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Prof. R. K. Pandey
Dept. of Mechanical Engg.
I.I.T. Delhi, New Delhi-110016, India
Email: [email protected]
Objectives of course
To provide training to students in the process of design of
machine elements/components in general for assembling
them to make machines in particular .
1. Engineering Mechanics,
2. Mechanics of Solids (Strength of Materials) ,
3. Material Science,
4. Mechanical Engineering Drawing,
5. Kinematics and Dynamics of Machines,
6. Manufacturing Processes
Dr. R. K. Pandey
Professor
Department of Mechanical Engineering
I.I.T. Delhi, New Delhi – 110 016, India
Office room: III-341
E-mail: [email protected]
(NB: If you are not able to meet coordinator in his office,
please send an e-mail for the appointment or for getting
the response of your query through e-mail itself.)
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi 15
What is expected of you?
• It is essential to attend all the classes since “design of
machines” cannot be learnt just by reading but by doing.
• Bring the main text book and handouts to the lecture and
practice classes.
• Keep separate note books for lecture and practical/design
classes.
• Will aid in studying for examinations
• Will aid review
• Submit assignments and practice exercises as and when
called for.
• Bring calculator (in lectures and practical classes), pencil,
eraser, and a 150 mm scale (i.e. ruler) in all classes.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi 16
Design Note Book
The American Society for Testing and Materials (ASTM) defines standards
for test specimens and test procedures for a variety of material-property
measurements. The most common material test used is the tensile test.
F
The bar is stretched slowly in tension until A0
it breaks, while the load and the distance
across the gage length (or alternatively the l lo l
strain) are continuously monitored.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi l0 l0 24
Stress and Strain
Uneven
materials
Typical stress-strain
diagram for different
materials
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi 33
Types of simple loading
Design
Technology is a
product of
engineering and
science.
What is design?
1. Adaptive design
2. Developmental design
3. New design
Typical design procedure (involves iterations)
1. Recognition of need and brain storming
2. Synthesis of mechanism
3. Analysis of mechanism
4. Material selection
5. Stresses and size determination
6. Production drawing
7. Fabrication of prototype
8. Testing and modification
9. Sell and feedback from field
10. Modification
Safety in Mechanical Design
Applied strength
Syt Sut
=
_____________________
= _____________________
Allowable load
FS = _________________________________________________________________________
Applied load
Fallow
= _____________________
FApplied
Counter conformal contacts
Counter
conformal
contacts
F = K. (Conformal)
????
Design of ceiling fan hanging rod
Statement of problem
A ceiling fan weighs 200 N. It is supported from the ceiling
by a AISI 1020 Cold Drawn (CD) steel (Sy = 393 MPa)
steel rod of 10 mm diameter. Will the rod fail?
FSD
Prof. R. K. Pandey
Dept. of Mechanical Engg.
I.I.T. Delhi, New Delhi-110016, India
Email: [email protected]
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
1
New Delhi-110016, India
Objectives of course
To provide training to students in the process of design of
machine elements/components in general for assembling
them to make machines in particular .
Syllabus (as per courses of study 2020-2021)
Conceptualization of a machine in terms of geometrical
requirements specified in terms of functional degrees of
freedom, degrees of constraints and stiffness.
Factors of safety.
1. Engineering Mechanics,
2. Mechanics of Solids (Strength of Materials) ,
3. Material Science,
4. Mechanical Engineering Drawing,
5. Kinematics and Dynamics of Machines,
6. Manufacturing Processes
Dr. R. K. Pandey
Professor
Department of Mechanical Engineering
I.I.T. Delhi, New Delhi – 110 016, India
Office room: III-341
E-mail: [email protected]
(NB: If you are not able to meet coordinator in his office,
please send an e-mail for the appointment or for getting
the response of your query through e-mail itself.)
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
16
New Delhi-110016, India
What is expected of you?
• It is essential to attend all the classes since “design of
machines” cannot be learnt just by reading but by doing.
• Bring the main text book and handouts to the lecture and
practice classes.
• Keep separate note books for lecture and practical/design
classes.
• Will aid in studying for examinations
• Will aid review
• Submit assignments and practice exercises as and when
called for.
• Bring calculator (in lectures and practical classes), pencil,
eraser, and a 150 mm scale (i.e. ruler) in all classes.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
17
New Delhi-110016, India
Design Note Book
A well-documented notebook
is critical for recording ideas
for later synthesis and to
provide legal groundwork for
patents and other proof of
intellectual ownership.
Extrados Intrados
The American Society for Testing and Materials (ASTM) defines standards
for test specimens and test procedures for a variety of material-property
measurements. The most common material test used is the tensile test.
F
The bar is stretched slowly in tension until A0
it breaks, while the load and the distance
across the gage length (or alternatively the l lo l
strain) are continuously monitored.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
New Delhi-110016, India
l0 l0 27
Stress and Strain Stress is the
term used
to define
the
intensity
and
direction of
the internal
forces
acting at a
given point
on a
particular
plane.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
28
New Delhi-110016, India
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
29
New Delhi-110016, India
Failed samples of ductile Failed samples of brittle
material under tension material under tension
Uneven
materials
Typical stress-strain
diagram for different
materials
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
37
New Delhi-110016, India
Stress-strain curves of different metals
σb = Force/Projected Area = P/ td
Cotter
Joint
Hand pump
Bicycle
chain
Slide spindle
and fork of
valve
mechanisms
Foundation bolt
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
53
New Delhi-110016, India
Joint between
piston rod and
crosshead in
steam engine.
Slide spindle
and fork of
valve
mechanisms
Foundation bolt
Design
Technology is a
product of
engineering and
science.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
70
New Delhi-110016, India
What is design?
1. Adaptive design
2. Developmental design
3. New design
Applied strength
Syt Sut
=
_____________________
= _____________________
This definition of FS is correct, when load is linearly proportional to
stress, but incorrect when non-linearity exists between load and stress.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
85
New Delhi-110016, India
Allowable load
FS = _________________________________________________________________________
Applied load
Fallow
= _____________________
FApplied
F = K. (Conformal)
????
FSD
FSd =1.1 x 1.0 x 1.0 x 1.0 x 1.0 x 1.0 x 1.0 x 1.0 x 1.0 =1.1
What is
difference in
pipe and tube?
In the Statement
In the Information or Data provided
In the Solution Strategy
In the Output or Results sought
1. Length of rod
2. Type of cross section
3. Cross sectional area of rod
4. Material and treatment to be used
5. Aesthetic considerations
6. Cost etc.
Note
All the above aspects might not be important or more aspects might
have to be added – the decision has to be taken by the Designer
after a well thought out process. More experienced the Designer
easier it would be. So design has to be learnt and cannot just be
studied from a book. R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
114
New Delhi-110016, India
Constraints and Criteria in
Engineering Design
In engineering design, Cost, Weight, Power,
Torque, Space required (i.e., Size) etc. can
become Constraints (i.e. restrictions) in the
Design or become Criteria to evaluate the
Best Design out of the various Alternative
Designs.
• Machining
Mild steel very good can go up to Carbon percentage 0.35% i.e.
AISI 1035.
Higher the carbon percentage more difficult to machine as
hardness increases with carbon percentage.
• Forging
Up to 0.10 % carbon lost during forging.
Hence select carbon percentage slightly higher, say 0.40 to 0.50
% carbon i.e. AISI 1040 to AISI 1050 when selecting Carbon
steels for parts to be forged.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
145
New Delhi-110016, India
Table - Typical Uses for Plain Carbon Steel*
0.05-0.07 High-ductility wire
0.07-0.15 Rimmed steel is used for sheet, strip, rod, and wire where excellent surface finish
is required, such as body and fender stock, panels, deep-drawing strip, steel for lamps, hoods,
sectors, pawls, clutch and transmission covers, oil pans, and a multitude of deep-drawn and
formed products. It is also used for cold heading wire for tacks, rivets, and low-carbon wire
products. Killed steel should be used in preference to rimmed steel for carburized parts,
especially where both the rim and the core of rimmed steel are involved in the heat treatment.
In the process of “rimming in” practically all the carbon is transferred from outer part of the
ingot for a depth of several inches, to the inner part. A cross section of the ingot or of a shape
rolled or forged from it, will have an outer layer of almost pure iron and a core in which
carbon has concentrated correspondingly. If the part to be carburized has been forged or
machined in such a manner as to bring both the rim and the core metal into the case, irregular
distortion may be expected. These steels are of low tensile values and should not be selected
where much strength is desired. Cold drawing or rolling improve their hardness and strength
about 20% over the properties in the hot rolled condition. All the properties acquired by cold
working are, however, lost when these steels are heated to temperatures of 10000 F or higher.
These steels, being ferritic in structure, do not machine freely and should be avoided for nuts,
cut screws, and operations requiring broaching or smooth finish on turning. Cold drawing,
however improves their mach inability. The higher manganese varieties have improved
machinability and hardening properties.
*James F. Young, Material and Processes, 2nd edition, Asia Publishing House, 1962, pp303-
304.
1.2-1.30 Files
1.3-1.5 Dies for wire drawing, paper knives, tools for turning iron.
1.5-1.6 Saws for cutting steels and dies for wire drawing.
Stress
cube
Normal stress
(Tension and
compression)
For normal: 𝜎𝑥x [on the (x) face in the (x) direction]
For shear: 𝜏𝑦𝑧 direction [on the (y) face in the (z) direction]
Thus, there are only six independent stress components, three normal
and three shear.
