MACHINE DESIGN 1 (MD 1)

Prepared by: Engr. Rodel T. Naval

FORMULAS AND EXERCISES

MODULE 1: V1

Machine Elements
1. Cylinders Rolling in opposite direction:
A. Tangential speed V1 = V2 =  D1 N1 =  D2 N2 V2
B. Relation of diameter and speed D1 N1 = D2 N2
Speed of Driver
C. Speed Ratio =
Speed of the Driven
D1  D2
D. Center Distance = R1  R 2 
2
2. Cylinders Rolling in the same direction V2
A. Tangential speed V1 = V2 =  D1 N1 =  D2 N2
B. Relation of diameter and speed D1 N1 = D2 N2
Speed of Driver
C. Speed Ratio =
Speed of the Driven
V1
D2  D1
D. Center Distance = R 2  R1 
2

Stresses
1. Stress (S) = a total resistance that a material offers to an applied load, lb/in2 , kg/cm2 , KN/m2
2. Ultimate stress (Su ) - is the stress that would cause failure
3. Yield stress(Sy) - maximum stress without causing deformation
4. Allowable stress(Sall) = Ultimate stress/Factor of Safety
S Sy
5. Design stress(Sd) - stress used in determining the size of a member. Sd = u or Sd =
FS FS
where: FS = factor of safety
F  2
1. Tensile Stress (St) St = t For solid circular cross-section: A = D
A 4

For hollow circular cross-section: A = (Do 2  Di2 )
4
For rectangular cross-section: A = base x height = b x h
Fc
2. Compressive Stress(Sc)Sc =
A
3. Shearing Stress(Ss)
F
A. For single bolt of rivet needed to join to plates together. Ss =
A
where: For single rivet: A = /4 D2 D
For double riveted joint: A = 2(π/4 D2) F
B. Shearing due to punching of hole. F
F
S= where A =  D t (for punching a hole) A = 4 S t (for square hole)
A
Where: S = length of side of square t = plate thickness
C. Pressure needed to punch a hole, F: F = d x t x 80, tons
Where: d = hole diameter, in t = thickness, in
4. Bearing Stress(Sb) Sb = Fb /A where: A = DL

5. Factor of safety(FS) a. Based on yield strength FS = Sy / Sall

b. Based on ultimate strength FS = Su / Sall

6. Torsional Shear Stress(Ss) F

Projected Area

D
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

where: J = polar moment of inertia = π D4 /32 (for solid shaft)

T = torque c = distance from neutral axis to the farthest fiber
c = r (for circular cross section) d = diameter
Mc 6M
7. Bending Stress(Sf) Sf = For rectangular beam Sf =
I b h2
where: M = moment
c = distance of farthest fiber from neutral axis
I = moment of inertia about the neutral axis
I = bh3/12 (for rectangular cross section)
I M
Z = section modulus = 
c Sf
Y F Stress FL FL
8. Strain and Elongation Strain = Stress = E = = Y =
L A Strain AY AE
where: y = elongation due to applied load L = original length
F = force A = area S = stress
9. Thermal Elongation; Stresses D
y
y = k L (t2 - t1) S = E = k E (t2 - t1) L
L
where: k = coefficient of thermal expansion, m/m-C
For steel k = 6.5 x 10-6 in/in-F = 11.7 x 10-6 m/m-C
E = 30 x 106 psi
Y
Relation between shearing and tensile stress based on theory of failure:
Stmax = Sty Ssmax = S ty / 2
10. Variable Stress
1 S S
 m  a where: FS = factor of safety
FS S y Sn
Sy = yield point Sn = endurance limit
Smax  Smin S  Smin
Sm = mean stress = Sa = variable component stress = max
2 2
Smax = maximum stress Smin = minimum stress
11. Poisson’s Ratio(u) = is the ratio of lateral unit deformation to axial unit deformation.
E F
u = 1 where: G = shear modulus of elasticity   strain 
2G AE

Lateral Strain y  L 2  L1 w 2  w1 t 2  t1
u= =  z x  y  z 
Longitudin al Strain x x L1 w1 t1
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

