Solution of Machine Design Problems

Problem #M1c: A 1-12 UNF steel bolt of SAE grade 5 is under direct shear
loading. The coefficient of friction between mating surfaces is 0.4.
The bolt is tightened to its full proof strength. Tensile area is 0.663 in2
Proof strength is 85 kpsi, and yield strength is 92 kpsi
a) What shear force would the friction carry?
b) What shear load can the bolt withstand w/o yielding if the friction
between clamped members is completely lost? Base the calculation
on the thread root area.

Data for this bolt:

At=0.663 in2 Sp=85000 psi Sy=92000 psi
The initial load in the bolt is:
Fi=AtSp=.663(85000)=56355 lbs
The friction force
Ff=Fi = 0.4(56355)=22542 lbs
The direct shear stress force w/o yielding is:
Fs = 2At(Sys)=2At(0.58Sy)=2(0.663)(0.58)(92000)=70740 lbs
If the bolt is subject to shear in the shank area, then use the larger shank area.

Problem #M3

Assuming a rigid bracket, the top bolts elongate or strain 3 times more than the lower
bolts. Taking moments about the pivot point we get:

F * L FT ( D ) FB ( d )
FB
5400(40) FT (12) ( 4)
3
FT 16200 lbs

The load per bolt is half of this amount or 8100 lbs. Incorporating a factor of safety of 4,
the design load per bolt is 4(8100)=32400 lbs. The required tensile area for each bolt is:
F 32400
At 0.27 in 2
S p 120000
The appropriate bolt is a Grade 8 10 UNC
Problem #M4

The bolts are -13UNC. The distance between bolts is 1.25. The load is
2700 lbs and L=8. Find the shear stress on each bolt.

The torsional shear force (balancing the force couple) is:

PL 27000(8)
F1 8640 lbs
2d 2(1.25)
The direct shear stress
F
F2 900 lbs
3
The total force is:
F F12 F22 8686 lbs
The shear stress in each bolt using the shank diameter is:

F 8686
44237 psi
A (.5) 2
4
Exercise # M1 : A pair of spur gears with a pitch of 6 are in mesh. The
pinion has 18 teeth and rotates at 1800 rpm transmitting 0.5 Hp.
Both gears have 20-degree pressure angles. The number of teeth
on the gear is 36. Determine the radial and tangential forces on the
pinion.

33000(hp) nd
Ft and V
V 12
(1800)3 33000(.5)
V 1413.7 and Ft 11 .7 lbs
12 1413.7

The radial force is:

Fr Ft tan(20) 11 .7 * tan(20) 4.25 lbs

Exercise # M2: A pair of helical gears transmit 15 KW power and the

pinion is rotating at 1000 rpm. The helix angle is 0.50 radians and
the normal pressure angle is 0.35 radians. The pitch diameter of
the pinion is 70 mm and the pitch diameter of the gear is 210 mm.
Determine the tangential, radial, and axial forces between the gear
teeth. (Answers: 4092, 1702, 2236 Newtons)

The tangential load is determined from the power relationship. The relationship in SI
units uses the driving torque:
9549W 9549(15)
T 143.23 N m
n 1000
where the power is in Kw. The tangential load creating this torque is:
T 143.23
Ft 4092 N
d 0.035
2
The radial and axial forces are:
Fr Ft tan( ) 4092 tan(0.394) 1702 N
Fa Ft tan( ) 4092 tan(.5) 2235 N
Note that:
tan(n ) tan(0.35)
tan( ) .416 0.394 rad
cos( ) cos(0.5)

Exercise #M3: A pair of straight-tooth bevel gears (as shown in the figure above) are in
mesh transmitting 35 hp at 1000 rpm (pinion speed). The gear rotates at 400 rpm. The
gear system has a pitch of 6 and a 20-degree pressure angle. The face width is 2 inches
and the pinion has 36 teeth. Determine the tangential, radial, and axial forces acting on
the pinion. Answers (839 lbs, 283 lbs, 113 lbs).

d
davg

b
From the gear geometric information:
N p 36
dp 6 in and d g 15 in
P 6

The pitch cone angle can be obtained from the ratio of pitch diameters.
dp 6
p tan 1 tan 1 ( ) 0.4 p 21.8 deg .
dg 15
From geometry, the average diameter of the pinion is:
d p , avg d p b sin( p ) 6 2 sin( 21.8) 5.26 in
The pinions average pitch-line velocity is:
dn (5.26)(1000)
Vavg 1377 ft / min
12 12
Now we can find the tangential force :
33000W 33000(35)
Ft 839 lbs
Vavg 1377
The axial and radial forces are:
Fr Ft tan( ) tan( ) 839 tan(20) cos(21.8) 283 lbs
Fa Ft tan( ) sin( ) 839 tan( 20) sin(21.8) 113 lbs
Exercise #M4: A worm gear reducer is driven by a 1200 rpm motor. The worm has 3
threads and the gear has 45 teeth. The circular pitch of the gear is p=0.5, the center
distance is 4.5 inches, the normal pressure angle is 20 degrees, and face-width of the gear
is b=1 inch. Use a coefficient of sliding friction of 0.029. Determine:
a) Gear and worm diameters, and worm Lead. (7.16, 1.84, 1.5 in)
b) The worm gear efficiency (88.6%)
c) Is the unit self-locking (No)

