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accurately computed.
Designer must understand material limits to
Design Factor
Factor of Safety (N)
Expected Stress
N
Stress at Component Failure
Suitable values depend on inherent danger,
sut
suc
1 1 2
N sut suc
Example
The Gray Cast Iron (Grade 40) cylinder carries
an axial compressive load of 75,000 lbs and a
torque of 20,000 in lbs. Compute the resulting
design factor.
R0.25
R0.25
4.00
5.00
su
N
'
'
s ys
max
sus
max
sy
2 max
Example
Specify a diameter for the middle portion of
the rod, if it is to be made from AISI 1040-hot
rolled steel.
450
5000 lbs
Example
For the seat support shown, specify a standard
structural tube to resist static loads shown.
The tube has properties similar to AISI 1020
hot-rolled steel. Use a design factor of 3.
400 lb
14
200 lb
20
Stress
Repeated Loads
alt
mean
Time
Example
The notched bar is machined from AISI 1020
steel. This bar is subjected to a load that
varies from 2000 lb to 3000 lb. Determine the
mean and alternating nominal stresses.
1.25
0.1 R
1
.75
Fatigue Strength
R.R. Moore Test
Motor
Alternating Stress, a
Endurance Strength, sn
103
104
105
106
107
108
Endurance Strength
sn = Endurance strength
Listed in tables
If no information is available, use
sn 0.5 su
(Steel)
sn 0.4 su
(Aluminum)
Example
The notched bar is machined from AISI 1020
steel. This bar is subjected to a load that
varies from 2000 lb to 3000 lb. Determine the
endurance limit of the material.
1.25
0.1 R
.75
Solderberg criterion
1 'm K t 'a
N
sy
s 'n
N
ssy
s'sn
ssy = 0.5 sy
ssn = 0.5 sn
Example
The notched bar is machined from AISI 1020
steel. This bar is subjected to a load that
varies from 2000 lb to 3000 lb. Comment on
the robustness of the design.
1.25
0.1 R
.75
Example
Comment on the robustness of a 1-1/4 round
bar made from AISI 1213 C-D steel. It carries
a constant tensile load of 1500 lbs, a bending
load that varies from 0 to 800 lbs at the senter
of the 48 length and a constant torque of
1200 in lbs.
48
Shafts
Connect power transmission components.
torsion.
Shaft Forces
Gears
As before
Wt
Wr
Shaft Forces
Chains
Ftight
2T
Ftight
D
D
T
Fslack = 0
Shaft Forces
V-belts
Ftight
2.5T
Ftight
D
D
Fslack
2D
Fslack
Shaft Forces
Flat belts
Ftight
3T
Ftight
D
D
Fslack
Fslack
Material Properties
For steady load (torsion)
sys=.5sy
sn=cs cR sn
cT = 1 (bending)
cm = 1 (wrought steel)
Stress Concentrations
Keyseats
Sled Runner Kt = 1.6
Profile
Kt = 2.0
Woodruff
Kt = 1.5
Stress Concentrations
Shoulders
Sharp, Bearing (r/d .03) Kt = 2.5
Round, Gear Bore (r/d .17) Kt = 1.5
Grooves
Retaining Rings Kt = 1.5
Strength Analysis
Kt M c Kt M
Bending stress
I
S
For round sections
Torsion stress
D3
32
Tr T
J
2S
J
I
2
r
c
Strength Analysis
Mohrs circle and Solderberg
3
2
K t M / sn ' T / s y
1
4
N
S
2
32 N
D
3
2
Kt M / sn ' T / s y
4
Example
Determine a suitable diameter for a shaft
made from AISI 1144 OQT 1000. It is
subjected to a reversing bending moment of
3000 ft lbs and a steady torque of 1800 ft lbs.
The shaft has a profile keyway.
Example
The shaft shown is part of a grain drying system
At A, a 34 lb. propeller-type fan requires 12 hp
when rotating at 475 rpm.
A flat belt pulley at D delivers 3.5 hp to a screw
conveyor handling the grain.
All power comes to the shaft through the v-belt at
C.
Example
12
Sheave C
C
10
10
150
Sheave D
Shafts Accessories
Components used to securely mount power
Keys
Allow torque to be transferred from a shaft
Key Design
Use a soft, low strength material
H
L
based on strength
W (in)
W
T
D H D2 W 2
S
2
D H D2 W 2
T
.005 in.
2
Key Design
T
2T
F
D/2 D
Key Shear
F
2T
A DLW
Failure Theory N
Length
4TN
L
DWsy
sy
2
s y LW
4TD
Example
Specify a key for a gear (grade 40, gray cast
iron) to be mounted on a shaft (AISI 1144, hot
rolled) with a 2.00 in. diameter. The gear
transmits 21000 lb-in of torque and has a hub
length of 4 in.
Retaining Rings
Also known as snap rings
Provides a removable shoulder to lock
strength.
Stamped, bent-wire, and spiral-wound.
Set Screws
Setscrews are fasteners that hold collars,
point style.
