DESIGN OF MACHINE

ELEMENTS (2)

MDP312
 Design of Machine Elements (2)

Instructor:Prof. Dr./M. Zahran and Dr.Hamdy Ebaied

Email: hamdy_ebaied@yahoo.com
Department: Mechanical Engineering
Meeting Time: Wednesday (1),at 90 minutes and Lab-
Sunday at 90 minutes.
Pre-requisite: Machine Design1
Credit hours = 3
Text:
•Shigley, Joseph E., Charles R. Mischke, and Richard G.Budynas, Mechanical Engineering
Design, Mc GrawHill. New York.
•Robert L. Norton," Design of Machinery: An Introduction to the Synthesis, 2003.
.
Course Description:
This course include, Introduction to machine design, Design of Rolling
and Sliding Bearing, Design of ( Gears, Gear Box, Machine Frame,).

Course Purpose:
By accomplishing this course, student is expected to:
•Differentiate between theoretical design and practical
implementation.
•Acquire design skills for simple mechanical elements.
.
Week Lecture Topic
Course Plan

1st Introduction to machine elements design.

2nd Design of Rolling Bearings

Design of Rolling Bearings
3rd

Design of Rolling Bearings

4th

5th Design of sliding bearings

6th Design of sliding bearings

Dr. Hamdy Ebied
7th Mid Term Exam.

8th Design of Gears

Design of Gears
9th

Design of Gears
10th

Design of Gear Box

11th

12th Design of Machine Frame

13th Oral Exam

14th Final Exam

Dr. Hamdy Ebied

Grading Criteria:
•One Midterm Exam: 20%
•Class work and Homework: 10%
•Oral Exam 10%
•Final Exam: 60%
DESIGN :
How you determine a suitable shape and size

Design Methods

I-Adaptive design.
2-Development design.
3-New design.
 Design Considerations:

I-Type of load and stresses caused by the load.

The load, on a machine component, may act in several

ways due to which the internal stresses are set up. The
various types of load and stresses are discussed in lecture
two

2-Motion of the parts or kinematics of the machine.

The successful operation of any machine depends largely

upon the simplest arrangement of the parts, which will give
the motion required. The motion of the parts may he:
 a) Rectilinear motion, which includes unidirectional and
reciprocating motions.
b) Curvilinear motion which includes rotary, oscillatory
simple harmonic.
c) Constant velocity.
d) Constant or variable acceleration

3-Selection of materials.

It is essential that a designer should have a through knowledge

of the properties of the material and their behaviour under'
working conditions. Some of the important characteristics of
materials are: Strength, durability, flexibility, weight, resistance
to heat and corrosion ability to cost, welded or hardened,
machinability, electrical, conductivity ….. etc.
4-Form and size of the parts.
The form and size are based on judgment. The smallest
practicable cross-section may be used, but it may be checked that
the stresses induced in the designed cross-section are reasonably
safe. In order to design any machine part for form and size, it is
also important to anticipate any suddenly applied or impact load
which may cause failure.

5-Frictional resistance and lubrication.

There is always a loss of power due to frictional resistance and it
should be noted that the friction of starting is higher than that of
running friction. It is, therefore, essential that a careful attention must
be given to the matter of lubrication of all surfaces which move in
contact with others, whether in rotating, sliding or rolling bearings.
6-Convenient and economical features.
In designing, the operating features of the machine should be
carefully studied. The starting, controlling and stopping levers
should be located on the basis of convenient handing. The
adjustment for wear must be provided employing the various
take-up device and arranging them so that the alignment of
parts is preserved. If parts are to be changed for different
products or replaced on account of wear or breakage, easy
access should be provided and the necessity of removing other
parts to accomplish this should he avoided if possible.

the economical operation of a machine where is to be used

for production, or for the processing of material should be
studied, in order to learn whether it has the maximum
capacity consistent with the production of good work.
7- Use of standard parts.

The use of standard is closely related to cost, because the

cost of standard parts or stock parts is only a friction of the
cost of similar parts made to order.

8-Safey of operation.

Some machines are dangerous to operate, especially those which

are speeded up to insure production at a maximum rate,
therefore any moving part of a machine which is within the zone
of a worker is considered an accident hazard and may be the
case of any injury. It is, therefore, necessary that a designer
should always provide safety devices for the safety of the
operator.
9-Workshop facilities.
A design engineer should be familiar with the limitations of his
employer's workshop, in order to avoid the necessity of having
work done in some other workshop. It is sometimes necessary to
plan and supervise the workshop operations and to draft
methods for casting, handling and machining special parts.

