Design of Machine Elements

UNIT - 1
The Design Process
Basic Procedure of Design of Machine Element
Basic Requirements of a Machine Element
1. Strength
2. Rigidity
3. Wear resistance
4. Minimum dimensions and weight
5. Manufacturability
6. Safety
7. Conformance to standards
8. Reliability
9. Maintainability
10. Minimum life cycle cost
Failure modes: Failure by elastic deflection ( Ductile material)

Failure by yielding (Ductile material)

Failure by fracture (Brittle material)

Failure criterion(for design purpose):

yielding strength for ductile materials
Ultimate strength for brittle materials
 Types of Loads

Case 1: Based on how the load is applied

a) Static or Dead load ( it is considered as gradually applied load)
b) Variable or Live load
c) Shock or sudden load
d) Impact load

* Examples of each case

* Effect of which load is severe
 Types of Loads continuation……
Case 2: Based on type of stress induced
a) Normal load-> normal stress(stress acting perpendicular to the cross section of the component)
b) Shear load -> shear stress(stress acting parallel to the cross section of the component)

Normal load: Shear load:

a) Tensile load -> tensile stress a) Direct shear load -> direct shear stress

b) Compressive load -> compressive stress b) Torsional load -> torsional shear stress

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Note: Bending stress is also a normal stress

Special case: crushing stress( also called as compressive stress)
DIFFERENCE BETWEEN COMPRESSIVE STRESS AND CRUSHING STRESS:
Crushing stress or bearing stress always occurs when two bodies are in contact which is not the case in
development of compressive stresses for example if rod is place in hole on the periphery of the rod in contact
with hole crushing stress will be developed (on the both components) where as compressive stresses are
developed when one apply force on a member (say rod) in axial direction or to be precise when direction of load
is perpendicular to area of failure
** for crushing stress, projected area only considered because load should be normal to the area
Design of machine elements under simple stress
(uni-axial stress)
These equations are valid only under static load condition
Special case:
Cursing stress or Bearing stress or compressive stress:

crushing stress = load/projected area

(σc )
The magnitude of factor of safety depends upon following factors:
1. Effect of failure
Low FOS when only a little inconvience or loss of time
High FOS when substantial financial loss or danger to human life
2. Type of load
Low FOS for static load
High FOS for variable or shockor impact load
3. Degree of accuracy in force analysis
Low FOS if forces are precisely determine
High FOS if magnitude and direction of forces uncertain and unpredictable
4. Material of component
Low FOS for homogeneous materials
High FOS for non homogeneous materials
5. Reliability of component
Low FOS if low reliable
High FOS if high reliable
6. Cost of component
Low FOS if cheap components
High FOS if high cost
The magnitude of factor of safety depends upon following factors:

7. Testing of machine element

Low FOS if testing is done under actual conditions of service and operation
High FOS if not possible to test under actual conditions
8. Service conditions
High FOS if the component is operated in corrosive or high temperature environment
9. Quality of manufacture
Low FOS for high quality manufacture
High FOS for low quality manufactured
 Instructions to solve the numerical problems
Basically three category of problems are there.

a. Machine component withstand or not (fails or not)

Data required: 1. dimensions of machine component
2. load or force acting on the machine component
3. material of the machine component( yield strength or ultimate strength)
Note: induced stress <= allowable stress

b. Calculate the unknown dimension of the machine component ( minimum dimensions)

Data required: 1. load or force acting on the machine component
2. material of the machine component( yield strength or ultimate strength)
Note: induced stress = allowable stress

c. Calculate the load or force at which the machine component can withstand without fail ( maximum force)
Data required: 1. dimensions of a machine component
2. material of the machine component( yield strength or ultimate strength)
Note: induced stress = allowable stress
 Numerical Problems on simple stress
Note: all problems belong to static load condition only
• A rod of 25mm in dia, 200 m length long deformed through 0.25mm under the tensile load of 40KN.
Calculate stress, strain and young’s modulus.?

• A cuboid of length 100mm, width 20mm and height 40mm is subjected to a tensile load of 45KN. Calculate
the maximum stress induced in the cuboid?

• A cuboid of length 100mm, width 20mm and height 40mm is subjected to a tensile load of 45KN. Cuboid
contains a through hole of radius 15mm along the width. Calculate the maximum stress induced?

• A cuboid of length 200mm, width 30mm and height 50mm is subjected to a tensile load of 90KN. It is made
with 40C8 material whose yield strength is 380N/mm2. Check the component withstand under the given
load?

• A circular rod of length 100mm, diameter 17mm is subjected to a tensile load of 100KN. Rod is made with
55C8material whose yield strength is 460N/mm2. Given factor of safety is 1.5. Check the component
withstand under the given load?
• A cuboid of length 200mm, width 50mm and height 100mm is subjected to a tensile load of 1000KN. It is
made with FG300 material and the given factor of safety is 1.3.check the component withstands under the
given load?
• Design the diameter of the rod whose length is 200mm.It is subject to a tensile load of 500KN and given
factor of safety is 1.5 and is made with 30C8 whose yield strength is 400N/mm2.
• A cast iron link is shown in the figure, is required to transmit a steady tensile load of 45KN. The permissible
stress of the link material is 55N/mm2. Check the link is safe or not?

• Design the rivet which is shown in the following figure. Rivet material yield strength is 400 N/mm2

Note: solve the same problem if the rivet undergoes double shear
• A beam of uniform rectangular cross section is fixed at one end and carries an electric motor weighing 400 N at a
distance of 300mm from fixed end. The maximum allowable bending stress in the beam is 40MPa. Find the width
and depth of the beam if depth is twice that of width?

