Mechanical Design

Al-Balqa’ Applied University
Al-Huson University College

Mechanical Engineering Department
Mechanical design (30131326)
Professor Dr. Musa K. AlAjlouni
Second Semester 2014/2015
Prof. Musa AlAjlouni 1 Mechanical Design

Al-Balqa’ Applied University
Al-Huson University College
Mechanical Engineering Department
Second Semester 2014/2015
Mechanical design (30131326)
Course Title: Mechanical design (30131326)

Prerequisite: Strength of Material (30129212)
Text Book: Shigley’s Mechanical Engineering Design, Budynas−Nisbett, 2011, Ninth
edition, McGraw-Hill Book Company..
Providing Dept.: Mechanical Engineering
Instructor: Prof. Dr. Musa K. AlAjlouni Office No: Tel:
Level: 3th year Credit Hours: 3
Semester: Second 2014-2015
Time: (08:00-09:00) Sundays, Tuesdays and Thursdays.
Office Hours: (to be announced soon after).
Time Schedule:
Duration: 16 Weeks Lectures: 3 hours / week
Objectives: Mechanical Engineering design is a study of design-making processes. It utilizes mathematics, the
material sciences and the engineering-mechanics sciences. In this course concentration will be on machine
elements design rather than machine design. This course will cover the following topics:
Course Contents
Subject week Subject week
1. Review of machine Drawing includes: 1-4 First Exam 2nd lecture 7th week (10th of
a. Assembly and detail drawings. March 2015) and submission of project
b. Manufacturing processes one (coupling);
c. Fit and Tolerance. 5. Power Screw and Screw Fasteners 8-9
d. Surface roughness. 6. Welding and riveted joints. 9
2. Introduction to design include: Second Exam 2nd lecture 12th week (21st 10-11
a. The meaning and phases of of April 2015) and submission of project
design. 5 two (Jack).
b. Simple stresses. 7. Clutch and brake design 13
c. Safety factors. 8. Mechanical Springs 14
d. Stress analyses 9. Pressure Vessels (Thick and thin 15
3. Theories of failure and bearing 6 cylinders) 16
4. Shaft and Couplings design 7 10. Belt, Chains Gear and Rope Design.
Final Exam
Mode of Assessment
1. First exam: (20%)
2. Second exam: (20%)
3. Reports, H. works, and/or Projects (10%)
4. Final exam: (50%)
References
 Machine Design, Abdul Mubeen, 1995, Second edition, Khanna Publishers.
 Machine Design: Theory and Practice, A. D. Deutschman, W. J. Maichels and C.E. Wilson, 1975,
 Machine Design, A .CAD approach, A. D. Demarogonas, 2001, First edition, Wiley and sons
First edition, Macmillan Publishing Company.
Publishing Company.

Part I
Introduction to Mechanical Engineering Design
This part includes:
 The Nature of Mechanical Engineering
 Design phases
Design
 Design Procedure
 Design Considerations
 Standards and Codes
 Materials Selection
 Dimensions, Tolerances, Limits and Fits
 Surface finish
 Relation between manufacturing processes,
tolerances and surface finish

The Nature of Mechanical Engineering Design:
Design is an iterative process with many interactive phases. Many resources exist to
support the designer, including many sources of information and an abundance of
computational design tools. The design engineer needs not only to develop
competence in their field but must also cultivate a strong sense of responsibility and
professional work ethic.
There are roles to be played by codes and standards, ever-present economics, safety,
and considerations of product liability. The survival of a mechanical component is
often related through stress and strength. Matters of uncertainty are ever-present in
engineering design and are typically addressed by the design factor and factor of
safety, either in the form of a deterministic (absolute) or statistical sense. The latter,
statistical approach, deals with a design’s reliability and requires good statistical data.
In mechanical design, other considerations include dimensions and tolerances, units,
and calculations.
Design is an innovative and highly iterative process. It is also a decision-making
process. Decisions sometimes have to be made with too little information,
occasionally with just the right amount of information, or with an excess of partially
contradictory information. Decisions are sometimes made tentatively, with the right
reserved to adjust as more becomes known. The point is that the engineering designer
has to be personally comfortable with a decision-making, problem-solving role.
Design phases:
The complete design process, from start to finish, is often outlined as in Fig. 1–1. The
process begins with an identification of a need and a decision to do something about
it. After many iterations, the process ends with the presentation of the plans for
satisfying the need. Depending on the nature of the design task, several design phases
may be repeated throughout the life of the product, from inception to termination.

Design Procedure :
Recognition
Experience
Synthesis
(Mechanism)
Codes,
Standards
Anlysis
(Forces)
Experiments
Selection of
Material
Cost
Calculation
(Stresses and
Sizes) Manufacturing
Processes
Modification
Human
Report
Factors
(Drawings)
Design Considerations:
Sometimes the strength required of an element in a system is an important factor in
the determination of the geometry and the dimensions of the element. In such a
situation we say that strength is an important design consideration. When we use the
expression design consideration, we are referring to some characteristic that
influences the design of the element or, perhaps, the entire system. Usually quite a
number of such characteristics must be considered and prioritized in a given design
situation. Many of the important ones are as follows (not necessarily in order of
importance):
1 Functionality 10 Cost 19 Thermal properties
2 Strength/stress 11 Friction 20 Surface
3 Distortion/deflection/stiffness 12 Weight 21 Lubrication
4 Wear 13 Life 22 Marketability
5 Corrosion 14 Noise 23 Maintenance
6 Safety 15 Styling 24 Volume
7 Reliability 16 Shape 25 Liability
8 Manufacturability 17 Size 26 Remanufacturing
9 Utility 18 Control 27 Resource recovery

Some of these characteristics have to do directly with the dimensions, the material,
the processing, and the joining of the elements of the system. Several characteristics
may be interrelated, which affects the configuration of the total system.
Standards and Codes:

A standard is a set of specifications for parts, materials, or processes intended to
achieve uniformity, efficiency, and a specified quality. One of the important purposes
of a standard is to place a limit on the number of items in the specifications so as to
provide a reasonable inventory of tooling, sizes, shapes, and varieties.
A code is a set of specifications for the analysis, design, manufacture, and
construction of something. The purpose of a code is to achieve a specified degree of
safety, efficiency, and performance or quality. It is important to observe that safety
codes do not imply absolute safety. In fact, absolute safety is impossible to obtain.
Sometimes the unexpected event really does happen. Designing a building to
withstand a 180 km/h wind does not mean that the designers think a 200 km/h wind is
impossible; it simply means that they think it is highly improbable.
All of the organizations and societies listed below have established specifications for
standards and safety or design codes. The name of the organization provides a clue to
the nature of the standard or code. Some of the standards and codes, as well as
addresses, can be obtained in most technical libraries. The organizations of interest to
mechanical engineers are:
Aluminum Association (AA)
American Gear Manufacturers Association (AGMA)
American Institute of Steel Construction (AISC)
American Iron and Steel Institute (AISI)
American National Standards Institute (ANSI)
ASM International
American Society of Mechanical Engineers (ASME)
American Society of Testing and Materials (ASTM)
American Welding Society (AWS)
American Bearing Manufacturers Association (ABMA)
British Standards Institution (BSI)
Industrial Fasteners Institute (IFI)
Institution of Mechanical Engineers (I. Mech. E.)
International Bureau of Weights and Measures (BIPM)
International Standards Organization (ISO)
National Institute for Standards and Technology (NIST)
Society of Automotive Engineers (SAE)
Materials Selection:
The selection of a material for a machine part or structural member is one of the most
important decisions the designer is called on to make. There is many important
material physical properties, various characteristics of typical engineering materials,
and various material production processes. The actual selection of a material for a
particular design application can be an easy one, say, based on previous applications
(1020 steel is always a good candidate because of its many positive attributes), or the
selection process can be as involved and daunting as any design problem with the
evaluation of the many material physical, economical, and processing parameters.
There are systematic and optimizing approaches to material selection. Here, for
simplification, we will start with steel if that’s work and more accurate method will be

lifted for future. Otherwise, look at how to approach some material properties. One
basic technique is to list all the important material properties associated with the
design, e.g., strength, stiffness, and cost. This can be prioritized by using a weighting
measure depending on what properties are more important than others. Next, for each
property, list all available materials and rank them in order beginning with the best
material; e.g., for strength, high-strength steel such as 4340 steel should be near the
top of the list. For completeness of available materials, this might require a large
source of material data. Once the lists are formed, select a manageable amount of
materials from the top of each list. From each reduced list select the materials that are
contained within every list for further review. The materials in the reduced lists can be
graded within the list and then weighted according to the importance of each property.
Dimensions, Tolerances, Limits and Fits:

The following terms are used generally in dimensioning:
• Basic or Nominal size. The size we use in speaking of an element. Either the
theoretical size or the actual measured size may be quite different.
• Limits. The stated maximum and minimum dimensions.
• Tolerance. The difference between the two limits.
• Bilateral tolerance. The variation in both directions from the basic dimension. That
is, the basic size is between the two limits, for example, 1.005 ± 0.002 in. The two
parts of the tolerance need not be equal.
• Unilateral tolerance. The basic dimension is taken as one of the limits, and variation
is permitted in only one direction, for example, 1.005 +0.004 −0.000 in
• Clearance. A general term that refers to the mating of cylindrical parts such as a bolt
and a hole. The word clearance is used only when the internal member is smaller than
the external member. The diametral clearance is the measured difference in the two
diameters. The radial clearance is the difference in the two radii.
• Interference. The opposite of clearance, for mating cylindrical parts in which the
internal member is larger than the external member.
• Allowance. The minimum stated clearance or the maximum stated interference for
mating parts. When several parts are assembled, the gap (or interference) depends on
the dimensions and tolerances of the individual parts.
The designer is free to adopt any geometry of fit for shafts and holes that will ensure
the intended function. There is sufficient accumulated experience with commonly
recurring situations to make standards useful. There are two standards for limits and
fits in the United States, one based on inch units and the other based on metric units.
These differ in nomenclature, definitions, and organization. No point would be served
by separately studying each of the two systems. The metric version is the newer of the
two and is well organized, and so here we present only the metric version but include
a set of inch conversions to enable the same system to be used with either system of
units.
In using the standard, capital letters always refer to the hole; lowercase letters are
used for the shaft.
The definitions illustrated in Fig. 7–20 are explained as follows:
• Basic size is the size to which limits or deviations are assigned and is the same for
both members of the fit.
• Deviation is the algebraic difference between a size and the corresponding basic
size.
• Upper deviation is the algebraic difference between the maximum limit and the
corresponding basic size.

• Lower deviation is the algebraic difference between the minimum limit and the
corresponding basic size.
• Fundamental deviation is either the upper or the lower deviation, depending on
which is closer to the basic size.
• Tolerance is the difference between the maximum and minimum size limits of a
part.
• International tolerance grade numbers (IT) designate groups of tolerances such that
the tolerances for a particular IT number have the same relative level of accuracy but
vary depending on the basic size.
• Hole basis represents a system of fits corresponding to a basic hole size. The
fundamental deviation is H.
• Shaft basis represents a system of fits corresponding to a basic shaft size. The
fundamental deviation is h. The shaft-basis system is not included here.
• Types of fits are clearance, translation and interference fit.
The magnitude of the tolerance zone is the variation in part size and is the same for
both the internal and the external dimensions. The tolerance zones are specified in
international tolerance grade numbers, called IT numbers. The smaller grade numbers
specify a smaller tolerance zone. These range from IT0 to IT16, but only grades IT6
to IT11 are needed for the preferred fits. These are listed in Tables A–11 to A–13 for
basic sizes up to 16 in or 400 mm.
The standard uses tolerance position letters, with capital letters for internal
dimensions (holes) and lowercase letters for external dimensions (shafts). As shown
in Fig. 7–20, the fundamental deviation locates the tolerance zone relative to the basic
size.
Table 7–9 shows how the letters are combined with the tolerance grades to establish a
preferred fit. The ISO symbol for the hole for a sliding fit with a basic size of 32 mm
is 32H7. Inch units are not a part of the standard. However, the designation (13.8 in)
H7 includes the same information and is recommended for use here. In both cases, the
capital letter H establishes the fundamental deviation and the number 7 defines a
tolerance grade of IT7.

For the sliding fit, the corresponding shaft dimensions are defined by the symbol 32g6
[(13.8 in)g6]. The fundamental deviations for shafts are given in Tables A–11 and A–
13. For letter codes c, d, f, g, and h,
Upper deviation = fundamental deviation
Lower deviation = upper deviation − tolerance grade
For letter codes k, n, p, s, and u, the deviations for shafts are
Lower deviation = fundamental deviation
Upper deviation = lower deviation + tolerance grade
The lower deviation H (for holes) is zero. For these, the upper deviation equals the
tolerance grade.
As shown in Fig. 7–20, we use the following notation:
D = basic size of hole
d = basic size of shaft
δu = upper deviation
δl = lower deviation
δF = fundamental deviation
ΔD = tolerance grade for hole
Δd = tolerance grade for shaft
Note that these quantities are all deterministic. Thus, for the hole,
Dmax = D + ΔD and Dmin = D
For shafts with clearance fits c, d, f, g, and h,
dmax = d + F dmin = d + F −Δd
For shafts with interference fits k, n, p, s, and u,
dmin = d + F dmax = d + F + Δd

Table of Preferred Limits and Fits for Cylindrical Parts, ANSI B4.1-1967. Preferred
Metric Limits and Fits, ANSI-B4.2-1978.

Surface finish:
By definition, surface finish is the allowable deviation from a perfectly flat surface
that is made by some manufacturing process. All machining processes will produces
some roughness on the surface. This roughness can be caused by a cutting tool,
cutting rate and environmental conditions and the type of material you are working
with. Surface texture consists of the repetitive and/or random deviations from the
nominal surface of an object.
Surface finish (as shown in the figure below) is generally broken up into four
components such as roughness, waviness, lay and flaws.

Roughness is generally the machined marks made on a surface by the cutting tool. It
refers to the small, finely spaced deviations from the nominal surface that are
determined by the material characteristics and the process that formed the surface.
Waviness. is defined as the deviations of much larger spacing; they occur because of
work deflection, vibration, heat treatment, and similar factors. Roughness is
superimposed on waviness.
Lay is the predominant direction or pattern of the surface texture. It is determined by
the manufacturing method used to create the surface, usually from the action of a
cutting tool. Figure below presents most of the possible lays a surface can take,
together with the symbol used by a designer to specify them.
Flaws are irregularities that occur occasionally on the surface; these include cracks,
scratches, inclusions, and similar defects in the surface. Although some of the flaws
relate to surface texture, they also affect surface integrity.
Surface Finish Measurements and Charts:

(Source: Wikipedia: http://en.wikipedia.org/wiki/Surface_finish)
The parameters of texture are vertical amplitude variations, horizontal spacing
variations, or some hybrid combination of these. All four surface finish components
exist simultaneously. They simply overlap one another. We often look at each

(roughness, waviness, and lay) separately, so we make the assumption that roughness
has a shorter wavelength than waviness, which in turn has a shorter wavelength than
form.
Surface roughness is a measurable characteristic based on the roughness. Surface
finish is a more subjective term denoting smoothness and general quality of a surface.
In popular usage, surface finish is often used as a synonym for surface roughness. The
most commonly used measure of surface texture is surface roughness. With respect to
Figure below, surface roughness can be defined as the average of the vertical
deviations from the nominal surface over a specified surface length. An arithmetic
average (Ra) is generally used, based on the absolute values of the deviations, and this
roughness value is referred to by the name average roughness. The Ra method is the
most widely used averaging method for surface roughness today. An alternative is the
root-mean-square (RMS) average, which is the square root of the mean of the squared
deviations over the measuring length. RMS surface roughness values will almost
always be greater than the Ra values because the larger deviations will figure more
prominently in the calculation of the RMS value.
Surface roughness suffers the same kinds of deficiencies of any single measure used
to assess a complex physical attribute. For example, it fails to account for the lay of
the surface pattern; thus, surface roughness may vary significantly, depending on the
direction in which it is measured. Another deficiency is that waviness can be included
in the Ra computation. To deal with this problem, a parameter called the cutoff length
is used as a filter that separates the waviness in a measured surface from the
roughness deviations. In effect, the cutoff length is a sampling distance along the
surface. A sampling distance shorter than the waviness width will eliminate the
vertical deviations associated with waviness and only include those associated with
roughness. The most common cutoff length used in practice is 0.8mm(0.030 in). The
measuring length Lm is normally set at about five times the cutoff length. The
limitations of surface roughness have motivated the development of additional
measures that more completely describe the topography of a given surface. These
measures include three-dimensional graphical renderings of the surface.
Depending on conventions in different countries, industries, applications, etc. the
units used to express surface finish or roughness will vary. Likewise, various industry
standards are used to specify the degree of roughness allowed or recommended in
different applications. These standards include those published by ANSI, ASME,
SAE, ISO, and other organizations.
Commonly used expressions of finish include:
Standard grit reference - refers to the grit of a surface finishing medium or method,
which does not provide a consistent measure of roughness, since results depend on a
part's material, finishing method, lubricant used (if any), and applied work pressure.
N- New ISO (Grade) Scale numbers. These are used on manufacturing drawings that
specify surface finish in terms of an ISO standard. Each roughness grade number can
be correlated to a specific Ra number that is expressed in microns.
Ra- Roughness average, most commonly expressed in micrometers (microns). This is
the most universally recognized and used international standard of roughness
measurements. It is the arithmetic mean of the absolute departures of a roughness
profile from the mean line of the measurement. Ra may also be expressed in
microinches.
Rp- Maximum profile peak height.
Rv- The deepest valley below the mean line.

Rt- The total height of a roughness profile, typically expressed in microns, is the
maximum peak-to-valley height along the assessment length.
Rz - The average Rt over a given length.
Rz=(Rp1+Rp2+Rp3)+(Rv1+Rv2+Rv3) / 3
CLA- Center Line Average in micro-inches. This is a conversion using Ra(μm) x
39.37.
RMS- Root Mean Square in micro-meters or micro-inches; i.e., the average of peaks
and valleys of a material's surface profile as calculated from a number (n) of
measurements (x) along the sampling length:
RSm- The mean spacing between profile peaks on the mean line, measured along the
sampling length.
Most expressions of roughness can be converted from one form to another. For
example, CLA (microinches) = Ra(μm) x 39.37(inches/meter)
Other conversions use factors that have been establish as generally acceptable over
time. In the case of RMS, a range of factor values from 1.1 to 1.7 can be acceptable.
A factor of 1.1 is probably use most often, i.e., RMS(μin.) = CLA(μin.) x 1.1. Table 1
lists conversions for some commonly used roughness expressions and values.
Table 1. Conversion chart for equivalent expressions of roughness.

Grit ISO Ra Ra CLA RMS Rt
No. No. (μm) (μin.) (μin.) (μin.) 1
(μm)2
----------- N12 50 2000 2000 2200 200
----------- N11 25 1000 1000 1100 100
----------- N10 12.5 500 500 550 50
60 N9 6.30 250 250 275 25
----------- N8 3.20 125 125 137.5 13
80 ----------- 1.80 71 71 78 9.0
----------- N7 1.60 63 63 64.3 8.0
120 ----------- 1.32 52 52 58 6.6
150 ----------- 1.06 42 42 46 5.3

----------- N6 0.80 32 32 32.5 4.0
180 ----------- 0.76 30 30 33 3.8
220 ----------- 0.48 19 19 21 2.4
----------- N5 0.40 16 15 17.6 2.0
240 ----------- 0.38 15 12 17 1.9
320 ----------- 0.30 12 9 14 1.5
400 ----------- 0.23 9 8 10 1.3
----------- N4 0.20 8 4 8.8 1.2
500 N3 0.10 4 2 4.4 0.8
----------- N2 0.05 2 1 2.2 0.5
----------- N1 0.025 1 1 1.1 0.3
Notes: 1. A factor of 1.1 X CLA is used throughout this table to calculate RMS(μin.)
2. Typically, for values of Ra from 50μm to 3.2μm, the conversion factor for Rt (μm) is 4. As surface roughness
decreases from 3.2μm, the conversion factor increases, reaching 12 at 0.025μm. This is reflected in the table
above.
Surface Finish Affects Performance

The surface finish of process vessels, piping and related components can be a critical
factor in their performance, maintenance costs, and service life. Until recently,
specifying and measuring surface finish involved varying degrees of speculation.
Today, it is more likely that this characteristic will be influenced by industry
standards, which manufacturers and processors must satisfy.
Increasingly stringent specifications are creating greater demand for improved surface
finish on most metal components that are part of process equipment. In particular
higher purity requirements for pharmaceutical and biotechnology products are
dictating the characteristics of surfaces in contact with process fluids. Increasingly,
process equipment components must meet requirements in the ASME Bio-processing
equipment standard, ASME-BPE-2009.
This standard provides specifications for the design, manufacture and acceptance of
vessels, piping and related components for application in equipment used by the
biotechnology, pharmaceutical, and personal care product industries. It includes
aspects related to sterility and cleanability, materials, dimensions and tolerances,
surface finish, material joining, and seals. Meeting the surface finish requirements of
this standard is rapidly becoming a universal necessity in the manufacture of other
fluid process equipment. As a result, suppliers of equipment and components are often
required to quantify the surface roughness of their finished products.
Some additional standards and specifications that directly or indirectly affect surface
finish requirements include:
ASME B46.1-2002 - Surface Roughness, Waviness, and Lay
ISO 4287 and 4288 - Geometrical Product Specifications (GPS)
DIN ISO 1302, DIN 4768 - Comparison of Roughness Values
ASME Y14.36M - Surface Texture Symbols
ASME B16.5 - Pipe Flange Face Roughness
DIN 7079 Standard for Fused-Glass Sight Glasses in Metal Frames
Such standards have come into play because process engineers realize that the surface
finish of vessels, piping and related components can have profound effects on how
well a fluid system performs. Typically, surface roughness is a critical parameter in
the assessment of surface finish on fluid system components. This parameter can
affect fluid flow resistance (friction), adsorption/desorption, the build-up of chemicals
from a process fluid, corrosion formation, pressure drop, etc. Ultimately, surface
finish can affect service life and maintenance costs.

Surface Finish on Engineering Drawings:
Symbols for Surface Texture Designers specify surface texture on an engineering
drawing by means of symbols looks like a square root sign as shown. The symbol
designating surface texture parameters is a check mark, with entries as indicated for
average roughness, waviness, cutoff, lay, and maximum roughness spacing.
Relation between manufacturing processes, tolerances and surface finish
Many factors contribute to the surface finish in manufacturing. In forming processes,

such as molding or metal forming, surface finish of the die determines the surface
finish of the workpiece. In machining the interaction of the cutting edges and the
microstructure of the material being cut both contribute to the final surface finish. In
general, the cost of manufacturing a surface increases as the surface finish improves.
Just as different manufacturing processes produce parts at various tolerances, they are
also capable of different roughnesses. Generally these two characteristics are linked:
manufacturing processes that are dimensionally precise create surfaces with low
roughness. In other words, if a process can manufacture parts to a narrow dimensional
tolerance, the parts will not be very rough.
Due to the abstractness of surface finish parameters, engineers usually use a tool that
has a variety of surface roughnesses created using different manufacturing methods.
Primary manufacturing processes establish the initial surface characteristics of
components and their roughness values. In the case of metallic components,
additional finishing processes may be used to reduce the degree of roughness to fit a
specific application. Table 2 lists typical Ra values for various metal finishing
methods. In the case of fluid system components, the motivation to reduce surface
roughness could be to reduce flow resistance and pressure drop, improve sealing,
reduce build-up of process chemicals on the metal surface, improve corrosion
resistance to increase life, etc. In sight glasses, for example, the surface roughness of

both the glass and the metal mounting ring are critical for achieving a good seal in the
installation.
Table 2. Typical range of Ra surface roughness values in various

metal forming operations
Various types of polishing operations are commonly used to reduce the surface
roughness of metals used in fluid vessels, piping and related components. These fall
into two categories: mechanical polishing and electropolishing. As the name implies,
mechanical polishing involves the application of physical force on abrasive media to
remove surface irregularities. While it's theoretically possible to achieve low
roughness values with certain mechanical polishing techniques, the time and cost
involved usually makes this impractical. Generally, mechanical polishing is used
when moderate roughness values are acceptable, which means numerous surface
scratches and other irregularities remain. These can cause many of the problems
mentioned earlier on this page.
Electropolishing is an electrolytic process (the reverse of plating) combining electric
current and chemicals to remove metal. The peaks of burr, folds, inclusion and other
anomalies of a metal surface are dissolved more quickly than valleys as a result of the
greater concentration of current over the protuberances. This electrochemical action
produces a smoothing and rounding of the surface profile, resulting in irregularities as

small as 0.01 micrometer (0.04 micro-inch). It prevents or reduces most of the
problems associated with rougher metal surfaces. The inherent benefits of
electropolishing subsequent to mechanical polishing include:
 Removal of surface occlusions
 Removal of inclusions and entrapped contaminants such as lubricants and grit
particles
 Cleaner surface of the a wet contact areas
 Reduced surface area/chemical reactivity for less absorption and adsorption
 Less contamination and build-up of process chemicals on a surface
 Superior surfaces for cleaning and sterilization
 Elimination of localized corrosive cells (galvanic differences) remaining after
mechanical polishing
 Resultant passivated surfaces enhance corrosion resistance
 High luster reflective appearance
 Reduced surface friction

Part II
Stress Analysis
This part includes:


Simple Stresses

Types of Loading

Combined stresses
Failure theories

Simple Stresses:
Most mechanical loading, whatever its complexity, convert at the end to three simple
types of stress. These three types are normal, shear and bearing stresses and they will
be explained in the following paragraphs and example.
Tensile and compressive stresses, called normal stresses are tend to pull on or crush
the element. For a load-carrying member in which the external load is uniformly
distributed across the cross-section area of the member, the magnitude of the stress
can be found by:
� = ⁄ = �/�
where tp is the permissible (allowable) tensile stress that can be found from tables or
Tensile Test in the following sense.
��
� = =
�
where y is the yield stress, ult is the ultimate stress, n is the safety factor based on
yield stress and N is the safety factor based on ultimate stress. N and n can be found
as explain in the next section. Note that for most ductile materials the compressive
strengths are about the same as the tensile strengths.
Selection of The Safety Factor

Selection of a design safety factor must be undertaken with care since there are
unacceptable consequences associated with selected values that are either too low or
too high. Engineers must accommodate uncertainty. Uncertainty always accompanies
change. Material properties, load variability, fabrication fidelity, and validity of
mathematical models are among concerns to designers. To implement the selection of
a design safety factor, consider separately each of the following eight factors:
1. The accuracy with loads, force, deflections or other failure-inducing agents
can be determined.
2. The accuracy with which the stresses or other loading severity parameters can
be determined from the force or other failure-inducing agents.
3. The accuracy with which the failure strengths or other measures of failure can
be determined for the selected material in the appropriate failure mode.
4. The need to conserve material, weight, space, or money.
5. The seriousness of consequences of failure of human life and/or property
damage.
6. The quality of workmanship in manufacture.
7. The conditions of operation.
8. The quality of inspection and maintenance available or possible during
operation.
For this course, we will simplify the selection of the safety factor and we will use the
following table that based and considered some factors which explained in the above
method.
Ductile Brittle
Type of load
N N N
Static load 3-4 1.5-2 5-6
Repeated, Reversed
8 4 10-12
(Mild shock)
Shock (Sudden) 10-15 5-7 15-20

Direct shear stress occurs when applied force tends to cut through the member as a
scissors or shears do when a punch and a die are used to punch a slug of material from
a sheet. Another important example of direct shear in machine is the tendency for a
key to be sheared off at the section between shaft and the hub of machine element
when transmitting torque. The method of computing direct shear is based that the
applied force is assumed to be uniformly distributed across section of the part that is
resisting the force.
� =� ⁄ = �/�
where p is the permissible (allowable) shear stress that can be found from shear test.
Unfortunately, these values are seldom reported and if this test is not available we can
estimate it as (0.5-0.66) of tp for simplicity.
Bearing stresses, sometimes called contact stresses, are occurs when one surface
crush the surface of other element. If we assume that the external load is uniformly
distributed across the contact area of the two surfaces, the magnitude of the bearing
stress can be found by:
� = ⁄ = �/�
where bp is the permissible (allowable) bearing stress that can be found from test and
if this test is not available we can estimate it as 1.33 of tp for simplicity.
The simple relation between different stresses is
� �
� = =
Case study (1): Design of the cutter joint:

The cutter joint is linking between two parts. The loading conditions are tension and
compression with maximum force of P. This force is transferring from one end to the
other. During this transformation, the stresses in each section will change from type to
type. Some sections will carry normal stress and other will carry shear stress or
bearing.
Cutter joint The Cotter

The Rod-socket
The Rod-spigot D
a Note that all sections are circular

Types of loading
Axial load( tensile stress): This is the simplest loading conditions, and the stress is
 = Force / Area
found by:
Bending moment: In this loading condition the maximum stress is the tensile stress
 = MY / I
at the most faraway point from the neutral axis and equal:
Torsion stress: The shear stress can be found from the well-known torsion formula:
 T Gl
 
r J l
Combined stresses
The real life stresses are normally a combined stresses consists of one or more of the
above stresses. The following cases are the main types.
One dimensional stresses:
If all the stresses are working on one dimension (shear only or normal stress only) the
resultant stress will be calculated simply as the summation of all of them.
Two dimensional stresses:
In two dimensional stresses Mohr's circle is used to determine the maximum normal
and shear stresses through the section. If two perpendicular normal stresses are
applied in addition to shear stress between them, the principle and shear stresses are
calculated as follows:
x y x y 

 1, 2 =    +  2xy
2

2  2 
x y  1 -  2
 max =   +  2xy
2

 
=
2 2

Three dimensional stresses:
BASIC DIMENSION OF THE TUBE AND XYZ CO-ORDINATE SYSTEM SHOWING

POSITIVE DIRECTION OF THE STRESSES.
In this loading conditions the following procedure can be used:

Step (1): The principle normal stresses are calculated by a procedure explained by
many text books This procedure is based on finding a series of (11) constants where
the last (3) are the principle normal stresses at the point analysed. These constants can
be summarised as the following:
A1= Sx + Sy + Sz
B1 = SxSy + SySz + SzSx -Sxy 2 -Syz2 -Szx 2
C1 = SxSySz + 2SxySyzSzx -SxSyz 2 -SySzx2 -SzSxy 2
D1 = A 2 3 - B
E1 = A B 3- C - 2 A 3 27
F1 = D 3 27
G1  arc cos(- E 2 F)
H1= D 3
J1 = 2H [cos(G 3 +120 )]  A 3
I1 = 2H cos(G 3) + A 3
K1 = 2H [cos(G 3 + 240 )]  A 3

As a check, if the algebraic sum I1+J1+K1 equals A1, within rounding errors, then the
calculations up to this point should be correct.
Step (2): I1, J1, and K1 are the maximum principal normal stresses.
Step (3): Calculate the true maximum shear stress by:
WSD = 0.5(PR1-PR2)
The largest value from I1, J1 and K1 is PR1 and alternatively the smallest is PR2.
Step (4): The maximum normal principal stresses and the maximum true shear stress
can be used now with various theories of failure.
Failure theories:
The tables of the mechanical properties of material usually contain design information
about a simple load case such as tensile or compression tests' results. In order to
determine suitable allowable stresses for the complicated condition, like ours, various
strength theories have been developed. Some of these theories will be summarised
here.
The maximum stress theory (Rankine's theory): This theory states that failure will
happen at the maximum or minimum of the principal stresses.
The maximum strain theory: This theory states that the failure happens at the place
where the strain becomes equal to maximum strain in the simple load case.
The maximum shear theory: This theory assumes that failure begins when the shear
stress in the material becomes equal to the maximum shear stress with a simple tensile
test. Timoshenko (1956) showed that the agreement between this theory and the
experiment is better especially with the ductile materials. This theory is simple to
apply because the allowable shear stress is normally one half of the tensile stress and
the actual maximum shear can be calculated by
Max. principal stress - Min. principal stress
Max. Shear =
2
So,
Max. allowable stress = Max. principal stress -Min. principal stress
The maximum energy theory: In this theory the quantity of strain energy per unit
volume of the material is used as the basis for determining failure. This can be
explained mathematically as:
� . ax = √ � +� +� − � � +� � +� �
Where  all. (max.) is the maximum allowable stress and 1, 2 and3 are the
normal principal stresses.
By reviewing many mechanical design references it was found that the maximum
shear theory is recommended for use with ductile materials and the maximum energy
theory with the brittle materials. This recommendation is used in this work.