10-Number of machines to be manufactured.

The number of articles or machines to be manufactured affects
the design in a number of ways. The engineering and shop costs
which a re called fixed charges or overhead expenses are
distributed over the number of articles to be manufactured.
 If only a few articles to be made, extra expenses are not
justified unless the machine is large or of some special design.
An order calling for a small number of the product will not
permit any undue expense in the workshop processes, so that
the designer should restrict his specification to standard parts
as much as possible.

1 1- Cost of construction.
The cost of construction of an article is the most important
consideration involved in design. In some cases it is quite possible
that the high cost of an article may immediately bar it from
further considerations If an article has been invented and tests of
hand made samples have been that it has commercial value it is
then possible to justify the expenditure of a considerable sum of
money in the design
 And development of automatic machines to produce the article,
especially if it can he sold in large numbers. The aim of design
engineer under all conditions, should be to reduce the
manufacturing cost to the minimum

12-Assembling.

Every machine or structure must be assembled as a unit before it

can function. Large units must often be assembled in the shop,
tested and then taken to be transported to their place of service.
The final location of any machine is important and the design
engineer must anticipate the exact location and the local facilities
for erection
13-Fits & Tolerance.
 General Procedure in Design

I-First of all make a complete statement of the problem,

indicating the purpose for which the machine is to be used.

2-Select the possible groups of mechanisms which will give the

desired motion.

3-Find the forces acting on each member of the machine and

the energy transmitted by each member.

4-Select the material best suited for each member of the

machine .
 5-Find the size of each member of the machine by considering
the forces acting and the permissible stresses for the material
used. It should be kept in mind that each member does not
deflect or deform than the permissible limit.

6-Modify the size of the member to a gree with the past

experience and judgment to facilitate manufacture.

7-Draw the detailed drawing of each component and the

assembly of the machine with complete specification for the
material and manufacturing processes suggested.
DESIGN :
How you determine a suitable shape and size

General Design Equation

Load = Material x Size
Load : Lateral,
Axial, Bending Moment,
Twisting Moment,….. etc

Material : Stresses
Size : dimensions (I (moment of inertia), A (area),
Z (section modulus))
 BearingS
a bearing is a device used to support and guide a rotating,
oscillating, or sliding shaft, pivot or wheel. Whenever a shaft
rotates, it needs a bearing for smooth, effective operation.

A bearing is designed to:

• Reducefriction
• Support a load
• Guide moving parts – wheel, shafts, pivots
 Classification of Bearings
1. Depending upon the direction of load to be supported

(a) Radial bearings, (b) Thrust bearings.

In radial bearings, the load acts perpendicular to the direction of

motion of the moving element as shown in Fig. (a) and (b).

In thrust bearings, the load acts along the axis of rotation as

shown in Fig. (c).
 2. Depending upon the nature of contact

(a) Sliding contact bearings, (b) Rolling contact bearings A. F.B

Journal (sleeve) Bearings – load is transferred through a thin film of
lubricant (oil).

Rolling Contact Bearings – load is transferred through rolling elements

such as balls, straight and tapered cylinders and spherical rollers.
The bearings with which we are concerned fit two basic categories
ball and roller.

We will discuss both categories, and cover bearing types,

installation, operating conditions, maintenance and troubleshooting.

In addition, we will feature one particular type – the tapered roller

bearing – which has numerous fleet applications.
The parts of a bearing

A bearing’s smooth performance is assured by a combination of four

basic working parts (fig. 1):
• Outer race (also called outer ring or cup)
• Inner race (also called inner ring or cone)
• Rolling elements (either balls or rollers)
• Separator (also called cage or retainer)
I. Ball Bearing: Outer
race

 Ball Bearing
 Incorporates hardened steel
balls
 Steel balls geometrically
contact inner and outer race at
a point
 This creates high stresses
locally

seals Inner race

cage
Advantages
1. Low starting and running friction except at very high speeds.
2. Ability to withstand momentary shock loads.
3. Accuracy of shaft alignment.
4. Low cost of maintenance, as no lubrication is required while in service.
5. Small overall dimensions.
6. Reliability of service.
7. Easy to mount and erect.
8. Cleanliness.

