Dme Book
Dme Book
Dme Book
1.1 Introduction
The subject Machine Design is the creation of new and better machines and
improving the existing ones. A new or better machine is one which is more
economical in the overall cost of production and operation. The process of design is a
long and time consuming one. From the study of existing ideas, a new idea has to be
conceived. The idea is then studied keeping in mind its commercial success and given
shape and form in the form of drawings. In the preparation of these drawings, care
must be taken of the availability of resources in money, in men and in materials
required for the successful completion of the new idea into an actual reality. In
designing a machine component, it is necessary to have a good knowledge of many
subjects such as Mathematics, Engineering Mechanics, Strength of Materials, Theory
of Machines, Workshop Processes and Engineering Drawing.
1. Adaptive design.
2. Development design.
This type of design needs considerable scientific training and design ability in
order to modify the existing designs into a new idea by adopting a new material or
different method of manufacture. In this case, though the designer starts from the
existing design, but the final product may differ quite markedly from the original
product.
3. New design.
This type of design needs lot of research, technical ability and creative
thinking. Only those designers who have personal qualities of a sufficiently high order
can take up the work of a new design. The designs, depending upon the methods used,
may be classified as follows:
1
(a) Rational design.
This type of design depends upon empirical formulae based on the practice and
past experience.
This type of design depends upon the production aspects to manufacture any
machine component in the industry.
It is the best design for the given objective function under the specified
constraints. It may be achieved by minimising the undesirable effects.
It is the design of any element of the mechanical system like piston, crankshaft,
connecting rod, etc.
This type of design depends upon the use of computer systems to assist in the
creation, modification, analysis and optimisation of a design.
1. Type of load and stresses caused by the load. The load, on a machine
component, may act in several ways due to which the internal stresses are set up. The
various types of load and stresses are discussed later.
2
(a) Rectilinear motion which includes unidirectional and reciprocating motions.
(b) Curvilinear motion which includes rotary, oscillatory and simple harmonic.
4. Form and size of the parts. The form and size are based on judgment. The smallest
practicable cross-section may be used, but it may be checked that the stresses induced
in the designed cross-section are reasonably safe.
Given:-
h = 15mm
l = 2.5 m= 2500mm
A = 500mm²
𝑠𝑙 =2mm
E = 2x10⁵N/mm²
To Find:-
Stress (σ)
Weight (w)
Solution:-
3
e =2/250
e =0.0008
σ = Exe
σ = 2x10⁵ x 0.0008
σ = 160/Nmm²
To find out the unknown weight, equating the strain energy and the loss in
potential energy.
P = stress+ Area
P = 160x500
P = 8x10⁴ N
P = ½ (8x10⁴) x2 = W*(15+2)
W = 4705.8N
Result:-
σ = 160N/mm²
W = 4705.8N
Given:-
L = 0.5m = 500mm
4
𝑊𝑚𝑎𝑥 = 45 KN = 45x10³ N
To find:-
Solution:-
=(5625x10³)+(2500x10³)/2
= 5625x10³-2500x10³/2
Z = 0.0981xd³ mm³
= 4062X10³/0.0981d³
𝜎𝑚 = 41.4x10⁶/d³ N/mm²
= 1562x10³/0.0981d³
𝜎𝑎 = 15.9x10⁶/d³N/mm²\
5
Soderberg formula
𝑘𝑓 = 𝑘𝑙 = 1
1/1.5 = 15208875/d³
D = 61.109 mm
D = 63 mm
Result :-
Given :-
n = 2
𝐾𝑓 = 1.5
𝜎𝑢 = 650N/mm²
𝜎𝑦 = 480N/mm²
𝐾𝑠𝑧 = 0.85
𝐾𝑠𝑓 = 0.5
To find:-
Shaft diameter
6
Solution:-
Ʈ𝑦 = 𝜎𝑦 /2 = 480/2
Ʈ𝑦 = 240N/mm²
Ʈ−1 = 0.22 𝜎𝑢
= 0.22(650)
Ʈ−1 = 142N/mm²
= (1800+900)x10³/2
𝑀𝑡𝑚 = 1350x10³N.mm
= (1800-900)x10³/2
= 16 x1350x10³/𝜋 x d³
= 16x450 x10³/ 𝜋 x d³
240/2 = 20451.12x10³/d³
7
d = 55.4 mm
Result :-
d = 56mm
Given:-
N = 180 rpm
Ʈ = 60Mpa = 60N/mm²
L=3m
Ø = 1°
C = 80 GPa
To find :-
Diameter of shaft
Solution :-
T = Px60/2𝜋N
T = 5172x10³ N.mm
𝜋
5172x 10³ = (60) x d³
16
8
D = 76 mm
T /J = CQ/ l
𝜋
5172x10³/𝜋/32x d⁴ = 80 x x10³/3000
180
d = 103.16 mm
Result :-
5.An axle 1 meter long supported in bearings at its ends carries a flywheel
weighing 30 KN at the centre .If the stress is not to exceed 60Mpa.Find the
diameter of the axle ?
Given:-
Length of beam l = 1 m
Weight of flywheel = 30 K
To find:-
Diameter of shaft
Solution:-
𝜋
D.B 6.1 Z= xd³
32
M = wl /4
M = 30x10³x10³/4
9
M = 7.5x10⁶ N.mm
D = 108.3 mm
Result :-
6.The frame of a punish press is shown in figure find the stress at the inner and
outer surface at section X-X of the frame if W = 5000N?
Given:-
W =5000 N
𝑏𝑖 =18 mm
𝑏𝑜 = 6mm
h = 40 mm
𝑅𝑖 = 25mm
𝑅𝑂 = 𝑅𝑖 + ℎ = 65𝑚𝑚
To find:-
10
Solution:-
A = 1/2x18+6)x40
A = 480mm²
𝑅𝑛 = 38.83mm
11
Radius of curvature of the centroidal axis
R = 25 + 40(18+2x6)/3(18+6)
R = 41.67mm
M = w.x=5000x41.67 =708350mm
W.K.T
𝑦𝑖 = 38.83-25 = 13.83mm
𝑦𝑜 = 65-38.83=26.17 mm
𝜎𝑏𝑖 = M. . 𝑦𝑖 / Ae 𝑅𝑖
= 26.17mm
𝜎𝑏𝑜 = M . 𝑦𝑜 / Ae𝑅𝑂
12
Result stress at the inner surface
= 𝜎𝑡 + 𝜎𝑏𝑖
= 10.42-287.4
𝜎𝑖 = 297.82Mpa (tensile)
= 𝜎𝑡 - 𝜎𝑏𝑜
= 10.42 -209.2
σo = -198.78Mpa (compressive)
Result :-
7.A shaft as show in figure is subject to a bending load of 3KN . Pure torque
of 1000x10³N.m and axial pulling force of 15KN . Calculate the stresses at A and
B?
Given :-
W =3KN
T = 1000x10³N.m
P = 15KN
d = 50mm
x =250mm
To find :-
Stresses at A & B
13
Solution :-
𝜎𝑜 = 7.64Mpa
𝜋
𝜎𝑏 = 750x10³/ x50³
32
𝜎𝑏 = 61.1Mpa
𝜎𝐴 = 𝜎𝑏 + 𝜎𝑜
= 61.1+7.64
𝜎𝐴 = 68.71Mpa
𝜎𝐵 = -𝜎𝑏 +𝜎𝑜
= -61.1+7.64
𝜎𝐵 = -53.64Mpa
14
𝜎𝐵 =53.64Mpa (- sing indicates compressive)
68.742 + (4𝑥40.74)2
= 68.74/2+1/2√
W.K.T
Ʈ = 16xT /𝜋d³
= 16x1x10⁶/𝜋x50³
Ʈ = 40.74Mpa
= -18.93Mpa
𝜎𝐵(min) = - 22Mpas
15
53.462 + 4(40.74)2
= 1/2√
Ʈ𝐵(max) = 48.73Mpa
= 1/2√68.74² + 4(40.74)²
Ʈ𝐴(max) = 53.3Mpa
Result :-
8. An overhang crank with pin and shaft is shown in figure . A tangential load
of 15KN. Acts on the crank Pin. Determine the maximum principal stress and
the maximum shear stress at the centre of the crankshaft bearing?
Given:-
W = 15KN = 15x10³N
d= 80mm
y=140mm
x=120mm
To find:-
𝜎𝑡(max)
Ʈ𝑚𝑎𝑥
Solution:-
= 15x10³x120
M = 1.8x10⁶ N.mm
T = w.y
16
= 15x10³ x140
T = 2.1x10⁶N.mm
W.K.T
𝜎𝑏 = 32x1.8x10⁶/𝜋x80³
𝜎𝑏 = 35.8Mpa
Ʈ = 16T/𝜋d³
Ʈ = 20.9Mpa
= 35.8/2+1/2√35.8² + 4(20.9)²
𝜎𝑡(max) = 45.4Mpa
17
= 1/2√35.8² + 4(20.9)²
Ʈ𝑚𝑎𝑥 =27.5Mpa
Result :-
𝜎𝑡(max) =45.4Mpa
Ʈ𝑚𝑎𝑥 = 27.5Mpa
9.A cylindrical shaft made of steel yield strength of 700Mpa is subject to static
loads consisting of bending moment 10KN.m and a torsional moment 30KN.m
.Determine the diameter of the shaft using two different theories of failure and
assuming a fos 2 , E =210Gpa , PR =0.25
Given :-
Fos =2
(1/m)P.R = 0.25
To find:-
Diameter ‘d’
Solution:-
Let us find max and min principal stress bending (tensile) stress due to Bending
moment
𝜋
𝜎1 = M/z =10x10⁶/ xd³
32
𝜎1 = 101.8x10⁶/d³N/mm²
Ʈ = 16T/𝜋d³
Ʈ = 152.8x10⁶/d³N/mm²
18
W.K.T Max principal stress
D.B7.2
106
= 101.8x10⁶/2d³+1/2√(101.8 × 106 /𝑑)² + 4(152.8 × )²
𝑑3
700/2x2= 161x10⁶/d³
d= 97.2mm
= (700/2)²
d= 90.8mm
Result :-
d=97.2mm
d=90.8mm
19
10. A wall bracket with a rectangular cross section is shown in figure the depth
of the cross section is twist of the width. The force P acting on the bracket at 60° to
the vertical is 5KN .The material of the bracket is grey cast iron SG200 and the
factor of safety is 3.5 .Determine the dimensions of the cross section of the bracket
.Assume maximum normal stress theory of failure ?
