IPS ACADEMY,

Institute of Engineering & Science, Indore

Department of Mechanical Engineering

“MACHINE COMPONENT
DESIGN”

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Prepared By:
Mr. Piyush Laad
(Asst. Prof.)
 CONTENT

 Stress Concentration & Fatigue

Design of Shaft & Keys Couplings
Design of Bearings
Design of Spring & Power Screw
Design of Gears

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 INTRODUCTION

 The Subject deals with the design of various

components used in the various machines &
engines. Within the subject the complete design
procedure of various components are assigned &
failure analysis of the parts are done.

After designing the component the method of

checking the part is evolved whether the
component is designed according to need or not.

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SHAFT:
 Shaft is a common and important machine
element. It is a rotating member, in general, has
a circular cross-section and is used to transmit
power. The shaft may be hollow or solid. The
shaft is supported on bearings and it rotates a set
of gears or pulleys for the purpose of power
transmission.
SHAFT DESIGN
Shaft Materials

 Steel (low to medium-carbon steel)

 Cast iron

 Bronze or stainless steel

 Case hardened steel

Shaft Stresses
 Bending Stress

 Torsional Shear Stress

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GENERAL CONSIDERATIONS
 To minimize both deflections and stresses, the
shaft length should be kept as short as possible
and overhangs minimized.
 A hollow shaft has a better stiffness/mass ratio
(specific stiffness) and higher natural frequencies
than a comparably stiff or strong solid shaft, but
will be more expensive and larger in diameter.
 General low carbon steel is just as good as higher
strength steels (since deflection is typical the
design limiting issue).

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COUPLINGS AND KEYS
 It is a device that mechanically connects a
member such as gear to a shaft.
 Most common type is a flat key.

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Rigid couplings
 A coupling is a device used to connect the end of
one shaft to the end of a second.
 Rigid couplings do not allow any misalignment of
connecting members.

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SCREW JACK –

Screw jack is a portable device consisting of a

screw mechanism used to raise or lower the load.
There are two types of jacks most commonly
used,
 1] Hydraulic

 2] Mechanical

Merits of Screw jack –

 Can be used to lift a heavy load against gravity.

 Load can be kept in lifted position.

 Due to leverage obtained by handle force

required to raise load is very less & can be
applied manually also. 9
 Stresses in power screws

 Torsional shear stress is developed in the screw

due to the turning moment
 Compressive stress is developed in a power screw
due to axial load
 Bending stresses are developed in the screw
thread.

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Bearings

 A bearing is machine part, which support a

moving element and confines its motion. The
supporting member is usually designated as
bearing and the supporting member may be
journal. Since there is a relative motion between
the bearing and the moving element, a certain
amount of power must be absorbed in overcoming
friction, and if the surface actually touches, there
will be a rapid wear.
DESIGN OF HELICAL SPRINGS

Definition of spring: Spring act as a flexible

joint in between two parts or bodies
Commonly used spring materials:
Hard-drawn wire
Oil-tempered wire
Chrome Vanadium
Chrome Silicon
Music wire
Stainless steel
Phosphor Bronze / Spring Brass
Bearings
A bearing is machine part, which support a moving element and confines its motion. The supporting member is usually designated as bearing and the supporting m
Classification:
Bearings are classified as follows:
 Depending upon the nature of contact between the
working surfaces:-
 Sliding contact bearings and

 Rolling contact bearings.

SLIDING BEARINGS:
 Hydrodynamically lubricated bearings

 Bearings with boundary lubrication

 Bearings with Extreme boundary lubrication.

 Bearings with Hydrostatic lubrication.

Rolling element bearings:

 Ball bearings

 Roller bearings

 Needle roller bearings

Lubrication:

Prevention of metal to metal contact by means of

an intervening layer of fluid or fluid like
material.
Types of sliding lubrication:

 Sliding with Fluid film lubrication.

 Sliding with Boundary lubrication.

 Sliding with Extreme boundary lubrication.

 Sliding with clean surfaces.

 Hydrodynamic / thick film lubrication /
fluid film lubrication
Selection Guide for Lubricants
 The viscosity of lubricating oil is decisively for
the right thickness of the lubricating film
(approx. 3-30µm) under consideration of the type
of lubricant supply.\

 Low sliding speed High Viscosity

 High sliding speed Low viscosity
 High bearing clearance High Viscosity
 High load ( Bearing pressures) Higher
Viscosity
BEARING MATERIALS
 Babbitt or White metal -- usually used as a
lining of about 0.5mm thick bonded to bronze,
steel or cast iron.
 Copper Based alloys - most common alloys are
copper tin, copper lead, phosphor bronze: harder
and stronger than white metal: can be used un-
backed as a solid bearing.
 Sintered bronze - Sintered bronze is a
porous material which can be impregnated
with oil, graphite or Ptfe. Not suitable for
heavily loaded applications but useful where
lubrication is inconvenient.

