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Clamping forces
Fe
kb
Fb Fi
Fe
kb kc
Where Kb and KC are the bolt and the clamping material stiffness and Fi is
the initial bolt tensioning. Calculating Kb and Kc are relatively difficult and
exam problems often give you theses stiffnesses or their ratio.
kc
Fc Fi
Fe
kb kc
Fb
Fi
Fc
Fe
kc
Fe
kb k c
225 2250
1
Fe
1 2
Fe 6075 lbs
Fb Fi
kb
2
Fe 2250 ( )(6075) 6300 lbs
kb k c
3
Example M1b
Select a bolt that would withstand 6300 lbs load in direct
tension. Apply a factor of safety of 2.5. Use a bolt with
SAE strength grade of 2 (which has a proof strength of 55
ksi).
3
(15750)
At 0.286 in 2
55000
F
D
Example M3
Consider the bracket shown above. Assume the bracket is
rigid and the shear loads are carried by friction. The
bracket is bolted by four bolts. The following is known:
F=5400 lbs, L=40 inches, D=12 inches, d=4 inches. Find
appropriate UNC bolt specifications for bolts of 120 Ksi
proof strength using a factor of safety of 4.
Answer: - 10UNC
5
Example M4
L
Where S a
Se Su i Se
and i is the stress due to initial
Se Su
tension
Example: A M16*2 SAE grade 8.8 bolt is subject to a
cyclic stress. The minimum nominal stress in the tensile
area is calculated to be 400 Mpa (for initial tension with no
external load) and maximum nominal stress is 500 Mpa
(for maximum external load). Determine the factor of
safety guarding against eventual fatigue failure for this bolt.
Fully corrected endurance limit, including thread effects, is
129 Mpa. The ultimate strength of the bolt material is 830
Mpa.
max min
500 400
50 MPa
2
2
129(830) 400(129)
Sa
57.8
129 830
57.8
n
1.15
50
Gear Geometry
Kinematic model of a gear set
dp
np
ng
dg
Np
Pressure Line
Ng
Terminology
Diametral pitch (or just pitch) P : determines the size of the
tooth. All standard pairs of meshing gears have the same
pitch.
N
P
d
d
p
N
d
m
N
Pp
n1
N2
n2
N1
n1 N 2
n2 N1
ARM
10
n2 n A n2 / A
n1 n A n1 / A
2) Regular gear train formula with Arm stationary
n2 / A
N1
n1 / A
N2
3
n2 / A n2 nA 100 nA
n4 / A n4 nA
0 nA
n2 / A n2 / A n3 / A
N3 N 4
( ) 2.5
n4 / A n3 / A n4 / A
N 2 N3
100 nA 2.5(nA ) nA 28.5 cw
11
n2 / A n2 n A 250 n A
n6 / A n6 n A
0 nA
n 2 / A n 2 / A n 4 / A n5 / A
N6
N4
(1)(
)
n 6 / A n 4 / A n5 / A n 6 / A
N2
N5
12
n2 / A
30
34
( )( ) 3.187
n6 / A
20 16
n A 114.3
Also
n4 / A n4 n A
n4 (114.3)
n2 / A n2 n A 250 (114.3)
n4 / A
N
20
( 2 )
n2 / A
N4
30
From above:
n4=-357.1 rpm
13
14
Fn Ft
d
Fr
Fn : Normal force
Ft : Torque-producing tangential force
Fr : Radial force.
When n is in rpm and d is in inches:
33000(hp)
Ft
V
and
and V
nd
12
Fr Ft tan
In SI units:
d
Watts T and T Ft ( )
2
15
Helical gears
Geometric parameters
Pn : Normal pitch
P : Plane of rotation pitch
: Helix angle
n: Normal pressure angle
: Plane of rotation pressure angle
N : Number of teeth
d: pitch diameter
pn and p : circular pitches
pa : axial pitch
Geometric relationships:
N
P
and P Pn cos( )
d
tan(n )
tan( )
cos( )
Pp Pn pn
and
pa
p
tan( )
Ft From Power
Fr Ft tan( )
Fa Ft tan( )
When shaft axes are parallel, the helix hands of the two gears must
be opposite of each other.