Given:-
P = 5KN
Fos = 3.5
d/w= 2
To find:-
Solution:-
20
tensile stresses. The force P is resolved into two components horizontal
component 𝑃ℎ and vertical component 𝑃𝑣
𝑀𝑏 = 1399.52X10³N.mm
𝜎𝑏 = 1399.52x10³x t/1/2xtx2t³
𝜎𝑏 = 2099.28x10³/t³ N/mm²
𝜎𝑚𝑎𝑥 = 𝜎𝑏 − 𝜎𝑡
Equating ① & ②
t³ −37.89t−36739.24 =0
t=33.65mm
t≅35mm
Result:-
11. A ‘C’ clamp is to bear the force ‘F’ applied onto it .It has a ‘T’ section shown
in figure .If the maximum tensile stress in the clamp is limited to 130Mpa then find
‘F’ ?
Given :-
21
To find:-
Solution:-
From the geometry, we can say that the maximum tensile stress will occur at
point ‘P’
22
D.B 6.3 𝑟𝑛 = (𝑏𝑖 −t) 𝑡𝑖 +(r xn)/( 𝑏𝑖 −t)/ n ( 𝑟𝑖 +𝑡𝑖 )/𝑟𝑖 +t/n(𝑟𝑜 /𝑟𝑖 )
From figure ②
𝑏𝑖 =20, t =3 , 𝑡𝑖 = 3
𝑟𝑛 = 30.5mm
R = 25 +(1/2x22² x3)+1/2x3²x(20-3)/(22x3)+(20-3)x3
R = 31.85 mm
C = R- 𝑟𝑛 = 31.85-30.5 = 1.35 mm
a=126mm²
𝑀𝑏 = Fx(50+31.85)
23
𝑀𝑏 = 81.85F N.mm
𝜎𝑏 = 81.85F x55/126x1.35x25
𝜎𝑏 = 0.105F N/mm²
𝜎𝑑 = F/126 N/mm²
𝜎𝑚𝑎𝑥 = 𝜎𝑏 +𝜎𝑑
𝜎𝑚𝑎𝑥 = 0.105F+F/126
Equating this to the maximum permissible tensile stress we have, 0.0129F = 130
F = 1151 N
Result:-
F = 1151N
12. A machine component is subjected to fluctuating stress that varies from 40 to 100
N/mm2 the corrected endurance limit stress for the component is 270N/mm2 the
ultimate tensile strength and yield strength material are 600 and 450 N/mm2
respectively find the factor of safety using 1) Gerber theory 2) soderberg line 3)
Goodman line 4) find factor of safety against static failure?
Given:-
𝜎𝑚𝑖𝑛 = 40N/mm²
𝜎𝑚𝑎𝑥 =100N/mm²
𝜎−1 = 270N/mm²
𝜎𝑢 = 600N/mm²
𝜎𝑦 = 450N/mm²
24
To find:-
2) Soderberg line
3) Goodman line
Solution:-
𝜎𝑚 = 100+40/2
𝜎𝑚 = 70N/mm²
𝜎𝑎 = 𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛 /2
𝜎𝑎 = 30N/mm²
𝜎𝑎 𝑥𝑛 / 𝜎−1 + ( 𝜎𝑚 𝑥𝑛 / 𝜎𝑢 )² =1
30 n/270 +(70n/600)² = 1
0.111x n +0.0136xn² -1 =0
1/n = 70/600+30/270
n= 4.39
25
Result:-
n = 5.41
n=3.75
n= 4.39
n=4.5
13)A pulley is keyed to a shaft midway b/w two antifriction bearings the bending
moment at the pulley varies from -170Nm and 510Nm as the torsional moment in
the shaft varies from 55Nm to165Nm the frequency of the variation of the loads
is the same as the shaft speed. The shaft is made of cold drawn steel having an
ultimate strength of 538Mpa and yield strength of 400Mpa .Determine the
required diameter for an indefinite life. The stress concentration factors the
keyway in bending and torsion may be taken as 1.6 and 1.3 respectively correction
factors A=1(for bending )A=0.6(for torsion) B=0.85 and C=0.88and Fos 1.5?
Given:-
𝜎𝑢 = 538Mpa C = 0.88
𝜎𝑦 = 400Mpa n = 1.5
To find:-
Solution:-
𝜎𝑚𝑎𝑥 = 5195x10³/d³
𝜎𝑚𝑖𝑛 = -1732x10³/d³
26
𝜎𝑚 = 𝜎𝑚𝑎𝑥 +𝜎𝑚𝑖𝑛 /2 = (5195/d³+(-1732/d³)/2)x10³
D.B 7.6
𝜎𝑚 = 1732/d³ x10³
𝜎𝑎 = 𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛 /2
𝜎𝑎 = ½(5195/d³ - (-1732)/d³)x10³
𝜎𝑎 = 3464/d³ x10³
𝜎𝑢
Assume that 𝜎−1 = = 538/2 =269Mpa
2
𝜎𝑎
D.B 7.6 𝜎𝑒𝑞 = 𝜎𝑚 + 𝐾𝑓𝑏 . 𝐴𝑏 . 𝐵. 𝐶(𝜎𝑦 / 𝜎−1 )
Ʈ𝑚𝑎𝑥 = 16x165x10³/ 𝜋𝑑 3
Ʈ𝑚𝑎𝑥 = 840x10³/d³
Ʈ𝑚𝑖𝑛 = 16x𝑀𝑡𝑚𝑖𝑛 / 𝜋𝑑 3
Ʈ𝑚𝑖𝑛 = 16x55x10³/ 𝜋𝑑 3
Ʈ𝑚𝑖𝑛 = 280x10³/d³
Ʈ𝑚 = Ʈ𝑚𝑎𝑥 +Ʈ𝑚𝑖𝑛 /2
Ʈ𝑚 = 840+280/2d³
Ʈ𝑚 = 560/d³ x10³
= 840-280/2d³
Ʈ𝑎 = 280/d³ x10³
27
D.B 7.6 Ʈ𝑒𝑞 = Ʈ𝑚 + 𝐾𝑓𝑡 . Ʈ𝑎 /𝐴𝑡 .B.C (Ʈ𝑦 /𝜎−1 )
Ʈ𝑦 = 𝜎𝑦 /2 =400/2=200Mpa
Ʈ𝑒𝑞 = 1163.01x10³/d³
Ʈ𝑚𝑎𝑥 = 1/2√𝜎𝑒𝑞²+4Ʈ𝑒𝑞 ²
=
1/2d³√1.275 × 10⁴ × 103 /𝑑³)² + (1163.01 × 103 /𝑑³)²
Ʈ𝑚𝑎𝑥 = 1.29x107/2d3
Result:-
d= 36.49mm
14)What maximum Axial forces can be applied on a plate of width 50mm and
thickness 10mm with a central holeof10mm diameter without exceeding the yield
point stress of 62.5Mpa across its width?
Given:-
To find:-
Load P =?
28
Solution:-
𝜎𝑜 = P/(w-a)h
𝜎𝑜 = P/400 N/mm²
𝐾𝑡 = 62.5/P/400
2.5 = 62.5x400/P
P = 10,000N
Result:-
P = 10KN
15)Taking stress concentration into account find the maximum stress induced when
a tensile load of 20KN is applied (a) a rectangular place of 80mm wide and 12mm
thick with a transverse hole of 16mm diameter(b) a stepped shaft if dia 60mm
and 30mm with a fillet radius of 6mm?
29
Given:-
P =20KN
W = 80mm
h =12mm
a =16mm
To find:-
Maximum stress
Solution:-
𝐾𝑡 = 2.5
𝐾𝑡 =𝜎𝑚𝑎𝑥 /20x10³/(80-16)12
D = 60mm
d = 30mm
r =6 mm
D/d = 60/30 = 2 (D.B 7.11)
𝐾𝑡 = 1.5
𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙 = P/A = 20000/706.5
𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙 = 2829 N/mm²
𝜋 𝜋
A = d² = (30)² =706.5 mm²
4 4
𝜎𝑚𝑎𝑥 = 42.44N/mm²
30
Result:-
16)A simply supported beam has a concentrated load at the centre which
fluctuates from a value of P to 4P .The span of the beam is 500mm and its cross
section circular with a diameter of 60mm . Taking for a beam material on
ultimate stress of 700Mpa stress of 500Mpa ,endurance limit ,Fos 1.3 calculate
the max value of P .Take size factor of 0.85, surface finish factor 0.9?
Given:-
Diameter d = 60mm
To find:-
Maximum value of P
Solution:-
𝑀𝑏(max)
(3) 𝜎𝑚𝑎𝑥 =
2
= 500P/2
𝜎𝑚𝑎𝑥 = 0.0235 P N/mm²
Mean stress 𝜎𝑚 = 𝜎𝑚𝑎𝑥 + 𝜎𝑚𝑖𝑛 /2
31
(4)Minimum bending moment 𝑀𝑏(min) = 𝑃𝑚𝑖𝑛 /2 xɩ/2
= P/2 x 500/2
𝑀𝑏(min) = 125P
= 125P/21205.75
𝜎𝑚 = 0.0147P N/mm²
Amplitude stress
𝜎𝑎 =𝜎𝑚𝑎𝑥 -𝜎𝑚𝑖𝑛 /2
𝜎𝑎 = 0.0235P – 0.00589P/2
𝜎𝑎 = 0.008805 P N/mm²
Result:-
17)A pump lever rotating shaft is shown figure .The pump lever exerts forces
of 25KN and 35KN concentration at 150mm and 200mm from the left and right
hand bearing respectively .Find the diameter of the central portion of the shaft, If
the stress is not to exceed 100Mpa?
