Problem:

Design a bell crank, similar to the one shown, to carry a mild shock load.
The mechanical advantage ( L1 / L2 = F2 / F1 ), the force F1, the length L1, and the
material are given in the accompanying table, a) Make all significant decisions
including tolerances and allowances. One approach could be to compute
dimensions of the yoke connections first: t should a little less than:
a.) An assumption for the shaft may be that, on occasion, the torque for F 1 is
transmitted through the shaft (ignoring bending for local convenience).
b.) Check all dimensions for good proportion; modify as desirable.
c.) Sketch to scale each part, showing all dimensions with tolerances
necessary to manufacture.
REQ: D:
a.
b.
c.
d.

Determine all dimensions including tolerances and allowances.

Check all dimensions for good proportion
Sketch to scale each part.
All dimensions with tolerances and allowances necessary to manufacture

Given Data:
Problem No.
115

SOLUTIONS:

Load
F1
600 lb

L1
20 in

AISI No.
as rolled
C1040

Mech.
Advantage
4

From given data:

Mechanical advantage =

( L1/L2 = F1/F2 ) = 4

L1
4
L2

L2

L1 20

4
4

L2 = 5 in

F2
4
F1

F2 F1 (4) 600( 4)

F2 = 2,400 lb

From Table AT 7 (page 576 text)

For AISI C1040, as rolled
Sy = 50,000 psi
For Design Stresses:
Ss

= 0.5 Sy / N

Ss

= 0.5 ( 50,000 ) / 3

Ss

= 8,333.33 psi

From table 1.1 ( page 20 text )

Design Factor ( Factor of Safety ), for repeated, one direction
N = 3, based on ultimate strength ( Su )

Solving for design stress (St):

St

= Sy / N
= 50,000 psi
3

St

= 16,666.67 psi

For Compression stress (Sc):

Sc

= Sy / N
= 50,000 psi
3

Sc

= 16,666.67 psi

For Shearing stress (Ss):

Sys

= Sys / N
= 30,000 psi
3

Sys

= 10,000 psi

A.) Tension across the circular section of F1 at joint A:

( @ Junction A )

F1

= SdD12
4

D12

F1(4)
Sd

D1

4(600)
(16,666.67)

D1

= 0.214 in ( 1/16 between 3/16 - 7/8 )

For Standard fraction:

3
0.1875
16
0.214 x

16 3.424

16
16
1
4

0.214 0.1875
x100% 12.38% 4 5%
0.214
Use D1 = 1/4 in.
The pin may fail by shearing stress in the rod (double shear):
Solving for pin diameter (d1):

Fig:

Ss

F
A

For area :

d1
x2
4
2

As

Ss

d1

F1
2
d1
2

600(2)
18,333.33

d1 = 0.214 in
For Standard Fraction Use d1 = 1/4 in.
The compressive stress between the pin and the rod:
Fig:

Sc

F
A

A a1d1

F1 Sca1d1

Sc

F1
a1d1

a1

600
(16,666.67)(0.25)

a1 = 0.144 in
For Standard Fraction Use a1 = 5/32 in.

The compressive stress between the pin and the yoke:

Projected area on one side of a yoke is ( bd ) and for two of the yoke (bd ):
Fig:

Sc

F1
F
1
2b1d1 A

Where:
F1
F
1
a1d1 2b1d1

a1 = 2 b 1

b1

F1
2d1Sc

b1

600
2 0.2516,666.67

b1 = 0.072 in
For Standard Fraction Use b1 = 5/64 in.
The rod and the yoke may fail in tension across the hole of the pin:
Fig:

For the Rod:

F1 SdtA

F1 Sd t ( m1 d1 )(a1 )

m1

F1
d1
Sdt (a1 )

m1

600
0.25
16,666.67 5 / 32

m1 = 0.48 in
For Standard Fraction Use m1 = 1/2 in.
For the Yoke:
Fig:

F1 SdtA

F1 Sdt (m1 d1 )(2b1 )

m1

F1
d1
Sdt (2b1 )

m1

600
0.25
16,666.67 (2) 5 / 64

m1 = 0.48 in

Use:

1/2 in

Shearing stress on the lever, solving for thickness ( t 1 ):

Fig:

10

Ss

F1
A

Ss

F1
m1t

t1

F1
Ssm1

t1

600
0.5 8,333.33

A m1t

t1 = 0.144 in
For Standard Fraction Use t1 = 5/32 in.

For the margin of the hole, the pin may tear at the end of rod or yoke:
Fig:

11

F1 = Ss A

F1
Ss( 2a1 )

e1

600
8,333.33 2 5 / 32

= 2a1 e1

e1 = 0.23 in
For Standard Fraction Use e1 = 1/4 in.