Part III
Design of Mechanical Elements
This part includes:


Shafts, axles and their components

Bearings

Couplings

Screws

Welding and Riveted joints

Mechanical Springs

Clutches

Brakes

Belt

Chain
Gears

Shaft and axle
Shafts are important elements of the machines. They are the elements that support
rotating parts like gears and pulleys and in turn are themselves supported by bearings
resting in the rigid machine housings. The shafts perform the function of transmitting
power from one rotating member to another supported by it or connected to it. Thus,
they are subjected to torque due to power transmission and bending moment due to
reactions on the members that are supported by them. Shafts are to be distinguished
from axles which also support rotating members but do not transmit power. Axles are
thus subjected to only bending loads and not to the torque.
Most the times, shafts have circular cross-section and could be either solid or hollow.
The shafts are classified as straight, cranked, cam, flexible or articulated. Straight
shafts are commonest to be used for power transmission. Such shafts are commonly
designed as stepped cylindrical bars, that is, they have various diameters along their
length, although constant diameter shafts would be easy to produce. The stepped
shafts correspond to the magnitude of stress which varies along the length. Moreover,
the uniform diameter shafts are not compatible with assembly, disassembly and
maintenance. Such shafts would complicate
the fastening of the parts fitted to them,
particularly the bearings, which have to be
restricted against sliding in axial direction.
While determining the form of a stepped
shaft it is borne in mind that the diameter of
each cross-section should be such that each
part fitted on to the shaft has convenient
access to its seat.
The parts carried by axle or shaft are
fastened to them by means of keys or splines
and for this purpose the shaft and axle are
provided with key ways or splines. The
bearings that support the shafts or axle may
be of sliding contact or rolling contact type.
In the former case the journal of the shaft
rotates freely on thin lubricant layer between
itself and bearing, while in the latter case the
inner race of the bearing is force fitted on the
journal of the shaft and rotates with the shaft
while outer race is supported in the housing
and remains stationary.
A shaft is joined with another in different
ways and configurations. The coaxial shafts
are connected through couplings which may
be rigid or flexible.
Types of shaft: the types of shaft are shown
in the figure that shows (in part a) a stepped
shaft with three seats for supported parts
which can be pulleys, gears or coupling. Two
seats for bearings are also indicated. These
bearings will be rolling contact type. Figure
(b) shows a single crank shaft. The crank
may be connected to another element like

connecting rod which may have a combined rotary and reciprocating motion. The
connection is through a bearing often called crank pin. The straight part of the shaft
may support a pulley or a gear. The connection will be through a key. Multiple crank
shaft is shown in Figure (c). Each crank pin would carry a connecting rod and each
crank pin will be between the supporting bearings. The other shaft types are
explanatory.
The adjacent sections of shafts with different diameters are joined by smooth
transition fillet with as large radius as permitted by supported part or bearing that
supports the shaft. The larger radius of fillets will reduce stress concentration factor.
Materials for shafts: From the above discussion the materials for the shaft would be
required to possess
(a) high strength,
(b) low notch sensitivity,
(c) ability to be heat treated and case hardened to increase wear resistance of journals,
and
(d) good machinability.
Shafts could be made in mild steel,

Standard Sizes of Commercial Shafting
carbon steels or alloy steels such as
(Diameter)
nickel, nickel-chromium or chrome-
Up to 25 mm in increment of 0.5 mm
vanadium steels.
25 to 50 mm in increment of 1.0 mm
The following Table describes
shafting available sizes 50 to 100 mm in increment of 2.0 mm
commercially. 100 to 200 mm in increment of 5.0 mm
Shaft design:
Shaft is an important machine element and transmits power. Shafts are many types
(see the figure above) and are made, mainly, cylindrical. They are subjected to torque
and bending moment, hence, at any point in the section of shaft there exists direct
bending stress due to bending moment and shearing stress due to torque. They are
designed against maximum principal stress or maximum shearing stress. The load
(comprising bending moment and torque) is converted into equivalent bending
moment or equivalent torque. The diameters are calculated by modifying the
expressions for equivalent bending moment and equivalent torque by considering
condition and manner of loading. The keyways become essential feature of shafts
because some part like gear or pulley has to be attached on it to transmit power. The
keys are standardized and can be selected from relevant table. Alloy steel shafts are
not uncommon if corrosive atmosphere exists. Cast iron shaft, though used rarely, will
tend to become heavier.
In general, shaft design is effected by the kind of the loading that depends on the
connecting parts like Pulley, spur gear, helical gear, or bevel gear. It is not necessary
to evaluate the stresses in a shaft at every point; a few potentially critical locations
will suffice. Critical locations will usually be on the outer surface, at axial locations
where the bending moment is large, where the torque is present, and where stress
concentrations exist. By direct comparison of various points along the shaft, a few
critical locations can be identified upon which to base the design. An assessment of
typical stress situations will help.
Shafts can be designed according to:

1. Strength: In this method we find the dimensions of the shaft that allow it to work
under stress level less than the maximum allowable stresses
2. Rigidity : In this method we find the dimensions of the shaft that allow it to
deflect in the range of allowable deflections)
Design according to the strength

The following cases will be discussed:
1. Shafts subjected to twisting moment only.
2. Shafts subjected to bending moment only.
3. Shafts subjected to twisting moment and bending moment.
4. Shafts subjected to twisting moment, axial force, and bending moment.
1. Shafts subjected to twisting moment only:
Torsion formula will be used directly to find the dimensions according to the working
shear stress.
��
= =
�
where is the allowable shear stress, T is the torsional torque, J is the polar moment
of inertia, r is the shaft radius and d is the shaft diameter.
2. Shafts subjected to bending moment only:
Bending moment formula will be used to find the shaft dimension that can carry the
maximum normal stress.
�
= =
�
where is the allowable normal stress, M is the bending moment, I is the moment of
inertia, Y is the shaft radius and d is the shaft diameter.
3. Shafts subjected to twisting moment and bending moment:
��
= =
�
�
= =
�
A. Using the maximum shear theory:
� = √ +
�
� = √( ) + ( )
� �
� = √ +�
�
� = � � � � = √ +�
�

B. Using the maximum normal stress theory
� = + √( ) +
�
� = ( ) + √[ ( )] + ( )
� � �
� = [ +√ +� ]
�
� = � � = [ +√ +� ]
�
Note:
All of the above equations used for sold circular cross section shafts. For hollow
shafts with internal diameter of D and external diameter d of we use:
�
� = √ +� = −
�
= [ ( +√ + � )] = −
�
Where =
Shafts subjected to fluctuating load:

In order to design such shafts, the combined shock and fatigue factor must be taken in
account. Thus the shafts subjected to bending and torsion:
� = {√ � + �� }
= { [ � +√ � + � � ]}
Where km combined shock and fatigue factor for bending, and kt combined shock and
fatigue factor for torsion. These factors can be choose according the following table:
No. Nature of the load km kt
1 Stationary shafts:
a) gradually applied load 1.0 1.0
b) suddenly applied load 1.5 to2 1.5to 2
2 Rotating shafts:
a) gradually applied load 1.5 1.0
Steady load 1.5 1.0
b) suddenly applied load
Minor shock 1.5 to 2 1.5 to 2
Heavy shock 2.0 to 3 1.5 to 3

4. Shafts subjected to twisting moment, axial force, and bending moment:
Stress due to axial load (F) for round solid shaft is:
=
�
Stress due both axial load and bending moment is:
�
= + = ( + )=
� � � � �
� = ( + )
�
Buckling effect:
In the case of long shafts subjected to compressive load F a factor α must be
introduced to take the column effect into account:
= �
�
Where α is column factor
�= � � <
− . � �
� = � �
��
Where: L: Length of shaft between bearing.

k: Least radiuses of gyration
σy: Compressive yields stress in shaft
E: Modules of elasticity
C: Coefficient in Euler's formula depending on the end conditions as in the following
table:
Conditions C
Both ends hinged 1
Both ends fixed 4
One end fixed and the other hinged 2
One end fixed and the other free 0.25
The general set of equations: Finally, we reach the most general equations to find
the equivalent torsional torque and bending moment of the hollow circular shaft as:
� − �
� = √ � + + �� = −
�

� −
= [ � +
�
� −
+√ � + + �� ]
�
�
= −
�
Where = D d
Stress concentration
Shaft must, in most cases, have shoulder, key way, holes, oil groves and notches of
various kinds. Any discontinuity alters the stress distribution in the neighborhood
area. Such discontinuities are called stress raisers and the regions in which they occur
called stress concentration.
Stress-concentration factors for a variety of geometries may be found in tables A-15
and A-16.
The value of allowable stress may be further reduced by 25% if keyway is present
As designers, we need to understand that the potential for stress concentrations to
produce fatigue cracking can be reduced in two ways.
Reduce the stress-concentration effect by making the change of shape more
gradual.
Relocate the stress concentration or change of shape to an area subjected to lower
stresses.
Design according to the rigidity
Shafts are often designed for strength as illustrated in theory so far. But all shafts have
to be stiff and rigid so that their deflection and twist are within permissible limits. If
the shaft exceeds in deflection and twist limits the diameter has to be increased. We
must remember that the deflection and twists are inversely proportional to cube of the
diameter hence, lesser diameter will result in greater deflection and twist. The
problem becomes important when high strength steel is used for shaft. Such shaft will
result in smaller diameter and hence, larger deflection. Moreover, using high strength
steel requires greater care for its greater notch sensitivity. The permissible values of
displacement (in bending and torsion) are decided with respect to the requirements of
machine in which shaft is placed, hence, such values vary from machine to machine.
For example, permissible deflection of shaft in machine tool may depend upon
module of the gear fitted on the shaft while the limit in shaft of the rotor of an electric
motor will be in function of air gap. In general, however, the maximum deflection in
shaft must not exceed 0.2% of the span between the bearings in case of machines with
gears mounted on shafts. The slope due to bending at the bearings must also be
limited. Following are the limits for precision machines :
Slope ≤ 0.001 rad if bearing sliding contact type.
Slope ≤ 0.008 rad if bearing rolling contact type.
Slope ≤ 0.050 rad if bearing self aligning type.
The angular twist may become basic design consideration for shaft such as in drilling

machine where the twist should not be greater than 0.035 radius over a length of 25 ×
diameter. The transmission shaft in a gantry crane is not allowed to twist more than
0.012 rad per meter length.
In general, the deflection of shaft is reduced by
(a) making mounted parts lighter,
(b) keeping mounted parts balanced, and
(c) mounting parts close to bearing.
For simplification purpose, two types of rigidity can be defined:
1. Torsional rigidity ( Ф not more than)
Two permissible amount of twist:
A. ≤ 0.25̊ per one meter
B. ≤ 1̊ per 20 diameters
2. Lateral rigidity (deflection not more than)
It must be consistent with the permissible lateral deflection for proper bearing
clearance and for correct gear teeth alignment. Deflection can be found by the
standard ways.
Summary:
Shaft Design Procedure
• Develop a static free-body diagram.
• Draw a bending moment diagram in two planes.
• Develop a torque diagram.
• Establish the location of the critical cross section.
• Perform a Stress Analysis for sizing.
Shaft Design Guidelines
• Keep shafts short and minimize cantilever designs.
• Hollow shafts have better stiffness/mass ratios, but are more expensive.
• Configure shaft geometry to reduce stress concentrations.
• Remember that gears can produce radial, tangential, and axial loads.
• Be aware of maximum shaft deflection requirements of bearings.
• Shaft natural frequency should be as high as practical.
A shaft may fail by:
Excessive lateral deflection, which causes items such as gears to move
laterally from their proper location, resulting in incorrect meshing.
Torsional deflection, which destroys the precise angular relationship or
"timing" between sections of a mechanism.
Wear. Wear may take place on bearing surfaces (JOURNALS) or other
contact areas, such as cams.
Fracture. Unless the shaft was grossly under-designed, fracture usually occurs by
FATIGUE CRACKING.

Examples on shaft design:
Example 1:
A shaft carries a 1000 N pulley in the centre of two ball bearings which are 2000 mm
apart. The pulley is keyed to the shaft and receives 30 kW of power at 150 rpm. The
power is transmitted from the shaft through a flexible coupling just outside the right
bearing. The belt derive is horizontal and the sum of the belt tension is 8000 N.
Calculate the diameter of the shaft if permissible stress in bending is 80 N/mm2 and
in shear it is 45 N/mm2.
Solution:
The belt tensions T1 and T2 cause horizontal transverse force while weight of the
pulley causes vertical transverse force in the middle of the span as shown. The BM
diagrams in vertical and horizontal planes and torque diagrams are also shown.
Force in vertical plane = FV = 1000 N
Force in horizontal plane = FH = 8000 N
Both FV and FH act at the mid span. Maximum BM occurs at mid span, assuming
that the bearings behave as simple support


Example 2:
A shaft is supported in ball bearings which are placed 200 mm apart. The shaft carries
a straight tooth spur gear of 20o pressure angle at a distance of 50 mm from right hand
bearing between the supports. 3.9 kW of power is transmitted by the shaft at 90 rpm.
The pitch circle diameter of the gear is 125 mm which receives power from a pinion
placed in the same vertical plane above the gear and power is taken off from right
hand through a coupling.
Solution:
The shaft is to be made in carbon steel (A1018) for which
p = 126 Mpa
Before proceeding to calculate diameter shaft loading has to be calculated
The torque Mt acts upon the gear at a radius of . 125/2 =62.5 mm. If a tangential force

Pt acts upon the gear at this radius
This force will act on shaft transversely in horizontal plane (tangential force on gear)
at a distance of 50 mm from right hand bearing, which is regarded as simple support
along with left hand bearing. The schematic of the shaft is shown in the Figure The
bending moment due to Pt is calculated below.

Out of the two diameters (a) and (b) the higher value will be chosen. So, d=35.3 mm
say 35.5 mm.
The designed shaft will look like the one shown in the following figure.
Constraining Parts on Shafts

• For Torque Transfer
– Keys
– Set screws
– Pins
– Splines
– Tapered fits
– Press or shrink fits
• For Axial Location
– Nut and cotter pins
– Sleeves
– Shoulders
– Ring and groove
– Collar and set screw
– Split hub
Keys and splines:

A key is, usually, a rigid connector between a shaft and the hub or boss of another
component such as a pulley, sprocket, lever, flywheel, impellers gear, or cam. It is a
piece of steel inserted between the shaft and hub or boss of the pulley to connect these
together. Its purpose is to prevent relative rotation between the two parts. It is always
inserted parallel to the axis of the shaft. Keys are used as temporary fastenings and are

subjected to considerable crushing and shearing stresses ( bp and p).. If a key is to be
used, a key-seat must be provided in the shaft and keyway in the hub of the other part.
A keyway is a slot or recess in the hub or boss of the pulley to accommodate a key. A
key-seat weakens the shaft by 25% of its allowable stresses. Sharp corner on a key
way and key-seat also introduce stress consternation that must be minimised as much
as possible. In some cases, tight fit is needed between the key and both the shaft and
the hub. In other cases, a tight fit is needed between the key and the shaft, but a loose
fit between the key and the hub. The particular type of key specified will depend upon
the magnitude of torque transmitted, type of loading (that is, steady, varying, or
oscillatory), fit required, limiting shaft stress and cost. Dimension of various types of
key have been standardised.
The following types of keys are important from the subject point of view :
(a) Sunk keys, (b) Saddle keys, (c) Tangent keys, (d) Round keys, and (e) Splines.
We shall now discuss the above types of keys, in detail, in the following sections.
Light duty keys:
With light, steady, no-oscillating loads are to be transmitted, the following keys can
be used:
Square key: Most common type key where W is equal to one quarter of the shaft
diameter.
Flat key: is used where the hub of the is thin. Extra thin flat key is used where both
the hollow shaft and the hub are thin.
Woodruff key: It is a light duty key, but has the advantage of being able to align
itself readily with the hub, as it is free to rotate within the semicircular key-seat. one
of its outstanding advantages is the fact that it cannot possibly be removed (slip out
accidentally) unless the shaft and the keyed-on member are separated. A woodruff
key is capable of tilting in a recess milled out in the shaft by a cutter having the same
curvature as the disc from which the key is made. This key is largely used in machine
tool and automobile construction.
The shear area for the Woodruff key is the area the top of the shaft. A role of thumb
for selecting it is to find one with a width of approximately one-fourth the shaft
diameter and a radius approximately one-half the shaft diameter.
Light duty pins:

For light duty or medium operation, it is also possible to use a taper pin as a key.
Light duty set screws
These are regarded as light-duty attachments. Sometimes the end of the screw merely
bears against the surface of the shaft. In other cases (dog-end or cone-end screws) the
end of the screw may enter a drilled hole in the shaft. Unlike bolts and cap screws,
which depend on tension to develop a clamping force, the setscrew depends on
compression to develop the clamping force. The resistance to axial motion of the
collar or hub relative to the shaft is called holding power. This holding power, which
is really a force resistance, is due to frictional resistance of the contacting portions of
the collar and shaft as well as any slight penetration of the setscrew into the shaft.
Medium duty keys:

These keys are similar to the previous category, but tapered.
Plain tapered key: A slope of around 1% is introduced to this type. It is locked in
place radialy and axially by wedging action of the key between the hub and the shaft.

Gib head keys: This type of key is tapered 1% and contains a head that projects
beyond the keyed members. The head is included to allow for easy removal. The taper
is provided to prevent axial displacement by tightly securing the two parts.
A feather key: It is used when it necessary to permit a hub to have axial movement
along the shaft and to prevent any rotation between the shaft and the hub. It is either
screwed to the shaft with a running fit in the hub or is held in the hub with a running
fit in the shaft. As a guide in sizing a feather key, the bearing pressure on its side
should not exceed 6.89 MPa
Heavy duty Keys:
There are many types of heavy duty keys such as Nordberg key, the Kennedy key, the
Lewis key, and the Barth key.
Figure Examples of types of keys in general use

Figure Round pins of various types are sometimes used in place of keys. Pins are
generally regarded as suitable only for light duty.
Figure Drawings of different types of setscrews or grub screws. Socket setscrews: (a)
flat point; (b) cup point; (c) oval point; (d) cone point; (e) half-dog point.

Design of a key:
When a key is used in transmitting torque from a shaft to a rotor or hub, the following
two types of forces act on the key :
(a) Forces (F1) due to fit of the key in its keyway, as in a tight fitting straight key or in
a tapered key driven in place. These forces produce compressive stresses in the key
which are difficult to determine in magnitude.
(b) Forces (F) due to the torque transmitted by the shaft. These forces produce
shearing and crushing stresses in the key.
The distribution of the forces along the length of the key is not uniform because the
forces are concentrated near the torque-input end. The non-uniformity of distribution
is caused by the twisting of the shaft within the hub
In designing a key, forces due to fit of the key are neglected and it is assumed that the
distribution of forces along the length of key is uniform.
Let T = Torque transmitted by the shaft,
F = Tangential force acting at the circumference of the shaft,
d = Diameter of shaft,
l = Length of key,
w = Width of key,
t = Thickness of key, and
p and bp.. = Shear and crushing stresses for the material of key.
A little consideration will show that due to the power transmitted by the shaft, the key
may fail due to shearing or crushing.
Considering shearing of the key, the tangential shearing force acting at the
circumference of the shaft,
F = Area resisting shearing x Shearing stress = l x w x p
The force, usually, calculated from the torque transmitted by the shaft,
F = T / (d/2)
Considering crushing of the key, the tangential crushing force acting at the
circumference of the shaft,
F = Area resisting crushing x Crushing stress ( bp) = (t /2) x l x bp
The force, also, calculated from the torque transmitted by the shaft,
F = T / (d/2)
In order to find the length of the key to transmit full power of the shaft, the
permissible shearing strength of the key is equal to the torsional shear strength of the
shaft and the permissible bearing stress of the key is considered the same as the shaft
(the same material). The width and the thickness of the key (w and t) are standard
values and can be found from standard tables. Two values of the length then can be
found and the larger between them will be used.
The maximum length of a key is limited by the hub length of the attached element,
and should generally not exceed about 1.5 times the shaft diameter to avoid excessive
twisting with the angular deflection of the shaft. Multiple keys may be used as
necessary to carry greater loads, typically oriented at 90° from one another. Excessive
safety factors should be avoided in key design, since it is desirable in an overload
situation for the key to fail, rather than more costly components.
Stock key material is typically made from low carbon cold-rolled steel, and is
manufactured such that its dimensions never exceed the nominal dimension. This
allows standard cutter sizes to be used for the key-seats. A setscrew is sometimes used
along with a key to hold the hub axially, and to minimize rotational backlash when the
shaft rotates in both directions.

.
Dimensions of Parallel
keys from BS 4235:1972
Width b
Shaft dia. Section Tolerance for class fit
mm Free Normal close Shaft t1 Hub t2 Rad. r
Shaft
over incl. bh Shaft Hub Shaft Hub Hub nom tol nom tol max. min
22 30 87 +0.036 +0.098 0.0 +0.018 -0.01 4 3.3 0.25 0.16
30 38 108 0.0 +0.040 - -0.018 -0.051 5 3.3 0.40 0.25
0.036
38 44 128 5 +0.2 3.3 +0.2 0.40 0.25
44 50 149 +0.043 +0.120 0.0 +0.021 -0.018 5.5 0.0 3.8 0.0 0.40 0.25
50 58 1610 0.0 +0.050 - -0.021 -0.061 6 4.3 0.40 0.25
0.043
58 65 1811 7 4.4 0.40 0.25

Table: Proportions of Standard Parallel, Tapered and Gib Head Key according to IS :
2292 and 2293-1974
Shaft Diameter (mm) Key Cross-section Shaft Diameter (mm) Key Cross-section
up-to and Including Width Thickness up-to and Including Width Thickness
(mm) (mm) (mm) (mm)
6 2 2 85 25 14
8 3 3 95 28 16
10 4 4 110 32 18
12 5 5 130 36 20
17 6 6 150 40 22
22 8 7 170 45 25
30 10 8 200 50 28
38 12 8 230 56 32
44 14 9 260 63 32
50 16 10 290 70 36
58 18 11 330 80 40
65 20 12 380 90 45
75 22 14 440 100 50
Woodruff key:
The Woodruff key, as shown in following figure, is of general usefulness, especially
when a wheel is to be positioned against a shaft shoulder, since the keyslot need not
be machined into the shoulder stress concentration region. The use of the Woodruff
key also yields better concentricity after assembly of the wheel and shaft. This is
especially important at high speeds, as, for example, with a turbine wheel and shaft.
Woodruff keys are particularly useful in smaller shafts where their deeper penetration
helps prevent key rolling. Dimensions for some standard Woodruff key sizes can be
found in the next table, gives the shaft diameters for which the different keyseat
widths are suitable.
Table Dimensions of woodruff key

Figure Dimensions of woodruff key
Splines
When a shaft is required to carry torque beyond that obtainable with keys (or when
the is frequently reversed), one solution is to spline the shaft and the hub of the
connected member. In this way, the keys are made integral with the shaft which fit in
the keyways broached in the hub. Such shafts are known as splined shafts. These
shafts usually have four, six, ten or sixteen splines. The splined shafts are relatively
stronger than shafts having a single keyway.
The splined shafts are used when the force to be transmitted is large in proportion to
the size of the shaft as in automobile transmission and sliding gear transmissions. By
using splined shafts, we obtain axial movement as well as positive drive.
Splines are essentially axial grooves or recesses which are machined into the shaft,
very like a series of keyways. Splines are an integral part of the shaft (opposite to
keys, which are loose parts). Corresponding grooves are cut (BROACHED) into the
bore of the hub so that the shaft/hub assembly forms a series of interlocking
projections. The resulting connection is stronger than a keyed joint and is used in
heavy-duty applications. Spline profiles may be square, involute or triangular. Splines
are often designed to allow axial movement of a gear or hub whilst continuing to
transmit torque. One particular application is in a multi-speed gearbox. For axial
sliding to occur satisfactorily, the bearing pressure on the faces of the spline must be
low and good lubrication must be provided.
Two types of splines have been standardised, the ASA involute spline with five
different angles and the SAE straight spline with four different number of splines.

Common designs use spline lengths of 0.75 D to 1.25 D, where D is the pitch
diameter of the spline. When these standard lengths are used, the shear strength of the
splines will exceed that of the shaft from which they are made.
Involute splines are typically made with pressure angles of 30°, 37.5°, or 45°.
Standard Diametral Pitches. The following are the 17 standard diametral pitches in
common use:
2.5, 3, 4, 5, 6, 8, 10, 12, 16, 20, 24, 32, 40, 48, 64, 80, 128
Length of Splines. Common designs use spline lengths from 0.75D to 1.25D, where
D is the pitch diameter of the spline. If these standards are used, the shear strength of
the splines will exceed that of the shaft on which they are machined.
Standard Modules. There are 15 standard modules:
0.25, 0.50, 0.75, 1.00, 1.25, 1.50, 1.75, 2.00, 2.50, 3, 4, 5, 6, 8, 10.
Figure: 30° involute spline

SAE Straight Splines, Nominal dimensions
Permanent Fit To slide when not To slide when All Fits

No. of under load under load
splines h d h d h d w
4 0.075 D 0.850 D 0.125 D 0. 750 D - - 0.241 D
6 0.050 D 0.900 D 0.075 D 0.850 D 0.100 D 0.800 D 0.250 D
10 0.045 D 0.910 D 0.070 D 0.860 D 0.095 D 0.810 D 0.156 D
16 0.045D 0.910 D 0.070 D 0.860 D 0.095 D 0.810 D 0.098 D

Bearings
Bearings may be classified in a number of different ways. However, for our purposes,
it is sufficient to use two groups:
 Sliding contact
 Rolling contact
Before moving on to consider these two groups, it is worth pointing out the necessary
conditions for stable and adequately constrained mounting of a shaft. Whilst being
free to rotate, the whole shaft must generally be constrained against RADIAL
movement and against AXIAL movement. In general, adequate radial constraint
requires two bearings, relatively widely spaced along the length of the shaft. Only in
the case of very short shafts should the use of only one bearing be considered. Again
in general, the shaft will need axial restraint in two directions. Sometimes both axial
restraints are applied by one bearing; in other cases, each of two bearings may provide
restraint in one axial direction. Long shafts usually require more than two bearings,
especially if lateral rigidity (small deflection under load) is required. Especially for
long shafts, questions of axial expansion due to heating must be considered. Potential
changes of the length of either the housing or the shaft (or both) due to heating while
in use usually require both axial constraints to be provided by the same bearing.
Sliding contact bearings
The design of sliding bearing is mainly based on a large number of design charts and
depends the type of the bearings. Many types of bearings are known. Only
introduction will be presented here, and full detailed design will be left for the future
when the engineer become in charge of such task.
Sliding bearings (also called plain bearings) are of two types: (1) journal or sleeve
bearings, which are cylindrical and support radial loads (those perpendicular to the
shaft axis); and (2) thrust bearings, which are generally flat and, in the case of a
rotating shaft, support loads in the direction of the shaft axis.
The simplest type of these bearings is known as a JOURNAL or PLAIN or
SLEEVE BEARING. A bearing of this type locates a shaft RADIALLY. There is no
provision for axial location.
Materials for plain bearings
Where rubbing contact occurs between two machine parts, it is usual to make the
parts of dissimilar materials. In the case of journal bearings, the shaft to be supported
is almost always made from carbon steel, so bearings are seldom made of steel.
 Bronze, usually in the form of a bush.

Frequently used bearing materials are:
 White metal, a tin/antimony/copper alloy which is often bonded to a steel
 Copper/lead/indium, often used for automotive engine bearings, usually

shell.
 Cast iron, with a shaft running directly in a machined bore in the cast
bonded to a steel shell.
 Various plastics such as PTFE, nylon, delrin.

component.
Lubrication of plain bearings

Plain bearings are usually lubricated by grease or oil, supplied by an oil drip
lubricator or a ring oiler or by periodic application of an oil-can. Alternatively, it is
possible to design a plain bearing as an air- or gas-lubricated bearing, which requires
a constant supply of gas under pressure. Gas-lubricated bearings are beyond the scope
of these notes.

 Friction is higher than for rolling-contact bearings. Starting friction of plain
Characteristics of plain bearings
 Well-designed plain bearings can have an extremely long life. However, they
bearings is significantly higher than running friction.
 Plain bearings run more quietly than rolling-contact bearings.

can fail without warning.
Lubrication Theory
Types of Lubrication: Lubrication is commonly classified according to the degree
with which the lubricant separates the sliding surfaces. The following figure illustrates
three basic cases.
FIGURE : Three basic types of lubrication. The surfaces are highly magnified.
1. In hydrodynamic lubrication the surfaces are completely separated by the lubricant

film. The load tending to bring the surfaces together is supported entirely by fluid
pressure generated by relative motion of the surfaces (as journal rotation). Surface
wear does not occur, and friction losses originate only within the lubricant film.
Typical film thicknesses at the thinnest point (designated h0) are 0.008 to 0.020 mm
(0.0003 to 0.0008 in.). Typical values of coefficient of friction ( f ) are 0.002 to 0.010.
2. In mixed-film lubrication the surface peaks are intermittently in contact, and there
is partial hydrodynamic support. With proper design, surface wear can be mild.
Coefficients of friction commonly range from 0.004 to 0.10.
3. In boundary lubrication surface contact is continuous and extensive, but the
lubricant is continuously “smeared” over the surfaces and provides a continuously
renewed adsorbed surface film that reduces friction and wear. Typical values of f are
0.05 to 0.20.
Complete surface separation (as in the above Figure a) can also be achieved by
hydrostatic lubrication. A highly pressurized fluid such as air, oil, or water is
introduced into the load-bearing area. Since the fluid is pressurized by external means,
full surface separation can be obtained whether or not there is relative motion between
the surfaces. The principal advantage is extremely low friction at all times, including
during starting and low-speed operation. Disadvantages are the cost, complication,
and bulk of the external source of fluid pressurization. Hydrostatic lubrication is used
only for specialized applications.
Whenever a solid surface moves over another, it must overcome a resistive, opposing
force known as solid friction. The first stage of solid friction, known as static friction,
is the frictional resistance that must be overcome to initiate movement of a body at
rest. The second stage of frictional resistance, known as kinetic friction, is the
resistive force of a body in motion as it slides or rolls over another solid body. It is
usually smaller in magnitude than static friction. Although friction varies according to
applied load and solid surface roughness, it is unaffected by speed of motion and
apparent contact surface area. When viewed under a microscope a solid surface will
appear rough with many asperities (peaks and valleys). When two solid surfaces
interact without a lubricating medium, full metal-to-metal contact takes place in

which the asperity peaks of one solid interferes with asperity peaks of the other solid.
When any movement is initiated the asperities collide causing a rapid increase in heat
and the metal peaks to adhere and weld to one another. If the force of motion is great
enough the peaks will plow through each other’s surface and the welded areas will
shear causing surface degradation, or wear. In extreme cases, the resistance of the
welded solid surfaces could be greater than the motive force causing mechanical
seizure to take place. Some mechanical systems designs, such as brakes, are designed
to take advantage of friction. For other systems, such as bearings, this metal-to-metal
contact state and level of wear is usually undesirable. To combat this level of solid
friction, heat, wear, and consumed power, a suitable lubricating fluid or fluid film
must be introduced as an intermediary between the two solid surfaces. Although
lubricants themselves are not frictionless, the molecular resistive force of a gas or
fluid in motion known as fluid friction is significantly less than solid friction. The
level of fluid friction is dependent on the lubricant’s Viscosity
Figure: Basic components of a journal bearing. and Typical pressure profile of

journal bearing.
The following is a list of important factors to be taken into account when designing a
bearing for hydrodynamic lubrication.
1. The minimum oil film thickness must be sufficient to ensure thick-film lubrication.
2. Friction should be as low as possible, consistent with adequate oil film thickness.
Try to keep in the “optimum zone”.
3. Be sure that an adequate supply of clean and sufficiently cooled oil is always
available at the bearing inlet. This may require forced feeding, special cooling
provisions, or both.
4. Be sure that the maximum oil temperature is acceptable (generally below 93° to
121°C or 200° to 250°F).
5. Be sure that oil admitted to the bearing gets distributed over its full length. This
may require grooves in the bearing. If so, they should be kept away from highly
loaded areas.
6. Select a suitable bearing material to provide sufficient strength at operating
temperatures, sufficient comformability and embeddability, and adequate corrosion
resistance.
7. Check the overall design for shaft misalignment and deflection. If these are
excessive, even a properly designed bearing will give trouble.

8. Check the bearing loads and elapsed times during start-up and shutdown. Bearing
pressures during these periods should preferably be under 2 MPa, or 300 psi. If there
are extended time periods of low-speed operations, thin-film lubrication requirements
must be considered.
9. Be sure that the design is satisfactory for all reasonably anticipated combinations of
clearance and oil viscosity. The operating clearance will be influenced by thermal
expansion and by eventual wear. Oil temperature and therefore viscosity is influenced
by thermal factors (ambient air temperature, air circulation, etc.), and by possible
changes in the oil with time. Furthermore, the user may put in a lighter or heavier
grade of oil than the one specified
Thrust Bearings
As the name implies, thrust bearings are used either to absorb axial shaft loads or to
position shafts axially. Brief descriptions of the normal designs for these bearings
follow with approximate design methods for each. The generally accepted load ranges
for these types of bearings are given in the following Table and the schematic
configurations are shown in the following Figure.
Figure: Types of thrust bearings.
Table : Thrust Bearing Loads

Type Normal Unit Loads, Maximum Unit Loads,
[Lb per Sq. In.] [Lb per Sq. In.]
Parallel surface <75 <150
Step 200 500
Tapered land 200 500
Tilting pad 200 500
The parallel or flat plate thrust bearing is probably the most frequently used type. It
is the simplest and lowest in cost of those considered; however, it is also the least
capable of absorbing load, as can be seen from Table 1. It is most generally used as a
positioning device where loads are either light or occasional.
The step bearing, like the parallel plate, is also a relatively simple design. This type
of bearing will accept the normal range of thrust loads and lends itself to low-cost,
high-volume production. However, this type of bearing becomes sensitive to
alignment as its size increases.
The tapered land thrust bearing, as shown in Table 1, is capable of high load
capacity. Where the step bearing is generally used for small sizes, the tapered land

type can be used in larger sizes. However, it is more costly to manufacture and does
require good alignment as size is increased.
The tilting pad or Kingsbury thrust bearing (as it is commonly referred to) is also
capable of high thrust capacity. Because of its construction it is more costly, but it has
the inherent advantage of being able to absorb significant amounts of misalignment.
Rolling contact bearings
These bearings use elements such as balls or rollers to avoid sliding contact. The
usual practice is to provide two more-or-less cylindrical housings or RACES, the
inner one of which fits onto the shaft and rotates with it, while the outer race fits into
the fixed or non-rotating component. The rolling members (balls or rollers) run freely
between the two races. In practice, it is impossible to achieve pure rolling and there
will always be some sliding movement within the bearing. Despite this, such bearings
run very freely and are often referred to as ANTI-FRICTION BEARINGS
 They have very low friction, particularly when starting.

Characteristics of rolling contact bearings:
 They require larger radial sizes than plain bearings but need shorter axial
 They are generally more costly than plain bearings.

length.
 They have a finite life. The rolling elements and races eventually fail by
 Rolling contact bearings are not as quiet in operation as plain bearings. As

flaking of the contact surfaces, a form of fatigue failure.
progressive surface flaking occurs, the bearings become increasingly noisy in

operation and provide ample warning of impending failure. Compare with
plain bearings which can fail very rapidly and almost without warning.
Bearing types:
Bearings are manufactured to take pure radial loads, pure thrust loads, or a
combination of the two kinds of loads. Rolling-element bearings are either ball
bearings or roller bearings. In general, ball bearings are capable of higher speeds, and
roller bearings can carry greater loads. Most rolling-element bearings can be classed
in one of three categories:
(1) radial for carrying loads that are primarily radial; (2) thrust, or axial-contact for
carrying loads that are primarily axial; and (3) angular-contact for carrying combined
axial and radial loads.
The nomenclature of a ball bearing is illustrated in following Figure, which also
shows the four essential parts of a bearing. These are the outer ring, the inner ring, the
balls or rolling elements, and the separator. In low-priced bearings, the separator is
sometimes omitted, but it has the important function of separating the elements so that
rubbing contact will not occur. In this section we include a selection from the many
types of standardized bearings that are manufactured. Most bearing manufacturers
provide engineering manuals and brochures containing lavish descriptions of the
various types available. In the small space available here, only a meager outline of
some of the most common types can be given. So you should include a survey of
bearing manufacturers’ literature in your studies of this section. Some of the various
types of standardized bearings that are manufactured are shown in the following
figure. The single-row deep-groove bearing, for example, will take radial load as well
as some thrust load. The balls are inserted into the grooves by moving the inner ring
to an eccentric position. The balls are separated after loading, and the separator is then
inserted.

As a second example, the following figure shows the nomenclature of a tapered roller
bearing, and the point G through which radial and axial components of load act. The
four components of a tapered roller bearing assembly are the:
• Cone (inner ring)
• Cup (outer ring)
• Tapered rollers
• Cage (spacer-retainer)
Figure : Nomenclature of a ball bearing. (General Motors Corp. Used with

permission, GM Media Archives.)

Figure Steps in the assembly of the CONRAD or DEEP GROOVE type ball
bearing.
Figure : Nomenclature of a tapered roller bearing. Point G is the location of the

effective load center; use this point to estimate the radial bearing load. (Courtesy of
The Timken Company.)
Ball bearings:
Deep groove ball bearings

In ball bearings in general, the rolling elements are spheres of high quality, hardened
and polished alloy steel, rolling in hardened alloy steel INNER and OUTER RINGS
or RACES.
An alternative to DEEP GROOVE BALL BEARINGS is the FILLING NOTCH
BALL BEARING, in which small “notches” are cut out of one side of the inner and
outer races. When the notches are aligned, the required number of balls may be
slipped into the raceways before being spaced by the cage, as for the deep groove
bearing. However, the notches create a slight discontinuity in the path of the balls,
tending to decrease the life of the bearing. Since in deep-groove bearings the balls run
in shallow grooves in the races these bearings are able to support some axial loading
as well as radial. Where greater axial thrust is expected, angular contact ball bearings
are preferred and, where the expected load is entirely axial, a ball thrust bearing, may
be used.
Angular contact ball bearings
Angular contact ball bearings, capable of carrying a combination of axial and radial
loading. Note how one side of the groove in both the inner and outer races provides
more contact with the balls than the other side. The bearing must therefore be
mounted in the correct orientation to carry the axial load.
A BALL THRUST BEARING; and: A ROLLER THRUST BEARING: Both
bearings are used in conjunction with THRUST WASHERS, one on top, one
underneath, made from hardened and polished steel.
Figure Various types of ball bearings.
Roller bearings:
Cylindrical roller bearings
Whereas ball bearings have theoretical "point" contact between the balls and races,
roller bearings have "line" contact and so can carry heavier loads. In practice, of
course, both balls and rollers deform under load and contact between the rolling
element and the races changes from a point or line to a small area.
In general, cylindrical roller bearings do not provide axial restraint – the rollers in
their cage are free to slide axially along the outer race. Whilst this feature may be

useful to allow for the change of shaft length due to heating, these bearings cannot be
used unless there is provision elsewhere to provide axial location and, if necessary,
carry axial loading or thrust.
Some types of cylindrical roller bearings do provide axial restraint in one direction by
means of a shoulder in the outer race. Note that any axial or thrust loading carried by
a roller bearing must be resisted by the ends of the rollers contacting the shoulders in
the inner and outer races. Since this must result in sliding motion rather than rolling,
axial loading must be kept low to avoid scoring, overheating and seizure.
Tapered roller bearings:
Tapered roller bearings have very high radial-load capacity and high axial-load
capacity in one direction. For this reason, tapered roller bearings are often used in
pairs, mounted in opposite directions, to cater for high radial loads and axial loads in
either direction. Tapered roller bearings are often used in the wheel bearings of cars
and heavy trucks. Note that each roller is actually a FRUSTRUM of a cone so that
true rolling contact is maintained over the whole length of the roller. A double row
tapered roller bearing, used to increase the load-carrying capacity of the bearing and
to provide axial restraint in two directions.
Roller thrust bearings
Roller thrust bearings are again tapered rollers to maintain true rolling over the
length of the roller. Roller thrust bearings have a greater load capacity than ball thrust
bearings.
Needle roller bearings
One of the main advantages of needle roller bearings is their small diameter, so they
can be fitted into small spaces. They usually do not have a separate inner race,
running directly onto the shaft, which must be suitably hard and with a precision
ground surface. When these bearings fail, they often damage the shaft surface and the
shaft needs to be replaced. Compare with ball and roller bearings, which have an inner
race so that bearing damage is normally confined to the bearing races and the shaft is
undamaged.