32
Given:-
𝜎𝑏 = 100Mpa
To Find:-
Diameter‘d’
Solution:-
𝜀𝑀𝐴 = 0
𝑅𝐵 x950 = (35x750)+(25x150)
𝐶 = 3000/950
𝑅𝐵 = 31.58KN → ①
Єv = 0
𝑅𝐴 + 𝑅𝐵 = (35+25) x10³
𝑅𝐴 = 60x10³ - 31.85x10³
𝑅𝐴 = 28.42x10³N
= 𝑅𝐴 x 150
= 28.42x10³x150
= 4.263x10⁶N.mm
33
Bending moment at ‘D’
=𝑅𝐵 x200
= 31.58x10³x200
=6.316x10⁶ N.mm
M = 6.316x10⁶ N.mm
𝜋
Section modules Z = d³
32
Z = 0.0982d³
d= 86.3mm
Result:-
34
UNIT-2
SHAFTS AND COUPLINGS
Given:-
𝑀𝑏𝑚𝑎𝑥 = 3000x10³N.mm
Ʈ𝑚𝑎𝑥 = 50N/mm²
𝐾𝑏 = 1.5
𝐾𝑡 =2
To Find:-
Shaft diameter
Solution:-
d³ =
16/50𝜋 √(1.5 × 3000 × 10³)² + (2 × 1500𝑥103 )²
d³ = 550887.65
d= 81.97 mm
Result:-
d=90mm D.B.7.20
35
Given:-
P = 50Kw = 50x10³w
N = 1200rpm
Ʈ = 60N/mm²
𝜋
Q =2° = 2x = 0.0349 rad
180
L = 2m
G = 80x10³ N/mm²
To find:-
Diameter ‘d’
Solution:-
P = 2𝜋N𝑀𝑡 /60
𝑀𝑡 = 50x10³x60/2𝜋𝑥1200
𝑀𝑡 = 397.887
𝑀𝑡 = 397.887x10³N.mm
𝛼𝑃𝑑𝑜
𝑑𝑜 ³ = 16/ x 𝐾𝑏 𝑀𝑏 + 2 + (𝐾𝑡 𝑀𝑡 )²/𝜋xƮ(1-(𝑑𝑖 /𝑑𝑜 )⁴
√ 𝑑2
8(1+ 2𝑖 )
𝑑𝑜
𝑑𝑜 = d, 𝑑𝑖 = 0, P = 0
Assume 𝐾𝑏 = 𝐾𝑡 = 1
d³ = 16/𝜋Ʈ√(𝐾𝑏 𝑀𝑏 )² + (𝐾𝑡 𝑀𝑡 )²
d= 34.49mm
36
d=35mm (R20 series)
D.B.7.1
𝑀𝑡
= GQ/l
𝐽
𝜋
397.88X10³/ d⁴ = 80x10³x0.0349/2x10³
32
d=41.27 mm
Result:-
3)Design a shaft to transmit 2Kw at 150rpm from an electric motor lath head
stock through a pulley using a flat belt drive. The pulley is located at 140mm
from the centre of the bearing diameter of the pulley is 200mm.The pulley
weights 250N angle of lap of the belt is 180° and the coefficient of friction
b/w belt and pulley is 0.3 shock factor in bending is 1.5 and in twisting 1
Take allowable shear stress for the shaft material as 44 N/mm²?
Given:-
P = 2Kw = 2x10³watts
N=150rpm l=140mm
D=200mm, w=250N
Q=180° =𝜋 radians
𝜇 = 0.3
𝐾𝑡 =1.5
𝐾𝑏 =1
Ʈ =44N/mm²
37
To find:-
Diameter ‘d’
Solution:-
𝑇1 /𝑇2 = 𝑒 0.3×𝜋
𝑇1 = 2.565𝑇2
P = (𝑇1 - 𝑇2 )V
V= 𝜋DN/60
V=𝜋 x 150x0.2/60
V = 1.571m/s
𝑇1 - 𝑇2 = 1273N
𝑇1 = 2.565𝑇2
𝑇2 = 813.5N
𝑇1 = 2086.5N
M =(2086.5+813.5+250)x140
M = 441000N.mm
T = (𝑇1 - 𝑇2 )xD/2
T = 127.3N.mm
4. Equivalent torque 𝐾𝑏
38
𝑇𝑒 = √(𝐾𝑏 M)² + (𝐾𝑡 𝑇)²
𝑇𝑒 = 708804N.mm
5. Diameter of shaft
Ʈ = 44x0.75 Ʈ = 44/1.3
Ʈ = 33N/mm² Ʈ = 33N/mm²
16x708804/𝜋d³ = 33
d³ = 16x708804/𝜋x33
d = 47.82mm
d = 50mm (standard)
Result:-
d=50mm (standard)
Given:-
D = 250mm
r = 125mm
𝜎𝑡 = 100Mpa = 100N/mm²
Ʈ = 600Mpa = 60N/mm²
39
To find:-
Diameter ‘d’
Solution:-
Let 𝑇1 & 𝑇2 are tensions on hght side and slack side on pulley ‘c’
𝑇1 /𝑇2 = 3
𝑇1 = 2x10³N
40
𝑇2 = 2x10³/3
𝑇2 = 666.67N
𝑇3 /𝑇4 = 3
𝑇3 = 2x10³N
𝑇4 = 2x10³/3
𝑇4 = 666.67N
Let 𝑅𝐴 + 𝑅𝐵 = 2666.67+2666.67
𝑅𝐴 + 𝑅𝐵 = 5333.34N
𝑅𝐵 = 4592.59N
𝑀𝐴 = 0, 𝑀𝐷 = 0
𝑀𝐶 = 333.33x10³N.mm
𝑀𝐵 = 533.33x10³N.mm
d³ = 16/𝜋Ʈ√( 𝐾𝑏 𝑀𝑏 )2 + (𝐾𝑡 𝑀𝑡 )²
41
d = 36.19mm
Result:-
d = 40mm
Given:-
To find:-
Solution:-
𝑑𝑖 = 0, 𝑑𝑜 = d, d =0.6
42
𝑀𝑡 (hollow) = 4.0306 ( 𝑀𝑡 )solid
Comparison of weight :-
𝑀𝐻 = p xA xl
𝑀𝐻 = 𝑝𝐻 × 𝜋/4(𝑑𝑜 ² - 𝑑𝑖 ²)× 𝑙𝐻
𝑀𝐻 = 𝑝𝐻 × 𝑙𝐻 × 𝜋/4 ×((𝑑𝑜 ²) –
(0.6𝑑𝑜 )²
𝑀𝐻 = 𝑝𝐻 × 𝑙𝐻 ×(0.5026) 𝑑𝑜 ² → ③
𝑀𝑆 = 𝑝𝑠 × 𝐴𝑆 × 𝑙𝑆
𝑀𝑆 = 𝑝𝑠 × 𝜋/4d² × 𝑙𝑆
𝑀𝑆 = 𝑝𝑠 × 𝑙𝑆 × (0.2827) 𝑑𝑜 ² → ④
③/④
𝑀𝐻 / 𝑀𝑆 = 1.777
𝑀𝐻 = 1.777 𝑀𝑆
\\\𝑙𝑦 𝑤𝐻 = 1.777𝑤𝑠
Comparison of stiffness:-
G → constant
J as stiffness
𝜋
𝐽𝐻 = (𝑑𝑜 ⁴ - 𝑑𝑖 ⁴)
32
𝜋
𝐽𝐻 = (((𝑑𝑜 ⁴- (0.6𝑑𝑜 )⁴)
32
𝐽𝐻 = 0.08545 𝑑𝑜 ⁴
𝜋
𝐽𝑆 = 𝑑𝑜 ⁴
32
43
𝜋
𝐽𝑆 = 0.6𝑑𝑜 ⁴
32
𝐽𝑆 = 0.01272𝑑𝑜 ⁴
𝐽𝐻 / 𝐽𝑆 = 0.8545 𝑑𝑜 ⁴/0.01272𝑑𝑜 ⁴
𝐽𝐻 / 𝐽𝑆 = 6.715
𝐽𝐻 = 6.715𝐽𝑆
Result:-
𝑤𝐻 = 1.777 𝑤𝑠
𝐽𝐻 = 6.715 𝐽𝑆
Given:-
𝐾𝑏 = 𝐾𝑡 = 1.5
Ʈ = 70 N/mm²
To find:-
Diameter‘d’
Solution:-
44
T1&T2 are the belt tensions on pulley ’C’
ie T1+T2=10KN(H)
T3+T4=10KN(V)
Let (RA)H and (RB)H are the support sections at A&B respectively
(RB)H*750=10*103*250
45
(RB)H=3.33*103N----------------------------- (2)
(RA)H=10*103-3.33*103
(RA)H=6.67*103N
(M)RBH=0
=(RA)H*250
=6.67*103*250
MCH=1.6675*106 N.mm
=(RB)H*250
=3.38*103*250
(RA)V+(RB)V = (12*103)+(2*103)
(RB)V =6.6*106/750
(RA)V=14*103-8.66*103
(RA)V = 5.34*103 N
46
(M)RAV=0, (M)RBV=0
=5.34*103*250
d3 = 16/𝜋(𝑡) √(KbMb)2+(ktMt)2
d3 = 0.4138*106
d=74.518mm
R20 Series
d=80mm
Result:-
d=80mm
47
Given:-
P =10kw =10*103 W
N = 750rpm
L =800 mm
𝑇𝐷 = 30
𝑀𝐷 = 5 mm
𝑇𝑐 = 100
𝑀𝑐 = 5 mm
To find:-
Diameter‘d’
48
Solution:-
Torque 𝑀𝑡 = Px60/2𝜋N
= 10x10³x60/2𝜋 x750
𝑀𝑡 = 127.32 N.m
Diameter of gear , C
𝐷𝑐 = 𝑇𝑐 x 𝑀𝑐
𝐷𝑐 = 100 x5
𝐷𝑐 = 500 mm
Radius of 𝑅𝐷 = 𝑇𝐷 x 𝑀𝐷 /2 = 30x5/2 = 75 mm
𝐹𝑡𝑐 = 509.28N
𝐹𝑡𝑐 = 2X127.32X10³/150
𝐹𝑡𝑐 = 1697.6N
𝑅𝐴𝑉 = 413.79 N
W.K.T
= 413.79x150
𝑀𝑐𝑣 = 62068.5N.mm
= 95.49 x120
𝑀𝐷𝑉 = 11458.8N.mm
𝑅𝐵𝐻 = 1442.96N
50
B.M at ‘D’ 𝑀𝐷𝐻 =𝑅𝐵𝐻 x120 = 1442.46x120 =173155N.mm
𝑀𝐶 = √(𝑀𝑐𝑣 )2 + (𝑀𝐶𝐻 )²
𝑀𝐶 = √(62068.5)2 + (38196)²
𝑀𝐶 = 72879 N.mm
𝑀𝐷 = √(𝑀𝐷𝑉 )2 + (𝑀𝐷𝐻 )²
𝑀𝐷 = 173533N.mm
𝑀𝑏 = 𝑀𝐷 =173533N.mm
𝑀𝑡𝑒 = √𝑀𝑏 ² + 𝑀𝑡 ²
𝑀𝑡𝑒 = 215219.2N.mm
𝜋
𝑀𝑡𝑒 = xƮxd³
16
F.O.S = 3.5
Ʈ = 190/3.5 = 54N/mm²
𝜋
215x10³ = x54xd³
16
d= 27.26 mm
d= 30mm
Result:-
51
2.2 Design of key:
8)Design a keyway and a key in motor shaft extension for a 20Kw , 1000
rpm motor having a mild steel shaft 50mm diameter , the extension of
80mm, the shear & crushing stresses mild steel are 60Mpa & 120Mpa,
check for the shear strength of the key against the normal strength of the
shaft ?