MODULE 2: MOTOR Machine Shaft

1. Shaft - is a rotating member that is used to transmit power. Main Shaft

2. Axle - a stationary member carrying rotating wheels, pulleys. Counter Shaft
3. Line shaft - transmission shaft driven by prime mover.
4. Machine shaft - shaft which is an integral part of the machine.
5. Counter shaft - transmission shaft intermediate between the line
shaft and the driven machine.
6. Spindles - is a short axles and shafts.
7. Transmission shaft - is a shaft used to transmit power between
the source and the machines absorbing the power, and include
countershafts, line shafts, head shafts, and all factory shafting. Driven Machine 1
Driven Machine 2

Formulas:

1. Power Formula in SI unit:

P = 2  T N where: P = power, KW T = torque, KN-m N = speed, rps
2TN
P = where: P = power, Hp T = torque, ft-lb N = speed, rpm
33,000

2. Torque, T T = FxR
where: F = applied force R = radius = D/2

3. Stresses in shaft when subjected to pure torsion(Ss)

Tc 16T 16 TD o
A. For solid shaft: Ss =  B. For hollow shaft: Ss =
J D 3 (Do 4  Di 4 )
C. For designed shearing stress and compressive stress with given Sy and Su.
SHEARING: Ss = 0.18 Su, Ss = 0.3 Sy COMPRESSIVE: Sc = 0.36 Su Sc = 0.6 Sy
Note: Choose whichever is smaller
where:
Do = outside diameter Di = inside diameter J = polar moment of inertia
c = is the distance of the farthest fiber from neutral axis T = torque
d = diameter of shaft
4. Torsional deflection(), rad
TL
 = , rad where: L = length of shaft
JG
d4 (Do 4  Di 4 )
J = polar moment of inertia = (for solid shaft) J = (for hollow)
32 32
G = modulus of rigidity in shear = 11.5 x 106 psi for steel

FROM MACHINERIES HANDBOOK

584 T L
A. For solid shaft: Θ = , deg
D4 G
584 T L
B. Using ALCORCON’S FORMULA for hollow shaft: Θ = , deg
(D o 4  Di 4 ) G

F
5. Stress in shaft when subjected to Torsion and Bending loads:

a. For solid shaft:

16
Ss = (K mM)2  (K t T )2
d3
16  
St = K M  (K mM)2  (K t T )2 
3  m
Note: Km and Kt not known, assume 1.0
d  
where: T = torqueM = moment Ss = maximum shear stress
St = maximum tensile or compressive stress
b. For hollow shaft:
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

16Do 16Do  2 2
Ss = (K mM)2  (K t T )2 St = KmM  (KmM)  (K t T ) 
4
(Do  Di )4
(Do4  Di4 )

6. Strength of shaft with assumed allowable stresses (PSME Code p. 18)

D3N
a. For Main Shafts: (S = 4000 psi) P =
80
D3N
b. For Line Shafts: (S = 6000 psi) P =
53 .5
D3N
c. For short shafts: (S = 8500 psi) P =
38
where: P = power, Hp N = speed, rpm D = diameter, inch

7. From Machineries Handbook Formula

A. Shaft diameter for 0.08 degrees per foot of length of shaft deflection.
4 P
For English units: D = 0.29 T or D = 4.6 4
N
Where: D = diameter, in T = torque, in-lb P = horsepower
N = speed, rpm
4 P
For SI units: D = 2.26 T or D = 125.70 4
N
Where: D = diameter, mm P = power, watts N = speed, rpm
T = torque, N-mm
3 P
B. Shaft deflection of 1 degree for a length of 20 times its diameter. D = 0.10 T or D = 4.0 3
N
Where: P = power, hp D = diameter, in N = speed, rpm T = torque, in-lb
C. Linear deflection of shafting
3
a. Shafting subjected to no bending action of pulleys except its own weight L = 8.95 D2
3
b. Shafting subjected to bending action of pulleys, etc L = 5.2 D2
Where: L = shaft length, ft D = shaft diameter, in
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

MODULE 3:
KEYS - a machine member employed at the interface of a pair of mating male and female circular cross-sectional
members to prevent relative angular motion between these mating members.
Types of keys: 1. square key 2. flat key 3. round key Pulley