 Nylon - similar to Ptfe but slightly harder: used

only in very light applications
Stress Concentration Effect
 Fatigue Stress Concentration

 The existence of irregularities or discontinuities,

such as holes, grooves, or notches, in a part
increase the magnitude of stresses significantly
in the immediate vicinity of the discontinuity.
Fatigue failure mostly originates from such
places. Hence its effect must be accounted and
normally a fatigue stress-concentration factor Kf
is applied when designing against fatigue, even if
the materials behavior is ductile.
 Concentration factor Kf
This form of definition needs that the fatigue stress
concentration factor or the endurance strength values
for different notch geometries on each of the material to
be used should be evaluated. However once sufficient
data was available a simple approach, useful at
preliminary design stages was evolved to determine the
fatigue stress concentration factor value from the
geometrical (theoretical) stress concentration values,
data charts for which is readily available, using a notch
sensitivity relation.
 Notch Sensitivity

 Notch sensitivity q is defined by the equation

K f −1 K −1
q = t
 FATIGUE CONSIDERATION IN DESIGN
OBJECTIVES AND SCOPE
 In this module we will be discussing on design
aspects related to fatigue failure, an important
mode of failure in engineering components.
Fatigue failure results mainly due to variable
loading or more precisely due to cyclic variations
in the applied loading or induced stresses So
starting from the basic concepts of variable (non-
static) loading, we will be discussing in detail
how it leads to fatigue failure in components,
what factors influence them, how to account
them and finally how to design parts or
components to resist failure by fatigue
 WHAT IS FATIGUE?
 Fatigue is a phenomenon associated with
variable loading or more precisely to cyclic
stressing or straining of a material. Just as we
human beings get fatigue when a specific task is
repeatedly performed, in a similar manner
metallic components subjected to variable loading
get fatigue, which leads to their premature
failure under specific conditions.

 WHAT IS FATIGUE LOADING?

 Fatigue loading is primarily the type of loading
which causes cyclic variations in the applied
stress or strain on a component. Thus any
variable loading is basically a fatigue loading.
 Nipping Of Leaf Springs
 As discussed, the stresses in extra full length
leaves are 50% more than the stresses in
graduated –length leaves. One of the methods of
equalizing the stresses in different leaves is to
pre-stress the spring. The pre-stressing is
achieved by bending the leaves to different radii
of curvature, before they are assembled with the
centre clip. As shown in Figure the full-length
leaf is given a greater radius of curvature than
the adjacent leaf.
IN MECHANICAL ENGINEERING, BACKLASH, SOMETIMES CALLED LASH OR PLAY, IS
CLEARANCE BETWEEN MATING COMPONENTS, SOMETIMES DESCRIBED AS THE AMOUNT OF
LOST MOTION DUE TO CLEARANCE OR SLACKNESS WHEN MOVEMENT IS REVERSED AND
CONTACT IS RE-ESTABLISHED.
FOR EXAMPLE, IN A PAIR OF GEARS, BACKLASH IS THE AMOUNT
OF CLEARANCE BETWEEN MATED GEAR TEETH.
THEORETICALLY, THE BACKLASH SHOULD BE ZERO, BUT IN ACTUAL PRACTICE SOME
BACKLASH MUST BE ALLOWED TO PREVENT JAMMING. IT IS UNAVOIDABLE FOR NEARLY ALL
REVERSING MECHANICAL COUPLINGS, ALTHOUGH ITS EFFECTS CAN BE NEGATED. DEPENDING
ON THE APPLICATION IT MAY OR MAY NOT BE DESIRABLE. REASONS FOR REQUIRING
BACKLASH INCLUDE ALLOWING FOR LUBRICATION, MANUFACTURING ERRORS, DEFLECTION
UNDER LOAD AND THERMAL EXPANSION.