Given:-
P = 20Kw = 20x10³ w
N = 1000 rpm
d = 50 mm
Ʈ = 60Mpa = 60 N/mm²
l= 80 mm
To find :-
Design a key
Solution :-
T = P x60/2𝜋N
b = 1.59mm
b= d/4 = 50/4
b= 12.5 mm
𝜎𝑐 = 2Ʈ
52
b= 13 mm & t= 13mm = h
e= 1-0.2(13/50) – 1.1x(13/2x50)
(iv) Strength of shaft with keyway
𝜋
= xƮxd³xe
16
𝜋
= x60x50³x0.805
16
= 1185460 N
= 80x13x60x50/2
= 1560000N
= 1.316
Result:-
b=13 mm
t= 13mm
Given:-
P = 56.25 Kw = 56.25x10³ w
N = 120 rpm
Ʈ𝑠ℎ𝑎𝑓𝑡 =60N/mm²
Ʈ𝑚𝑢𝑓𝑓 =10N/mm²
Ʈ𝑘𝑒𝑦 =40N/mm²
53
𝜎𝑘𝑒𝑦 =100N/mm²
To find :-
Solution:-
𝑀𝑡 = 𝜋(Ʈ𝑠ℎ𝑎𝑓𝑡 )d³/16
P = 2𝜋N𝑀𝑡 /60
𝑀𝑡 = Px60/2𝜋N
𝑀𝑡 = 4476.23x10³N.mm
d³ = 16x4476.23x10³/𝜋x60
d= 72.423mm
d=80 mm
D → Outside Diameter
d → Inside Diameter
D → 2d+13
D → 2 x80+13
L = 3.5 d
L = 3.8 x8
L = 280 mm
54
Ʈ(𝑠𝑙𝑒𝑒𝑣𝑒) = 16x4476.23x10³ /𝜋 x173³ x(1-0.4624⁴)
Ʈ𝑠 =4.61N/mm² <10N/mm²
iii)Design of key :-
b=22 mm, h = 14 mm
l=140 mm
𝑀𝑡 = bxlxƮxd/2
Ʈ = 36.3N/mm²< 40 N/mm²
𝑀𝑡 = h/2 . l. 𝜎𝑐 .d/2
𝜎𝑐 = 𝑀𝑡 x2 x2/hxlx d
𝜎𝑐 = 4476.23x10³x2x2/14x140x80
l =160mm
Recalculate, 𝜎𝑐
55
Ʈ = 𝑀𝑡 x2/b.l.d = 4467.23 x10³ x2 /14 x160 x80
𝜎𝑐 = 𝑀𝑡 x 2x2/bxlxd
𝜎𝑐 = 4467.23x10³x2x2/14x160x80
𝜎𝑐 = 99.91 N/mm² < 100N/mm²
Result:-
D= 173mm b=22mm
d= 80 mm h = 14 mm
L =280mm l= 180 mm
Given :-
d= 180mm
P = 60 kw
N = 300 rpm
𝜎𝑐 = 172 N/mm²
To find :-
Solution:-
D.B.5.21 width of b = 28 mm
h= 16 mm
p= 2𝜋N𝑀𝑡 /60
60x10³ = 2𝜋x300x𝑀𝑡 /60
𝑀𝑡 = 1909.85 N.m
𝑀𝑡 = 0.5 𝜇1 b l d 𝜎𝑐
56
Assume 𝜇1 = 0.25
1909.85 x10³ = 0.5 x0.25x28x2xlx100x175
L = 31.18mm
D.B.5.21
L = 1.25d
L =1.25 x100
L = 125 mm
Taper key has a standard slope of 1:100
Result:-
b=28mm
h= 13 mm
l= 125mm
Taper = 1 : 100
Given:-
P = 10 kw
N = 960 rpm
To find:-
Solution:-
𝑀𝑡 = 99.47 N.m
𝑀𝑡 = 99.47x10³ N.mm
Assume (shaft, key , bolt, as mild steel with shear strength 50 N/mm² ,
crushing strength 90 N/mm² )
𝜋
99471.8 = x50xd³
16
d= 21.638 mm
57
d=25mm
𝜋
999471.8 = xƮℎ (50⁴ - 25⁴)/50
16
(iv)Design of key :-
d=25mm
b=9mm
h=7.5mm
Design is safe
(b) Design of flange :-
(v)Design of flange :-
𝜋𝐷 2
𝑀𝑡 = xƮℎ x𝑡𝑓
2
(iv)Design of bolts :-
𝜋
𝑀𝑡 = 𝑑𝑏 ²xƮ𝑏 xhx𝐷1 /2 (h=3 for D up to 50mm)
4
𝜋
99471.8 = x𝑑𝑏 ² x50x3x75/2
4
𝑑𝑏 = 4.74 mm
𝑑𝑏 = 6 mm
Result:-
d. D . L ,D, 𝑡𝑓 , 𝐷2 , 𝑡𝑝 (flange)
l. b, h (key)
𝑑𝑏 (bolt)
n(no of bolt)
59
Given:-
d= 35 mm Ʈ𝑠 = 63 N/mm²
n= 6 Ʈ𝑏 = 56 N/mm²
𝐷1 /2= 25 mm Ʈℎ = 10 N/mm²
To find:-
Solution :-
𝑑𝑏 = 11.01 mm
𝑑𝑏 =12 mm
D= 2d = 2x35=70 mm
Design is safe
(iii)Key dimensions
d=35mm
Width b = 10 mm
Height h = 8 mm
60
Length L = L = 1.5 d= 1.5(35) =52.5mm
𝑀𝑡 = lxbxƮ𝑘 xd/2
b= 20 mm, h = 11 mm
(v)Power transmitted
P = 2𝜋 N 𝑀𝑡 /60
P = 2𝜋x600 x800000/60
P = 50.26 x10⁶N.mm/s
P = 50.26 x10³N.m/s
P = 50.26 kw
Result :-
61
Material of the pin is as same as that of shaft and key, Draw the sketch
of the following coupling?