Figure Types of roller bearings: (a) straight roller; (b) spherical roller, thrust; (c)
tapered roller, thrust; (d) needle; (e) tapered roller; ( f ) steep-angle tapered roller.
(Courtesy of The Timken Company.).
Bearings Standard dimensions:

The ABMA has established standard boundary dimensions for bearings, which define
the bearing bore, the outside diameter (OD), the width, and the fillet sizes on the shaft
and housing shoulders. The basic plan covers all ball and straight roller bearings in
the metric sizes. The plan is quite flexible in that, for a given bore, there is an
assortment of widths and outside diameters. Furthermore, the outside diameters
selected are such that, for a particular outside diameter, one can usually find a variety
of bearings having different bores and widths.
This basic ABMA plan is illustrated in following figure. The bearings are identified
by a two-digit number called the dimension-series code. The first number in the code
is from the width series, 0, 1, 2, 3, 4, 5, and 6. The second number is from the
diameter series (outside), 8, 9, 0, 1, 2, 3, and 4. The Figure shows the variety of
bearings that may be obtained with a particular bore. Since the dimension-series code
does not reveal the dimensions directly, it is necessary to resort to tabulations. The
housing and shaft shoulder diameters listed in the tables should be used whenever
possible to secure adequate support for the bearing and to resist the maximum thrust
loads.

Figure The basic ABMA plan for boundary dimensions. These apply to ball bearings,
straight roller bearings, and spherical roller bearings, but not to inch-series ball
bearings or tapered roller bearings. The contour of the corner is not specified. It may
be rounded or chamfered, but it must be small enough to clear the fillet radius
specified in the standards..
Figure Relative proportions of bearings of different series.
Figure The basic ISO plan for boundary dimensions. These apply to tapered roller
bearings.

Fitting of Rolling-Element Bearings
σormal practice is to fit the stationary ring with a “slip” or “tap” fit and the rotating
ring with enough interference to prevent relative motion during operation.
Recommended fits depend on bearing type, size, and tolerance grade. For example, a
typical ABEC-1 ball-bearing fit would be in the range of 0.0005-in. clearance for the
stationary ring and 0.0005-in. interference for the rotating ring. Manufacturing
tolerances on the shaft and housing bearing interface dimensions are typically in the
range of 0.0003 in. for ABEC-1 ball bearings. Proper fits and tolerances are
influenced by the radial stiffness of the shaft and housing, and sometimes by thermal
expansion.
It is important to recognize that bearing-fit pressures influence the internal fits
between the balls or rollers and their races. Too tight a fit can cause internal
interference that shortens the bearing life.
Care must be taken in the installation and removal of bearings to ensure that the
required forces are applied directly to the bearing ring. If these forces are transmitted
through the bearing, as when applying a force on the outer race to force the bearing
into place on the shaft, the bearing can be damaged. Interference-fit installations are
sometimes facilitated by heating the outer member or by “freezing” the inner member,
by packing it in dry ice (solidified carbon dioxide). Any heating of the bearing must
not be sufficient to damage the steel or any preinstalled lubricant.
Detailed information regarding bearing fits is contained in bearing manufacturers’
literature and in ANSI and AFBMA standards. Adhesives are sometimes used
together with slightly reduced tolerances on the shaft and housing bore dimensions,
particularly for non-precision applications.
Bearing alignment
Ball and roller bearings are precision components and are manufactured with very
small internal clearances. They therefore provide very accurate positioning of the
shaft. However, due to the small clearances, they do not perform well if they are
misaligned. If there are doubts concerning accurate alignment of the housing into
which the bearing will fit (or the amount of deflection of the shaft on which they are
mounted), SELF-ALIGNING BEARINGS may be specified. In these bearings, self-
aligning is achieved by allowing the plane of the balls or rollers to tilt relative to the
spherical race in the outer housing. Double row ball bearing (which has greater radial
load capacity than a single-row bearing) allowing the outer race to tilt within a
spherical seating. An alternative construction has an outer race with an external
spherical surface, enclosed within an additional casing which has an internal spherical
surface.
Lubrication of bearings
 Prevents corrosion.
Lubrication of rolling contact bearings is important because it:
 Greatly reduces the effects of the sliding friction present in all bearings,
 particularly roller bearings.
 Carries heat away from heavily loaded bearings.
 Drip, splash or mist (oil only).

Lubrication may be achieved by
 Lubricators (oil or grease).



Oil circulation within a gearbox by entrainment and splashing, etc.
Grease is a suitable lubricant provided rotational speed is not too high and
mineral oils are good general purpose bearing lubricants, although many
modern applications demand special high-pressure lubricants.
Sealing:
 Keep dirt out, thereby preventing premature wear of the bearing.

Good sealing is essential. Seals should:
 Keep lubricant in, ensuring that the bearing (and possibly other components)
will not run short of lubricant.
Bearings Design:
Bearing Life
When the ball or roller of rolling-contact bearings rolls, contact stresses occur on the
inner ring, the rolling element, and on the outer ring. Because the curvature of the
contacting elements in the axial direction is different from that in the radial direction,
the equations for these stresses are more involved than in the Hertz equations. If a
bearing is clean and properly lubricated, is mounted and sealed against the entrance of
dust and dirt, is maintained in this condition, and is operated at reasonable
temperatures, then metal fatigue will be the only cause of failure. Inasmuch as metal
fatigue implies many millions of stress applications successfully endured, we need a
quantitative life measure. Common life measures are
• σumber of revolutions of the inner ring (outer ring stationary) until the first tangible
evidence of fatigue
• σumber of hours of use at a standard angular speed until the first tangible evidence
of fatigue
The commonly used term is bearing life, which is applied to either of the measures
just mentioned. It is important to realize, as in all fatigue, life as defined above is a
stochastic variable and, as such, has both a distribution and associated statistical
parameters. The life measure of an individual bearing is defined as the total number of
revolutions (or hours at a constant speed) of bearing operation until the failure
criterion is developed. Under ideal conditions, the fatigue failure consists of spalling
of the load carrying surfaces. The American Bearing Manufacturers Association
(ABMA) standard states that the failure criterion is the first evidence of fatigue. The
fatigue criterion used by the Timken Company laboratories is the spalling or pitting of
an area of 0.01 in2. Timken also observes that the useful life of the bearing may
extend considerably beyond this point. This is an operational definition of fatigue
failure in rolling bearings.
The rating life is a term sanctioned by the ABMA and used by most manufacturers.
The rating life of a group of nominally identical ball or roller bearings is defined as
the number of revolutions (or hours at a constant speed) that 90 percent of a group of
bearings will achieve or exceed before the failure criterion develops. The terms
minimum life, L10 life, and B10 life are also used as synonyms for rating life. The
rating life is the 10th percentile location of the bearing group’s revolutions-to-failure
distribution.

Median life is the 50th percentile life of a group of bearings. The term average life has
been used as a synonym for median life, contributing to confusion. When many
groups of bearings are tested, the median life is between 4 and 5 times the L10 life.
Each bearing manufacturer will choose a specific rating life for which load ratings of
its bearings are reported. The most commonly used rating life is 106 revolutions. The
Timken Company is a well-known exception, rating its bearings at 3 000 hours at 500
rev/min, which is 90(106) revolutions. These levels of rating life are actually quite low
for today’s bearings, but since rating life is an arbitrary reference point, the traditional
values have generally been maintained.
Bearing Load Life at Rated Reliability
A catalog load rating is defined as the radial load that causes 10 percent of a group of
bearings to fail at the bearing manufacturer’s rating life. We shall denote the catalog
load rating as C10 or C. The catalog load rating is often referred to as a Basic Dynamic
Load Rating, or sometimes just Basic Load Rating, if the manufacturer’s rating life is
106 revolutions.
The radial load that would be necessary to cause failure at such a low life would be
unrealistically high. Consequently, the Basic Load Rating should be viewed as a
reference value, and not as an actual load to be achieved by a bearing.
“Catalogue Information” for Rolling-Element Bearings
Bearing manufacturers’ catalogues identify bearings by number, give complete
dimensional information, list rated load capacities, and furnish details concerning
mounting, lubrication, and operation. Dimensions of the more common series of
radial ball bearings, angular ball bearings, and cylindrical roller bearings are given in
the following table and illustrated in the figure. For bearings of these types having
bores of 20 mm and larger, the bore diameter is five times the last two digits in the
bearing number. For example, No. L08 is an extra-light series bearing with a 40-mm
bore, No. 316 is a medium series with an 80-mm bore, and so on. Actual bearing
numbers include additional letters and numbers to provide more information. Many
bearing varieties are also available in inch series.

Figure: Shaft and housing shoulder dimensions
TABLE 14.1 Bearing Dimensions
Bearings Ball Bearings Roller Bearing

Bore
Basic OD w ra dS dH OD w ra dS dH
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
Number
L00 10 26 8 0.30 12.7 23.4
200 10 30 9 0.64 13.8 26.7
300 10 35 11 0.64 14.8 31.2
L01 12 28 8 0.30 14.5 25.4
201 12 32 10 0.64 16.2 28.4
301 12 37 12 1.02 17.7 32.0
L02 15 32 9 0.30 17.5 29.2
202 15 35 11 0.64 19.0 31.2
302 15 42 13 1.02 21.2 36.6
L03 17 35 10 0.30 19.8 32.3 35 10 0.64 20.8 32.0
203 17 40 12 0.64 22.4 34.8 40 12 0.64 20.8 36.3
303 17 47 14 1.02 23.6 41.1 47 14 1.02 22.9 41.4
L04 20 42 12 0.64 23.9 38.1 42 12 0.64 24.4 36.8
204 20 47 14 1.02 25.9 41.7 47 14 1.02 25.9 42.7
304 20 52 15 1.02 27.7 45.2 52 15 1.02 25.9 46.2
L05 25 47 12 0.64 29.0 42.9 47 12 0.64 29.2 43.4
205 25 52 15 1.02 30.5 46.7 52 15 1.02 30.5 47.0
305 25 62 17 1.02 33.0 54.9 62 17 1.02 31.5 55.9
L06 30 55 13 1.02 34.8 49.3 47 9 0.38 33.3 43.9
206 30 62 16 1.02 36.8 55.4 62 16 1.02 36.1 56.4
306 30 72 19 1.02 38.4 64.8 72 19 1.52 37.8 64.0
L07 35 62 14 1.02 40.1 56.1 55 10 0.64 39.4 50.8
207. 35 72 17 1.02 65.0 42.4 72 17 1.02 41.7 65.3
307 35 80 21 1.52 45.2 70.4 80 21 1.52 43.7 71.4
L08 40 68 15 1.02 45.2 62.0 68 15 1.02 45.7 62.7
208 40 80 18 1.02 48.0 72.4 80 18 1.52 47.2 72.9

Bore
(mm)
Number (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
308 40 90 23 1.52 50.8 80.0 90 23 1.52 49.0 81.3
L09 45 75 16 1.02 50.8 68.6 75 16 1.02 50.8 69.3
209 45 85 19 1.02 52.8 77.5 85 19 1.52 52.8 78.2
309 45 100 25 1.52 57.2 88.9 100 25 2.03 55.9 90.4
L10 50 80 16 1.02 55.6 73.7 72 12 0.64 54.1 68.1
210 50 90 20 1.02 57.7 82.3 90 20 1.52 57.7 82.8
310 50 110 27 2.03 64.3 96.5 110 27 2.03 61.0 99.1
L11 55 90 18 1.02 61.7 83.1 90 18 1.52 62.0 83.6
211 55 100 21 1.52 65.0 90.2 100 21 2.03 64.0 91.4
311 55 120 29 2.03 69.8 106.2 120 29 2.03 66.5 108.7
L12 60 95 18 1.02 66.8 87.9 95 18 1.52 67.1 88.6
212 60 110 22 1.52 70.6 99.3 110 22 2.03 69.3 101.3
312 60 130 31 2.03 75.4 115.6 130 31 2.54 72.9 117.9
L13 65 100 18 1.02 71.9 92.7 100 18 1.52 72.1 93.7
213 65 120 23 1.52 76.5 108.7 120 23 2.54 77.0 110.0
313 65 140 33 2.03 81.3 125.0 140 33 2.54 78.7 127.0
L14 70 110 20 1.02 77.7 102.1 110 20 Not Available
214 70 125 24 1.52 81.0 114.0 125 24 2.54 81.8 115.6
314 70 150 35 2.03 86.9 134.4 150 35 3.18 84.3 135.6
L15 75 115 20 1.02 82.3 107.2 115 20 Not Available
215 75 130 25 1.52 86.1 118.9 130 25 2.54 85.6 120.1
315 75 160 37 2.03 92.7 143.8 160 37 3.18 90.4 145.8
L16 80 125 22 1.02 88.1 116.3 125 22 2.03 88.4 117.6
216 80 140 26 2.03 93.2 126.7 140 26 2.54 91.2 129.3
316 80 170 39 2.03 98.6 152.9 170 39 3.18 96.0 154.4
L17 85 130 22 1.02 93.2 121.4 130 22 2.03 93.5 122.7
217 85 150 28 2.03 99.1 135.6 150 28 3.18 98.0 139.2
317 85 180 41 2.54 105.7 160.8 180 41 3.96 102.9 164.3
L18 90 140 24 1.52 99.6 129.0 140 24 Not Available
218 90 160 30 2.03 104.4 145.5 160 30 3.18 103.1 147.6
318 90 190 43 2.54 111.3 170.2 190 43 3.96 108.2 172.7
L19 95 145 24 1.52 104.4 134.1 145 24 Not Available
219 95 170 32 2.03 110.2 154.9 170 32 3.18 109.0 157.0
319 95 200 45 2.54 117.3 179.3 200 45 3.96 115.1 181.9
L20 100 150 24 1.52 109.5 139.2 150 24 2.54 109.5 141.7
220 100 180 34 2.03 116.1 164.1 180 34 3.96 116.1 167.1
320 100 215 47 2.54 122.9 194.1 215 47 4.75 122.4 194.6
L21 105 160 26 2.03 116.1 146.8 160 26 Not Available
221 105 190 36 2.03 121.9 173.5 190 36 3.96 121.4 175.3
321 105 225 49 2.54 128.8 203.5 225 49 4.75 128.0 203.5
L22 110 170 28 2.03 122.7 156.5 170 28 2.54 121.9 159.3
222 110 200 38 2.03 127.8 182.6 200 38 3.96 127.3 183.9
322 110 240 50 2.54 134.4 218.2 240 50 4.75 135.9 217.2
L24 120 180 28 2.03 132.6 166.6 180 28 Not Available
224 120 215 40 2.03 138.2 197.1 215 40 4.75 139.2 198.9
324 120 Not Available 260 55 6.35 147.8 235.2
L26 130 200 33 2.03 143.8 185.4 200 33 3.18 143.0 188.2
226 130 230 40 2.54 149.9 210.1 230 40 4.75 149.1 213.9
326 130 280 58 3.05 160.0 253.0 280 58 6.35 160.3 254.5
L28 140 210 33 2.03 153.7 195.3 210 33 Not Available
228 140 250 42 2.54 161.5 228.6 250 42 4.75 161.5 232.4
328 140 Not Available 300 62 7.92 172.0 271.3
L30 150 225 35 2.03 164.3 209.8 225 35 3.96 164.3 212.3

Bore
(mm)
Number (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
230 150 270 45 2.54 173.0 247.6 270 45 6.35 174.2 251.0
L32 160 240 38 2.03 175.8 223.0 240 38 Not Available
232 160 Not Available 290 48 6.35 185.7 269.5
L36 180 280 46 2.03 196.8 261.6 280 46 4.75 199.6 262.9
236 180 Not Available 320 52 6.35 207.5 298.2
L40 200 310 51 Not Available
240 200 Not Available 360 58 7.92 232.4 334.5
244 220 Not Available 400 65 9.52 256.0 372.1
248 240 Not Available 440 72 9.52 279.4 408.4
a
Maximum fillet radius on a shaft and in housing that will clear the bearing corner radius
The following Table lists rated load capacities, C. These values correspond to a
constant radial load that 90 percent of a group of presumably identical bearings can
endure for 9 * 107 revolutions (as 3000 hours of 500-rpm operation) without the onset
of surface fatigue failures.
Caution: Rated capacities given by different bearing manufacturers are not always
directly comparable. The basis for ratings must always be checked.
Bearing Selection
For specific bearing application, we select the bearing type, grade of precision
(usually ABEC 1), lubricant, closure (i.e., open, shielded, or sealed), and basic load
rating. Often, special circumstances must be taken into account. For example, if the
bearing will be subjected to a heavy load when not rotating, its static load capacity
(given in bearing manufacturers’ catalogues) should not be exceeded. τtherwise, the
balls or rollers will slightly indent the rings. This is called brinelling because the
indentations resemble marks produced by a Brinell hardness tester. The indentations
will make subsequent rotation noisy. (If noise is not objectionable, the static capacity
can often be exceeded by a factor of up to 3.) It is interesting that similar extremely
slight indentation during rotation is not harmful because it leaves the ring surfaces
smooth and annular. Another special consideration is maximum speed. The limitation
is one of linear surface speed rather than rotating speed; hence, small bearings can
operate at higher rpm than large bearings. Lubrication is especially important in high-
speed bearing applications, the best being a fine oil mist or spray. This provides the
necessary lubricant film and carries away friction heat with a minimum “churning
loss” within the lubricant itself. For ball bearings, nonmetallic separators permit
highest speeds. ABEC 1 precision single-row ball bearings with nonmetallic
separators and oil mist lubrication can run at inner ring surface speeds up to 75 m/s
and have a life of 3000 hours while carrying one-third of the rated load capacity This
translates to a DN value (bore diameter in millimeters times rpm) of about 1.25 * 106.
For oil drip or splash lubrication this figure is reduced by about one-third, and for
grease lubrication by about two-thirds. Under the most favorable conditions, roller
bearings can operate up to a DN value of about 450,000. For applications with

extreme rotating speeds, it is advisable to consult the bearing manufacturer. In
selecting bearings, attention should be given to possible misalignment and to sealing
and lubrication. If temperatures are extreme, the bearing manufacturer should be
consulted.
The size of bearing selected for an application is usually influenced by the size of
shaft required (for strength and rigidity considerations) and by the available space. In
addition, the bearing must have a high enough load rating to provide an acceptable
combination of life and reliability. The major factors influencing the load rating
requirement are discussed below.
Life Requirement
Bearing applications usually require lives different from that used for the catalogue
rating. Palmgren determined that ball-bearing life varies inversely with approximately
the third power of the load. Later studies have indicated that this exponent ranges
between 3 and 4 for various rolling-element bearings. Many manufacturers retain
Palmgren’s exponent of 3 for ball bearings and use (10/3) for roller bearings.
Following the recommendation of other manufacturers, this note will use the exponent
(3.33) for both bearing types. Thus
L = LR(C/Fr)3.33
or
Creq = Fr(L/LR)0.3
where
C = rated capacity (as from Table) and Creq = the required value of C for the
application, LR = life corresponding to rated capacity (i.e., 9 x 107 revolutions)
Fr = radial load involved in the application, L = life corresponding to radial load Fr ,
or life required by the application.
Thus doubling the load on a bearing reduces its life by a factor of about 10. Different
manufacturers’ catalogues use different values of LR. Some use LR = 106 revolutions.
A quick calculation shows that the values in the Table must be multiplied by 3.86 to
be comparable with ratings based on a life of 106 revolutions.
Reliability Requirement
Tests show that the median life of rolling-element bearings (ball bearings in
particular) is about five times the standard 10 percent failure fatigue life. The standard
life is commonly designated as the L10 life (sometimes as the B10 life). Since this life
corresponds to 10 percent failures, it also means that this is the life for which 90
percent have not failed, and corresponds to 90 percent reliability. Thus, the life for 50
percent reliability is about five times the life for 90 percent reliability.
Many designs require greater than 90 percent reliability. The distribution of fatigue
lives of a group of presumably identical parts does not correspond to the normal
distribution curve. Rather, fatigue lives characteristically have a skewed distribution.
This corresponds generally with a mathematical formula proposed by W. Weibull of
Sweden, known as the Weibull distribution. Using the general Weibull equation
together with extensive experimental data, the AFBMA has formulated recommended
life adjustment reliability factors, Kr , plotted in the following figure. These factors
are applicable to both ball and roller bearings. The rated bearing life for any given

reliability (greater than 90 percent) is thus the product, KrLR. Incorporating this factor
into the proceeding equations gives
L = Kr LR (C/Fr)3.33
or
Creq = Fr (L/KrLR)0.3
Figure: Reliability factor Kr

Influence of Axial Loading
Cylindrical roller bearings are very limited in their thrust capacity because axial loads
produce sliding friction at the roller ends. Even so, when these bearings are properly
aligned, radially loaded, and oil-lubricated, they can carry thrust loads up to 20
percent of their rated radial capacities. This enables pairs of cylindrical roller bearings
to support shafts subjected to light thrust, as by spur gears or chain sprockets. Tapered
roller bearings can, of course, carry substantial thrust as well as radial loads. For ball
bearings, any combination of radial load (Fr) and thrust load (Ft) results in
approximately the same life as does a pure radial equivalent load, Fe, calculated from
the equations that follow. Load angle (α) is defined before. Radial bearings have a
zero load angle. Standard values of (α) for angular ball bearings are 15°, 25°, and 35°.
Space permits including only the treatment of 25° angular ball bearings in this notes.
For α=0̊ (radial ball bearings)
For 0 < Ft/Fr < 0.35, Fe = Fr
For 0.35 < Ft/Fr < 10 Fe = Fr [1 + 1.115(Ft/Fr- 0.35)]
For Ft/Fr > 10, Fe = 1.176 Ft
For α=25̊ (angular ball bearings)
For 0 < Ft/Fr < 0.68, Fe = Fr
For 0.68 < Ft/Fr < 10 Fe = Fr [1 + 0,870(Ft/Fr- 0.68)]
For Ft/Fr > 10, Fe = 0.911 Ft
Influence of elevated Temperature
At elevated temperature dynamics load carrying capacity is reduced. The reduction in
the capacity at different temperatures is taken into account by multiplying the rated
capacity C by a temperature factor (Kt) obtained from the following table:

Table: Temperature factor (Kt)
Bearing temperature
150 200 250 300
[◦C]
Temperature factor
1.00 0.90 0.75 0.60
(Kt)
Influence of Shock Loading

The standard bearing rated capacity is for the condition of uniform load without
shock. This desirable condition may prevail for some applications (such as bearings
on the motor and rotor shafts of a belt-driven electric blower), but other applications
have various degrees of shock loading. This has the effect of increasing the nominal
load by an application factor Ka. Experience within the specific industry is the best
guide. The Table gives representative sample values.
The load-application factors in next Table serve the same purpose as factors of safety;
use them to increase the equivalent load before selecting a bearing.
Table: Application Factors Ka
Type of Application Ball Bearing Roller Bearing
Uniform load, no impact 1.0 1.0
Gearing 1.0–1.3 1.0
Light impact 1.2–1.5 1.0–1.1
Moderate impact 1.5–2.0 1.1–1.5
Heavy impact 2.0–3.0 1.5–2.0
Substituting Fe for Fr and adding Ka modifies Equations to give

L = Kr Kt LR (C/FeKa)3.33
or
Creq = Fe Kt Ka (L/KrLR)0.3
When the preceding equations are used, the question is what life, L should be
required. The Table of typical bearing life (next section) may be used as a guide when
more specific information is not available. It is worth noting that the useful life of a
bearing in industrial applications where noise is not a factor may extend significantly
beyond the appearance of the first small area of surface fatigue damage, which is the
failure criterion in standard tests.
Typical Bearing Life for Various Design Applications
To assist the designer in the selection of bearings, most of the manufacturers’
handbooks contain data on bearing life for many classes of machinery, as well as
information on load-application factors. Such information has been accumulated the
hard way, that is, by experience, and the beginner designer should utilize this
information until he or she gains enough experience to know when deviations are
possible.
The following Table contains recommendations on bearing life for some classes of
machinery. When the preceding equations are used, the question is what life, L should
be required. The following Table may be used as a guide when more specific

information is not available. (It is worth noting that the useful life of a bearing in
industrial applications where noise is not a factor may extend significantly beyond the
appearance of the first small area of surface fatigue damage, which is the failure
criterion in standard tests.)
Bearing manufacturers formerly reduced life ratings when the outer ring rotated
relative to the load (as with a trailer wheel, rotating around a fixed spindle). As a
result of more recent evidence, this is no longer done. If both rings rotate, the relative
rotation between the two is used in making life calculations.
Many applications involve loads that vary with time. In such cases, the Palmgren
linear cumulative-damage rule is applicable.

6
TABLE: Bearing Rated Capacities, C, for LR 90 x 10 Revolution Life with 90 Percent
Reliability
Radial Ball, Angular Ball, Roller
L00 200 300 L00 200 300 1000 1200 1300
Bore Xlt lt med Xlt lt med Xlt lt med
(mm) (kN) (kN) (kN) (kN) (kN) (kN) (kN) (kN) (kN)
10 1.02 1.42 1.90 1.02 1.10 1.88
12 1.12 1.42 2.46 1.10 1.54 2.05
15 1.22 1.56 3.05 1.28 1.66 2.85
17 1.32 2.70 3.75 1.36 2.20 3.55 2.12 3.80 4.90
20 2.25 3.35 5.30 2.20 3.05 5.80 3.30 4.40 6.20
25 2.45 3.65 5.90 2.65 3.25 7.20 3.70 5.50 8.50
30 3.35 5.40 8.80 3.60 6.00 8.80 2.40a 8.30 10.0
35 4.20 8.50 10.6 4.75 8.20 11.0 3.10a 9.30 13.1
40 4.50 9.40 12.6 4.95 9.90 13.2 7.20 11.1 16.5
45 5.80 9.10 14.8 6.30 10.4 16.4 7.40 12.2 20.9
50 6.10 9.70 15.8 6.60 11.0 19.2 5.10a 12.5 24.5
55 8.20 12.0 18.0 9.00 13.6 21.5 11.3 14.9 27.1
60 8.70 13.6 20.0 9.70 16.4 24.0 12.0 18.9 32.5
65 9.10 16.0 22.0 10.2 19.2 26.5 12.2 21.1 38.3
70 11.6 17.0 24.5 13.4 19.2 29.5 23.6 44.0
75 12.2 17.0 25.5 13.8 20.0 32.5 23.6 45.4
80 14.2 18.4 28.0 16.6 22.5 35.5 17.3 26.2 51.6
85 15.0 22.5 30.0 17.2 26.5 38.5 18.0 30.7 55.2
90 17.2 25.0 32.5 20.0 28.0 41.5 37.4 65.8
95 18.0 27.5 38.0 21.0 31.0 45.5 44.0 65.8
100 18.0 30.5 40.5 21.5 34.5 20.9 48.0 72.9
105 21.0 32.0 43.5 24.5 37.5 49.8 84.5
110 23.5 35.0 46.0 27.5 41.0 55.0 29.4 54.3 85.4
120 24.5 37.5 28.5 44.5 61.4 100.1
130 29.5 41.0 33.5 48.0 71.0 48.9 69.4 120.1
140 30.5 47.5 35.0 56.0 77.4 131.2
150 34.5 39.0 62.0 58.7 83.6
160 113.4
180 47.0 54.0 97.9 140.1
200 162.4
220 211.3
240 258.0
a
1000 (Xlt) series bearings are not available in these sizes. Capacities shown are for the 1900 (XXlt)
series. Source: New Departure–Hyatt Bearing Division, General Motors Corporation.

Table: Typical Bearing Life for Various Design Applications
Uses Design life Uses Design life
[in hours] [in hours]
Agricultural equipment 3000 - 6000 Gearing units
Aircraft equipment 500 - 2000 Automotive 600 - 5000
Automotive Multipurpose 8000 - 15000
Race car 500 - 800 Machine tools 20000
Light motor cycle 600 - 1200 Rail Vehicles 15000 - 25000
Heavy motor cycle 1000 - 2000 Heavy rolling mill > 50000
Light cars 1000 - 2000 Machines
Heavy cars 1500 - 2500 Beater mills 20000 - 30000
Light trucks 1500 - 2500 Briquette presses 20000 - 30000
Heavy trucks 2000 - 2500 Grinding spindles 1000 - 2000
Buses 2000 - 5000 Machine tools 10000 - 30000
Electrical Mining machinery 4000 - 15000
Household appliances 1000 - 2000 Paper machines 50000 - 80000
Motors ≤hp 1000 - 2000 Rolling mills
Motors ≤3 hp 8000 - 10000 Small cold mills 5000 - 6000
Motors, medium 10000 - 15000 Large multipurpose 8000 - 10000
mills
Motors, large 20000 - 30000 Rail vehicle axle
Elevator cables sheaves 40000 - 60000 Mining cars 5000
Mine ventilation fans 40000 - 50000 Motor rail cars 16000 - 20000
Propeller thrust 15000 - 25000 Open-pit mining cars 20000 - 25000
bearings
Propeller shaft bearings > 80000 Streetcars 20000 - 25000
Gear drives Passenger cars 26000
Boat gearing units 3000 - 5000 Freight cars 35000
Gear drives > 50000 Locomotive outer 20000 - 25000
bearings
Ship gear drives 20000 - 30000 Locomotive inner 30000 - 40000
bearings
Machinery for 8 hour 14000 - 20000 Machinery for short or 4000 - 8000
service which are not intermittent operation
always fully utilized where service
interruption is of minor
importance
Machinery for 8 hour 20000 - 30000 Machinery for 8000 - 14000
service which are fully intermittent service
utilized where reliable
operation is of great
importance
Machinery for 50000 - 60000 Instruments and 0 - 500
continuous 24 hour apparatus in frequent
service use
Design procedure for bearing:

1. Find the equivalent load Fe that considering both radial and thrust load.
For α=0̊ (radial ball bearings)
For 0 < Ft/Fr < 0.35, Fe = Fr
For 0.35 < Ft/Fr < 10 Fe = Fr [1 + 1.115(Ft/Fr- 0.35)]
For Ft/Fr > 10, Fe = 1.176 Ft
For α=25̊ (angular ball bearings)
For 0 < Ft/Fr < 0.68, Fe = Fr

For 0.68 < Ft/Fr < 10 Fe = Fr [1 + 0,870(Ft/Fr- 0.68)]
For Ft/Fr > 10, Fe = 0.911 Ft
2. Find the Application Factors Ka from table according to the loading conditions.
3. Find the Temperature Factors Kt from table according to the bearing temperature.
4.. Estimate the required life that matches with the application in according to the
table of typical bearing life.
5. Find Reliability factor Kr from the figure according to the reliability requirements.
6. Use LR as required.
7. Find the required capacity Creq from the equation:
Creq = Fe Kt Ka (L/KrLR)0.3
8. Select the suitable bearing from the manufacture's catalogue or the table of the
Bearing Rated Capacities, C.
9. Extract all dimensions of the select bearing from the table of bearing dimensions.

Couplings
Couplings: They are used to connect sections of shafts or connect the shaft of a
driving machine to the shaft of a driven machine. This afford a permanent connection,
contrasted with clutches which provide for engagement or disengagement at will.
Couplings can be either rigid or flexible. Rigid coupling are used for accurately
aligned shafts. Flexible couplings are used to take care of small amount of
misalignment, to provide axial movement of a shaft or to absorb some of the vibration
of the system. Shafts axes with couplings can be collinear(e.g. Flanged coupling),
intersect(e.g. Universal coupling) or parallel but not collinear( e.g. Oldham coupling).
Couplings are usually designed according to torsion only.
Couplings connect coaxial shafts. They are formed by two discs attached to shafts
through key and jointed by bolts, parallel to shaft axis. The discs are made as flanges
integral with the hub. The flanges are often made in cast iron. Muff couplings are
thick cylinders which could be used as sleeves or split to be bolted around the shaft.
The driving force in muff coupling is friction between the inner surface of muff and
outer surface of shaft. The muff can be a single piece sleeve keyed to shafts or split in
halves which are tightened by the bolts. The muff is made in cast iron.
Couplings
• Couplings transmit torque and motion between shafts in the presence of various
types of misalignment
• Types of Misalignment
– Angular
– Parallel
– Torsional
– Axial
COUPLINGS TYPES
RIGID FLEXIBLE
Sleeve Falk
Clamp Oldham
Flange Gear
Universal
Elastic

Types of Couplings
• Rigid Couplings
– Set-screw
– Keyed
– Clamped
• Flexible Couplings
– Jaw type
– Gear, spline, grid, chain
– Helical and bellows
– Linkages
– Universal Joints
• Used in pairs
• Basic Specs Include: nominal and peak torque, misalignment tolerances, shaft size,
operating temp, speed range, and backlash.

FIGURE :Rigid shaft coupling
FIGURE : Rubber element flexible couplings. (a, b, c, Courtesy Lord Corporation. d,

Courtesy Reliance Electric Company.)

FIGURE : Metallic element flexible couplings. (Courtesy Reliance Electric
Company.)
FIGURE : Oldham or slider block couplings. Both versions have a freely sliding
center slider block that provides pairs of sliding surfaces at 90° orientation. The
greater the shaft misalignment, the greater the sliding. Lubrication and wear must be
considered.

Figure: Cross-type universal joints. (Courtesy Dana Corporation.)

DESIGN OF SPRINGS
Springs are flexible machine elements used to exert force and store energy. A spring
is an elastic object used to store mechanical energy. Springs are elastic bodies
(generally metal) that can be twisted, pulled, or stretched by some force. They can
return to their original shape when the force is released. In other words it is also
termed as a resilient member. A spring is a flexible element used to exert a force or a
torque and, at the same time, to store energy.
The force can be a linear push or pull, or it can be radial, acting similarly to a rubber
band around a roll of drawings. The torque can be used to cause a rotation, for
example, to close a door on a cabinet or to provide a counterbalance force for a
machine element pivoting on a hinge.
 To provide Cushioning, to absorb, or to control the energy due to shock

Objectives of spring
and vibration: Car springs or railway buffers to control energy, springs-
 To Control motion: Maintaining contact between two elements (cam and

supports and vibration dampers.
its follower). Creation of the necessary pressure in a friction device (a
 To Measure forces: Spring balances, gages

brake or a clutch)
Springs classification: Springs can be classified according to the direction and the
nature of the force exerted by the spring when it is deflected (see the following table).

