PANIMALAR ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

21ME1502-DESIGN OF MACHINE ELEMENTS AND APPLICATIONS

UNIT I : STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS

PART A
1. Define: Factor of safety. List out the factors involved in arriving at factor of
safety
The ratio between maximum stresses to working stress is known as factor of safety.
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑆𝑡𝑟𝑒𝑠𝑠
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 =
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠
The factors involved in arriving at factor of safety:
 Material properties
 Nature of loads
 Presence of localized stresses
 Mode of failures
 Effects of size, working environment, manufacturing process
 Effects of stress concentration
 Reliability requirements
 Risk to life and property
2. Give the different failure theories and the type of materials for which these
theories are applicable.
• Maximum principal stress theory. (Rankine theory) – Brittle material.
• Maximum shear stress theory. (Guest’s or Coulomb’s theory) – Ductile material
• Maximum principal strain theory. (St. Venant’s theory) – Not confirmed
• Maximum strain energy theory. (Haigh’s Theory) – Ductile Materials.
• Maximum distortion energy theory. (Shear Energy / Von Mises Hencky /
Octahedral theory) – Ductile materials.
3. What is stress concentration? Give some methods of reducing stress
concentration.
Whenever a machine component changes the shape of its cross-section, the simple
stress distribution no longer holds good and the neighbourhood of the discontinuity
is different. This irregularity in the stress distribution caused by abrupt changes of
form is called stress concentration. It occurs for all kinds of stresses in the presence
of fillets, notches, holes, keyways, splines, surface roughness or scratches etc.
Methods of reducing stress concentration.
• Avoiding sharp corners.
• Providing fillets.
• Use of multiple holes instead of single hole
• Undercutting the shoulder parts.
4. What is the importance of principal stresses?
There are many cases in practice, in which machine members are subjected to
combined stresses due to simultaneous action of either tensile or compressive
stresses combined with shear stresses. In many shafts such as propeller shafts, C-
 frames etc., there are direct tensile or compressive stresses due to the external force
and shear stress due to torsion, which acts normal to direct tensile or compressive
stresses. The shafts like crank shafts, are subjected simultaneously to torsion and
bending. In such cases, the maximum principal stresses, due to the combination of
tensile or compressive stresses with shear stresses may be obtained.
5. What is meant by ‘hole basis system’ and ‘shaft basis system’? Which one is
preferred and why?
1. Hole basis system. When the hole is kept as a constant member (i.e. when the lower
deviation of the hole is zero) and different fits are obtained by varying the shaft size, as
shown in Fig. (a), then the limit system is said to be on a hole basis.

2. Shaft basis system. When the shaft is kept as a constant member (i.e. when the upper
deviation of the shaft is zero) and different fits are obtained by varying the hole size, as
shown in Fig. (b), then the limit system is said to be on a shaft basis.
It may be noted that from the manufacturing point of view, a hole basis system is always
preferred. This is because the holes are usually produced and finished by standard tooling
like drill, reamers, etc., whose size is not adjustable easily. On the other hand, the size of
the shaft (which is to go into the hole) can be easily adjusted and is obtained by turning
or grinding operations.
PART B
1. A wall bracket with a rectangular cross section is shown in Fig. 1.1. The depth
of the cross section is twice the width. The force P acting on the bracket at 60°
to the vertical is 5 kN. The material of the bracket is grey cast iron FG 200 and
the factor of safety is 3.5. Determine the dimensions of the cross section of the
bracket. Assume maximum principal stress theory of failure.