Note:
1 psi= 6895 Pa 7000 Pa = 7 kPa
1 ksi= 6.895E+6 7 MPa
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
159
New Delhi-110016, India
Elements in plane stress
Stresses R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi, Forces 160
New Delhi-110016, India
To find the maximum and minimum values of stress,
𝜎 equitation is differentiated and set the result equal
to zero.
𝑑𝜎/𝑑 = −(𝜎𝑥 − 𝜎𝑦)𝑠𝑖𝑛(2) + 2 𝜏𝑥𝑦𝑐𝑜𝑠(2) = 0
Solving for angle 𝑝 results:
𝑡𝑎𝑛2𝑝 = 2𝜏𝑥𝑦/( 𝜎𝑥 − 𝜎y)
At this angle, 𝑝, the normal stresses are maximum (𝜎1) and
minimum (𝜎2) and the shear stress 𝜏 = 0.
This direction is called the principal direction and the stresses are
called the principal normal stresses.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
New Delhi-110016, India
162
Similarly, finding the angle that defines the direction
associated with max and min values of shear stress, we get:
𝜎 = (𝜎𝑥 + 𝜎𝑦)/ 2
Solution:
R. K. Pandey,
Professor,
Dept. of Mech. Engg.,
IIT Delhi, India
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
195
New Delhi-110016, India
MCL211 (Lect.): Design of Machines
[Credit: 3 (L-T-P: 3-0-0)]
Prof. R. K. Pandey
Dept. of Mechanical Engg.
I.I.T. Delhi, New Delhi-110016, India
Email: [email protected]
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
1
New Delhi-110016, India
Objectives of course
To provide training to students in the process of design of
machine elements/components in general for assembling
them to make machines in particular .
Syllabus (as per courses of study 2020-2021)
Conceptualization of a machine in terms of geometrical
requirements specified in terms of functional degrees of
freedom, degrees of constraints and stiffness.
Factors of safety.
1. Engineering Mechanics,
2. Mechanics of Solids (Strength of Materials) ,
3. Material Science,
4. Mechanical Engineering Drawing,
5. Kinematics and Dynamics of Machines,
6. Manufacturing Processes
Dr. R. K. Pandey
Professor
Department of Mechanical Engineering
I.I.T. Delhi, New Delhi – 110 016, India
Office room: III-341
E-mail: [email protected]
(NB: If you are not able to meet coordinator in his office,
please send an e-mail for the appointment or for getting
the response of your query through e-mail itself.)
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
16
New Delhi-110016, India
Part-3
Sources:
1. A. P. Boresi and O. M. Sidebottom, Advanced Mechanics of Materials; Wiley, 6th Edition, 2018.
2. J. M. Gere and S. P. Timoshenko, Mechanics of Materials; PWS/CBS Publisher, 2004.
3. R. C. Hibbeler, Mechanics of Materials. Pearson, 6th edition, 2007.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
19
New Delhi-110016, India
Design of machine components require
the following aspects:
The octahedral planes are the oblique planes that intersect the
principal axes (1, 2, 3) at equal distance from the origin 0 as
shown in above figure The unit normal vectors to these planes
satisfy the relation: l2+m2+n2=1/3
Or
Since
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
35
New Delhi-110016, India
The octahedral shearing stress (τoct) can
be determined as follows:
𝜏12= (𝜎1-𝜎2)/ 2 ,
𝜏23= (𝜎2-𝜎3)/ 2 ,
𝜏13= (𝜎1-𝜎3)/ 2
where the maximum shear stress is ‘𝜏1 3’
1 = Syt OR 1 = Sut
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
52
New Delhi-110016, India
Experimental
investigations
suggest that the
maximum
principal stress
theory gives good
predictions for
brittle materials
i.e. it is not
recommended for
ductile materials.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
53
New Delhi-110016, India
Experimental data from tensile tests superposed on three failure
theories (Reproduced from Fig. 7.11, p. 252, in Mechanical Behavior of
Materials by N. E. Dowling, Prentice-Hall, Englewood Cliffs, NJ, 1993)
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
54
New Delhi-110016, India
(ii) Maximum Shear Stress Theory (MSST)
max = 1/2
U = Uh + Ud
For 2D case:
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
71
New Delhi-110016, India
(v) Maximum principal strain theory
Maximum principal strain in the complex stress system
must be less than the elastic limit in simple tests.
R. K. Pandey,
Professor,
Dept. of Mech. Engg.,
IIT Delhi, India
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
85
New Delhi-110016, India
MCL211 (Lect.): Design of Machines
[Credit: 3 (L-T-P: 3-0-0)]
Prof. R. K. Pandey
Dept. of Mechanical Engg.
I.I.T. Delhi, New Delhi-110016, India
Email: [email protected]
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
1
New Delhi-110016, India
Objectives of course
To provide training to students in the process of design of
machine elements/components in general for assembling
them to make machines in particular .
Syllabus (as per courses of study 2020-2021)
Conceptualization of a machine in terms of geometrical
requirements specified in terms of functional degrees of
freedom, degrees of constraints and stiffness.
Factors of safety.
1. Engineering Mechanics,
2. Mechanics of Solids (Strength of Materials) ,
3. Material Science,
4. Mechanical Engineering Drawing,
5. Kinematics and Dynamics of Machines,
6. Manufacturing Processes
Dr. R. K. Pandey
Professor
Department of Mechanical Engineering
I.I.T. Delhi, New Delhi – 110 016, India
Office room: III-341
E-mail: [email protected]
(NB: If you are not able to meet coordinator in his office,
please send an e-mail for the appointment or for getting
the response of your query through e-mail itself.)
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
16
New Delhi-110016, India
Part-3
Sources:
1. A. P. Boresi and O. M. Sidebottom, Advanced Mechanics of Materials; Wiley, 6th Edition, 2018.
2. J. M. Gere and S. P. Timoshenko, Mechanics of Materials; PWS/CBS Publisher, 2004.
3. R. C. Hibbeler, Mechanics of Materials. Pearson, 6th edition, 2007.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
19
New Delhi-110016, India
Design of machine components require
the following aspects:
The octahedral planes are the oblique planes that intersect the
principal axes (1, 2, 3) at equal distance from the origin 0 as
shown in above figure The unit normal vectors to these planes
satisfy the relation: l2+m2+n2=1/3
Or
Since
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
35
New Delhi-110016, India
The octahedral shearing stress (τoct) can
be determined as follows:
𝜏12= (𝜎1-𝜎2)/ 2 ,
𝜏23= (𝜎2-𝜎3)/ 2 ,
𝜏13= (𝜎1-𝜎3)/ 2
where the maximum shear stress is ‘𝜏1 3’
1 = Syt OR 1 = Sut
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
52
New Delhi-110016, India
Experimental
investigations
suggest that the
maximum
principal stress
theory gives good
predictions for
brittle materials
i.e. it is not
recommended for
ductile materials.
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
53
New Delhi-110016, India
Experimental data from tensile tests superposed on three failure
theories (Reproduced from Fig. 7.11, p. 252, in Mechanical Behavior of
Materials by N. E. Dowling, Prentice-Hall, Englewood Cliffs, NJ, 1993)
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
54
New Delhi-110016, India
(ii) Maximum Shear Stress Theory (MSST)
max = 1/2
U = Uh + Ud
For 2D case:
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
71
New Delhi-110016, India
(v) Maximum principal strain theory
Maximum principal strain in the complex stress system
must be less than the elastic limit in simple tests.
Modified-Mohr theory
Across corners
k = (7/8) d for inch bolts e = 1.5 d
e
d
Across Flats
Thread length
Steel Nuts
• Notice bolts not threaded for
http://www.keystonethreaded. the whole length but partially.
com/acme.htm
• Also notice the marking on the
bolt heads.
http://www.fortressfasteners.co.nz/Desktop
Default.aspx?pageid=161
Thread Terminology
External thread
Internal thread
Stud
Studs used on a
coupling to connect
two shafts.
Studs on automobile wheel
Bolted joints in
an automobile
wheel. Here the
outer four
fasteners are
studs with nuts
that secure the
wheel. The
central nut (with
locking cover
and pin) secures
the wheel
bearing to the
spindle.
http://en.wikipedia.org/wiki/File:Car_hub_cotter_pin.jpg
Washers
• Metallic washers
Split Lock Washers
http://www.getscrews.com/
Left Hand and Right Hand
threads are both shown.
http://www.boltscience.co.uk/
pages/vibloose.htm
Turnbuckle use RH and LH
thread at each end to double
displacement.
Fastener Types
www1.coe.neu.edu.ppt
Thread Standards and Definitions
F F
2
dpdr
F At
t 4 2 2
At
For At refer Tables 14-1 and 14-2
Thread standards
Screw Thread Standards
Sir Joseph Whitworth developed in mid 1800s the first screw thread
standard for a fastening thread which bears his name. Later, the Unified
Screw Thread standard came to be developed and was adopted by
Britain, Canada and the United States. This is the inch thread which is
in wide use now-a-days and known as Unified National (UN) thread.
www.roton.com
Threaded fasteners (cont.)
A thread 'system' is a ‘standard’ set of thread
proportions to suit different screw sizes and defines
the thread geometry.
P/4
External
thread
Pitch, P
dr d
Profile of fastener threads
To avoid sharp edges in the manufacture of the fastener threads the
roots and crest can be flattened, otherwise it may be rounded. At Pitch
diameter the width in the thread material and width of empty space are
same.
p
Crest
600
a
H p/8
Height
Pitch
Diameter
p/4
Root
d dr dp
Major
Diameter
Minor Pitch External Threads
Diameter Diameter
Inch threads
• Coarse Thread Series, UNC: The coarse thread series UNC is the most
commonly used thread system. It is used in the majority of screws, bolts, and
nuts. It is used for producing threads in low strength materials such as cast iron,
mild steel, and softer copper alloys, aluminum etc. The coarse thread is also used
for rapid assembly or disassembly. As the name suggests, it is coarser and
cheaper.
