Design of Machine Elements by Graphical Methods

for Engineers and Machine Builders

Majid Yaghoubi

E-mail: ma.yaghoub@gmail.com

Tel.: +98 912 881 11 94

Persian Publication
This work is subject to copyright. All rights are solely and exclusively
licensed, whether the whole or part of the material is concerned, specifically,
the rights of translation, reprinting, reuse of illustrations, recitation,
broadcasting, reproduction on microfilms or in any other physical way, and
transmission or information storage and retrieval, electronic adaptation,
computer software, or by similar or dissimilar methodology now known or
hereafter developed.
Preface

Mechanical design of machine components requires performing calculations

using formulas, which is usually a sophisticated and time-consuming
procedure. This book aims to provide students, engineers in mechanical
engineering and related disciplines, practicing engineers, technicians and
manufacturers and machine builders with an easy-to-use reference;
which is based on using graphs instead of the formulas for designing
common machine elements. It is assumed that the user has had basic
knowledge in Mechanics, Strength of Materials, and Materials Properties.

The contents are based on the basic methods used in mechanical engineering
design that have been modified by the author, as well as several years of
practical experiences of the author in designing and manufacturing machine
elements and mechanisms, in academia and industry.

In this book, all graphs are drawn based on the latest formulas and
experimental and laboratory data that cannot be found in any book.
However, out of respect for some authors, we put their names on some
graphs that you may not be able to find the formulas by referring to the
relevant book.

It should be noted that the correctness of all diagrams has been checked
by the computer.

The book is composed of 24 self-contained chapters, and 109 examples

covering design of various machine elements such as joints, bolts, power
screws, shafts, keys, splines, couplings, belt drives, chain drives, gear drives,
rolling bearings, and the like. In general, the chapters are structured into four
sections, namely, Introduction, Design method(s), Equations, and
References. In some of the chapters, Supplementary material is also

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included.

The Introduction gives a brief overview about the element(s). The Design
method(s) section introduces the graphical method(s). The procedure of
applying the method(s) are explained through several examples. Since the
aim is to use graphs instead of sophisticated formulas, we put all the related
equations at the end of each chapter, for those readers who are interested.

In this book all of graphs were checked by computer.

A special characteristic of this book is, proposing a simple, rapid and novel
method for a rough design of some of the elements based on the shaft size.
We refer to this method as M.Y method. The method is very useful for the
maintenance and repair engineers. They can quickly find solutions for
replacing parts by applying the method.

All the graphs have been created using the DESMOS software.

The International System of Units (SI) is used in this book.

In spite of efforts of the author for writing and preparing the contents of the
book in a very careful manner, errors are unavoidable. Therefore, any
suggestions and feedbacks that can help us to improve the book are warmly
welcomed.

Majid Yaghoubi

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Acknowledgement

The author would like to warmly thank the companies Autodesk Inc.,
DAIDO KOGYO CO. (DID), Parker corp., Renold plc., and SKF Group,
and the publishers Springer, Carl Hanser Verlag, Wiley, Infra-Engineering,
Academy for giving free permissions for reusing some content provided by
them.

Special thanks are also due to the developers of the DESMOS software.

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Contents
Preface .......................................................................................................... i
Acknowledgement .....................................................................................iii
About the author .....................................................................................xiii
1 Torque ................................................................................................. 1
1.1 Introduction ................................................................................... 1
1.2 Design method ............................................................................... 1
1.3 Equations for engineers ................................................................. 3
2 Hertzian contact stress ....................................................................... 4
2.1 Introduction ................................................................................... 4
2.2 Design method ............................................................................... 5
2.2.1 Line contact ............................................................................ 5
2.2.2 Point contact (New) ............................................................... 8
2.3 Equations for engineers ............................................................... 11
3 Press-Connect Joints ........................................................................ 12
3.1 Introduction ................................................................................. 12
3.2 Design methods ........................................................................... 13
3.2.1 Estimation of the minimum interference (∆min).................... 13
3.2.2 Estimation of the maximum interference (∆max) .................. 16
3.2.3 Standard interference ............................................................ 19
3.2.4 Heating elements for the assembly....................................... 21
3.2.5 M.Y method ......................................................................... 22
3.2.6 Equations for engineers ........................................................ 25
4 Welded joints .................................................................................... 27
4.1 Introduction ................................................................................. 27
4.2 Design methods ........................................................................... 28
4.2.1 Axial loading ........................................................................ 29
4.2.2 Bending loading ................................................................... 32

