Design of Machine

Elements
S. S. ROY
 Basic Procedure of Design of
Machine Elements
Specify functions of element

Determine Load acting on element

Select suitable Material for element

Determine failure mode (s) of element

Determine geometric dimensions of

element based on above failure mode

Check & modify dimensions for assembly & manufacture

Check design at critical cross-sections

Prepare detail engineering drawing of element

27 January 2022 Machine Design 2

Load Determination

Load: external forces, Moments etc.

Applied forces
External Forces
Reactive forces

Vector representing physical quantities

 Magnitude
 Direction
 Line of action
 Point of application

Free vector

Vectors Sliding vector

Fixed vector
 F F F F F F

M=Fd
B
d A d d d

F
F
 Load Classification

w.r.t time w.r.t the area over w.r.t location & method of
which it is applied application

Static Cyclic Impact

load load load Concentrated Distributed Normal Shear Torsion Bending
load load load load load load

Combined
 Magnitude load
 Direction
 Line of action
 Point of application Design for Static Loading
Design for Cyclic/Fluctuating/ Fatigue/Variable Loading
Design for Impact Loading

The behavior of machine parts is entirely different when they are subjected to time varying loading
 Design Criteria
 One of the major decisions confronting the designer is the selection of appropriate “Design Criteria” or
“Failure-prevention”. This is largely influenced by the Modes of Failure of the machine elements or
structural elements.
 Designer should find the nature of action in the member that may cause it to fail.
 Some quantity such as stress, deflection etc. which characterizes the action that may cause its failure
 The action that initiates failure frequently is referred to as the Mode of Failure

Common Modes of Failures

Shearing U
 Yielding
Crushing E
Y1
 Fracture Bending
P Y2 F

Stress
 Excessive elastic deflection
 Buckling
 Wear O Strain
 Corrosion etc…

27 January 2022 MACHINE DESIGN 8

Curved Beams
Design Analysis of Straight Beams
Consider a prismatic member AB possessing a plane of symmetry &
subjected to equal & opposite couples M & M’ acting in that plane.

We observed that if a section is passed through the member AB at

some arbitrary point C, the conditions of equilibrium of the portion
AC of the member require that the internal forces in the section at C
be equivalent to the couple M.
 Design Analysis of Straight Beams
Thus, the internal forces in any cross-section of a symmetric
member in pure bending are equivalent to a couple.

The Moment of the couple formed by internal forces is referred as

Bending Moment
Concept of pure bending
Elastic Flexure formula : Bernoulli-Euler Flexure Formula

M  E M M
   max  y max 
I y R I Z
SFD
Section Modulus Z=I/ymax

The following assumptions must be satisfied BMD

 The beam is subjected to pure bending (shear force=0, no torsion, no axial loads).
 The beam is initially straight with a c/s that is constant throughout the length.
 The beam has an axis of symmetry in the plane of bending.
 Plane c/s of the beam remain plane during bending.
 Couples are assumed to be loaded in the plane of symmetry.
 The beam material is homogeneous, isotropic & obeys Hooke’s law.
Design Analysis of Straight Beams
From statics
Any couple actually consists of two equal & opposite
forces.
The sum of the components of these forces is equal to
zero.
Design Analysis of Curved Beams
 Design Analysis of Curved Beams
Assumption
Our discussion will be limited to curved members of uniform cross-section possessing a plane of symmetry in
which the bending couples are applied.
It will be assumed that all stresses remain below the proportional limit.

When the initial curvature of the member is large i.e., if its radius of curvature & the
dimensions of the cross-section of the member are of the same order of magnitude, we
must use a different method of analysis, which was first introduced by the German
Engineer E. Winkler (1835-1888)

In its unstressed state, its upper & lower surfaces intersect the
vertical XY plane along arcs of circle AB & FG centered at C.
Now apply two equal & opposite couples M & M’ in the plane of
symmetry of the member.
Design Analysis of Curved Beams
In its unstressed state, its upper & lower
surfaces intersect the vertical XY plane
along arcs of circle AB & FG centered at
C.
Now apply two equal & opposite couples
M & M’ in the plane of symmetry of the
member.
Design Analysis of Curved Beams
Design Analysis of Curved Beams
Design Analysis of Straight Beams
From statics
Any couple actually consists of two equal & opposite
forces.
The sum of the components of these forces is equal to
zero.
Remarks:
The neutral axis of a transverse section does not pass through the centroid of that section
If a beam has significant curvature, then the NA will no longer be coincident with the centroidal axis
From Eq. (10)
Location of Neutral Axis in Curved Beams
Location of Neutral Axis in Curved Beams
Location of Neutral Axis in Curved Beams
Location of Neutral Axis in Curved Beams
Location of Neutral Axis in Curved Beams
Location of Neutral Axis in Curved Beams
SUMMARY
SUMMARY
Design for Static Loading
Design of Crane hooks and C-frames
Problem Statement:
A crane hook having an approximate trapezoidal cross-section carrying load of 95 KN as shown in Fig. It is made of
plain carbon steel 45C8 & assume FoS is 3.5. Find out the stress distribution and maximum stress in the cross-
section at XX.
Main Steps in Design Analysis of Crane Hook

Step 1 - Check Given data & materials

Step 2 - Calculation of A, R & r
Step 3 - Check the loading pattern (Direction, line of action & magnitude)
Step 4 - Identify the stresses induced due to above loading pattern
Step 5 - Estimation of load induced stresses

Step 5.1 - Estimation of stress due to bending (i.e., bending stress)

Step 5.2 - Estimation of direct tensile stress

Step 5.3 - Determine the maximum stress due to combined effect.

Step 6 - Calculation of allowable stresses, Apply failure criteria & estimate dimensions of cross-
section
Step 1 Given data & Materials

Step 2 - Calculation of A, R & r

Calculation of A Calculation of R
Calculation of R

Calculation of r
 F F F F F F

M=Fd
B
d A d d d

F
F
Step 3 - Check the loading pattern (Direction, line of action & magnitude)

P
M=P.r

P P

Step 4 - Identify the stresses induced due to above loading pattern

Step 4 - Identify the stresses induced due to above loading pattern

M=P.r

P
Estimation of stress due to bending (i.e., bending stress)
Problem Statement:
The C-frame having T-section of a 100 kN capacity press is shown in Fig.. The material of the frame is grey Cast Iron
FG 200 & the FoS is 3. Determine the dimensions of the frame.

Main Steps in Design Analysis of C-frame

Step 1 - Check Given data & materials

Step 2 - Calculation of A, R & r
Step 3 - Check the loading pattern (Direction, line of action & magnitude)
Step 4 - Identify the stresses induced due to above loading pattern
Step 5 - Estimation of stresses

Step 5.1 - Estimation of stress due to bending (i.e., bending stress)

Step 5.2 - Estimation of direct tensile stress

Step 5.3 - Determine the combined effect.

Step 6 - Calculation of allowable stresses, Apply failure criteria & estimate

dimensions of cross-section
Step 1 Given data & Materials

Step 2 - Calculation of A, R & r

Calculation of A

Calculation of r
Step 2 - Calculation of A, R & r Calculation of R
P
M=P.r

P P
 P M=P.r

P P
Thank You