Disadvantages

1. More noisy at very high speeds.

2. Low resistance to shock loading.
3. More initial cost.
4. Design of bearing housing complicated.
Ball and Roller Bearings
●Classification and Characteristics of Rolling Bearings

Rolling bearing construction

Most rolling bearings consist of rings with

raceway (inner ring and outer ring), rolling
elements (either balls or rollers) and cage. The
cage separates the rolling elements at regular
intervals, holds them in place within the inner
and outer raceways, and allows them to rotate
freely.

Raceway (inner ring and outer ring) or raceway

washer, Rolling elements

Rolling elements classify in two types: balls and rollers.

Rollers come in four types: cylindrical, needle, tapered, and spherical.
Cages
Cages function to maintain rolling elements at a
uniform pitch so load is never applied directly
to the cage and to prevent the rolling elements
from falling out when handling the bearing.
Types of cages differ according to
way they are manufactured, and include
pressed, machined and formed cages
 Classification of rolling bearings

Rolling bearings divide into two main classifications:

Ball bearings and roller bearings.

Ball bearings are classified according to their bearing ring configurations:
Deep groove type and angular contact type.
Roller bearings on the other hand are classified according to the shape of
the rollers: cylindrical, needle, tapered and spherical.

 Rolling bearings can be further classified according to the direction in which the
load is applied;
radial bearings carry radial loads and thrust bearings carry axial loads.
Other classification methods include:
1) number of rolling rows (single, double, or 4-row),
2) separable and non-separable, in which either the inner ring or the outer
ring can be detached.
Bearings are manufactured to take pure radial loads, pure
thrust loads, or a combination of the two kinds of loads.
• How to remove, inspect, and install bearings;
• How to improve performance with proper lubrication and maintenance techniques;
• How to spot bearing failures, correct them and prevent them from happening again.

Support a load
A shaft will try to push the bearing in the same direction in which the load
moves. The load is dependent on both weight and direction. If the wrong
type of bearing is used it may not be able to carry the required load.
The arrows above show how a load is dispersed through the balls or rollers of a bearing.
 In addition to the inner and outer races, rolling element and separator, there are
three accessory components frequently used with ball bearings:
• Snap rings
• Shields
• Seals

Snap rings are separate components used to locate ball bearings

in the housing (fig. 1). They hold the bearing in place the same way
a shoulder on the shaft or in the housing would.

Shields are circular rims that cover the open space between the two races,
on one or both sides of the bearing (fig. 2). They are attached to the edge
of only one race, with clearance left at the inner race. Shields prevent dirt
and particles from getting in the bearing, while letting excess lubrication
flow through the bearing and escape if necessary.
A seal is a metal-based ring lined with a single,
double or triple
lip made of rubber, elastomers, synthetic or
non-synthetic materials (fig.3). It is a barrier
designed to retain lubricants while excluding
moisture, fine dirt, dust, or other contaminants
from damaging the bearing. Unlike shields,
seals prevent lubricants from leaking out of the
bearing.

There are four different ball bearing types

used in automotive and fleet applications:
• Single row
• Angular contact
• Double row
• Ball thrust
Single row ball bearing
The single row is one of the most popular ball bearing designs.
A crescent-shaped cut in both the inner and outer races forms
a wide groove in which a single row of balls roll (fig. 5). Though designed
primarily for radial load capacity, this bearing can support substantial thrust
loads in either direction, even at high operating speeds (fig. 6). Careful
alignment between the shaft and housing is critical to its performance.
The bearing is available with seals and shields for extra protection against
contaminants, plus retention of lubricant.
A variation of the single row bearing is the maximum capacity bearing.
Additional balls can be assembled in the bearing for greater radial load
capacity (fig. 7). However, the extra loading area limits the bearing’s thrust
load capacity.
Benefits/advantages
•Good performance under radial loads
•Deep groove permits thrust load capacity
in either shaft direction
•Assures contaminant-free operation when
seals are mounted on the bearing

Applications
• Transmission
• Alternator
• Differential
• Steering gear
• Air conditioner clutch
Double row ball bearing
The double row ball bearing combines the design principles of the single
row and angular contact bearings. Like the angular contact bearing, it has
grooves in the outer and inner races which are positioned so that the load
lines through the balls form either an outwardly or inwardly converging
angle of contact (fig. 9).
The two rows of balls assure a lower axial displacement than the single
row design. That is, the bearing is less likely to become misaligned on the
shaft or in the housing. The double rows can support heavy radial loads
and work well under thrust loads in either direction.

