2- Hertzian contact stress
can tolerate the load.
However, to ensure a safe design, we apply a safety factor of 1.5. Therefore,
the minimum values for the diameter of the roller or width of the rail should
be:
𝑑 = 1.5 × 50 = 75 𝑚𝑚
Or
𝑙 = 1.5 × 50 = 75 𝑚𝑚
The number of cycles to failure at maximum allowable stress in Figure
2-2 is 180 × 106 for H ≤ 350 HB and 3000 × 106 for H ≥ 350 HB. For
instance, in Example 2-1, after 3000 × 106 cycles the roller starts to fail.
2.2.2 Point contact
In point or spherical contacts the contact between parts is as a point (Figure
2-4). To calculate the stress, the Hertz formula can be used. However, for
two elements which are made of steel, Equation 2-12-2 (see section 2.3) can
be simply used for calculating the stress.
Figure 2-4: Spherical contacts
Instead of Equation 2-12-2, the graphs of Figure 2-6 may be used. The
following example shows the use of the graphs.
8
2- Hertzian contact stress
Example 2-2: A force of 200 kg is applied to a one of a roller coaster wheel
with a diameter of D=270 mm (Figure 2-5-a). The wheel is on a rail with a
diameter of 250 mm, the rail and the wheel are made of st37 (hardness of
250HB) and Ck45 (hardness of 350HB) respectively. Check if the wheel and
rail will withstand Hertz stress or not?
Figure 2-5: An illustration of Example 2-2
Solution:
1. At first, between wheels and rails, we choose the weaker material. ,
i.e. the wheel with the material of st37 and the hardness of 250HB.
2. In Figure 2-2, from the lower left of the graph, choose hardness of
st37 (250HB) and go up to cross the curve (For safety we choose
the lower limit of the graph). Then go left to find the allowable
contact stress of st37 with the hardness of 250HB.
𝜎𝐻 ≈ 600 𝑀𝑃𝑎
9
2- Hertzian contact stress
Since the contact in Figure 2-5-a is as a point contact (sphere on flat
plate ) we should use Figure 2-6.
3. From the left horizontal axis of Figure 2-6, find F=200 kg
4. Go up to cross the curve d=250 mm (between the diameter of the
wheel (d=270 mm) and rail (d=250 mm), choose the smaller one)
5. Go right to cross the 𝑛 = ∞ “sphere on flat plate ”
6. Go down to find the maximum stress between the rail and wheel:
𝜎 ≈ 650 𝑀𝑃𝑎
Since the calculated stress ( 𝜎 ≈ 650 𝑀𝑃𝑎) is higher than the allowable
stress ( 𝜎𝐻 ≈ 600 𝑀𝑃𝑎), so the rail wheel will be damaged.
Now we are going to change the shape of the wheel as shown in Figure 2-5-
b. (A wheel with concave curved diameter D=300 mm in contact with the
rail)
In Figure 2-5-b the value n is:
𝐷 300
𝑛= = = 1.2
𝑑 250
7. From the left horizontal axis of Figure 2-6, find F=200 kg.
8. Go up to cross the curve d=250 mm (the smaller diameter between
wheel and rail curves)
9. Go to the right to cross the line n= 1.2 in area of the “convex-
concave contacts”( )
10. Go down to find the maximum stress between rail and wheel
𝜎 ≈ 200 𝑀𝑃𝑎
10
2- Hertzian contact stress
11. Since the calculated stress ( 𝜎 ≈ 200 𝑀𝑃𝑎) is less than the
allowable stress ( 𝜎𝐻 ≈ 600 𝑀𝑃𝑎), therefore the design is safe.
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Figure 2-6: graphs for estimating Hertzian stress of point contacts
2.3 Equations for engineers
Stress in line contact:
2 𝐹 1 2-1
𝜎 = 275 × √ (1 ± )
𝑙𝑑 𝑛
Stress in point contact:
3 𝐹 1 2-2
𝜎 = 2120 × √𝑑2 (1 ± 𝑛)2
The allowable contact stress (cams and followers) (Uvarov, Boyko,
Podarevsky, & Vlasenko, 1987):
(2.5 … 3) × 𝐻𝐵 𝑓𝑜𝑟 𝐻𝐵 ≤ 350
𝜎𝐻 (𝑓𝑜𝑟 𝑠𝑡𝑒𝑒𝑙𝑠) ≤ {
(23 … 30) × 𝐻𝑅𝐶 𝑓𝑜𝑟 𝐻𝑅𝐶 ≥ 350
For cast irons :𝜎𝐻 = 1.5𝑅𝑢
For friction gears under dry conditions (without
lubrication): (1.2 … 1.5) × 𝐻𝐵
For 𝑁 = 108 ∶ 𝜎𝐻 = 2.76𝐻𝐵 − 70
According to AGMA standard: {
For 𝑁 = 107 ∶ 𝜎𝐻 = 2.22𝐻𝐵 + 176.8
11
3- Press-Connect Joints
3 Press-Connect Joints1
Nomenclature
D outer diameter of hub, mm l connection length, mm
outer diameter of shaft,
d Re yield strength, MPa
mm
inner diameter of shaft,
di T torque, N.m
mm
E elastic modulus, MPa ∆ interference, µm
Faxial axial force, N μ coefficient of friction
unit pressure on the stress on surface of
k σ
surface of joint, MPa components, MPa
3.1 Introduction
Joining elements through press-connect creates durable and permanent
connections that can transmit largly and abruptly applied loads or
fluctuating forces. Since this kind of joining does not require any connecting
parts such as keys and consequently any keyways or grooves in which the
stress concentration occurs, it has a high design strength (operational
strength)
In this chapter, we propose unique methods that give very good
approximations and easy calculations for the design of press-connect
1
This work is subject to copyright. Design of Machine Elements by Graphical Methods for
Engineers and Machine Builders. Majid Yaghoubi
12
3- Press-Connect Joints
joints.
3.2 Design methods
To design press-connect joints, Equations 3-1, 3-2, 3-3, 3-4 and 3-5 (see
section 3.2.6) can be used (also see Figure 3-1a).
(a) (b)
Figure 3-1: (a): cross-section view of a hollow shaft connected to a hub by
press-connect. (b): the press-connect joint of Example 3-1
Instead of using the equations above, we propose a graphical method for
designing press-fit joints a presented in the following subsections. In the
graphical method, the coefficient of friction and connection length are
assumed to be μ = 0.1 and l = d, respectively.
3.2.1 Estimation of the minimum interference (∆min)
Example 3-1 shows use of the graphical method for rough calculation of the
minimum interference.
Example 3-1: In the powertrain of a heavy machine, there is a hollow shaft
connected to a hub by press-fit and supposed to transmit a torque of 40 kg.m
as shown in Figure 3-1-b. Find the minimum interference for the press-fit
joint.
13
