PrePared by

AjAy kumar
AssociAte professor
Mechanical engineering departMent
Kiet, ghaziabad
 MACHINE DESIGN-I (NME-501)
UNIT I
Introduction
Definition, Design requirements of machine elements, Design procedure, Standards in design,
Selection of preferred sizes, Indian Standards designation of carbon & alloy steels, Selection of
materials for static and fatigue loads. 3
Design for Static Load
Modes of failure, Factor of safety, Principal stresses, Stresses due to bending and torsion, Theory
of failure. 4

UNIT II
Design for Fluctuating Loads Cyclic stresses, Fatigue and endurance limit, Stress concentration
factor, Stress concentration factor for various machine parts, Notch sensitivity, Design for finite
and infinite life, Soderberg, Goodman & Gerber criteria. 4
Riveted Joints
Riveting methods, materials, Types of rivet heads, Types of riveted joints, Caulking and
Fullering, Failure of riveted joint, Efficiency of riveted joint, Design of boiler joints, Eccentric
loaded riveted joint. 4
UNIT III
Shafts
Cause of failure in shafts, Materials for shaft, Stresses in shafts, Design of shafts subjected to
twisting moment, bending moment and combined twisting and bending moments, Shafts
subjected to fatigue loads, Design for rigidity. 4
Keys and Couplings
Types of keys, splines, Selection of square & flat keys, Strength of sunk key, Couplings, Design
of rigid and flexible couplings. 4

UNIT IV
Mechanical Springs
Types, Material for helical springs, End connections for compression and tension helical springs,
Stresses and deflection of helical springs of circular wire, Design of helical springs subjected to
static and fatigue loading. 4
Power Screws
Forms of threads, multiple threads, Efficiency of square threads, Trapezoidal threads, Stresses in
screws, Design of screw jack 3
Note: Design data book is allowed in the examination
Books and References:
1. Design of Machine Elements,V.B. Bhandari, Tata McGraw Hill Co.
2. Machine Design-Sharma and Agrawal, S.K. Kataria& Sons.
3. Machine Design, U C Jindal, Pearson Eductaion.
4. Design of Machine Elements, Sharma and Purohit, PHI.
5. Design of Machine Elements-M.F. Spott, Pearson Eductaion
 Riveted Joints

Riveting methods, materials, Types of rivet heads, Types of riveted joints, Caulking and
Fullering, Failure of riveted joint, Efficiency of riveted joint, Design of boiler joints,
Eccentric loaded riveted joint. 4
 Rivet

Material of Rivets
The material of the rivets must be tough and ductile. They are usually made of steel (low carbon
steel or nickel steel), brass, aluminum or copper, but when strength and a fluid tight joint is the
main consideration, then the steel rivets are used.
Types of rivets
 Types of
riveted joint

Lap joint
Butt joint
 Terminology

Pitch (p)
Back Pitch or Transverse Pitch (pb)
Diagonal Pitch (pd)
Margin (m)=1.5d
 Failures of a Riveted Joint
1. Tearing of the plate at an edge.
2. Tearing of the plate across a row of rivets.
3. Shearing of the rivets.
4. Crushing of the plate or rivets.

Let
Pt = Tearing strength of the plate per pitch length,
Ps = Shearing strength of the plate per pitch length,
Tearing of the plate at an edge. Pc = Crushing strength of the plate per pitch length,
P = Load applied to the plate per pitch length,
For safe m ≥1.5d

For safe Pt ≥ P

Tearing of the plate across the rows of rivets.

 Shearing of rivets.

For safe Ps ≥ P

For safe Pc ≥ P

Crushing of a rivet
Example 9.1. A double riveted lap joint is made between 15 mm thick plates. The rivet diameter
and pitch are 25 mm and 75 mm respectively. If the ultimate stresses are 400 MPa in tension,
320 MPa in shear and 640 MPa in crushing, find the minimum force per pitch which will rupture
the joint.
If the above joint is subjected to a load such that the factor of safety is 4, find out the actual
stresses developed in the plates and the rivets.