Pins
A pin is placed in double shear
8T N
d
D sy
(FN1 fit)
Example
Specify a pin for a gear (grade 40, gray cast
iron) to be mounted on a shaft (AISI 1144, hot
rolled) with a 2.00 in. diameter. The gear
transmits 21000 lb-in of torque and has a hub
length of 4 in.
Roll Pins
Easier disassembly
Collars
Creates a shoulder on shaft without
Mechanical Couplings
Couplings are used to join two shafts
Rigid couplings are simple and low cost.
Mechanical Couplings
In connecting two shafts, misalignment is
Mechanical Couplings
Selection factors include:
Amount of torque (or power & speed)
Shaft Size
Misalignment tolerance
Definition of important
Terminologies
Screw Designations
United National
Standard UNS
International Standard
Organization
1/4
5/16
3/8
1/2
5/8
3/4
7/8
1 1/4
p,in
1/16
1/14
1/12
1/10
1/8
1/6
1/6
1/5
1/5
Fd m l fd m sec
TR
(
)
2 d m fl sec
Wedging action, it
increases friction
16T
d 3
F
d m nt p / 2
6F
b
d r nt p
3V
3F
2 A d r nt p
ld
t2
lt=L- ld
Type of Joints
Lap Joint (single Joint)
But Joint
Example 1
Example 2
Example 2
Example 3
Weld
Springs
Flexible machine elements
Used to:
Exert force
Store energy
Spring Rate
Effective springs have a linear deflection
curve.
Slope of the spring deflection curve is the
rate
Force
k
1
Deflection
F
k
L
Example
A compression spring with a
rate of 20 lb/in is loaded with
6 lbs and has a length of 1.5
in. Determine the unloaded
spring length (free length)
Geometry
Di
Dw
Dw
Do
Dm = Do - Dw
Spring Parameters
Spring index
Dm
C
Dw
Deflection
Deflection for helical springs
8FDm3 N a 8FC 3 N a
4
GDw
GDw
G = Shear modulus
GDw
k 3
8C N a
Example
A helical compression spring is formed from
35 gage music wire with 10-1/4 turns and an
O.D. if 0.850 in. Its ends are squared. The
free length is 2 inches. Determine the force to
press the spring solid.
Stress Analysis
Spring wire is in torsion
T r 8K F C
2
J
Dw
Wahl factor, K
Accounts for the
curvature of the wire
4C 1 .615
K
4C 4
C
Example
A helical compression spring is formed from
35 gage music wire with 10-1/4 turns and an
O.D. if 0.850 in. Its made from A228 and
the ends are squared. The free length is 2
inches.
If the spring is repeatedly compressed to 1.3
in, do you expect problems?
Design Procedure
Select a material
Example
Design a helical compression spring to exert a
force of 22 lbs when compressed to a length
of 1.75 in. When its length is 3.0 in, it must
exert 5 lb. The spring will be cycled rapidly.
Use ASTM A401 steel wire.
m=0.001 - 0.005
Types
Single-row
Radial Ball
Angular
Contact Ball
Radial Roller
Angular
Roller
Types
Spherical
Roller
Tapered Roller
Needle
Thrust
Ball Bearings
Stress Analysis
Contact Stress
Bearing Load/Life
Test (fatigue) data
Radial Load (lbs)
Empirical relationship:
L2 P1
L1 P2
k=3.0 (ball)
k=3.33 (roller)
Example
A bearing is mounted on a shaft rotating at
1200 rpm. The bearing has been tested to have
a L10 life of 300 hrs, when loaded with 500
lbs. Determine the expected L10 life, if the
load is increased to 700 lbs.
Manufacturers Data
Vendors publish the
Bearing Selection
Determine the design life (in cycles)
Determine the design load
Pd = V R
Example
Specify suitable bearings for a shaft used in an
grain dryer. The shaft rotates at 1700 rpm.
The required supporting loads at the bearing
are
R =589 lb
Bx
RBy=164 lb
Mounting of Bearings
Shaft/bearing bore has a light interference
fit.
Housing/outer race has a slight clearance fit.
Check manufacturers catalog
Match maximum permissible fillet radius.
Shaft or housing shoulders not to exceed
20% of diameter.
Mounted Bearings
Pillow block
duty cycle.
Fi p N i
Fm
Ni
1
p
Fm=equivalent load
Fi= load level for
condition i
Ni= cycles for
condition i
p = exponent for
load/life
Example
Bearing 6211 is carrying the following load
cycle, while rotating at 1700 rpm.
Stage
Load (lbs)
Time (min)
1
600
480
2
200
115
3
100
45
Compute the bearing L10 life in minutes.
P=VXR +YT
T=thrust load
X
factors depending
=
Y
on bearing
Thrust factors, Y
Deep -groove, ball bearings
Example
A bearing is to carry a radial load of 650 lb
and a thrust load of 270 lb. Specify a suitable
single-row, deep-groove ball bearing if the
shaft rotates at 1150 rpm and the design life is
20,000 hrs.