16
Pinion
d
davg
where Vavg
nd avg
12
and
d avg d b sin( )
Fr Ft tan( ) cos( )
Fa Ft tan( ) sin( )
These forces are for pinion and act through the tooth
midpoint. Forces acting on the gear are the same but
act on opposite directions.
17
dw
dg
N
w
g
Nw = Number of threads (single thread =1, double thread =2, etc)
L pa NW
The worms axial pitch pa must be the same as the gears
plane of rotation circular pitch p.
The worms lead angle is the same as the gears helix
angle he gear and worm must have the same hand.
18
Example
For a speed reduction of 30 fold and a double threaded
worm, what should be the number of teeth on a matching
worm gear.
Ng = (2) (30) = 60 teeth
The geometric relation for finding worm lead angle
tan( )
L
d w
Fgt = Fwa
Fwt
Fga = Fwt
Fwa
Fwr
cos(n ) f tan( )
cos(n ) f cot( )
Where f is the coefficient of friction. Condition for selflocking when worm is the driver
f cos(n ) tan( )
Note: In a RH worm, the teeth spiral away as they turn in a
CW direction when observed along the worm axis. When
the worm in turning in CW direction, the teeth sweep
toward the observer seen along the axis of the worm
(imagine a regular bolt and nut).
RH Worm
20
Fr
Fa
Ft
F
Fa
F Fr2 Ft 2
21
Flat Belts
Flat belts have two configurations: Open
Dd
)
2C
Dd
D 2 sin 1 (
)
2C
d 2 sin 1 (
Closed (Crossed)
d D 2 sin 1 (
Dd
)
2C
Where
C: Center-to-center distance
D,d: Diameters of larger and smaller rims
: Angle of wrap around pulley
22
Slippage Relationship
(True only at the verge of slippage)
Tight side
F1
F1
e
F2
is in radians.
Driver
F2
Slack side
Transmitted Hp is
Hp
( F1 F2 )V
33000
23
Problem M7
A 10-wide flat belt is used with a driving pulley of
diameter 16 and a driven pulley of rim diameter 36 in an
open configuration. The center distance between the two
pulleys is 15 feet. The friction coefficient between the belt
and the pulley is 0.80. The belt speed is required to be
3600 ft/min. The belts are initially tensioned to 544 lbs.
Determine the following. (answers are in parentheses)
a) Belt engagement angle on the smaller pulley (3.03
radians).
b) Force in belt in the tight side just before slippage.
(1000 lbs).
c) Maximum transmitted Hp. (99.4 hp)
P1 Pc
e / sin
P2 Pc
where
Pc m ' 2 r 2
m=Mass per unit length
r=Pulley radius
24
D
Torque capacity under Uniform Wear condition per
friction surface (when brake pads are not new)
fp a d
8
(D 2 d 2 )
Where
f: Coefficient of friction
pa: Maximum pressure on brake pad
d,D: Inner and outer pad diameters
Torque capacity under Uniform Pressure conditions per
friction surface (when brake pads are new)
fp a
12
( D3 d 3 )
25
p a d
2
(D d )
pa
4
( D2 d 2 )
Example M8
Given: A multi-plate disk clutch
d=0.5
D=6
Pmax=100 psi
Coefficient of friction=0.1
Power transmitted= 15 hp at 1500 rpm
Find: Minimum number of friction surfaces required
Answer: N=2 (uniform pressure)
N=9 (uniform wear)
26
I1
I2
I 1 I 2 (1 2 )
t
T ( I1 I 2 )
where
T: Common transmitted torque
: angular speed in rad/sec
The total energy dissipated during clutching (braking) is:
I1I 2 (1 2 ) 2
E
2( I1 I 2 )
If the answer is needed in BTU, divide the energy in in-lb
by 9336.
27
Problem M9
A brake with braking torque capacity of 230 ft-lb brings a
rotational inertia I1 to rest from 1800 rpm in 8 seconds.
Determine the rotational inertia. Also, determine the energy
dissipated by the brake.
