Professional Documents
Culture Documents
Design Process: .
• The design prOCf!SS or approach varies with individual requirements, size
of the project, company practices etc.
• A logical order of, lesign steps is given below:
IRec: gnition of a need - Specific machine function
t ~ "':!'
'-t-
Step 3: Feasibility Study: The possible success of the proposal should be
verified from technical and economical stand points.
Step 4: Creative Design Synthesis: Synthesis of various new and or old ideas
in such a way as to produce new idea, using .the various sources like 1)
already existing methods, 2) Kinemetics, 3) Machine elements and
mechanism like levers, screws, wheels, gears, couplings, hydraulic and
pneumatic elements etc. 4) Standards, "5) Technical Journals, 6) Exhibitions,
and 7) Experiments.
Step 7: Prototype Building: 'This building and testing may .lead to some
modifications in the preliminary design and detailed design (F~edback
Loops)
Step 7: Design for Production: Design changes are introduced to suit the
most economical methods of production.
A part may be considered suitable for manufacturing by casting or
forging rather than by welding from several smaller parts; sometimes
commercially available purchased item cart. replace a manufactured
component leading to cost reduction.
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Types of Design:
a) Adaptive Design: Adaptation of the existing design
b) Development Design: Improvement of the existing design
c) New Design: Design of an entirely new product.
Standards:
When designing machine elements, the calculated dimensions should be
rounded off to standard values wherever possible. By using standard dimensions
interchangeability of components is possible and hence the components can be
mass produced at lower costs.
Preferred Sizes:
When manufacturing a product in different sizes, it is better to have
minimum number ofsizes to cover a certain range, from economic considerations.
Here Size of a product may mean dimensions, power, speed, etc. It has been found
that if the numbers derived from geometric series (preferred numbers) are used to
specify the sizes, the demands are met with minimumnumber of sizes.
Refer Data Book Page No. 7.20 for the preferrednumbers.
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Material Selection:
• One of the first steps in machine design ~ selection of proper material.
• Following factors are considered in the selection of the material:
o Mechanical properties of materials
o Manufacturing ease
o Quantity required
o Space Available
o Material cost
o Manufacturing cost
o Availability of material
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4. Stiffness (Rigidity): enables the material to resist deformation under loads.
Rigidity is of great importance in members whose deflections are limited by
service requirements as in machine tool spindles.
5. Ductility: enables the material to be drawn into wire when tensile force is
applied.
Steel, aluminium and copper are ductile materials, which have large
plastic deformation before rupture while brittle materials have a small plastic
deformation. .
Ductility is important because it permits the. material to absorb large
overloads and it permits the material to be cold worked.
6. Brittleness: means lack of ductility. Cast Iron is a brittle material.
7. Malleability: enables the material to be flattened or squeezed under a
compressive force. (Gold & Aluminium) Malleability isa compressive
quality while ductility i1 a tensile quality.
8. Resilience: is the material's capacity to absorb energy within the elastic
range. This enables material to -resist shock and impact and hence it is
desired in springs. .
9. Toughness: enaeles the material to -absorb energyin the plastic range; .it
. enables the m.aerial to be twisted or bent. under a sudden load before
rupture. _
10.Hardness: enables the material to resist indentation, wear or plastic
deformation.
11.Creep: At elevated temperatures materials yield and Undergo permanent
deformation at a stress lower than the yield pomt stress. In addition to the
loss of strength, there is a continuous gradual elongenon of the members at
. high temperature over a long period of time, known as.creep.
12.Strain· Hardening: When drawing ductile material through dies or when
rolling them between rollers, plastic deformation takes p1acemd this
increases the yield point stress and ultimate strength. This is known as strain
hardening.
13.Damping Capacity: is the ability of a material to damp vibrations by
absorbing the kinetic energy of vibration. CI has greater damping capacity.
14.Hardenability: is the ability of steel to through harden. Hardenability can be
improved by using alloying elements like boron, vanadium, manganese,
chromium and molybdenum.
I5.Machinability: is the ease with which the metal can be removed in
machining operations. This is an important factor, Good machinability
results in less tool wear, good surface finish and less power consumption.
This can be achieved by adding sulphur and lead in steel, which reduce the
tensile strength.
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y
The function of a key is to prevent relative rotation of a shaft and
. .. Ke"0" • '. lS'! the member (hub of pulley, gear or crank) to which it is connected. In
other words, key is used to transmit torque from a shaft to a gear, pulley
or similar device or vice versa.