Table: Springs classification
Uses Types of springs
Helical compression spring, Belleville spring, Torsion spring, force acting at the end
Push of torque arm. flat spring, such as a cantilever spring or leaf spring
Helical extension spring, Torsion spring, force acting at the end of torque arm. Flat
Pull spring, such as a cantilever spring or leaf spring, Draw bar spring (special case of
the compression spring) constant – force spring.
Radial torque Garter spring, elastomeric band, spring clamp, Torsion spring, Power spring
In general, springs may be classified as wire springs, flat springs, or special shaped
springs, and there are variations within these divisions. Wire springs include helical
springs of round or square wire, made to resist and deflect under tensile, compressive,
or torsional loads. Flat springs include cantilever and elliptical types, wound motor- or
clock-type power springs, and flat spring washers, usually called Belleville springs.
Spring manufacturing processes:
If springs are of very small diameter and the wire diameter is also small then the
springs are normally manufactured by a cold drawn process through a mangle.
However, for very large springs having also large coil diameter and wire diameter one
has to go for manufacture by hot processes. First one has to heat the wire and then use
a proper mangle to wind the coils. Two types of springs which are mainly used are,
helical springs and leaf springs. We shall consider in this course the design aspects of
two types of springs.
HELICAL SPRING:
Definition: It is made of wire coiled in the form of helix having circular, square or
rectangular cross section.
Terminology of helical spring:
The main dimensions of a helical spring subjected to compressive force are shown in
the figure. They are as follows:
d = wire diameter of spring (mm)
Di = inside diameter of spring coil (mm)
Do =outside diameter of spring coil (mm)
D = mean coil diameter (mm)
Therefore D = (Di + Do) /2
There is an important parameter in spring design called spring index. It is denoted by
letter C. The spring index is defined as the ratio of mean coil diameter to wire
diameter. Or C = D/d
In design of helical springs, the designer should use good judgment in assuming the
value of the spring index C. The spring index indicates the relative sharpness of the
curvature of the coil.
A low spring index means high sharpness of curvature. When the spring index is low
(C < 3), the actual stresses in the wire are excessive due to curvature effect. Such a
spring is difficult to manufacture and special care in coiling is required to avoid
cracking in some wires. When the spring index is high (C >15), it results in large
variation in coil diameter. Such a spring is prone to buckling and also tangles easily
during handling. Spring index from 4 to 12 is considered better from manufacturing
considerations. Therefore, in practical applications, the spring index in the range of 6
to 9 is still preferred particularly for close tolerance springs and those subjected to
cyclic loading.
There are three terms - free length, compressed length and solid length that are
illustrated in the figure. These terms are related to helical compression spring. These
lengths are determined by following way

1) Solid length: solid length is defined as the axial length of the spring which is so
compressed, that the adjacent coils touch each other. In this case, the spring is
completely compressed and no further compression is possible. The solid length is
given by.
Solid length = Nt d
Where Nt = total number of coils
2) Compressed length: Compressed length is defined as the axial length of the spring
that is subjected to maximum compressive force. In this case, the spring is subjected
to maximum deflection. When the spring is subjected to maximum force, there should
be some gap or clearance between the adjacent coils. The gap is essential to prevent
clashing of the coils. The clashing allowance or the total axial gap is usually taken as
15% of the maximum deflection. Sometimes, an arbitrary decision is taken and it is
assumed that there is a gap of 1 or 2 mm between adjacent coils under maximum load
condition. In this case, the total axial gap is given by,
Total gap = (Nt-1) x gap between adjacent coils
3) Free length: Free length is defined as the axial length of an unloaded helical
compression spring. In this case, no external force acts on the spring. Free length is an
important dimension in spring design and manufacture. It is the length of the spring in
free condition prior to assembly. Free length is given by,
Free length = compressed length + y = solid length + total axial gap + y
The pitch of the coil is defined as the axial distance between adjacent coils in
uncompressed state of spring. It is denoted by p. It is given by,
p = free length/(Nt -1)
The stiffness of the spring (k) is defined as the force required producing unit
deflection. Therefore
k=p/δ
Where k= stiffness of the spring (N/mm)
p = axial spring force (N)
Y or δ = axial deflection of the spring corresponding to force p (mm)
There are various names for stiffness of spring such as rate of spring, gradient of
spring, scale of spring or simply spring constant. The stiffness of spring represents the
slope of load deflection line. There are two terms are related to the spring coils, called
active coils and inactive coils. Active coils are the coils in the spring, which
contribute to spring action, support the external force and deflect under the action of
force. A portion of the end coils, which is in contact with the seat, does not contribute
to spring action and called inactive coils. These coils do not support the load and do
not deflect under the action o external force. The number of inactive coils is given by,
Inactive coils = Nt – N
where N = number of active coils.
If we look at the free body diagram of the shaded region only (the cut section) then
we shall see that at the cut section, vertical equilibrium of forces will give us force, F
as indicated in the figure. This F is the shear force. The torque T, at the cut section
and its direction is also marked in the figure. There is no horizontal force coming into
the picture because externally there is no horizontal force present. So from the
fundamental understanding of the free body diagram one can see that any section of
the spring is experiencing a torque and a force. Shear force will always be associated
with a bending moment. However, in an ideal situation, when force is acting at the
centre of the circular spring and the coils of spring are almost parallel to each other,
no bending moment would result at any section of the spring ( no moment arm),

except torsion and shear force. From the free body diagram, we have found out the
direction of the internal torsion T and internal shear force F at the section due to the
external load F acting at the centre of the coil. The cut sections of the spring,
subjected to tensile and compressive loads respectively, are shown separately in the
figure.
Stresses in Helical Springs
The following figure shows a round-wire helical compression spring loaded by the
axial force F. We designate D as the mean coil diameter and d as the wire diameter.
Now imagine that the spring is cut at some point (part b of Fig.), a portion of it
removed, and the effect of the removed portion replaced by the net internal reactions.
Then, as shown in the figure, from equilibrium the cut portion would contain a direct
shear force F and a torsion
T = FD/2.
The maximum stress in the wire may be computed by superposition of the direct shear
stress, with V = F and the torsional shear stress. The result is
τmax = Tr/ J + F/ A
Figure: (a) Axially loaded helical spring; (b) free-body diagram showing that the
wire is subjected to a direct shear and a torsional shear.
The shear stress in the spring wire due to torsion is
Average shear stress in the spring wire due to force F is

The above equation gives maximum shear stress occurring in a spring. Ks are the
shear stress correction factor. The resultant diagram of torsional shear stress and
direct shear stress is shown
From the above equation it can be observed that the effect of direct shear stress i.e.,
= + =
� � �
where Ks is a shear stress-correction factor and is defined by the equation
+
=
The use of square or rectangular wire is not recommended for springs unless space
limitations make it necessary. Springs of special wire shapes are not made in large
quantities, unlike those of round wire; they have not had the benefit of refining
development and hence may not be as strong as springs made from round wire. When
space is severely limited, the use of nested round-wire springs should always be
considered. They may have an economical advantage over the special-section springs,
as well as a strength advantage.
The Curvature Effect
The above equation is based on the wire being straight. However, the curvature of the
wire increases the stress on the inside of the spring but decreases it only slightly on
the outside. This curvature stress is primarily important in fatigue because the loads
are lower and there is no opportunity for localized yielding. For static loading, these
stresses can normally be neglected because of strain-strengthening with the first

application of load. Unfortunately, it is necessary to find the curvature factor in a
roundabout way. The reason for this is that the published equations also include the
effect of the direct shear stress. Suppose Ks is replaced by another K factor, which
corrects for both curvature and direct shear. Then this factor is given by either of the
equations
− . +
= + =
− −
The first of these is called the Wahl factor, and the second, the Bergsträsser factor.
Since the results of these two equations differ by the order of 1 percent, the next
equation is preferred. The curvature correction factor can now be obtained by
canceling out the effect of the direct shear. Thus, the curvature correction factor is
found to be
Kc = KB / Ks = 2C(4C + 2)/(4C − 3)(2C + 1)
Now, Ks , KB or KW , and Kc are simply stress-correction factors applied
multiplicatively to Tr/J at the critical location to estimate a particular stress. There is
no stress concentration factor. In this notes we will use
=
�
to predict the largest shear stress.
Is appreciable for springs of small spring index ‘C’ Also the effect of wire curvature
is neglected in equation (A)
Stresses in helical spring with curvature effect. What is curvature effect? Let us look
at a small section of a circular spring, as shown in the figure. Suppose we hold the
section b-c fixed and give a rotation to the section a-d in the anti clockwise direction
as indicated
in the figure, then it is observed that line a-d rotates and it takes up another position,
say a'-d'. Stresses in helical spring with curvature effect
What is curvature effect?
Let us look at a small section of a circular spring, as shown in the figure. Suppose we
hold the
section b-c fixed and give a rotation to the section a-d in the anti clockwise direction
as indicated
in the figure, then it is observed that line a-d rotates and it takes up another position,
say a'-d'.
Deflection of Helical Springs
The deflection-force relations are quite easily obtained by using Castigliano’s
theorem. The total strain energy for a helical spring is composed of a torsional
component and a shear component. From previous equations the strain energy is
= +
Substituting T = FD/2, l = πDN, J = πd4/32, and A = πd2/4 results in
= +

where N = Na = number of active coils. Then using Castigliano’s theorem to find total
deflection y gives
= = +
Since C = D/d, this equation can be rearranged to yield
= ( + )=
The spring rate, also called the scale of the spring, is k = F/y, and so
=
Compression Springs
The four types of ends generally used for compression springs are illustrated in
following figure and table.
Figure : Types of ends for compression springs: (a) both ends plain; (b) both ends
squared; (c) both ends squared and ground; (d) both ends plain and ground
A spring with plain ends has a noninterrupted helicoid; the ends are the same as if a
long spring had been cut into sections. A spring with plain ends that are squared or
closed is obtained by deforming the ends to a zero-degree helix angle. Springs should
always be both squared and ground for important applications, because a better
transfer of the load is obtained. The table shows how the type of end used affects the
number of coils and the spring length.

Table : Formulas for the Dimensional Characteristics of Compression-Springs.(Na =
Number of Active Coils) Source: From Design Handbook, 1987, p. 32. Courtesy of
Associated Spring
Type of Spring Ends
Term Plain and Squared or Squared and
Plain
Ground Closed Ground
End coils, Ne 0 1 2 2
Total coils, Nt Na Na + 1 Na + 2 Na + 2
Free length, L0 pNa +d p(Na + 1) pNa + 3d pNa + 2d
Solid length, Ls d(Nt + 1) dNt d(Nt + 1) dNt
Pitch, p (L0 - d)/ Na L0 /(Na + 1) (L0 - 3d) /Na (L0 - 2d)/Na
Note that the digits 0, 1, 2, and 3 appearing in the table are often used without
question. Some of these need closer scrutiny as they may not be integers. This
depends on how a springmaker forms the ends. Forys pointed out that squared and
ground ends give a solid length Ls of
Ls = (Nt − a)d
where a varies, with an average of 0.75, so the entry dNt in the table may be
overstated. The way to check these variations is to take springs from a particular
springmaker, close them solid, and measure the solid height. Another way is to look at
the spring and count the wire diameters in the solid stack. Set removal or presetting is
a process used in the manufacture of compression springs to induce useful residual
stresses. It is done by making the spring longer than needed and then compressing it
to its solid height. This operation sets the spring to the required final free length and,
since the torsional yield strength has been exceeded, induces residual stresses opposite
in direction to those induced in service. Springs to be preset should be designed so
that 10 to 30 percent of the initial free length is removed during the operation. If the
stress at the solid height is greater than 1.3 times the torsional yield strength,
distortion may occur. If this stress is much less than 1.1 times, it is difficult to control
the resulting free length. Set removal increases the strength of the spring and so is
especially useful when the spring is used for energy-storage purposes. However, set
removal should not be used when springs are subject to fatigue.
Stability
In previous section we learned that a column will buckle when the load becomes too
large. Similarly, compression coil springs may buckle when the deflection becomes
too large. The critical deflection is given by the equation
′ ⁄
′
= [ − − ]
where ycr is the deflection corresponding to the onset of instability. This equation is
verified experimentally. The quantity eff in this equation is the effective slenderness
ratio and is given by the equation
�
=
C'1 and C'2 are elastic constants defined by the equations
′
=
−

− ′
�
=
+
One of these equations contains the end-condition constant α. This depends upon how
the ends of the spring are supported. The following table gives values of α for usual
end conditions. Note how closely these resemble the end conditions for columns.
Table : End-Condition Constants α for Helical Compression Springs*
End Condition Constant α
Spring supported between flat parallel surfaces (fixed ends) 0.5
One end supported by flat surface perpendicular to spring axis (fixed);other end pivoted 0.707
(hinged)
Both ends pivoted (hinged) 1
One end clamped; other end free 2
∗
Ends supported by flat surfaces must be squared and ground.
′
2
Absolute stability occurs when the term �2
is greater than unity. This means that
the condition for absolute stability is that
⁄
� −
< [ ]
� +
For steels, this turns out to be
L0 < 2.63 D/α
For squared and ground ends α = 0.5 and L0 < 5.26 D.
Commonly used spring materials:

One of the important considerations in spring design is the choice of the spring
material. Some of the common spring materials are given below.
Hard-drawn wire: This is cold drawn, cheapest spring steel. Normally used for low
stress and static load. The material is not suitable at subzero temperatures or at
temperatures above 1200C.
Oil-tempered wire: It is a cold drawn, quenched, tempered, and general purpose
spring steel. It is not suitable for fatigue or sudden loads, at subzero temperatures and
at temperatures above 1800C.
Chrome Vanadium: This alloy spring steel is used for high stress conditions and at
high temperature up to 2200C. It is good for fatigue resistance and long endurance for
shock and impact loads.
Chrome Silicon: This material can be used for highly stressed springs. It offers
excellent service for long life, shock loading and for temperature up to 2500C.
Music wire: This spring material is most widely used for small springs. It is the
toughest and has highest tensile strength and can withstand repeated loading at high
stresses. It cannot be used at subzero temperatures or at temperatures above 1200C.
Stainless steel: Widely used alloy spring materials.
Phosphor Bronze / Spring Brass: It has good corrosion resistance and electrical
conductivity. it is commonly used for contacts in electrical switches. Spring brass can
be used at subzero temperatures.
Spring Manufacturing
Springs are manufactured either by hot- or cold-working processes, depending upon
the size of the material, the spring index, and the properties desired. In general,
prehardened wire should not be used if D/d < 4 or if d > 14 in. Winding of the spring
induces residual stresses through bending, but these are normal to the direction of the
torsional working stresses in a coil spring. Quite frequently in spring manufacture,

they are relieved, after winding, by a mild thermal treatment. A great variety of spring
materials are available to the designer, including plain carbon steels, alloy steels, and
corrosion-resisting steels, as well as nonferrous materials such as phosphor bronze,
spring brass, beryllium copper, and various nickel alloys. Descriptions of the most
commonly used steels will be found in following table.
Table: High-Carbon and Alloy Spring Steels Source: From Harold C. R. Carlson,
“Selection and Application of Spring Materials,” Mechanical Engineering, vol. 78,
1956, pp. 331–334.
Name of Similar
Description
Material Specifications
Music wire, UNS G10850 This is the best, toughest, and most widely used of all
0.80–0.95C AISI 1085 spring materials for small springs. It has the highest
tensile strength and can withstand higher stresses under
ASTM A228-51 repeated loading than any other spring material. Available
in diameters 0.12 to 3mm(0.005 to0.125 in). Do not use
above 120°C(250°F) or at subzero temperatures.
Oil-tempered UNS G10650 This general-purpose spring steel is used for many types
wire, AISI 1065 of coil springs where the cost of music wire is prohibitive
and in sizes larger than available in music wire. Not for
0.60–0.70C ASTM 229-41 shock or impact loading. Available in diameters 3 to 12
mm (0.125 to0.5000 in), but larger and smaller sizes may
be obtained. Not for use above 180°C (350°F) or at
subzero temperatures.
Hard-drawn UNS G10660 This is the cheapest general-purpose spring steel and
wire, AISI 1066 should be used only where life, accuracy, and deflection
are not too important. Available in diameters 0.8 to 12
0.60–0.70C ASTM A227-47 mm (0.031 to 0.500 in). Not for use above 120°C (250°F)
or at subzero temperatures.
Chrome- UNS G61500 This is the most popular alloy spring steel for conditions
vanadium AISI 6150 involving higher stresses than can be used with the high-
carbon steels and for use where fatigue resistance and
ASTM 231-41 long endurance are needed. Also good for shock and
impact loads. Widely used for aircraft-engine valve
springs and for temperatures to 220°C (425°F). Available
in annealed or pre-tempered sizes 0.8 to 12 mm (0.031 to
0.500 in) in diameter.
Chrome-silicon UNS G92540 This alloy is an excellent material for highly stressed
AISI 9254 springs that require long life and are subjected to shock
loading. Rockwell hardnesses of C50 to C53 are quite
common, and the material may be used up to
250°C(475°F). Available from 0.8 to 12 mm (0.031 to
0.500 in) in diameter.
The UNS steels listed in Appendix A should be used in designing hot-worked, heavy-
coil springs, as well as flat springs, leaf springs, and torsion bars.
Spring materials may be compared by an examination of their tensile strengths; these
vary so much with wire size that they cannot be specified until the wire size is known.
The material and its processing also, of course, have an effect on tensile strength. It
turns out that the graph of tensile strength versus wire diameter is almost a straight
line for some materials when plotted on log-log paper. Writing the equation of this
line as
Sut = A / dm

furnishes a good means of estimating minimum tensile strengths when the intercept A
and the slope m of the line are known. Values of these constants have been worked
out from recent data and are given for strengths in units of kpsi and MPa in the
following table. In the above equation when d is measured in millimeters, then A is in
(MPa · mmm ) and when d is measured in inches, then A is in (kpsi · inm).
Although the torsional yield strength is needed to design the spring and to analyze the
performance, spring materials customarily are tested only for tensile strength perhaps
because it is such an easy and economical test to make. A very rough estimate of the
torsional yield strength can be obtained by assuming that the tensile yield strength is
between 60 and 90 percent of the tensile strength. Then the distortion-energy theory
can be employed to obtain the torsional yield strength (Sys = 0.577Sy). This approach
results in the range
0.35Sut ≤ Ssy ≤ 0.52Sut
for steels.
For wires listed in the following table, the maximum allowable shear stress in a spring
can be seen in column 3. Music wire and hard-drawn steel spring wire have a low end
of range Ssy = 0.45Sut . Valve spring wire, Cr-Va, Cr-Si, and other (not shown)
hardened and tempered carbon and low-alloy steel wires as a group have
Ssy ≥ 0.50Sut .
Many nonferrous materials (not shown) as a group have Ssy ≥ 0.35Sut . In view of this,
authors use the maximum allowable torsional stress for static application shown in the
next table. For specific materials for which you have torsional yield information use
this table as a guide. They provide set-removal information in the table, that
Ssy ≥ 0.65Sut increases strength through cold work, but at the cost of an additional
operation by the spring maker. Sometimes the additional operation can be done by the
manufacturer during assembly. Some correlations with carbon steel springs show that
the tensile yield strength of spring wire in torsion can be estimated from 0.75Sut . The
corresponding estimate of the yield strength in shear based on distortion energy theory
is
Ssy = 0.577(0.75) Sut = 0.433 Sut .= 0.45 Sut .
Others discusses the problem of allowable stress and shows that
Ssy = τall = 0.56Sut
for high-tensile spring steels, which is close to the first value given for hardened alloy
steels. They point out that this value of allowable stress is specified by Draft Standard
2089 of the German Federal Republic when shear formela is used without stress
correction factor.

Table: Constants A and m of Sut = A/dm for Estimating Minimum Tensile Strength of
Common Spring Wires. Source: From Design Handbook, 1987, p. 19. Courtesy of
Associated Spring.
Relative
ASTM Exponent Diameter, A, Diameter,
A,
Material Cost of
No. m in Kpsi.inm mm MPammm
Wire
Music wire* A228 0.145 0.004–0.256 201 0.10–6.5 2211 2.6

τQ&T wire† A229 0.187 0.020–0.500 147 0.5–12.7 1855 1.3
Hard-drawn wire‡ A227 0.190 0.028–0.500 140 0.7–12.7 1783 1.0
Chrome-vanadium wire§ A232 0.168 0.032–0.437 169 0.8–11.1 2005 3.1
Chrome-silicon wire|| A401 0.108 0.063–0.375 202 1.6–9.5 1974 4.0
0.146 0.013–0.10 169 0.3–2.5 1867 7.6–11
302 Stainless wire# A313 0.263 0.10–0.20 128 2.5–5 2065
0.478 0.20–0.40 90 5–10 2911
0 0.004–0.022 145 0.1–0.6 1000 8.0
Phosphor-bronze wire** B159 0.028 0.022–0.075 121 0.6–2 913
0.064 0.075–0.30 110 2–7.5 932
∗Surface is smooth, free of defects, and has a bright, lustrous finish.
†Has a slight heat-treating scale which must be removed before plating.
‡Surface is smooth and bright with no visible marks.
§Aircraft-quality tempered wire, can also be obtained annealed.
||Tempered to Rockwell C49, but may be obtained untempered.
#Type 302 stainless steel.
∗∗Temper CA510.

Table :Mechanical Properties of Some Spring Wires
Elastic Limit, Diameter E G
Material Percent of Sut
Tension Torsion d, in Mpsi GPa Mpsi GPa
Music 65–75 45–60 <0.032 29.5 203.4 12.0 82.7
wire 0.033–0.063 29.0 200 11.85 81.7
A228 0.064–0.125 28.5 196.5 11.75 81.0
>0.125 28.0 193 11.6 80.0
HD Spring 60–70 45–55 <0.032 28.8 198.6 11.7 80.7
A227 0.033–0.063 28.7 197.9 11.6 80.0
0.064–0.125 28.6 197.2 11.5 79.3
>0.125 28.5 196.5 11.4 78.6
Oil tempered 85–90 45–50 28.5 196.5 11.2 77.2
A239
Valve spring 85–90 50–60 29.5 203.4 11.2 77.2
A230
Chrome- 88–93 65–75 29.5 203.4 11.2 77.2
vanadium A231
A232 88–93 29.5 203.4 11.2 77.2
Chrome- 85–93 65–75 29.5 203.4 11.2 77.2
silicon A401
Stainless steel
A313* 65–75 45–55 28 193 10 69.0
17-7PH 75–80 55–60 29.5 208.4 11 75.8
414 65–70 42–55 29 200 11.2 77.2
431 65–75 45–55 29 200 11.2 77.2
420 72–76 50–55 30 206 11.5 79.3
Phosphor- 75–80 45–50 15 103 46 41.4
bronze B159
Beryllium- 70 50 17 117.2 6.5 44.8
copper B197 75 50–55 19 131 7.3 50.3
Inconel alloy 65–70 40–45 31 213.7 11.2 77.2
X-750
*Also includes 302, 304, and 316.
Note: See the next table for allowable torsional stress design values.
Table : Maximum Allowable Torsional Stresses for Helical Compression Springs in

Static Applications Source: Robert E. Joerres, “Springs,” Chap. 6 in Joseph E. Shigley, Charles R.
Mischke, and Thomas H. Brown, Jr. (eds.), Standard Handbook of Machine Design, 3rd ed., McGraw-
Hill,New York, 2004.
Maximum Percent of Tensile Strength
Material Before Set Removed After Set Removed
(includes KW or KB) (includes Ks)
Music wire and cold-drawn 45 60–70
carbon steel
Hardened and tempered 50 65–75
carbon and low-alloy steel
Austenitic stainless steels 35 55–65
Nonferrous alloys 35 55–65

Design Procedure:
The preferred range of spring index is 4 C 12, with the lower indexes being more
difficult to form (because of the danger of surface cracking) and springs with higher
indexes tending to tangle often enough to require individual packing. This can be the
first item of the design assessment.
The recommended range of active turns is 3 Na 15. To maintain linearity when a
spring is about to close, it is necessary to avoid the gradual touching of coils (due to
nonperfect pitch). A helical coil spring force-deflection characteristic is ideally linear.
Practically, it is nearly so, but not at each end of the force-deflection curve. The
spring force is not reproducible for very small deflections, and near closure, nonlinear
behavior begins as the number of active turns diminishes as coils begin to touch. The
designer confines the spring’s operating point to the central 75 percent of the curve
between no load, F = 0, and closure, F = Fs . Thus, the maximum operating force
should be limited to Fmax 7/8 Fs. Defining the fractional overrun to closure as ξ,
where
Fs = (1 + ξ)Fmax
it follows that
Fs = (1 + ξ)Fmax = (1 + ξ)(7/8) Fs
From the outer equality ξ =1/7≈ 0.15. Thus, it is recommended that ξ 0.15. In
addition to the relationships and material properties for springs, we now have some
recommended design conditions to follow, namely:
4 C 12
3 Na 15
ξ 0.15
ns 1.2
where ns is the factor of safety at closure (solid height).
When considering designing a spring for high volume production, the figure of merit
can be the cost of the wire from which the spring is wound. The fom would be
proportional to the relative material cost, weight density, and volume:
fom = −(relative material cost)( π2d2Nt D/4)
For comparisons between steels, the specific weight can be omitted.
Spring design is an open-ended process. There are many decisions to be made, and
many possible solution paths as well as solutions. In the past, charts, nomographs, and
“spring design slide rules” were used by many to simplify the spring design problem.
Today, the computer enables the designer to create programs in many different
formats—direct programming, spreadsheet, MATLAB, etc. Commercial programs are
also available. There are almost as many ways to create a spring-design program as
there are programmers. Here, we will suggest one possible design approach.
Make the a priori decisions, with hard-drawn steel wire the first choice (relative
material cost is 1.0). Choose a wire size d. With all decisions made, generate a
column of parameters: d, D, C, OD or ID, Na , Ls , L0, (L0)cr, ns, and fom. By
incrementing wire sizes available, we can scan the table of parameters and apply the
design recommendations by inspection. After wire sizes are eliminated, choose the
spring design with the highest figure of merit. This will give the optimal design
despite the presence of a discrete design variable d and aggregation of equality and
inequality constraints. The procedure suggests to work in a table form like the one
shown in the following figure and table. It is general enough to accommodate to the
situations of as-wound and set-removed springs, operating over a rod, or in a hole free
of rod or hole.

d is chosen from the preferred wire sizes and then A can be calculated
d
A
Kc
C
Na
D
Ls
L0
(L0)cr
ns
fom
Figure: The Design Procedure for the Helical Spring
Table: Spring's wire preferred diameters (Metric sizes).

Preferred 13.0, 12.0, 11.0, 10.0, 9.0, 8.5, 8.0, 7.0, 6.5, 6.0, 5.5, 5.0, 4.8, 4.5, 4.0, 3.8, 3.5, 3.0, 2.8,
metric 2.5, 2.0, 1.8, 1.6, 1.4, 1.2, 1.0, 0.90, 0.80, 0.70, 0.65, 0.60 or 0.55, 0.50 or 0.55, 0.45,
0.45, 0.40, 0.40, 0.35, 0.35, 0.30 or 0.35, 0.30, 0.28, 0.25, 0.22, 0.22, 0.20, 0.20, 0.18
diameters
(d)*
*
The preferred metric sizes are from Associated Spring. Barnes Group, Inc., and are listed as the
nearest preferred metric size to the U.S. Steel Wire Gage. The gage numbers do not apply.
Now examine the table and perform the adequacy assessment. The shading of the
table indicates values outside the range of recommended or specified values. The
spring index constraint 4 C 12 rules out diameters that make C out of range. The
constraint 3 Na 15 rules out wire diameters that result in values out of the range.
The Ls 1 constraint rules out diameters less than 0.080 in. The L0 4 constraint
rules out other diameters. The buckling criterion rules out free lengths longer than
(L0)cr, which rules out more diameters. The factor of safety ns is exactly 1.20 because
the mathematics forced it. Had the spring been in a hole or over a rod, the helix
diameter would be chosen without reference to (ns)d. The result is that there are only
few springs. The figure of merit decides and the decision is the design with the best of
them.
Critical Frequency of Helical Springs
If a wave is created by a disturbance at one end of a swimming pool, this wave will
travel down the length of the pool, be reflected back at the far end, and continue in
this back-and-forth motion until it is finally damped out. The same effect occurs in
helical springs, and it is called spring surge. If one end of a compression spring is
held against a flat surface and the other end is disturbed, a compression wave is
created that travels back and forth from one end to the other exactly like the
swimming-pool wave. Spring manufacturers have taken slow-motion movies of
automotive valve-spring surge. These pictures show a very violent surging, with the
spring actually jumping out of contact with the end plates. When helical springs are
used in applications requiring a rapid reciprocating motion, the designer must be
certain that the physical dimensions of the spring are not such as to create a natural
vibratory frequency close to the frequency of the applied force; otherwise, resonance

may occur, resulting in damaging stresses, since the internal damping of spring
materials is quite low.
The governing equation for the translational vibration of a spring is the wave
equation. The harmonic, natural, frequencies for a spring placed between two flat and
parallel plates, in radians per second, are
�= �√ = , , , ….
where the fundamental frequency is found for m = 1, the second harmonic for m = 2,
and so on. We are usually interested in the frequency in cycles per second; since ω =
2π f , we have, for the fundamental frequency in hertz,
= √
assuming the spring ends are always in contact with the plates.
Studies show that the frequency is
= √
where the spring has one end against a flat plate and the other end free. They also
point out that this equation applies when one end is against a flat plate and the other
end is driven with a sine-wave motion.
The weight of the active part of a helical spring is
� �
= = � =
where is the specific weight.
The fundamental critical frequency should be greater than 15 to 20 times the
frequency of the force or motion of the spring in order to avoid resonance with the
harmonics. If the frequency is not high enough, the spring should be redesigned to
increase k or decrease W.

Threads
The helical-thread screw was undoubtedly an extremely important mechanical
invention. It is the basis of power screws, which change angular motion to linear
motion to transmit power or to develop large forces (presses, jacks, etc.), and threaded
fasteners, an important element in nonpermanent joints.
Screw threads serve three basic functions in mechanical systems;
1) to provide a clamping force
2) to restrict or control motion, and
3) to transmit power.
Geometrically, a screw thread is a helical incline plane. A helix is the curve defined
by moving a point with uniform angular and linear velocity around an axis. The
distance the point moves linear (parallel to the axis) in one revolution is referred to as
pitch or lead. The term “internal threads” refers to threads cut into the sidewall of an
existing hole. External threads refers to threads cut or rolled into the external
cylindrical surface of a fastener or stud. The size most commonly associated with
screw threads is the nominal diameter. Nominal diameter is a more of a label than a
size. For example, a bolt and nut may be described as being (M16) diameter. But
neither the external threads of the bolt nor the internal threads of the nut are exactly
16 mm diameter. In fact, the bolt diameter is a little smaller and the nut diameter a
little larger. But it is easier to specify the components by a single size designation
since the bolt and nut are mating components.
Thread Joint can be classified as part of the temporary fasteners as shown in the
following figure.
Figure Types of Fasteners.
Definitions and Threads Terminology:

Bolts: They are basically threaded fasteners normally used with nuts.
Screws: They engage either with preformed or self-made internal threads.
Studs: They are externally threaded headless fasteners. One end usually meets a tapped
component and the other with a standard nut.
There are different forms of bolt and screw heads for a different usage. These include bolt
heads of square, hexagonal or eye shape and screw heads of hexagonal, Fillister, button
head, counter sunk or Phillips type. These are shown in the following figures.
Crest: the peak of the thread for external threads, the valley of the thread for internal
threads.
Major Diameter [d]: The largest diameter of a screw thread.

Minor Diameter (or root) [dr]: The smallest diameter of a screw thread.
Pitch Diameter [dp]: nominally the mean of the major and minor diameters.
Thread Angle : The included angle between two adjacent thread walls.
Pitch : The distance measured axially, between corresponding points on the
consecutive thread forms in the same axial plane and on the same side of axis is
known as pitch length. The pitch in U.S. units is the reciprocal of the number of
thread forms per inch n.
Lead : It is axial distance a screw thread advances in one revolution. For a single
thread the lead is the same as the pitch. A multiple-threaded product is one having
two or more threads cut beside each other (imagine two or more strings wound side
by side around a pencil). Standardized products such as screws, bolts, and nuts all
have single threads; a double-threaded screw has a lead equal to twice the pitch, a
triple-threaded screw has a lead equal to 3 times the pitch, and so on. All threads are
made according to the right-hand rule unless otherwise noted. That is, if the bolt is
turned clockwise, the bolt advances toward the nut.
Square Thread : A square thread is formed if the generating plane section is square.
Acme Thread : The vee thread is created by a triangular section while trapezoidal
thread has a trapezium section. This thread is also known as the Acme thread.
Figure: Thread Terminology and Profile [ after Shigley, 2011]

Threaded Fastener
Apart from transmitting motion and power the threaded members are also used for
fastening or jointing two elements. The threads used in power screw are square or
Acme while threads used in fastening screws have a Vee profile. Because of large
transverse inclination the effective friction coefficient between the screw and nut
increases by equation( ̅ = / co� � ) where f is the basic coefficient of friction of
the pair of screw and nut, θ is the half of thread angle and ̅ is the effective
coefficient of friction. The wedging effect of transverse inclination of the thread
surface was explained before. According to IS : 1362-1962 the metric thread has a
thread angle of 60o. The other proportions of thread profile are shown in the above
figure. IS : 1362 designates threads by M followed by a figure representing the major
diameter, d. For example a screw or bolt having the major diameter of 2.5 mm will be
designated as M 2.5. The standard describes the major (also called nominal) diameter
of the bolt and nut, pitch, pitch diameter, minor or core diameter, depth of bolt thread
and area resisting load (Also called stress area). Pitch diameter in case of V-threads
corresponds to mean diameter in square or Acme thread. The following two tables
describes V-thread dimensions according to IS : 1362.
Table: Dimensions of V-threads (Coarse) [IS : 1362]
DC Thread Stress
p d or D Dp
Designation (mm) Depth Area
(mm) (mm) (mm)
Nut Bolt (mm) (mm )
2
M 0.4 0.1 0.400 0.335 0.292 0.277 0.061 0.074

M 0.8 0.2 0.800 0.670 0.584 0.555 0.123 0.295
M1 0.25 1.000 0.838 0.729 0.693 0.153 0.460
M 1.4 0.3 1.400 1.205 1.075 1.032 0.184 0.983
M 1.8 0.35 1.800 1.573 1.421 1.371 0.215 1.70
M2 0.4 2.000 1.740 1.567 1.509 0.245 2.07
M 2.5 0.45 2.500 2.208 2.013 1.948 0.276 2.48
M3 0.5 3.000 2.675 2.459 2.387 0.307 5.03
M 3.5 0.6 3.500 3.110 2.850 2.764 0.368 6.78
M4 0.7 4.000 3.545 3.242 3.141 0.429 8.78
M5 0.8 5.000 4.480 4.134 4.019 0.491 14.20
M6 1 6.000 5.350 4.918 4.773 0.613 20.10
M8 1.25 8.000 7.188 6.647 6.466 0.767 36.60
M 10 1.5 10.000 9.026 8.876 8.160 0.920 58.30
M 12 1.75 12.000 10.863 10.106 9.858 1.074 84.00
M 14 2 14.000 12.701 11.835 11.564 1.227 115.00
M 16 2 16.000 14.701 13.898 13.545 1.227 157.00
M 18 2.5 18.000 16.376 15.294 14.933 1.534 192
M 20 2.5 20.000 18.376 17.294 16.933 1.534 245
M 24 3 24.000 22.051 20.752 20.320 1.840 353
M 30 3.5 30.000 27.727 26.211 25.706 2.147 561
M 36 4 36.000 33.402 31.670 31.093 2.454 976
M 45 4.5 45.000 42.077 40.129 39.416 2.760 1300
M 52 5 52.000 48.752 46.587 45.795 3.067 1755
M 60 5.5 60.000 56.428 54.046 53.177 3.374 2360

Table: Dimensions of V-threads (Fine) [IS : 1362]
DC Thread Stress
p d or D dp (mm)
Designation Depth Area
(mm) (mm) (mm)
Nut Screw (mm) (mm )
2
M8×1 1 8.000 7.350 6.918 6.773 0.613 39.2

M 10 × 1.25 1.25 10.000 9.188 8.647 8.466 0.767 61.6
M 12 × 1.25 1.25 12.000 11.184 10.647 10.466 0.767 92.1
M 14 × 1.5 1.5 14.000 13.026 12.376 12.166 0.920 125
M 16 × 1.5 1.5 16.000 15.026 14.376 14.160 0.920 167
M 18 × 1.5 1.5 18.000 17.026 16.376 16.160 0.920 216
M 20 × 1.5 1.5 20.000 19.026 18.376 18.160 0.920 272
M 22 × 1.5 1.5 22.000 21.026 20.376 20.160 0.920 333
M 24 × 2 2 24.000 22.701 21.835 24.546 1.227 384
M 27 × 2 2 27.000 25.701 24.835 24.546 1.227 496
M 30 × 2 2 30.000 28.701 27.835 27.546 1.227 621
M 33 ×2 2 33.000 31.701 30.335 30.546 1.227 761
M 36 × 3 3 36.000 34.051 32.752 32.391 1.840 865
M 39 × 3 3 39.000 37.051 35.752 35.391 1.840 1028
Wide variety of threaded fasteners are used in engineering practice. These are cylindrical
bars, which are threaded to screw into nuts or internally threaded holes. The following figure
depicts three commonly used fasteners. A bolt has a head at one end of cylindrical body. The
head is hexagonal in shape. The other end of the bolt is threaded. The bolt passes through
slightly larger holes in two parts and is rotated into hexagonal nut, which may sit on a circular
washer. The bolt is rotated into the nut by wrench on bolt head.
Figure: Three Types of Threaded Fasteners, (a) two parts are clamped between bolt head
and nut (b) A screw with a head and threads on part of its cylindrical body threaded into an
internally threaded hole. (c) A stud is threaded at both ends and does not have a head. One
of its end screws into threaded hole while the other threaded end receives nut.
The bolts are available as ready to use elements in the market. Depending upon
manufacturing method they are identified as black, semi finished or finished. The
head in black bolt is made by hot heading. The bearing surfaces of head or shank are
machine finished and threads are either cut or rolled. In semi finished bolts the head is
made by cold or hot heading. The bearing surfaces of head or shank are machine
finished and threads are either cut or rolled. A finished bolt is obtained by machining

a bar of same section as the head. The threads are cut on a turret lathe or automatic
thread cutting machine.
Besides hexagonal head the bolt or screw may have shapes as shown in the following
figure, except the hexagonal and square head which are common in bolts, other forms
are used in machine screws. Those at (a) and (b) are tightened with wrench, the bolt or
screw with internal socket is rotated with a hexagonal key, at (c) and the screws
carrying slits in the head are rotated with screw driver.
Figure: Heads of Threaded Fasteners; (a) Hexagonal; (b) Square; (c) Internal Socket;
(d) Circular with a Slit; (e) Button with Slit; (f) Counter Sunk with a Silt; (g) Plain
with a Slit
Effect of thread angle on strength:

The lower the value of the thread angle, the greater the load carrying capability of the
thread. The force of mating threads is normal to the surface of the thread. This is
shown in the following figure as F. The components of the force F transverse and
parallel to the axis are shown as Ft and Fa. The component of force typically
responsible for failure is that applied transverse to the axis of the thread. It is this load
that can cause cracking in internal threads, especially under cyclic loads. Internal
threads are more susceptible since they are typically cut and cutting operations in
metals produce surface
irregularities that can
contribute to crack
growth. External threads
are typically rolled onto a
fastener and therefore lack
the surface flaws of cut
threads. As the thread
angle decreases, the
component Ft gets
smaller. This is why
square and buttress
threads are usually used
for power transfer
applications.
Figure Thread Forces
Failure Of Bolts And Screws
The bolts and screws may fail because of following reasons :

(a) Breaking of bolt shank
(b) Stripping of threads
(c) Crushing of threads
(d) Bending of threads
Invariably when bolt is tightened it is subjected to tensile load along its axis. There
may be rare occasion where bolt is pretentioned. The bolt loading situations may be
identified as :
(a) No initial tension, bolt loaded during operation.
(b) Only initial tension and no loading afterwards.
(c) After initial tension bolt is further loaded in tension during operation.
(d) In addition to loading initially bolt may be subjected to bending moment and/or
shearing forces.
(e) In eccentrically loaded bolted joint, the bolts are subjected to shearing stress which
is dominant. Initial tension is additional. We will analyze this problem as riveted joint.
Permissible Stresses In Bolts
Bolts are often made in steel having carbon percentage varying between 0.08 to 0.25.
However, high quality bolts and particularly those of smaller diameter are made in
alloy steel and given treatment of quenching followed by tempering. Medium carbon
steels may also be improved in tensile strength by similar heat treatment. Since it is
not always possible to determine the wrench torque when bolts are fitted on shop
floor, the initial tightening torque often tends to be higher than necessary. This will
obviously induce higher stress in the bolt even without external load. Such stresses are
particularly high in case of smaller diameter bolt and reduce as the bolt diameter
increases. This kind of tightening stresses call for varying permissible stresses in case
of bolt which are small when bolt diameter is small and high when bolt diameter is
large. This is unlike other machine
parts where trend of permissible stress
is just the reverse. The correlation of
permissible stress and bolt diameter
requires that the process of selection of
diameter will be reiterative. An
empirical formula that correlates the
permissible tensile stress, tp, and bolt
diameter at the stress section d1, is
usually, used and this formula is
plotted in the following Figure which
can be used as an alternative to
formula. Both the formula and the
Figure are applicable to medium
carbon steel bolts only.
Figure: Permissible Bolt Stress as Function of Minor (Core) Diameter for Medium
Carbon Steel Bolts
The student must see that the core section in V-thread means the same thing as in case
of square thread. It is the core section, which carries the stress and is identified by
core diameter d1. This diameter can be seen in the figures and tables. The Standard
tables also describe the area of the core section under the heading of stress area. The
design equation for the bolt or screw is same with the difference that the fastener will
always be in tension. So, if the permissible tensile stress is � , then

× . .
� = =
� �
Threads Production:
Threads are produced in various ways as follows:
1. Cutting Process.
2. Forming process.
3. Grinding process.
Standardization of Threads: (Standard Inch Units)

To facilitate their use, screw threads have been standardized. In 1948, the United
States, Great Britain and Canada established the current system for standard inch
dimension threads. This is the Unified thread series and consists of specifications for
Unified Coarse (UNC) Unified Fine (UNF) and Unified Extra Fine (UNEF) threads.
Metric threads are also standardized. Metric thread specification is given through ISO
standards. Thread information is available in tabular form from many sources
including Mechanical Drawing texts and Machine Design handbooks.
Thread form:
Thread form is a classification based upon the cross-sectional profile of the thread.
The standard thread form for inch unit threads in U.S. is the Unified (UN) thread
form. This thread form is
characterized by a 60 degree
thread angle and a flat crest and
rounded root.
Thread series:
Thread series is a standard based
upon the number of threads/inch
for a specific nominal diameter.
Standards for standard inch units
are:
Coarse (C), Fine (F), Extra-Fine
(EF). The figure at right shows
fine and coarse thread fasteners.
The designation is based upon
the number of threads per unit
length. A short discussion of
each thread series is given below.
Figure: Photograph of Course and Fine Threads
Threads per Inch:
Literally a measure of the number of crests per unit of length measured along the axis
of the thread. The number of threads/inch for a thread series is given by standard and
may be found in thread tables. The Tap Chart shown later in this document gives the
number of threads/inch based upon threads series and nominal diameter.
Descriptions of the Thread Series:
Unified Coarse. UNC is the most commonly used thread on general-purpose
fasteners. Coarse threads are deeper than fine threads and are easier to assemble
without cross threading. UNC threads are normally easier to remove when corroded,
owing to their sloppy fit. A UNC fastener can be procured with a class 3 (tighter) fit if
needed (fit classes covered below).

Unified Fine. UNF thread has a larger minor diameter than UNC thread, which gives
UNF fasteners slightly higher load-carrying (in shear) and better torque-locking
capabilities than UNC fasteners of the same material and outside diameter. The fine
threads have tighter manufacturing tolerances than UNC threads, and the smaller lead
angle allows for finer tension adjustment. UNF threads are frequently used in cases
where thread engagement is minimized due to thinner wall thickness.
Unified national extra fine. UNEF is a thread finer than UNF and is common to the
aerospace field. This thread is particularly advantageous for tapped holes in hard
materials as well as for tapped holes in thin materials where engagement is at a
minimum.
Class fit:
Class fit is a specification of how tightly mating external and internal threads will
mesh. It is based upon the difference in the values of the respective pitch diameters.
These differences are in the thousandths of an inch. For the Unified thread form, the
classes of fit are:
Class 1: Loose fit. Threads may be assembled easily by hand. Used in cases where
frequent assembly/disassembly required. Typically require use of locking devices
such as lock washers, locking nuts, jam nuts, etc. Class 1 fits are common for bolts
and nuts.
Class 2: Standard fit. Threads may be assembled partly by hand. Most common fit in
use. Used in semi-permanent assemblies.
Class 3: Tight fit. Can be started by hand, but requires assistance (tools) to advance
threads. Common for set screws. Used in permanent assemblies.
An additional designation is made for external (A) versus internal (B) threads and is
included as a postscript to the numerical designation.
Figure: Thread designation (Standard Inch Units)
Standard inch unit thread specification examples

.4375 - 20UNF - 2A, LH
.500 - 13UNC – 1A

.375 - 24UNEF - 2B
Specification of Metric Threads:
Metric threads are defined in the standards document ISO 965-1. Metric thread
specifications always begin with thread series designation (for example M or MJ),
followed by the fastener’s nominal diameter and thread pitch (both in units of
millimeters) separated by the symbol "x".
Metric thread specification examples
MJ6 x 1 - 4H5H
M8 x 1.25 - 4h6h LH (i.e. Left hand thread)
M10 x 1.5 - 4h5h
Metric thread series:
There exists multiple metric thread series used for special applications. The standard
is the M series. The MJ series is one of the most common of the special application
threads.
M Series: Standard metric thread profile
MJ Series: Modified series in which crest and root radii are specified
Metric thread fits:
A fit between metric threads is indicated by internal thread class fit followed by
external thread tolerance class separated by a slash; e.g., M10 x 1.5-6H/6g. The class
fit is specified by tolerance grade (numeral) and by tolerance position (letter).
General purpose fit
6g (external) 6H (internal)
Close fit
5g6g (external) 6H (internal)
If thread fit designation (e.g., "-6g") is omitted (e.g., M10 x 1.5), it specifies a
"medium" fit, which is 6H/6g. The 6H/6g fit is the standard ISO tolerance class for
general use.
English unit internal and external thread class fit 2B/2A is essentially equivalent to
ISO thread class fit 6H/6g. English unit class fit 3B/3A is approximately equivalent to
ISO class fit 4H5H/4h6h.
Default metric fastener thread pitch. If metric thread pitch designation (e.g., " x
1.5") is omitted, it specifies coarse pitch threads. For example, M10 or M10-6g, by
default, specifies M10 x 1.5. The standard metric fastener thread series for general
purpose threaded components is the M thread profile and the coarse pitch thread
series.

Figure: Thread designation (Standard Metric Units)
Metric fastener thread series compatibility. Metric fastener thread series M is the
common thread profile. Thread series MJ designates the external thread has an
increased root radius (shallower root relative to external M thread profile), thereby
having higher fatigue strength (due to reduced stress concentrations), but requires the
truncated crest height of the MJ internal thread to prevent interference at the external
MJ thread root. M external threads are compatible with both M and MJ internal
threads.
M10 x 1.5-6g means metric fastener thread series M, fastener nominal size (nominal
major diameter) 10 mm, thread pitch 1.5 mm, external thread class fit 6g. If referring
to internal thread tolerance, the "g" would be uppercase.
Left Hand Threads:
Unless otherwise specified, screw threads are assumed to be right-handed. This means
that the direction of the thread helix is such that a clockwise rotation of the thread will
cause it to advance along its axis. Left-handed threads advance when rotated counter
clockwise. Left-handed threads are often used in situations where rotation loads
would cause right-hand threads to loosen during service. A common example is the
bicycle. The pedals of a bicycle are attached to the crank arm using screw threads.
The pedal on one side of the bicycle uses right-hand threads and the other uses left-
hand. This prevents the motion of pedals and crank from unscrewing the pedal and
having it fall off during use. Left-hand threads must be indicated in the thread
specification. This is accomplished by appending “LH” to the end of the specification.
Local Notes
Local notes, also referred to as callouts, are included on a drawing to specify
information for a specific feature of a component or assembly. The feature being
referenced is indicated through the use of a leader line. The leader line points to the
feature in question and terminates at the note. One common example of a local note is
the specification of the size dimension of a hole feature. When a callout is made to a
hole feature, the leader line should reference the circular view of hole with line
pointing toward the center of the circle. The note should be written in the order of
operations performed. (e.g. drill then thread) and the leader arrowhead should touch
the representation of the last operation performed.

Figure: Callout Examples and Common Callout Symbols
The two examples of callouts below reference counterbored and countersunk holes. In
case you have forgotten, counterboring and countersinking are secondary machining
operations used to create cylindrical and conical (respectively) enlargements of a hole,
usually for the purpose of recessing a fastener head.
The two examples of callouts below reference counterbored and countersunk holes. In
case you have forgotten, counterboring and countersinking are secondary machining
operations used to create cylindrical and conical (respectively) enlargements of a hole,
usually for the purpose of recessing a fastener head.
Figure: Counterbored and Countersunk Holes
In the examples shown at right the pilot hole is specified first then the counterbore or
countersink is specified. Notice that no specification of operation is given for the pilot
hole. τperation specifications such as “DRILL” or “BτRE” are no longer included in
notes and callouts. Rather only the feature sizes (and tolerances, if applicable) are
included.
Counterbore specification:

Include the diameter of the counterbore, which is based upon fastener head diameter
with a clearance value added. ( Refer to Head Dimension Tables) Include the depth of
the counterbore, which is based upon head profile height. ( Refer to Head Dimension
Tables for this information )
Figure: Counterbore and Countersink Callouts

Countersink specification:
Include the angle of countersink

and either;
1) depth of countersink or
2) diameter of maximum opening
(based upon fastener head
diameter plus 1/64 typ. or
equivalent)
Examples of metric notes for
counterbored, countersunk and
spot-faced holes are given at
right. The depth of a machined
hole is categorized as being
either thru or blind. A thru hole
begins at the penetrating surface
and terminates at another
surface. Therefore the “depth” of
the hole is based upon the
distance between the two
surfaces.
Figure: Metric Notes for Counterbored,

Countersunk and Spotfaced Holes.
Because of this, the thru hole requires no specification of depth in the note. The word
“THRU” should not be included with the note. If no depth is specified, a hole is by
default a thru feature. This is demonstrated in the notes for the countersunk and
counterbored holes shown in the Figures.
A blind hole is machined to a specified
depth. This depth specification must be
included in the note for a blind hole. The
depth value refers to the cylindrical
(useable) portion of the hole (see the next
Figure). The tip angle in not included in
the value of hole depth. When multiple
occurrences of the same hole specification
exist in a single component, it is not
necessary to write a callout to each hole in
the pattern. Rather, the preferred procedure
is to write the note to one hole, and then
include within that note a reference to the
total number of identical features in the
pattern. The proper form for these notes is
given below and in the figure at right.
4 x φ.375
Figure: Hole Depth

Writing notes for threaded holes:
The note for a threaded
hole is a specification of
all information required
for the creation
of the hole. This includes;
1) the diameter (and depth
if blind) of the pilot hole
drilled
prior to thread creation. 2)
the specification of the
internal threads for the
hole. Again a
depth is given if the hole
is blind.
The creation of the
internal threads is a metal
cutting process referred to
as “tapping”.
Figure: Multiple Occurrences

It should be apparent that in order to cut metal, the diameter of the pilot hole must be
smaller than the major diameter of the threads. This difference in diameters is very
important. If the pilot hole diameter is too small, too much material will have to be cut
and the thread cutting tool (tap), being very hard (and therefore brittle) will break. If
the pilot hole diameter is too large, the thread height will be too small and load
carrying capability of threads will be compromised. In practice, the diameter of the
pilot hole will set the minor diameter of the internal threads. Typically the thread
height for internal threads is approximately 75% of the mating external threads (it
may be as low as 50% for materials such as steel). This means a gap will exist
between the crest of the external thread and the root of the internal. For this reason,
threads may not be considered a seal in and of themselves.
The diameter of the pilot hole is specific for each thread series and form. This unique
diameter is determined by referencing the thread series and form within a standard
table. Typically this value is referred to in the table as the “tap drill diameter”.
(although in the table below it is given as “Drill Size”) The following table also
provides the values of Threads per Inch for specific nominal diameters and thread
series. Notice that in the table shown above, the tap drill diameter is given in
fractions, letters, and numbers. These are all drill sizes, just designated in different
ways. When including these diameters in the annotation, use the following.
Diameter from table a fraction: write as exact decimal equivalent or fraction
Diameter from table a letter: write letter and give decimal equivalent* as
reference (in parentheses)
Diameter from table a number: write number and give decimal equivalent*
as reference
* these values may be obtained from Number and Letter Drill Size decimal equivalence tables
The note for the threaded hole is then written in order of operation. That is, the
specification of the pilot hole, then the specification of the threads being cut, and
depth (if required)

Table: Tap Chart - UNC/UNF Threads
Basic
Basic minor
Basic Basic minor dia of
major effective dia of int ext.
Tap NF/NC Threads dia dia threads threads Drill
size UNF/UNC per inch (inches) (inches) (inches) (inches) size
1/4-20 UNC 20 .2500 .2175 .1887 .1959 #7
1/4-28 UNF 28 .2500 .2268 .2062 .2113 #3
5/16-18 UNC 18 .3125 .2764 .2443 .2524 F
5/16-24 UNF 24 .3125 .2854 .2614 .2674 I
3/8-16 UNC 16 .3750 .3344 .2983 . 3073 5/16.
3/8-24 UNF 24 .3750 .3479 .3239 .3299 Q
7/16-14 UNC 14 .4375 .3911 .3499 .3602 U
7/16-20 UNF 20 .4375 .4050 .3762 .3834 25/64
1/2-13 UNC 13 .5000 .4500 .4056 .4167 27/64
1/2-20 UNF 20 . 5000 .4675 .4387 .4459 29/64
9/16-12 UNC 12 .5625 .5084 .4603 .4723 31/64
9/16-18 UNF 18 .5625 .5264 .4943 .5024 33/64
5/8-11 UNC 11 .6250 .5660 .5135 .5266 17/32
5/8-18 UNF 18 .6250 .5869 .5568 .5649 37/64
3/4-10 UNC 10 .7500 .6650 .6273 .6417 21/32
3/4-16 UNF 16 .7500 .7094 .6733 .6823 11/16
7/8-9 UNC 9 .8750 .8028 .7387 .7547 49/64
7/8-14 UNF 14 .8750 .8286 .7874 .7977 13/16
1-8 UNC 8 1.000 .9188 .8466 .8647 7/8
1-14 UNF 14 1.000 .9459 .8978 .9098 15/16
Figure: Machining a Threaded Hole

Examples of notes for threaded holes.
Figure: Examples of notes for threaded holes.
Threaded Mechanical Fasteners

In order to fully understand engineering prints and to provide adequate information
when ordering components, one should be able to both create and read complete
mechanical fastener specifications. This will give you the ability to write accurate
specification of desired fastener and to associate a given specification with the
respective fastener.
The specification of a fastener includes the following:
A Complete Thread Specification
Head type
Fastener type
Fastener length
It also may include a specification of material and grade (strength).
Examples of fastener specification for the various fastener types are given later in this
course notes.
There exist many different head types for mechanical fasteners. Some are very
specialized such as castellated and tamper proof heads. We will only consider six
basic head types. These six basic types are listed below along with the standard
abbreviation for each.
Hexagonal head (HEX HD)
Fillister head (FIL HD
Flat head (FLAT HD)
Oval head (OVAL HD)
Round head (RND HD)
Hexagonal socket head (SOC HD)
Note: The fillister, flat, oval and round head types are commonly available with slot
or Phillips drive. Other drive types (such as hex socket) are also available, but less
common

Figure: Common Head Types
Mechanical Fasteners:
There are three basic types of mechanical fastener. They are the
Cap Screw (CAP SCR)
Machine Screw (MACH SCR) and
The Set Screw (SET SCR).
Cap screws and machine screws are very similar. Both are available with the same
type of head. They are both used in conjunction with internally threaded holes for the
purpose of clamping components together. There are however, difference between cap
and machine screws.
Clamping Force:
When a cap or machine screw is used to attach to components to one another, the
fastener is inserted through a clearance hole in one component and onto a threaded
hole in another. An alternative assembly would be to pass the fastener through two
clearance holes and use a nut for clamping. Clamping force is applied through contact
between the bottom face of head and the contact between the internal and external
threads. When these methods are used, the fastener is inserted into the internally
threaded component (either the threaded hole or the nut) and advanced by rotating the
fastener. When the head of the fastener make contact with surface of the component
being attached, the head can advance no further. However, some additional rotation of
the fastener can be made, usually by means of some fashion or tool (a wrench for
example). Since the threads will advance during this rotation but the head cannot a
tensile load is generated in the shank of the fastener. This tensile load is proportional
to the force used to rotate the fastener. The rotational force is referred to as “seating
torque” and the tensile force is referred to as “pre-load”.
Cap Screws (CAP SCR)
Cap screws tend toward larger diameters. The threaded end of a cap screw is
chamfered. The minimum thread length is a function fastener nominal diameter. For
most cap screws, the minimum length of thread equals 2 * DIA + 0.25. For socket
head cap screws, the minimum thread length equals 2 * DIA + 0.50. A cap screw
specified with a nut is referred to as a bolt.

Metric Cap Screws Tables
Notes that all linear dimensions in millimeters The dimensions are generally in accordance with BS EN ISO 4762
BS 3643- 2 & BS 4168
Table: Socket Head Cap Screws (metric)
Hex Body diameter [D] Head Diameter [A] Soc

Nominal Thread
Socket and Head height [H] length
Size Pitch
Size [J] Max Min Max Min [K].
M3 0.5 2.50 3.00 2.86 5.50 5.20 1.3
M4 0.70 3.00 4.00 3.82 7.00 6.64 2.00
M5 0.8 4.00 5.00 4.82 8.50 8.14 2.70
M6 1.0 5.00 6.00 5.82 10.00 9.64 3.30
M8 1.25 6.00 8.00 7.78 13.00 12.57 4.3
M10 1.5 8.00 10.00 9.78 16.00 15.57 5.50
M12 1.75 10.00 12.00 11.73 18.00 17.57 6.60
M16 2.0 14.00 16.00 15.73 24.00 23.48 8.80
M20 2.5 17.00 20.00 19.67 30.00 29.48 10.70
M24 3.0 19.00 24.00 23.67 36.00 35.38 12.90
Table Flat Head Cap Screws ( Metric)
Hex Max Head Dia Head Soc.

Nominal Thread
Socket Cone [A]_max [A]_Min Height Length
Size [D] Pitch
Size [J] Dia [A1] [H] [K]
M3 0.5 2,0 6,72 6,00 5,82 1,86 1,05
M4 0.70 2,5 8,96 8,00 7,78 2,48 1,49
M5 0.8 3,0 11,2 10,00 9,78 3,1 1,86
M6 1.0 4,0 13,44 12,00 11,75 3,72 2,16
M8 1.25 5,0 17,92 16,00 15,73 4,96 2,85
M10 1.5 6,0 22,4 20,00 19,67 6,2 3,60
M12 1.75 8,0 26,88 24,00 23,67 7,44 4,35
M16 2.0 10,0 33,6 32,00 29,67 8,8 4,89
M20 2.5 10,0 40,32 40,00 35,61 10,16 5,49

Machine Screws (MACH SCR)
Machine screws are only available in smaller diameters. The threaded end of the
fastener not chamfered but rather simply sheared. The minimum thread length is a
function of fastener length as follows:
if fastener length > 2, then min. thread length = 1.75
if fastener length < 2, then min. thread length = fastener length
Examples of Cap and Machine Screw Fastener Descriptions
The following example is the specification for a 1.50 long cap screw with a hexagonal
head and using 7/16 nominal diameter Unified fine threads of a standard fit.
1.50 X .4375 – 20UNF –2A HEX HD, CAP SCR
Set Screws (SET SCR)
The function of set screws is to restrict or control motion.. They are commonly used
in conjunction with collars, pulleys, or gears on shafts.
With the exception of the antiquated square head, set
screws are headless fasteners and therefore threaded
for their entire length. Lacking heads, set screws are
categorized by drive type (similar to head type) and
point style. Most set screws use Class 3 fit threads.
This is to provide resistance to the set screw “backing
out” of its threaded hole during service. In addition, set
screws have a specified point type. The point is used to provide various amounts of
holding power when used. Holding power concerns will be discussed below. The
available point types for set screws are the Cone, Cup, Flat, Oval, and Dog (full or
half) points. Profiles of these point type are shown in the following figure.
Figure Drawings of different types of setscrews or grub screws. Socket setscrews: (a)
flat point; (b) cup point; (c) oval point; (d) cone point; (e) half-dog point.( Repeated)
Set Screw Holding Power:

The following table lists values of the seating torque and the corresponding holding
power for inch-series setscrews. The values listed apply to both axial holding power,
for resisting thrust, and the tangential holding power, for resisting torsion. Typical
factors of safety are 1.5 to 2.0 for static loads and 4 to 8 for various dynamic loads.
Setscrews should have a length of about half of the shaft diameter. Note that this
practice also provides a rough rule for the radial thickness of a hub or collar.

Table :Typical Holding Power (Force) for Socket Setscrews* Source: Unbrako
Division, SPS Technologies, Jenkintown, Pa.
Seating Holding Seating Holding
Size, Torque, Power, Size, Torque, Power,
. in Lbf. in lbf . in Lbf. in lbf
#0 1.0 50 5/16 165 1500
#1 1.8 65 3/8 290 2000
#2 1.8 85 7/16 430 2500
#3 5 120 1/2 620 3000
#4 5 160 9/16 620 3500
#5 10 200 5/8 1325 4000
#6 10 250 3/4 2400 5000
#8 20 385 7/8 5200 6000
#10 36 540 1 7200 7000
1/4 87 1000
*Based on alloy-steel screw against steel shaft, class 3A coarse or fine threads in class 2B holes, and cup-point socket setscrews
In many applications, set screws are used to prevent the rotational and axial
movement of parts such as collars, couplings, and pulley sheaves mounted to shafts.
Failure of the set screw in these cases is relative motion of .01 inch between
components. An important consideration in setscrew selection is the holding power
provided by the contact between the setscrew point and attachment surface (typically
a cylindrical shaft). Holding power is generally specified as the tangential force in
pounds. Axial holding power is assumed to be equal to the torsional holding power.
Some additional resistance to rotation is contributed by penetration of the set screw
point into the attachment surface. In cases where point penetration is desired, the set
screw should have a material hardness at least 10 points higher on the Rockwell scale
than that of the attachment material. Cup-point set screws cut into the shaft material.
Cone-point setscrews also penetrate the attachment surface and may be used with a
spotting hole to enhance this penetration. Oval-point and flat-point setscrews do not
penetrate the surface and hence have less holding power.
Set screw selection often begins with the common axiom stating that set screw
diameter should be equal to approximately one-half shaft diameter. This rule of thumb
often gives satisfactory results, but its usefulness may be limited. Manufacturers' data
or data supplied by standard machine design texts will give more reliable results.
Seating torque: Torsional holding power is almost directly proportional to the
seating torque of cup, flat, and oval-point setscrews.
Point style: Setscrew point penetration contributes as much as 15% to the total
holding power. When the cone-point setscrew is used, it requires the greatest
installation torque because of its deeper penetration. Oval point, which has the
smallest contact area, yields the smallest increase in holding power.
Relative hardness: Hardness becomes a significant factor when the difference
between setscrew point and shafting is less than 10 Rockwell C scale points. Lack of
point penetration reduces holding power.
Flatted shafting: About 6% more torsional holding power can be expected when a
screw seats on a flat surface. Flatting, however, does little to prevent the 0.01-in.
relative movement usually considered as a criterion of failure. Axial holding power is
the same.

Length of thread engagement: The length of thread engagement does not have a
noticeable effect on axial and torsional holding power, provided there is sufficient
engagement to prevent thread stripping during tightening. In general, the minimum
recommended length of engagement is 1 to 1.5 times the major diameter of the
setscrew for threading in brass, cast iron, and aluminum; and 0.75 to 1 times the
diameter for use in steel and other materials of comparable hardness. Be aware that
the lengths of
engagement specified are for full threads engaged, not overall screw length.
Thread type: A negligible difference exists in the performance of coarse and fine
threads of the same class of fit. Most set screws are class 3A fit.
Drive type: Most set screws use socket (either hex or fluted) drive or a slot drive. The
type of drive affects the seating torque that can be attained because it determines how
much torque can be transmitted to the screw. Less torque can be transmitted through a
slot drive than a socket drive. Therefore, holding power of the slotted screw is about
45% less.
Number of setscrews: Two setscrews give more holding power than one, but not
necessarily twice as much. Holding power is approximately doubled when the second
screw is installed in an axial line with the first but is only about 30% greater when the
screws are diametrically opposed. Where design dictates that the two screws be
installed on the same circumferential line, displacement of 60° is recommended as the
best compromise between maximum holding power and minimum metal between
tapped holes. This displacement gives 1.75 times the holding power of one screw.
Torque force: The compressive force developed at the point depends on lubrication,
finish, and material.
Setscrews and keyways: When a setscrew is used in combination with a key, the
screw diameter should be equal to the width of the key. In this combination, the
setscrew holds the parts in an axial direction only. The key, keyseat and keyway
assembly carries the torsional load on the parts. The key should be tight fitting so that
no motion is transmitted to the screw. Under high reversing or alternating loads, a
poorly fitted key will cause the screw to back out and lose its clamping force.
Examples of Set Screw Fastener Descriptions
The following example is the specification for a 1.00 long set screw with a hexagonal
socket drive, a cup point, a 1/4 nominal diameter, Unified fine threads and a class 3
fit.
1.00 X .250 – 28UNF – 3A SOC HD, CUP PT, SET SCR
Eccentric Loaded bolted Joint
When the line of action of the load
does not pass through the centroid of
the bolts system and thus all bolts are
not equally loaded, then the joint is
said to be an eccentric loaded bolted
joint, as shown in the following
Figure. The eccentric loading results
in secondary shear caused by the
tendency of force to twist the joint
about the centre of gravity in addition
to direct shear or primary shear.
Riveted and bolted joints loaded in
shear are treated exactly alike in
design and analysis. ( will be treated later) Figure Eccentric Loaded bolted Joint

(Dimensions in millimeters).

Power Screw
Power screws and ball screws are designed to convert rotary motion to linear motion
and to exert the necessary force to move a machine element along a desired path.
Power screws operate on the classic principle of the screw thread and its mating nut.
If the screw is supported in bearings and rotated while the nut is restrained from
rotating, the nut will translate along the screw. If the nut is made an integral part of a
machine, for example, the tool holder for a lathe, the screw will drive the tool holder
along the bed of the machine to take a cut. Conversely, if the nut is supported while it
is rotating, the screw can be made to translate. The screw jack uses this approach.
A ball screw is similar in function to a power screw, but the configuration is different.
The nut contains many small, spherical balls that make rolling contact with the
threads of the screw, giving low friction and high efficiencies when compared with
power screws. Modern machine tools, automation equipment, vehicle steering
systems, and actuators on aircraft use ball screws for high precision, fast response,
and smooth operation. Visit a machine shop where there are metal-cutting machine
tools. Look for examples of power screws that convert rotary motion to linear motion.
They are likely to be on manual lathes moving the tool holder. Or look at the table
drive for a milling machine. Inspect the form of the threads of the power screw. Are
they of a form similar to that of a screw thread with sloped sides? Or are the sides of
the threads straight? Compare the screw threads with those shown in the following
figure for square, Acme, and buttress forms.
Figure : Forms Of Power Screw Threads [(a) Square (b), Acme (ANSI Standard B
1.5-1973); (c) Buttress ( ANSI Standard B 1.9-1973)]
While in the shop, do you see any type of material-testing equipment or a device
called an arbor press that exerts large axial forces? Such machines often employ
square thread power screws to produce the axial force and motion from rotational
input, through either a hand crank or an electric motor drive. If they are not in the
machine shop, look for them in the metallurgy lab or another room where materials
testing is done. Now look further in the machine shop. Are there machines that use

digital readouts to indicate position of the table or the tool? Are there computer
numerical control machine tools? Any of these types of machines should have ball
screws rather than the traditional power screws because ball screws require
significantly less power and torque to drive them against a given load. They can also
be moved faster and positioned more accurately than power screws. You may or may
not be able to see the recirculating balls in the nut of the power screw. But you should
be able to see the different shaped threads looking like grooves with circular bottoms
in which the spherical balls roll. Have you .seen such power screws or ball screws
anywhere outside a
machine shop? Some
garage door openers
employ a screw drive, but
others use chain drives.
Perhaps your home has a
.screw jack or a scissors
jack for raising the car to
change a tire. Both use
power screws. Have you
ever sat in a seat on an
airplane where you can
see the mechanisms that
actuate the flaps on the
rear edge of the wings?
Try it .sometime, and
observe the actuators
during takeoff or landing.
It is likely that you will
see a ball screw in action.
This chapter will help you
learn the methods of
analyzing the
performance of power
screws and ball screws
and to specify the proper
size for a given
application. [ Ref. Mott,
2004]
Figure : Types Of Power Screw Threads
Power Screw Dimensions: The above Figure shows three types of power screw
threads: the square thread, the Acme thread, and the buttress thread. Of these, the
square and buttress threads are the most efficient. That is, they require the least torque
to move a given load along the screw. However, the Acme thread is not greatly less
efficient, and it is easier to machine. The buttress thread is desirable when force is to
be transmitted in only one direction. The following Tables gives the preferred

combinations of basic major diameter, D. and number of threads per inch, n. for Acme
screw threads. The pitch, p. is the distance from a point on one thread to the
corresponding point on the adjacent thread, and p = 1/n. Other pertinent dimensions
listed in the Table include the minimum minor diameter and the minimum pitch
diameter of a screw with an external thread. When you are performing stress analyses
on the screw, the safest approach is to compute the area corresponding to the minor
diameter for tensile or compressive stresses. However, a more accurate stress
computation results from using the tensile stress area (listed in the Table).
TABLE Preferred Acme screw threads
Nominal Threads Pitch. Minimum Minimum Tensile Shear

major per in, p = 1/n minor pitch stress stress
diameter, diameter, diameter, area, At area, As
D Dr Dp
(in) n (in) (in) (in) (in2) (in2)
1/4 16 0.0625 0.1618 0.2043 0.026 32 0.3355
5/16 14 0.0714 0.2140 0.2614 0.044 38 0.4344
3/8 12 0.0833 0.2632 0.3161 0.065 89 0.5276
7/16 12 0.0833 0.3253 0.3783 0.097 20 0.6396
1/2 10 0.1000 0.3594 0.4306 0.1225 0.7278
5/8 8 0.1250 0.4570 0.5408 0.1955 0.9180
3/4 6 0.1667 0.5371 0.6424 0.2732 1.084
7/8 6 0.1667 0.6615 0.7663 0.4003 1.313
1 5 0.2000 0.7509 0.8726 0.5175 1.493
1 1/8 5 0.2000 0.8753 0.9967 0.6881 1.722
1 1/4 5 0.2000 0.9998 1.1210 0.8831 1.952
1 3/8 4 0.2500 1.0719 1.2188 1.030 2.110
1 1/2 4 0.2500 1.1965 1.3429 1.266 2.341
1 3/4 4 0.2500 1.4456 1.5916 1.811 2.803
2 4 0.2500 1.6948 1.8402 2.454 3.262
2 1/4 3 0.3333 1.8572 2.0450 2.982 3.610
2 1/2 3 0.3333 2.1065 2.2939 3.802 4.075
2 3/4 3 0.3333 2.3558 2.5427 4.711 4.538
3 2 0.5000 2.4326 2.7044 5.181 4.757
3 1/2 2 0.5000 2.9314 3.2026 7.388 5.700
4 2 0.5000 3.4302 3.7008 9.985 6.640
4 1/2 2 0.5000 3.9291 4.1991 12.972 7.577
5 2 0.5000 4.4281 4.6973 16.351 8.511
Alternative Thread Forms for Power Screws

Modifications are frequently made to both Acme and square threads. For instance, the
square thread is sometimes modified by cutting the space between the teeth so as to
have an included thread angle of 10 to 15◦. This is not difficult, since these threads are
usually cut with a single-point tool anyhow; the modification retains most of the high
efficiency inherent in square threads and makes the cutting simpler. While the
standard Acme thread is probably the most widely used, others are available. The stub
Acme thread has a similar form with a 29° angle between the sides, the depth of the
thread is shorter, providing a stronger, more rigid thread. Metric power screws are
typically made according to the ISO trapezoidal form that has a 30° included angle.
The relatively low efficiency of standard single-thread Acme screws (approximately

30% or less) can be a strong disadvantage. Higher efficiencies can be achieved using
high lead, multiple thread designs. The higher lead angle produces efficiencies in the
30% to 70% range. It should be understood that some mechanical advantage is lost so
that higher torques are required to move a particular load as compared with single
thread screws.
Table: Basic Dimensions of Square Thread, (mm)
Pitch, p 5
Core Dia. d1 17 19 24 23
Major Dia. d 22 24 26 28
Pitch, p 6
Core dia. d1 24 26 28 30
Major dia. d 30 32 34 36
Pitch, p 7
Core dia. d1 31 33 35 37
Major dia. d 38 40 43 44
Pitch, p 8
Core Dia. d1 38 40 42 44
Major Dia. d 46 48 50 56
Pitch, p 9
Core dia. d1 46 49 51 53
Major dia. d 55 58 60 62
Pitch, p 10
Core Dia. d1 55 58 60 62 65 68 70 72
Major Dia. d 65 68 70 72 75 78 80 82
The Forces and torques analysis of Power Screws

Familiar applications include the lead screws of lathes, and the screws for vises,
presses, Universal testing machine, and jacks. In order to design these applications
forces and torques must be calculated. The next figure shows a free body diagram of
one thread of a square-threaded power screw moves on its nut. The thread having a
mean diameter dm, a pitch p, a lead angle , and a helix angle is loaded by the axial
compressive force F. We wish to find an expression for the torque required to raise
this load, and another expression for the torque required to lower the load.
Figure : Force diagrams: (a) lifting the load; (b) lowering the load.