The gear pitch diameter can be found from the number of teeth and its circular pitch:
 Ng p 45(.5)
dg 7.16

The pitch diameter of the worm can be obtained from the center distance and the pitch
diameter of the gear:
d w 2c d g 2(4.5) 7.16 1.84 in
The lead is the number of threads in the worm times the worms axial pitch which is the
same as the gears circular pitch:
L pa NW 0.5(3) 1.5 in
The gear efficiency can be obtained knowing the sliding friction as well as the normal
pressure angle and the lead angle of the worm. The lead angle of the worm is:
L 1.5
tan( ) 0.26 14.5 deg
d w (1.84)
The efficiency:
cos(n ) f tan( ) cos(20) 0.029 tan(14.5)
e 0.886
cos(n ) f cot( ) cos(20) 0.029 cot(14.5)
e 88.6%
The gear set is overhauling (reversible) because the friction coefficient f=0.029 is less
than that required for locking which is:
cos(n ) tan( ) cos(20) cos(14.5) 0.24

Problem M #7: 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):
Belt engagement angle on the smaller pulley (3.03 radians).
Force in belt in the tight side just before slippage. (1000 lbs).
Maximum transmitted Hp. (99.4 hp)
The engagement angle is:
Dd 36 16
d 2 sin 1 ( ) 2 sin 1 ( ) 3.03 rad
2C 2(15)(12)
At the verge of slippage:
F1
e d e 0.8(3.03) F1 11 .3F2
F2
Also:
F1 F2 2 Fi 2(544) F1 1000 lbs and F2 88 lbs
The transmitted Hp is:
( F F2 )V (1000 88)(3600)
HP 1 99.5 hp
33000 33000

Problem #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: Number of friction surfaces

Required Torque Capacity for uniform wear

63000hp 63000(15)
T 630 lb in
n 1500
Torque capacity per surface
fpa d 2 (.1)(100)(.5) 2
T (D d 2 ) (6 0.52 ) 70.2 in lb
8 8
The required number of surfaces is 630/70.2 which is approximately 9
surfaces.

For uniform pressure brake pads (when they are new):

fpa 3 (.1)(100) 3
T (D d 3 ) (6 .53 ) 565 in lb
12 12

Only two surfaces are needed for constant pressure pads.

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.

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
 2
1800( ) 188.5 rad / s
60
The time to stop is:
I1 I 2 (1 2 ) II 1
t 8 1 2 (188.5 0)( ) 9.76
T ( I1 I 2 ) I1 I 2 230
Since I2>>I1, we conclude: I1=9.76 slugs-ft2

The energy is:

I1 I 2 (1 2 ) 2 9.76
E (188.5 0) 2 173397 ft lb
2( I1 I 2 ) 2
E 18.6 BTU

Example #M10: Consider a helical compression spring with the following information
(not all are necessarily needed):
Ends: Squared and ground
Spring is not preset
Material: Music wire (steel) with Sut=283 ksi
d=.055 inches and D=0.48 inches
Lf=1.36 inches and Nt=10

Find the following. Answers are given in parentheses.

Spring constant, K (14.87 lb/in)
Length at minimum working load of 5 lbs (1.02)
Length at maximum load of 10 lbs (0.69)
Solid length (0.55)
Load corresponding to solid length (12.04 lbs)
Clash allowance (0.137)
Shear stress at solid length (77676 psi)
Surge frequency of the spring (415 Hz)

The spring constant and various lengths:

d 4G (.055) 4 (1
K
8D 3 N 8( 0.48) 3

LW , min L f F mi n 1

LW , max L f F max 1

Lsoli d N t d 10( 0.055

Lsoli d L f Fsoli d 0

Clash allowance:
 CA Lw,max Lsolid 0.687 .55 0.137"
Stresses
8 FD 8(12.04)(0.48)
Ks 1.057 93496 psi
d 3
(.055) 3
1
Ks 1 1.057
2C
The surge frequency is:
13900d
fn HZ
ND 2
13900d 13900(0.055)
fn 415 Hz
ND 2 8(0.48) 2

Problem #M12

Application Life
LD = 5000(60)(480) = 1440 million cycles
If the reliability was different than 90%, we divide the application life by the reliability
factor. But this problem only asks for 90% reliability.

Application Load
FD = (1.4)(610)(4.45) = 3800 N
Note that one pound is 4.45 Newtons.

Using the Life-Load relationship with application condition on one side and catalog
conditions on the other we get:
FD L0D.333 C10 (1000000).333
The catalog life rating is based on 1million cycles. Therefore the equivalent capacity for
increased life is:
C10 3800(1440).333 42900 N

Problem # M13

Major diameter
p 0.25
d dm 1 1.125 in
2 2
Torque required to lift the load
Fd m L fd m Ff c d c
TR
2 d m fL 2
With
12500(1) .025 (0.1)(1) 125000(0.1)(1.5)
TR 2069 in lb
2 (1) (0.1)(.25) 2
Minimum friction for self-locking
L 0.25
f 0.08
d m (1)
The screw is self-locking. The efficiency:

FL 12500(0.25)
e 0.24
2TR 2 ( 2070)