• Fine Thread Series, UNF: This is used for applications that require a higher
tensile strength than the coarse thread series and where a thin wall is required. It
is also required where large vibration exists. As the name suggests, it is fine and
costlier.
• Extra-Fine Thread Series, UNEF: This is used when the length of engagement
is smaller than the fine-thread series. It is also applicable in all applications where
the fine thread can be used. It is the costliest.
• Unified Standard Series and Selected Combinations, Unified Standard
Series: The preferred threads to be used are either the coarse thread series or the
fine thread series described above. The fit of screws threads (class 2A/2B and
class 3A/3B), as well as the allowances, max and min. major/minor, pitch
diameters are described in the table provided in the Standards and partial details
are available in the Table given in the book, for the various threads, including
UNC, UNF, UNEF, series
Representation of inch threads
Fine d =20 mm
d =0.75” ¾-16 UNF –A Metric M 20 x 2.5
fine d =12mm
d=0.25” metric
¼-20 UNF – A M12 x 1.75
external
20 threads/in. threads p=1.75 mm/thread
**see Tables 14-1 and 14-2 for standard sizes**
Note: Always the Major diameter is stated in specifications
for external threads and therefore for internal threads
of nut it will be the maximum internal diameter
Bolt and nut assembly
Washer Bolt Washer (integral with
(separate member) under-face of bolt)
/2 /2 Clamped
members
Notice the
unequal
External
Load P clearance
between
bolt and
holes in
/2 /2 clamped
members
Washer Nut Washer (integral
(separate member) with under-face of nut)
External force on the bolt and members
Bolted joint is clamping the members & resisting external force P. For
analysis, force P is assumed as acting at points symmetrical on both
sides of the bolt, which is a reasonable assumption. External force P
tries to separate the joint. The bolt is in tension and the clamped
members are in compression.
P /2 P /2
(Members to be joined)
lbolt = Bolt length
ls lg ls= Unthreaded shank length
lbolt lt
lthd = Threaded length of bolt
lt = Stressed threaded length
l thd l = lg = Grip
Bolted joint is clamping the members & resisting external force P. For analysis,
force P is assumed as acting at points symmetrical on both sides of the bolt,
which is a reasonable assumption. External force P tries to separate the joint. The
bolt is in tension and the clamped members are in compression.
Joint separation m
The failure of
fastener joint due to
separation of
members is
indicated in the
adjoining figure.
m
Bolt and members as springs
Km is a combination of
Km1 and Km1
Why nut & bolt assembly?
The nut and bolt assembly looks pretty simple and its
complexity is often underestimated.
Base
Screw
Types of Power Screws
• Square Thread
• ACME Thread
Square Thread Form
Square thread form is used for power/force transmission i.e. linear
jacks, clamps.
1
Buttress Threads
A strong low friction thread.
However it is designed only to take large loads in on
direction.
For a given size this is the strongest of the thread forms.
When taking heavy loads on the near vertical thread face
this thread is almost as efficient as a square thread form.
Power Screw Types – a Comparison
• Square
• strongest
• no radial load
• hard to manufacture 900 angle; hence slight
angle of about 70 from vertical formed when
manufactured
• Acme
• 29° included angle
• easier to manufacture
• common choice for loading in both directions
• Buttress
• great strength
• only unidirectional loading
Thread Backlash
Nut and Screw threads in mesh to show Backlash.
Zero Backlash with these types of Power Screws is
not possible. With Ball Screws it is possible. With
usage wear causes increase in Backlash.
Helix Unwound
• A screw is an inclined plane that winds around itself and has ridges
and is not smooth like a nail. Some screws are used to lower and
raise things while others are used to hold objects together. A screw is
like the ramp -the width of the thread is like the angle of an inclined
plane. The wider the thread of a screw, the harder it is to turn it.
• The distance between the threads depends on the slope of the
inclined plane - the steeper the slope, the wider the thread and
screws with less distance between the threads are easier to turn.
• The screw is an inclined plane wound around a central cylinder.
Power Screw Threads
Power Screw
The Helix
A helix is the locus
of a point as it
moves on the
surface of a
cylinder so that it
rotates at a
constant rate
around the surface
of the cylinder,
while also
progressing in the
direction of the axis at
a constant rate
Opening out a Helix
Up
Model for Load Action
• The load is carried by the threads of the power Screw and the Nut within which it
moves. The load is distributed over the width of the screw thread as shown in the
figure. Doing an analysis based on such a distribution will be mathematically
complicated. Designers always use as simple a model that serves the purpose and
it is found here that assuming a point load acting at what is known as pitch
diameter serves the purpose. However one should be able to obtain the pitch
diameter and if not the analysis is done assuming the point load to act at mean
diameter and serves the purpose equally well. Books use any of these diameters.
P
F L = Lead
l
dp
Load Analysis following Norton
What “simple machine” does a power screw utilize?
y P
x f
F
N L
l
dp
LIFTING
tan l
L
Pd p d p L
TSu
d p
2 d p L
More Completely…
LIFTING
P
d p L
Tu TSu Tcollar d p c dc
2
d p L
LOWERING
P
d p L
d p c dc
TTd
d 2
d p L
y P y P
x f x F
F f
N L N L
l l
dp dp
LIFTING LOWERING
For Acme Threads as per Norton
Lifting
P
d p L cos a
Tu TSu Tcollar d p c dc
2
d p cos a L
Lowering
P
d p L cos a
Td d p c dc
Td
2
d p cos a L
Self-Locking / Back Driving as per Norton
self-locking – screw cannot turn from load P
back-driving – screw can be turned from load P
P
d p L cos a
Td d p c dc
Td
2
d p cos a L
torque/torque)
(also
Buckling
Column Loading
Screws which are loaded in compression may be so slender
(long in relation to diameter) that they can fail by elastic
instability (buckling) much before they reach their static load
limit or compressive strength. A screw system design which
undergoes a compressive load must be checked for safe
column loading.
Buckling equations are
provided in the book (see
Index) and then check for
buckling failure can be
done as a final check
on the design.
Power Screw and Nut materials
• Power Screws are simple and inexpensive for use in many different
applications such as machine tools, clamping mechanisms, farm machinery,
medical equipment, aerospace and other mechanisms of many industries.
Power screws are typically made from carbon steel, alloy steel, or stainless
steel and they are usually used with bronze, plastic, or steel mating nuts.
Bronze and plastic nuts are popular for higher duty applications and they
provide low coefficients of friction for minimizing drive torques. Steel nuts are
used for only limited duty where relative speeds are low or manual driven
situations (so as to avoid galling of like materials). Roton Engineering Bulletin
No. 971 gives information about using nuts with Acme threads.
www.roton.com
Right Hand and Left Hand Threads
• Hand of the Thread
The hand of the thread can be easily determined by visual inspection.
Simply compare the screw threads with the right hand and left hand
threads illustrated below. Most threads are right hand and right hand
is assumed if no left hand designation is specified. Left hand threads
are common on manual drives where clockwise handle rotation
raises, tightens, extends, or creates motion away from the operator.
On fine threads, it may be necessary to lay a small wire in the thread
grooves to determine hand. Matching the angle of lie of the wire with
the illustrations will indicate the hand of thread.
www.roton.com
Major, Minor and Pitch Diameters
• Major Diameter: the major diameter can be measured with a
micrometer, caliper or steel rule. Major diameters are generally the
first numbers found in thread designations.
• Minor Diameter: the minor diameter is equal to major diameter
minus twice the depth of thread.
• Pitch Diameter: the pitch diameter is the diameter at which the
thread tooth and the thread space are equal. To accurately measure
the pitch diameter might not be easy and requires what is called the
optical comparator or thread wires.
www.roton.com
Exercise
P P/2 P/2
P
P/2 P/2
Collar Torque
load, A isxcross
Where, P is external force orForce(P) l Force (P)areaForce (P)
sectional
Hence
taking up the force or load and l Ais length =
x E of bolt
=
A xor(Ethickness
/l) k
of clamped members as the case might be. Hence for db >
dm (i.e. bolt deflectionD
deflection l = is more than clamped member in
tensile
= d
compression), the value of kb < km i.e. bolt stiffness is less than
combined stiffness of clamped members.
• When external load of force P is applied to the bolted connection,
the tensile deflection of both the bolt and the clamped members is D
d. For bolt the tensile deflection
adds up and for the clamped members the tensile deflection
decreases the compression.
Load or Force on Bolt and Members (cont.)
• If relative stiffness of material and bolt as explained earlier with
reference to the deflection figures (given in text book) is such that
km > kb then the clamped material will resist a major portion of the
external load or force P i.e., portion of P taken by members (Pm)
and portion of P taken by bolt (Pb) is such that:
Pm > Pb
• This is what is desired in practice. The implication of this is that: if
the bolt does not fail when preloaded during the initial tightening of
the nut on the bolt then it probably won’t fail in service
• However if external load or force P is large enough to cause the load
or force taken up or resisted by the clamped members Pm to exceed
the initial preload Fi (when the nut is initially tightened on the bolt),
then the separation of the clamped members will take place and all
the load or force will come on the bolt causing bolt failure.
