CHAPTER 1 MACHINE

DESIGN
Science of Mechanism
The science of mechanism is divided into two parts:
Pure Mechanism or Kinematics of Machines
Treats of the motion and forms of the parts of
a machine, and the manner of supporting and
guiding them, independent of their strength.
Constructive Mechanism or Machine Design
Involves the calculation of the forces acting on
different parts of the machine;
Selection of materials on the basis of strength
durability, and other physical properties in
order to withstand these forces,
The convenience for repairs and facilities for
manufacture also being taken into account
Stress
The force intensity at a point, called stress, which plays a central role
in the design of load-bearing members.
It is the force per unit area

Measured in or , .
2

= ; =


Analysis of Internal Forces: STRESS

P: The component of V: The component of the

T: The component of
the resultant force that resultant force lying in the
the resultant couple M: The component
is perpendicular to the plane of the cross
that tends to twist of the resultant
cross section, tending to section, tending to shear
(rotate) the bar is couple that tends to
elongate or shorten the (slide) one segment of the
called the TWISTING bend the bar is
bar, is called the bar relative to the
MOMENT or called the
NORMAL FORCE. other segment, is called
TORQUE. BENDING
the SHEAR FORCE.
MOMENT.
=
= =
/ / =
/
Shear Stress

LAP JOINTS CLEVIS PUNCHING

Shear Stress

LAP JOINTS CLEVIS PUNCHING

Bearing Stress
If two bodies are pressed against each other, compressive forces are
developed on the area of contact. The pressure caused by these
surface loads is called BEARING STRESS.
Example:
The contact pressure between a rivet and the side of its hole.
Bearing Stress: Lap Joint
 Deformations or Strain
In general terms, strain is a geometric quantity
that measures the deformation of a body.
Normal Strain
Characterizes dimensional changes
Shear Strain
Describes distortion (changes in angles).
 Normal (Axial) Strain
The normal strain (lowercase Greek epsilon) is defined as the
elongation per unit length.
Strain Formula:

= =
0

= , ,

= = , , , .
= , , , ,
+ =
=
= ()
 STRAIN OFFSET METHOD
Stress-Strain Curve
 Modulus of Elasticity

=



=

=
,
For ordinary steel usually falls between 28,000 to
31,000 ksi, and most designers use either 29,000 or
30,000 ksi.
TABLE AT-7
Deformation

= (1)

= = (2)
0 0

= (3)

0
= =

Bending TENSION

Bending, or flexure, produces

COMPRESSION
two kinds of normal stresses,
tension on one side of a neutral
plane and compression on the
other.
 Bending/Flexure Formula

=

Note that a positive bending moment M causes negative
(compressive) stress above the neutral axis and positive (tensile) stress
below the neutral axis, as discussed previously.

=

largest bending moment
distance from the neutral axis to the outermost point of the cross
section


=


=

 I-Beam: Determine Polar Moment of Inertia
(I)
Determine the location of NA
(Neutral Axis) based on the
bottom of the I beam:
1 1 + 2 2
=
1 + 2
Determine the Moment of
Inertia:
2
= +

3
=
12
Table AT 1 Properties of Sections @ pg 563
Torsion
Torsion
Torsion describes a twisting effect, where different parts of an object
undergo different angular displacements (referred to as the angle of
twist) about the rotational axis. To create torsion, a torque is necessary.
Depends on the ff:
Magnitude of Torque
Type of Material
Shape of the Material
Torsion Formula: Angle of Twist

=

:
,
, , ,
, ,
, 4 4
Torsion Formulas: Maximum Shear Stress
Maximum Shear Stress

=

:

, lb-ft, N-m
,
, 4 4

=
Torsion Formulas
Polar Moment of Inertia
Solid Shaft (in4 or cm4)
4 4
= =
2 32
Hollow Shaft (in4 or cm4)
(4 4 ) ( 4 4 )
= =
2 32
Maximum Shear Stress (MPa or psi)
Torsion Formulas
Polar Moment of Inertia
Solid Shaft (in4 or cm4)
4 4
= =
2 32
Hollow Shaft (in4 or cm4)
(4 4 ) ( 4 4 )
= =
2 32
Maximum Shear Stress (MPa or psi)
Poissons Ratio
In 1811,Simeon D. Poisson showed that the ratio of the
transverse strain to the axial strain is constant for
stresses within the proportional limit. This constant,
called Poissons ratio, is denoted by (lowercase Greek
nu).

=

 Shear Loading:
The shear strain, which measures the amount
of distortion, is the angle (lowercase Greek
gamma), always expressed in radians.
= =

=
2(1 + )
:
G= shear modulus, modulus of
elasticity of shear, modulus of
rigidity or transverse module
Thin Walled Vessels Torsion Formula

= 2
; =
2 (2 3 )

Considering the thin wall buckling locally before elastic stresses are
exceeded.
3 3
= 2
; =
2 2 3
Torque
Torque
Torque is defined as a twisting force that tends to cause rotational
motion.
Force, Direction, and Separation of Forces Applied

=
:



Power Transmission
=
:
,
, ,
, /

= 2 = 2
:
,
, ,
,
, /
Factor of Safety
There will always be uncertainties in characterizing the magnitude of
applied loads and their associated stress levels for in-service
applications; ordinarily load calculations are only approximate.
Furthermore, virtually all engineering materials exhibit a variability
in their measured mechanical properties.
Consequently, design allowances must be made to protect against
unanticipated failure.
Factor of Safety would indicate by what factor the design is safe.
Design Factor

=

Where:

=

Where:



Design Factor
Design Factor
Selection of N will depend on a number
of factors:
Economics, previous experience, the
accuracy with which mechanical forces
and material properties may be
determined, and, most important, the
consequences of failure in terms of loss
of life and/or property damage.
Factors of Safety Table (Table 1.1 on pg. 20)
Table AT 7 Typical Properties of Wrought
Ferrous Metals pg. 576
Table AT 7 Typical Properties of Wrought
Ferrous Metals pg. 576

Modulus of Elasticity of Wrought Steel

Table AT 7 Typical Properties of Wrought
Ferrous Metals pg. 576

SHEAR STRESS BASED ON YIELD STRENGTH

IN TORSION USE .

= . NORMAL STRESS BASED ON YIELD

STRENGTH IN TORSION USE .
Table AT 7 Typical Properties of Wrought
Ferrous Metals pg. 576
Normal Stress based on
Ultimate
Strength(Compression or
Tension)
Table AT 7 Typical Properties of Wrought
Ferrous Metals pg. 576

Shear Stress based on

Ultimate Strength
Table AT 7 Typical Properties of Wrought
Ferrous Metals pg. 576

Material: C1020 Normalized

Kind of Load: Repeated, one direction
Determine:
Sd based on ultimate strength (Normal Stress)
Ssd based on ultimate strength (Shear Stress)
Sd based on yield strength (Normal Stress)
Ssd based on yield strength (Shear Stress)
Problem 1:
Let the shaft in the figure shown is to
be subjected to a twisting moment by
loads W = 100 lb. at a = 20 in. on each
side. The material is C1030, as rolled,
and a design factor of 4 based on yield
strength should be sufficient (to cover
the loss of strength from cutting the
keyway, too). (a) Determine the shaft
diameter D. (b) If the torsional
deflection is to be limited to 0.2 deg./ft
of length, wil the diameter found be
satisfactory? (c) What is the torsional
stress at a point in. from the axis of
the shaft found in (a).