Machine Design

ME - 211

Dr. Sujeet Kumar Mishra

Department of Mechanical Engineering
Birla Institute of Technology
(In the service of the Nation since 1955
(A Deemed University)
Mesra, Ranchi – 835 215 India

E-mail: [email protected]
Mob: 9431927250
 SYLLABUS (ME – 211 Machine Design)
Module –I
Failure of materials: Principles of Machine Design, standardization, Tolerances, Design against static and fluctuating loads, Theories of failures,
Design of cotter joint and knuckle joint, Fatigue failure, Endurance limit, Notch Sensitivity, Gerber, Soderberg, Goodman, and Modified
Goodman criteria, Design against combined loads.. (8L)

Module –II
Design of threaded, welded, and riveted joints: Threaded joints: Basic types of screw fastening, Bolt of uniform strength, Terminology of screw
threads, Bolt under tension, Welded joints: Butt joints, Fillet joints, Strength of butt and fillet welds. Riveted joints: Types of rivet heads, types of
rivet joints, Strength equations, Efficiency of joint, Caulking and fullering, Eccentrically loaded bolted, riveted and welded joints. (8L)

Module – III
Design of brakes and clutches: Types of Brakes and Clutches, Clutch/Brake selection and specification, Clutch and Brake materials, Disc
Clutches, Shoe, Band and Disk Brakes. (8L)

Module – IV
Design of springs and bearing: Spring configuration, Spring materials, Design of helical compression/extension springs. Bearings, Types of sliding
contact bearings, Bearing materials, Lubricating oils, Petroff’s equation, Mckee’s Investigation, Hydrostatic bearing, Rolling contact bearings .
(8L)

Module –V
Design of Gears: Types of gear, Terminology of gear, standard systems of gear tooth, Force analysis of spur, helical, bevel, and worm gears, Beam
and wear strength of gears, Lewis and Buckingham’s equation, Effective load on spur gear tooth. (8L)

Text Books:
1. Shigley’s Mechanical Engineering Design, by Richard Budynas (Author), Keith Nisbett (Author)
2. Introduction to Machine Design by V. B. Bhandari
3. Machine Design by Khurmi
Reference Books:
1. Machine Design, An Integrated Approach by Robert L. Norton, Second Edition.
2. Machine Design Data Handbook by K. Lingaiah
3. Mechanical Design of Machine Components by Ansel C. Ugural
Threaded Joints
Threaded joint is defined as a separable joint of two or more machine parts that are
held together by means of a threaded fastening such as a bolt and a nut
It is used to hold two or more machine parts together. These parts can be dismantled
if required without any damage to machine parts or fastening, therefore detachable
joints
BOLTED JOINT
A bolted joint subjected to tensile force P is shown in Fig. below. The cross-
section at the core diameter dc is the weakest section. The maximum tensile
stress in the bolt at this cross-section is given by,

The height of the nut h can be determined by equating

the strength of the bolt in tension with the strength in
shear.
strength of the bolt in tension is given by,

The threads of the bolt in contact with the nut are

sheared at the core diameter dc. The shear area is equal
to (∏ dc h), where h is the height of the nut.
The strength of the bolt in shear is given by,

Therefore, for standard coarse threads, the threads are equally strong in
failure by shear and failure by tension, if the height of the nut is
approximately 0.4 times of the nominal diameter of the bolt. The height of
the standard hexagonal nut is (0.8d). Hence, the threads of the bolt in the
Q. An electric motor weighing 10 kN is lifted by means of an eye bolt as
shown in Fig. below. The eye bolt is screwed into the frame of the motor.
The eye bolt has coarse threads. It is made of plain carbon steel 30C8 (Syt =
400 N/mm2) and the factor of safety is 6. Determine the size of the bolt.
ECCENTRICALLY LOADED BOLTED JOINTS IN SHEAR
In structural connections, a group of bolts is frequently employed, as shown
in Fig. 7.15. Let A1, A2, ..., A5 be the cross-sectional areas of the bolts. The
co-ordinates (x1, y1), (x2, y2), ..., (x5, y5) indicate the position of bolt-
centres with respect to the origin. G is the centre of gravity of the group of
bolts. The co-ordinates (x, y) indicate the location of the centre of gravity

