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STEADY STRESSES AND
VARIABLE STRESSES IN
MACHINE MEMBERS
UNIT-1
Design process
Design is a series of activities to gather all the
information necessary to realize the designer’s idea as
a real product.
Designer’s
Idea
Real
Product
Design Process
DESIGN PROCESS
DESIGN PROCESS
DESIGN PROCESS
OPTIMUM DESIGN
FACTORS INFLUENCING MACHINE DESIGN
1. Strength and Stiffness
2. Surface Finish and Tolerance
3. Manufacturability
4. Ergonomics and aesthetics
5. Working atmosphere
6. Wear and Hardness Requirement
7. Cooling and Lubrication
8. Safety and Reliability
9. Noise requirement
10. Cost
SELECTION OF MATERIAL BASED ON MECHANICAL
PROPERTIES
INDIAN STANDARDS (BIS)
for Plain Carbon Steel
.
Alloys
PREFERRED NUMBERS
Arithmetic Progression
Geometric Progression
Geometric Progression
Meaning & Designation
R 10 Series
Meaning & Designation
R 20 Series
.
.
LIMITS , FITS AND TOLERANCE
Terms Used
Terms Used
Terms Used
Terms Used
Terms
Used
Terms
Used
Unilateral – Bilateral Tolerances
Hole Base & Shaft Base System
Hole Base System
Shaft Base System
FITS
Introduction
FITS
TYPES - FITS
Clearance Fit
Types Of Clearance Fit
INTERFERENCE FIT
TRANSITION FITS
Features of types of fits
tolerance grades Usage
Basic Hole and Basic Shaft
Letter H
Letter h
Calculation of Tolerance Grades
.
.
38.73mm + (10.92861/ 1000)
= 38.73 + 0.01092861
= 38.7409 mm
.
HOLE
SHAFT
.
.
Notch Sensitivity (q)
Fatigue stress Concentration Factor
(Kf)
Relation Kt , q and Kf
Design for variable loading
Static Stress
Varying Stress
Cyclic loads produce cyclic stress which can lead to mechanical fatigue
failure:
Mechanical Fatigue = The progressive and localized structural damage
that occurs when a material is subjected to cyclic loading. The cyclic
stress is well below tensile, Su and yield, Sy , strengths!
Varying Stress -Types
1. Completely Reversed or Cyclic Stresses
2. Fluctuating Stresses
3. Repeated Stresses
4. Alternating Stresses
1.Completely Reversed or Cyclic Stresses
2. Fluctuating Stresses
3. Repeated Stresses
4. Alternating Stresses
FATIGUE CRACK
• Fatigue limit, endurance limit, and fatigue
strength are all expressions used to describe a
property of materials.
Endurance
• Endurance strength is the stress level that a
material can survive for a given number of load
cycles.
• Endurance limit is the stress level that a
material can survive for an infinite number of
load cycles.
• Estimate for Wrought Steel:
Endurance Strength = 0.50(Su)
• Most nonferrous metals (aluminum) do not
have an endurance limit.
Factors affecting endurance limit
1. Load Factor (KL)
2. Surface Finish Factor (KSF)
3. Size Factor (KSZ)
4. Reliability Factor (KR)
5. Miscellaneous Factors (K)
S-N Curve
• S of S-N curve stands for "Stress". That means repeatitive load.
• N stands for "Number of cycles to failure".
S describes a vertical axis and N describes a cross axis. Those make a
graph below.

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Dme unit 1