Load or Force on Bolt and Members (cont.)
See book and check the derivation.
• Pb = CP where C = kb
+ kb check)
Similarly one can obtain Pm = (1- C )kPm (students
• The total force on bolt due to preloading Fi and the external force P is given by:
• Fb = Fi + Pb = Fi + CP
• Similarly the total force on clamped members due to preloading Fi and external
force P is:
• Fm = Fi - Pm = Fi - (1- C )P
•Note that C is to be found and hence stiffness
of both the bolt and clamped members
Standard Bolt Sizes
• Made to order bolts are few. Usually mass produced bolts are used
as these are economical, rather than made to order bolts. Mass
produced bolts have uniform strength. Length of standard bolts are
as follows. Bolts shorter than standard length are threaded as close
to the bolt head as possible.
2d + 6 mm; l ≤ 150 mm
2d +12 mm; 150 < l ≤ 200 mm Metric
lthd = 2d +25 mm; l > 200 mm bolts
2d + 0.25 in; l ≤ 6 in
2d + 0.50 in; l > 6 in Inch
lthd = bolts
lthd = threaded length l = total bolt length
d = nominal bolt diameter i.e. the crest diameter
Bolt Threaded & Unthreaded Lengths
• Bolt threaded and unthreaded lengths to find Bolt stiffness kb
If no other
Unthreaded Shank dia. ds data
shank available,
ls
ls
ds = d
lg=lb=Gr Major
l=lboltip diameter
lt dt lt
lthd
As
t
Top and bottom
Frusta Members not
symmetrically
placed
of t w
equal
l
1Thickness
1
2 1 2 l /2 m
l3 lm
(l3=lm /2 - l1)
lb=lm+2tw l2
lm/2
Neglect tw if 3 3
data unavailable
Stiffness of tw
Thickness of
three regions members not same
1 , 2 & 3 but Top and bottom
evaluated, as Frusta always
1 ≠ 3 symmetrical
Stiffness of members
Stiffness of the members d2
is evaluated by finding f0 d
stiffness separately
of the two annular
regions 1 & 2 1 Space 1 2 l1 lm/2
2 of the upper occup
frusta (with l3
l
region 1 in top d 3 ied by m
member and region l3 = (lm /2-l1)
bolt l2 lm/2
2 in bottom member), 3 3
and the annular region
3 of the lower
(situated frusta in the lower member), as the top clamped
completely
member (of thickness l1 < lm /2) and bottom clamped member
[of thickness (l2 + l3)> lm /2] are of unequal thicknesses. The
frustums however will be of equal heights = lm /2, where
lb =lm+2tw is the combined thickness of the members
lm+ twice thickness of washers tw (neglect if tw data unavailable)
Cone Frustum
• The frustum of the cones represent the stressed region within
clamped members when an external tensile load is applied to
separate the members, which is resisted by the bolt.
• The frustum of the cones are always symmetrical i.e., exactly of
same size at top and bottom irrespective of:
1. Whether the members are equal or unequal thickness.
2. Whether two or more members are clamped.
Exercise 1
• An example is considered to find equivalent stiffness km of the
members. Assume equal thickness of steel clamped members as in
figures. During calculation the designer found bolt diameter d =14
mm (Coarse threads)
is suitable. d
2= 1.5
d
d2=1.5 d
1 1 27.5
27.5 300
dd
Steel 300 55
Steel
2 2
27.5
17
d3
d3
(c)
d is Major diameter of bolt
Hamrock et al.
Exercise 2
• An example is considered to find equivalent stiffness km of the
earlier problem but with clamped members of different materials
as in figure. During calculation the designer has found that a bolt
with Major diameter d =14 mm is suitable.
d2d=1.5
d2 =1.5 d
d
27.5 300
dd 1 1 27.5
Aluminum 300
Steel 55
17
27.5
2 2
d3
d3
d is Major diameter of bolt (c)
Hamrock et al.
Exercise 3
• An example is considered to find equivalent stiffness km of the
problem considered earlier, assuming unequal thickness of members
with different clamped materials as shown.
d2 =1.5 d
d
Aluminum
Steel
17
d3
d is Major diameter of bolt
Hamrock et al.
Cone Frustums Falling
Outside Material
• A bolted joint assembly, where the
material is such that the cone
frustums are falling outside the
materials, hence one has to visualize
the area of the frustum within the
material, or even could approximate
the area as a cylinder of size D as seen
in the figure.
d2
Bolt Design – Static Loading
• Total force or load on the bolt under static loading is due to Preload Fi and
external force on the bolt assembly P . The effect of preload Fi is same on
both bolt and clamped members, while external force P is partially taken by
bolt and partially by the clamped members. The external force taken up by the
bolt is Pb= CP . Hence total load Fb is:
• F b = F i + Pb = F i + C P
Therefore stress developed in the bolt b is:
• Fb Fi P
At At At
• The design equation based on the failure criteria for
static loading is: stress in bolt b ≤ Sp proof strength
b = or b = + C
Proof Stress Sp
It is difficult to determine accurately the yield strength of a full size
threaded connector ( as opposed to a cylindrical test piece ) because of
the different strain rates of shank, and thread. For this reason it is
better that the proof stress rather than the yield stress is used as a
criterion for failure assessment. The proof stress Sp is the largest stress
which does not lead to any permanent set. The proof load of a screw
made from a particular material is the maximum load the screw can
withstand without permanent deformation, and is given by the
product of stress area and proof stress.
The stress area for a threaded fastener can be obtained from the
Table for standard threads both inch and metric or it can be calculated
from the formula. The proof stress can be read off from the Bolt Table
for standard threads both inch and metric.
Bolt Strength
Bolt strength is
specified by:
1.minimum proof
Thestrength Sp is the
proof load
2.or minimum
maximum load
proofthat
(force) load Fp,
a bolt
can
3.andwithstand
minimum
without acquiring a
tensile
permanent
strength,set.
Sut
Bolt Strength
The SAE
specifications are
given in Table 14-6
bolt grades are
If Sp not available
numbered
use:
according to
Bolt Design – Static Loading (cont.)
• The design equation for bolt design as the bolt is subjected uni-axial tension is:
• b ≤ Sp and by adopting equality sign b = Sp. Hence, substituting for b
from previous slide yields the following equation:
Sp Fi P x NS x NG x NR x NFA x NE x ND x NEI
NM At At
This is the design equation to design a bolt to be safe
under tensile loading and extension due to Fi and P .
Many books
= are+notCgiving this equation nor explaining
how to design bolts against tensile failure due to Fi
and P . Since Sp is used instead of Sy , take NM = 1.0
since Sy is already downgraded for safety to Sp
Bolt Design – Static Loading (cont.)
• Difficulty in using the Design Equation stated earlier is that there are three
unknown quantities in the equation, namely: Fi, C and diameter of the bolt
to be designed. Also selection of Sp value is not possible as Sp depends on the
Grade No. of bolt (both SAE or Metric bolts). Hence, unless bolt diameter is
known, Fi and C cannot be found and Sp cannot be selected.
• On the other hand if Fi and C are not known then the diameter of the bolt
cannot be found. Books are also not explaining the procedure. The following
procedure as explained in next slide is being suggested.
Bolt Design Steps for Static Loading
• In first iteration assume C=0.2. The justification for this is the experimental
result quoted in Shigley’s book (next slide) which shows that bolt takes a
smaller percentage of external load P namely not exceeding 20%, while the
clamped members take up more than 80% of the external load P.
• kb is a measure of the proportion of the
km + kb external force or load taken up by the bolt
as the ratio of bolt stiffness and total stiffness of both bolt and clamped
members is a measure of the proportion of total external that the bolt will bear.
Similarly (1-C) is a measure of the proportion of the external force or load
C = or supported by the clamped members.
sustained
Sample Data for C and (1-C )
• Bolt: ½ -13 UNC-2A kb
C=
• Material: Steel km + kb
Bolt M lb/in
Grip
(in) kb km C 1-C
NM ( dr 2)/4
=
where, Ssp = 0.577 Sp , using
be assumed
F
Shear Failure of Nut Threads
Another failure mechanism is stripping of the nut threads, which is
essentially shear failure of the nut material on the cylindrical surface at the
thread major diameter. Stripping of the bolt threads is a similar to shear of
the bolt material at the minor diameter - but this is rare. Other possible
failure mechanisms, such as crushing of the nut bearing surface and tearing
of a thin nut due to very little thickness of the Nut material, may not be
critical in themselves, but contribute to other modes of failure – similar to
the case of the Power Screws
Where have you seen power screws?
• jacks for cars
• C-clamps
• vises
• Instron material testing machines
• machine tools (for positioning of table)
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
218
New Delhi-110016, India
Screw Jack for Mechanical Advantage
Power Screw Examples
Scissor Style
Car Jack Power Screw
C-Clamp
Power Screw
http://www.clamp-it.com/ with handle Vice
C-Clamps
http://www.hartvilletool.com/product/11573
C-Clamp in Various Sizes
http://www.dickblick.com/products/c-clamps/
Machine Vise
http://en.wikipedia.org/wiki/Lathe_%28metal%29
Lathe Parts
The
feedscrew (H8)
is a long
driveshaft that
allows a series
of gears
to drive the
carriage
mechanisms.
http://en.wikipedia.org/wiki/Lathe_%28metal%29
Lathe Parts
http://en.wikipedia.org/wiki/Lathe_%28metal%29
Power Screw Example (contd.)
extensometer specimen
Power Screws
Picture of a Power Screw used for Precise
Movements
Screw and nut in Power screw
Cut view showing how a screw and nut interact in a Power screw
Trapezoid screw
• The Trapezoidal screw is suitable
for heavy load at low speed.