Quite often, the centre of gravity is located by

symmetry
An eccentrically loaded bolted
connection is shown in Fig. below. The
eccentricity of the external force P is e
from the centre of gravity. This eccentric
force can be considered as equivalent to
an imaginary force P at the centre of
gravity and a moment (P x e) about the
same point.
This is illustrated in Fig. below. The imaginary force P at the centre of
gravity results in primary shear forces P′1, P′2 , ,..., etc., given by the
following equation,

The primary and secondary shear

forces are added by vector addition
method to get the resultant shear
forces P1, P2, P3, and P4. In this
analysis, it is assumed that the
components connected by the bolts are
Q. The structural connection shown in Fig. below is subjected to an
eccentric force P of 10 kN with an eccentricity of 500 mm from the CG of
the bolts. The centre distance between bolts 1 and 2 is 200 mm, and the
center distance between bolts 1 and 3 is 150 mm. All the bolts are identical.
The bolts are made from plain carbon steel 30C8 (Syt = 400 N/mm2) and
the factor of safety is 2.5. Determine the size of the bolts.
Welded Joints
Welding is the process of joining metallic parts by heating to a suitable temperature with
or without the application of pressure
Welding is an economical & efficient method for obtaining a permanent joint of metallic
parts
There are two distinct applications of welded joints –
Used as a substitute for riveted joint & welded structure as an alternative method for
casting or forging
Advantages of Welded Joints
• Riveted joints require additional cover plates, straps, clip angles & large number which
increase the weight
•Due to elimination of these components, the cost of welded assembly is lower than that
of riveted joints
• Welded assemblies are tight & leak proof as compared with riveted assemblies
• The production time is less for welded assemblies
• When two parts are joined by the riveting method, holes are drilled in the parts to
accommodate the rivets. The holes reduce the cross-section of the members & result in
stress concentration. There is no such problem in welded joints
• The strength of welded joint is high
 Stress Relieving of Welded Joints

Welded joints are subjected to residual stresses due to non-uniform heating of the parts
being joined.
There is always a possibility that localized thermal stresses may result from uneven
heating and cooling during fusion and subsequent cooling. This also results in distortion.
The magnitude of residual stresses cannot be predicted with any degree of certainty

This is the major disadvantages of welded joints

The following two methods can reduce the residual stresses:

• preheating of weld area to retard cooling of the metal in the vicinity of the joint
•stress relieving of weld area by using proper heat treatment such as normalizing &
annealing in temperature range of 550º to 675º
 Classification of Welded joints
Butt Joints: A joint between two components lying approximately in the same plane.
A butt joint connects the ends of the two plates
Lap Joints (Fillet Joint): A joint between two overlapping plates or components

Types of Welded Joint

Types of Butt Joint Types of Fillet Joint

 Strength of Butt Welds
The butt welded joint subjected to tensile force ‘P’ is shown in fig. below.

The average tensile stress in the weld is given by

σt = P/hl
Where,
σt = tensile stress in the weld (N/mm2)
P = tensile force on the plates (N)
h = throat of the butt weld (mm)
l = length of the weld (mm)
The throat of the weld does not include the bulge or reinforcement. The reinforcement is
provided to compensate for flaws in the weld.
Equating the throat of the weld ‘h’ to the plate thickness ‘t’ in the above equation
The strength equation of butt joint can be written as
P = σt t l
Where,
P = tensile force on plates (N)
σt = permissible tensile stress for the weld (N/mm2)
t = thickness of the plate (mm)
If ɳ is the efficiency of the welded joint
Then strength of butt joint can be re-written as
P = σt t l ɳ
 Strength of parallel Lap welds
A parallel lap weld subjected to a tensile force ‘P’ is shown in fig. below