B.) FOR ANALYSIS OF JOINT B:

Tension across circular section of F2 @ joint b:
Fig:

12

St

F2
A

For the area:

D2
A
4

D2

4 F2
Sdt ( )

D2

4(2,400)
(16,666.67)( )

D2 = 0.428 in
For Standard fraction: use: D2 = 7/16 in
The pin may fail by shearing stress in the Rod (Double Shear):
Fig:

13

Ss

F2
2A2

As

d 2
2

for area :

Ss

F2
2
d 2
2

d2

2 F2
( Ssd )

d2

2,400(2)
(8,333.33)

d2 = 0.428 in
For Standard Fraction Use d2 = 7/16 in.
The compressive stress between the pin and the rod:
Fig:

14

a2

F2
Sc(d 2 )

a2

2,400
16,666.67 7 / 16

a2 = 0.329 in
For Standard fraction:

1/16 between 3/16 7/8

5
0.313in
16

0.329 x

16 5.264

16
16
3
8

0.329 0.313
x100% 4.86% 4 5%
0.329
Use a2 = 5/16 or 3/8 in.
The compressive stress between the pin and the yoke projected on the
two side of the yoke ( A = 2 bd ):
Fig:

15

Sc

F2
F
2
2b2 d 2
A

b2

F2
2d 2 Sc

b2

2,400
2 0.437516,666.67

b2 = 0.165 in
For Standard Fraction Use b2 = 3/16 in.
The rod and the yoke may fail in tension across the hole of the pin:
Fig:

16

F = SA
F = St ( m - d2 ) a2
For the Rod:
m2

F2
d2
Sta2

m2

2,400
0.4375
16,666.67 0.375

m2 = 0.821 in
For Standard Fraction Use m2 = 13/16 in.
For the Yoke:
m2

F2
d2
St 2b2

m2

2,400
0.4375
16,666.67 0.1875 (2)

m2 = 0.821 in
For Standard Fraction Use m2 = 13/16 in.
For Shearing stress on the lever, solving for thickness ( t 2 ):
Fig:

17

Ss

F2
mt2

For the area: A2

A2 = m2 t2

t2

F2
Ssd (m2 )

t2

2,400
0.8125 8,333.33

t2 = 0.354 in
For Standard Fraction Use t2 = 3/8 in.
Solving for the margin of the hole, the pin may tear at the end of rod or
yoke:
Fig:

18

a = 2 a2 e2
F2 = Ss 2a2 e2

e2

F2
Ss 2a2

e2

2,400
8,333.33 0.375 2

e2 = 0.384 in

For Standard Fraction Use e1 = 3/8 in.

C.) ANALYSIS AT JOINT C:

The shaft is subjected to torsional stress:

For the Torque:

T 1 = F 1 x L1
T1 = 600 x 20

19

T1 = 12,000 psi
Solving for shaft diameter ( Ds):

Fig:

From Table 9.1 ( Page 279, Text )

Using minor shafts ;

d2

ks = 1.0

2,400(2)
(8,333.33)

Ds 3

16(1.0)(12,000)
(8,333.33)

Ds = 1.943 in
For Standard Fraction Use Ds = 1 7/8 in.
Solving for hub Diameter ( Dh ): page388
Dh = 1.8 Ds
Dh = 1.8 ( 1 7/8 in )
Dh = 3.375 in
For Standard Fraction Use Dh = 3 1/4 in.

20

FOR THE KEY DIMENSION:

From Table AT 19, ( Page 594, Text )
Ds = 1 7/8 in
Range:
1 13/16 - 2 1/4

b = 1/2

t = 3/8

Tolerance on b = - 0.0025 in
For the size of the Key ( L ):

SsbLDs
2

2T
SsbDs

2(12,000)
(8,333.33)(1 / 2)(1.875)

L = 3.07

SctLDs
4

4(12,000)
(16,666.67)(3 / 8)(1.875)

L = 4.096 in for compression

21

Therefore: use L = 4.096 in, with 1/2 x 3/8 in cross section

For the Length of the hub (Lh):

From Chapter 10, of the Text on page 283 (Typical hub length fail between 1.25
to 2.4 Ds, where D is the shaft diameter:
Lh = 2.4 Ds
Lh = 2.4 ( 1.875 )
Lh = 4.5 in

TOLERANCE AND ALLOWANCES:

For the Yoke at section A & B connection use loose running fit (Rc-9)
At Yoke C:
Ds = 1 7/8 in = 1.875 in
From table 3.1, page 83 (Tolerance and allowances)
Nominal size:

Hole

Shaft

1.19 - 1.97

+ 6.0

- 8.0

22

x 10 -3
0

- 12.0

Hole tolerance: 0.006 - 0.0000 = 0.006 in

Shaft tolerance: - 0.008 - (- 0.012) = 0.004 in
Allowance: 0.000 - (- 0.008) = 0.008 in
FOR THE HOLE:
Hole = Nominal size + Hole tolerance
- 0.0000
Hole = 1.875 + 0.006
- 0.000
FOR THE SHAFT:
Shaft = ( 1.875 - 0.008 ) + 0.0000
- 0.004
Shaft = 1.867 + 0.000
- 0.004
For the yoke at Joint B:
d2 = 7/16 in = 0.4375 in
From Table 3.1 ( Tolerance and Allowances )
Class Rc 9
Nominal size:

Hole

Shaft

23

0.40 - 0.71

Hole Tolerance:

+ 4.0

- 6.0

- 8.8

= 0.004 in

Shaft Tolerance: - 0.0060 - ( -0.0088 ) = 0.0028 in

Allowance: 0.000 - ( -0.006 )

= 0.006 in

FOR DIMENSIONING:
FOR THE HOLE:
Hole = 0.4375 + 0.0040 in
- 0.000
FOR THE PIN AND SHAFT:
Shaft = 0.4315 - 0.0028
+ 0.000
AT YOKE A:
d1 = 1/4 in = 0.25 in
Nominal size range = 0.24 - 0.40
From Table 3.1 ( Tolerance and Allowances )
Class Rc 6
Nominal size:

Hole

Shaft

0.24 - 0.40

+ 3.5

- 5.0

- 7.2

24

Hole Tolerance: = 0.0035 in

Shaft Tolerance: = 0.0022 in
Allowances: = 0.005 in
DIMENSIONING:
FOR THE HOLE:
Hole:

0.25 + 0.0035
- 0.000

FOR THE SHAFT:

Shaft: 0.245 + 0.000

- 0.0022

SUMMARY OF COMPUTED AND ADJUSTED VALUES

Parts

L1
D1
d1

Computed values
Computed values Adjusted values
( inches )
( mm )
( mm )
20
1/4
1/4

508
6.35
6.35

508
7
7

25

a1
b1
m1
t1
e1
L2
D2
d2
a2
b2
m2
t2
e2
Ds
Dh

5/32
5/64
1/2
1/8
1/4
5
7/16
7/16
3/8
3/16
13/16
3/8
3/8
1 7/8
3 1/4

3.969
1.984
12.7
3.175
6.35
127
11.11
11.11
9.525
4.763
20.638
9.525
9.525
47.625
82.55

4
2
13
4
7
127
12
12
10
5
21
10
10
48
83

GLOSSARY

Allowance - it is the difference in size, which in running fits is the maximum specified
difference between the dimensions of the pin and the hole.

Allowable Stress - the stress used in design for a safe one to use for computations if
failure is not occur.
Compress - flattened from side to side.
Cotter - A key of wedge, used to fasten parts of machinery together, as a wheel on its
shaft.

26

Design Factor - is a number that is divided into a criterion of strength in order to obtain
a design criteria.
Ductility

- is that property that permits permanent deformation before fracture on

tension.

Design stress (Working stress) - it is a design, used in such a way all criteria of strength
are modified.
Machine design - which involve the calculation of the forces acting on different part of
the machines.
Stress - the state of an elastic body under conditions of strain expressed quantity as force
applied per unit area.
Shear - a deformation within a body on which two adjacent planes tend to move in a
parallel direction relative to one another while remaining parallel.
Tension - a force tending to cause extension of a body, or the shape of an extended
elastic object.
Tolerance - it is the stated permissible variation of the size of a dimension.
Strength of material - it is the capacity to resist the action or applied forces.
Ultimate strength or tensile strength - the highest point on the stress strain curves, is the
maximum load divided by the original before straining occurs.
Yield strength - is the stress for a specified deviation from the straight part of the stress strain curve.

B I B LI O G R APH Y

Doughtie,Venton Levy, Design of Machine Members, 4th Edition, New York:

Mcgraw-Hill Book Company, Inc. 1964.

27

Faires,Virgil Moring, Design of machine Elements, 4th Edition, New York:

Mcmillan Publishing Company, Inc. 1965.

Clark, Donalds, Engineering Materials and Processes , 3rd

Edition, International Textbook Company, Pennsy Lvania, C 1967.

Parker, Sybil P., McGraw-Hill Dictionary of Engineering , 3rd Edition,

McGraw-Hill Book Company, New York, C 1984.

Faires, Virgil Moring, Design of Machine Elements , 4th Edition, The

Macmillan Company, New York, C 1969.