BACKLASH IS THE ERROR IN MOTION THAT OCCURS WHEN GEARS CHANGE DIRECTION. IT
EXISTS BECAUSE THERE IS ALWAYS SOME GAP BETWEEN THE TRAILING FACE OF THE DRIVING
TOOTH AND THE LEADING FACE OF THE TOOTH BEHIND IT ON THE DRIVEN GEAR, AND THAT
GAP MUST BE CLOSED BEFORE FORCE CAN BE TRANSFERRED IN THE NEW DIRECTION. THE
TERM "BACKLASH" CAN ALSO BE USED TO REFER TO THE SIZE OF THE GAP, NOT JUST THE
PHENOMENON IT CAUSES; THUS, ONE COULD SPEAK OF A PAIR OF GEARS AS HAVING, FOR
EXAMPLE, "0.1 MM OF BACKLASH." A PAIR OF GEARS COULD BE DESIGNED TO HAVE ZERO
BACKLASH, BUT THIS WOULD PRESUPPOSE PERFECTION IN MANUFACTURING, UNIFORM
THERMAL EXPANSION CHARACTERISTICS THROUGHOUT THE SYSTEM, AND NO LUBRICANT.
THEREFORE, GEAR PAIRS ARE DESIGNED TO HAVE SOME BACKLASH. IT IS USUALLY PROVIDED
BY REDUCING THE TOOTH THICKNESS OF EACH GEAR BY HALF THE DESIRED GAP DISTANCE. IN
THE CASE OF A LARGE GEAR AND A SMALL PINION, HOWEVER, THE BACKLASH IS USUALLY
TAKEN ENTIRELY OFF THE GEAR AND THE PINION IS GIVEN FULL SIZED TEETH. BACKLASH CAN
ALSO BE PROVIDED BY MOVING THE GEARS FARTHER APART.
GEAR MATERIALS:-

Numerous nonferrous alloys, cast irons, powder-metallurgy and

even plastics are used in the manufacture of gears. However steels
are most commonly used because of their high strength to weight
ratio and low cost. Plastic is commonly used where cost or weight
is a concern. A properly designed plastic gear can replace steel in
many cases because it has many desirable properties, including dirt
tolerance, low speed meshing, and the ability to "skip" quite well.
Manufacturers have employed plastic gears to make consumer
items affordable in items like copy machines, optical storage
devices, VCRs, cheap dynamos, consumer audio equipment, servo
motors, and printers.
Material Outstanding features Applications Precision Rating
Ferrous:
Low cost, good Big size, moderate
Cast Iron machining, high internal power rating, Commercial quality
damping Commercial gears
Power Gears, medium
Cast Steel Low cost, high strength Commercial quality
rating
Good machining, Heat Power Gears, medium Commercial to medium
Plain Carbon Steel
treated rating precision
Heat treated, high Strict power
Alloy Steels High precision
strength and durability requirements
High corrosion
Stainless Steel Low power rating Good Precision
resistance, nonmagnetic
Non Ferrous:
Light weight,
Very light duty
Aluminium alloys noncorrosive, good High precision
instrument gears
mach inability
Low cost, noncorrosive, Low cost commercial
Brass alloys Medium precision
good mach inability equipment
High production, low
Die cast alloys Low cost, low strength Low grade commercial
quality, commercial
Non Metallic:
No friction or lubricant, Long life, low nose, low
Nylon Commercial quality
high water absorption loads
Delrin Wear resistant, long life Low loads Commercial quality
SPUR GEAR
HELICAL GEAR
HELICAL GEAR
HERRINGBONE GEAR:- DOUBLE
HELICAL GEAR
WORM GEAR
WORM GEAR
RACK & PINION GEAR
INSIDE GEAR
EPICYCLIC GEAR
SUN & PLANET GEAR
Pressure angle, also known as the angle of obliquity, is in
general the angle at a pitch point between the line of pressure
which is normal to the tooth surface, and the plane tangent to the
pitch surface. The pressure angle gives the direction of the normal
to the tooth profile. The pressure angle is equal to the profile angle
at the standard pitch circle and can be termed the “standard”
pressure angle at that point. Standard values include 14.5, 20 and
25 degrees. Earlier gears with pressure angle 14.5 were more
commonly used because for a given pressure angle, cosine would
be larger for smaller angle, thus resulting in more power
transmission and less pressure on the bearing. But for a given
material, smaller pressure angles correlate with weaker teeth. To
run gears together properly one must match pressure angles.

Pressure Angle : If you can draw a common normal line to the

meshing teeth surfaces at the contact point between the meshed
teeth and a tangent plane common to the pitch circles of both the
gear then angle between the common normal line and the tangent
plane is called pressure angle.
PRESSURE ANGLE
GEAR PROFILE