Example 9.16 The dimensions of a Woodruff key for a 30 mm diameter shaft are shown in Fig. 9.26(a). The shaft is transmitting 5 kW power 20-4 1B Fig. 9.26 Woodruff Keyat 300 rpm The key is made of steel 50C4 (S,, = 8, = 460 Nimm?). Calculate the factor of safety used in design.Solution Given kKW=5 n=300rpm 5S,,=5,,.=460 Nimm? d= 30mm StepI Torque transmitted by the shaft The torque transmitted by the shaft is given by, _ 60x 10°(KW) _ 60 x 10°(5) ir 2nn 2m (300) = 159 154.94 N-mm Step II Force induced by torque The torque is transmitted by two, equal and opposite, forces P. It is assumed that the force P acts at the shaft surface. Therefore, Px15=M, pat = EA = 10610.33N Step I Key area Referring to Fig. 9.26(b), cos@ = ——=— or 6@=66.42° CD =2CE =20Csin@ = 2(10) sin (66.42°) = 18.33 mm Total area of the key 1 4 = —| 7 (20)? | = 157.08 mm? 2|4 Area of sector OCFD 2 2(66.42) = (i asz.08 = -( 25 Jas7.08)Areaat AOCD = 5 CDxOE = 5 (18.33)4) = 36.66mm" Area of key in contact with the shaft = 115.93 - 36.66 = 79.27 mm? Area of key in contact with the hub = 157.08 - 79.27 = 77.81 mm?Step IV Factor of safety against compression failure The area of the key in contact with the hub is less and the compressive stress in the area is given by, OS eee a | 77.81 S,. 460 . fs) = = = —— = 3,37 (i) Us) co. 136.36 Step V_ Factor of safety against shear failure The shear failure will occur in the plane CD, and its area is (CD x 6 or (18.33 x 6) mm? Therefore, P 10610.33 =— =——__ = 96.48 N/mm2 A (18.336) “x Sy _ 0577S, fs) = —— = ——_——— f Tt T sg CORED | 95 (ii) 96.48Example 6.10 7 js required to design a_fty- press, as shown in Fig. 6.17, which is capable of punching 50 mm diameter circles from a 1.5 mm Lg — of Fig.6.17 Fly-pressthick mild steel sheet. The ultimate shear strength of the sheet metal is 375 N/m? and it can be assumed that shearing will be complete when the punch penetrates through half the thickness of the sheet. The screw, with square threads, is made of steel 30C8 (S\, = 400 N/émm?), while the nut is made of bronze. The factor of safety is 3. The operator is expected to sit in front of the fly-press, insert the sheet by his left hand and operate the handle by the right hand. The total working stroke consists of a one-quarter revolution, 45° in front of the press and 45° behind the press. During the return stroke, the punch is raised by 5 mm to provide clearance to insert the sheet. The forward or working stroke is completed in I second. The balls are made of cast iron, with a mass density of 7280 kg/m’ and the radius R,, is 500 mm. Neglecting collar friction, calculate (i) the dimensions of the screw;(ii) the length of the nut; and (iii) the size of the balls. Solution Given For screw, S,,=400N/mm? (fs) =3 For punched holes, d=50mm = 1.5 mm 5, = 375 N/mm? Mass density of balls = 7280 kg/m* -R,, = 500 mm Step I Diameter, pitch and number of starts for screw The force W required to shear the sheet is given by W = wdtS,, = n(50) (1.5) (375) = 88 357.29 N The lower portion of the screw is subjected to compressive stress. Assuming, Sy. = Sy = 400 Nimm? Ss ye 400 133.93 N/mm? oO, = = (f) 3 The core diameter d_ of the screw is given by dy (OO ce [MEST 2 205 sea 1, (133.33)In addition to compressive stress, the screw is subjected to torsional shear stress. Therefore, the core diameter is to be increased. As a first trial value, a nominal diameter of 50 mm with 8 mm pitch is recommended for the screw. Since the punch is to be raised by 5 mm during the return stroke of one- quarter revolution, the minimum lead should be 20 mm. The screw is therefore triple-threaded. 1= 3p = 3(8) =24 mm d,, = d—0.5p = 50 —0.5(8) = 46 mm Step II Check for stresses in screw i 24 nO 7d, (46) Assuming the coefficient of friction as 0.15, tan@=u=0.15 or @=8.531° or @=9.429° Wa, M,= > (9 + @) _ (88 357.29) (46) eT = 658 739.29 N-mm Stresses in screw body d,=d-p=50-8=42 mm _W__ 88 357.29 tan (8.531 + 9.429) g.= = 63.78 N/mm? 2 P Fay a4 = (42)2 63.78 - (24) + (45.28)” =55.38 Nimm? According to the maximum shear stress theory, S,, = 0.5 S,,= 0.5 (400) = 200 N/mm? (= 22 = 20 — =—— =3.61 Tae DDD Therefore, the factor of safety is more than 3. The efficiency of the screw is given by tan a tan (9.429) 1” tan (@ +a) _ tan (8.531 + 9.429) =0.5123 or 51.23% Step IT Length of nut For steel screw with a bronze nut, the unit bearing pressure (S,) is taken as 18 N/mm/. From Eq. (6.23), 4 _ __4(88357.29) mS,(d? —d*) 7 (18)(50° —427) =8.49 or 9 threads Length of nut = zp = 9(8)=72 mmThe shear stresses in the threads of the screw and the nut are as follows: t= pi2=8/2=4mm Ww 88 357.29 r= = ——— = 18.6 N/mm* md.tz m(42)(4)(9) 1, = Pi 15.62 N/mm? " ndtz — m(50)(4)(9) Step IV Size of balls Since the process of shearing is complete when the punch penetrates through half the thickness of the sheet, the work done by the punch is given by, work done = punching force x 0.5 (sheet thickness) = 88 357.29 x 0.5 (1.5) = 66 268 N-mm = 66.268 N-m or J The efficiency of the screw is 51.23% and the collar friction is to be neglected. Therefore, the input or the work done by the balls is given by,66.268 0.5123 This is achieved by the kinetic energy of the Work done by balls = = 129.35] (a) rT moving balls. The forward stroke consists of (2) rotation and takes | second 7 a oe The initial velocity of the balls is zero. Ona, +0 Oye = or Oya, = 204. 2( Z| = nas The kinetic energy of a rotating body of mass a concentrated at a radius of gyration & and rotating with angular velocity «,,., 15 given by, mk*@7 . KE=_™ (i) 2 k=R,,= 500 mm=0.5m Equating the work done by the balls with the kinetic energy stored in them, we get 129.35 = MOS) ty or m= 104.85 kg This is the mass of the two balls. Hence, the mass of each ball is 52.425 kg. mass = volume x density nd* 52.425 = (=) (7280) or @=0.2396m or 239.6mm The diameter of the balls is 240 mm.Ae Design of 2 Gia te gs ee __ Final_( 2093) 3 = os ce ____ Sheet _to be puucieds 7 Stew indo im “Nut ay? 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