• Main components: Power Screw
pair and Worm-gears pair.
• It is self-locking and can hold up
load without braking device when
screw stops traveling.
Note: Braking device equipped for
self-lock might malfunction
accidentally when large jolt &
impact
load occur.
Working of a Ball Ball Screws, first invented in the
Screw late 1800s, did not come into
widespread use until the 1940s
when they were adapted for use in
automotive steering gear. Since
that time they have been used in a
variety of industrial and
commercial applications due to
their high efficiency and
predictable service life. Ball screws
utilize a series of ball bearings
between the screw and nut
threads so that movement is
achieved through rolling friction
(see figure ).
www.roton.com
Design of Nut and Screw type of Power
Screw
Base
Screw
Schematic of Power Screw and Nut
• Power Screw rotates and
the Nut moves (or is it P
the reverse?) without
rotation and supports
the load W. Thread
friction exists at threads
C
of Power Screw and Nut.
• A thrust collar of
diameter dc formed at
Ball Bearing. Friction Power Screw
exists at Ball Bearing
which is the Collar
Friction in this case.
is the friction between threads of
the power screw and the nut
www.roton.com
Single and Multiple Start Threads
Multiple start threads are used where a greater distance has to be traversed
by lesser number of rotations, e.g., cap of a pen to be unscrewed from the pen
body by only few turns of the cap, since
Lead L = n x p; n = no. of starts.
Single and Multiple Start Threads
Schematic of how multiple threads are formed with each thread
Starting from a different angular position on the cylinder on which
the threads are cut.
Types of Power Screws
• Square Thread
• ACME Thread
Square Thread Form
Square thread form is used for power/force transmission i.e. linear
jacks, clamps.
1
Buttress Threads
A strong low friction thread.
However it is designed only to take large loads in on
direction.
For a given size this is the strongest of the thread forms.
When taking heavy loads on the near vertical thread face
this thread is almost as efficient as a square thread form.
Power Screw Types – a Comparison
• Square
• strongest
• no radial load
• hard to manufacture 900 angle; hence slight
angle of about 70 from vertical formed when
manufactured
• Acme
• 29° included angle
• easier to manufacture
• common choice for loading in both directions
• Buttress
• great strength
• only unidirectional loading
Thread Backlash
Nut and Screw threads in mesh to show Backlash. Zero Backlash with these
types of Power Screws is not possible. With Ball Screws it is possible. With
usage wear causes increase in Backlash
Load to be moved
Primary concern in any screw and nut system is the amount
of load to be moved.
The load must be determined by the designer before the
proper type and size of screw can be selected.
If the load is to be moved vertically, the nut load is equal to
the weight to be moved plus the friction load.
If a load is to be moved horizontally, the weight must be
multiplied by the coefficient of friction to determine the net
load on the nut.
Loads can also be measured with a spring scale or
dynamometer. For loads which are neither horizontal or
vertical, this may be the easiest method.
The higher the load, the larger the size of the screw and nut
that will be needed.
UP and DOWN the Inclined Plane
• For the Design of the Power Screw, the expression for the Torque
required to move the Load is of paramount importance. This will
now be attempted – first for Square thread Power screw and then
for ACME thread screw
• The expressions for ‘Torque required’ are derived for Raising Load
(UP) the inclined plane and Lowering Load (DOWN) the inclined
plane
• However UP and DOWN are generic terms and the equations are
equally valid when the Load is moved to the Left of to the Right in
the Horizontal direction as in a Lathe Lead screw. It is applicable for
a Power Screw at any inclination. What has to be compared is: which
are the equations of equilibrium applicable – is it the situation
comparable to ‘UP’ the plane or is it the situation
comparable to ‘DOWN’ the plane
Glossary of Terms
• Pitch Diameter The pitch diameter of a screw thread is the diameter
at which the thread thickness and the thread space are equal.
• Root Diameter A term referring to the minor diameter of a screw
thread or the major diameter of a nut thread. Root diameter has
been replaced by the more accurate terms "major diameter" and
"minor diameter".
• Major Diameter On a screw thread, the major diameter is the
diameter of a cylinder formed by the crests of the screw. On a nut
thread, the major diameter is the diameter of a cylinder formed by
the roots of the threads. It is common to specify threads beginning
with their major diameter.
• Minor Diameter On a nut thread, the minor diameter is the diameter
of a cylinder formed by the crests of the nut threads. On a screw
thread, the minor diameter is the diameter of a cylinder formed by
the roots of the threads. Formerly, the minor diameter was called
the "root diameter" and it still commonly referred to as root
diameter.
www.roton.com
Helix Unwound
• A screw is an inclined plane that winds around itself and has ridges
and is not smooth like a nail. Some screws are used to lower and
raise things while others are used to hold objects together. A screw is
like the ramp -the width of the thread is like the angle of an inclined
plane. The wider the thread of a screw, the harder it is to turn it.
• The distance between the threads depends on the slope of the
inclined plane - the steeper the slope, the wider the thread and
screws with less distance between the threads are easier to turn.
• The screw is an inclined plane wound around a central cylinder.
Helix Unwound
Make Your Own Inclined Plane to show that a screw is an
inclined plane. Take a paper, pencil, tape and crayon or pen
Procedure: Cut a sheet of paper in half to obtain right angle
triangles and colour the longest side. Tape one of the uncolored
sides of the triangle to the pencil. Wrap the triangle around the
pencil and tape down. The triangle wraps in a spiral
Several examples of incline planes exist, which make life easier,
such as a ramp and there are others such a screw or bolt to
reduce work during fastening or even when used as jacks to
raise or lower weights.
Screw Shape
• A screw is an inclined plane
wrapped around a cylinder,
forming the path and pitch.
• It is used as a threaded
fastener and to change rotary
motion to linear force.
Helices
• Plural of helix is helices. When a string is wound around a pencil or
any cylinder, the string takes the form of a helix. Similarly, all screw
threads are helices winding around a shaft. Springs, bolt threads and
stairways also contain helices. Below some helices are shown (Rt and
Lt hand).
Power Screws
Power screws are used for providing linear motion in a smooth
uniform manner. They transform rotary motion into linear
motion.
To obtain precise axial movements e.g. machine tool lead screw
Power Screw Threads
Power Screw
The Helix
A helix is the locus
of a point as it
moves on the surface
of a cylinder so that
it rotates at a
constant rate around
the surface of the
cylinder, while also
progressing in the
direction of the axis
at a constant rate
Opening out a Helix
P
F L = Lead
l
dp
Mechanics of Power Screws
y P
x F
f A square-threaded
L
l N
power screw with
dp
single thread
dp Lowering having a pitch
diameter dp, a pitch
p, a lead angle l,
F
and a helix angle y
P
is loaded by the
axial compressive
Pitch force F.
y P
Nut x F
f
l N L
dp
P/2 P/2
Lifting
For Lifting load-Resolution of Forces
y P
x
F
N L
l
dp
y N Lifting
x
F L
l P
dp
Lifting
Σ FH = F – N sinλ – f cosλ
Σ FV = P + f sinλ – N cosλ
For Lowering load-Resolution of Forces
y P
x F
f L
N
l
dp
y N Lowering
x F
L
l P
dp
Lowering
Σ FH = – F – N sinλ + f cosλ
Σ FV = – P + f sinλ + N cosλ
More completely… dp/2 F
dp
LIFTING: +
P
d p L
Tu TSu Tcollar d p c dc
2
d p L
LOWERING:
P
d p L
d p c dc
TTd
d 2
d p L
y P y P
x f x F
F f
N L N L
l l
dp dp
LIFTING LOWERING
Total Torque Tu
• The total torque to lift the load with a Square Thread is:
P dp ( dp + L)
dc
Tu = Tsu + Tc = + c P
2 ( d p – L) 2
dp
dp dp F
Torque Tsu = F P
2
F Pitch
P
Tsu Nut
P/2 P/2
Nut If value of dp is not available then
one has to adopt mean diameter dm
P/2 P/2 instead of dp in the equation.
Force on SQUARE and ACME threads
(a) Force normal to a square (b) Force normal to an ACME thread
thread
P P P
cos f
f=14.50
2 f=00
2 f=290
Lifting
P
d p L cos a
Tu TSu Tcollar d p c dc
2
d p cos a L
Lowering
P
d p L cos a
Td d p c dc
Td
2
d p cos a L
Self-Locking / Back Driving as per Norton
Self-locking – screw cannot turn from load P
Back-driving – screw can be turned from load P
P
d p L cos a
Td d p c dc
Td
2
d p cos a L
torque/torque)
(also
Buckling
Column Loading
Power screws are typically made from carbon steel, alloy steel,
or stainless steel and they are usually used with bronze, plastic,
or steel mating nuts.
www.roton.com
Torsional Stress Depends on friction at screw-nut interface
R. K. Pandey,
Professor,
Dept. of Mech. Engg.,
IIT Delhi, India
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi,
272
New Delhi-110016, India
MCL211 (Lect.): Design of Machines
[Credit: 3 (L-T-P: 3-0-0)]
Prof. R. K. Pandey
Dept. of Mechanical Engg.
I.I.T. Delhi, New Delhi-110016, India
Email: [email protected]
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT Delhi, New Delhi-110016, India 1
Objectives of course
To provide training to students in the process of design of
machine elements/components in general for assembling
them to make machines in particular .