First, imagine that a single thread of the screw is unrolled or developed for exactly a
single turn. Then one edge of the thread will form the hypotenuse of a right triangle
whose base is the circumference of the mean thread diameter circle and whose height
is the lead. The angle λ is the lead angle of the thread. We represent the summation of
all the axial forces acting upon the normal thread area by F.
To raise the load, a force PR acts to the right (part a of the figure), and to lower the
load, PL acts to the left (part b). The friction force is the product of the coefficient of
friction f with the normal force N, and acts to oppose the motion. The system is in
equilibrium under the action of these forces, and hence, for raising the load, we have
∑ = � − �� − co� =
}…(a)
∑ = − − �� + co� =
In a similar manner, for lowering the load, we have
∑ = −� − �� + co� =
}… (b)
∑ = − + �� + co� =
Since we are not interested in the normal force N, we eliminate it from each of these
sets of equations and solve the result for P. For raising the load, this gives
i �+ c �
� = …(c)
c �− i �
and for lowering the load,
c �− i �
� =
c �+ i �
…(d)
Next, divide the numerator and the denominator of these equations by cos and use
the relation tan λ = l/πdm (see figure). We then have, respectively,
[ ⁄� � + ]
� = ⁄
…(e)
− � �
[ − ⁄� � ]
� =
+ ⁄� �
…(f)
Finally, noting that the torque is the product of the force P and the mean radius dm/2,
for raising the load we can write
+�
= � �
…(g)
� �−
where TR is the torque required for two purposes: to overcome thread friction and to
raise the load.
The torque required to lower the load, from Eq. ( f ), is found to be
� �−
= � � �+
...(h)
This is the torque required to overcome a part of the friction in lowering the load. It
may turn out, in specific instances where the lead is large or the friction is low, that
the load will lower itself by causing the screw to spin without any external effort. In
such cases, the torque TL from Eq. (h) will be negative or zero. When a positive
torque is obtained from this equation, the screw is said to be self-locking. Thus the
condition for self-locking is
π f dm > l …(i)

Now divide both sides of this inequality by πdm. Recognizing that l/πdm = tan , we
get
f > tan …(j)
This relation states that self-locking is obtained whenever the coefficient of thread
friction is equal to or greater than the tangent of the thread lead angle.
An expression for efficiency is also useful in the evaluation of power screws. If we let
f = 0 in Eq. (g), we obtain
T0 = Fl / 2π …(k)
which, since thread friction has been eliminated, is the torque required only to raise
the load. The efficiency is therefore
� ℎ � � a �
=
� ℎ � �
= 0= = …(l)
� � � a �+�
The preceding equations have been developed for square threads where the normal
thread loads are parallel to the axis of the screw. In the case of Acme or other threads,
the normal thread load is inclined to the axis because of the thread angle 2α and the
lead angle . Since lead angles are small, this inclination can be neglected and only
the effect of the thread angle (see the next figure) considered. The effect of the angle
α is to increase the frictional force by the wedging action of the threads.
Figure : (a) Normal thread force is increased because of angle α; (b) thrust collar has
frictional diameter dc.
Therefore the frictional terms in Eq. (g) must be divided by cos α. For raising the
load, or for tightening a screw or bolt, this yields
+�
= � � − � sec �
…(m)
� ec �
In using Eq. (m), remember that it is an approximation because the effect of the lead
angle has been neglected.
For power screws, the Acme thread is not as efficient as the square thread, because of
the additional friction due to the wedging action, but it is often preferred because it is
easier to machine and permits the use of a split nut, which can be adjusted to take up
for wear.
Usually a third component of torque must be applied in power-screw applications.
When the screw is loaded axially, a thrust or collar bearing must be employed

between the rotating and stationary members in order to carry the axial component.
Part (b) of the above figure shows a typical thrust collar in which the load is assumed
to be concentrated at the mean collar diameter dc. If fc is the coefficient of collar
friction, the torque required is
= � � …(n)
For large collars, the torque should probably be computed in a manner similar to that
employed for disk clutches.
Example 1:
A square threaded screw is required to work against an axial force of 6.0 kN and has
following dimensions. Major diameter d = 32 mm; pitch p = 4 mm with single start, f
= 0.08. Axial force rotates with the screw.
Calculate :
(a) Torque required when screw moves against the load.
(b) Torque required when screw moves in the same direction as the load.
(c) Efficiency of the screw.
Solution
Remember the relationship between p, d and d1 which has been shown Using
d = 32 mm and p = 4 mm
dm= 32-2= 30 mm
The angle of helix is related to the circumference of mean circle and the pitch from
description above.
�a� = = = .
� �
∴ = .
and tan α = f = 0.08 → α = 4.57o
Using equation (g), the torque required to move screw against load, TR,
× × × − × − +�× . × × −
= = .
�× × − − . × × −
The torque required to lower the load, from Eq. ( h ), is found to be
== . .
�ℎ � � × .
= = ≡ = . = . %
�ℎ � � � × .
Example 2:
If in the Example 1, the screw has the Acme thread with thread angle 2θ = 29 o instead of
square thread, calculate the same quantities.
Solution
There is no difference in calculation for square and the Acme thread except that in
case of the Acme thread the coefficient of friction is modified and effective
coefficient of friction is given by divided f by cos α
f '= 0.08/0.968 = 0.0826 and α '= 4,724 o
From Figure for the Acme thread note that
dm =d - p/2 - 0.125 = 32- 2- 0.125 = 29.875 mm
�a� = = = . → = . °
� � .
For raising the load, or for tightening a screw or bolt, this yields
+�
= � � − � sec �
ec �
= . .
�
When the screw moves in the same direction as the load, the torque = 3.58 N.m

�ℎ � � × .
= = ≡ = . = . %
�ℎ � � � × . .
Comparing the results of Examples 1 and 5 we can see that the screws have got same major
diameter and pitch and for this reason their helix angles are different. Coefficients of friction
are inherently different. But the torque on the screw increases by 2.41% and efficiency
decreases by 1.744%.
The stress analysis of Power Screws

Nominal body stresses in power screws can be related to thread parameters as
follows:
Figure: Geometry of square thread useful in finding bending and transverse shear
stresses at the thread root.
 The maximum nominal shear stress in torsion of the screw body can be
expressed as
p = 16T/ πd …(o)
3
 The axial stress in the body of the screw due to load F is

tp = F/A = 4F/πdr
2
…(p)
in the absence of column action. For a short column the J. B. Johnson buckling
formula which is
�
= − …(q)

� . �
Nominal thread stresses in power screws can be related to thread
parameters as follows: The bearing stress in the above figure, bp, is

� = − = − …(r)
� � � / � � �
 The bending stress at the root of the thread

where nt is the number of engaged threads.
b is found from
� �
= = =
� = = � � � 2
= ...(s)
� � �
 The transverse shear stress at the center of the root of the thread due to
load F is
= = � /
= …(t)
� � � � �
and at the top of the root it is zero. The compound at the top of the root “plane” is
found by first identifying the orthogonal normal stresses and the shear stresses. From
the coordinate system of the above figure, we note
� = =
�
� = − =
� �
� = =
then use the equations of two dimensional stresses( using the maximum shear theory)
to find the right size of the power screw.
� = √ +
�
� � = √ +
�
The screw-thread form is complicated from an analysis viewpoint. Remember the

origin of the tensile-stress area At , which comes from experiment. A power screw
lifting a load is in compression and its thread pitch is shortened by elastic
deformation. Its engaging nut is in tension and its thread pitch is lengthened. The
engaged threads cannot share the load equally. Some experiments show that the first
engaged thread carries 0.38 of the load, the second 0.25, the third 0.18, and the
seventh is free of load. In estimating thread stresses by the equations above,
substituting 0.38 F for F and setting nt to 1 will give the largest level of stresses in the
thread-nut combination.
Ham and Ryan (1932) showed that the coefficient of friction in screw threads is
independent of axial load, practically independent of speed, decreases with heavier
lubricants, shows little variation with combinations of materials, and is best for steel
on bronze. Sliding coefficients of friction in power screws are about 0.10–0.15. The
following table shows safe bearing pressures on threads, to protect the moving
surfaces from abnormal wear.
The next table shows the coefficients of sliding friction for common material pairs.
And the after next table shows coefficients of starting and running friction for
common material pairs.

Screw Nut
Table Screw pb Source: H. A. Rothbart and T. H. Brown, Jr., Mechanical Design
Handbook, 2nd ed., McGraw-Hill, New York, 2006.
Safe Bearing
Screw Material Nut Material Notes
Pressure, pb (psi)
Steel Bronze 2500–3500 Low speed
Steel Bronze 1600–2500 ≤10 fpm
Cast iron 1800–2500 ≤8 fpm
Steel Bronze 800–1400 20–40 fpm
Cast iron 600–1000 20–40 fpm
Steel Bronze 150–240 ≥50 fpm
Table: Screw-Nut Material Combination and Safe Bearing Pressure

Material Safe Bearing Rubbing Velocity at
Application
Pressure Mean Diameter
Screw Nut (MPa) m/min
Hand Press Steel Bronze 17.5-24.5 Well lubricated
Steel C.I 12.5-17.5 Low Velocity
Screw Jack Steel C.I 12.5-17.5 Velocity < 2.5
Steel Bronze 10.5-17.5 Velocity < 3.0
Hoisting Steel C.I 4.0-7.0 6-12
Machine Steel Bronze 35.0-100.0 6-12
Lead Screw Steel Bronze 10.5-17.0 > 15.0
Table : Coefficients of Friction f for Threaded Pairs Source: H. A. Rothbart and T. H.

Brown, Jr., Mechanical Design Handbook, 2nd ed., McGraw-Hill, New York, 2006
Nut Material
Screw Material
Steel Bronze Brass Cast Iron
Steel, dry 0.15–0.25 0.15–0.23 0.15–0.19 0.15–0.25
Steel, machine oil 0.11–0.17 0.10–0.16 0.10–0.15 0.11–0.17
Bronze 0.08–0.12 0.04–0.06 — 0.06–0.09
Table: Thrust-Collar Friction Coefficients Source: H. A. Rothbart and T. H. Brown,

Jr., Mechanical Design Handbook, 2nd ed., McGraw-Hill, New York, 2006.
Combination Running Starting

Soft steel on cast iron 0.12 0.17
Hard steel on cast iron 0.09 0.15
Soft steel on bronze 0.08 0.10
Hard steel on bronze 0.06 0.08

Design procedure of Power screw:
1.Find d by considering that power screw is under pure compression as staring
estimate .
2. Find the standard dimensions that close to the above estimate.
3. Find TL to rotate the power screw against friction at the thread area and the collar
torque (Tc ) and the total torque ( Tt ) will be their sum.
4. Find the shear stress according the above torque.
5. Find the actual compression stress for the selected dimension (note: use the root
cross sectional area of the screw.
6. Find the principal stresses and if max. shear theory is used then
� = √ + �
Note here if the applied shear found to be above the permissible shear then the size
must be enlarged and the starting again from step 2.
7. Find the efficiency of the power screw
8. Find the active number of the threads of the nut (n) from the permissible pressure
between the screw and the nut.
= �
( − )
9. Find the number of the threads of the nut (n) from shear stress of the nut
=
�
10. Choose the number of the threads (n) of the nut as the larger between the two
values.
11. Find the height of the nut (H) as:
H = (n+2) p
12. Find the outer diameter of the nut Dnut from:
� = �
(� − )
13. Find the other dimensions of the nut that depends in the design of the nut.
14. Show the mechanism of the collar and if it large use the theory of friction disk.
15. Design the mechanism of the handle that provide the working torque. Find the
dimension of the handle. Assume that person can apply around 300-400 N by his
hand.
16. Check screw for buckling ( use Euler's formula for long column and Johnson
formula for short column).
17.Find The other dimensions of body and other accessories (according to the design
of them).
18. Check for self-locking conditions.

Rivets and Riveted Joints:
The rivets are used to make permanent fastening between the two or more plates such
as in structural work, ship building, bridges,
tanks and boiler shells. The riveted joints are
widely used for joining light metals. A rivet is
a short cylindrical bar with a head integral to
it. The cylindrical portion of the rivet is called
shank or body and lower portion of shank is
known as tail.
Methods of Riveting
The function of rivets in a joint is to make a
connection that has strength and tightness.
The strength is necessary to prevent failure of
the joint. The tightness is necessary in order to
contribute to strength and to prevent leakage
as in a boiler or in a ship hull (The frame or
body of ship). When two plates are to be
fastened together by a rivet as shows below,
the holes in the plates are punched and reamed or drilled. Punching is the cheapest
method and is used for relatively thin plates and in structural work. Since punching
injures the material around the hole, therefore drilling is used in most pressure-vessel
work. The creation of head by process of upsetting is shown in the following figure
The upsetting of the cylindrical portion of the rivet can be done cold or hot. When
diameter of rivet is 12 mm or less, cold upsetting can be done. For larger diameters
the rivet is first heated to light red and inserted. The head forming immediately
follows. The rivet completely fills the hole in hot process. Yet it must be understood
that due to subsequent cooling the length reduces and diameter decreases. The
reduction of length pulls the heads of rivet against plates and makes the joint slightly
stronger. The reduction of diameter creates clearance between the inside of the hole
and the rivet. Such decrease in length and diameter does not occur in cold worked
rivet.
Figure: Methods of Riveting
Material of Rivets
The material of the rivets must be tough and ductile. They are usually made of steel
(low carbon steel or nickel steel), brass, aluminum or copper, but when strength and a
fluid tight joint is the main consideration, then the steel rivets are used. The rivets for

general purposes shall be manufactured from steel conforming to the following Indian
Standards:
1. IS: 1148–1982 (Reaffirmed 1992) – Specification for hot rolled rivet bars (up to 40
mm diameter) for structural purposes; or
2. IS: 1149–1982 (Reaffirmed 1992) – Specification for high tensile steel rivet bars
for structural purposes.
3. The rivets for boiler work shall be manufactured from material conforming to IS:
1990 – 1973 (Reaffirmed 1992) – Specification for steel rivets and stay bars for
boilers.
Manufacture of Rivets
The rivets may be made either by cold heading or by hot forging.
1. If rivets are made by the cold heading process, they heat treated so that the stresses
set up in the cold heading process are eliminated.
2. If they are made by hot forging process, care shall be taken to see that the finished
rivets cool gradually.
Note: when the diameter of rivet is 12 mm or less generally cold riveting is adopted.
Types of Rivets
1. Button Head
2. Counter sunk Head
3. Oval counter Head
4. Pan Head
5. Conical Head
Figure: Different Types of Rivet Heads
Types of Riveted Joints

1. According to purpose
2. According to position of plates connected
3. According to arrangement of rivets
1. According to purpose:

a) Strong Joints: In these Joints strength is the only criterion ( e.g.: Beams, Trusses
and Machine Joints).
b) Tight joints: These joints provide strength as well as are leak proof against low
pressure ( e.g. Reservoir, Containers and tanks).
c) Strong-Tight Joints: These are the joints applied in boilers and pressure vessels and
ensure both strength and leak proofness.
2. According to position of plates:
a) Lap Joint: A lap joint is that in which one plate overlaps the other and the two
plates are then riveted together.
b) Butt Joint: A butt joint is that in which the main plates are touching each other
and a cover plate (i.e. Strap) is placed either on one side or on both sides of the main
plates. The cover plate is then riveted together with the main plates. Butt joints are of
the following two types:
I) In a single strap butt joint, the edges of the main plates butt against each other and
only one cover plate is placed on one side of the main plates and then riveted together.
II) In a double strap butt joint, the edges of the main plates butt against each other and
two cover plates are placed on both sides of the main plates and then riveted together.
3. According to arrangement of rivets:
a) A single riveted joint is that in which there is a single row of rivets in a lap joint as
shown in following figure and there is a single row of rivets on each side in a butt
joint as shown in part (a) of the figure.
b) A double riveted joint is that in which there are two rows of rivets in a lap joint as
shown in the following figure and there are two rows of rivets on each side in a butt
joint as shown in parts (b and c) of the figure.
Figure Types of riveted joints according to arrangement of rivets
Important terms of Riveted joints:

1. Pitch (p): The Distance between two adjacent rivet holes in a row.
2. Back pitch (pb): The Distance between two adjacent rows of rivets.
3. Diagonal pitch (pd): The smallest distance between centers of two rivet holes in
adjacent rows of Zig-Zag riveted joints.
4. Margin (m): It is the distance between center of a rivet hole and nearest edge of
the plate.

5. The plates to be jointed are often of the same thickness and their thickness is
denoted by t. However, if the thicknesses are different, the lower one will be denoted
by t1.
6. The thickness of the cover plate (also known as strap) in a butt joint will be
denoted as tc.
7. The rivet hole diameter is denoted by d. This diameter is normally large than the
diameter of the rivet shank which is denoted by d1.
A problem of designing of a riveted joint involves determinations of p, pb, pd, m, t, tc
and d, depending upon type of the joint.
Modes of Failures of a Riveted Joint

1. Tearing of the plate at the section weakened by holes: Due to the tensile stresses
in the main plates, the main plate or cover plates may tear off across a row of rivets as
shown in Fig. In such cases, we consider only one pitch length of the plate, since
every rivet is responsible for that much length of the plate only.
Figure : Modes of Failures of a single lap Riveted Joint (Tearing of the plate).
2. Shearing of Rivet: The failure will occur when all the rivets in a row shear off
simultaneously. Considers the strength provided by the rivet against this mode of
failure, one consider number of rivets in a pitch length which is obviously one.
Further, in a lap joint failure due to shear may occur only along one section of rivet as
shown in Figure (a). However, in case of double cover butt joint failure may take
place along two sections in the manner shown in Figure (c).
3. Crushing of Plate and Rivet: Due to rivet being compressed against the inner
surface of the hole, there is a possibility that either the rivet or the hole surface may be
crushed. The area, which resists this action, is the projected area of hole or rivet on
diametral plane.

4. Shearing of Plate Margin near the Rivet Hole : The following Figure shows this
mode of failure in which margin can shear along planes ab and cd. If the length of
margin is m, the area resisting this failure is, 2mt.
(c) Shearing off a rivet in a double cover butt joint.

Figure : Modes of Failures of a Riveted Joint (Shearing of Rivet ).
In writing down the above equations for strength of the joint certain assumptions have
been made. It is worthwhile to remember them. Most importantly it should be
remembered that most direct stresses have been assumed to be induced in rivet and
plate which may not be the case. However, ignorance of actual state of stress and its
replacement by most direct stress is compensated by lowering the permissible values
of stresses tp, p and bp, i.e. by increasing factor of safety. The assumptions made in
calculations of strengths of joint are :
(a) The tensile load is equally distributed over pitch lengths.

(b) The load is equally distributed over all rivets.
(c) The bending of rivets does not occur.
(d) The rivet holes do not produce stress concentration. The plate at the hole is not
weakened due to increase in diameter of the rivet during second head formation.
(e) The crushing pressure is uniformly distributed over the projected area of the rivet.
(f) Friction between contacting surfaces of plates is neglected.
Figure : Modes of Failures of a Riveted Joint (Crushing of Plate and Rivet).

Figure : Modes of Failures of a Riveted Joint (Shearing of Plate Margin near the
Rivet Hole)
Table : Standard Rivet Hole and Rivet Diameters

d
(mm)
13 15 17 19 21 23 25 28.5 31.5 34.5 37.5 41 44
d1
(mm)
12 14 16 18 20 22 24 27 30 33 36 39 42
Table : Load sharing factor in multiple riveting

Load Sharing in Multiple Riveting
No. of Rivet
Max. Fraction Average
3 0.353 0.33
4 0.29 0.25
5 0.26 0.2
6 0.24 0.166

Eccentric Loaded Riveted Joint
When the line of action of the load does not pass through the centroid of the rivet
system and thus all rivets are not equally loaded, then the joint is said to be an
eccentric loaded riveted joint, as shown in the following Figure. The eccentric loading
results in secondary shear caused by the tendency of force to twist the joint about the
centre of gravity in addition to direct shear or primary shear.
Let P = Eccentric load on the joint, and e = Eccentricity of the load i.e. the distance
between the line of action of the load and the centroid of the rivet system i.e. G.
The following procedure is adopted for the design of an eccentrically loaded riveted
joint.
1. First of all, find the centre of gravity G of the rivet system. Let A = Cross-
sectional area of each rivet, x1, x2, x3 etc. = Distances of rivets from O-Y, and y1, y2,
y3 etc. = Distances of rivets from O-X. We know that
Where;
n = Number of Rivet and note that all of rivets are with the same size
Figure Eccentric Loaded Riveted Joint

2. Introduce two forces P1 and P2 at the centre of gravity ‘G’ of the rivet system.
These forces are equal and opposite of P as shown in the figure.
3. Assuming that all the rivets are of the same size, the effect of P 1 = P is to produce
direct shear load on each rivet of equal magnitude. Therefore, direct shear load on
each rivet, Ps = P/n , acting parallel to the load P.
4. The effect of P2 = P is to produce a turning moment of magnitude P × e which
tends to rotate the joint about the centre of gravity ‘G’ of the rivet system in a
clockwise direction. Due to the turning moment, secondary shear load on each rivet is
produced. In order to find the secondary shear load, the following two assumptions
are made:

a). The secondary shear load is proportional to the radial distance of the rivet
under consideration from the centre of gravity of the rivet system.
b). The direction of secondary shear load is perpendicular to the line joining
the centre of the rivet to the centre of gravity of the rivet system.
Let F1, F2, F3 ... = Secondary shear loads on the rivets 1, 2, 3...etc.
l1, l2, l3 ... = Radial distance of the rivets 1, 2, 3 ...etc. from the centre of
gravity ‘G’ of the rivet system.
∴ From assumption (a),
� ; �
= = =⋯
= , =
We know that the sum of the external turning moment due to the eccentric load and of
internal resisting moment of the rivets must be equal to zero.
∴ P. e = F1.l1 + F2.l2 + F3.l3 +...
= × = × × + × × +⋯
= [ + + +⋯
From the above expression, the value of F1 may be calculated and hence F2 and F3 etc.
are known. The direction of these forces are at right angles to the lines joining the
centre of rivet to the centre of gravity of the rivet system, as shown in the figure. and
should produce the moment in the same direction (i.e. clockwise or anticlockwise)
about the centre of gravity, as the turning moment (P × e).
Figure Eccentric Loaded Riveted Joint analysis
5. The primary (or direct) and secondary shear load may be added vectorially
to determine the resultant shear load (R) on each rivet as shown in the figure. It may
also be obtained by using the relation

=√ � + + � × × co� �
θ = Angle between the primary or direct shear load (Ps) and secondary shear load (F).
When the secondary shear load on each rivet is equal, then the heavily loaded rivet
will be one in which the included angle between the direct shear load and secondary
shear load is minimum. The maximum loaded rivet becomes the critical one for
determining the strength of the riveted joint. Knowing the permissible shear stress
( p), the diameter of the rivet hole may be obtained by using the relation,
Maximum resultant shear load (R) = (4/π) × d2 ×
From Table, the standard diameter of the rivet hole (d) and the rivet diameter may be
specified, according to IS: 1929 – 1982 (Reaffirmed 1996).
Steps involving for solving the eccentricity Problems:
1. Firstly find the centre of gravity G.
2. Find Direct Shear load Ps.
3. Find Turning moment produced by the load P due to eccentricity e. (P x e).
4. Find Radial distance of the rivets (l1, l2, l3, l4………….).
5. Find Secondary shear loads on the rivets (F1, F2, F3, F4………..).
6. Find the Angle between the direct and secondary shear load of the rivets.
7. Resultant Shear load (R) on the rivets.
8. Find Diameter of rivet hole (d).
9. Then find the diameter of rivet (Dr) from the Design Data Book or the previous
table.
Example: According to part (a) of the following figure, the distances between
columns and rows of rivets are shown. Calculate the maximum shearing stress in
rivets if the force P = 1kN note that each rivet is 5 mm in diameter. Note that all
dimensions on the figure are in mm.
Figure : Torsional Loading And Eccentric Loading Of Riveted Joint

Solution (Analysis)
Plate A is riveted to structural element B. A torque is applied to the Plate A. The plate
will rotate, of course by slight elastic amount, about some point as O in part (a) of the
above Figure. It is not wrong to assume that any straight line such as O-C which
passes through the centre of a rivet, remains straight before and after application of

the torque. Then the deformation, hence strain and so the average shearing stress
across the section of the rivet will be proportional to the distance between O and the
centre of the rivet. Since the average shearing stress is equal to the shearing force
divided by area of cross section of the rivet, the shearing force on the rivet will be
proportional to the distance between O and centre of the rivet. The direction of this
force will be perpendicular to the joining line.
The forces F1, F2, etc. on individual rivets are shown in part (b) of the Figure. For
satisfying condition of equilibrium, components of forces in vertical direction should
sum up to zero. If the forces F1, F2, etc. make angles θ1, θ2, etc. respectively with y-
axis, then
F1 cosθ1 + F2cosθ2 + ……+ Fn cos θn = 0
or . . . ∑�= � co� θ = …. …… (i)
But Fi = i Ai = ( i /ri ) ri Ai
And since i α ri or i = k ri
So, Fi = k ri Ai …… (ii)
Here k is a constant, i = shearing stress in ith rivet whose area of cross section is Ai
and its centre is at a distance ri from O.
Use (ii) and (i) to obtain
∑ � � co� �i =
�=
See from Figure part (b) that ri cosi θi = x
∑ � =
�=
Which is same as ̅ At = 0
Where ̅ is the x-coordinate of centroid of all the rivet and sum of their areas of cross
sections is At. And since neither k nor At is zero therefore, ̅ =0. If then we consider
sum of forces along x-axis we would arrive at the result ̅ =0. This means that 0 is the
point coinciding with the centroid of the rivet area system.
Solution (Numerical value)
The five rivets have been numbered as 1, 2, . . . , 5. Take centre of rivet 3 as origin
and x and y axes along 3-2 and 3-5 respectively. Areas of all rivets is
Hence centroid is on the horizontal line through rivet 4. We can calculate various
distances of rivet centers from centroid.

We can find each of F1, F2, F3, F4 and F5 in terms of k or we can find each force in terms of
F2. We may like to choose F2 because F2 is grater than all other forces because r2 is larger
than all other r.

Clutches: A clutch is a machine member used to connect a driving shaft to a
driven shaft so that the driven shaft may be started or stopped as will, without
stopping the driving shaft. It is, also, a friction device which permits the connection
and disconnection of shafts. Clutches could be either positive or friction type. In
positive(Jaw) clutch the two shaft are rigidly connected and rotate at the same speed
in “in” position and remain entirely disconnected in the “out” position. τn the other
hand friction clutches are gradually engaging until the fully engagement the two shaft
rotate as one.
CLUTCHES TYPES
POSTIVE FRICTION
Disc or Plate Cone
Single Multiple
General notes:
1. For multiple disc clutch Torque most be multiplied by n, where n is the number of
pairs of contact surfaces. If there are n1 discs on the driving shaft and n2 disc on the
driven shaft then the number of the contact surfaces:
n = n1+ n2
2. In the case of new clutch use uniform pressure. In the case of old clutch use
3. Recommended R1/R2  0.6-0.8 and if (b = disc width) then

uniform wear.
b/rm = (R1-R2)/ 0.5(R1-R2)  0.22-0.5

4. The design torque is higher than the motor torque because of engagement
T design =  T motor
factor().
 can be fond in the following table:
Application 
Metal-cutting machine tool 1.26-1.5
Tractor 2 - 2.5
Automobile 1.2-1.5
Crane machine > 1.15

R2: Inner radius of the clutch
R1: Outer radius of the clutch
T: Torque transmitted R
: Coefficient of friction
P: Axial pressure to held surfaces R2
R1

Brakes: Are machine element that absorb either kinetic or potential energy in
the process of slowing down or stopping a moving part. The absorbed energy is
dissipated as heat. Brake capacity depends upon the unit pressure between the braking
surfaces, the coefficient of friction, and the ability of the brake to dissipate heat
equivalent to the energy being absorbed. The performance of brakes is similar to that
of clutches except that clutches connect one moving part to another moving part,
whereas brakes connect a moving part to a frame.
BRAKES TYPES
BAND DISK BLOCK
External Shoe Internal Shoe
Single Double
Power Transmission Systems
In the design of a power transmission, you would typically know the following:
• The nature of the driven machine: It might be a machine tool in a factory that cuts
metal parts for engines; an electric drill used by professional carpenters or home craft
workers; the axle of a farm tractor; the propeller shaft of a turbojet for an airplane; the
propeller shaft for a large ship; the wheels of a toy train; a mechanical timing
mechanism; or any other of the numerous products that need a controlled-speed drive.
• The level of power to be transmitted: From the examples just listed, the power
demanded may range from thousands of horsepower for a ship, hundreds of
horsepower for a large farm tractor or airplane, or a few watts for a timer or a toy.
• The rotational speed of the drive motor or other prime mover: Typically the prime
mover operates at a rather high speed of rotation. The shafts of standard electric
motors rotate at about 1200. 1800. or 3600 revolutions per minute (rpm). Automotive
engines operate from about 1000 to 6000 rpm. Universal motors in some hand tools
(drills, saws, and routers) and household appliances (mixers, blenders, and vacuum
cleaners) operate from 3500 to 20 000 rpm. Gas turbine engines for aircraft rotate
many thousands of rpm.
• The desired output speed of the transmission: This is highly dependent on the
application. Some gear motors for instruments rotate less than 1.0 rpm. Production
machines in factories may run a few hundred rpm. Drives for assembly conveyors
may run fewer than 100 rpm. Aircraft propellers may operate at several thousand rpm.
The designer of a power transmission system must do the following:
• Choose the type of power transmission elements to be used: gears, belt drives, chain
drives, or other types. In fact, some power transmission systems use two or more
types in series to optimize the performance of each.
• Specify how the rotating elements are arranged and how the power transmission
elements are mounted on shafts.
• Design the shafts to be safe under the expected torques and bending loads and
properly locate the power transmission elements and the bearings. It is likely that the
shafts will have several diameters and special features to accommodate keys,
couplings, retaining rings, and other details. The dimensions of all features must be
specified, along with the tolerances on the dimensions and surface finishes.
• Specify suitable bearings to support the shafts and determine how they will be
mounted on the shafts and how they will be held in a housing.
• Specify keys to connect the shaft to the power transmission elements; couplings to
connect the shaft from the driver to the input shaft of the transmission or to connect
the output shaft to the driven machine; seals to effectively exclude contaminants from
entering the transmission; and other accessories.
• Place all of the elements in a suitable housing that provides for the mounting of all
elements and for their protection from the environment and their lubrication.
General notes:
1. It is very common to find a power transmission system interposed between the
driving prime movers, e.g. electric motor, engine, turbine and etc. and driven
machine.
2. In many cases power will not transmitted directly from the driving machine.
Velocity change, velocity control, torque change, many output for one driving
machine, velocity direction and safety consideration are examples for the intermediate
elements.
3. Types of a power transmission system are include electrical, hydraulic, pneumatic
and mechanical means like friction or mesh.

4. The following table shows the main characteristics of different transmission
systems:
Table: Power transmission systems characteristics.
No. Characteristics System(s)
1 Controlled power supply Electrical, Pneumatic
2 Transmission of power over large distance Electrical
3 Accumulation of power Hydraulic
4 Step-by-step velocity change over a wide Electrical, Mechanical
range (friction type)
5 Step-less change of velocity over a wide Electrical, Mechanical (both
range friction and mesh type)
6 Accurate velocity ratio Mechanical (mesh type)
7 High velocities of rotation Electrical, Pneumatic
8 No effect of ambient temperature Electrical, Mechanical (mesh
type)
9 Easy control (Remote or Automatic Electrical
5. Mechanical drives classified:

A. According to the mode of transmission as :
 Disk
Friction type
 Belt (flexible)
 Chain (flexible)
Mesh type
 Gear
 No change
B. According to change of velocity ratio
 Step-by-step change
 Steplees
 Parallel
C. Position of the shaft
 Intersecting
 Skew
6. The following table shows a comparison of different Mechanical drives for 75 KW

and Velocity Ratio 1000:25:
Centre Face
No. Drive Distance Width Weight (N) Cost
(mm) (mm)
1. Flat Belt 5000 350 5000 106
2. Flat Belt with idler 2300 250 5500 125
pulley
3. V-Belt 1800 130 5000 100
4. Chain 830 360 5000 140
5. Toothed Gear 280 160 6000 165
6. Worm and Gear 280 60 4500 125
7. The following table shows the main characteristics of Mechanical drives:

Table: Characteristics Of Mechanical Drives
Transmitted Peripheral
Drive Speed Ratio Efficiency %
Power (kW) speed (m/sec)
1. Flat Belt ≤ 100 (1500)* 5—30 (100) ≤4 (10) 80-92
2. V-Belt ≤ 50(300) 5—30 ≤7 (15) 92-98
3. Chain ≤200 (5000) ≤25 ≤15 94-98
4. Straight ≤10,000 ≤25 ≤6,(10) 92-99
Toothed Gear
5. Helical ≤50,000 ≤25 (150) ≤7 (20) 94-99
Toothed Gear
6. Worm and ≤100 ≤35 (worm) ≤8—100 10-98
Gear (1000)
* Quantities in parentheses are highest known values
8. Power transmission Example (Gear-type speed reducer [Mott, 2004]):

The following figure shows a typical industrial application of these elements
combined with a gear-type speed reducer. This application illustrates where belts,
gear drives, and chains are each used to best advantage. Rotary power is developed by
the electric motor, but motors typically operate at too high a speed and deliver too low
a torque to be appropriate for the final
drive application. Remember, for a
given power transmission, the torque is
increased in proportion to the amount
that rotational speed is reduced. So,
some speed reduction is often
desirable. The high speed of the motor
makes belt drives somewhat ideal for
that first stage of reduction. A smaller
drive pulley is attached to the motor
shaft, while a larger diameter pulley is
attached to a parallel shaft that
operates at a correspondingly lower
speed. Pulleys for belt drives are also
called sheaves. However, if very large ratios of speed reduction are required in the
drive, gear reducers are desirable because they can typically accomplish large
reductions in a rather small package. The output shaft of the gear-type speed reducer
is generally at low speed and high torque. If both speed and torque are satisfactory for
the application, it could be directly coupled to the driven machine. However, because
gear reducers are available only at discrete reduction ratios, the output must often be
reduced more before meeting the requirements of the machine. At the low-speed,
high-torque condition, chain drives become desirable. The high torque causes high
tensile forces to be developed in the chain. The elements of the chain are typically
metal, and they are sized to withstand the high forces. The links of chains are engaged
in toothed wheels called .sprockets to provide positive mechanical drive, desirable at
the low-speed, high-torque conditions. In general, belt drives are applied where the
rotational speeds are relatively high, as on the first stage of speed reduction from an
electric motor or engine. The linear speed of a belt is usually 10 to 30 m/sec. which

results in relatively low tensile forces in the belt. At lower speeds, the tension in the
belt becomes too large for typical belt cross sections, and slipping may occur between
the sides of the belt and the sheave or pulley that carries it. At higher speeds, dynamic
effects such as centrifugal forces, belt whip, and vibration reduce the effectiveness of
the drive and its life. A speed of 20 m/sec is generally ideal. Some belt designs
employ high-strength, reinforcing strands and a cogged design that engages matching
grooves in the pulleys to enhance their ability to transmit the high forces at low
speeds. These designs compete with chain drives in many applications.
As the designer, you must decide what type and size of belt drive to use and what the
speed ratio between the driving and the driven sheave should be. How is the driving
sheave attached to the motor shaft? How is the driven sheave attached to the input
shaft of the gear reducer? Where should the motor be mounted in relation to the gear
reducer, and what will be the resulting center distance between the two shafts? What
speed reduction ratio will the gear reducer provide? What type of gear reducer should
be used: helical gears, a worm and worm-gear drive, or bevel gears? How much
additional speed reduction must the chain drive provide to deliver the proper speed to
the driven shaft? What size and type of chain should be specified? What is the center
distance between the output of the gear reducer and the input to the chopper? Then
what length of chain is required? Finally, what motor power is required to drive the
entire system at the stated conditions?
Flexible Mechanical Drives: Belt and Chain

This chapter will help you learn to identify the typical design features of
commercially available belt and chain drives. You will be able to specify suitable
types and sizes to transmit a given level of power at a certain speed and to accomplish
a specified speed ratio between the input and the output of the drive. Installation
considerations are also described so that you can put your designs into successful
systems. Belts and chains are the major types of flexible power transmission elements.
Belts operate on sheaves or pulleys, whereas chains operate on toothed wheels called
sprockets.
Belts, ropes, chains, and other similar elastic or flexible machine elements are used in
conveying systems and in the transmission of power over comparatively long
distances. In many cases their use simplifies the design of a machine and substantially
reduces the cost. In addition, since these elements are elastic and usually quite long,
they play an important part in absorbing shock loads and in damping out and isolating
the effects of vibration. This is an important advantage as far as machine life is
concerned. Most flexible elements do not have an infinite life. When they are used, it
is important to establish an inspection schedule to guard against wear, aging, and loss
of elasticity. The elements should be replaced at the first sign of deterioration.
The mechanism of working of the belt:
A belt is a flexible power transmission element that seats tightly on a set of pulleys or
sheaves. The following Figure shows the basic layout. When the belt is used for speed
reduction, the typical case, the smaller sheave is mounted on the high-speed shaft,
such as the shaft of an electric motor. The larger sheave is mounted on the driven
machine. The belt is designed to ride around the two sheaves without slipping. The
belt is installed by placing it around the two sheaves while the center distance
between them is reduced. Then the sheaves are moved apart, placing the belt in a
rather high initial tension. When the belt is transmitting power, friction causes the belt
to grip the driving sheave, increasing the tension in one side, called the "tight side," of
the drive. The tensile force in the belt exerts a tangential force on the driven sheave,

and thus a torque is applied to the driven shaft. The opposite side of the belt is still
under tension, but at a smaller value. Thus, it is called the "slack side."
Figure : Basic belt drive geometry
Types of belt drives:

Many types of belts are available: flat belts, grooved or cogged belts, standard V-
belts, double-angle V-belts. and others.
The flat belt is the simplest type, often made from leather or rubber-coated fabric. The
sheave surface is also flat and smooth, and the driving force is therefore limited by the
pure friction between the belt and the sheave. Some designers prefer flat belts for
delicate machinery because the belt will slip if the torque tends to rise to a level high
enough to damage the machine.
Synchronous belts, sometimes called timing belts ride on sprockets having mating
grooves into which the teeth on the belt seat. This is a positive drive, limited only by
the tensile strength of the belt and the shear strength of the teeth. Some cog belts, such
are applied to standard V-grooved sheaves. The cogs give the belt greater flexibility
and higher efficiency compared with standard belts. They can operate on smaller
sheave diameters.
The four principal types of belts are shown, with some of their characteristics, in the
following table. Crowned pulleys are used for flat belts, and grooved pulleys, or
sheaves, for round and V belts. Timing belts require toothed wheels, or sprockets. In
all cases, the pulley axes must be separated by a certain minimum distance, depending
upon the belt type and size, to operate properly.