Solution :-
𝑀𝑡 = Px60/2𝜋N
𝑀𝑡 = 3183 x10³N.mm
d= 36 mm
D.B. 7.108 F= 12 mm D = 90 mm
n= 4 C = 55 mm
G = 30 mm E = 40 mm
t=4 mm H = 15 mm
𝑑𝑏 = 25 mm B = 132 mm
= ½ √28.48² + 4(17.99)²
= 22.94 N/mm²
Design of key
d= 36 mm
h=8 mm
l=E/2 = 40/2 = 20 mm
= 1.15 (318.3)
Ʈ𝑘 < Ʈ𝑘𝑖
b= 366.05 x10³x2/20x36x40
b= 25mm
𝑀𝑡 = W xn x D/2
W = 2033.6 N
𝜋
Ʈ =w/ xF²
4
Ʈ = 2033.6/𝜋/4 x12²
Ʈ = 17.99 N/mm²
𝑀𝑏 = W(G/2+t)
= 2033.6 (30/2+4)
𝑀𝑏 = 38638 N.mm
𝑀𝑏
𝜎𝑏 =
𝑍
𝜋
= 38638/ (12)³
4
𝜎𝑏 = 28.48N/mm²
𝜎𝑏
Maximum Principal stress = +1/2√𝜎𝑏 ² + 4Ʈ²
2
= 28.48/2+1/2√28.98² + 4(17.99)²
= 37.2N/mm²
Since the max. Principal stress l max.shear within limit ,Design is safe
63
𝑀𝑡 = lxh/2x𝜎𝑐𝑘𝑖 xd/2
h= 25mm
\ Design of Bush :-
L = G+t – 2/3 xF
= 30+4-2/3x12
L = 26 mm
𝑑𝑏 = 97.76 mm
Design of Hub :-
𝜋
𝑀𝑡 = x Ʈℎ x(𝐶 4 - A⁴)/C
16
Ʈℎ = 13.72 N/mm²
Design of flange :-
𝑀𝑡 = 𝜋c²/2xƮℎ xG
Result:-
d, F, n, G , t, 𝑑𝑏 , D, C, E, H
64
UNIT-3
TEMPORARY AND PERMANENT JOINTS
Given:-
b=100mm
t=12.5mm
𝜎𝑡 = 70 N/mm²
Ʈ = 56 N/mm²
To find:-
Single transverse ( 𝑙1 )
Solution:-
𝑙1 = d-t
65
𝑙1 = 100 -12.5
𝑙1 = 87.5 mm
P = b x t x 𝜎𝑡
P = 87500 N
𝑃1 = 0.707 x h x 𝑙1 x 𝜎𝑡
𝑃1 = 36112.23N
𝑃2 = 2 x0.707xh x 𝑙2 x Ʈ
𝑃2 = 366.5 𝑙2 N
P = 𝑃1 + 𝑃2
𝑙2 = 140.18mm
= 140.18 +12.5
= 152.68 mm
66
𝑙2 = 153 mm
Result:-
𝑙1 = 87.5 mm
𝑙1 = 153mm
Given:-
D= 60 mm
P = 7 KN = 7000 N
Ʈ = 85N/mm²
To find:-
67
Solution:-
𝜎𝑏 = 5.66 𝑀𝑏 /𝜋D²h
𝑀𝑏 = P x e
𝑀𝑏 = 7000x 150
𝑀𝑏 = 1050000 N.mm
𝜎𝑏 = 2 xƮ = 2 x 85 = 170 N.mm
170 = 5.66 x1050000 / 𝜋 x 60 ² x h
h= 3.09 mm
Result:-
h= 3.09 mm
Given:-
P = 25 KN
e = 500mm
Cross section = 100 x 150 mm
h= 6 mm
To find:-
68
Solution :-
A = t (2b + 2d)
A = 0.707 x6 x (2 (150) +2 (100))
(Area ) A = 2121 mm²
(shear stress) Ʈ = P/A
Ʈ = 25000/2121
Ʈ = 11.78 N/mm²
(Bending moment ) 𝑀𝑏 = P xe
𝑀𝑏 = 25000 x 500
𝑀𝑏 = 12.5 x 10 ⁶ N.mm
(Section Modulus) 𝑍𝑤 = t (bd + d²/3)
𝑍𝑤 = 0.707 x 6x (100 x 150 + 150²/3)
𝑍𝑤 = 95445 mm³
(Bending 𝜎𝑏 = 𝑀𝑏 /Z = 12.5 x10⁶ /95445 = 130.96 N/mm²
69
(maximum shear stress)
Ʈ𝑚𝑎𝑥 = ½ √𝜎𝑏 ² + 4Ʈ²
Ʈ𝑚𝑎𝑥 = ½ √130.96² + 4(11.78)²
Ʈ𝑚𝑎𝑥 = 66.53 N/mm²
Result:-
4)A plate of 200mm width and 600mm long is welded to a vertical plate
by placing it on the vertical plate to from a cantilever with projecting
length of 480mm and overlap b/w plates as 120 mm fillet weld is done
on all three sides. A vertical load 30KN is applied at the free end of the
cantilever plate parallel to its width of 200 mm . If the allowable weld
stress is 95Mpa, determine weld size ?
Given:-
d= 200 mm
L= 600 mm\
Projecting length = 480 mm
Overlap b/w the plate = 120 mm
P = 30 kN = 30 x10³ N
σ = 95 Mpa = 95x10⁶ N/m² = 95 N/mm²
To find:-
70
Solution :-
Twisting moment 𝑀𝑡 = P xe
𝑀𝑡 = 30 x10³ x567
𝑀𝑡 = 17010000 N.mm
r= √𝐺𝐵 2 + 𝐴𝐵2
71
200
r=√(120 − 𝑁𝑦 )² + ( )²
2
𝐽𝑤 = ((2x120+200)³/12 - 120²(120+200)²/2x120+200)
0.707 h
𝐽𝑤 = 2649407.5 h
Ʈ2 = 𝑀𝑡 x r/𝐽𝑤
Ʈ2 = 17010000 x 132.54/2649407.5h
Ʈ2 = 851/h N/mm² Ʈ1 Ʈ2
Ʈ
=√(964/ℎ)² + (851/ℎ)² + 2(96.4/ℎ)(851/ℎ)0.656
95 = 917.16 /h
h= 917.16/95
h = 9.65 mm
h= 10 mm
Result:-
h=10mm
72
Given:-
P = 40 KN
e= 300 mm
Ʈ = 100N/mm²
To find:-
Weld size h
Solution:-
Ʈ = P/A = 40000/268.66 h
Ʈ = 148.8/h N/mm²
𝑀𝑏 = P x e
73
𝑀𝑏 = 40000 x300
𝑀𝑏 = 12 x10⁶ N.mm
D.B.11.6
𝑍𝑤 = 4bd +d²/3
𝑍𝑤 = (4bd+d²/3)x0.707 h
𝑍𝑤 = 14705.6 h mm³
𝜎𝑏 = 816/h N/mm²
D.B.7.2
Ʈ𝑚𝑎𝑥 = ½ √𝜎𝑏 ² + 4Ʈ²
816 2 1488
= 1/2√( ) +( )²
ℎ ℎ
100 = 434.3 /h
h= 4.34 mm
Result:-
h=5mm
74
Given:-
P = 25 kN
Ʈ = 75 N/mm²
To find:-
Solution:-
A = t (2b+2d)
A = 0.707x h x(2(150)+2x100)
A = 353.5 h mm²
Ʈ = P/A= 25000/353.5h
Ʈ = 70.72/h N/mm²
𝑀𝑏 = P xe
= 25000 x 500
𝑀𝑏 = 12.5x10⁶N.mm
𝑍𝑤 = t (bd + d²/3)
𝑍𝑤 = 0.707 xh (100 x150+150²/3)
𝑍𝑤 =15907.5h mm³
𝜎𝑏 = 𝑀𝑏 /𝑍𝑤
75
785.79 2 70.72 2
75 = ½√( ) +4×( )
ℎ ℎ
h= 5.32 mm
Result:-
h= 5.32mm
Given:-
P = 2KN =2000 N
Ʈ = 25 N/mm²
Solution:-
A = 2x0.707 xh x s
A =2 x 0.707 x h x40
A = 56.56 h mm²
Ʈ = P/A = 2000/56.56(h)
Ʈ = 35.36/h N/mm²
e= 120 mm
D.B.16.3 𝜎𝑏 = 4. 24 Pe/hl²
𝜎𝑏 = 4.24 x2000x120/h x40²
𝜎𝑏 = 636/h N/mm²
Ʈ𝑚𝑎𝑥 = ½√𝜎𝑏2 + 4Ʈ2
636 2 35.36
= 1/2√( ) + 4( )²
ℎ ℎ
Ʈ𝑚𝑎𝑥 =320/h N/mm²
76
320/h = 25
h=12.8 mm
Result:-
8)Find the minimum shear stress induced in the weld of 6mm size when
a channel shown in figure is weld to plate and loaded with 20KN
force at a distance of 200 mm?
Given:-
h= 6 mm
P = 20 KN = 20x10³ N
e= 200mm
To find:-
Ʈ𝑚𝑎𝑥
Solution:-
A = t(2b +d)
A = 0.707 x6 (2x40+90)
A = 721.14 mm²
Ʈ =P/A
Ʈ =20000/72.14N/mm²
77
𝑀𝑏 =Px e
𝑀𝑏 =20000 x200
𝑀𝑏 =4x10⁶ N.mm
𝑍𝑤 = 20997.9 mm³
𝜎𝑏 = 𝑀𝑏 /𝑍𝑤
= 4 x10⁶ /20997.9
𝜎𝑏 =190.49 N/mm²
Result:-
Given:-
D = 60mm
h= 6 mm
Ʈ = 140 N/mm²
To find:-
78
Solution:-
Ʈ = 2.83 𝑀𝑡 /𝜋hD²
𝑀𝑡 = 3356.95 x10³N.mm
Result:-
𝑀𝑡 = 3356.95x10³ N.mm
𝑀𝑏 =3356.95x10³N.mm
Given:-
σ =100 N/mm²
P = 60 KN = 60 x10³ N
To find:-
79
(ii) Length of weld at the top 𝑙𝑎
(iii) Length of weld at the bottom 𝑙𝑏
Solution:-
D.B. 11.3
𝑙𝑎 = 1.414 P 𝑒2 /σhb
𝑙𝑎 = 1.414 x60x10³x80/100x5x130
𝑙𝑎 = 104.4mm
𝑙𝑎 = 104.4 +12.5 (adding 12.5 mm for stopping & starting of weld run)
𝑙𝑎 = 117 mm
𝑙𝑏 = 1.414x60x10³x50/100x5x130
𝑙𝑏 = 65.26 mm
80
𝑙𝑏 = 65.26+12.5
𝑙𝑏 = 77.76 mm
Result:-
h= 5 mm
𝑙𝑎 = 117 mm
𝑙𝑏 = 78 mm
Given:-
P =140KN
𝜎𝑡 = 75 N/mm²
Ʈ = 65N/mm²
𝜎𝑐 =140N/mm²
To find:-
Solution:-
𝜋
P = d² 𝜎𝑡
4
𝜋
140 x10³ = x d² x 75
4
d=48.75 mm = 50mm
81
Thickness of pin head 𝑡2 = 0.5d = 25 mm
𝜋
P = 2x 𝑑1 ² Ʈ
4
𝜋
140x10³= 2 x x50² x Ʈ
4
P = (𝑑2 - 𝑑1 )t xƮ
140 x10³ = (100-50)x 62.5 xƮ
Ʈ = 44.8 N/mm² < 65 N/mm²
Design is safe
P =(𝑑2 - 𝑑1 )t 𝜎𝑡
Design is safe
P = (𝑑2 - 𝑑1 ) 𝑡1 2𝜎𝑡
82
𝜎𝑡 = 37.33 N/mm² < 75 N/mm²
Design is safe
P = 𝑑1 t 𝜎𝑡
Design is safe
P = 𝑑1 𝑡1 2 𝜎𝑐
Design is safe
Result:-
d, 𝑑1 , 𝑑2 , 𝑑3 , t , 𝑡1 , 𝑡2
12)Design a cotter joint with one gib to transmit a force of 50KN along
a rod of square section .Assume that the gib, rod and cotter are made of
same material with the following available stresses?