Figure 1.1
Solution:
Given: b = 2t, FG 200, σu = 200 MPa and FOS = 3.5, then [σt] = 200/3.5 = 57 MPa.
Resolve the inclined fore P=5 kN into vertical and horizontal components.
 PH = 5000 x sin 60 = 4.33 kN = 4330 N
PV = 5000 x cos 60 = 2.5 kN = 2500 N
The force PH induces
a) A direct tensile stress in the cross section
b) A bending stress due to the bending moment MbH =PH x lH
MbH = 4330x 150 Nmm = 649500 Nmm
The force PV induces
a) A direct shear stress which can be negligible.
b) A bending stress due to the bending moment MbV =PV x lV
MbV = 2500 x 300 = 750000 Nmm
Direct tensile Stress due to PH
𝑃𝐻 4330 4330 2165 𝑁
𝜎𝑑 = = = = 2 ⁄𝑚𝑚2
𝐴 𝑏. 𝑡 2𝑡. 𝑡 𝑡
Bending Stress due to PH
𝑀𝑏𝐻 649500 649500 × 6 974250
𝜎𝑏𝐻 = = = = 𝑀𝑃𝑎
𝑍 𝑡. 𝑏 2 𝑡. (2𝑡)2 𝑡3
6
Bending Stress due to PV
𝑀𝑏𝑉 750000 750000 × 6 1125000
𝜎𝑏𝑉 = = = = 𝑀𝑃𝑎
𝑍 𝑡. 𝑏 2 𝑡. (2𝑡)2 𝑡3
6
Therefore total stress induced in the bracket
[σt ] = 𝜎𝑑 + 𝜎𝑏𝐻 + 𝜎𝑏𝑉
2165 974250 1125000
57 = 2 + +
𝑡 𝑡3 𝑡3
By solving the cubic equation
t = 33.66 mm ≈ 34 mm
b = 2 x 34 = 68 mm

2. The C-frame of 100 kN capacity press is shown in Fig. 1.2. The material of the,
frame is grey cast iron and the factor of safety is 3 Determine the dimensions of
the frame.

Figure 1.2
Solution:
Given: P = 100 x 103 N, FOS = 3,
Assume Grey Cast Iron FG300, σu= 300 MPa, then [σ] = σu/FOS = 300/3 = 100 MPa.
Area of the section @ X-X
a = (t × 3t)+(2t × 0.75t)= 4.5 t2 mm2.
ro = 5t, ri = 2t, bi = 3t, ti = t, t = 0.75t, h = 3t
The frame is subjected to eccentric loading
Introduce P1=P2=P along the centroidal axis of the curved beam.
P1 induces a direct tensile stress
𝑃 100 × 103 22222.22
𝜎𝑑 = = = 𝑀𝑃𝑎
𝑎 4.5𝑡 2 𝑡2

P and P2 induces bending moment which induce bending stress in the cross section.
Distance between the centroidal axis and neutral axis e = R – rn = 3t – 2.657 t = 0.343 t
Distance between the load P and centroidal axis X = 1000 + R = 1000+3t
Where R = the radius of curvature of centroidal axis
1 2 1 1 1
ℎ 𝑡 + 2 𝑡𝑖 2 (𝑏𝑖 − 𝑡) (3𝑡)2 × 0.75𝑡 + 2 (𝑡)2 (3𝑡 − 0.75𝑡)
𝑅 = 𝑟𝑖 + [ 2 ] = 2𝑡 + [ 2 ] = 3𝑡 𝑚𝑚
ℎ. 𝑡 + 𝑡𝑖 (𝑏𝑖 − 𝑡) (3𝑡 × 0.75𝑡) + 𝑡(3𝑡 − 0.75𝑡)

Therefore bending moment about the centroidal axis

Mb = P x X = (100 x 103) (1000+3t)
Mb = (1 x 108+300 x 103t) N-mm
The bending stress at the inner fibre
𝑀𝑏 ℎ𝑖
𝜎𝑏𝑖 =
𝑎. 𝑒. 𝑟𝑖
The radius of curvature of the neutral axis
𝑡𝑖 (𝑏𝑖 − 𝑡) + 𝑡ℎ
𝑟𝑛 = 𝑟 + 𝑡𝑖 𝑟𝑜
(𝑏𝑖 − 𝑡)𝑙𝑛 ( 𝑖
𝑟𝑖 ) + 𝑡. 𝑙𝑛 ( 𝑟𝑖 )
𝑡(3𝑡 − 0.75𝑡) + (0.75𝑡 × 3𝑡)
=
2𝑡 + 𝑡 5𝑡
(3𝑡 − 0.75𝑡)𝑙𝑛 ( ) + 0.75𝑡. 𝑙𝑛 (
2𝑡 2𝑡)
= 2.8125 𝑡 𝑚𝑚
e = R - rn = 3t – 2.8125 t = 0.1875t mm
hi = rn - ri =2.8125t – 2t = 0.8125t mm
Therefore
(1 × 108 + 300 × 103 𝑡) × 0.8125𝑡
𝜎𝑏𝑖 = 𝑀𝑃𝑎
4.5 t 2 × 0.1875t × 2t
48148148 144444.4
𝜎𝑏𝑖 = + 𝑀𝑃𝑎
𝑡3 𝑡2
The inner fibre subjected to tensile stress due to direction of load
[σ]i = σt+ σb
 22222.22 48148148 144444.4
100 = + +
𝑡2 𝑡3 𝑡2
By solving the equation t= 85.45 mm ≈ 86 mm
The Dimensions of the frame are