• A shaft is transmitting 97.5 KW at 180 rpm. If the allowable shear stress in the material is 60MPa, find the
suitable diameter for the shaft. The shaft is not to twist more than that 10 in a length of 3 meters. Take C=80GPa.
KNUCKLE JOINT
Problem: It is required to design a knuckle joint to two circular rods subjected to an
axial tensile force of 50kN. The rods are co-axial and a small amount of angular
movement between their axes is permissible. Design the joint and specify the
dimensions of its components. Select suitable materials for the parts.
SOCKET AND SPIGOT
COTTER JOINT
Problem: Two rods are connected by means of a cotter joint. The inside diameter of the
socket and outside diameter of the socket collar are 50 mm and 100 mm respectively.
The rods are subjected to a tensile force of 50kN. The cotter is made of steel 30C8
whose yield strength in tension is 400 N/mm2 and factor of safety is 4. The width of the
cotter is five times of thickness. Design the cotter joint.
 Design of machine elements under bi-axial stresses
(plane stress condition)
Introduction:
Calculate the maximum stress induced in the component shown in figure.
L= 100mm, W = 30mm, H = 20mm
Principal stresses and principal planes:
At any point in a strained material, there are three planes mutually perpendicular to each
other which carry direct stresses only and no shear stresses. It may be noted that out of these 3direct
stresses, one will be maximum and one will be minimum. These perpendicular planes which have no
shear stresses are known as principal planes and direct stresses along these planes are known as
principal stresses.

Where τxy is maximum shear strress

Where σ1 is maximum principal stress and

σ2 is minimum principal stress
 Theories of failure
There are number of machine components that are subjected to several types of stresses simultaneously i.e.,
bi- axial or tri-axial stresses.
Eg: power screw – torsional and axial stresses
Shaft – bending, torsional and axial stresses
Crank – bending and torsional stresses
Then how to predict the failure of such components?
In practice, the mechanical properties are obtained from simple tension test. They include yield
strength, ultimate strength and percentage elongation. However it is not possible to conduct the tests for
different possible combinations of loads and obtain mechanical properties.

Remedy: Theories of failure provide a relationship between the strength of machine component subjected to
complex state of stress with the mechanical properties obtained in tension test. With the help of these
theories, the data obtained in tension test can be used to determine the dimensions of the component,
irrespective of the nature of stresses induced in the component due to complex loads.

Note: theories of failure are applicable to elastic failure of machine parts, so these failure theories are called
theories of elastic failure.
Maximum principal stress theory (or) maximum normal stress theory (or) Rankine’s theory
Maximum principal strain theory or Saint venant’s theory
 Maximum strain energy theory (or) Haigh’s theory
Statement:
The theory states that when a mechanical component is subjected to bi-axial or tri-axial stresses, failure
occurs when the maximum strain energy per unit volume in the component equal to the strain energy per
unit volume at yield point in a simple tension test

Umax = Uyt
if FOS is givne, then Umax = Uyt/ FOS
Maximum distortion energy theory (or) Hencky’s and Vonmises theory
Statement:
The theory states that when a mechanical component is subjected to bi-axial or tri-axial stresses, failure
occurs when the maximum distortion energy per unit volume in the component becomes equal to the
distortion energy per unit volume at yield point in a simple tension test.

Ud max = Ud yt

If FOS is given, then Ud max = Ud yt /FOS

Numerical problems
Q2. The load on a bolt consists of an axial pull of 10KN together with a
transverse shear force of 5KN. Find the diameter of the bolt required
according to maximum shear stress theory and maximum distortion
energy theory. Take permissible stress = 100 MPa and poisons ratio = 0.3
take youngs modulus as 300 N/mm2
Q3. For the state of stress at a point of a bi-axially loaded member shown in fig. Determine the factor of safety using
maximum principal stress theory, maximum principal strain theory and maximum strain energy theory. The critical
stress of the material is 300N/mm2. Take poisons ratio is 0.3

50 N/mm2

20 N/mm2

100 N/mm2
100 N/mm2

20 N/mm2

50 N/mm2
 Impact load(freely falling load)
Impact is defined as a collision of one component in motion with a second
component that may either be in motion or at rest. Impact load is the load that is
rapidly applied to the machine component.
Eg: driving a nail with hammer, Breaking a coconut, Punches, clutches and breaks etc..
Where l is length of a bar,
A is the crosssectional area,
W is the falling weight,
h is the height through which weight falls,
p is impact force acting on the disc,
δ is deflection produced in the bar

σi is the impact stress induced in the bar,

E is the young’s modulus of the bar material
The potential energy released by the falling weight is absorbed by the bar and stored in the form of strain
energy.
Vertical distance travelled by the weight includes deflection of bar due to impact force.

Potential energy of freely falling weight = strain energy stored in the circular rod
Preferred numbers or preferred sizes:
In engineering design, the designer has to specify the size of the product. The size of the
product is a general term, which includes different parameters like power transmitting capacity, load
carrying capacity, speed and dimensions of the component such as height, length and width and
volume or weight of the product.
Charles Renard first introduced preferred numbers in the 19th century. The system is based on
the use of geometric progression to develop a set of numbers.
There are five basic series.
If the given ranges is x to y, then

Basic series Series factor Number of models

R5 6

R10 11

R20 21

R40 41

R80 81

Where y/x is called ratio factor.

Problems:
1. It is required to standardise 11 speeds from 72 to 720 rpm for a machine tool. Specify the speeds?
2. A manufacturer is interested in starting a business with five different models of tractors ranging from
7.5KW 75 KW capacities. Specify power capacities of models?