Parallel fillet weld in shear

There are two terms related to the dimensions of the fillet weld viz., leg ‘h’ and throat ‘t’
The size of the weld is specified by the leg length
The cross-section of the fillet weld consists of a right angled triangle having two equal
sides. The length of each of the two equal sides is called a leg. As a rule, the leg length
‘h’ is equal to plate thickness.
The throat is the minimum cross-section of the weld located at 45º to the leg dimension.
Therefore
t = h cos(45º) = 0.707 h
Failure of the fillet weld occurs due to shear along the minimum cross-section at the
throat
It is proved that for parallel fillet weld, the inclination of the plane where maximum shear
stress is induced, is 45º to the leg dimension.
Shear failure of the weld shown in fig.(b)
The cross-sectional area at the throat is ( t l) or (0.707 h l)
The shear stress in the fillet weld is given by
Ʈ = P / 0.707 h l
The strength equation of the parallel fillet weld is written as
P = 0.707 h l Ʈ
Where,
P = tensile force on the plates (N)
h = leg of the weld (mm)
l = length of weld (mm)
Ʈ = permissible shear stress for the weld (N/mm2)
Usually there are two welds of equal length on two sides of the vertical plate, in that case
P = 2 (0.707 h l Ʈ )
= 1.414 h l Ʈ
 Strength of transverse fillet welds
A transverse fillet weld subjected to a tensile force ‘P’ is shown in fig. below

Failure of fillet weld

The transverse fillet welds are subjected to tensile stress.

The minimum cross-section of the weld is at the throat, therefore the failure due to
tensile stress will occur at the throat section. The cross-section area at throat is (t l)
The tensile stress in the transverse fillet is given by
σt = P/t l
= P/0.707 h l
or, P = 0.707 h l σt
Where,
σt = permissible tensile stress for the weld (N/mm2)
Q1. A Plate 100 mm wide and 10 mm thick is welded to another steel plate by means of
double parallel fillet welds as shown in fig. The plates are subjected to a static tensile
force of 50 kN. Determine the required length the welds if the permissible shear stress in
the weld is 94 N/mm2

Q2. Two steel plates 120 mm wide and 12.5 mm thick are joined together by means of
double transverse fillet welds as shown in fig. The maximum tensile stress for the plates
and the welding material should not exceed 110 N/mm2. Find the required length of the
weld, if the strength of the weld is equal to the strength of the plates.

Q3. A plate 100 mm wide and 10 mm thick is joined with another steel plate by means of
single transverse and double parallel fillet welds as shown in fig. The strength of the
welded joint should be equal to the strength of the plates to be joined. The permissible
tensile and shear stresses in the weld material are 70 and 50 N/mm2 respectively. Find
the on the length of each parallel fillet weld. Assume the tensile force acting on the
plates as static.
Riveted Joints
Riveted & Welded joints are permanent joints
Permanent joints are those joints which cannot be disassembled without damaging the
assembled parts
Bolted joints, cotter joints are separable joints, which permit disassembly & reassembly
without damaging the assembled parts
A rivet consists of a cylindrical shank with a head at one end as shown in fig. This head
is formed on the shank by an upsetting process in a machine called an automatic header
The rivet is inserted in the holes of the parts being assembled and the head is firmly held
against the back up bar.
In the riveting process, the protruding end of the shank is upset by hammer blows to
form the closing head.
In rivet terminology, the closing head is called the point
The head, shank and point are three main parts of the rivet

A rivet is specified by the shank diameter of the rivet e.g., a 20 mm rivet means a rivet
having 20 mm as the shank diameter
Riveted Joint
 Types of riveted joints

Riveted joints used for joining the plates are classified into two groups
Lap joint & Butt joint
Lap joint consists of two overlapping plates, which are held together one or more rows of
rivets.
Depending upon the number of rows, the lap joints are further classified into
• single-riveted lap joint
• double-riveted lap joint
• triple riveted lap joint
In double or triple riveted lap joints, the rivets can be arranged in chain pattern or zig-zag
pattern as shown in fig (b) and fig (c) respectively

A chain riveted joint is a joint in which the rivets are arranged in such a way that rivets in
different rows are located opposite to each other.