4. barth key 5. woodruff key 6. gib-head key 7. saddle key

Shaft
8. kennedy key 9. feather key
Key

FORMULAS

1. Power of key: P = 2 T N, KW
T T
2. Force transmitted, F F =  where: d = shaft diameter
r d/ 2
Fc
3. Compressive Stress (Sc) of key Sc =
(h / 2 )L /2
Fs
4. Shearing Stress (Ss) of key Ss =
wL
F
where: L = length of key w = width of key h = height of key L
5. Relation of key and shaft for the same material:
D
w = L = 1.2 D
4 Compressive area
6. Force tangent to pulley rim T = T’ F . r = F’ . R Shear Area
F’
7. Ff = force tends to remove key from
the hub and shaft = 2 f F F R
F = force tangent to the key T’
T
F’ = force tangent to pulley rim
L
R = radius of pulley
F
W

7. SPLINE SHAFT
Is recommended when the power transmitted is too high that three keys is not enough.
1. Types of Fits

Types of 6 Splines 4 Splines 10 Splines

Fits
Permanent d = 0.9D d = 0.85D d = 0.91D
Fit w = 0.25D w = 0.241D w = 0.156D Id D
h = 0.05D h = 0.075D h = 0.045D
Iw
To slide d = 0.85D d = 0.75D d = 0.86D
when not w = 0.25D w = 0.24D w = 0.156D
under load h = 0.075D h = 0.125D h = 0.07D
To slide d = 0.80D d = 0.81D
when w = 0.25D w = 0.156D
under load h = 0.10D h = 0.095D
In
Where: d = minor diameter, in or mm
D = major diameter, in or mm
r = radius, in or mm = d/2; R = D/2 R w
Ir Rm
= width, in or mm
L = length of spline Id
r R Iw
Ih
2. Rm = mean radius =
2
Note:
If L is not given use the recommended, L = 1.5 D, L
from Vallance, Machine Design Flange
T
3. Calculations for safe dimensions of splines: F

3.1 Based on shearing of splines

Dc

Shaft
Bolt
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

F F
Ss  
A s Ns w L
d 2T
Since Ts = F  or F 
2 d
3.2 Based on Compression between splines and hub.
F F
Sc  
A c h L Ns T
NS = number of splines Ac = compressive area
r R r R Fb
Tc  F Rm = F( ) or F = 2Tc / ( )
2 2
F = compressive force
16 Tt Dc
3.3. Based on Torsion of splined Shaft Ss 
 d3
Tt
Note: For torque capacity, T for one spline is: T (1.1)
Ns
This recommendation is based by shearing one spline only.
Shear Area

FLANGE COUPLING
1. Coupling - is a mechanical device which is used to
Flange
connect length of shafts permanently.
FORMULAS

1. Power transmitted: P = 2  T N , KW

T T
2. Total force transmitted, (F) F =  Dc
r Dc / 2
F
3. Force transmitted per bolt, (Fb) Fb =
n
where: n = no. of bolts Dc = bolt circle diameter
Fb Compressed Area
4. Shearing of bolts(Ss) Ss =
 2
d
4
5. Compressive stress on bolts and flange(Sc)
F
Sc = b where:
td
t = thickness of flange d = bolt diameter

KEYS AND SPLINES PROBLEMS

1. A flat key is to be designed for 100 mm diameter shaft which will transmit 200 kW at
300 rpm. If the allowable shearing stress is 300 MPa and key width is 10 mm, determine
the length of key.
a. 42.44 mm b. 44.24 mm c. 44.24 in d.
42.44 in
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

2. A 101.6 mm diameter shafting SAE 1040 grade, cold rolled, having a yield point of 60
ksi and 2/3 x 8/10 x 5 inches key. Compute the minimum yield point in the key in order
to transmit the torque of the shaft. The factor of safety is 2.
a. 92.45 kPa b. 92.45 ksi c. 94.25 ksi d.
94.25 kPa

3. A 15/16 in. wide key has depth of 5/8 in. It is 12 inches long and is to be used on a
200 hp, 1160 rpm, squirrel-cage induction motor. The shaft diameter of 3 7/8 inches.
The maximum running torque is 200% of the full-load torque. Compute the maximum
torque.
a. 23,117 in-lb b. 21,733 in-lb c. 23,117 N-m d.
21,733 N-m

