Machine Design: Useful data and formulae

1. Stress = Force 19. The angle of twist, θ = T L

Area of crosssection G J
where T = torque in the shaft
2. Strain = Change in length
Original length L = length of the shaft
J = polar moment of inertia of shaft cross-section (App
3. Deformation, δ = Force  length 3)
Area  E G = shear modulus of elasticity of the shaft material
E = Modulus of elasticity (App 4)
4.Poisson’s ratio= Lateral strain 20. Bending stress, S = M C
Axial strain I
where M = bending moment acting on the shaft (App
5. Lateral strain = Change in dia
Original dia 2); C = shaft outside radius
I = moment of inertia of the shaft cross-section (App 3)
6. Shear stress = Shear force 21. Shear stress, τ = T C
Shear area J
7. Torque = Power where T = torque being transferred by the shaft; C =
Rotational speed shaft outside radius
8. 1 hp = 550 ft-lb/s J = Polar moment of inertia of the shaft cross-section
(App 3)
9. 1 hp = 746 W
π d4
10. Power = 2 π n T 22. Polar moment of inertia of a solid shaft, J =
60000 32 ,
where T = torque in N-mm π (d 4  D 4 )
n = rotational speed in rpm for a hollow shaft,
32
16 T
11. Shear stress, τ =
23. Moment of inertia of a solid shaft, I = π d where
4

π d3 64 ,
where T = torque being transferred by the shaft d = outside diameter of the shaft
d = diameter of the shaft D = inside diameter of the shaft
12. Stress concentration factor = Max. stress Springs
Average stress F = k (Lf – L0)
Where Lf = full length, L0 = current length
13. Allowable stress = Ultimate stress
Factor of safety Spring rate, k =
F
14. Thermal deformation,  = l  T L
15. Torque, T  C D Fi Spring index, C = Dm
D = nominal diameter of thread Dw
Fi = desired initial preload Dm = mean diameter, Dw = wire diameter
C = torque coefficient (p 119) See Appendix 10 for wire sizes
δ 360 See Table 8.1 for spring formulae
16. Required torque angle =
δ = elongation pitch Allowable stress, Su = ( LF ) Q
17. Secondary shear force in fasteners = ( Dw ) x
P e l1 Q = expected ultimate strength of a 1 inch bar
F1  2 x = factor (see App. 11), LF = loading factor
l1  l22  l32  l42
8 K F Dm
Torsional shear stress, Ss =
where e = eccentricity of load, in  Dw3
P = Acting load, lb
F = force on the spring
l1, l2, l3, l4 = length of bolt from the centroid
18. Horse power = T n Wahl factor, K = (4C 1)  0.615
63,000 (4C  4) C
where T = torque in lb-in
n = rotational speed in rpm
 8 K F Dm N a
3 Nsf = factor of safety (See table 12.2)
Deflection of a spring, δ = Belts
G Dw4 Driving force, Fd = Ff – Fb
G = shear modulus of wire material (Tab. 8.2) Torque, T = (Ff – Fb) r = Fd r
Na = Number of active coils (D2  D1 ) 2
4 2 C  1.57 (D1  D 2 ) 
Length of belt, L =
Spring rate, k = G Dw 4C
8 Dm3 N a B  B2  32 ( D2  D1 ) 2
Centerline distance, C =
Gears 16
Speed ratio, Vr = Do  N o Where, B = 4 L – 6.28 (D2 + D1)
Di N i
 D 2  D1 
Wrap angle, θ = 180  2 sin  
o 1
o = output; i = input;  2C 
D = Pitch diameter; N = number of teeth + for larger pulley
Diameter of base circle, Db = D cos φ
Keys 2T
Radius of base circle, rb = r cos φ L
Ss = shear stress (lb/in2)
r = radius of pitch circle; b D Ss
F = force (lb)
Diametral pitch, Pd = N b = width of the key 4T
D L = length of the key (in) L
Sc t D
D = shaft diameter
Circular pitch, Pc =  D Sc = compressive stress (lb/in2) = Sy
N
t = total height of the key (in.)
Addendum, a = 1 ; Dedendum, b = 1.25 Clutches R R 
Pd Pd Rotating torque, Tf = f N o i 
Clearance, c = b – a Ro = outside radius  2 
Pd  Pc =  Ri = inside radius
Dg  D p Ng  N p Cone clutch
Center to center dist. =  Tf = Ff rm= f N rm Tf 
f rm Fa
2 2 Pd Normal force, N sin α  f cos α
Metric gears (remember units should be mm) Fa = axial force; α = cone angle
1 Shafts 5.1
τ  3 T2  M2   1/2

Module, m =  = Maximum combined shear stress D

Pd S = normal stress from bending or axial loads
Circular pitch, Pc =  m SS = shear or torsional stress
T = Torque in the shaft
Addendum, a = m; Dedendum, b = 1.25 m
M = Maximum moment
T = Torque on gear σ = equivalent combined normal stress
2T
Force on gear, Ft 
Dp σ
5.1
D3

M  (T 2  M 2 )1/2 
π Dp n
Surface speed (Vm) = ft/min

π Dp n
12
D 3 
5.1 2
T  M 2 1/2  D3
5.1
σ

M  (T 2  M 2 )1/2 
m/min τ
1000 1
Critical speed, Nc N c  187.7
Sn Y b δ
Lewis equation Fs 
Pd Bearings
Fs = Allowable dynamic bending force (lb) P = pressure (psi); V = Bearing velocity (ft/min) PV  π F n
Sn = Allowable stress (lb/in2). Use endurance limit and L = bearing length (in); d = shaft diameter (in) 12 L
account for the fillet as the stress concentration factor F = load on shaft (lb); n = speed (rpm)
b = Face width (in.); Y = Lewis form factor (Table k
Ld = desired life; Pd = design load L d  Cd 
Lc = life from the table (manufacturers catalog) L   P 
12.1)
600  Vm 1200  Vm  d
Fd  Ft Fd  Ft Cd = dynamic rating from manufacturer c

600 1200 k = 3 for ball bearings; = 10/3 for roller bearings

78  Vm0.5 50  Vm0.5
Fd  Ft Fd  Ft 1/k k
78 50 L  C 
Cd  Pd  d  Ld  Lc  d 
Fs 8 12.5  Lc   Pd 
 Fd b
N sf Pd Pd