Given:-
𝜎𝑡 = 20N/mm²
𝜎𝑐 = 50 N/mm²
Ʈ = 15 N/mm²
F = 50 KN
To find:-
83
Solution:-
F = h² (𝜎𝑡 )
50x10³ = h² x 20
h= 50 mm
w=h= 50mm
F = 2 B t Ʈ𝑎𝑙𝑙
50000 = 2B x 15 x15
F = 2 (w. 𝑡1 - t. 𝑡1 ) (𝜎𝑡 )
𝑡1 = 35.7mm say 36 mm
F = 2 t 𝑡1 𝜎𝑐
50000 = 2 x36 x 15 x 𝜎𝑐
𝜎𝑐 = 46.29 N/mm²
Design is safe
84
F = 2 x𝑙2 x hxƮ𝑎𝑙𝑙
𝑙2 = 34 mm
7. Other Parameters
𝑙1 = t = 15 mm
= 50+2(36+20)
= 162 mm
Result :-
13)A cast iron cylinder head is fastened to cylinder of 500mm bone &stud
bolts .The maximum pressure inside the cylinder is 2Mpa. The stiffness of
part is thrice the stiffness of the bolt. What should be the initial tightening
load so that the point is leak proof at maximum pressure? Alse choose a
suitable bolt for the above application?
Given:-
D =500 mm
n=8
𝑃𝑚𝑎𝑥 = 2 N/mm²
𝑞𝑝 = 3𝑞𝑏
To find:-
85
Solution:-
𝜋
P = 2x x 500²
4
P = 392699.08 N
4)If the force this force is not enough to maximum external load
𝑃𝑗 = 36065.54 N
𝑃𝑏 = 𝑃𝑖 + ∆P
𝑃𝑏 = 49271.84 N
𝐴𝑐 = (60x49271.84/300)⅔
𝐴𝑐 = 459.56mm²
Result:-
86
14)A bracket is fitted to a channel with 4 bolts shown in figure ,distance
b/w bolts 1 and 3 is equal to the distance b/w bolts 2 and 4 which is
150 mm. Eccentricity is 300mm find a suitable bolts?
Given:-
P = 40000 N
e= 300mm
To find:-
Bolt diameter
Solution:-
= 40000 N
87
FR =√F1 ² + F2 ² + 2F1 F2 cosQ
FR =F1 + F2
= 10000+ 40000
FR = 50000 N
FR /Ac = σy /n
50000/Ac =300/ 3
Ac = 500 mm²
Result:-
Given:-
P =20000 N
e=200 mm
𝑙1 = 50 mm
𝑙2 = 250 mm
𝑛1 = 2
𝑛2 = 3
To find :-
88
Solution:-
F1 = 1038.96 N
F2 = 5194.8N
F2 > F1
σ2 = F2 /Ac = 5194.8/ Ac
Ʈ = P/( n1 + n2 ) Ac = 20000/(2+3) Ac
= 4000 / 𝐴𝑐
= ½√(5194.8/ 𝐴𝑐 )² + 4(4000/ 𝐴𝑐 )²
Ʈ𝑚𝑎𝑥 = 4768.65/ 𝐴𝑐
But, Ʈ𝑚𝑎𝑥 = 𝜎𝑦 /n
89
𝜎𝑦 = 300 N/mm² and FOS = 3
4768.65/ Ac = 300/3
Ac = 47.68 mm²
90
UNIT-4
ENERGY STORING ELEMENTS AND ENGINE COMPONENTS
1)A helical spring is made from a wine of 8mm diameter and outside
diameter of 75mm .The spring has 6 Numbers of active coils. If the
permissible stress in shear is 350 N/mm², and the modulus of rigidity is
84 KN/mm², Find the axial load which the spring can taken and the
deflection produced?
Given:-
Spring wine d = 8 mm
n= 6
Ʈ = 350N/mm²
G =84 KN/mm²
To find:-
Solution:-
= 4(8.375)-1/4(8.375)-4+0.615/8.375
K s = 1.175
Ʈ = K s 8 P C/π d²
P = 893.9N
91
y= 8 P C³n/Gd
y= 8 ×893.9×8.375²×6/84 × 10³ × 8
y= 37.5 mm
Result:-
(i) P = 893.9 N
(ii) y= 37.5 mm
Given:-
Pmin = 90 N
Pmax = 135 N
Deflection y = 7.5 mm
Spring index C= 10
Ʈ = 480 N/mm²
To find:-
Solution :-
K s =1.1448
Ʈ = K s 8 P C/π d²
d= 2.86 mm
d= 3 mm
D =c×d
D = 10×3
D = 30 mm
Do = D +d = 30+3
Do = 33 mm
y= 8 P C³ n/Gd
= 5+2
nt =7
Result:-
d, Do , D , n , Lf
93
3) A helical spring is subjected to a load varying from 400N to 1000N
having the spring index of 6 and the design factor of safety is 1.25, the
compression of the spring at the maximum load is 30mm,Design the
helical compression spring take the yield stress in shear as 110N/mm²
endurance shear as 350 N/mm², and the modulus of rigidity for the spring
material as 80× 10³ N/mm²?
Given:-
Pmin = 400N
Pmax = 1000N
C =6
ns = 1.25
y=30 mm
Ʈy = 110 N/mm²
G = 80×10³N/mm²
To find:-
Solution:-
Pm = 1000+400/2
Pm = 700 N
= 1000-400/2
Pa = 300 N
= 1+ 0.615/6
K sh = 1.1025
94
Mean shear stress
Ʈm =11791.47/d²
Ʈa = 8K s Pa C/ πd²
1/1.25 = 5879.96/d²/110+11623.02/d²
1/1.25=87.57/d²
d= 109.46
d= 10.46mm
D = C× d
D = 6 × 10.6 =63.6 mm
n= 14.72
n=15
7.101 nt = n+2
95
nt = 15+2 = 17
Ls = dn+2d
Ls = 180.2 mm
Lf =Ls + y
= 180.2 +30
Lf = 210.2 mm
P = Lf -Ls /nt + d
P = 12.76 mm
α = tan−1 (P/πD)
α = 3.65°
(viii)Spring rate(q)
q= Pmax /y
q= 1000/30
q= 33.33 N/mm
Result:-
d, D, n , nt , Ls , Lf , P, α , q
96
4)A relief value must blow off at a pressure of 1.25 Mpa and should lift
by 6mm for a 6% increase in pressure .The value diameter is 65mm .Take
the spring index as 8 maximum allowable shear stress of the spring
material is 600N/m² .The diameter of the available spring wires in mm
13.14.15.16 and 18. Modulus of rigidity is 81370N/mm consider Wahl’s
correction factor Take inactive numbers of turns as 1 design the value
spring?