Benefits/advantages
Thrust capacity in either direction
High radial capacity
Less axial displacement
Applications
• Air conditioner clutch
Ball thrust
Designed primarily for clutch release applications, the ball thrust
bearing has high thrust capacity. The load line runs parallel through
its balls to the shaft axis, so there is little axial displacement (fig.
10). Flat shoulders on the shaft and housing are recommended
under heavy loads.

Benefits/advantages
High thrust capacity
Minimal axial displacement
Applications
• Clutch release
Angular contact ball bearing
The angular contact ball bearing features two high thrust supporting
shoulders – one on the inner race, the other at the opposite side on the
outer race. The two shoulders form a steep contact angle slanted toward
the bearing’s axis, assuring the highest thrust capacity and axial rigidity.
This design can support a heavy thrust load in one direction, sometimes
combined with a moderate radial load

Benefits/advantages
High thrust capacity
Axial rigidity
Applications
• Clutch release
1 ☆ The number of stars indicates the degree to which that
bearing type displays that particular characteristic.
2★ Not applicable to that bearing type.
3 Indicates dual direction.
4 ○ Indicates single direction axial movement only.
5 indicates movement in the axial direction is possible
for the raceway surface;
6 ○ indicates movement in the axial direction is possible
for the fitting surface of the outer ring or inner ring.
7 ○ Indicates both inner ring and outer ring are detachable.
8 ○ Indicates inner ring with tapered bore is possible.
Bearing numbering system
Radial bearings Ball bearings
 The bearings are designated by a number. In general, the
number consists of at least three digits. Additional digits or letters
are used to indicate special features e.g. deep groove, filling notch
etc. The last three digits give the series and the bore of the bearing.
The last two digits from 04 onwards, when multiplied by 5, give
the bore diameter in millimetres. The third from the last digit
designates the series of the bearing. The most common ball
bearings are available in four series as follows :
1. Extra light (100), 2. Light (200),
3. Medium (300), 4. Heavy (400)

Notes :
1. If a bearing is designated by the number 305, it means that the
bearing is of medium series whose bore is 05 × 5, i.e., 25 mm.
2. The extra light and light series are used where the loads are
moderate and shaft sizes are comparatively large and also where available
space is limited.
3. The medium series has a capacity 30 to 40 per cent over the light series.
4. The heavy series has 20 to 30 per cent capacity over the medium series. This series
is not used extensively in industrial applications.
 Design Considerations
Bearings are selected from catalogs, before referring to catalogs you should know the
followings:

• Bearing load – radial, thrust (axial) or both

Thrust load

Radial load Radial load

 Bearing life and reliability

 Bearing speed (rpm)
 Space limitation
 Accuracy
 ●Bearing Selection

A)Overall study and tabulation of criteria of application :

•Importance and relative value of radial and axial load (load calculation).
•Available location.
•Assembling and adjusting conditions.

B).

•Choice the type ( ball, roller,…..etc) according to step A.

•Choice the dimension according to the bearing type and use this
dimension to obtain the operating load.
 ●Bearing Load Calculation
•Given : Bearing type. Required : service life Ln , Lh

•Given : service life Ln , Lh Required : Bearing type.

Definition of important terms

Co: basic static load Kg (It the load caring by non-rotating bearing)

• Radial for radial bearing.

• Axial for thrust bearing.

C: a load under which a specific bearing ensure correct operation for

an agreed laps of time .
Equivalent dynamic load equation

•X : radial factor.
•Y : thrust factor.
•V : rotation factor.
•Fr: radial load.
•Fa: thrust factor.
•Calculate
•X,y from table according to:
, then determine the parameter e from table ( ).

•Calculate

Compare with e if

x=1 , y=0

use table ( )
 Service life equations

Ln :service life in rev.

C :basic dynamic oad.
P :equivalent dynamic load.
n : 3 for ball bearing.
: 3.3 for roller bearing
N : r.p.m
Example 1:
Given: type of bearing ( single row deep groove ball bearing type
6206 at N = 425 r.p.m.)
- radial load on bearing Fr= 400 Kp
-axial load on bearing Fa= 120 Kp
Required:
-Service life in revolutions Ln
- Service life in hours Lh

Solution
According to the single row deep groove ball bearing BB-6206
and from table ()
C = 1530 Kp , Co= 1050 Kp
V=1 inner race rotates table ( )

e = 0.30 from table ( )

then x =1 , y= 0

P = 1x1x400 = 400 Kp
 Bearing Type is Required
Example 2:
Given:
-shaft diameter d = 55 mm, N = 100 r.p.m
- radial load on bearing Fr = 300 Kp
-axial load on bearing Fa = 0 Kp
- service factor Lh= 10000 hrs
Required:
-ball bearing type
Fa=0 then x=v=1 and y=0

