Point of maximum stress

Internal Loadings

Basic stress formulae

 AXIAL

 BENDING

 TORSION + POLAR MOMENT OF INERTIA (SOLID/TUBE SHAFT) Shear and bending moment

 TRANSVERSE (MAX IN CIRCULAR/RECTANGULAR BEAMS)

Plane stress positive convention In-plane principal stress (max/min normal stress)

Plane stress transformation equation

Max in-plane shear stress

Mohr’s circle
Failure theories Shaft – static loading
 TRESCA

 VON MISES(PLANAR)

 VON MISES(GENERAL)

 MAX NORMAL STRESS

𝜎1 ≥ 𝑈𝑇𝑆 Shaft – minimum diameter

Safety Factor
𝜎𝑦 Tresca
𝑆𝐹 =
𝜎𝑒𝑥𝑝𝑜𝑠𝑒𝑑

Von Mises
Generalized fatigue strength (106 𝑐𝑦𝑐𝑙𝑒𝑠) Mean and alternating stress
 SHAFT

Goodman diagram
 GEAR

Endurance limit (𝑠𝑛′ )

𝑆𝑛′ = 0.5𝑆𝑢 (𝑈𝑇𝑆)
Alternating stress limit
3
Generalized fatigue strength (10 𝑐𝑦𝑐𝑙𝑒𝑠) 𝑆𝑛 1
𝑆𝑎 = × , 𝑛 𝑖𝑠 𝑠𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟
 SHAFT 𝑛 (1 + 𝜎𝑚 𝑆𝑛 )
𝜎𝑎 𝑆𝑢
𝑆𝑓 = 0.9𝑆𝑢 𝐶𝑇 (𝑏𝑒𝑛𝑑)
𝑆𝑓 = 0.75𝑆𝑢 𝐶𝑇 (𝑎𝑥𝑖𝑎𝑙)
𝑆𝑓 = 0.9𝑆𝑢𝑠 𝐶𝑇 (𝑏𝑒𝑛𝑑), 𝑆𝑢𝑠 𝑖𝑠 𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
Shaft deflection Shaft angular deflection

Shaft critical speed

Superposition
Bearing safety factors Fit tolerances
 PV 1. Look at alphabet
𝑃𝑉𝑙𝑖𝑚𝑖𝑡 2. 𝑒𝑠 /𝑒𝑖 (𝑒𝑠 always above Fundamental Deviation, 𝑒𝑖
𝑆𝐹 = below)
𝑃𝑉𝑙𝑜𝑎𝑑𝑖𝑛𝑔
3. International Tolerance (IT), + if 𝑒𝑠 , - if 𝑒𝑖
 DN
𝐷𝑁𝑙𝑖𝑚𝑖𝑡
𝑆𝐹 = , 𝑑 𝑖𝑠 𝑖𝑛 𝑚𝑚 𝑎𝑛𝑑 𝑁 𝑖𝑛 𝑟𝑝𝑚
𝐷𝑁𝑙𝑜𝑎𝑑𝑖𝑛𝑔

Rad to rev conversion

1
𝑟𝑎𝑑 × = 𝑟𝑒𝑣
2𝜋

Bearing Life

Fit allowances

L in terms of revolutions

Rated capacity
Or
𝐴𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 = 𝐿𝑜𝑜𝑠𝑒𝑠𝑡 − 𝑇𝑖𝑔ℎ𝑡𝑒𝑠𝑡 (ℎ𝑜𝑙𝑒 − 𝑠ℎ𝑎𝑓𝑡)

Fit classes
 RUNNING FIT (BOTH +VE)
 CLEARANCE FIT (LOWER BOUND IS ZERO )
 TRANSITION FIT (MIX OF +VE AND -VE)
 INTERFERENCE (BOTH -VE)
Gear trains Diametral pitch/module
 IDEAL
𝑃𝑖𝑛 = 𝑇𝜔 = 𝑃𝑜𝑢𝑡

Gear kinematics law (No slip condition)

Speed ratio (link 𝑤 to N)

Gear torque law Mechanical advantage (link T, 𝑤, N)

Involute gear forces Planetary gear fundamental equation

Train ratio

Functional schematic

Gear tooth stress

Gear train fatigue Gear safety factor

 DRIVING/DRIVEN GEAR  DRIVING/DRIVEN GEAR

 IDLER GEAR  IDLER GEAR

For Kms
1.0 for idler gears (two way bending)
1.4 for input/output gears (one way bending)

Bearing Reliability Factor

Fasteners Fastener Failure Analysis
Von Mises Criteria → 𝜏𝑦 = 0.58𝑆𝑦
𝜋
𝑃 = 𝐴𝑡 𝑆𝑦 = 4
(0.9𝑑)2 𝑆𝑦 𝑉 = 𝐴𝑠 𝜏𝑦 = 𝜋𝑑(0.75𝑡)𝜏𝑦

