MACHINE DESIGN II

MDP 2140
1
Instructor:
Dr. Mohamed El-Shazly
Associate Professor of Mechanical Design

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2
INTRODUCTION

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‫‪3‬‬ ‫‪COURSE CONTENTS‬‬

‫‪ ‬نظرية وطرق التصميم‪ ،‬االحتياج‪،‬االبتكار‪ ،‬والتصور للنماذج‪،‬‬

‫‪ ‬التصميم المبدئي لعناصر نقل القدرة‪ :‬أعمدة االدارة – التروس المسننة –‬
‫‪ ‬القارنات – القوابض – الفرامل – السيور –جنازير القدرة – االدارة بالحبال‬
‫‪ ‬نظرية وطرق التصميم التفصيلي ألعمدة االدارة وكراسي التحميل المتدحرجة تحت‬
‫االحمال المختلفة‬
‫‪ ‬التركيب المناسب لكراسي التحميل المتدحرجة‬
‫‪ ‬نظرية و تصميم الكراسي الهيدروديناميكية والهيدروستاتيكية–‬
‫‪ ‬التفاصيل االنشائية لتجميع عناصر الماكينات كأعمدة االدارة‬
‫‪ ‬تطبيقات الكمبيوتر في اختيار عناصر الماكينات‪..‬‬
‫‪26 February 2022‬‬
  Complete Machine Design-1
4
 Threaded joints
 Design of bolted joints
 Mechanical springs; compression coil springs

 Machine Design 2
 SHAFTS AND COUPLINGS
 SPUR GEARS
 CLUTCHES AND BRAKES
 Bearings
 Belts and Chains

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 Assessment
5 Schedule of Assessment Tasks for Students During the
Semester

Assessment Assessment task Week due Marks

1 In Class Assignment T.B.D 20

2 Mid Term Exam 6-8 20

3 Term Project 12 20

4 Final Exam 15 40

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 Introduction
6

A shaft is a rotating or stationary member usually

having a circular section much smaller in diameter
than the shaft length and having mounted on it
such power transmitting elements as gears,
pulleys, belts, chains, cams, flywheels, cranks,
sprockets, and rolling bearing elements.
In practical applications, the shaft may often be
stepped instead of having a constant diameter
with under cuts or grooves at the step.
Some of the main consideration in designing a
shaft are strength, using yield or fatigue (or both)
as criterion; deflection; or the dynamics
established by the critical speeds.
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 Shaft Design Procedure
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1. Develop a free-body
diagram by replacing the
various machine elements
mounted on the shaft by
their statically equivalent
load or torque
components.
2. Draw a bending moment
diagram in the x-y and x-z
planes. The resultant
internal moment at any
section along the shaft
may be expressed as

M x = M xy2 + M xz2 26 February 2022

 Shaft Design Procedure
8
3. Develop a torque diagram. Torque
developed from one power-
transmitting element must balance
the torque from other power-
transmitting elements.
6. Establish the location of the critical
cross-section, or the x location
where the torque and moment are
the largest.
7. For ductile materials use the
maximum-shear-stress theory
(MSST) or the distortion-energy
theory (DET).
8. For brittle materials use the
maximum-normal-stress theory
(MNST), the internal friction theory
(IFT), or the modified Mohr theory
(MMT. 26 February 2022
9
Example
The power from the motor of a front-wheel car is transmitted to the gearbox by
a chain drive. The two chain wheels are the same size. The chain is not
prestressed, so the loose chain exerts no force. The safety factor is 4. The
shaft is to be made of AISI 1080 steel. The chain transmits 100 kW of power at
the chain speed of 50 m/s when the motor speed is 6000 rpm. Find the
appropriate shaft diameter by using the DET.

(a) Chain drive assembly

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10
Example
The force transmitted through the chain is
h 100, 000
P= P = = 2000 N
u 50
The chain radius is
u 50
r= = = 0.07958 m = 79.58 mm
 6000 ( 2 / 60 )
From the free body diagram,
the torque being applied by the chain is
T = P r = (2000)(0.07958) = 159.15 N .m
Force and monment equilibrium give
− RA + RB − P = 0
M A = 0 → 0.2 P − RB = 0
 RB = 2500 N , RA = 500 N
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(a) Chain drive assembly; (b) free-body
diagram; (c) bending moment diagram.
11
Example 1
From the bending moment diagram,
the critical section occurs at x=0.16 m where the moment
is 80 N.m with steady torque of 159.15 N.m
16T 2546.4 M ( d / 2 ) 2560
 xy = = ,  = =
d3 d3 x
( / 64 ) d 4  d 3
The equation for principal stresses when  y = 0 are