A zig-zag riveted joint is a joint in which the rivets are arranged in such a way that every
rivet in a row is located in the middle of the two rivets in the adjacent row.
(a) Single riveted lap joint (b) Double riveted chain joint (c) Double riveted zig-zag joint
Types of Single-riveted Butt Joint Types of Double-strap Butt Joint
(a) Single Strap (b) Double Strap (a) Chain pattern (b) Zig-zag pattern
 Terminology of riveted joints

Pitch (p): Distance between the centre of one rivet to the centre of the adjacent rivet in
the same row.
Usually p = 3d where ‘d’ is the shank of the rivet

Margin (m): Distance between the edge of the plate to the centreline of rivets in the
nearest row.
Usually m = 1.5d

Transverse pitch (pt): Also called back pitch or row pitch, is the distance between two
consecutive rows of rivets in the same plate
Usually pt = 0.8p (for chain riveting)
= 0.6p (for zig-zag riveting)

Diagonal pitch (pd): Distance between the centre of one rivet to the centre of adjacent
rivet located in the adjacent row
 Rivet Materials

Rivets used in most of the applications are made of mild steel

There are two varieties of steel rivet bars – hot rolled steel rivet bar and high tensile steel
rivet bar
Their chemical composition is as follows
carbon = 0.23% (max)
sulphur = 0.05% (max)
phosphorus = 0.05% (max)

Rivets used in corrosive atmosphere are made of stainless steel

Rivets used for connecting non ferrous metals and soft materials are made of copper,
brass, bronze and aluminium alloys
 Types of failure in Riveted joints
• shear failure of the rivet
• tensile failure of the plate between two consecutive rivets
• crushing failure of the plate
• shear failure of the plate in the margin area
• tearing of the plate in the margin area
 Strength Equations
(i) Shear strength of rivets:
The strength equation is given as Ps = πd2Ʈ/4

Where,
Ps = shear resistance of rivet per pitch length (N)

d = shank diameter of rivet (mm)

Ʈ = permissible shear stress for rivet material (N/mm2)
In case of double or triple riveted lap joints, there are number of rivets & above equation
can be modified as
Ps = πd2Ʈn / 4 (for single shear)
Where, n = number of rivets per pitch length
For double riveted joint, n = 2
For triple-riveted joint n = 3 and so on……………
In case of double strap single-riveted butt joint, the rivets are subjected to double shear
as shown in fig (b).
The area that resists shear failure is twice the c/s area of the rivet
P = 2 (πd2Ʈn /4) (for double shear)
(ii) Tensile strength of plate between rivets

The tensile resistance of plate between two rivets is given by

Pt = (p - d) t σt
Where,
Pt = tensile resistance of plate per pitch length (N)
p = pitch of rivets (mm)
t = thickness of plate (mm)
σt = permissible tensile stress of plate material (N/mm2)

(iii) Crushing strength of plate

The crushing resistance of the plate is given by
Pc = d t σ c n
Where,
Pc = crushing resistance of plate per pitch length (N)
σc = permissible compressive stress of plate material (N/mm2)
(iv) Efficiency of joint
It is the ratio of the strength of riveted joint to the strength of unriveted solid plate
ɳ = Lowest of Ps, Pt and Pc / P
Where,
P = strength of solid plate of width, equal to the pitch ‘p’ and thickness ‘t’ subjected
to tensile stress σt
Caulking & Fullering
In applications like pressure vessels & boilers, the riveted joint should be leak proof &
fluid tight.
Caulking & fullering processes are used to obtain such leak proof riveted joints. The
caulking process is applied to the edges of plates in a lap joint & the edges of strap plate
in butt joint. These edges are first beveled to approximately 70º to 75º and the caulking
tool is hammered on the edge as shown in fig (a) The caulking is done either by hand
hammer or by the use of pneumatic or hydraulic hammer. The head of the rivet is also
hammered down with the caulking tool.
The blows of caulking tool closes the surface asperities & cracks on the contacting
surfaces between two plates & also between the rivet & the plates, resulting in leak proof
joint.
Fullering is similar to the caulking process except for the shape of the tool. The width of
the fullering tool is equal to the thickness of the plate being hammered.
Q1. A brake band attached to the hinge by means of a riveted joint as shown in fig (a)
Determine the size of the rivets needed for the load of 10 kN. Also, determine the
width of the band. The permissible stresses for the band and rivets in tension, shear
and compression are 80, 60 and 120 N/mm2 respectively. Assume
margin (m) = 1.5 d
transverse pitch (pt) = P
Find the pitch of the rivets Fig (a)