Given:-
Pv = 1.25Mpa = 1.25N/mm²
y= 6 mm
Increase in Pv = 6%
dv = 65 mm
C =8
G = 81370 N/mm²
In Active no of turns = 1
To find :-
Solution:-
= π × 65²/4
Av = 3318.3 mm²
= 1.25×3318.3
P1 = 4147.87 N
97
Pv max = Pv +increase in Pr
= 1.25+6/100 ×1.25
= 1.325 ×3318.3
P2 = 4396.75N
Ks = 1.184
d² = 176.75
d = 13.29 mm
Choose d = 14 mm
D = C× d
= 8× 4
D = 112 mm
Do = D+d
= 112+14
Do = 126 mm
P = P2 -P1
98
= 4396.75 – 4147.87
P = 248.88 N
y= 8P C³n/G.d
n
6 = 8× 248.88 × 83 × × 14
81370
n= 6.7
Solid length = Ls
Ls = dn + d
Ls = 107.8 mm
Lf = Ls +deflection
= 107.8 +6
Lf = 113.8 mm
P = Lf - Ls / nt + d
P = 14.78 mm
∝ =tan−1 (P/πD)
∝ = 2.4°
q= Gd/8C³n
99
14
= 81370× × 83 × 6.7
8
q = 41.51 N/m
Result:-
d, D, Do , n , nt , Lf , Ls , P, ∝ , q
5)A close coiled helical compression spring has plain ends and is to fit
over a 2.5mm diameter rod When a compression force of 100N is applied
to the spring it compresses by 50mm.If the spring has a preferred wire
diameter 4 mm, and the spring material has a maximum allowable shear
stress of 180MN/m² and a modulus of rigidity of 81GN/m² Determine the
Given:-
Diameter of rod = 25 mm
Force P = 100 N
Deflection y = 50 mm
Wire diameter d = 4 mm
To find :-
(ii)Diametrical clearance
(iii)Number of coils n
(iv)Solid length Ls
100
Solution :-
= 4(D/d)-1/4(D/d)-4 +0.615/(D/d)
D = 39.44 mm
D = 40 mm
(ii)Diameter clearance
40-4- 25 = 11mm
(iii)Deflection
y= 8PD³ n/ Gd⁴
n= 20.25 coils
Ls = d(n+1)
= 4(20.25+1)
Ls = 85mm
101
Result:-
D = 40 mm
Clearance = 11 mm
n=20.25
Ls = 85 mm
Given:-
Number of spring ns = 4
σ= 600 N/mm²
No of leaves =10
y= 80mm
To find:-
Solution:-
2P = 140× 10³/4
P = 17500 N
102
600 = 6× 17500 × 500/10× bt²
bt³ = 8750
bt³ = 82031.25
bt² .t = 82031.25
8750 t = 82031.25
t= 82031.25/8750
t = 9.375 mm
t = 10 mm
b = 90 mm
Result:-
Given:-
Deflection y = 150 mm
σb = 800 N/mm²
L = 600mm
To find :-
103
(ii)Thickness of the leaf t’
Solution :-
E1 = ½×P×y
P = 8000N
σb = 6PL/nbt²
600
800= 6 × 8000 ×
nbt2
nbt² = 36000
y=6PL³/Enbt³
E = 2× 105 N/mm²
nbt³ = 345600
nbt².t = 345600
(36000) t = 345600
t=345600/36000
t= 9.6 mm
nb = 345600/t³
nb= 345600/9.6³
nb = 390.625
n= 390.625/80
n= 5
104
Result:-
Number of leaves n = 5
Given:-
σb = 420N/mm²
To find:-
105
Solution:-
n= ng +ne = 12+ 3 = 15
n× t /b = 3
15t/b = 3
b=5t
2L = 900 mm
L =450 mm
Since all the leaves are stressed to the same stress when loaded
σb = 6PL/nbt²
t³ = 2142.86
t = 12.89mm
t = 13 mm
b= 5 × 13
b= 65 mm
x = 6PL³/Enbt³
4503
= 6× 25 × 103 × × 105 × 15 × 65 × 13³
2.1
X = 30.38 mm
106
= 2× 3 × 12 × 25 × 10³/15(2 × 12 + 3 × 3)
Pb = 3636.36 N
Result:-
b=65 mm
t = 13 mm
x= 30.38mm
Pb = 3636.36N
Given:-
N =500rpm
P = 7200 kg/m³
To find:-
Solution :-
π π
1 cm = 60× = rad
180 3
π
1 c.m² on turning moment diagram = 2500 ×
3
= 2617.99 N.m
107
Total energy A = F
Energy at B = E+ 1.60
G = E+1.62-1.62 =Eenergy at A
∆E = 1.97× 2617.99
∆E = 5157.44 Nm
∆E = Iw² Cs
6x10⁶=7200 x V²
V = 28.87 m/s
(peripheral velocity)
V = πDN/60
28.87 = π × D × 500/60
D =1m
∆E = Ex2 Cs
5157.44 = E x2 x0.02
E = 128936 N.m
E = ½ mv²
m= 311.76 kg
311.76 = 2h xh x π x 1 x 7200
h= 0.083 m = 83 mm
b=2h = 2 x 83 = 166 mm
Result :-
D = 1 m , m = 311.76 kg, h = 83 mm
b = 166 mm
109
UNIT-5
BEARINGS
Given:-
D = 150 mm
W = 40KN = 40x10³
n= 900 rpm
To find:-
Solution:-
Step 1:-
D.B.7.31 L/ D = 1 to 2 =1.5
L = 1.5 x 150
L = 225 mm
Step 2 :-
P = W/LD
P = 1.185 N/mm²
Step 3 :-
P =1.185 N/mm
110
P = 11.85 kgf/cm²
D.B.7.41 40 cp and 60° c the net standard higher value of SAE 40 oil
Z = 40 c.p
Step 4
𝜇 = 0.0121
Step 5
D.B 7.34
Hg = 𝜇 . w.v
V = 𝜋DN/60
V =𝜋 x 0.15x900/60
V = 7.0686 m/s
Hg = 0.0121 x40000x7.0686
Hg = 3421.56 w
∆𝑡 = ½ (𝑡𝑜 - 𝑡𝑎 )
∆𝑡 = ½ (60 -28 )
∆𝑡 = 16° C
𝐻𝑑 = 80.6 W
111
𝐷𝑏 = D +C
= 150 +0.15
𝐷𝑏 = 150.15 mm
Result:-
Given:-
P = 12 Mw = 12 x10⁶ W
n= 1000 rpm
𝑇𝑎 = 16° C
𝑇𝑜 = 60 ° C
Z = 23 CP = 23 x10−3 N.S/m²
To find:-
Solution:-
D.B.7.31 P = 7 to 20 kgf/cm²
Zn/ P = 1422.3
23 x1000/P = 1422.3
L/D = 1 to 2
L/D = 1.5
112
P = 2𝜋N(𝑀𝑡 )/60
𝑀𝑡 = 114591.56 N.m
FOS = 1.5
Ʈ = 0.55 𝜎𝑦 /FOS
Ʈ = 256.68 N/mm²
𝜋
W.K.T 𝑀𝑡 = Ʈ D³
16
D = 131.5 mm
D = 132 mm
L/D = 1.5
L = 198 mm
𝜇 = 0.00616
𝜋𝐷𝑁 1000
V = = 𝜋 × 0.132 × = 6.91 m/s
60 60
Hg = 𝜇w v
113
Hg = 1799.3 w
∆𝑡 = ½ (𝑡𝑜 - 𝑡𝑎 )
∆𝑡 =1/2(60 -16 )
∆𝑡 = 22 ° C
Hd = 86.4 w
Hg > Hd
Result :-
3)Design a journal bearing for centrifugal pump for the following data,
Load on the journal 12 KN, Diameter of the journal 75 mm, Speed 1440
rpm, Atmosphere temp 16° C and operating temp 60° absolute viscosity
of oil at 60°𝐶 23 centipoise ?
Given:-
W = 12 KN
D = 75 mm
n= 1440 rpm
𝑡𝑎 =16 °𝐶
𝑡0 = 60°𝐶
Z = 23 centipoises
To find:-
Step 1 :
L/D = 1.5
L = 1.5 (75 )
L = 112.5 mm
Step 2:
P = W/LD
Step 3 :
Step 4:
𝜇 =0.005933
Step 5:
Hg = 𝜇 w v
V = 5.66 m/s
∆t = ½ (𝑡𝑜 - 𝑡𝑎 )
= ½ (60-16)
∆t = 22 °𝐶
Hd = (∆t+18)² 𝐿𝐷/𝐾
Hd = 27.8 w
𝐷𝑏 = D+C
= 75 +0.15
𝐷𝑏 = 75.15 mm
Result:-
4)A 50mm diameter journal bearing rotates 1500 rpm , L/D =1 , radial
clearance is 0.05mm, minimum film thickness 0.01mm , calculate the
maximum radial load that the journal bearing can carry and this load
, calculate the power lost in friction and increase in the oil temperature
assumed Hg = Hd Absolute viscosity = 20 x10³ Pas , SP gravity of oil
0.88, SP. heat of oil 2.1 kJ/kg °𝐶 ?
Given:-
D = 50 mm = 0.05 m
n= 1500 rpm
L/D = 1
C /2 = 0.05 mm
ℎ𝑜 = 0.01 mm
116
L = 50 mm
S = 0.88
To find :-
Solution:-
S = 𝑍 ′ 𝑛′ /P (D/C)²
P = 2802690.58 N/m²
P = W/LD
W = 7006.73 N
𝜋𝐷𝑁
V =
60
V = 3.93 m/s
D.B.7.40
B = 360° , S = 0.0446
𝜇 (D/C) =1.7
𝜇 =3.4x 10−3
117
Hg = 𝜇 w v
Hg = 93.62 w
Hd = 93.62 w
D.B. 7.36
Q = 4.62 x r x(C/2) NL
Q = 7218.75 mm³/s
m= Density x discharge
W.K.T
Hd = mCp∆t
∆𝑡= 7.02°𝐶
Result:-
Given:-
D = 40 mm
118
N = 400 rpm
𝐹𝑟 = 5000 N
𝐹𝑎 = 3000 N
𝐿ℎ = 1000 hrs
To find:-
Bearing type
Solution :-
𝐹𝑎
= 3000/ 5000 = 0.6
𝐹𝑟
𝐹𝑎
< 0.7 , a single row deep grove ball bearing may be
𝐹𝑟
suitable
Equivalent load
P= ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
P = 7788 N
119
C/P = 2.9
C = 2.9 x7788
C = 22588.2 N
Since, the dynamic load rating of SKF 6208 bearing , is more than the
required dynamic load capacity, the select bearing is suitable
Result :-
Given:-
𝐹𝑟 = 10 KN
𝐹𝑎 = 3 KN
n= 800 rpm
𝐿ℎ = 4000 hrs
Bearing series 63
To find :-
Solution:-
𝐹𝑎
= 3000 /10000 = 0.3 >e
𝐹𝑟
Equivalent load
P = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
P = 12120 N
120
D.B.4.6 800 rpm and 4000 hrs
C/P = 5.75
𝐿ℎ = 4300 hrs
L = 60 n 𝐿ℎ /10⁶
Result :-
7)Find the rated load of a deep groove ball bearing for the following
load cycle
1. 3000 1000 15
2. 3500 1000 20
3. 3500 100 30
4. 500 2000 35
Also find the 90% life of ball bearing used is 6207 with dynamic
capacity 19620N?