Example 9.2. Find the efficiency of the following riveted joints :

1. Single riveted lap joint of 6 mm plates with 20 mm diameter rivets having pitch 50 mm.
2. Double riveted lap joint of 6 mm plates with 20 mm diameter rivets having pitch 65mm
Assume Permissible tensile stress in plate = 120 MPa
Permissible shearing stress in rivets = 90 MPa
Permissible crushing stress in rivets = 180 MPa

Example 9.3. A double riveted double cover butt joint in plates 20 mm thick is made with 25 mm
diameter rivets at 100 mm pitch. The permissible stresses are :
σt = 120 MPa; τ = 100 MPa; σc = 150 MPa. Find the efficiency of joint, taking the strength of the
rivet in double shear as twice than that of single shear.
Example 9.4. A double riveted lap joint with zig-zag riveting is to be designed for 13 mm thick
plates. Assume
σt = 80 MPa ; τ = 60 MPa ; and σc = 120 MPa
State how the joint will fail and find the efficiency of the joint.

Example 9.5. Two plates of 7 mm thick are connected by a triple riveted lap joint of zig-zag
pattern. Calculate the rivet diameter, rivet pitch and distance between rows of rivets for the joint.
Also state the mode of failure of the joint. The safe working stresses are as follows :
σt = 90 MPa ; τ = 60 MPa ; and σc = 120 MPa.

Example 9.6. Two plates of 10 mm thickness each are to be joined by means of a single riveted
double strap butt joint. Determine the rivet diameter, rivet pitch, strap thickness and efficiency of
the joint. Take the working stresses in tension and shearing as 80 MPa and 60 MPa respectively.
Example 9.7. Design a double riveted butt joint with two cover plates for the longitudinal seam
of a boiler shell 1.5 m in diameter subjected to a steam pressure of 0.95 N/mm2. Assume joint
efficiency as 75%, allowable tensile stress in the plate 90 MPa; compressive stress 140 MPa ; and
shear stress in the rivet 56 MPa.
Example 9.8. A pressure vessel has an internal diameter of 1 m and is to be subjected to an
internal pressure of 2.75 N/mm2 above the atmospheric pressure. Considering it as a thin
cylinder and assuming efficiency of its riveted joint to be 79%, calculate the plate thickness if the
tensile stress in the material is not to exceed 88 Mpa.

Example 9.9 Design a longitudinal double riveted double strap butt joint with equal straps for
this vessel. The pitch of the rivets in the outer row is to be double the pitch in the inner row and
zig-zag riveting is proposed.
The maximum allowable shear stress in the rivets is 64 MPa. You may assume that the rivets in
double shear are 1.8 times stronger than in single shear and the joint does not fail by crushing.
Make a sketch of the joint showing all calculated values. Calculate the efficiency of the joint.
 Eccentric Loaded Riveted Joint

P = Eccentric load on the joint, and

e = Eccentricity of the load
i.e. the distance between the line of action of the load and the centroid of the rivet system i.e. G.

First of all, find the centre of gravity G of the rivet system

Assuming that all the rivets are of the same size,

the effect of P1 = P is to produce direct shear load
on each rivet of equal magnitude.
Therefore, direct shear load on each rivet
In order to find the secondary shear load, the following two
assumptions are made :
(a) The secondary shear load is proportional to the radial
distance of the rivet under consideration from the centre of
gravity of the rivet system.
(b) The direction of secondary shear load is perpendicular to
the line joining the centre of the rivet to the centre of gravity
of the rivet system.
Example 9.14. An eccentrically loaded lap riveted joint is to be designed for a steel bracket as
shown in Fig. The bracket plate is 25 mm thick. All rivets are to be of the same size. Load on the
bracket,
P = 50 kN ; rivet spacing, C = 100 mm; load arm, e = 400 mm.
Permissible shear stress is 65 MPa and crushing stress is 120 MPa. Determine the size of the
rivets to be used for the joint.
 Caulking and Fullering

Caulking: Operation of burring

down the edges of the plates
and heads of the rivets to form
a metal to metal joint
Fullering is a better option