Syllabus (as per courses of study 2020-2021)
Conceptualization of a machine in terms of geometrical
requirements specified in terms of functional degrees of
freedom, degrees of constraints and stiffness.
Factors of safety.
11
Fatigue Failure Theories
(Dynamic failure theories)
R. K. Pandey, Professor,
Dept. of Mechanical Engg., IIT Delhi, India
Summary of the topics covered
till date:
• Background, Procedure of design,
Material selection, Factor of safety
• Stresses arising due to simple and
combined static loadings on machine
components
• Static failure theories (MSST, DET, MNST)
• Diving board, Screw jack, Wall crane
• Fasteners: Turn-buckle
Dynamic/ variable/ alternating loading
and its consequences:
• Take a piece (small length) of
aluminum/steel wire and load it in
transverse direction by bending. It
will sustain significant load.
• Now bend it by applying reversal
loads. You may notice its failure even
at much less magnitude of the load.
• Why it is so?
Many mechanical systems are subjected
to variable/alternate loading/stress
Crack will
continue to
grow as long as
cyclic tensile
stress is
present.
Measuring fatigue failure strength
Rotating
beam test
a ( max min ) / 2
fatigue strength (S ) :
f'
Steels:
Irons:
Alumin-
ums:
Copper
alloys:
Correction Factors for Theoretical
Fatigue Strength or Endurance Limit
Cload 1.0
Step-3
The part is not round, thus:
Step-4
Csurf = 0.584
Step-5
Temperature factor
Step-6
Reliability factor from table:
Step-7
Corrected endurance limit
Step-8
Estimate strength Sm at 103 cycles:
Step-9
Estimate a and b:
S-N diagram (Life at 100 MPa)
Stress concentration due to notch
1. Avoid abrupt
and/or large
magnitude
change in cross-
section.
2. Avoid sharp
corners
Force
flow
analogy
Kt, Kts =Geometrical stress
concentration factor (also called static
stress concentration factor) for normal
stress and shear stress, respectively.
Notch sensitivity (q):
Notch sensitivity (q) is defined for
various materials and used to modify
the geometric stress concentration
factors Kt and Kts for a given material
under dynamic loading.
Determination of geometric stress
concentration factors (Kt and Kts)
Fatigue stress concentration factor (Kf):
Notch sensitivity:
Materials have different sensitivity to
stress concentrations.
3. Find Kf
Determination of Fatigue stress
concentration factors
A rectangular stepped bar similar to that shown
in following figure is to be loaded in bending.
Determine the fatigue stress concentration factor
for the given dimensions.
Ex: Design of a Cantilever Bracket
for Fully Reversed Bending
A feed roll assembly is to be mounted at each end
on support brackets cantilevered from the machine
frame as shown in the associated figure. The feed
roll experiences a fully reversed load of 1000 lb
amplitude. Design a cantilever bracket to support a
fully reversed bending load of 500 lb for 1x109
cycles with no failure. Its dynamic deflection can
not exceed 0.01 in.
… continued design of a cantilever bracket for Fully Reversed Bending
1. Mean stress
2. Alternating stress
1. When alternating stress is zero, the load
is purely static and criterion of failure is
Syt or Sut.
2. When mean stress is zero, the stress is
completely reversing and the criterion
of failure is the endurance limit.
3. When the machine component is
subjected to both components of stress,
failure occurs at different scattered
points shown in the following figure.
Fatigue failure lines/curves:
Fatigue failure lines/curves:
Modified Goodman line:
Goodman line is widely used as the
criterion of fatigue failure when
machine component is subjected to
mean stress as well as alternating
stress.
Design steps of machine components
subjected to fluctuating stresses
Step-1:
Step-5:
Convert the geometric stress
concentration factors (Kt) to fatigue
concentration factors (Kf) using the
materials’ q.
Step-6:
Calculate the alternating tensile stress
amplitudes at critical locations in the
part.
New dimensions:
b = 2, d = 1.2, D = 1.4, r = 0.5, a = 5.0, and l = 6.0
Old dimensions:
b = 2, d = 1, D = 1.125, r = 0.5, a = 5.0, and l = 6.0
167
Step-9 Iterations
170
A shaft typically transmits torque from the
driving device (motor, or engine).
Sometimes shafts will carry gears, sheaves
(pulleys), or sprockets, which transmit the
rotary motion via mating gears, belts, or
chains from shaft to shaft. The shaft may be
an integral part of the driver, such as a
motor shaft or engine crankshaft, or it may
be a free standing shaft connected to its
neighbour by coupling.
171
Automated production machinery often has
line shafts that extend the length of the
machine (10 m or more) and carry the power
to all the workstations. Shafts are carried in
bearings, in a simply supported (straddle-
mounted) configuration, cantilevered, or
overhung, depending on the machine
configuration.
172
Steps or shoulders are necessary to provide
accurate and consistent axial location of the
attached elements as well as to create the
proper diameter to fit standard parts such as
bearings.
173
Keys, snap rings, or pins are often used to secure
attached elements to the shaft in order to transmit the
required torque or to locate the parts axially. Keys
require a groove in both shaft and part and may need a
setscrew to prevent axial motion. Snap rings groove
the shaft, and cross-pins create a hole through the
shaft. Each of these changes in contour will contribute
some stress concentration and this must be accounted
for in the design of the shaft. 174
Materials:
In order to minimize deflections, steel is the logical
choice for a shaft material because of its high modulus of
elasticity.
178
Shaft is typically first designed using stress considerations
and then the deflections calculated once the geometry is
completely defined.
179
Standard diameters of steel shafts
180
Transmission shafts are subjected to axial tensile force,
bending moment or torsional moment or their combinations.
Most of the transmission shafts are subjected to combined
bending and torsional moments. The design of transmission
shaft consists of determining the correct shaft diameter from
strength and rigidity considerations.
181
Some key points:
To minimize both deflections and stresses, the shaft
length should be kept as short as possible and
overhangs minimized.
182
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.
185
ASME code for shaft design
186
If keyways are present, the above values are to be reduced
by 25 per cent. According to the ASME code, the bending
and torsional moments are to be multiplied by factors kb
and kt respectively, to account for shock and fatigue in
operating condition. The ASME code is based on
maximum shear stress theory of failure. Thus, modifying
the earlier mentioned equations:
187
where,
kb = combined shock and fatigue factor applied to
bending moment
kt = combined shock and fatigue factor applied to
torsional moment
The values of kb and kt for rotating shafts are given as:
188
Example: The layout of a transmission shaft carrying
two pulleys B and C and supported on bearings A and
D is shown in the associated figure. Power is supplied
to the shaft by means of a vertical belt on the pulley B,
which is then transmitted to the pulley C carrying a
horizontal belt. The maximum tension in the belt on
the pulley B is 2.5 kN. The angle of wrap for both the
pulleys is 180° and the coefficient of friction is 0.24.
The shaft is made of plain carbon steel 30C8 (Syt =
400 Mpa) and the factor of safety is 3. Determine the
shaft diameter on strength basis.
189
Given:
Syt = 400 MPa, FOS= 3
190
191
192
ASME method/approach for the design of shafts
193
Starting with the relationship for the failure envelope in
adjoining figure:
194
Introduce a safety factor Nf
195
196
Solving previous relation for yields:
197
The ASME standard gives non-conservative results if
either of the loading components that it assumes to
be zero. Thus, it is recommend using the more
general approach of equation given below, which
covers all loading situations.
198
Problems:
199
Example:
Note: Since the torque is steady and the bending moment fully reversed, the
ASME method can be used.
200
201
1. Transmitted torque from the given power
and angular velocity
203
3. The tangential force at the spur-gear tooth is:
204
4. Solve for the reaction forces in the xz and yz planes
using ΣFx = 0, ΣMx = 0 and ΣFy = 0, ΣMy = 0 with the
trial dimensions, a = 1.5, b = 5, and c = 6.5 (which
make p = 2 and q = 6.75).
205
5. The shear load and bending moment acting on the
shaft can now be found
206
207
6. The shear and moment distributions over the shaft
length are shown in previous figures. The applied torque
is uniform over the portion of shaft between points B
and D. Within that length, there are three locations of
concern where a moment occurs in combination with a
stress concentration: point B at the step and keyway
under the gear (MB = ±33 lb-in), point C at the right
bearing where there is a step with a small radius to fit
the bearing (MC = ±63 lb-in), and point D at the sheave
step (MD = ±9 lb-in). Note that because of its high stress
concentration, the snap ring groove used for axial
location has been placed at the end of the shaft where
the moment and torque both are zero.
208
7. Taking low-carbon, cold-rolled steel such as SAE 1020
with Sut = 65 kpsi and Syt = 38 kpsi. Though not
exceptionally strong, this material has low notch
sensitivity, which will be an advantage given the large
stress concentrations. The uncorrected endurance strength
for material:
209
8. The material’s notch sensitivity is found from either
equation 6.13 (p. 345) or Figure 6-36 (pp. 344–345) and is
q = 0.5 in bending and q = 0.57 in torsion, assuming a
notch radius of 0.01 in.
210
10. The shaft diameter at point C can be found from using
the moment magnitude as follows:
211
11. At point B, under the gear, the moment is less, but the
fatigue stress-concentration factors Kf and Kfs are greater so
diameter should also be calculated at poit B:
212
13. Another location of possible failure is the step against
which the sheave seats, at point D. The moment is lower
than at C, being about 9.1 lb-in. However, the shaft will be
stepped smaller there and will have the same order of
stress concentration as at point C. (The keyway for the
sheave is in a region of zero moment and so will be
ignored.). Diameter at point D:
213
All dimensions are in mm.