Given:-
121
Radial load 𝐹𝑟 = 3000 N , 𝐹𝑎 = 1000 N, 𝑡1 = 15 %
C = 19620 N
To find:-
Solution:-
𝐹𝑎
= 1000 /3000 = 0.333 > e
𝐹𝑟
Equivalent load 𝐹1 = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
𝐹1 = 4320 N
𝐹2 = (X 𝐹𝑟 + Y 𝐹𝑎 ) S
𝐹2 = 4740 N
𝐹3 = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
𝐹3 = 2940 N
𝐹4 = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
𝐹4 = 4020
122
𝐹𝑚 = {(4320³𝑛1 0.15)+(472 0³𝑛2 0.2) + 2940³𝑛3 0.3) +
(4020³𝑛4 0.35))/n+n+n+n}⅓
𝐹𝑚 = 2513.07 N
Equivalent P = 𝐹𝑚 = 2513.07N
C/P = 7.81
𝐿ℎ = 7940hrs
Result :-
Given:-
Bearing 6002
𝐹𝑎 = 1000 N
𝐹𝑟 = 2200 N
To find:-
Solution:-
D.B.4.14 𝐶𝑜 = 28500N
C = 55900 N
D.B.4.4
𝐹𝑎 /𝐶𝑜 = 0.035
X = 0.56 , Y = 1.83
Equivalent load P = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
P = 39806 N
𝐶
L= ( )𝑏
𝑃
= (55900/ 39806 )³
𝐿50 = 5 x2.77
Result:-
9)A 30BCo3 deep groove ball bearing is to operate at 1600 rpm and
carries 8KN radial load and 6 KN thrust load. The bearing is subjected to
a light shock load. Determine the rating life of the bearing?
Given:-
N=1000 rpm
𝐹𝑟 = 8 KN = 8000 N
124
𝐹𝑎 = 6 KN = 6000 N
To find :-
Solution:-
X = 0.411 y =?
𝑥1 = 0.25 𝑦1 = 0.37
𝑥2 =0.5 𝑦2 = 0.44
Y = 0.415
𝐹𝑎
= 6000/8000 = 0.75
𝐹𝑟
X = 0.411 , y =?
𝑥1 = 0.25 , 𝑦1 = 1.2
𝑥2 =0.5 , 𝑦2 = 1
Y = 1.07
X = 0.56 , y = 1.07
125
P = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
P =16350 N
L= 60 n𝐿ℎ /10⁶
Result :-
126
TWO MARKS QUESTIONS AND ANSWERS
UNIT-1
127
Optimization by numerical algorithm
Illustration 40Cr14
It means average carbon content is (40/100)=0.4% it means , it
can vary from say , 0.3% to 0.5%
Chromium is the principle alloying element with (14/100)=0.14%
It means, it can vary from say, 0.13% to 0.15%
128
9. Define tolerance?
Fit refers to the relative tightness or looseness between two mating parts.
129
For component subjected to static loading Yield strength is
considered .
130
18. What is meant by eccentric loading ?
Eccentric loading refers to loads applied away from the
centroidal axis of the member.
2. Providing fillets
Solution :
22. List the important factors that influence the magnitude of factor
of safety
131
23.What are the factors that govern selection of materials while
designing a machine component ?
(iv) Cost
Whichever is maximum
132
28.Define the terms “Equivalent torque and equivalent moment”
And
Ʈ 𝑒𝑞 = Ʈ𝑦 /n = Ʈ𝑚 + 𝐾𝑓 . Ʈ𝑎 . Ʈ𝑦 / Ʈ−1
𝜎𝑒𝑞 = 𝜎𝑦 /n = 𝜎𝑚 + 𝐾𝑓 . 𝜎𝑎 . 𝜎𝑦 / 𝜎−1
Where
Ʈ 𝑒𝑞 = Equivalent twisting
133
32.What are the methods used to improve fatigue strength ?
Unit- 2
Given data:
Length of the shaft , l = 750 mm
Shear stress, Ʈ = 40 Mpa = 40 N/mm²
Angle of twist , 𝜃 = 0.017 radian
Modulus of rigidity , G =0.8 x10⁵
134
To find:
Diameter of shaft , d
Solution:
We know that the torsional moment of the shaft
𝜋
𝑀𝑡 = x Ʈ x d³ and
16
𝜋 𝜋𝑑4
Angle of twist , 𝜃 = 𝑀𝑡 x l /GJ = x Ʈ x d³ x l / G x( )
16 32
= 2Ʈl / Gd
0.017 = 2 x 40 x750 / 0.8 x 10⁵ xd
d= 44.11 mm.
The standard diameter , d = 45 mm
𝜋 𝜋
Power ratio, 𝑃𝐵 /𝑃𝐴 = x Ʈ𝐵 x 𝑑𝐵 ³ / xƮ𝐴 x 𝑑𝐴 ³ = 𝑑𝐵 ³/ 𝑑𝐴 ³
16 16
= 80 x (1/2)³ = 10kW
5. Why a hollow shaft has greater strength and stiffness than solid
shaft of equal weight ?
135
6. What do you mean by stiffness and rigidity with reference to
shafts?
136
12. Difference between keys and splines?
i) Shear force
ii) Bearing force
iii) Tensile force
14. What is coupling ?
The elements which join two shafts are called coupling .It is
used to connect sections of long transmission shafts to the shaft of
a driving machine . Couplings are used to connect sections of long
transmission shafts and connect the shaft of a driving machine to
the shaft of a driven machine .
15. What are the various factors Involved in good shaft coupling ?
1) Rigid couplings
i) Sleeve couplings
ii) Flange couplings
iii) Clamp couplings
2) Flexible couplings
i) Universal couplings
ii) Oldham’s couplings
iii) Pushed pin couplings
Unit-3
1. What is a stud?
2. What do you understand by the single start and double start threads?
138
Single starts means that there is only one ridge wrapped around
the cylinder of the screw’s body. Each time that the screw’s body
rotates one turn (360°) , it has advanced axially by the one pitch
distance. Double -start means that there are two ridges wrapped
around the cylinder of the screw’s body. Each time that the
screw’s body rotates one turn (360°), it has advanced axially by
the two pitch distance.
3. Why are ACME threads preferred over square thread for power
screw?
Acme thread is easier to machine and is stronger than the
square thread. Acme threads are thicker and wider and they operate
better in environments with dirt and debris .
139
v) Bending stress if the surfaces under the bolt head or
nut are not perfectly normal to the bolt axis.
i) Bolts in a crankshaft
ii) Bolts used in the head of a cylindrical pressure vessel
with repeated filling and discharging.
10. Under what force, the big end bolts and caps are designed ?
The big end bolts and caps are designed for inertia (𝐹𝑖 )
force due to reciprocating parts.
i) High clamping
ii) Small tightening force requirement
iii) Easy manufacture
iv) Simple design.
i) High clamping
ii) Small tightening force requirement
iii) Easy manufacture
iv) Simple design.
140
If the friction angle (∅ ) is greater than helix angle (𝛼 ) of the
power screw, the torque required to lower the load will be
positive indicating that an effort is applied to lower the load. This
type is screw is known as self - locking screw. The efficiency of
the self - locking screw is less than 50 %.
i) Forge welding
ii) Electric resistance welding and
iii) Fusion welding
18. Write any two advantages of welded joints over riveted joints?
141
iii) The design of welded assemblies can be easily and
economically modified to meet the changing product
requirement.
iv) The quality and strength of welded joints also depend
upon the skill of the labours.
i) Forge welding.
ii) Electric resistance welding and
iii) Fusion welding.
142
It is defined as the minimum size of the weld for a a given
thickness of the thinner part joined or plate to avoid cold cracking
by escaping the rapid cooling.
25. What are the reasons of replacing riveted joint by welded joint in
modern equipment ?
1. Crushing of rivets
2. Shear of rivets
3. Tearing of the plate at the edge
4. Tearing of the plate between rivets
28. What is meant by the efficiency of the riveted joint?
Unit-4
i) Helical spring
ii) Spiral spring
iii) Leaf spring
iv) Conical spring
v) Disc spring or Belleville springs
Given data :
Stiffness of first spring 𝑞1 = 12 N/mm
Stiffness of second spring , 𝑞2 = 8 N/mm
Deflection , y = 50 mm
To find:
Force, P
Solution :
When two springs are arranged in series ,
1/q = 1/𝑞1 + 1/𝑞2
= 1/12 +1/8
Total stiffness , q = 4.8 N/mm
Stiffness , q = Load / Deflection
4.8 = P/ 50
144
P = 240 N
145
11. What are the different styles of end for helical compression
spring?
Given data:
𝑞1 = 100 N/mm
𝑞2 = 50 N/mm
P = 750 N
To find:
Deflection
Solution :
146
= 5 mm
𝑌𝑒𝑞𝑢 = 𝑦1 +𝑦2
1. Structural members
2. Energy absorbing devices.
148
22. What is the purpose of flywheel that is used in an IC engine?
∆E = 𝐸𝑚𝑎𝑥 - 𝐸𝑚𝑖𝑛
149
= 2(𝑤𝑚𝑎𝑥 - 𝑤𝑚𝑖𝑛 )/𝑤𝑚𝑎𝑥 +𝑤𝑚𝑖𝑛
1. Radial stress
2.Tangential stress
28. What are the type of external forces act on connecting rod?
29.Why is piston end of a connecting rod kept smaller than the crankpin
end ?
31. At what angle of the crank the twisting moment is maximum in the
crankshaft?
The crank angle for maximum moment usually lies between 25°
and 35° from TDC for petrol engine and between 30° and 40° for diesel
engines.
150
∆E = 𝐸𝑚𝑎𝑥 - 𝐸𝑚𝑖𝑛
Unit-5
151
A journal bearing is a sliding contact bearing which gives lateral
support to the rotating shaft.
152
7. Explain the term dynamic load carrying capacities of rolling
contact bearing?
153
v) Creep.
154