Hub
•
, -h
b .
- ~
/ a pe,linIDO r b -\ rb1l-/aper I inlOO r l .i.t l
b
-, Hub
[ -:=l El he
L.. ~I h 0
T
(d) Flat (sunk) IL---~L - - . I h = b T~ L---I
10) Square (b). Flat (sunk)
Z$;rnicircular slo t
Woodruff key
.-" ---
L..--l~~~~--"~5hafl
(a) (b)
Ke y instalied
.FEATHER KEYS
bet ween rna ting
Wheel palts
.GIB HEAD TAPERED· KEY'
(b).lnvolute spline
(a).Para"el side spline titling
~"@
• Keyway
Torque
'Area in cru~hing
L2d-=1
.LOAD DIAGRAM FOR
=O.Shl
A RECTANGULAR KEY
I----"'" ~
Shaft
~I
Fig. II Sleeve or-muff coupling.
DESIGN OF SHAFT
COUPLINGS: D = Outside dian eter of sleeve
Muff Coupling: (F l{;j. I I) L = Length of the sleeve
D= 2d+13mm d = Diameter ofthe shan
L = S.od ~ 4-<;t T = Torque transmitted by coupling
4 Shear stress of shaft material, 14 MPa for CI
Irit.= ~ lr (D4 - d ) ] 't's
I
=
= Length of the key in each shaft
16'Cs D
\V = Width ofthe key ,
1= 3.5d =!:. t = Thickness ofthe key
2 2
-t4} t= I.w.'t.d 't = Shear stress of key material
2 (Jc = Crushing stress ofkeymaterial
,~ = d!.)·"C,·l(
, \2
~I
2}
~ ..
~--L----'--..l
Flange Coupling:
a)Proportions: da. = Nominal Diameter of bolts
b.l. t==~4 tt
tp
= Thickness of flange
= Thickness of protecting flange.
b) Shaft Design: 'tS, 'tb) 'tk)= Allowable shear stress for shaft)bolt and
z.,
tft= 16 S'
d8
't.: =
key material respectively
Allowableshear £tress for flange material
c) Hub Design: (Jtb, (Jck = Allowable crushing stress for bolt and key
t'\ =~T.[(l>4 - 4
d )1 material respectively
16 C I) t'ft:. = Torque transmitted by the coupling.
c) Key Design:
Mt == lW·'tk .d
2
Nt= t(~}CT~{~)
d) Flange Design:
tft=,.(D;},.t f D,
Dz
= Pitch circle diameter of bolts
= Outside diameter of'flange
e) Bolts Design: d = Shaft diameter
~== n.( ~ )(dt)·'tb .r~]
I" J L
T
'tb
= Torque transmitted by the coupling.
= Allowable shear stress for bolt material
= Allowableshear stress for shaft material
Ht n.~tf''''b.[;]
'ts
= d1 = Nominal diameter ofthe bolts.
n =No.ofbolts
=4 when 35 < d< 55 mm
Marine Coupling: (F /G!. 14-)
= 6 when 56 < d < 150 mm
Flange thickness = d/3= tf
=8 when 151 <d<250 mm
Taper of-bolt = 1 in 20 to 1 in 40
DI = 1.6d . = 10 when 251 <d < 390 mm
D2= 2.2 d
= 12 when d > 390 mm
...... rnl
,-, ,,== 1- r(q ):ti;J.n·I- 1
2 r~ 1
L4 J L2 j
Fig. 14- Marine type flange coupling.
····-·----1
Turnbuckle,-1
_..:.......- ------
1 d
~+_-__t_--- ----
____ _ __ -.1----+----' 1 --~"'1~5mm
5mm °
1=1-1 1-1-1
Bushed-pin flexible coupling.
Flexible
Where
L = Hub Length
I = Length of the bush in the flange.
d.2 = Diameter of bush
d = Shaft diameter
PI;, = Bearing pressure on bush,
:s 0.5 to 0.8 MPa
n
D! = Pitch circle Diameter ofpins.