( 2560 )
2
x  x2 1280 1
1,  2 =  +  xy2 =  ( ) +
2
2546.4
2 4 d3 d3 4
4130 1570
1 = ,  = −
d3 2
d3
The von Mises stress for biaxial stress state is
1  1/ 2 S
 e = 3 ( 4130 ) + (1570 ) + ( 4130 )(1570 )  y

2 2

d   ns
d  0.02576 m
The shaft diamter should be 26 mm
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(a) Chain drive assembly; (b) free-body
diagram; (c) bending moment diagram.
 Design Against Static Loading
I- Bending Moment and Torsion
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The transverse forces and torques applied to the shaft will produce both bending
and shear stresses given by

For a circular cross section

For the plane stress state, the principal normal stresses when y is zero are given by

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 Design Against Static Loading
I- Bending Moment and Torsion
13

Using the Distortion Energy Theory (DET)

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 Design Against Static Loading
I- Bending Moment and Torsion
14

Using the Maximum Shear Stress Theory (MSST)

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15
Example 2

An assembly of belts has a tensile forces applied as shown in the figure

and frictionless journal bearings at locations A and B. The yield strength
of the shaft material is 500 MPa and the safety factor is 2.

(a) Assembly drawing; (b) free-body diagram; (c) moment diagram in xz plane; (d) moment
diagram in xy plane; (e) torque diagram. 26 February 2022
16
Example 2

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 Design Against Static Loading
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II- Bending Moment, Torsion, and Axial
Load
The axial stress in this case will be given by

For the plane stress state, the principal normal stresses when y is zero are given by

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 Design Against Static Loading
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II- Bending Moment, Torsion, and Axial
Load
The Distortion Energy Theory

The Maximum Shear Stress Theory

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 Design Against Cyclic Loading
I- Ductile Materials
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 Design Against Cyclic Loading
I- Ductile Materials
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Recall Soderberg line, for shear loading the end points

are Sse=Se/(2ns) and Ssy=Sy/(2ns)

Soderberg line for shear stresses.

Substitute the expressions for a and m

Where
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 Design Against Cyclic Loading
I- Ductile Materials
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We are interested in finding the combination of stresses that produce

the smallest safety factor , differentiate the equation below to find the
minimum

This yields

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 Design Against Cyclic Loading
I- Ductile Materials
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 Design Against Cyclic Loading
I- Ductile Materials
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 Design Against Cyclic Loading
II- Brittle Materials
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For brittle material, the forces in this case are assumed to be

normal rather than tangent to the diagonal along the cut
element. The maximum normal stress theory (MNST) extends
from Se/ns to Su/ns. Following similar procedure, the safety
factor and the shaft diameter will be given by

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25
Critical Speed of Rotating Shafts
The critical speed of the shaft (also called
Natural Frequency) is the speed at which the
rotating shaft becomes dynamically unstable
and large vibration amplitudes are likely to
develop.
Usually, the shaft has infinite number of critical
speeds. We are interested in the first critical
speed.

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 Single-Mass System
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 The first critical speed (or lowest natural
frequency) can be obtained by observing the rate
of interchange between the kinetic (energy of
motion) and potential (energy of position) energies
of the system during its cyclic motion.
 A single mass on a shaft can be represented by the
simple spring and mass shown in Fig. The dashed
line indicates the static equilibrium position.
 The potential energy of the system is

Where:
ma = mass, kg
g = gravitational acceleration, 9.807 m2/s
k = spring rate, N/m
δ = deflection, m
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 Critical Speed of Rotating Shafts
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 The kinetic energy of the system with the mass moving with a velocity of 𝛿ሶ is:

The total mechanical energy is the sum of the potential and kinetic energies and is constant
at any time. Therefore,

Substituting

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 Critical Speed of Rotating Shafts
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The general solution to this differential equation is

where C1 is an integration constant. The first critical speed(or lowest natural frequency) is ω .
Substituting gives

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 Multiple-Mass System
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 The kinetic energy for n masses is

FOR :

ymax = C1

Therefore, the maximum kinetic energy is

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 Multiple-Mass System
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The potential energy for n masses is

and the maximum potential energy is

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 Multiple-Mass System
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Rayleigh equation

Multiple Mass - Dunkerley Equation

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 Example
32
 Given: Figure shows a simply supported shaft arrange- low-carbon steel is used.
The following are given: x1 = 0.750 m, x2 = 1.000 m, x3 = 0.500m, PA = 300N,
and PB = 500 N.
 Find: Determine the first critical speed by using
 (a)The Rayleigh method
 (b)The Dunkerley method

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 Solution
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