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Machine Element and Design I

1. A machine part experiences different types of loads including dead loads that do not change, live loads that change continually, shock loads that are suddenly applied or removed, and impact loads that are applied with initial velocity. 2. Stress is the internal force per unit area that resists external forces on a body. It is calculated as stress = force/area and is measured in units of pascals or megapascals. 3. Strain is the deformation per unit length of a body under stress. It is calculated as strain = change in length/original length. Hooke's law states that within the elastic limit, stress is directly proportional to strain.

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Emmanuel Matutu
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30 views

Machine Element and Design I

1. A machine part experiences different types of loads including dead loads that do not change, live loads that change continually, shock loads that are suddenly applied or removed, and impact loads that are applied with initial velocity. 2. Stress is the internal force per unit area that resists external forces on a body. It is calculated as stress = force/area and is measured in units of pascals or megapascals. 3. Strain is the deformation per unit length of a body under stress. It is calculated as strain = change in length/original length. Hooke's law states that within the elastic limit, stress is directly proportional to strain.

Uploaded by

Emmanuel Matutu
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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MACHINE ELEMENT AND DESIGN I

INTRODUCTION AND BASIC CONCEPTS

MWAKYONYA, MICHAEL

Mbeya University of Science and Technology


Fundamental of design are: Emphasis, Balance and

Alignment, Contrast, Repetition, Proportion,

Movement and White Space. Design differs from art

in that it has to have a purpose. Visually, this

functionality is interpreted by making sure an image

has a center of attention, a point of focus.


Design is a plan to make something.

“Design is a plan for arranging elements in

such a way as best to accomplish a

particular purpose”.
Machine Elements was traditionally seen as basic

mechanical parts, mostly used as the building blocks

in the design of machines. Most of the classical

elements such as shafts, bearings, gears, couplings,

fasteners, springs, seals, belts, clutches, brakes and

chains are standardized to common sizes.


Machine Design is the creation of new and better

machines and improving the existing ones. A new or

better machine is one which is more economical in the

overall cost of production and operation.


Classifications of Machine Design
The machine design may be classified as follows :
1. Adaptive design. In most cases, the designer’s work is concerned
with adaptation of existing
designs. This type of design needs no special knowledge or skill and
can be attempted by designers of ordinary technical training. The
designer only makes minor alternation or modification in the existing
designs of the product.
2. Development design. This type of design needs considerable
scientific training and design
ability in order to modify the existing designs into a new idea by
adopting a new material or different method of manufacture. In this
case, though the designer starts from the existing design, but the final
product may differ quite markedly from the original product.
3. New design. This type of design needs lot of research, technical
ability and creative thinking.
Only those designers who have personal qualities of a sufficiently
high order can take up the work of a new design.
Method used to design depend on the following classification
(a) Rational design. This type of design depends upon mathematical

formulae of principle of mechanics.


(b) Empirical design. This type of design depends upon empirical
formulae based on the practice and past experience.
(c) Industrial design. This type of design depends upon the production
aspects to manufacture any machine component in the industry.
(d) Optimum design. It is the best design for the given objective function
under the specified constraints. It may be achieved by minimising the
undesirable effects.
(e) System design. It is the design of any complex mechanical system like
a motor car.
(f) Element design. It is the design of any element of
the mechanical system like piston, crankshaft,
connecting rod, etc.
(g) Computer aided design. This type of design
depends upon the use of computer systems to assist in
the creation, modification, analysis and optimisation
of a design.
STEADY STRESSES AND VARIABLE STRESSES IN
MACHINE MEMBERS
Load

 It is defined as any external force acting upon a


machine part. The following four types of the load are
important from the subject point of vie

Dead or steady load. A load is said to be a dead or steady


load, when it does not change in magnitude or direction.

Live or variable load. A load is said to be a live or


variable load, when it changes continually.
Suddenly applied or shock loads. A load is said to

be a suddenly applied or shock load, when it is

suddenly applied or removed.

Impact load. A load is said to be an impact load,

when it is applied with some initial velocity.


Stress
When some external system of forces or loads acts on a body, the
internal forces (equal and opposite) are set up at various sections of the
body, which resist the external forces. This internal force per unit area
at any section of the body is known as unit stress or simply a stress. It
is denoted by a Greek letter sigma (σ).

Mathematically,

Stress, σ = P/A

Where P = Force or load acting on a body, and A = Cross-


sectional area of the body.
Strain
When a system of forces or loads acts on a body, it
undergoes some deformation. This deformation per
unit length is known as unit strain or simply
a strain. It is denoted by a Greek letter epsilon (ε).

 Mathematically,

Strain, ε = δl / l or δl = ε.l where δl = Change in


length of the body, and
 Tensile Stress and Strain
When a body is subjected to two equal and
opposite axial pulls P (also called tensile
load) as shown in Fig. (a), then the stress
induced at any section of the body is known
as tensile stress as shown in Fig. (b). A
little consideration will show that due to the
There will be a decrease in cross-sectional
area and an increase in length of the body.
The ratio of the increase in length to the
original length is known as tensile strain.
Let    P = Axial tensile force acting on the body,

A = Cross-sectional area of the body,

l = Original length, and

δl = Increase in length.

Tensile stress, σt = P/A


Tensile strain,εt = δl / l
Compressive stress, σc = P/A

Compressive strain, εc = δl /l


Young's Modulus or Modulus of Elasticity
Hooke's law states that when a material is loaded
within elastic limit, the stress is directly proportional
to strain, i.e.