Q2. Two flat plates subjected to a tensile force P are connected together by means of
double-strap butt joint as shown in fig (b) The force P is 250 kN and the width of the
plate w is 200 mm. The rivets and plates are made of the same steel and the
permissible stresses in tension, compression and shear are 70, 100, and 60 N/mm 2
respectively. Calculate
i) The diameter of the rivets
ii) The thickness of the plates
Fig (b)
iii) The dimensions of the seam,
viz., p, pt and m and
There are two types of riveted joints in a cylindrical boiler shell. They are called
longitudinal butt joint & circumferential lap joint. The plate of the boiler shell is
bent to form the ring and the two edges of the plate are joined by a longitudinal butt
joint. This longitudinal joint is usually a double strap triple riveted butt joint.
The circumferential joint is used to get the required length of the boiler shell by
connecting one ring to another. For this purpose, one ring is kept overlapping over
the adjacent ring and the two rings are joined by a circumferential lap joint.
Longitudinal butt joint for Boiler shell
i) Thickness of boiler shell
t = Pt Dt / 2 σt
Where,
t = thickness of cylinder wall (mm)
Pt = internal pressure (N/mm2)
Di = inner diameter of the cylinder (mm)
σt = permissible tensile stress for the cylinder material (N/mm2)
If ɳ is the efficiency of the riveted joint, then
t = Pt Dt / 2 σt ɳ
The wall of the boiler shell is subjected to thinning due to corrosion, which reduces the
useful life of the shell. Provision has to be made by suitable increase in the wall
thickness to compensate for the thinning due to corrosion.
Introducing corrosion allowance (mm)
t = (Pt Dt / 2 σt ɳ) + CA
ii) Diameter of Rivet
d = 6 (t)1/2
iii) Pitch of Rivet
iv) Transverse pitch (Pt)
Pt = 0.33 p + 0.67 d (for zig zag riveting)
Pt = 2 d (for chain riveting)
v) Margin (m)
m = 1.5 d
vi) Thickness of straps (t1)
t1 = 0.75 t (for wide strap)
t1 = 0.625 t (for narrow strap)
P.1: A cylindrical pressure vessel with a 1.5 m inside diameter is subjected to
internal steam pressure of 1.5 MPa. It is made from steel plate by triple-
riveted double-strap longitudinal butt joint with equal straps. The pitch of the
rivets in the outer row is twice of the pitch of the rivets in the inner rows. The
rivets are arranged in a zigzag pattern. The efficiency of the riveted joint
should be at least 80%. The permissible stresses for the plate and rivets in
tension, shear and compression are 80, 60 and 120 N/mm2 respectively.
Assume that the rivet in double shear is 1.875 times stronger than in single
shear. Design the joint and calculate:
(i) thickness of the plate;
(ii) diameter of rivets;
(iii) pitch of rivets;
(iv) distance between the rows of rivets;
(v) margin;
(vi) thickness of the straps; and
(vii) efficiency of the joint.
Draw a neat sketch of the riveted joint
showing calculated values of dimensions.
CIRCUMFERENTIAL LAP JOINT FOR BOILER SHELL
The circumferential lap joint is used to connect different cylindrical rings
together and form the boiler shell. In this case, one ring is kept overlapping
over another ring and the two rings are fastened by circumferential riveted
joint. This type of joint is also used to connect the end cover to the cylindrical
shell. A single-riveted circumferential lap joint for a cylindrical shell is shown
in Fig.
The 8.65.of circumferential lap joint consists
design
of the following steps:
 Circumferential lap joint for boiler shell

Q1. A cylindrical pressure vessel with 1 m inner diameter is subjected to internal steam
pressure of 1.5 MPa. The permissible stresses for the cylinder plate and the rivets in
tension, shear and compression are 80, 60 and 120 N/mm2 respectively. The
efficiency of longitudinal joint can be taken as 80% for the purpose calculating the
plate thickness. The efficiency of circumferential lap joint should be at least 62%.
Design the circumferential lap joint and calculate
i) Thickness of the plate
ii) Diameter of the rivets
iii) Number of rivets
iv) Pitch of rivets
v) Number of rows of rivets and
vi) Overlap of the plates