W23(tan.)=2400 N, W54 (tan.)=-10800 N
W23 (rad.)=-870 N, W54 (rad.)=-3900 N
RAz= 422 N
RAy=1439 N
RBz=8822 N
RBy=3331 N
Torque=360 N.m
Start with point I:
q=0.82
Kf=1.49
Kts=1.35, qs= 0.95
Kfs=1.33
Se=173 MPa
Thank you for
kind attention
Prof. R. K. Pandey
Dept. of Mechanical Engg.
I.I.T. Delhi, New Delhi-110016, India
Email: [email protected]
R. K. Pandey, Professor, Dept. of Mech. Engg., IIT
Delhi, New Delhi-110016, India 1
Objectives of course
To provide training to students in the process of design of
machine elements/components in general for assembling
them to make machines in particular .
Syllabus (as per courses of study 2020-2021)
Conceptualization of a machine in terms of geometrical
requirements specified in terms of functional degrees of
freedom, degrees of constraints and stiffness.
Factors of safety.
11
Fatigue Failure Theories
(Dynamic failure theories)
R. K. Pandey, Professor,
Dept. of Mechanical Engg., IIT Delhi, India
Summary of the topics covered
till date:
• Background, Procedure of design,
Material selection, Factor of safety
• Stresses arising due to simple and
combined static loadings on machine
components
• Static failure theories (MSST, DET, MNST)
• Diving board, Screw jack, Wall crane
• Fasteners: Turn-buckle
Dynamic/ variable/ alternating loading
and its consequences:
• Take a piece (small length) of
aluminum/steel wire and load it in
transverse direction by bending. It
will sustain significant load.
• Now bend it by applying reversal
loads. You may notice its failure even
at much less magnitude of the load.
• Why it is so?
Many mechanical systems are subjected
to variable/alternate loading/stress
Crack will
continue to
grow as long as
cyclic tensile
stress is
present.
Measuring fatigue failure strength
Rotating
beam test
a ( max min ) / 2
fatigue strength (S ) :
f'
Steels:
Irons:
Alumin-
ums:
Copper
alloys:
Correction Factors for Theoretical
Fatigue Strength or Endurance Limit
Cload 1.0
Step-3
The part is not round, thus:
Step-4
Csurf = 0.584
Step-5
Temperature factor
Step-6
Reliability factor from table:
Step-7
Corrected endurance limit
Step-8
Estimate strength Sm at 103 cycles:
Step-9
Estimate a and b:
S-N diagram (Life at 100 MPa)
Example-2: Design the driving shaft as
per ASME code if the maximum output
of engine is 35kW at the vehicle speed of
85 km/h. The transmission system is
above (300 inclined with vertical) and
forward of the driving shaft.
Hints:
ASME code is used for design of shafts
normally acted upon by gradual and sudden
loads. Hence suitable load factors (bending and
torsion factors) are used with bending moment
and torsion.
Load gradually applied: kb=1.5, kt=1.0
Load suddenly applied (minor shock): kb=1.5-
2.0, kt=1.0-1.5
Load suddenly applied (heavy shock): kb=2-3,
kt=1.5- 3.
Allowable design stress max = 0.30Syt (without
keyway), Allowable design stress max = 0.18Sut
(without keyway) [These relations nicely hold
for commercial/purchased steels].
1. Avoid abrupt
and/or large
magnitude
change in cross-
section.
2. Avoid sharp
corners
Force
Flow
Analogy
Fatigue stress concentration factor (Kf):
Notch sensitivity:
Materials have different sensitivity to
stress concentrations.
3. Find Kf
Determination of Fatigue stress
concentration factors
A rectangular stepped bar similar to that shown
in following figure is to be loaded in bending.
Determine the fatigue stress concentration factor
for the given dimensions.
Ex: Design of a Cantilever Bracket
for Fully Reversed Bending
A feed roll assembly is to be mounted at each end
on support brackets cantilevered from the machine
frame as shown in the associated figure. The feed
roll experiences a fully reversed load of 1000 lb
amplitude, split equally between the two support
brackets. Design a cantilever bracket to support a
fully reversed bending load of 500 lb amplitude for
1E9 cycles with no failure. Its dynamic deflection
can not exceed 0.01 in.
… continued design of a cantilever bracket for Fully Reversed Bending
(Read from
graph)
Step-V
1. Mean stress
2. Alternating stress
1. When alternating stress is zero, the load
is purely static and criterion of failure is
Syt or Sut.
2. When mean stress is zero, the stress is
completely reversing and the criterion
of failure is the endurance limit.
3. When the machine component is
subjected to both components of stress,
failure occurs at different scattered
points shown in the following figure.
Fatigue failure lines/curves:
Goodman line is widely used as the
criterion of fatigue failure when
machine component is subjected to
mean stress as well as alternating
stress.
Machine components, which are subjected
to fluctuating stresses are designed using
modified Goodman line criteria:
Design steps of machine components
subjected to fluctuating stresses
Step-1:
Step-5:
Convert the geometric stress
concentration factors (Kt) to fatigue
concentration factors (Kf) using the
materials’ q.
Step-6:
Calculate the alternating tensile stress
amplitudes at critical locations in the
part.
Required ymax=0.005 in
Thus, increase the part cross-section
and do iterations.
Another example:
Torque=360 N.m
Start with point I:
q=0.82
Kf=1.49
Kts=1.35, qs= 0.95
Kfs=1.33
Se=173 MPa
Thank you for
kind attention
2
1
1
Screw Jack - Summary of Design Procedure
1. Find core diameter of the power screw on the basis of compression or tension
only.
2. Select the standard (preferred size) outer diameter, core diameter and pitch of the
threads.
3. Find the torsional moment to be transmitted by the nut and screw.
4. Find bending moment if existing.
5. Put direct stress (and bending stress if present) and torsional shear stress and do
Design Check using DET equation for σ.
6. Check for safety from buckling of power screw.
7. Find nut height using bearing pressure. Also find the other dimensions.
8. Find length of handle by equating torque to lift or lower load (whichever is
higher) and torque applied at the end of the handle such that:
Ttotal = T + Tc = F × L
Step 1. Configuration
Square or ACME?
Screw: Circular diameter d (outer thread diameter) and d1 (minimum thread
diameter) and height (Lifting Height + H + h + …)
Step 2. Input(s)
2
5. At handle end: with single hand: about 200 N applied; with both hands:
about 400N applied, and if hammer used, it will be 4 to 5 times more (not
recommended).
(ii) Wear of Screw
(Tables 1 to 3 supplied for coefficient of friction to be referred).
Depends on material combination of screw and nut, relative speed and lubricated
or unlubricated to decide coefficient of friction information to be supplied (Table
2). Power screw may be made harder than the nut, so that nut wears out and
replaced, since it is just a bush and easy to replace. It is a sort of fuse (discussed
later).
3
Fig. 2
Considering only one type of loading, say, Axial Force (P) (Fig. 2), to calculate initial
estimate of screw diameter:
Syt or
Syc P x NM x NS x NG x NFA x NR x NE x ND x NEI x ZP
=
d 2core /4
Select FS values from (Table supplied) and decide Zp from 2-5. Hence core diameter
estimated. Take preferred size.
Design Check: Substitute preferred size in DET for this, calculate torque (to raise or
lower?). Collar friction may or may not be incorporated initially and later introduced.
Step 1. Configuration
Nut: Circular-diameter D (collar diameter D1) and height H (collar height a)
Step 2. Input(s)
Subjected to:
a) Bearing pressure on nut portion (to take care of wear)
4
b) Shearing stress in nut portion
c) Shearing of collar portion of nut
d) Crushing of the collar of the nut
e) Tearing of the nut
The various design equations necessary for design of the nut are discussed.
5
The LOAD should be along the axis
Figure 3 (a) and (b) shows engagement of nut and screw to show bearing action as threads
bear against each other due to load, and bearing pressure is developed. This is critical to
design of screw and nut because this causes wear of threads. Loads act as shown.
The threads of screw may shear at core (root) diameter, while threads of nut shear at
major diameter due to axial load. The load as shown is assumed uniformly distributed is
contact otherwise it is very complicated (Fig. 3(c)).
Bearing Pressure: Can cause stress of different kind on the nut and the screw i.e., it may
be tensile on screw and compressive on nut as shown.
(a) (b)
6
Fig. 4
Sb Load x NS x NG x NF x NR x NE x ND x NEI
NM = Projected Area
Load x NS x NG x NF x NR x NE x ND x NEI
=
(do 2 dc 2) n
Load x NS x NG x NF x NR x NE x ND x NEI
=
dm h n
Load x NS x NG x NF x NR x NE x ND x NEI
=
2 rm h n
From above equation, knowing value of bearing strength Sb (Table 1 – which will
obviously give the value based on the softer material in the combination) between the
material combination of the power screw and the nut threads, the number. of threads (n)
required for the thread engagement of screw and nut to prevent failure of the threads, may
be obtained such that:
Load x NS x NG x NF x NR x NE x ND x NEI
n ≥
(/do2dc2) (Sb /NM)
Or, Load x NS x NG x NF x NR x NE x ND x NEI
n ≥
dm h (Sb /NM)
This allows calculation of number of threads and hence height of nut, since n = H / pitch
Or, H = n × pitch
Note:
do = outside diameter
di = inside or core diameter of thread
dm = mean diameter of screw
h = depth of thread
= Pitch / 2
n = number of threads in contact
= height of nut / pitch of thread
= H / pitch
H = total height of nut
7
Also,
do2 – dc2 do + dc do – dc
=
4 2 2
= (dm) (pitch/2)
Shearing of threads: To find the width ‘e’ (i.e., ‘e’ in figures of threads provided with
the standard sizes of threads to choose from Tables 5-7) of the thread.