∝ ε
      

= E.ε
      

E = σ / ε

= P l / (A×δ l)
Where E is a constant of proportionality known
as Young's modulus or modulus of elasticity. In
S.I. units, it is usually expressed in GPa i.e.
GN/m  or kN/mm . It may be noted that Hooke's law
2 2

holds good for tension as well as compression.


Shear Stress and Strain

When a body is subjected to two equal and opposite

forces acting tangentially across the resisting section,

as a result of which the body tends to shear off the

section, then the stress induced is called shear stress.


The corresponding strain is known as shear strain and it is measured

by the angular deformation accompanying the shear stress. The shear

stress and shear strain are denoted by the Greek letters tau (τ) and phi

(φ) respectively. Mathematically,

Shear stress, τ =Tangential force / Resisting area


Consider a body consisting of two plates connected by a rivet as shown in Fig. (a). In

this case, the tangential force P tends to shear off the rivet at one cross-section as

shown in Fig.(b). It may be noted that when the tangential force is resisted by one

cross-section of the rivet (or when shearing takes place at one cross-section of the

rivet), then the rivets are said to be in single shear. In such a case, the area resisting

the shear off the rivet,

A = (π/4) × d2

and shear stress on the rivet cross-section,


limit, the shear stress is directly proportional to shear
strain. Mathematically
        ∝ φ

        =C.φ

      /φ=C

where

τ = Shear stress,

φ = Shear strain, and

C = Constant of proportionality, known as shear modulus or


modulus of rigidity. It is also denoted by N or G.
Working Stress

When designing machine parts, it is desirable

to keep the stress lower than the maximum or

ultimate stress at which failure of the material

takes place. This stress is known as

the working stress
 

Factor of Safety
It is defined, in general, as the ratio of the maximum stress to the working stress.

Mathematically,

Factor of safety = Maximum stress / Working or design stress

In case of ductile materials e.g. mild steel, where the yield point is clearly defined,

the factor of safety is based upon the yield point stress. In such cases,

Factor of safety = Yield point stress / Working or design stress

In case of brittle materials e.g. cast iron, the yield point is not well
defined as for ductile materials. Therefore, the factor of safety for
brittle materials is based on ultimate stress.
Factor of safety = Ultimate stress / Working or design stress

This relation may also be used for ductile materials


 

Poisson's Ratio
It has been found experimentally that when a body is stressed within
elastic limit, the lateral strain bears a constant ratio to the linear strain,
Mathematically,
 

Lateral strain / Linear strain = Constant

This constant is known as Poisson's ratio and is denoted by 1/m or µ.


Bulk Modulus
When a body is subjected to three mutually perpendicular
stresses, of equal intensity, then the ratio of the direct
stress to the corresponding volumetric strain is known
as bulk modulus. It is usually denoted by K.
Mathematically, bulk modulus,
 

K = Direct stress / Volumetric strain


Relation Between Bulk Modulus and Young’s
Modulus
The bulk modulus (K) and Young's modulus (E) are related by the following relation,

E= 3K (1 - 2 µ)

Relation Between Young’s Modulus and Modulus


of Rigidity
The Young's modulus (E) and modulus of rigidity (G) are related by the following
relation,

E= 2G (1 + µ)
3. Suddenly applied or shock loads. A load is said
to be a suddenly applied or shock load, when it is
suddenly applied or removed.
4. Impact load. A load is said to be an impact load,
when it is applied with some initial velocity.
Note: A machine part resists a dead load more
easily than a live load and a live load more easily
than a shock load.
Stress
When some external system of forces or loads act on a body, the internal
forces (equal and opposite) are set up at various sections of the body,
which resist the external forces. This internal force per unit area at any
section of the body is known as unit stress or simply a stress. It is
denoted by a Greek letter sigma (σ).
Mathematically,
Stress, σ = P/A
where P = Force or load acting on a body, and
A = Cross-sectional area of the body.
In S.I. units, the stress is usually expressed in Pascal (Pa) such that 1 Pa
= 1 N/m2. In actual
practice, we use bigger units of stress i.e. megapascal (MPa) and
gigapascal (GPa), such that
1 MPa = 1 × 106 N/m2 = 1 N/mm2
and 1 GPa = 1 × 109 N/m2 = 1 kN
Strain
When a system of forces or loads act on a body, it undergoes
some deformation. This deformation per unit length is known
as unit strain or simply a strain. It is denoted by a Greek letter
epsilon (ε).
Mathematically,
Strain, ε = δl / l or δl = ε.l
where δl = Change in length of the body, and
l = Original length of the body.
Tensile Stress and Strain

When a body is subjected to two equal and opposite axial pulls


P (also called tensile load) as shown in Fig. 4.1 (a), then the
stress induced at any section of the body is known as tensile
stress as shown in Fig. 4.1 (b). A little consideration will show
that due to the tensile load, there will be a decrease in cross-
sectional area and an increase in length of the body. The ratio
of the increase in length to the original length is known as
tensile strain.
STEADY STRESSES AND VARIABLE STRESSES IN
MACHINE MEMBERS
 

Load
 
It is defined as any external force acting upon a machine part. The following four types
of the load are important from the subject point of view:
 
Dead or steady load. A load is said to be a dead or steady load, when it does not change
      

in magnitude or direction.
 
Live or variable load.A load is said to be a live or variable load, when it changes
      

continually.
 
Suddenly applied or shock loads. A load is said to be a suddenly applied or shock load,
      

when it is suddenly applied or removed.


 
Impact load. A load is said to be an impact load, when it is applied with some initial velocity.
      

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