P = Fr = 300 Kp
The bearing is
Single row deep groove ball bearing for which
C = 2220 Kp > 1173

No. Co Kp C Kp
6011 1850 2220
-If axial load on bearing Fa = value Kp
- service factor Lh= 10000 hrs

Required:
-ball bearing type
Take
 Roller Bearings
Roller bearings have higher load capacity than ball bearings, load is
transmitted through line contact instead of point contact.

Straight cylindrical roller Needle type

 Roller Bearings
Roller bearings have higher load capacity than ball bearings, load is
transmitted through line contact instead of point contact.

Straight cylindrical roller Needle type

Taper Roller Bearing
Tapered bearings
Designed to withstand high radial loads, high thrust
loads, and combined loads at moderate to high speeds.
They can also withstand repeated shock loads.

Form

The four components of a tapered roller bearing

assembly are the

• Cone (inner ring)

• Cup (outer ring)
• Tapered rollers
• Cage (spacer-retainer)
The assembled bearing consists of two
separable parts:

(1) the cone assembly:

The cone, the rollers, and the cage;

(2) the cup.

• Bearings can be made as single-row, two-row,

four-row, and thrust-bearing assemblies.
• A tapered roller bearing can carry both radial
and thrust (axial) loads, or any combination of
the two. However, even when an external
thrust load is not present, the radial load will
induce a thrust reaction within the bearing
because of the taper. To avoid the separation
of the races and the rollers, this thrust must
be resisted by an equal and opposite force
• Two bearings can be mounted with the cone
backs facing each other, in a configuration called
direct mounting, or with the cone fronts facing
each other, in what is called indirect mounting.

• These bearings are available in various combinations

as double row bearings and with different cone
angles for use with different relative magnitudes of
radial and thrust loads.
Thrust load on opposed bearing ( O-arrangement)

Indirect mounting
provides greater rigidity
when pair of bearings is
closely spaced: front
wheel of a car, drums,
sheaves,..
Indirect mounting

Direct mounting
provides greater rigidity
when pair of bearings is
not closely spaced:
transmission, speed
reducers, rollers,..

Direct mounting
Bearing I Bearing II

Fa
Consider two cases
X=1 , Y=0
Example:
Find the nominal life for taper roller bearing arrangement in
(O-arrangement) having the following loads:

Bearing I : 30207 C= 4550 Kp YI =1.6

Bearing II: 30210 C= 6700 Kp YII=1.4

FrI = 510 Kp Fa= 158 Kp

FrII= 665 Kp
 158

From (1) and (2)

158
X= 0.4 ; Y = Y1=1.4

443
For Bearing I:
C = 4550 Kp ; P = 825 Kp

hours
For Bearing II:
C = 6700 Kp ;
( X-arrangement)

Direct mounting
provides greater rigidity
when pair of bearings is
not closely spaced:
transmission, speed
reducers, rollers,..

Direct mounting
EXAMPLE:

The shaft depicted in Fig. a carries a helical gear

with a tangential force of 3980 N, a separating
force of 1770 N, and a thrust force of 1690 N at the
pitch cylinder with directions shown. The pitch
diameter of the gear is 200 mm. The shaft runs at a
speed of 1050 rev/min, and the span (effective
spread) between the direct-mount bearings is 150
mm. The design life is to be 5000 h .
Select a suitable type of taper bearing.
1.A single row ball bearing is mounted on the
shaft of gear box with diameter d = 50 mm,
which rotates at 1200 r.p.m.
Select the bearing for this working condition,
if given:

A) 1. Radial load Fr= 420 Kp.

2.Thrust load Fa=118 Kp .
3. Service life Lh=12000 hours.
( X-arrangement)

Direct mounting
provides greater rigidity
when pair of bearings is
not closely spaced:
transmission, speed
reducers, rollers,..

Direct mounting
 Mounting Bearings

Pillow Block Flange

Alternative method, inner ring is

Common mounting, inner ring held Alternative
press fitted method,
onto the inner
shaft.ring is Two-bearing mounting
in Common mounting,
position by inner ring
nuts threaded held
onto press fitted onto the shaft. Two-bearing mounting
thein shaft.
position by nuts threaded onto
the shaft.