= No. of pins
I I
W = Load on each pins
M = Bending moment on pin °1
Gb = Bending stress in pin material ,
't = Allowable shear stress for pin material I
SPLlNED CONNECTIoNS:
Torque carrying capacity of the
p = perm issible bearing pressure,
splined connection
<7MPa
T = p.A.rm
A = Total area of the splines, (h/N)
h = Height of the splines = (D - d)j2
SLEEVE AND COTTER
I = length ofthe hub
.JOINTS: (F 16i. 4-) N = No. of splines
(D + d)\ /
Empirical relations: I'm. = Mean radius = ~ I~
d, = 1.3 d
d2 = 2.5 d Where
a = 1.3 d d = Diameter of'the rods to be connected
L=8d d1 = Diameter of'the enlarged end
1=4d d2 = Outside diameter of'the sleeve
b = 1.3d a = distance of'the slotfrom the sleeve end
c=lAd L = Length of the sleeve
e = O.5d 1 =Length of the cotter
t = O.3d = O.25d1. b = Width of'the cotter
P = 11:4' d 2 .[Oot] c = Distance of'the slot from the rod end
e = Length of the- enlarged end outside the
sleeve
........ __. _ - - - - t = Thickness of the cotter
p = Load acting on the joint
p =[; (d.)2 - dt.f JrCT+j
= Crushing Stress
P = dt .t. [C5aJ = Shear stress
p=[;r d2 f - (d. )2]_(d;z -dd. t } [ C5tl crt
= Tensile Stress
. p = 2b.t.['t]
P = 2a.d:. ['t] clearance 1.5to 3 mm
P= 2.(d2 - d1 ).c.['t]
SCOKET A..ND SPIGOT JOINT:
p =[ ~ KD1 )2 - (~ 'f]-(D1 - d1 ). t} [crt]
P= (D - d1 ).t.[O'c]
P= 2.c.(I:> - d1 ).['t]
P = ~ (~2 - cit 2)[crc ]
P = n.dt •tt. ['t] "'-::==::::::=o:>'t hic k ne 55 t
P.(D+O.5~) ~-W///////~""""~/A
-.1 t
°b = 2.t.b~
COHERED JOI~T
--r
FOR RODS
4d~
d
P P
Split pin
KNUCKLE JOINT
KNUKLE JOINTS:
Solid RQd in Tension [CS"t1;~ 4.P,:> Pm m b'endiing 2P(. -+
t1 t \ 1t d 3
4 ~ -32 1 .ob
o ' •
1t.d~
3 -) .
Prijportions: .
Pin in double shear p ~ 2.~d12['tJ
4 Diameter of'the rod = d
Rod end in tension Diameter ofthe pin d1 = d
p ~ (d2 - d1).t.[Ot] Outer diameter of eye d2 = 2d
Rod end in Double shear Diameter of Pin head <h = L5d
p 52. (d2 -4) t.['t] Thickness of eye t = 1.25d
2 Thickness of Fork t1 = O.75d
Rod end in crushing p ::; dJ.t.[ocl Thickness of pin Head t2 = O.5d
Forked end in tension
p::; 2.(~ - c\).fl.[crt] Where P = Load acting on the joint.'
Forked ends in double shear 't = Shear stress
p ~ 4.(~ - (U.t1.['t] O"c = Crushing stress
crt = Tensile stress
Forked ends in crushing
p ~ 2A .t1·[ocl
'E'~~
)i'~..:..;
LlJ~]
.~~I . At
f bJ
(0)
~ F-tG.~ Icl
(dJ
:
i
Proportions
Diameter of rod = d
Diameter of pin = d 1 = d
Octagonal
Outer dia. of eye = d z = 2d
end Dia, of pin head = d 3 = 1.5d
Split pin
Knucle pin collar--
Knuckle pin
KNUCKLE JOINT
Area resisting 2
shear = 2 x TTd,
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Area resisting shearing=2(drd1 x ~
?Q resisting learing = (dZ- dl) t
-.-2- y
FAILURES OF EYE END
4>45
(JJ)
-E:>-I:SO a=J)
(;, : O"IJi~
~ :: "2'-d
DiQ 04wet e tl
D'A FfJ p,n D =e4
p OJ) 'tJ Ese a, = 2cl
_~-.A-"'--L"""- DI'~ '" A.,. ~etAtl d 2 :
'·rsJ
I-r----.-!::x::t~ Th""", '" ESe. l; = '·2 so d
n" " etwta' t, = Doo:J,tJ
Fig.IO.IS Knuckle joint 1hk , p,nheao( t 2 ': O·l5d