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 4.2.3 Torsional loading (welded shaft).......................................... 39
4.2.4 M.Y method(New) ............................................................... 42
4.2.5 Combined loading ................................................................ 44
4.3 Equations for engineers ............................................................... 46
5 Bolts ................................................................................................... 47
5.1 Introduction ................................................................................. 47
5.2 Design methods ........................................................................... 48
5.2.1 Method I ............................................................................... 48
5.2.2 Method II .............................................................................. 54
5.2.3 Method III (M.Y method) .................................................... 64
5.2.4 Bolt size of gear reducers(New) ........................................... 66
5.2.5 Wrench size and rule of thumb(New) .................................. 67
5.3 Equations for engineers ............................................................... 69
6 Power screws ..................................................................................... 71
6.1 Introduction ................................................................................. 72
6.2 Design methods ........................................................................... 73
6.2.1 Sliding screws ...................................................................... 73
6.2.2 Method II (M.Y method) ...................................................... 80
6.2.3 Ball screws (New) ................................................................ 84
6.3 Equations for engineers ............................................................... 90
7 Shafts ................................................................................................. 92
7.1 Introduction ................................................................................. 92
7.2 Design methods ........................................................................... 93
7.2.1 Rough estimation (M.Y method) ......................................... 94
7.2.2 Precise design for engineers (checking) ............................... 99
7.3 Polygonal shafts ......................................................................... 106
7.4 Changing shaft material (New).................................................. 107
7.5 Equations for engineers ............................................................. 109

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8 Rectangular keys ............................................................................ 110
8.1 Introduction ............................................................................... 110
8.2 Design methods ......................................................................... 110
8.2.1 Method I ............................................................................. 111
8.2.2 Method II ............................................................................ 114
8.2.3 Method III (M.Y method) .................................................. 116
8.3 Supplementary material ............................................................. 118
8.4 Equations for engineers ............................................................. 119
9 Splines .............................................................................................. 120
9.1 Introduction ............................................................................... 120
9.2 Design method ........................................................................... 121
9.3 Equations for engineers ............................................................. 128
10 Conical joints .................................................................................. 129
10.1 Introduction ............................................................................... 129
10.2 Design methods ......................................................................... 130
10.2.1 Method I ............................................................................. 130
10.2.2 Method II ............................................................................ 133
10.3 Equations for engineers ............................................................. 136
11 Couplings......................................................................................... 137
11.1 Introduction ............................................................................... 137
11.2 Design method ........................................................................... 138
12 Flanged couplings ........................................................................... 141
12.1 Introduction ............................................................................... 141
12.2 Design methods ......................................................................... 142
12.2.1 Method I ............................................................................. 142
12.2.2 Method II (M.Y method) .................................................... 147
12.3 Equations for engineers ............................................................. 148
13 Universal joints ............................................................................... 149

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 13.1 Introduction ............................................................................... 149
13.2 Design methods ......................................................................... 150
13.2.1 Relationship between torque and U-joint width ................. 150
13.2.2 Estimation of the bearing life ............................................. 152
13.3 CV joints .................................................................................... 153
13.4 Equations for engineers ............................................................. 155
14 Pin Joints ......................................................................................... 156
14.1 Introduction ............................................................................... 157
14.2 Design methods ......................................................................... 158
14.2.1 General method .................................................................. 158
14.2.2 M.Y method (New) ............................................................ 167
14.2.3 Clevis joint ......................................................................... 169
14.2.4 Dowel pin ........................................................................... 181
14.3 Equations for engineers ............................................................. 191
15 Shafts and their associated elements all togetherError! Bookmark
not defined.
15.1 Introduction ............................................................................... 193
15.2 Design method (M.Y method) ................................................... 194
15.3 Equations for engineers ............................................................. 205
16 V-Belts ............................................................................................. 206
16.1 Introduction ............................................................................... 206
16.2 Design methods ......................................................................... 207
16.2.1 Method I ............................................................................. 207
16.2.2 Method II (M.Y method) .................................................... 221
16.3 Belt tensioning ........................................................................... 223
16.4 Equations for engineers ............................................................. 225
17 Timing belts .................................................................................... 227
17.1 Introduction ............................................................................... 227

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 17.2 Design methods ......................................................................... 228
17.2.1 Initial estimate .................................................................... 228
17.2.2 Checking estimations ......................................................... 239
17.2.3 M.Y method (New) ............................................................ 243
17.2.4 Belt installation .................................................................. 244
17.3 Equations for engineers ............................................................. 246
18 Chain drives .................................................................................... 248
18.1 Introduction ............................................................................... 249
18.2 Design methods ......................................................................... 250
18.2.1 Rough design ...................................................................... 250
18.2.2 Accurate design .................................................................. 253
18.2.3 Sag adjustment for roller chains ......................................... 258
18.2.4 Design based on the tensile strength of chains ................... 261
18.2.5 Lubrication method ............................................................ 264
18.2.6 M.Y method ....................................................................... 266
18.2.7 Estimating the minimum center distance ........................... 268
18.2.8 Silent chain (New) .............................................................. 270
18.2.9 M.Y method for silent chains (New) .................................. 273
18.3 Supplementary graphs and equations ........................................ 274
18.4 Equations for engineers ............................................................. 275
19 Spur and helical gear drives .......................................................... 278
19.1 Introduction ............................................................................... 279
19.2 Design methods ......................................................................... 280
19.2.1 Estimating the width and pitch circle diameter of pinion .. 283
19.2.2 Estimating the teeth number of pinion, and module .......... 286
19.2.3 Specifying the gear quality ................................................. 292
19.2.4 Specifying the helix angle .................................................. 294
19.2.5 Determining the center distance ......................................... 296