3. A shaft, as shown in Fig. 1.3, is subjected to a bending load of 3 kN, pure torque
of 1000 N-m and an axial pulling force of 15 kN. Calculate the stresses at A and
B.

Figure 1.3
Solution:
Given: Pb = 3x103 N, Pt = 15x103 N, Mt =1000 Nm = 1000x103 N-mm,
d = 50 mm, l = 250 mm
Tensile force Pt induces a direct tensile stress in the point A and B
𝑃𝑡 15 × 103
𝜎𝑡 = = 𝜋 = 7.64 𝑁/𝑚𝑚2
𝐴 2
4 × 50
Bending force Pb induces torsional shear stress at Point A and B
𝑀𝑏 𝑃𝑏 × 250 3 × 103 × 250
𝜎𝑏𝐴 = = 𝜋 = 𝜋 = 61.12 𝑀𝑃𝑎 (𝑇𝑒𝑛𝑠𝑖𝑙𝑒)
𝑍 × 𝑑 3 × 503
32 32
Similarly
𝜎𝑏𝐴 = 61.12 𝑀𝑃𝑎 (𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒)
Torque induces torsional shear stress at Point A and B
50
𝑀𝑡 × 𝑟 𝑀𝑡 × ( 2 ) 1000 × 103 × 16
𝜏𝑥𝑦 = = 𝜋 = = 40.75 𝑀𝑃𝑎
𝐽 × 50 4 𝜋 × 503
32
Therefore the net tensile stress at Point A
𝜎𝑥𝐴 = 𝜎𝑡 + 𝜎𝑏𝐴 = 7.64 + 61.12 = 68.76 𝑀𝑃𝑎
The net tensile stress at Point B
𝜎𝑥𝐵 = 𝜎𝑡 − 𝜎𝑏𝐴 = 7.64 − 61.12 = −53.48 𝑀𝑃𝑎
The total stress induced at Point A (PSGDB 7.2)
1
𝜎𝐴𝑚𝑎𝑥 = [(𝜎𝑥𝐴 ) + √(𝜎𝑥𝐴 )2 + 4𝜏𝑥𝑦 2 ]
2
 1
𝜎𝐴𝑚𝑎𝑥 = [68.76 + √(68.76)2 + 4(40.75)2 ] = 87.7 𝑁/𝑚𝑚2
2
The total stress induced at Point B (PSGDB 7.2)
1
𝜎𝐵𝑚𝑎𝑥 = [(𝜎𝑥𝐵 ) + √(𝜎𝑥𝐵 )2 + 4𝜏𝑥𝑦
2 ]
2
1
𝜎𝐵𝑚𝑎𝑥 = [(−53.48) + √(−53.48)2 + 4(40.75)2 ] = 22 𝑁/𝑚𝑚2
2

4. A bolt is subjected to a direct tensile load of 25 kN and a shear load of 15 kN.

Considering various theories of failure, determine the suitable size of bolt if the
yield stress in tension is 250 MPa. Take F.O.S as 2 and Poisson’s ratio as 0.3

Solution:
Given: Pt = 25 x 103 N, Ps = 15 x 103 N, σy = 250 MPa, n= 2, ν = 0.3
Let d= Minor diameter of the screw thread.
Tensile stress σx
𝑃𝑡 25 × 103 31831
= = 𝜋 = 𝑀𝑃𝑎
𝐴 × 𝑑 2 𝑑2
4
Shear stress τxy
𝑃𝑠 15 × 103 19099
= = 𝜋 = 𝑀𝑃𝑎
𝐴 × 𝑑 2 𝑑2
4
By Principal stresses (PSGDB 7.2)
1 2
𝜎1,2 = [(𝜎𝑥 + 𝜎𝑦 ) ± √(𝜎𝑥 − 𝜎𝑦 ) + 4𝜏𝑥𝑦 2 ]
2

