1.

Simple stresses : normal and shear stress and strain

P DL s PL
s = ,e = ,E = =
L L e ADL
P
t = , t = Gj
A

crushing stress bearing pressure

p P
sc = Pb =
d .t.n l.d
thermal stress impact stress

s th =� .t .E si =
w
A
[1 + 1 +
2hAE
WL
]

2.Torsional and Bending stresses

p
T = .t. d 3
16
p d 4 -d4
T = t[
0 i
]
16 d 0

s 1 + s2 1
s =
t1,2 � [s1 - s2] 2 + 4t 2
2 2
1
t =max s 2 + 4t 21
2
s yt 2
(s ) 2 + (s ) 2 + 2us s = [
t1 t2 ] t1 t2
F.s

1
 3.Variable stresses in machine parts:
s e ' = K sur.K rK. tK i.s eb = K bK sur.K rK. tK i.s e
s e ' = K sur.K rK. tK i.s ea = K aK sur.K rK. tK i.s e
s e ' = K sur.K rK. tK i.t es = K bK sur.K rK. tK i.t e

Kf-1
q=
K t- 1
1 sm s vK f
= [ ] 2 F.s+
F.s su se
1 sm s vK f
= +
F.s s u s eK surK sz
1 s mK f s vK f
= +
F.s su s eK surK sz
1 s m s vK f
= +
F.s s y s eK surK sz
4. Riveted Joints:
R t = [ P - d ] . t .s t
p
R s = n . . d2 . t
4
R c = n.d.t.s c

2
 5.Welded Joints:

a. circular fillet weld subjected to torsion

2T 2.83T
t= t max =
p .t.d 2 p .s.d 2
b. circular fillet weld subjected to bending moment :
4M 5.66 M
sb= s bmax =
p .t.d 2 p .s.d 2
c. long fillet weld subjected to torsion :
3T 4.242T
t= 2 t max =
t.L s.L2
d. tensile strength of butt joint
R = t.L.s t

6.Screwed Joints :

Tensile stress due to stretching of bolts : R i = 2840 d (N) R i = 1420 d (N)

a. Torsional shear stress caused by frictional resistance of thread due to
16T
Tightening: t =
p .(dc)3
R
b. Shear stress across the thread : t s =
p .dc.b.n
c. Crushing stress on thread
R
sc=
p [ d - dc 2 ] n
2

p
d. Tensile stress due to external forces : R = [ dc ] 2 .s t
4
e. Shear stress due to external forces :
p 2
R s = d .t. n
4

3
 T =Pb .d2 .l .n . (D1/2)

W( L/2+5mm)
s = M/z =
p /32 (d1)3

7.Keys and couplings :

a. Design of muff and key :

Frictional force between shaft and muff p2

F = µ [db] 2 .s t.n
8

Torque transmitted by coupling p2

T= µ [db] 2 .s t.n.d
8
b. Design for flange coupling:
p D 4 -d 4
Hub design T= .t c. [ ]
16 D
p D2
Flange design T = .t c. tf
2
D1
Bolt design T = n .d1. tf .s cb
2
Checking for crushing
D1
T = n .d1. tf .s cb
2
c. Design for Flexible coupling:
w
t =
Direct shear stress due to pure torsion p
(d1) 2
4
Torque transmitted by coupling
T = 2 .( p / 4 ) .(dp) 2 .t1. d
Bending Stress
W( L/2+5mm)
s = M/z =
p /32 (d1)3

4
d. Design for universal coupling:
T = 2 .( p / 4 ) .(dp) 2 .t1. d

8.Shafts :

16
t max = M 2 +T 2
T e= M 2 +T 2
Me = ½[M + M 2 +T 2
]
pd 3
s b(max) = ½s b+½ s b 2 + 4t 2
32
s b(max) = +½[M + M 2 +T 2
]
pd 3

considering fluctuating loads

T e = ( kmM) 2 + (kT)
t
2
Me = ½[kmM +Te]

considering axial load in addition to combined torsion and bending loads

32M1 F.d
s1 = M1 =M+
pd 3 8
considering torsional rigidity

T .L p
q = J = d4
J .G 32 for solid shafts ,but for hollow shafts
p
J = [ d 0 4 - di 4 ]
32

considering lateral rigidity: d2y M

=
dx 2 EI

5
9.Power Screws:
d
Torque required to overcome friction between screw and nut T1 = W tan( a + j)
2
Torque required to overcome friction at collar

T2 =
2
.u.W [
( R1)3 - ( R 2)3
]
considering uniform pressure
3 ( R1) 2 - ( R 2) 2

R1 + R 2
T2 = u.W.[ ] considering uniform wear
2
Total torque required T=T1+T2=P1.L
tan a
Efficiency h = tan(a + j )

10.Flat belt drives :

42.6
**Coefficient of friction between belt and pulley m = 0.54 -
152.6 + v

** Slip of belt between driver and belt(s1),belt and driven(s2)

N 2 d1 s1 s2
= [1 - - ]
N1 d 2 100 100
( r1 + r 2) (r1 + r 2) 2
** Length of belt : L = p (r1 + r 2) + 2 (r1 + r 2) + 2 x -
x x
T1 T1
** Relation of belt tensions : = e mq 2.3 log [ ] = mq
T2 T2

11. V-belt and Ropes:

T1
2.3 log [] = mq cosec q
T2
Total power transmitted
number of V-belts = power transmitted per belt