4. A 2 in diameter 6-spline shaft ( d= 0.85D, W= 0.25D, h= 0.075D ) and to slide when

not under load has a compressive force of 2500 lbs. Find the torque applied if hub
length is 2 1/2 in.
a. 2132.5 in-lb b. 2321.5 N-m c. 2312.5 N-m d. 2312.5 in-
lb

5. A 10-spline shaft ( d= 0.91D, w= 0.156D, h= 0.045D ) and permanent fit has a

diameter of 70 mm. Find the shearing stress if shearing force is 2000 lbs. Hub length is
120 mm.
a. 97.48 psi b. 97.48 kPa c. 98.47 kPa d.
98.47 psi

6. A 100 mm diameter 4-spline shaft ( d= 0.75D, w= 0.24D, h= 0.125D ) and to slide

when not under load has a compressive force of 2100 lbs. Find the compressive stress
if the hub length is 3 1/2 inches.
a. 304.8 psi b. 308.4 psi c. 304.8 kPa d.
403.8 psi

7. A 1 in height x 6 in length flat keyed to a 5 inches diameter shaft. Determine the

torque in the key if bearing stress allowable is 30 ksi.
a. 220,000 in-lb b. 225,000 in-lb c. 222,000 N-m d. 225,000
N-m

8. A 2.5 in diameter 10 spline shaft ( d= 0.86D, w= 0.156D, h= 0.07D ) to slide when not
under load has a compressive force of 2500 lb. Find the torque applied if hub length is 1
1/2 in.
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

a. 2609.25 in-lb b. 2609.25 N-m c. 2906.25 in-lb d. 2906.25

N-m

9. A 5 in diameter 4 splines shaft ( d= 0.85D, w= 0.24D, h= 0.075D ) and permanent fit

has a compressive force of 3000 lb. Find the compressive stress if hub length is 2 1/2 in.
a. 700 psi b. 700 kPa c. 800 kPa d. 800
psi

10. A 6 spline shaft (d= 0.80D, w= 0.25D, h= 0.10D) and to slide when under load has a
diameter of 4 in. Find the shearing stress if shearing force is 5000 lbs, if hub length is 1
in.
a. 260.42 psi b. 833.33 psi c. 2083.33 psi d.
3906.25 psi
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

MODULE 4:
Wah

Dm
Arm

Hub Wr

Shaft Rim
Flywheel - a rotating energy reservoir which absorbs energy from a power source during a portion of the operating
cycle and delivers that stored energy as useful work during the other portion of the cycle.
Flywheel applications:
1. Punch press 2. Shears 3. Internal combustion engines 4. Compressors
5. Reciprocating pumps 6. Steam engines

FORMULAS

1. Kinetic energy released by the flywheel(KE).

2
W C Wv
KE = ( v12  v 2 2 ) = f
2g g
where: Dm
v1 = maximum speed =  D N1
v2 = minimum speed =  D N2
W = total weight of the flywheel
g = acceleration due to gravity = 9.81 m/sec2
v = average velocity
Cf = coefficient of fluctuation

2. Total weight of Flywheel(W)

W = Wr + Wah
where:
Wr = weight of the flywheel rim
Wah = weight of arm an the hub

3. Weight of the flywheel rim (Wr)

Wr = V x w
Wr = ( D b t)(w)

where: b = width of the flywheel rim

t = thickness of flywheel rim
w = density of flywheel material
For cast iron: w = 7200 kg/m3
4. Energy required to punch a metal(E)

E = 1/2 F tp E = 1/2(Ssu x A)tp

For circular hole: E = E = 1/2(Ssu x A)tp
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

where:
A = shearing area
A =  d tp (for circular hole)
F = average force needed to punch a hole
Ssu = ultimate shear stress
tp = thickness of the plate
d = hole diameter
Dm = mean diameter of flywheel

5. Power needed to punch a hole(P)

Energy
P =
Time needed to punch a hole

6. Kinetic energy released by the flywheel = Energy needed to punch a hole

W
1/2(Ssu x A)tp = ( v12  v 2 2 )
2g
7. Coefficient of fluctuation(Cf)

v1  v 2
Cf 
v

v1  v 2
where: v
2

2( v1  v 2 ) 2(N1  N2 )
Cf  
v1  v 2 N1  N2
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