Table Characteristics of Some Common Belt Types (Figures are cross sections except
for the timing belt, which is a side view).
Other characteristics of belts are:

• They may be used for long center distances.
• Except for timing belts, there is some slip and creep, and so the angular-velocity
ratio between the driving and driven shafts is neither constant nor exactly equal to the
ratio of the pulley diameters.
• In some cases an idler or tension pulley can be used to avoid adjustments in center
distance that are ordinarily necessitated by age or the installation of new belts.
The next figure illustrates the geometry of open and closed flat-belt drives. For a flat
belt with this drive the belt tension is such that the sag or droop is visible, when the
belt is running. Although the top is preferred for the loose side of the belt, for other
belt types either the top or the bottom may be used, because their installed tension is
usually greater. Two types of reversing drives are possible (see references for details).
Reversing can be provided by crossed belt. Crossed belts must be separated to prevent
rubbing if high-friction materials are used. Also, reversing can be provided for open-
belt drive by adding additional pulleys.
A flat-belt drive with out-of-plane pulleys can be used. The shafts need not be at right
angles as in this case. The pulleys must be positioned so that the belt leaves each
pulley in the mid-plane of the other pulley face. Other arrangements may require
guide pulleys to achieve this condition.
Belt materials: Flat belts are made of urethane and also of rubber-impregnated fabric
reinforced with steel wire or nylon cords to take the tension load. One or both surfaces
may have a friction surface coating. Flat belts are quiet, they are efficient at high
speeds, and they can transmit large amounts of power over long center distances.
Usually, flat belting is purchased by the roll and cut and the ends are joined by using
special kits furnished by the manufacturer. Two or more flat belts running side by
side, instead of a single wide belt, are often used to form a conveying system.
A V belt is made of fabric and cord, usually cotton, rayon, or nylon, and impregnated
with rubber. In contrast with flat belts, V belts are used with similar sheaves and at
shorter center distances. V belts are slightly less efficient than flat belts, but a number
of them can be used on a single sheave, thus making a multiple drive. V belts are
made only in certain lengths and have no joints.
Timing belts are made of rubberized fabric and steel wire and have teeth that fit into
grooves cut on the periphery of the sprockets. The timing belt does not stretch or slip

and consequently transmits power at a constant angular-velocity ratio. The fact that
the belt is toothed provides several advantages over ordinary belting. One of these is
that no initial tension is necessary, so that fixed-center drives may be used. Another is
the elimination of the restriction on speeds; the teeth make it possible to run at nearly
any speed, slow or fast. Disadvantages are the first cost of the belt, the necessity of
grooving the sprockets, and the attendant dynamic fluctuations caused at the belt-
tooth meshing frequency.
Figure : Flat-belt geometry. (a) Open belt. (b) Crossed belt.

Figure: Forces and torques on a pulley.
Figure: Flat-belt tensions.

A widely used type of belt, particularly in industrial drives and vehicular applications,
is the V-belt drive. The V-shape causes the belt to wedge tightly into the groove,
increasing friction and allowing high torques to be transmitted before slipping occurs.
Most belts have high-strength cords positioned at the pitch diameter of the belt cross
section to increase the tensile strength of the belt. The cords, made from natural
fibers, synthetic strands, or steel, are embedded in a firm rubber compound to provide
the flexibility needed to allow the belt to pass around the sheave. Often an outer fabric
cover is added to give the belt good durability. The selection of commercially
available V-belt drives is discussed in the next section. The typical arrangement of the
elements of a V-belt drive is shown in the following figure. The important
observations to be derived from this arrangement are summarized here:
1. The pulley, with a circumferential groove carrying the belt, is called a sheave
(usually pronounced "shiv").
2. The size of a sheave is indicated by its pitch diameter, slightly smaller than the
outside diameter of the sheave.
3. The speed ratio between the driving and the driven sheaves is inversely
proportional to the ratio of the sheave pitch diameters. This follows from the
observation that there is no slipping (under normal loads). Thus, the linear speed of
the pitch line of both sheaves is the same as and equal to the belt speed, vb. Then
vb = R1 1= R2ω2
Then the angular velocity ratio is
R1 / R2= ω2 / 1
Figure :Cross section of V-belt and sheave groove

4. The relationships between pitch length, L. center distance, C, and the sheave
diameters are
−
= + . + +
+√ − −
=
Where B = 4L – 6.28 ( D2+D1)
5. The angle of contact of the belt on each sheave is

−
−
� = °− � [ ]
−
−
� = °+ � [ ]
These angles are important because commercially available belts are rated with an
assumed contact angle of 180o. This will occur only if the drive ratio is 1 (no speed

change). The angle of contact on the smaller of the two sheaves will always be less
than 180o, requiring a lower power rating.
6. The length of the span between the two sheaves, over which the belt is
unsupported, is
−
= √ −[ ]
This is important for two reasons: You can check the proper belt tension by measuring
the amount of force required to deflect the belt at the middle of the span by a given
amount. Also, the tendency for the belt to vibrate or whip is dependent on this length.
7. The contributors to the stress in the belt are as follows:
(a) The tensile force in the belt, maximum on the tight side of the belt.
(b) The bending of the belt around the sheaves, maximum as the tight side of the belt
bends around the smaller sheave.
(c) Centrifugal forces created as the belt moves around the sheaves.
The maximum total stress occurs where the belt enters the smaller sheave, and the
bending stress is a major part. Thus, there are recommended minimum sheave
diameters for standard belts. Using smaller sheaves drastically reduces belt life.
8. The design value of the ratio of the tight side tension to the slack side tension is 5.0
for V-belt drives. The actual value may range as high as 10.0.
Standard Belt Cross Sections

Commercially available belts are made to one of the different standards. The
alignment between the inch sizes and the metric sizes indicates that the paired sizes
are actually the same cross section. A "soft conversion" was used to rename the
familiar inch sizes with the number for the metric sizes giving the nominal top width
in millimeters. The nominal value of the included angle between the sides of the V-
groove ranges from 30° to 42°. The angle on the belt may be slightly different to
achieve a tight fit in the groove. Some belts are designed to "ride out" of the groove
somewhat. One example of these standards that used in Automotive applications is
shown below.
Figure: Automotive V-belts

V-belt Design:
The factors involved in selection of a V-belt and the driving and driven sheaves and
proper installation of the drive are summarized in this section. Abbreviated examples
of the data available from suppliers are given for illustration. Catalogs contain
extensive data, and step-by-step instructions are given for their use. The basic data
required for drive selection are the following:
• The rated power of the driving motor or other prime mover
• The service factor based on the type of driver and driven load
• The center distance
• The power rating for one belt as a function of the size and speed of the smaller
sheave
• The belt length
• The size of the driving and driven sheaves
• The correction factor for belt length
• The correction factor for the angle of wrap on the smaller sheave
• The number of belts
• The initial tension on the belt
Many design decisions depend on the application and on space limitations. A few
guidelines are given here:
• Adjustment for the center distance must be provided in both directions from the
nominal value. The center distance must be shortened at the time of installation to
enable the belt to be placed in the grooves of the sheaves without force. Provision for
increasing the center distance must be made to permit the initial tensioning of the
drive and to take up for belt stretch. Manufacturers' catalogs give the data. One
convenient way to accomplish the adjustment is the use of a take-up unit.
• If fixed centers are required, idler pulleys should be used. It is best to use a grooved
idler on the inside of the belt, close to the large sheave. Adjustable tensioners are
commercially available to carry the idler.
• The nominal range of center distances should be
D2 < C < 3 (D2 + D1)
• The angle of wrap on the smaller sheave should be greater than 120°.
• Most commercially available sheaves are cast iron, which should be limited to 30-
m/sec. belt speed.
• Consider an alternative type of drive, such as a gear type or chain, if the belt speed is
less than 5 m/sec.
• Avoid elevated temperatures around belts.
• Ensure that the shafts carrying mating sheaves are parallel and that the sheaves are
in alignment so that the belts track smoothly into the grooves.
• In multi-belt installations, matched belts are required. Match numbers are printed on
industrial belts, with 50 indicating a belt length very close to nominal. Longer belts
carry match numbers above 50; shorter belts below 50.
• Belts must be installed with the initial tension recommended by the manufacturer.
Tension should be checked after the first few hours of operation because seating
and initial stretch occur.
Design Data
Catalogs typically give several dozen pages of design data for the various sizes of
belts and sheave combinations to ease the job of drive design. The data typically are
given in tabular form (.see References). Graphical form is also used so that you can
get a feel for the variation in performance with design choices.

Note that the power used is design power, the rated power of the prime mover times
the service factor from Tables.
Figures 7-10, 7-11, and 7-12 give the rated power per belt for the three cross secfions
as a function of the pitch diameter of the smaller sheave and its speed of rotation. The
i„u..i.,^ vertical lines in each figure give the standard sheave pitch diameters
available.
TABLE : V-belt service factors

Driver type
AC motors: High torqueb
a
AC motors: Normal torque DC motors: Series-wound,
DC motors: Shunt-wound compound-wound Engines: 4-
Engines: Multiple-cylinder cylinder or less
<6h 6-15h >l5h <6h 6-15 h >15h
Driven machine type per day per day per day per day per day per day
Agitators, blowers, fans,
centrifugal pumps, light conveyors 1.0 1.1 1.2 1.1 1.2 1.3
Generators, machine tools, mixers,
gravel conveyors 1.1 1.2 1.3 1.2 1.3 1.4
Bucket elevators, textile machines,
hammer mills, heavy conveyors 1.2 1.3 1.4 1.4 1.5 1.6
Crushers, ball mills, hoists, rubber
extruders 1.3 1.4 1.5 1.5 1.6 1.8
Any machine that can choke 2.0 2.0 2.0 2.0 2.0 2.0
a
. Synchronous, split-phase, three-phase with starting torque or breakdown torque less than 175% of
full-load torque.
b
. Single-phase, three-phase with starting torque or breakdown torque greater than 175% of full-load
torque.
Synchronous Belt Drives

Synchronous belts are constructed with ribs or teeth across the underside of the belt,
as shown in following figure. The teeth mate with corresponding grooves in the
driving and driven pulleys, called sprockets, providing a positive drive without
slippage. Therefore, there is a fixed relationship between the speed of the driver and
the speed of the driven sprocket. For this reason synchronous belts are often called
timing belts. In contrast, V-belts can creep or slip with respect to their mating sheaves,
especially under heavy loads and varying power demand. Synchronous action is
critical to the successful operation of such systems as printing, material handling,
packaging, and assembly. Synchronous belt drives are increasingly being considered
for applications in which gear drives or chain drives had been used previously. Figure
shows a synchronous belt mating with the toothed driving sprocket. Typical driving
and driven sprockets are shown in Figure. At least one of the two sprockets will have
side flanges to ensure that the belt does not move axially. Figure shows the four
common tooth pitches and sizes for commercially available synchronous belts. The
pitch is the distance from the center of one tooth to the center of the next adjacent
tooth. Standard pitches are 5 mm, 8 mm, 14 mm, and 20 mm. Figure 7-3(c) shows
detail of the construction of the cross section of a synchronous belt. The tensile
strength is provided predominantly by high-strength cords made from fiberglass or
similar materials. The cords are encased in a flexible rubber backing material, and the
teeth are formed integrally with the backing. Often a fabric covering is used on those
parts ofthe belt that contact the sprockets to provide additional wear resistance and
higher net shear strength for the teeth. Various widths ofthe belts are available for

each given pitch to provide a wide range of power transmission capacity.
Commercially available sprockets typically employ .split-taper bushings in their hubs
with a precise bore that provides a clearance of only 0.001 to 0.002 in (0.025 to 0.050
mm) relative to the shaft diameter on which it is to be mounted. Smooth, balanced,
concentric operation results. The process of .selecting appropriate components for a
synchronous belt drive is similar to that already discussed for V-belt drives.
Figure: Dimensions of standard synchronous belts (Numbers in parentheses are inches)
Manufacturers provide selection guides similar to those shown in Figure 7-19 that
give the relationship between design power and the rotational speed of the smaller
sprocket. These are used to determine the basic belt pitch required.
Also, numerous pages of performance data are given showing the power transmission
capacity for many combinations of belt width, driving and driven sprocket size, and
center distances between the axes of the sprockets for specific belt lengths. In general
the selection process involves the following steps. Refer to data and design
procedures for specific manufacturers as listed in Internet sites 2-5.
General Selection Procedure for Synchronous Belt Drives
1. Specify the speed of the driving sprocket (typically a motor or engine) and the
desired
speed of the driven sprocket.
2. Specify the rated power for the driving motor or engine.
3. Determine a service factor, using manufacturers' recommendations, considering
the type of driver and the nature of the driven machine.
4. Calculate the design power by multiplying the driver rated power by the service
factor.
5. Determine the required pitch of the belt from a specific manufacturer's data.
6. Calculate the speed ratio between the driver and the driven sprocket.
7. Select several candidate combinations of the number of teeth in the driver sprocket
to that in the driven sprocket that will produce the desired ratio.
8. Using the desired range of acceptable center distances, determine a standard belt
length that will produce a suitable value.

9. A belt-length correction factor may be required. Catalog data will show factors less
than 1.0 for shorter center distances and greater than 1.0 for longer center distances.
This reflects the frequency with which a given part of the belt encounters the high-
stress area as it enters the smaller sprocket. Apply the factor to the rated power
capacity for the belt.
10. Specify the final design details for the sprockets such as flanges, type and size of
bushings in the hub, and the bore size to match the mating shafts.
11. Summarize the design, check compatibility with other components of the system,
and prepare purchasing documents. Installation of the sprockets and the belt requires a
nominal amount of center distance allowance to enable the belt teeth to slide into the
sprocket grooves without force. Subsequently, the center distance will normally have
to be adjusted outward to provide a suitable amount of initial tension as defined by the
manufacturer. The initial tension is typically less than that required for a V-belt drive.
Idlers can be used to take up slack if fixed centers are required between the driver and
driven sprockets. However, they may decrease the life of the belt. Consult the
manufacturer.
In operation, the final tension in the tight side of the belt is much less than that
developed by a V-belt and the slack side tension is virtually zero. The results are
lower net forces in the belt, lower side loads on the shafts carrying the sprockets, and
reduced bearing loads.
Chain Drives
Basic features of chain drives include a constant ratio, since no slippage or creep is
involved; long life; and the ability to drive a number of shafts from a single source of
power.
Roller chains have been standardized as to sizes by the ANSI. The figure shows the
nomenclature. The pitch is the linear distance between the centers of the rollers. The
width is the space between the inner link plates. These chains are manufactured in
single, double, triple, and quadruple strands. The dimensions of standard sizes are
listed in following table.

Figure :Portion of a double-strand roller chain.

Table : Dimensions of American Standard Roller Chains—Single Strand Source:
Compiled from ANSI B29.1-1975.
Minimum Average Multiple-
ANSI Tensile, Weight, Roller Strand
Chain Pitch Width Strength lbf/ft Diameter Spacing
Number in (mm) in (mm) lbf (N) (N/m) in (mm) in (mm)
25 0.250 0.125 780 0.09 0.130 0.252
(6.35) (3.18) (3470) (1.31) (3.30) (6.40)
35 0.375 0.188 1760 0.21 0.200 0.399
(9.52) (4.76) (7830) (3.06) (5.08) (10.13)
41 0.500 0.25 1500 0.25 0.306 —
(12.70) (6.35) (6670) (3.65) (7.77) —
40 0.500 0.312 3130 0.42 0.312 0.566
(12.70) (7.94) (13920) (6.13) (7.92) (14.38)
50 0.625 0.375 4880 0.69 0.400 0.713
(15.88) (9.52) (21700) (10.1) (10.16) (18.11)
60 0.750 0.500 7030 1.00 0.469 0.897
(19.05) (12.7) (31300) (14.6) (11.91) (22.78)
80 1.000 0.625 12500 1.71 0.625 1.153
(25.40) (15.88) (55600) (25.0) (15.87) (29.29)
100 1.250 0.750 19500 2.58 0.750 1.409
(31.75) (19.05) (86700) (37.7) (19.05) (35.76)
120 1.500 1.000 28000 3.87 0.875 1.789
(38.10) (25.40) (124500) (56.5) (22.22) (45.44)
140 1.750 1.000 38000 4.95 1.000 1.924
(44.45) (25.40) (169000) (72.2) (25.40) (48.87)
160 2.000 1.250 50000 6.61 1.125 2.305
(50.80) (31.75) (222000) (96.5) (28.57) (58.55)
180 2.250 1.406 63000 9.06 1.406 2.592
(57.15) (35.71) (280000) (132.2) (35.71) (65.84)
200 2.500 1.500 78000 10.96 1.562 2.817
(63.50) (38.10) (347000) (159.9) (39.67) (71.55)
240 3.00 1.875 112000 16.4 1.875 3.458
(76.70) (47.63) (498000) (239) (47.62) (87.83)

Table : Roller chain sizes
Average
Chain Pitch Roller Roller Link plate tensile
number (in) diameter width thickness strength
(lb)
25 1/4 None - 0.030 925
35 3/8 None - 0.050 2100
41 1/2 0.306 0.250 0.050 2000
40 1/2 0.312 0.312 0.060 3700
50 5/8 0.400 0.375 0.080 6100
60 3/4 0.469 0.500 0.094 8500
80 1 0.626 0.625 0.125 14 500
100 1 1/4 0.750 0.750 0.156 24 000
120 1 1/2 0.875 1.000 0.187 34 000
140 1 3/4 1.000 1.000 0.219 46 000
160 2 1.125 1.250 0.250 58 000
180 2 1/4 1.406 1.406 0.281 80 000
200 2 1/2 1.562 1.500 0.312 95 000
240 3 1.875 1.875 0.375 130 000
The following figure shows a sprocket driving a chain and rotating in a

counterclockwise direction. Denoting the chain pitch by p, the pitch angle by γ , and
the pitch diameter of the sprocket by D, from the trigonometry of the figure we see
/
�� = =
/ �� /
◦
Since γ = 360 /N, where N is the number of sprocket teeth, the above equation can be
written
=
�� °/
The angle γ/2, through which the link swings as it enters contact, is called the angle of
articulation. It can be seen that the magnitude of this angle is a function of the
number of teeth. Rotation of the link through this angle causes impact between the
rollers and the sprocket teeth and also wear in the chain joint. Since the life of a
properly selected drive is a function of the wear and the surface fatigue strength of the
rollers, it is important to reduce the angle of articulation as much as possible. The
number of sprocket teeth also affects the velocity ratio during the rotation through the
pitch angle γ . At the position shown in the figure, the chain AB is tangent to the pitch
circle of the sprocket. However, when the sprocket has turned an angle of γ/2, the
chain line AB moves closer to the center of rotation of the sprocket.

Figure: Engagement of a chain and sprocket.
This means that the chain line AB is moving up and down, and that the lever arm
varies with rotation through the pitch angle, all resulting in an uneven chain exit
velocity. You can think of the sprocket as a polygon in which the exit velocity of the
chain depends upon whether the exit is from a corner, or from a flat of the polygon.
Of course, the same effect occurs when the chain first enters into engagement with the
sprocket. The chain velocity V is defined as the number of feet coming off the
sprocket per unit time. Thus the chain velocity in feet per minute is
V = Npn/12
where N = number of sprocket teeth
p = chain pitch, in
n = sprocket speed, rev/min
The maximum exit velocity of the chain is
� �
= =
�� /
where the first Equation has been substituted for the pitch diameter D. The minimum
exit velocity occurs at a diameter d, smaller than D. Using the geometry of the figure,
we find
d = D cos (γ/2)
Thus the minimum exit velocity is
� � co� /
� = =
�� /
Now substituting γ/2 = 180◦/N and employing the previous equations, we find the
speed variation to be
Δ − � �
= = [ − ]
�� °/ �a� °/

This is called the chordal speed variation and is plotted in the following figure. When
chain drives are used to synchronize precision components or processes, due
consideration must be given to these variations. For example, if a chain drive
synchronized the cutting of
photographic film with the
forward drive of the film, the
lengths of the cut sheets of film
might vary too much because of
this chordal speed variation. Such
variations can also cause
vibrations within the system.
Although a large number of teeth
is considered desirable for the
driving sprocket, in the usual case
it is advantageous to obtain as
small a sprocket as possible, and this requires one with a small number of teeth. For
smooth operation at moderate and high speeds it is considered good practice to use a
driving sprocket with at least 17 teeth; 19 or 21 will, of course, give a better life
expectancy with less chain noise. Where space limitations are severe or for very slow
speeds, smaller tooth numbers may be used by sacrificing the life expectancy of the
chain.
Driven sprockets are not made in standard sizes over 120 teeth, because the pitch
elongation will eventually cause the chain to “ride” high long before the chain is worn
out. The most successful drives have velocity ratios up to 6:1, but higher ratios may
be used at the sacrifice of chain life.
Roller chains seldom fail because they lack tensile strength; they more often fail
because they have been subjected to a great many hours of service. Actual failure may
be due either to wear of the rollers on the pins or to fatigue of the surfaces of the
rollers.
Roller-chain manufacturers have compiled tables that give the horsepower capacity
corresponding to a life expectancy of 15 kh for various sprocket speeds. These
capacities are tabulated in Table 17–20 for 17-tooth sprockets. Table 17–21 displays
available tooth counts on sprockets of one supplier. Table 17–22 lists the tooth
correction factors for other than 17 teeth. Table 17–23 shows the multiple-strand
factors K2. The capacities of chains are based on the following:
• 15 000 h at full load
• Single strand
• AσSI proportions
• Service factor of unity
• 100 pitches in length
• Recommended lubrication
• Elongation maximum of 3 percent
• Horizontal shafts
• Two 17-tooth sprockets
The fatigue strength of link plates governs capacity at lower speeds. The American
Chain Association (ACA) publication Chains for Power Transmission and Materials
Handling (1982) gives, for single-strand chain, the nominal power H1, link-plate
limited, as H1 = 0.004N1.08

. . − . [ℎ ]
= .
and the nominal power H2, roller-limited, as
. .
= . [ℎ ]
where N1 = number of teeth in the smaller sprocket
n1 = sprocket speed, rev/min
p = pitch of the chain, in
Kr = 29 for chain numbers 25, 35; 3.4 for chain 41; and 17 for chains 40–240
The constant 0.004 becomes 0.0022 for no. 41 lightweight chain. The nominal
horsepower in the Table is Hnom = min(H1, H2). For example, for N1 = 17, n1 = 1000
rev/min, no. 40 chain with p = 0.5 in, from equations,
H1 = 0.004(17)1.0810000.90.5[3−0.07(0.5)] = 5.48 hp
And,
H2 = 1000(17)17 1.5(0.5 0.8)/1000 1.5 = 21.64 hp
The tabulated value in the table 17–20 is Htab = min(5.48, 21.64) = 5.48 hp.
It is preferable to have an odd number of teeth on the driving sprocket (17, 19, . . .)
and an even number of pitches in the chain to avoid a special link. The approximate
length of the chain L in pitches is
+ −
= + +
� /
The center-to-center distance C is given by
−
= [– + √ − ( ) ]
�
Where
+
= −
The allowable power Ha is given by
Ha = K1K2Htab
where K1 = correction factor for tooth number other than 17 (see the above table)
K2 = strand correction (see the above table)
The horsepower that must be transmitted Hd is given by
Hd = Hnom Ks nd
The equation that find H1 above is the basis of the pre-extreme power entries (vertical
entries) of the Table, and the chain power is limited by link-plate fatigue. The
equation that find H2 is the basis for the post-extreme power entries of these tables,
and the chain power performance is limited by impact fatigue. The entries are for
chains of 100 pitch length and 17-tooth sprocket. For a deviation from this
. . .
.
= [ ( ) (
) ] [ℎ ] ) (
ℎ
where Lp is the chain length in pitches and h is the chain life in hours. Viewed from a
deviation viewpoint, this equation can be written as a trade-off equation in the
following form:
.
ℎ
, =
If tooth-correction factor K1 is used, then omit the term N1 3.75.

Note that (N1 1.5 )2.5 = N1 3.75
In the above equation one would expect the h/Lp term because doubling the hours can
require doubling the chain length, other conditions constant, for the same number of
cycles. Our experience with contact stresses leads us to expect a load (tension) life
relation of the form FaL = constant. In the more complex circumstance of roller-
bushing impact, the Diamond Chain Company has identified a = 2.5.
The maximum speed (rev/min) for a chain drive is limited by galling between the pin
and the bushing. Tests suggest
n1 ≤ 1000[ 82.5 / (7.95p (1.0278)N1 (1.323)F/1000] 1/(1.59 log p+1.873) rev/min
where F is the chain tension in pounds.

Table: Rated Horsepower Capacity of Single-Strand Single-Pitch Roller Chain for a
17-Tooth Sprocket Source: Compiled from ANSI B29.1-1975 information only
section, and from B29.9-1958.rev/min 25 35 40 41 50 60
Sprocket ANSI Chain Number
Speed,
rev/min
25 35 40 41 50 60
50 0.05 0.16 0.37 0.20 0.72 1.24
100 0.09 0.29 0.69 0.38 1.34 2.31
150 0.13* 0.41* 0.99* 0.55* 1.92* 3.32
200 0.16* 0.54* 1.29 0.71 2.50 4.30
300 0.23 0.78 1.85 1.02 3.61 6.20
400 0.30* 1.01* 2.40 1.32 4.67 8.03
500 0.37 1.24 2.93 1.61 5.71 9.81
600 0.44* 1.46* 3.45* 1.90* 6.72* 11.6
700 0.50 1.68 3.97 2.18 7.73 13.3
800 0.56* 1.89* 4.48* 2.46* 8.71* 15.0
900 0.62 2.10 4.98 2.74 9.69 16.7
1000 0.68* 2.31* 5.48 3.01 10.7 18.3
1200 0.81 2.73 6.45 3.29 12.6 21.6
1400 0.93* 3.13* 7.41 2.61 14.4 18.1
1600 1.05* 3.53* 8.36 2.14 12.8 14.8
1800 1.16 3.93 8.96 1.79 10.7 12.4
2000 1.27* 4.32* 7.72* 1.52* 9.23* 10.6
2500 1.56 5.28 5.51* 1.10* 6.58* 7.57
3000 1.84 5.64 4.17 0.83 4.98 5.76
Type A Type B Type C
*Estimated from ANSI tables by linear interpolation.

Note: Type A—manual or drip lubrication; type B—bath or disk lubrication; type C—oil-
stream lubrication.

Table: Rated Horsepower Capacity of Single-Strand Single-Pitch Roller Chain for a
17-Tooth Sprocket Source: Compiled from ANSI B29.1-1975 information only
section, and from B29.9-1958 (Continued)
Sprocket ANSI Chain Number
Speed, Lubrication
rev/min Type 80 100 120 140 160 180 200 240
50 Type A 2.88 5.52 9.33 14.4 20.9 28.9 38.4 61.8
100 5.38 10.3 17.4 26.9 39.1 54.0 71.6 115
150 7.75 14.8 25.1 38.8 56.3 77.7 103 166
200 10.0 19.2 32.5 50.3 72.9 101 134 215
300 14.5 27.7 46.8 72.4 105 145 193 310
400 18.7 35.9 60.6 93.8 136 188 249 359
Type B
500 22.9 43.9 74.1 115 166 204 222 0

600 27.0 51.7 87.3 127 141 155 169
700 31.0 59.4 89.0 101 112 123 0
800 35.0 63.0 72.8 82.4 91.7 101
900 39.9 52.8 61.0 69.1 76.8 84.4
1000 37.7 45.0 52.1 59.0 65.6 72.1
1200 28.7 34.3 39.6 44.9 49.9 0
1400 22.7 27.2 31.5 35.6 0
Type C
1600 18.6 22.3 25.8 0

1800 15.6 18.7 21.6
2000 13.3 15.9 0
2500 9.56 0.40
3000 Type C' 7.25 0
Note: Type A—manual or drip lubrication; type B—bath or disk lubrication; type C—oil-stream
lubrication; type C'—type C, but this is a galling region; submit design to manufacturer for evaluation.

Table :Single-Strand Sprocket Tooth Counts Available from One Supplier*
No. Available Sprocket Tooth Counts
25 8-30, 32, 34, 35, 36, 40, 42, 45, 48, 54, 60, 64, 65, 70, 72, 76, 80, 84, 90, 95,
96, 102, 112, 120
35 4-45, 48, 52, 54, 60, 64, 65, 68, 70, 72, 76, 80, 84, 90, 95, 96, 102, 112, 120
41 6-60, 64, 65, 68, 70, 72, 76, 80, 84, 90, 95, 96, 102, 112, 120
40 8-60, 64, 65, 68, 70, 72, 76, 80, 84, 90, 95, 96, 102, 112, 120
50 8-60, 64, 65, 68, 70, 72, 76, 80, 84, 90, 95, 96, 102, 112, 120
60 8-60, 62, 63, 64, 65, 66, 67, 68, 70, 72, 76, 80, 84, 90, 95, 96, 102, 112, 120
80 8-60, 64, 65, 68, 70, 72, 76, 78, 80, 84, 90, 95, 96, 102, 112, 120
100 8-60, 64, 65, 67, 68, 70, 72, 74, 76, 80, 84, 90, 95, 96, 102, 112, 120
120 9-45, 46, 48, 50, 52, 54, 55, 57, 60, 64, 65, 67, 68, 70, 72, 76, 80, 84, 90, 96,
102, 112, 120
140 9-28, 30, 31, 32, 33, 34, 35, 36, 37, 39, 40, 42, 43, 45, 48, 54, 60, 64, 65, 68,
70, 72, 76, 80, 84, 96
160 8-30, 32–36, 38, 40, 45, 46, 50, 52, 53, 54, 56, 57, 60, 62, 63, 64, 65, 66, 68,
70, 72, 73, 80, 84, 96
180 13-25, 28, 35, 39, 40, 45, 54, 60
200 9-30, 32, 33, 35, 36, 39, 40, 42, 44, 45, 48, 50, 51, 54, 56, 58, 59, 60, 63, 64,
65, 68, 70, 72
240 9-30, 32, 35, 36, 40, 44, 45, 48, 52, 54, 60
*Morse Chain Company, Ithaca, NY, Type B hub sprockets.
Table : Tooth Correction Factors, K1

K1 K1
Number of Teeth on Pre-extreme Post-extreme
Driving Sprocket Horsepower Horsepower
11 0.62 0.52
12 0.69 0.59
13 0.75 0.67
14 0.81 0.75
15 0.87 0.83
16 0.94 0.91
17 1.00 1.00
18 1.06 1.09
19 1.13 1.18
20 1.19 1.28
N (N1/17)1.08 (N1/17)1.5

Table : Multiple-Strand Factors, K2
Number of K2
Strands
1 1.0
2 1.7
3 2.5
4 3.3
5 3.9
6 4.6
8 6.0
Lubrication of roller chains is essential in order to obtain a long and trouble-free life.
Either a drip feed or a shallow bath in the lubricant is satisfactory. A medium or light
mineral oil, without additives, should be used. Except for unusual conditions, heavy
oils and greases are not recommended, because they are too viscous to enter the small
clearances in the chain parts.

Gears
Introduction:
In transmitting rotary power from one shaft to another, gears provide a positive ratio
type drive. If the shafts are parallel any one of three type may be used, spur, helical,
or herring. Spiral gears are used to connect two shafts and which are non-intersection.
Worm and worm gear are used where high speed ratios where the shafts are non-
intersecting and at right angles. Bevel gears are often used where two shaft are at right
angle to each other. Spiral bevel may be used in the same type application as straight-
tooth bevel gear but are capable of high speed and quitter operation. Hypoid are
similar to spiral bevel gear except that the extension of the center lines are non-
intersecting. Hypoid gear are originally developed for the automotive rear-axle drive.
Rack and pinion drive are used are used when it is desired to transfer the rotary
motion of the part into translating motion for the other part and vice versa.
Gear classification:
Gears are classified according to:
Position of shafts:
Parallel (spur)
Intersecting (bevel)
Position of teeth with respect to gear axis:
Straight tooth
Helical
Curved teeth
Atmospheric conditions:
Open
Closed
Manufacturing accuracy (12 degree of accuracy for spur gear):
Fine surface finish.
Coarse surface finish.
Profile of teeth:
Involute
Cycloid
Material:
Steel
Cast iron.
Bronzes.
Non-metallic materials
Types of gears
Spur gear:
Helical gear
Herringbone (double helical
Bevel gear
Worm and Worm gear: irreversible
Rack and pinion
Advantages of gears:
High efficiency (except the worm and worm gear)
So compact
Disadvantages of gears:

High cost
Gear forces:
Spur gear force components are:
Tangential force:
Ft = T / r
where T = gear torque and r = pitch radius of the gear
Fr = Ft tan 
Radial force (always toward the center of the gear)
where  is the pressure angle.

Helical gear force depends upon how the pressure angle defined. There are two
(1) The pressure angle  is measured in the plane perpendicular to the axis of the gear.
standards:
The components are:

(One) Tangential force
Ft = T / r
Fr = Ft tan .
(Two) Radial force
Fa = Ft tan 
(Three) Axial (thrust) force
where  is helix angle measured from the axis of the gear.