12. Chain Drives :

Pitch P=D sin (1800/T)

Velocity ratio V.R=N1/N2=T2/T1
Length of chain L=K.P K=(T1+T2)/2 +2X/P +[ (T2-T1) /2p ]2P/X

6
 T1 + T 2 2 T 2 - T1 2
X=P/4[K-(T1+T2)/2+ [ K - ] - 8[ ] ]
2 2p

Power transmitted by chain

P=(WB x V) / n x Ks
Where WB breaking load in Newtons
Ks Service factor

13. Springs:

8W .D
Torsional shear stress t1 =
pd3

4W
Direct shear stress t2 =
pd2
8W .D
Total shear stress t = t1 �t2 = ks
p d3
16.W .D 2 .n
Angular deflection of wire : q =
G.d 4

8.W .C 3 .n
Axial deflection of wire d =
G.d
W G.d
Stiffness of spring or spring rate =
d 8.C 3 .n
t2
Energy Stored in helical springs of circular cross section U = .V
4.k 2G
Design of helical spring subjected to fatigue loading :

1 t m- t v 2t y
= +
F .S ty te
8.Wm.D
t m = ks
pd3
8.Wv.D
tm=k
pd3

7
14.Clutch:

 Total frictional torque acting on the friction surface or on clutch:

2 r13 - r2 3 2
Considering uniform pressure:T = .m.W.[ ] = .m.W.R
3 r1 - r2
2 2
3
r1 +r2
Considering uniform wear :T = m.W.[ ] = m.W.R
2
On all friction surfaces :T = n.m.W.R
 For multiple disc clutch : n = n +n -1.......T = n.m.W.R
1 2

 For Cone clutch:

1.Total axial load transmitted to the clutch or the axial spring
W = p .Pn.[ r 12 - r 2 2 ]
2.Friction force Fr = m.dWn = mP .2p .rdr cos ec a
n

3.Friction Torque T r =Frx r = mP .2p .rdr cos ec a . r

n

2 r1 3 - r2 3
uniform pressure T = m.W.cos ec a. [ 2 ]
3 r1 - r2 2
r1 +r2
uniform wear T = m.W.cos ec a [ ]
2
 For Centrifugal Clutch:
T = m. [Pc - Ps].R.n Pc = mw 2 r1
Ps = m(w1) 2 r1

15.Brakes:

Heat generated E = H g = m.R.A.V J /S or Watt

Heat dissipated Hd =C(t1 - t2).Ar

4m sin q
Equivalent coefficient of friction m, =
2.q + sin 2q
Total breaking torque : T B = m.R1.b.r ( cos q1 - cos q2)
2

Moment of normal force : MN =½.P1.b.r.oo1.[( q1 - q2) + ( sin2q1 - sin2q2)]

oo1
Moment of friction force: Mf = m.P1.b.r [ r(cosq1 - cosq2) + ( cos2q2 - cos2q1)]
4

16. Rolling Contact Bearing :

8
Basic static load rating : Co =fo.i.Z.D 2 .cos a
Static equivalent load : WoR = XoWR +YoWA
Basic dynamic load rating : C =fc.(i.cos a )0.7 z 2/3 .D1.8
Dynamic equivalent load : WR = X.V.WR +Y.WA
C k
Rating life : L = [ ] .106
W
Rolling contact bearing subjected to variable loads:
n1(W1)3 +n2(W2)3 +n3(W3)3 +..... 3
W =[ ]
n1+n2 +n3 +.......

L1(W1)3 +L2(W2)3 +L3(W3)3 +..... 3

=[ ]
L1+L2 +L3 +.......

17. Spur Gears :

WT = s w.b.m.p .y s O = s w.CV
21V.(b.c +WT)
WD =WT +Wi =WT +
21V + b.c +WT
Ws = s e.b.m.p .y
( s eS) 2 sin j 1 1
Ww =Dp.b.Q.K K= [ + ]
1.4 E p EG
WT
WN =
cos j

18.Helical Gears :
WT = s o.CV.b.m.p .y ,
21V.(b.c.cos 2a +WT).cos a
WD =WT +Wi =WT +
21V + b.c.cos 2a +WT
Ws = s e.b.m.p .y ,
( s eS) 2 sin j 1 1
Ww = [ Dp.b.Q.K ] / cos 2a K= [ + ]
1.4 E p EG
1.15p m T
b= TE = PN =Pc cos a
tana cos 3a

19. Bevel Gears :

9
 L- b DG 2 DP 2
WT = s o.CV.b.m.p .y ,.[ ] L= ( ) +( )
L 2 2
21V.(b.c +WT)
WD =WT +Wi =WT +
21V + b.c +WT
Ww = [ Dp.b.Q.K ] / cosqR1
2TEG
Q=
TEG +TEP
NG NP
q1 = Tan-1 [ ] q2 = Tan -1 [ ]
NP NG

20. Worm Gears:

m.n
WT = s o.CV.b.m.p .y tan l =
Dw
WT
WD = P N = R a.cos l LN = L.cos l
CV
Ws = s e.b.m.p .y
Ww =DG.b.K
L.Nw p .DG.NG
Vw = VG =
60 60

Power lost in friction: Qg =P(1- h )

Heat Dissipated : Qd = A.(t2 - t1).K

2T WT WA
WT = WA = WR =
Dw Tan l Tan F
Dw +DG X 1 1 V .R
X= = [ + ]
2 LN 2p Sin l COS l
V.R =cot3 l

10
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