I1
I2
Solution hints:
Convert rpm to rad/sec: 1 = 188 rad/sec
Note that 2=0
Find the ratio (I1I2/I1+I2) using time and torque=>9.79
Note that I2 is infinitely large => I1=9.79 slugs-ft
Find energy from equation=>173000 ft-lb
28
Springs
Coverage:
Helical compression springs in static loading
Terminology:
d: Wire diameter
D: Mean coil diameter
C: Spring index (D/d)
Nt: Total # of coils
N: Num. of active coils
p: Coil pitch
Lf: Free length = N*p
Ls: Solid length
(Nt+1)d
N
pN+d
Plain &
Ground
Ntd
N+1
p(N+1)
Square
(Nt+1)d
N+2
pN+3d
Square &
Ground
Ntd
N+2
pN+2
29
d 4G
dG
k
3
3
8D N 8 NC
where : N is the number of active coils
G: shear modulus = E/2(1+)
G=11.5*106 psi for steels
Shear stress in helical springs for static loading
max
8FD
Ks
3
d
1
30
fn
1 kg
2 Wa
Design of Welds
Welds in parallel loading and transverse loading
OR
Weld Geometry
Throat: t
Leg : h
Analysis Convention
Critical stresses are due to shear stresses in throat area
of the weld in both parallel and transverse loading.
For convex welds, t=0.707h is used.
The shear strength in weld analysis is taken as 30% of
the weld ultimate strength.
32
Analysis Methodology
Under combined loading, different stresses are
calculated and combined as vectors.
Stresses based on weld leg (h)
Direct tension/compression:
F 1.41
Lt Lh
Direct shear:
1.41V
Lh
Bending:
Mc Mc
I
Iut
Torsion:
Tr
J ut
Formulas for Iu, and Ju are attached for different weld
shapes.
33
34
35
1.41V
1.41P
0.6284 P
Lh
6(.375)
psi
36
Tc (20000)(2.25)
3571 psi
Jt
12.6
I u r 3 (2.25) 3 35.78 in 3
I t 35.78(0.25)(0.707) 6.32 in 4
Mc (35000)(2.25)
12460 psi
It
6.32
37
38
F1L10.333 F2 L02.333
This means if we double the load, the life of the ball
bearing would be reduced by a factor of 10. This formula
is for ball bearings. For roller bearings use 0.3 as the
exponent.
Example: By what factor the radial load capacity of a
roller bearing has to be increased if the bearing is to last
twice as long as its catalog rating.
0.3
F1 L2
F
2
1.23 F2 1
1.23
1
F2 L1
0.3
Example: Given:
02 series Deep Groove ball bearing,
Radial load is 4 KN,
Application factor KD = 1.2
Design life 540 million cycles
95% reliability
Find: Suitable bearing catalog rating based on 106 cycle L10 life.
39
Solution:
Life multiplier due to reliability
x1= 0.65 (at 95%) - See reliability multiplier below
Adjusted design life:
LD = 540/0.65 = 830.77 million cycles
Force multiplier due to life being different from 106 cycles
K1=(830.77).333 = 9.38
Adjusted Design Load
FDA = 4 (1.2) (9.38) = 45 KN
Selection: 60 mm bore with 47.5 KN capacity.
40
50% : Kr = 5
99% : Kr = 0.20
Ft
Fe Fr 1 1.115( .35)
Fr
RD n Rsys
41
Keys
Square keys
w = d/4 (d is shaft diameter)
Length = L
Shear stresses at torque T
8T
d 2L
(0.58 S y )
8
Tmax
4T
Dd 2
D
d
Dd 2
4
(0.58S y )
Other key types and splines are all treated similarly: Equating the
shear area to the force created by the transmitted torque.
42
Power Screws
LOAD
Collar
TR
2 d m fL
2
F: Load , dm=Screw mean diameter
L: Screw lead = NW * p
f: Thread coefficient of friction
fc : Collar coefficient of friction
dc: Mean collar diameter
Torque required to lower the load
Fd m L fd m Ff c d c
TL
2 d m fL
2
Note: All formulas are for power screws with square
threads which are the most common type.
43
L
f tan( )
d m
Efficiency of power screws (includes collar losses)
FL
2TR
44