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 19.2.6 M.Y method ....................................................................... 301
19.3 Bending strength (New)............................................................. 303
19.4 Automotive gearboxes (New) .................................................... 305
19.4.1 M.Y method in automotive gearboxes ............................... 311
19.5 Supplementary material ............................................................. 312
19.5.1 The material properties of gears ......................................... 312
19.5.2 The transmission ratio in multi-stage gearboxes ................ 314
19.6 Equations for engineers ............................................................. 315
20 Bevel gear drives ............................................................................. 319
20.1 Introduction ............................................................................... 320
20.2 Design methods ......................................................................... 320
20.2.1 The pinion design ............................................................... 321
20.2.2 Specifying the gear quality ................................................. 331
20.2.3 M.Y method I ..................................................................... 332
20.2.4 M.Y method II .................................................................... 335
20.3 Equations for engineers ............................................................. 338
21 Wormgear drives ............................................................................ 341
21.1 Introduction ............................................................................... 341
21.2 Design methods ......................................................................... 342
21.2.1 Method I ............................................................................. 343
21.2.2 Method II ............................................................................ 350
21.3 Material, lubrication and efficiency........................................... 355
21.4 M.Y method (New).................................................................... 359
5.12 Equations for engineers ............................................................. 361
22 Rolling contact bearings ................................................................ 363
22.1 Introduction ............................................................................... 363
22.2 Design methods ......................................................................... 364
22.2.1 Equivalent load ................................................................... 364

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 22.2.2 Bearing life ......................................................................... 368
22.2.3 Allowable shaft speed for rolling bearings ........................ 376
22.2.4 Tolerances .......................................................................... 377
22.3 Rule of thumb ............................................................................ 381
22.4 Static capacity (New)................................................................. 384
22.5 Calculations of loads on bearing (New) .................................... 386
22.5.1 Axial load ........................................................................... 386
22.5.2 Radial load.......................................................................... 391
22.6 Equations for engineers ............................................................. 398
23 Hydraulic systems .......................................................................... 400
23.1 Introduction ............................................................................... 400
23.2 Design methods ......................................................................... 401
23.2.1 The piston and rod diameters of the hydraulic cylinder ..... 402
23.2.2 The maximum force of the hydraulic cylinder ................... 404
23.2.3 The hydraulic pump flow rate and the cylinder speed ....... 405
23.2.4 The diameter of hydraulic pipes and the required power of
pumps 407
23.2.5 The maximum allowable stroke of hydraulic cylinders ..... 409
23.2.6 The length of hydraulic cylinders ....................................... 411
23.2.7 The hydraulic cylinder thickness ........................................ 412
23.3 The oil viscosity (New) ............................................................. 416
23.4 Thickness of steel pipes (New) .................................................. 418
23.5 Equations for engineers ............................................................. 422
24 Overhead Cranes (New)................................................................. 424
24.1 Introduction ............................................................................... 425
24.2 Box Girders................................................................................ 425
24.2.1 Static design ....................................................................... 425
24.2.2 Beam weight ....................................................................... 434

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 24.2.3 Longitudinal stiffeners ....................................................... 435
24.2.4 End truck ............................................................................ 439
24.2.5 Design check ...................................................................... 443
24.3 Underslung cranes ..................................................................... 445
24.3.1 Standard I-Beam ................................................................. 446
24.3.2 Welded I beams .................................................................. 450
24.3.3 Pressure on the lower flange caused by the hoist wheel .... 452
24.4 Jib cranes ................................................................................... 458
25 References ....................................................................................... 462

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About the author

Dr. Majid Yaghoubi is the author of the book. He obtained his PhD in the
field of Mechanical Engineering from University of Tehran, Iran, in 2015.
During his study, he was an outstanding and ingenious student; he achieved
Iran's Elites Foundation award in 2010. His main expertise and interest are
designing and fabrication of mechanical mechanisms and machines. He has
more than 14 years experiences of working as designer of dozens of projects,
and manager of technical engineering departments, R&D departments, and
production lines, in various industries such as automotive, injection
molding, Oil & Gas, heavy machines, steel, mining, petrochemical and
agricultural machinery, etc. He has been also active in publishing papers in
peer-reviewed journals and books. In addition, he has patented several
mechanisms nationally and internationally.

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