNT

P- Power (kW)
N- Speed (rps)
T- Torque (KN-m)

B. Power Formula in English Units

P= 2πNT/ 33,000

P- Power (hp)
N- Speed (rpm)
T- Torque (ft-lb)

6.6 STANDARD AND EMPIRICAL FORMULAS

Strength of shaft with assumed allowable stresses (Based on PSME Code pg 18)

a. For Main Shafts:

b. For Line Shafts:

c. For Short Shafts:

Where:
P- power (hp)
N- speed (rpm)
D- diameter (inch)

6.6 STANDARD AND EMPIRICAL FORMULAS

·Shaft diameter for 0.08 degrees per foot length of shaft deflection

For English Units:

Where:
D- diameter (in)
T- torque (lb-in)
P- horsepower
N- speed (rpm)

For SI Units:

Where:
D- diameter (mm)
T- torque (N-mm)
P- Power (Watts)
N- speed (rpm)

6.6 STANDARD AND EMPIRICAL FORMULAS

Shaft deflection of 1 degree for a length of 20 times its diameter

Where:
D- diameter (in)
T- torque (lb-in)
P- horsepower
N- speed (rpm)

 6.6 STANDARD AND EMPIRICAL FORMULAS

Linear Deflection of shafting

a) Shafting subjected to no bending action of pulleys except its own weight

b) Shafting subjected to bending action of pulleys, etc

Where:
L- Shaft length (ft)
D- Shaft diameter (in)

6.6 STANDARD AND EMPIRICAL FORMULAS

Angular Deflection of shafting

CHAPTER 7
KEYS AND COUPLINGS
EXPECTED LEARNING OUTCOMES:

Be able to identify various types of keys

Be able to design and select proper keys based on application
Be able to design couplings
7.0 INTRODUCTION
A key is a machine member employed at the interface of a pair of mating male and
female circular cross-sectional members to prevent relative angular motion
between these mating members

A Keyway a groove ill the shaft and mating member to which the key fits.

7.1 TYPES OF KEYS

A Spline is a permanent keys made integral with the shaft
and fitting Into keyways broached Into the mating

A Square Key has a square cross-section with half of Its

depth sunk in the shaft and half in the hub.

A flat key has a reqular cross section With a smaller

dimension placed In the radial direction with half sunk in
the shaft and half In the hub and is used where the
weakening of the shaft by the keyway is serious

7.1 TYPES OF KEYS

A Round key - has circular cross section

Barth key is a square key With bottom two corners

beveled.

Woodruff key consists of one-half of a circular disk fitting

into a rectangular keyway in the female member and a
semi-circular keyway in the male member.

Gib-head taper key - is a flat key with a special gib-head to

facilitate easy driving and removal of the key.

7.1 TYPES OF KEYS

Saddle key is a flat key used without a 'Keyway In the shaft

Kennedy keys are tapered square keys with the diagonal

dimension in a circumferential direction.

Feather key is one which has a tight fit into one member
and a loose sliding fit in the other member thus allowing
the hub to move along the shaft but prevents rotation on
the shaft.
7.2 FORMULAS
Force Transmitted

Stress

Relation of key and shaft for the same

material

Force tangent to pulley rim

7.2 FORMULAS
Force Transmitted

Stress

Relation of key and shaft for the same

material

Force tangent to pulley rim

7.3 COUPLINGS
A Coupling is a mechanical device which is used to connect length of shafts
permanently.

When do we need to have a flange coupling? And Why is it essential part of power
transmission?

7.3 COUPLINGS
A good shaft coupling should have the following requirement:

1. It should be easy to connect or disconnect.

2. It should transmit the full power from one shaft to the other shaft without losses.
3. It should hold the shafts in perfect alignment.
4. It should reduce the transmission of shock loads from
one shaft to another shaft.
5. It should have no projecting parts.

7.3 TYPES OF COUPLINGS

Rigid couplings do not allow angular, or
rotational flexibility and used with collinear
shafts.
Flange coupling type of rigid coupling which
consist of two halves of flanges connected
by each other by bolts.
Sleeve or collar couplings rigid coupling
which is a cylindrical collar pressedover the
ends of two colinear shafts.