Assuming shearing of thread occurs at radius rm, since point Load assumed to act at rm.
σs (screw) = σs (nut)
Or,
Sys Load x NS x NG x NF x NR x NE x ND x NEI
=
NM 2 rm e n
This allows ‘e’ to be found. For design to be safe from failure due to shearing of the
threads, the ‘e’ found should be less than ‘e’ given in the Tables 5-7 for threads - Fine,
Normal or Coarse, depending on which ‘Series’ was selected for the design.
8
To determine minimum value of outside diameter D1 check nut in tension or compression
as the case may be and for twisting moment due to torsion considering initially only
tension or compression to follow the Design Check Method.
Here, d0 known from screw size (designed earlier), allows obtaining initial estimate of
D1, which can then be finalized by Design Check Method by considering even Torque,
simultaneously in the Design Equation.
However, some designers prefer to select D1 empirically ≥ 2d0 and then check whether it
is safe and usually it is found safe.
As the nut is also subjected to torsion and one requires considering whether failure due to
torsional shear also occurs. In fact due to the presence of tensile or compressive loading
along with torsion requires the Distortion Energy theory to be used to check for failure.
This above approach is applicable for the case of a Screw Jack with a separate replaceable
bush. However in the case of the Clamp which is being designed as part of the design
9
exercise, this approach is not applicable as the bush is not separate from the bush but
integral with the frame.
The xy to which the bush portion is subjected to because of the interaction (meshing)
with the screw threads of the Power Screw is the same xy to which the Power Screw is
subjected and was calculated earlier.
Crushing:
Consider crushing of collar portion of nut.
Hence,
(Syc) 4 x Load x NS x NG x NF x NR x NE x ND x NEI
=
NM (D22 – D12)
Or,
(D22 – D12) (Syc / NM) = Load x NS x NG x NF x NR x NE x ND x NEI
10
This allows D2 to be calculated.
Shearing:
Tearing:
From Fig. 7,
(Syc) Load x NS x NG x NF x NR x NE x ND x NEI
=
NM (D12 – d02)
Or,
(D12 – d02) (Syc / NM) = Load x NS x NG x NF x NR x NE x ND x NEI
11
Tearing results if section is very thin.
Design of Handle
Step 1. Configuration
Handle: Circular diameter dp and length Lp
12
Choose material (CD or HR?).
Hence knowing Syt for material chosen, estimate diameter based on loading.
The handle can fail due to Pure Shear also. Imagine the final human effort at the
end of the handle may cause shear failure at the other end held in the head of the
power screw. This type of failure might not be critical in the case of a Screw Jack
but would be important to check for the case of a Screw Clamp, for example.
Finally check for Buckling of screw to know that the power screw will not fail in
buckling, for the dimensions designed.
Design of Cup
Is it of Steel or CI?
Since cup size is more than Power Screw diameter, it will be safe if made of same
material as the Power Screw and no deign required, since size and configuration will be
dictated by the way it has to support the load. If only subjected to compressive load, then
even Cast Iron is suitable, but size has to be checked for safety from failure. However,
Cast Iron will make it heavy.
Design of Frame
Depends on type of loading and processing. Selection of processing also depends on
number of pieces required. However the detail design is not dealt with here.
13
Table 1 Limiting values of bearing pressure Sbrg between screw and nut of power
screw (source in fps units: H. A. Rothbart, Mechanical design and systems Handbook, 2nd
edition McGraw Hill, New York 1985)
14
Table 4 Calculation of Tc
Initially Tc may be neglected. It is included later when screw diameter found and total
torque Ttotal obtained later with inclusion of Tc.
1 2 3
Fig. (b)
Fig. (a) Friction in conical region. Set Fig. (c)
screw only to prevent cup
‘d’ is the reduced diameter to from being removed and still Screw provided to prevent
accommodate ball bearing. D is the have relative motion with accidental removal of cup and
diameter to accommodate handle in respect to screw so as to not to provide relative motion
the 'head' portion of the screw and rotate with the screw. Here if between the cup and screw
'D' can be 1.25 to 1.5 or even 2 simple method same equations as in case
times screw diameter, based on used then application i.e.,
need. Even D can empirically be ≈ Pc Dc
Tc = 2 D+d
2d. Pc Dc Dc =
Hence, Tc = 2 2
( Dc shown)
D+d More accurate Other configurations are
Where, Dc = Same as for Fig.(a) case.
( Simple method)
2 Pc (D3 – d3)
Tc = 3 sin (D2 – d2) Take c from Table 3.
More accurate: (Uniform pressure theory)
Pc (D3 – d3) Pc (D + d)
Tc =
(D2– d2) Tc =
4sin
(Uniform pressure theory) (Uniform wear theory)
(See clutch and brake chapter) Tc= Tc1+Tc2
P c (D + d) Where, Tc1 for cone portion
Tc = and Tc2 for flat portion
4
(Uniform wear theory)
(See clutch and brake chapter of
design book or kinematics/
dynamics book).
For ball bearings c is very small;
c = 0.005 to 0.0001. Some even
take c = 0 for ball bearings for
collar friction calculation.
15
Fig. 8 Detailed representation of square thread (modified)
16
Table 5 Basic Dimensions For Square Threads Fine Series
All dimensions are in mm
Fig. 12
22 22.5 19 284
24 24.5 21 346
26 26.5 23 415
28 28.5 25 491
30 30.5 27 573
32 32.5 29 661
(34) (34.5) 31 755
36 36.5 33 855
(38) (38.5) 35 962
40 40.5 37 1075
42 42.5 39 3 1.5 0.12 1.25 0.25 1.5 0.25 1.75 1195
44 44.5 41 1320
(46) (46.5) 43 1452
48 48.5 45 1590
50 50.5 47 1735
52 52.5 49 1886
55 55.5 52 2124
(58) (58.5) 55 2376
60 60.5 57 2552
(62) (62.5) 59 2734
17
Table 5 Basic Dimensions For Square Threads Fine Series (continued)
All dimensions are in mm
Nom Major Major Minor Pitch Area
Dia. Dia. Dia. Dia. of
Bolt Nut core
D D d1 P e r H2 b h1 a H mm2
65 65 65.5 61 2922
(68) (68) (68.5) 64 3217
70 70 70.5 66 3421
(72) (72) (72.5) 68 3632
75 75 75.5 71 3959
(78) (78) (78.5) 74 4301
80 80 80.5 76 4536
(82) (82) (82.5) 78 4778
85 85 85.5 81 4 2 0.12 1.75 0.25 2 0.25 2.25 5153
(88) (88) (88.5) 84 5542
90 90 90.5 86 5809
(92) (92) (92.5) 88 6082
95 95 95.5 91 6504
(98) (98) (98.5) 94 6940
100 100 100.5 96 7238
(105) (105) (105.5) 101 8012
110 110 110.5 106 8835
(115) (115) (115.5) 109 9331
120 120 120.5 114 10207
(125) (125) (125.5) 119 11122
130 130 130.5 124 6 3 0.25 2.5 0.5 3 0.25 3.25 12076
(135) (135) (135.5) 129 13070
140 140 140.5 134 14103
(145) (145) (145.5) 139 15175
150 150 150.5 144 16286
18
Table 6 Basic Dimensions For Square Threads Normal Series
All dimensions are in mm
30 30 30.5 24 452
32 32 32.5 26 531
(34) 34 34.5 28 6 3 0.25 2.5 0.5 3 0.25 3.25 616
36 36 36.5 30 707
55 55 55.5 46 1662
(58) 58 58.5 49 1886
60 60 60.5 51 9 4.5 0.25 4 0.5 4.5 0.25 4.75 2043
(62) 62 62.5 53 2206
65 65 65.5 55 2376
(68) 68 68.5 58 2642
70 70 70.5 60 2827
(72) 72 72.5 62 3019
75 75 75.5 65 10 5 0.25 4.5 0.5 5 0.25 5.25 3318
(78) 78 78.5 68 3632
80 80 80.5 70 3848
(82) 82 82.5 72 4072
19
Table 6 Basic Dimensions For Square Threads – Normal Series (continued)
All dimensions are in mm
20
Table 7 Basic Dimensions for Square Threads Coarse Series
All dimensions are in mm
30 30 30.5 20 314
32 32 32.5 22 380
(34) 34 34.5 24 10 5 0.25 4.5 0.5 5 0.25 5.25 452
36 36 36.5 26 531
(38) 38 38.5 28 616
40 40 40.5 28 616
(42) 42 42.5 30 707
44 44 44.5 32 804
(46) 46 46.5 34 12 6 0.25 5.5 0.5 6 0.25 6.25 908
48 48 48.5 36 1018
50 50 50.5 38 1134
52 52 52.5 40 1257
55 55 56 41 1320
(58) 58 59 44 1521
60 60 61 46 14 7 0.5 6 1 7 0.5 7.5 1662
(62) 62 63 48 1810
(68) 68 69 52 2124
70 70 71 54 2290
(72) 72 73 56 2463
75 75 76 59 16 8 0.5 7 1 9 0.5 8.5 2734
(78) 78 79 62 3019
80 80 81 64 3217
(82) 82 83 66
21
Table 7 Basic Dimensions For Square Threads – Coarse Series (continued)
All dimensions are in mm.
22