(2) The pressure angle  is measured in the plane normal to a tooth. The components
are:
(One) Tangential force
Ft = T / r
Fr = Ft (tan n/ cos  )

(Two) Radial force
Fa = Ft tan 
(Three) Axial (thrust) force
where  is helix angle measured from the axis of the gear.
Straight tooth bevel gear force component are:

Tangential force
Ft = Tt / r
where this force is acting at the mean pitch diameter.
Fr = Ft tan 
Radial force
where  is the pressure angle. This force can be resolved into two component; Fp
( Fp = Ft tan  sin )
( Fg = Ft tan  cos  )
along the shaft axis of the pinion and Fg
along the shaft axis of the gear.

For other type of gears see any one of the references.
Nomenclature of Spur gear
Pitch diameter (do):
It is an imagining circle which if assuming rolling action, would give the same motion
as actual gear. It very importat value in speed calculation.

Figure :Nomenclature of spur-gear teeth.
Addendum (hk):
It is a radial distance of tooth from the pitch to the top of the tooth.
Dedendum (hf):
It is a radial distance of tooth from the pitch to the bottom of the tooth.
Addendum circle (dk):
It is the circle drawn through the top of the teeth
d k = d o + 2 hk
Dedendum circle (df)
It is the circle drawn through the bottom of the teeth
df = do - 2 hf
Circular pitch (to):
It is the distance measured on the circumference of the pitch circle from a point of one
tooth to the corresponding point on the next tooth. Thus the circular pitch is equal to
to =  do /z =  m
the sum of the tooth thickness and the width of space.
where z is the number of teeth and m is the module.

Module (m):
It is the ratio of the pitch circle diameter in (mm) to the number of teeth. They
customary unit of length used is the millimeter. The module is the represented of
m = do / z = to / 
tooth size in SI.
The diameteral pitch P is the ratio of the number of teeth on the gear to the pitch
diameter. Thus, it is the reciprocal of the module.
Whole depth (h):

It is a radial distance between the Addendum: Dedendum
h = h k + hf :
Clearance (Sk):

It is the radial distance from the top of the tooth to the bottom of the tooth in meshing
gear. The circle passing through the top of the meshing gear is known as a clearance
circle
Center distance (a):

a = (do1 + do2) /2 = Sk + df1/2 + dk2/2
Tooth thickness (So):

It is the width of the tooth measured along the pitch circle.
Tooth space (Lo):

It is the width of the space between two adjacent teeth measured along the pitch
circle.
Back lash (Sd) :

It is the difference between the tooth space and tooth thickness as measured on the
pitch circle. It is the amount by which the width of tooth space exceeds the thickness
of the engaging tooth measured on the pitch circles.
Face width (b):

It is the width of the gear tooth measured parallel to its axis.
Profile:
It is the curve formed by the face and flank of the tooth.
Path of contact:
It is the bath traced by the point of contact of two teeth from the beginning to the end
of engagement.
Pressure angle ():

It is the angle between the common normal to the two teeth in contact and common
Base circle diameter = Pitch diameter * cos. 

tangent to the pitch circle. Standard value are 14.4, 20 and 25
where the base circle is the circle which the tooth profile start with.
Conjugate action:
Mating gear teeth acting against each other to produce rotary motion are similar to
cams. When the tooth profiles or cams are designed so as to produce a constant
angular-velocity during meshing, they said to have conjugate action.
Form of gear tooth profile:

Since the velocity ratio of two gears is required to be constant, than the tooth profile
must satisfy the fundamental requirements of a pair of curves in direct sliding contact.
The most common forms are the involute and cycloid.
Involute:
The involute is the locus of a point as a string which is unwounded from a circle, the
circle is known as base circle. The string is kept tight during unwinding process.
One way to construct this form is to divide part of the circumference of the base circle
by draw equal angles () from the circle center. The accuracy of the curve depends in

the value of this angle( the smaller the value the better the result). The next step is to
number the cross points between the radii and the circumference by 0, 1, 2, ..n. Draw
a tangent from each point on the circumference (this is with right angle with the
distance of (r ) from point 1 measured in the tangent at this point. The third point
radius at this point). The profile starts at point 0. The second point will be at a
will be at a distance of (2 r ) from point 2 measured in the tangent at this point. The
following points are drawn at a distance of (n r ) from the point n measured in the
tangent of that point.
Low of gearing:
The angular velocities are universally proportional to the parts in which the line of
center is divided by the common normal at the point of contact. Therefore for constant
angular velocity ratio the common normal through the point of contact must divide
1 / 2 = r1 /r2
the line of centers in a fixed ratio. This is the low of gearing.
If there is any sliding, that the contact is a way from the pitch point by a distance (e),
(VG) = (1 + 2) e

then the sliding velocity (VG) can be found as:
Interference:
Interference is a big disadvantage of the involute gear. It occurs when the tip of the
tooth digs into the radial flank of the tooth in the pinion. Interference occurs when it
desire to increase the addendum to the maximum possible, i.e. to increase the length
of contact and hence to increase the number of teeth simultaneously in contact. The
maximum possible addendum is when E, leis on F2. If e1 lies after f2 interference
occur. Normally interference is possible when the smallest gear meshes with largest
gear, 12 tooth pinion and rack.
Figure : Terminology of bevel gears.

Table : Standard modules
Module Equivalent Closest standard Pd
(mm) Pd (teeth/in)
0.3 84.667 64
0.4 63.500 48
0.5 50.800 32
0.8 31.750 24
1 25.400 20
1.25 20.320 16
1.5 16.933 12
2.5 12.700 10
2 10.160 8
3 8.466 6
4 6.350 5
5 5.080 4
6 4.233 3
8 3.175 2.5
10 2.540 2
12 2.117 1.5
16 1.587 1.25
20 1.270 1
25 1.016 80
Stresses in Spur and Helical Gears

This section is devoted primarily to analysis and design of spur and helical gears to
resist bending failure of the teeth as well as pitting failure of tooth surfaces. Failure by
bending will occur when the significant tooth stress equals or exceeds either the yield
strength or the bending endurance strength. A surface failure occurs when the
significant contact stress equals or exceeds the surface endurance strength.
The American Gear Manufacturers Association1 (AGMA) has for many years been
the responsible authority for the dissemination of knowledge pertaining to the design
and analysis of gearing. The general AGMA approach requires a great many charts
and graphs—too many for shown here. We have omitted many of these here by
choosing a single pressure angle and by using only full-depth teeth. This
simplification reduces the complexity but does not prevent the development of a basic
understanding of the approach. Furthermore, the simplification makes possible a
better development of the fundamentals and hence should constitute an ideal
introduction to the use of the general
The Lewis Bending Equation, AGMA Stress and Strength Equations

Wilfred Lewis introduced an equation for estimating the bending stress in gear teeth
in which the tooth form entered into the formulation. The equation, announced in
1892, still remains the basis for most gear design today.
To derive the basic Lewis equation, refer to following figure part a, which shows a
cantilever of cross-sectional dimensions F and t, having a length l and a load Wt,
uniformly distributed across the face width F (b in SI equations).

Figure G-1: a cantilever with uniformly distributed force F model of gear tooth
The derivation will not be presented in this introductory notes (for more detail see
one of the design text books and please be aware of different symbols used in
different text books ) and the final metric equation will be presented.
Two fundamental stress equations are used in the AGMA methodology, one for
bending stress and another for pitting resistance (contact stress). In AGMA
terminology, these are called stress numbers, as contrasted with actual applied
stresses, and are designated by a lowercase letter s instead of the Greek lower case
we have used in this notes (and shall continue to use).
Bending Stress and strength
The fundamental equations are
�=
where for (SI units),
Wt is the tangential transmitted load, (N)
Kv is the dynamic factor
Ko is the overload factor
Ks is the size factor
b is the face width of the narrower member, in (mm)
KH is the load-distribution factor
KB is the rim-thickness factor
YJ is the geometry factor for bending strength (which includes root fillet
stress-concentration factor Kf )
mt is the transverse metric module
Note here, that if the face width b and the module m are both in millimeters (mm).
Expressing the tangential component of load Wt in Newton (N) then results in stress
units of MegaPascals (MPa).
The equation for the allowable bending stress (SI units) is

� = �
�
where
St is the allowable bending stress, (N/mm2)

YN is the stress cycle factor for bending stress
Yθ is the temperature factor
YZ is the reliability factor
SF is the AGMA factor of safety, a stress ratio
Note here, instead of using the term strength, AGMA uses data termed allowable
stress numbers and designates these by the symbols sat and sac. It will be less
confusing here if we continue the practice in these notes of using the uppercase letter
S to designate strength and the lowercase Greek letters and for stress. To make it
perfectly clear we shall use the term gear strength as a replacement for the phrase
allowable stress numbers as used by AGMA. Following this convention, values for
gear bending strength, designated here as St , are to be found in the following figures
and tables. Since gear strengths are not identified with other strengths such as Sut , Se,
or Sy as used elsewhere in these notes, their use should be restricted to gear problems.
In this approach the strengths are modified by various factors that produce limiting
values of the bending stress and the contact stress.
Contact Stress and strength (Pitting Resistance)

The fundamental equation for pitting resistance (contact stress) is
� = √ �
where Wt, Ko, Kv , Ks, and b are the same terms as defined for bending equation. For
SI units, the additional terms are
ZE is an elastic coefficient, (N/mm2)
ZR is the surface condition factor
dw1 is the pitch diameter of the pinion, (mm)
ZI is the geometry factor for pitting resistance
The equation for the allowable contact stress c,all is
� , = �
�
where
Sc is the allowable contact stress, (N/mm2)
ZN is the stress cycle life factor
ZW is are the hardness ratio factor for pitting resistance
Yθ is the temperature factor
YZ is the reliability factor
SH is the AGMA factor of safety, a stress ratio
The values for the allowable contact stress, designated here as Sc, are to be found in
the following figures and Tables. AGMA allowable stress numbers (strengths) for
bending and contact stress are for
• Unidirectional loading
• 10 million stress cycles
• 99 percent reliability
Before you try to digest the meaning of all these terms, view them as advice
concerning items the designer should consider whether he or she follows the voluntary
standard or not. These items include issues such as
• Transmitted load magnitude
• τverload

• Dynamic augmentation of transmitted load
• Size
• Geometry: pitch and face width
• Distribution of load across the teeth
• Rim support of the tooth
• Lewis form factor and root fillet stress concentration
Bending Stress And The Contact strengths:

In this approach the strengths are modified by various factors that produce limiting
values of the bending stress and the contact stress. (Source: ANSI/AGMA 2001-D04,
2101-D04.)
*Allowable bending stress number for through-hardened steels. The SI equations are
St = 0.533HB + 88.3 MPa, grade 1,
St = 0.703HB + 113 MPa, grade 2.
*Allowable bending stress number for nitrided through-hardened steel gears (i.e.,
AISI 4140, 4340), St . The SI equations are
St = 0.568HB + 83.8 MPa, grade 1,
St = 0.749HB + 110 MPa, grade 2.
*Allowable bending stress numbers for nitriding steel gears St . The SI equations are
St = 0.594HB + 87.76 MPa for Nitralloy grade 1
St = 0.784HB + 114.81 MPa for Nitralloy grade 2
St = 0.7255HB + 63.89 MPa for 2.5% chrome, grade 1
* Contact-fatigue strength Sc at 107 cycles and 0.99 reliability for through-hardened

steel gears. The SI equations are
Sc = 2.22HB + 200 MPa, grade 1
Sc = 2.41HB + 237 MPa, grade 2.
*When two-way (reversed) loading occurs, as with idler gears, AGMA recommends
using 70 percent of St values.
Lewis form factor (Y):

Values of Y are tabulated in Table G 1.

Table G-1: Values of the Lewis Form Factor Y (These Values Are for a Normal
Pressure Angle of 20°, Full-Depth Teeth, and a Diametral Pitch of Unity in the Plane
of Rotation)
Number of Teeth Y Number of Teeth Y
12 0.245 28 0.353
13 0.261 30 0.359
14 0.277 34 0.371
15 0.290 38 0.384
16 0.296 43 0.397
17 0.303 50 0.409
18 0.309 60 0.422
19 0.314 75 0.435
20 0.322 100 0.447
21 0.328 150 0.460
22 0.331 300 0.472
24 0.337 400 0.480
26 0.346 Rack 0.485
Dynamic Effects �
When a pair of gears is driven at moderate or high speed and noise is generated, it is
certain that dynamic effects are present. Note that the definition of dynamic factor Kv
has been altered. AGMA standards. Dynamic factor Kv has been redefined as the
reciprocal of that used in previous AGMA standards. It is now greater than 1.0. In
earlier AGMA standards it was less than 1.0. Care must be taken in referring to work
done prior to this change in the standards.
In SI units, we use the following equations.
. +
= � , �
.
. +
= � �
.
. +√
= ℎ ℎ �
.
. +√
=√ ℎ �
.
where V is in meters per second (m/s).
Geometry Factors (ZI )and (YJ)
We have seen how the factor Y is used in the Lewis equation to introduce the effect of
tooth form into the stress equation. The AGMA factors ZI and YJ are intended to
accomplish the same purpose in a more involved manner.
The determination of ZI and YJ depends upon the face-contact ratio mb . This is
defined as
mb = b/px
where px is the axial pitch and b is the face width. For spur gears, mb = 0.
Low-contact-ratio (LCR) helical gears having a small helix angle or a thin face width,
or both, have face-contact ratios less than unity (mb ≤ 1), and will not be considered
here. Such gears have a noise level not too different from that for spur gears.

Consequently we shall consider here only spur gears with mb = 0 and conventional
helical gears with mb > 1.
The load-sharing ratio mN is equal to the face width divided by the minimum total
length of the lines of contact. This factor depends on the transverse contact ratio mp,
the face-contact ratio mb , the effects of any profile modifications, and the tooth
deflection. For spur gears, mN = 1.0. For helical gears having a face-contact ratio mF
> 2.0, a conservative approximation is given by the equation
mN = pN/0.95Z
where pN is the normal base pitch and Z is the length of the line of action in the
transverse plane Use the following figure to obtain the geometry factor YJ for spur
gears having a 20◦ pressure angle and full-depth teeth. Use the next figures for helical
gears having a 20◦ normal pressure angle and face-contact ratios of mb = 2 or greater.
For other gears, consult the AGMA standard.
Figure Spur-gear geometry factors YJ. Source: The graph is from AGMA 218.01,
which is consistent with tabular data from the current AGMA 908-B89. The graph is
convenient for design purposes.

Figure Helical-gear geometry factors YJ _. Source: The graph is from AGMA 218.01,
which is consistent with tabular data from the current AGMA 908-B89. The graph is
convenient for design purposes

The modifying factor can be applied to the YJ factor when other
than 75 teeth are used in the mating element
Figure YJ '-factor multipliers for use with the previous figure to find YJ. Source: The
graph is from AGMA 218.01, which is consistent with tabular data from the current
AGMA 908-B89. The graph is convenient for design purposes
Surface-Strength Geometry Factor (ZI)
The factor ZI is also called the pitting-resistance geometry factor by AGMA. We will
develop an expression for ZI.
Now define speed ratio mG as
mG = NG/NP= dG/dP
The geometry factor ZI for external spur and helical gears by adding the load-sharing
ratio mN , we obtain a factor valid for both spur and helical gears. The equation is then
written as
ZI
where mN = 1 for spur gears.

Certain precautions must be taken in using the above. The tooth profiles are not
conjugate below the base circle, and consequently, if either one or the other of the
first two terms in brackets is larger than the third term, then it should be replaced by
the third term. In addition, the effective outside radius is sometimes less than r + a,
owing to removal of burrs or rounding of the tips of the teeth. When this is the case,
always use the effective outside radius instead of r + a.
The Elastic Coefficient (ZE)
Values of ZE may be computed directly from the following equation or obtained from
Table.
ZE

Table G-2 Elastic Coefficient Cp (ZE,), √psi (√MPa) Source: AGMA 218.01
Pinion Gear Material and Modulus of Elasticity EG, lbf/in2
Modulus (MPa)*
Pinion of Malleable Nodular Aluminum Tin
Material Elasticity Steel Cast Iron
Iron Iron Bronze Bronze
Ep psi 30 × 106 25 × 106 24 × 106 22 × 106 17.5×106 16 × 106
(MPa)* (2 ×105) (1.7×105) (1.7 × 105) (1.5 × 105) (1.2 × 105) (1.1 × 105)
6
30×10 2300 2180 2160 2100 1950 1900
Steel 5
(2 ×10 ) (191) (181) (179) (174) (162) (158)
Malleable 25 ×106 2180 2090 2070 2020 1900 1850
iron (1.7×105) (181) (174) (172) (168) (158) (154)
Nodular 24 × 106 2160 2070 2050 2000 1880 1830
iron (1.7×105) (179) (172) (170) (166) (156) (152)
Cast 22 × 106 2100 2020 2000 1960 1850 1800
iron (1.5×105) (174) (168) (166) (163) (154) (149)
Aluminum 17.5×106 1950 1900 1880 1850 1750 1700
bronze (1.2×105) (162) (158) (156) (154) (145) (141)
Tin 16× 106 1900 1850 1830 1800 1700 1650
bronze (1.1×105) (158) (154) (152) (149) (141) (137)
Poisson’s ratio = 0.30.
∗When more exact values for modulus of elasticity are obtained from roller contact tests, they may be
used.
Overload Factor (Ko)

The overload factor Ko is intended to make allowance for all externally applied loads
in excess of the nominal tangential load Wt in a particular application. Examples
include variations in torque from the mean value due to firing of cylinders in an
internal combustion engine or reaction to torque variations in a piston pump drive.
There are other similar factors such as application factor or service factor. These
factors are established after considerable field experience in a particular application.
The role of the overload factor Ko is to include predictable excursions of load beyond
Wt based on experience. A safety factor is intended to account for unquantifiable
elements in addition to Ko. When designing a gear mesh, the quantity SF becomes a
design factor (SF )d within the meanings used in these notes. The quantity SF evaluated
as part of a design assessment is a factor of safety. This applies equally well to the
quantity SH .
Table: of Overload Factors, Ko
Driven Machine
Power source Uniform Light shock Medium shock
Uniform 1.00 1.25 1.50
Moderate shock 1.25 1.50 1.75
Heavy shock 1.75 2.00 2.25
Surface Condition Factor (ZR)

The surface condition factor ZR is used only in the pitting resistance equation. It
depends on
• Surface finish as affected by, but not limited to, cutting, shaving, lapping,
grinding, shot-peening
• Residual stress

• Plastic effects (work hardening)
Standard surface conditions for gear teeth have not yet been established. When a
detrimental surface finish effect is known to exist, AGMA specifies a value of ZR
greater than unity.
Size Factor (Ks)

The size factor reflects non-uniformity of material properties due to size. It depends
upon
• Tooth size
• Diameter of part
• Ratio of tooth size to diameter of part
• Face width
• Area of stress pattern
• Ratio of case depth to tooth size
• Hardenability and heat treatment
Standard size factors for gear teeth have not yet been established for cases where there
is a detrimental size effect. In such cases AGMA recommends a size factor greater
than unity. If there is no detrimental size effect, use unity. AGMA has identified and
provided a symbol for size factor. Also, AGMA suggests Ks = 1, which makes Ks a
placeholder until more information is gathered. Following the standard in this manner
is a failure to apply all of your knowledge.
Noting that Ks is the reciprocal of kb , we find the result of all the algebraic
substitution is
.
√
= = .
�
Ks can be viewed as Lewis’s geometry incorporated into the Marin size factor in
fatigue. You may set Ks = 1, or you may elect to use the preceding equation. This is a
point to discuss with your instructor. We will use the preceding equation to remind
you that you have a choice. If Ks in the equatiois less than 1, use Ks = 1.
Load-Distribution Factor (KH)

The load-distribution factor modified the stress equations to reflect nonuniform
distribution of load across the line of contact. The ideal is to locate the gear
“midspan” between two bearings at the zero slope place when the load is applied.
However, this is not always possible. The following procedure is applicable to
• σet face width to pinion pitch diameter ratio F/d ≤ 2
• Gear elements mounted between the bearings
• Face widths up to 40 in
• Contact, when loaded, across the full width of the narrowest member
The load-distribution factor under these conditions is currently given by the face load
distribution factor, Cmf , where
KH = Cmf = 1 + Cmc(Cpf Cpm + CmaCe)
Hardness-Ratio Factor CH
The pinion generally has a smaller number of teeth than the gear and consequently is
subjected to more cycles of contact stress. If both the pinion and the gear are through-
hardened, then a uniform surface strength can be obtained by making the pinion

harder than the gear. A similar effect can be obtained when a surface-hardened pinion
is mated with a through hardened gear. The hardness-ratio factor CH is used only for
the gear. Its purpose is to adjust the surface strengths for this effect. The values of CH
are obtained from the equation
where
The terms
HBP and HBG are
the Brinell
hardness (10-mm ball at 3000-kg load) of the pinion and gear, respectively. The term
mG is the speed ratio and is given before.
Figure: Hardness-ratio factor CH(through-hardened steel). (ANSI/AGMA 2001-D04.)

For
When surface-hardened pinions with hardnesses of 48 Rockwell C scale (Rockwell

C48) or harder are run with through-hardened gears (180–400 Brinell), a work
hardening occurs. The CH factor is a function of pinion surface finish fP and the
mating gear hardness. The following figure displays the relationships.
CH = 1 + B' (450 − HBG)
where B' = 0.000 75 exp[−0.0112 fP] and fP is the surface finish of the pinion
expressed as root-mean-square roughness Ra in in.

Figure :Hardness-ratio factor CH (surface-hardened steel pinion). (ANSI/AGMA
2001-D04.)
Stress-Cycle Factors (YN) and (ZN)
The AGMA strengths as given before in figures and in Tables for bending fatigue,
and for contact-stress fatigue are based on 107 load cycles applied. The purpose of the
load cycle factors YN and ZN are to modify the gear strength for lives other than 107
cycles. Values for these factors are given in the following figures. Note that for 107
cycles YN = ZN = 1 on each graph. Note also that the equations for YN and ZN change
on either side of 107 cycles. For life goals slightly higher than 107 cycles, the mating
gear may be experiencing fewer than 107 cycles and the equations for (YN )P and (YN
)G can be different. The same comment applies to (ZN )P and (ZN )G.
Table : Recommended design life
Design life
Application
(h)
Domestic appliances 1000-2000
Aircraft engines 1000-4000
Automotive 1500-5000
Agricultural equipment 3000-6000
Elevators, industrial fans, multipurpose gearing 8000-15 000
Electric motors, industrial blowers, general industrial machines 20 000-30 000
Pumps and compressors 40 000-60 000
Critical equipment in continuous 24-h operation 100 000-200 000

Figure : Repeatedly applied bending strength stress-cycle factor YN. (ANSI/AGMA
2001-D04.)
Figure: Pitting resistance stress-cycle factor ZN. (ANSI/AGMA 2001-D04.)
Reliability Factor (YZ)

The reliability factor accounts for the effect of the statistical distributions of material
fatigue failures. Load variation is not addressed here. The gear strengths St and Sc are
based on a reliability of 99 percent. The following table is based on data developed by
the U.S. Navy for bending and contact-stress fatigue failures. The functional
relationship between KR and reliability is highly nonlinear. When interpolation is
required, linear interpolation is too crude. A log transformation to each quantity
produces a linear string. A least-squares regression fit is
. − . �� − . < < .
= { }
. − . �� − . < < .

For cardinal values of R, take KR from the table. Otherwise use the logarithmic
interpolation afforded.
Table G-3 Reliability Factors (YZ ) Source: ANSI/AGMA 2001-D04.

Reliability (YZ)
0.9999 1.50
0.999 1.25
0.99 1.00
0.90 0.85
0.50 0.70
Temperature Factor (Yθ)

For oil or gear-blank temperatures up to 250°F (120°C), use KT = Yθ = 1.0. For higher
temperatures, the factor should be greater than unity. Heat exchangers may be used to
ensure that operating temperatures are considerably below this value, as is desirable
for the lubricant.
Rim-Thickness Factor (KB)

When the rim thickness is not sufficient to provide full support for the tooth root, the
location of bending fatigue failure may be through the gear rim rather than at the tooth
fillet. In such cases, the use of a stress-modifying factor KB or (tR) is recommended.
This factor, the rim-thickness factor KB, adjusts the estimated bending stress for the
thin-rimmed gear. It is a function of the backup ratio mB,
mB = tR / ht
where tR = rim thickness below the tooth, in, and ht = the tooth height. The geometry
is depicted in the following figure. The rim-thickness factor KB is given by
.
. �� < .
= { }
.
Figure : Rim-thickness factor KB. (ANSI/AGMA 2001-D04.)
Safety Factors (SF) and (SH)

The ANSI/AGMA standards 2001-D04 and 2101-D04 contain a safety factor SF
guarding against bending fatigue failure and safety factor SH guarding against pitting
failure.
The definition of SF is,
⁄ ℎ
= =
�
when c is estimated as before. This, too, is a strength-over-stress definition but in a
case where the stress is not linear with the transmitted load Wt .
While the definition of SH does not interfere with its intended function, a caution is
required when comparing SF with SH in an analysis in order to ascertain the nature and
severity of the threat to loss of function. To render SH linear with the transmitted load,
Wt it could have been defined as
ℎ
= ( )
with the exponent 2 for linear or helical contact, or an exponent of 3 for crowned teeth
(spherical contact). With the definition compare SF with S2H (or S3H for crowned teeth)
when trying to identify the threat to loss of function with confidence.
Design of a Gear Mesh

A useful decision set for spur and helical gears includes
a priori decisions:
• Function: load, speed, reliability, life, Ko
• Unquantifiable risk: design factor nd
• Tooth system: φ, , addendum, dedendum, root fillet radius
• Gear ratio mG, Np, NG
• Quality number Qv
design decisions :
• Module m
• Face width b
• Pinion material, core hardness, case hardness
• Gear material, core hardness, case hardness
The first item to notice is the dimensionality of the decision set. There are four design
decision categories, eight different decisions if you count them separately. This is a
larger number than we have encountered before. It is important to use a design
strategy that is convenient in either longhand execution or computer implementation.
The design decisions have been placed in order of importance (impact on the amount
of work to be redone in iterations). The steps, after the a priori decisions have been
made are:
• Choose a Model.
• Examine implications on face width, pitch diameters, and material
properties. If not satisfactory, return to pitch decision for change.
• Choose a pinion material and examine core and case hardness requirements.
If not satisfactory, return to pitch decision and iterate until no decisions are
changed.
• Choose a gear material and examine core and case hardness requirements. If
not satisfactory, return to pitch decision and iterate until no decisions are
changed.
With these plan steps in mind, we can consider them in more detail. First select a trial
Module pitch.
Pinion bending:

• Select a median face width for this pitch, 4π/P
• Find the range of necessary ultimate strengths
• Choose a material and a core hardness
• Find face width to meet factor of safety in bending
• Choose face width
• Check factor of safety in bending
Gear bending:
• Find necessary companion core hardness
• Choose a material and core hardness
• Check factor of safety in bending
Pinion wear:
• Find necessary Sc and attendant case hardness
• Choose a case hardness
• Check factor of safety in wear
Gear wear:
• Find companion case hardness
• Choose a case hardness
• Check factor of safety in wear
Completing this set of steps will yield a satisfactory design. Additional designs with
Module pitches adjacent to the first satisfactory design will produce several among
which to choose. A figure of merit is necessary in order to choose the best.
Unfortunately, a figure of merit in gear design is complex in an academic
environment because material and processing cost vary. The possibility of using a
process depends on the manufacturing facility if gears are made in house.
After examining and seeing the wide range of factors of safety, one might entertain
the notion of setting all factors of safety equal. In steel gears, wear is usually
controlling and (SH)P and (SH)G can be brought close to equality. The use of softer
cores can bring down (SF )P and (SF )G, but there is value in keeping them higher. A
tooth broken by bending fatigue not only can destroy the gear set, but can bend shafts,
damage bearings, and produce inertial stresses up- and downstream in the power train,
causing damage elsewhere if the gear box locks.
To have a satisfactory design for mesh. Material could be changed, as could pitch.
There are a number of other satisfactory designs, thus a figure of merit is needed to
identify the best. One can appreciate that gear design was one of the early applications
of the digital computer to mechanical engineering. A design program should be
interactive, presenting results of calculations, pausing for a decision by the designer,
and showing the consequences of the decision, with a loop back to change a decision
for the better. The program can be structured in totem-pole fashion, with the most
influential decision at the top, then tumbling down, decision after decision, ending
with the ability to change the current decision or to begin again. Such a program
would make a fine class project. Troubleshooting the coding will reinforce your
knowledge, adding flexibility as well as bells and whistles in subsequent terms.
Standard gears may not be the most economical design that meets the functional
requirements, because no application is standard in all respects.10 Methods of
designing custom gears are well understood and frequently used in mobile equipment
to provide good weight-to-performance index. The required calculations including
optimizations are within the capability of a personal computer.
Bevel and Worm Gears

The American Gear Manufacturers Association (AGMA) has established standards
for the analysis and design of the various kinds of bevel and worm gears. The
previous sections are an introduction to the AGMA methods for spur and helical
gears. AGMA has established similar methods for other types of gearing, which all
follow the same general approach.
Bevel Gearing—General
Bevel gears may be classified as follows:
• Straight bevel gears
• Spiral bevel gears
• Zerol bevel gears
• Hypoid gears
• Spiroid gears
A straight bevel gears are usually used for pitch-line velocities up to 1000 ft/min (5
m/s) when the noise level is not an important consideration. They are available in
many stock sizes and are less expensive to produce than other bevel gears, especially
in small quantities.
A spiral bevel gears are recommended for higher speeds and where the noise level is
an important consideration. Spiral bevel gears are the bevel counterpart of the helical
gear; it can be seen that the pitch surfaces and the nature of contact are the same as for
straight bevel gears except for the differences brought about by the spiral-shaped
teeth.
Figure :Cutting spiral-gear teeth on the basic crown rack.

The Zerol bevel gear is a patented gear having curved teeth but with a zero spiral
angle. The axial thrust loads permissible for Zerol bevel gears are not as large as those
for the spiral bevel gear, and so they are often used instead of straight bevel gears.
The Zerol bevel gear is generated by the same tool used for regular spiral bevel gears.
For design purposes, use the same procedure as for straight bevel gears and then
simply substitute a Zerol bevel gear.
It is frequently desirable, as in the case of automotive differential applications, to have
gearing similar to bevel gears but with the shafts offset. Such gears are called hypoid

gears, because their pitch surfaces are hyperboloids of revolution. The tooth action
between such gears is a combination of rolling and sliding along a straight line and
has much in common with that of worm gears. Figure shows a pair of hypoid gears in
mesh. Figure is included to assist in the classification of spiral bevel gearing. It is seen
that the hypoid gear has a relatively small shaft offset. For larger offsets, the pinion
begins to resemble a tapered worm and the set is then called spiroid gearing.
Figure : Comparison of intersecting and offset-shaft bevel-type gearings. (From Gear

Handbook by Darle W. Dudley, 1962, pp. 2–24.)
Bevel-Gear Stresses and Strengths

In a typical bevel-gear mounting, one of the gears is often mounted outboard of the
bearings. This means that the shaft deflections can be more pronounced and can have
a greater effect on the nature of the tooth contact. Another difficulty that occurs in
predicting the stress in bevel-gear teeth is the fact that the teeth are tapered. Thus, to
achieve perfect line contact passing through the cone center, the teeth ought to bend
more at the large end than at the small end. To obtain this condition requires that the
load be proportionately greater at the large end. Because of this varying load across
the face of the tooth, it is desirable to have a fairly short face width. Because of the
complexity of bevel, spiral bevel, Zerol bevel, hypoid, and spiroid gears, as well as
the limitations of space, only an introduction that refer to straight-bevel gears is
presented here. Straight-bevel gears are designed in similar method as spur and helical
gears with a small deviations in dealing with factors and introducing new factors as
will. Details of design will be left for student to learn if needed.
Worm Gearing—AGMA Equation
Since they are essentially non-enveloping worm gears, the crossed helical gears,
shown in the following figure, can be considered with other worm gearing.

Figure : View of the pitch cylinders of a pair of crossed helical gears.
Because the teeth of worm gears have point contact changing to line contact as the
gears are used, worm gears are said to “wear in,” whereas other types “wear out.”
Crossed helical gears, and worm gears too, usually have a 90◦ shaft angle, though this
need not be so. The relation between the shaft and helix angles is
∑ = �� ± �
where ∑ is the shaft angle. The plus sign is used when both helix angles are of the
same hand, and the minus sign when they are of opposite hand. The subscript P refers
to the pinion (worm); the subscript W is used for this same purpose. The subscript G
refers to the gear, also called gear wheel, worm wheel, or simply the wheel.
In the force calculation section we introduced worm gears, and developed the force
analysis and efficiency of worm gearing to which we will refer. Here our interest is in
strength and durability. Good proportions indicate the pitch worm diameter d falls in
the range
. .
.
where C is the center-to-center distance. AGMA relates the allowable tangential force
on the worm-gear tooth (Wt ) all to other parameters.
Compared to other gearing systems worm-gear meshes have a much lower
mechanical efficiency. Cooling, for the benefit of the lubricant, becomes a design
constraint sometimes resulting in what appears to be an oversize gear case in light of
its contents. If the heat can be dissipated by natural cooling, or simply with a fan on

the worm-shaft, simplicity persists. Water coils within the gear case or lubricant
outputmping to an external cooler is the next level of complexity. For this reason,
gear-case area is a design decision. To reduce cooling load, use multiple-thread
worms. Also keep the worm pitch diameter as small as possible. Multiple-thread
worms can remove the self-locking feature of many worm-gear drives.
We will stop discussion here, and details of design will be left, too, for student to
learn if needed.

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Al-Balqa’ Applied University

Al-Huson University College

Mechanical design (30131326)

Professor Dr. Musa K. AlAjlouni

Second Semester 2014/2015

Prof. Musa AlAjlouni 1 Mechanical Design

Course Title: Mechanical design (30131326)

Prof. Musa AlAjlouni 2 Mechanical Design

 The Nature of Mechanical Engineering

Prof. Musa AlAjlouni 3 Mechanical Design

Prof. Musa AlAjlouni 4 Mechanical Design

Prof. Musa AlAjlouni 5 Mechanical Design

Standards and Codes:

Prof. Musa AlAjlouni 6 Mechanical Design

Dimensions, Tolerances, Limits and Fits:

Prof. Musa AlAjlouni 7 Mechanical Design

Prof. Musa AlAjlouni 8 Mechanical Design

Prof. Musa AlAjlouni 9 Mechanical Design

Prof. Musa AlAjlouni 10 Mechanical Design

Prof. Musa AlAjlouni 11 Mechanical Design

Surface Finish Measurements and Charts:

Prof. Musa AlAjlouni 12 Mechanical Design

Prof. Musa AlAjlouni 13 Mechanical Design

Table 1. Conversion chart for equivalent expressions of roughness.

Prof. Musa AlAjlouni 14 Mechanical Design

Surface Finish Affects Performance

Prof. Musa AlAjlouni 15 Mechanical Design

Relation between manufacturing processes, tolerances and surface finish

Many factors contribute to the surface finish in manufacturing. In forming processes,

Prof. Musa AlAjlouni 16 Mechanical Design

Table 2. Typical range of Ra surface roughness values in various

Prof. Musa AlAjlouni 17 Mechanical Design

Prof. Musa AlAjlouni 18 Mechanical Design

Prof. Musa AlAjlouni 19 Mechanical Design

Selection of The Safety Factor

Prof. Musa AlAjlouni 20 Mechanical Design

Case study (1): Design of the cutter joint:

Cutter joint The Cotter

a Note that all sections are circular

Prof. Musa AlAjlouni 21 Mechanical Design

x y x y 

Prof. Musa AlAjlouni 22 Mechanical Design

BASIC DIMENSION OF THE TUBE AND XYZ CO-ORDINATE SYSTEM SHOWING

In this loading conditions the following procedure can be used:

Prof. Musa AlAjlouni 23 Mechanical Design

Prof. Musa AlAjlouni 24 Mechanical Design

Prof. Musa AlAjlouni 25 Mechanical Design

Prof. Musa AlAjlouni 26 Mechanical Design

Shafts could be made in mild steel,

Prof. Musa AlAjlouni 27 Mechanical Design

Design according to the strength

1. Shafts subjected to twisting moment only:

A. Using the maximum shear theory:

Prof. Musa AlAjlouni 28 Mechanical Design

Shafts subjected to fluctuating load:

Prof. Musa AlAjlouni 29 Mechanical Design

Stress due both axial load and bending moment is:

Where: L: Length of shaft between bearing.

Prof. Musa AlAjlouni 30 Mechanical Design