𝑉 = 𝐴𝑠 𝜏𝑦 = 𝜋𝑑(0.75𝑡)0.58𝑆𝑦

Bolt Tensile Failure

𝑃
𝜎 = 𝐴 > 𝑆𝑦 Given P=V → 𝑡 > 0.47𝑑
𝑡

Thread Stripping Failure

𝑉
𝜏= 𝐴𝑠
> 𝜏𝑦 Given P=V → 𝑡 < 0.47𝑑

Thread Stress Number of Threads

1 𝑡ℎ𝑟𝑒𝑎𝑑
Bearing (Compressive) Stress × (0.47 × 𝑆𝑖𝑧𝑒)
𝑃 𝜋(𝑑 2 −𝑑𝑖2 ) 𝑡 𝐿𝑒𝑛𝑔𝑡ℎ
𝜎= 𝑤ℎ𝑒𝑟𝑒 𝐴𝑝 =
𝐴𝑝 4 𝑝
Static Bolted Joint Failure – Sheer Type
4𝑉 16𝑇
𝜏𝑚𝑎𝑥 = 3𝐴 = 3𝜋𝑑2 where d = dr

Shear (Stripping) Stress Static Bolted Joint Failure – Tensile Type

𝑉 𝐹𝑏 = 𝐾𝑖 𝐴𝑡 𝑆𝑝 + 𝑓1 (𝐹𝑒 )= 𝐾𝑖 𝐴𝑡 𝑆𝑝 +
𝑘𝑏
(𝐹 ) =𝐾𝑖 𝐴𝑡 𝑆𝑝 +
𝑘𝑏
(𝐹 )
𝜏= 𝑤ℎ𝑒𝑟𝑒 𝐴𝑠 = 𝜋𝑑(0.75𝑡) 𝑘𝑒𝑞 𝑒 𝑘𝑏 +𝑘𝑐 𝑒
𝐴𝑠
𝑘 𝑘𝑏
𝐹𝑐 = 𝐾𝑖 𝐴𝑡 𝑆𝑝 − 𝑓1 (𝐹𝑒 )= 𝐾𝑖 𝐴𝑡 𝑆𝑝 − 𝑘 𝑏 (𝐹𝑒 ) =𝐾𝑖 𝐴𝑡 𝑆𝑝 − 𝑘 (𝐹𝑒 )
Bolt Stress 𝑒𝑞 𝑏 +𝑘𝑐

𝑇𝑅 16𝑇
Torsion: 𝜏 = = where d = dr Ki is a constant based on loading condition
𝐽 𝜋𝑑 3

𝐹  K = 1 for Dynamic Loading

Axial: 𝜎 = 𝐴 |
𝑡  K = 0.9 for Static Loading
 K = 0.75 for Reused
At is the tensile stress area of fasteners
Sp is the proof strength of the material
Effective Clamping Area

Bolt Fatigue Analysis Procedure

𝑆𝑎 𝐹𝑖
𝑆𝐹 = 𝜎𝑖 =
𝜎𝑎 𝐴𝑡

Link Types (Kinematic Diagram)

Linkage Mobility
𝐷𝑒𝑔𝑟𝑒𝑒 𝑜𝑓 𝐹𝑟𝑒𝑒𝑑𝑜𝑚 = 3𝑛 − 2𝑗 − 3
n = number of links
Cycloidal Rise and Return
j = number of revolute/prismatic joints
When n links are connected together at a particular
joint, the number of joints at that connection is n-1

Grashof Condition

Cam Follower
Simple harmonic Motion

Β is defined as the phase change of the Rise or fall and is independent of

previous phase
4R Linkage Analysis Solving Loop Equations
Constraint Equation

Kinematics of Linkages

Loop Equation
Cam Dynamics
Spring index C

Cam Profile (Knife Follower) Spring end conditions

𝑐𝑜𝑠𝛼(𝑦𝑖 , 𝜃𝑖 )
𝐴⃗𝑖 = 𝑅(𝑦𝑖 , 𝜃𝑖 ) [ ]
𝑠𝑖𝑛𝛼(𝑦𝑖 , 𝜃𝑖 )
𝑅(𝑦𝑖 , 𝜃𝑖 ) = 𝑦 + 𝑏 where b is radius of the base circle

𝛼(𝑦𝑖 , 𝜃𝑖 ) = 𝜃

Cam Profile (Flat-Faced Follower)

𝑅(𝑦𝑖 , 𝜃𝑖 ) = √(𝑓′(𝜃)2 + (𝑓(𝜃) + 𝑏)2 )

𝑓′(𝜃)
𝛼(𝑦𝑖 , 𝜃𝑖 ) = 𝑡𝑎𝑛−1 ( )+ 𝜃
𝑓(𝜃) + 𝑏

N=𝑁𝑡 N=𝑁𝑡 − 1 N=𝑁𝑡 − 2 N=𝑁𝑡 − 2

Solid and clash deflection

 Spring potential energy (conservation with GPE)
Spring lengths

Spring shear stress (Static)

Spring shear stress (Dynamic)

Spring setting
Spring deflection
Avoid no more than 2% from creep

To accept around 2% setting from creep

Spring force/ rate K

, ,
Number of active coils N
Spring materials Stress correction factor (get 𝑘𝑤 and C from 𝑘𝑤 𝐶)
Spring diameter – UTS relation
Buckling analysis

Surge analysis
 To avoid surge, choose natural frequency 𝑓𝑛 > 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑓

Helical extension springs

 Buckling occurs for conditions above and to right of curves

Spring fatigue
Disk clutch (Uniform pressure and wear) Inner and outer radius

Disk clutch (Uniform wear rate)

,

, Actual clutches employ 2N friction

interface to increase torque transmission capacity
Disk brake Drum brake (Long)

Drum brake (overheating)