MODULE 5:
PRESSURE VESSEL
Thin wall pressure vessel
If the ratio of wall thickness to the inside diameter (t / Di) is less than 0.07, then the cylinder is
considered as thin-wall.
A. For Cylindrical Pressure Vessel
PDi
1. St = tangential stress or hoop stress S
2t
PDi
2. SL = longitudinal stress SL =
4t
P Di PDi
3. If efficiency of joint is considered: S t  SL = where: Di
2te 4t e
e = joint efficiency Di = inside diameter S = tangential stress
t = thickness of the wall Di = Do - 2t Do = outside diameter
4. For a cylindrical vessel filled with fluid:
P = maximum pressure at the bottom = w h = (SG x w) h

B. For Spherical Pressure Vessel

PDi
1. If efficiency of joint is not considered: S P
4t
P Di
2. If efficiency of joint is considered: S Di
4t e
3. Di = Do - 2t

where: e = joint efficiency P

Thick wall pressure vessel

If the ratio of t/Di is greater than 0.07, then the vessel is considered as
thick-wall. Di
Do
D  S  Pi 
Using Lame’s equation for internal pressure: t   t  1
2  S t  Pi 
where: t = wall thickness D = inside diameter St = tangential stress Pi = internal pressure
Vessel is subjected to an internal and external pressures.
Pi (ro 2  ri2 )  2Poro 2 Po
For Maximum Internal Stress: S ti 
ro 2  ri2
2Piri2  Po (ro 2  ri2 ) Pi
For Maximum External Stress: S to 
ro 2  ri2
where: Sti = maximum internal tangential stress
Sto = maximum external tangential stress Pi = internal pressure
i
Po = external pressure ro = outside radius ri = inside radius
O
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval

SPRING
Tabulated Data of springs: ( p = pitch)
Types of coil end Actual no. of coil Solid Length Free Length
Plain N (n + 1)d np + d
Ground N Nd np
Squared n+2 (n + 3) d np + 3d
Squared & Ground n+2 (n + 2) d np + 2d
8KFDm
1. Stress of coil spring(Ss) Ss =
d3
4C  1 0.615
2. Stress factor(K) or Wahl Factor: K =  FL
4C  4 C
Dm CL
3. Spring Index (C) C = SL
d
Where: Dm = Do – d Dm = Di + d
8FC3n Dm
4. Deflection(y) y =
Gd
where: F = axial load Dm = mean diameter
Di
d = wire diameter n = no. of active or effective coils
G = modulus of rigidity Do
5. Deflection at solid force(ys) ys = Free length - Solid
length
F2  F1
6. Spring rate(K) K = F/y = F1 / y1 = F2 / y2 = constant =
y 2  y1
7. Impact load on spring:
F F F
W(h + y) = y Fave  Energy  W (h  y )  y W
2 2 2
where: F = maximum force acting on the spring
y = deflection on spring W = weight of the object
h = height of the object Fave = average force
8. For series connected spring: Y F
y = total elongation = y1 + y2 + y3
F F F
y = 1  2  3 K1
K K2 K3
F = total load = F1 = F2 = F3 = K y
9. For parallel connected spring: K2
y = total elongation = y1 = y2 = y3
F F F
y = 1  2  3
K K2 K3 K3
F = F1 + F2 + F3 = k1y1  k 2 y 2  k 3 y 3
11. Leaf spring: F

18FL 2 6FL 12 F L3
A. Sf = 2
B. Sg = Sf C. Smax  2
D. y = 3
where: Sf =
bt ( 2ng  3nf ) 3 bt (ng  nf ) bt E ( 2ng  3nf )
flexural stress F = load at the supports
L = distance of force to produce maximum moments b = width of plates
t = thickness of plates ng = no. of graduated leaves nf = no. of full length leaves
y = deflection of spring E = modulus of elasticity = 30 x 106 psi for steel
MACHINE DESIGN 1 (MD 1)
Prepared by: Engr. Rodel T. Naval