ME 307T MECHANICAL DESIGN I

Assoc. Prof. Tahany William Sadak

Production Engineering and Design Department
Faculty of Engineering,
Beni–Suef University, Beni–Suef, Egypt.
 ME 307T MECHANICAL DESIGN I 3(2-2-0):Design
Course content
 Design philosophy and methodology
 Engineering materials in mechanical design.
 Factors affecting constructional details .
 Stress and deformation analysis .
 Failure Theories. Design of machine elements for various types of
loading including design for fatigue and life .
 Column Design.
 Tolerances and fits
 Fasteners. Machine frames bolted connections and welded joints.
4 Stress and deformation analysis .
 Stresses due to Change in Temperature—Thermal Stresses
Whenever there is some increase or decrease in
the temperature of a body, it causes the body to
expand or contract.
Increase or decrease in length, δl = l. α.t

l = Original length of the body,

t = Rise or fall of temperature, and
α = Coefficient of thermal expansion,
 If the ends of the body are fixed to rigid supports, so that its expansion
is prevented, then compressive strain induced in the body,

Notes : 1. When a body is composed of two or different materials having different coefficient of thermal
expansions, then due to the rise in temperature, the material with higher coefficient of thermal expansion will be
subjected to compressive stress whereas the material with low coefficient of expansion will be subjected to
tensile stress.
2. When a thin tyre is shrunk on to a wheel of diameter D, its internal diameter d is a little less than the
wheel diameter. When the tyre is heated, its circumferance π d will increase to π D. In this condition, it is
slipped on to the wheel. When it cools, it wants to return to its original circumference π d, but the wheel if it is
assumed to be rigid, prevents it from doing so.

Circumferential or hoop stress,

 Linear and Lateral Strain

Poisson's Ratio
It has been found experimentally that when a body is stressed
within elastic limit, the lateral strain bears a constant ratio to the
linear strain, Mathematically,
 Volumetric Strain
εv = δV / V
where δV = Change in volume, and V = Original volume.
Notes : 1. Volumetric strain of a rectangular body subjected to an axial force is given as

where ε = Linear strain.

2. Volumetric strain of a rectangular body subjected to three mutually

perpendicular forces is given by
εv = εx + εy + εz
where εx, εy and εz are the strains in the directions x-axis, y-axis and z-axis
respectively.
 Bulk Modulus

Relation Between Bulk Modulus and Young’s Modulus

Relation Between Young’s Modulus and Modulus of Rigidity

 Impact Stress
Sometimes, machine members are subjected to the load with impact.
The stress produced in the member due to the falling
load is known as impact stress.
Consider a bar carrying a load W at a height h and falling
on the collar provided at the lower end, as shown in the Fig.
Let A = Cross-sectional area of the bar,
E = Young's modulus of the material of the bar,
l = Length of the bar,
δl = Deformation of the bar,
P = Force at which the deflection δl is produced,
σi = Stress induced in the bar due to the application of impact load, and
h = Height through which the load falls

We know that energy gained by the system in the form of strain energy

and potential energy lost by the weight

Since the energy gained by the system is equal to the potential energy lost by the weight, therefore
 Resilience ‫صمود‬
When a body is loaded within elastic limit, it changes its dimensions and
on the removal of the load, it regains its original dimensions. So long as it
remains loaded, it has stored energy in itself. On removing the load, the
energy stored is given off as in the case of a spring.
Mathematically, strain energy stored in a body due to tensile or compressive load or resilience

σ = Tensile or compressive stress,

V = Volume of the body, and
E = Young's modulus of the material of the body.

Notes : 1. When a body is subjected to a shear

load, then modulus of resilience (shear)
2. When the body is subjected to torsion, then
modulus of resilience
A mild steel rod supports a tensile load of 50 kN. If the stress in the rod is limited
to 100 MPa, find the size of the rod when the cross-section is 1. circular, 2. square,
and 3. rectangular with width = 3 × thickness.
  5 Torsional and Bending Stresses in Machine Parts
5.1 Introduction
Sometimes machine parts are subjected to pure torsion or bending
or combination of both torsion and bending stresses.

5.2 Torsional Shear Stress

When a machine member is subjected to the action of two equal and
opposite couples acting in parallel planes (or torque or twisting
moment), then the machine member is said to be subjected to torsion.
The stress set up by torsion is known as torsional shear stress. It is zero
at the centroidal axis and maximum at the outer surface.
Where τ = Torsional shear stress induced at the outer surface of the shaft or maximum shear stress,
r = Radius of the shaft,
T = Torque or twisting moment,
J = Second moment of area of the section about its polar axis or polar moment of inertia,
C = Modulus of rigidity for the shaft material,
l = Length of the shaft, and
θ = Angle of twist in radians on a length l.
 The equation (i) is known as torsion equation. It is based on the
following assumptions:

1. The material of the shaft is uniform throughout.

2. The twist along the length of the shaft is uniform.
3. The normal cross-sections of the shaft, which were plane and
circular before twist, remain plane and circular after twist.
4. All diameters of the normal cross-section which were straight
before twist, remain straight with their magnitude unchanged, after
twist.
5. The maximum shear stress induced in the shaft due to the
twisting moment does not exceed its elastic limit value.
Notes : 1. Since the torsional shear stress on any cross-section
normal to the axis is directly proportional to the distance from the
centre of the axis, therefore the torsional shear stress at a distance x
from the centre of the shaft is given by
 5.3 Shafts in Series and Parallel
When two shafts of different diameters are connected together to form one shaft,
it is then known as composite shaft.
If the driving torque is applied at one end and the resisting torque at the other end, then the shafts are said to
be connected in series as shown in Fig. 5.2 (a)

When the driving torque (T) is applied at the junction of the two shafts, and the resisting torques T1 and T2 at the other
ends of the shafts, then the shafts are said to be connected in parallel, as shown in Fig. 5.2 (b).
 5.4 Bending Stress in Straight Beams
In engineering practice, the machine parts of structural members may be subjected to static or
dynamic loads which cause bending stress in the sections besides other types of stresses such as
tensile, compressive and shearing stresses.
Consider a straight beam subjected to a bending moment M as shown in Fig. 5.4. The following
assumptions are usually made while deriving the bending formula.

1. The material of the beam is perfectly homogeneous

2. The material of the beam obeys Hooke’s law.
3. The transverse sections (i.e. BC or GH) which were plane before bending,
remain plane after bending also.
4. Each layer of the beam is free to expand or contract, independently, of the
layer, above or below it.
5. The Young’s modulus (E) is the same in tension and compression.
6. The loads are applied in the plane of bending.
The stress distribution of a beam is shown in Fig. 5.4. The bending equation is given
by
Since E and R are constant, therefore within elastic limit, the stress at
any point is directly proportional to y, i.e. the distance of the point from
the neutral axis. Also from the above equation, the bending stress,
The ratio I/y is known as section modulus and is denoted by Z.
Example. A pump lever rocking shaft is shown in Fig. 5.5. The pump lever exerts
forces of 25 kN and 35 kN concentrated at 150 mm and 200 mm from the left and
right hand bearing respectively. Find the diameter of the central portion of the
shaft, if the stress is not to exceed 100 MPa.
5.5 Bending Stress in Curved Beams

Fig. 5.8. Bending stress in a curved beam.

Example 5.11. The crane hook carries a load of 20 kN as shown in Fig. 5.11. The section at X-X is rectangular
whose horizontal side is 100 mm. Find the stresses in the inner and outer fibres at the given section.
Slide 38
Any Question
Principal Stresses and Principal Planes