Flexible couplings coupling which allows

angularity to take care of misalignment of the
shafts
7.3 TYPES OF COUPLINGS
7.4 FORMULAS
Total Force Transmitted

Force transmitted per bolt

Shearing of Bolts

Compression of Bolts
EXAMPLES
EXAMPLES
7.4 FORMULAS
Sleeve or Muff Coupling
7.4 FORMULAS
CHAPTER 8
BOLTS AND SCREW
EXPECTED LEARNING OUTCOMES:

Be able to define nomenclature of a screw

Be able to design and select proper screw based on application
Be able to calculate forces such as torque
8.0 INTRODUCTION
Screw and Bolts are threaded fasteners which are used to hold together
machine members which require easy dismantling.
A screwed joint is mainly composed of two elements i.e. a bolt and nut. The
screwed joints are widely used where the machine parts are required to be
readily connected or disconnected without damage to the machine or the
fastening.
8.1 ADVANTAGES AND DISADVANTAGES OF
SCREWED JOINTS
Following are the advantages and disadvantages of the screwed joints.

Advantages
1. Screwed joints are highly reliable in operation.
2. Screwed joints are convenient to assemble anddisassemble.
3. A wide range of screwed joints may be adopted to various operating conditions.
4. Screws are relatively cheap to produce due to standardisation and highly efficient
manufacturing processes.

Disadvantages
The main disadvantage of the screwed joints is the stress concentration in the threaded
portions which are vulnerable points under variable load conditions.
8.2 IMPORTANT TERMS USED IN SCREW
THREADS
1. Major diameter. It is the largest
diameter of an external or internal screw
thread. The
screw is specified by this diameter. It is
also known as outside or nominal diameter.

2. Minor diameter. It is the smallest

diameter of an external or internal screw
thread. It is also known as core or root
diameter.
8.2 IMPORTANT TERMS USED IN SCREW
THREADS
3. Pitch diameter. It is the diameter of an
imaginary cylinder, on a cylindrical screw
thread, the surface of which would pass
through the thread at such points as to
make equal the width of the thread and the
width of the spaces between the threads. It
is also called an effective diameter. In a nut
and bolt assembly, it is the diameter at
which the ridges on the bolt are in
complete touch with the ridges of the
corresponding nut.
8.2 IMPORTANT TERMS USED IN SCREW
THREADS
4. Pitch. It is the distance from a point on one
thread to the corresponding point on the next.
This is measured in an axial direction between
corresponding points in the same axial plane.
Mathematically,

5. Lead. It is the distance between two

corresponding points on the same helix. It may
also be defined as the distance which a screw
thread advances axially in one rotation of the
nut. Lead is equal to the pitch in case of single
start threads, it is twice the pitch in double start,
thrice the pitch in triple start and so on.
8.2 FORMS OF SCREW THREADS
1. UNC(Unified National Course) - for
general use, and for applications that
requires high strength.

2. UNF (Unified National Fine)- most

suitable for sealing.

3. UNEF(Unified National Extra Fine)

used in aeronautical equipment and
where very fine adjustment is required
8.3 COMMON TYPES OF BOLTS AND
SCREWS
1. Machine bolts
2. Stud bolt
3. Eye bolt
4. U-bolt
5. stove bolt
6. cap screw
7. set screw
8.4 DESIGNATION OF SCREW THREADS
1. US (Imperial System)

2. Metric System
8.4 DESIGNATION OF SCREW THREADS
8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
The following stresses in screwed fastening due to static loading are important from the
subject point of view :

1. Internal stresses due to screwing up forces,

2. Stresses due to external forces, and
3. Stress due to combination of stresses
8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
Initial Stresses due to Screwing up Forces

on the basis of direct tensile stress with a large factor of safety in order to account for the
indeterminate stresses. The initial tension in a bolt, based on experiments, may be found
by the relation

For joint fluid tight:

not required as tight as fluid-tight joint

8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
Stresses due to External Forces
8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
Stresses due to External Forces
8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
Stresses due to External Forces
8.5 STRESSES IN SCREWED FASTENING DUE
TO STATIC LOADING
8.5 FORMULAS
8.5 FORMULAS
8.5 FORMULAS
8.5 FORMULAS