1 38831 38831 2 19099 2

𝜎1,2 √
= [( 2 ) ± ( 2 ) + 4 × ( 2 ) ]
2 𝑑 𝑑 𝑑
1 38831 49723 40777 −8946
𝜎1,2 =
[ 2 ± 2
]= ,
2 𝑑 𝑑 𝑑2 𝑑2
40777 −8946
𝜎1 = 𝑀𝑃𝑎 𝑎𝑛𝑑 𝜎 2 =
𝑑2 𝑑2
a) By Maximum Principal stress theory (PSGDB 7.3)
𝜎𝑦
Maximum (σ1 or σ2 ) =
𝑛
40777 250
=
𝑑2 2
d = 18.06 mm
b) By Maximum Shear Stress Theory
𝜎𝑦
Maximum (σ1 − σ2 ) =
𝑛
40777 −8946 250
−( )=
𝑑2 𝑑2 2
=> d = 19.95 mm
c) By Maximum strain Theroy
𝜎𝑦
σ1 – ν(σ2 + σ3 ) = 𝑛
40777 −8946 250
2
− 0.3 × ( 2
)=
𝑑 𝑑 2
=> d = 18.65 mm
d) By Maximum strain energy theory
𝜎𝑦 2
σ1 2+ σ2 2– 2ν(σ1 σ2 ) = ( 𝑛 )
40777 2 −8946 2 40777 −8946 250 2
( 2 ) +( ) − 2 × 0.3 × ( 2 ) × ( )=( )
𝑑 𝑑2 𝑑 𝑑2 2
=> d = 18.83 mm
e) By Maximum Distortion Energy Theory
𝜎𝑦 2
σ1 2+ σ2 2 – (σ1 σ2 ) = ( 𝑛 )
40777 2 −8946 2 40777 −8946 250 2
( 2 ) +( ) − [( 2 ) × ( )] = ( )
𝑑 𝑑2 𝑑 𝑑2 2
=> d = 19.16 mm
We can take the larger diameter
d = 19.95mm by maximum shear stress theory.
The major diameter of bolt
D = d/0.84 = 23.75 mm = M24 mm
We can select M24 bolts.

5. A shaft is subjected to a bending moment varying from -200 N-m to 500 N-m and
a twisting moment varying from 50 N-m to 175 N-m. The material 30C8 steel has
σu = 600 MPa, σe = 300 MPa, Ka (surface finish factor) = 0.76, Kb (size factor) =
0.85, Kc (endurance limit correction factor for the type of loading) = 0.897, K
(theoretical stress concentration factor) =1.85, and q (notch sensitivity index)
=0.95. Find the diameter of the shaft using Hencky and Von-Misses theory.
Factor of safety = 1.5.
Solution:
Given: Mbmax = 500 N-m = 500 × 103 N-mm
Mbmin = -200 N-m = −200 × 103 N-mm
Mtmax = 175 N-m = 175 × 103 N-mm
Mtmin = 60 N-m = 60 × 103 N-mm
σu = 600 MPa, σy= 300 MPa,
Load factor Klb = 1 for bending, Klt = 0.76 for torsion,
Surface finish factor Ka = 0.85,
Size factor Kb = 0.897,
Theoretical stress concentration factor Kt = 1.85,
Notch sensitivity q = 0.95, (FS)= n = 1.5
Mean Bending Moment
 𝑀𝑏𝑚𝑎𝑥 + 𝑀𝑏𝑚𝑖𝑛 500 + (−200)
𝑀𝑏𝑚 = = = 150 𝑁𝑚 = 150 × 103 𝑁 − 𝑚𝑚
2 2
Variable Bending Moment
𝑀𝑏𝑚𝑎𝑥 − 𝑀𝑏𝑚𝑖𝑛 500 − (−200)
𝑀𝑏𝑎 = = = 350 𝑁𝑚 = 350 × 103 𝑁 − 𝑚𝑚
2 2
Mean twisting Moment
𝑀𝑡𝑚𝑎𝑥 + 𝑀𝑡𝑚𝑖𝑛 175 + 60
𝑀𝑡𝑚 = = = 117.5 𝑁𝑚 = 117.5 × 103 𝑁 − 𝑚𝑚
2 2
Variable twisting Moment
𝑀𝑡𝑚𝑎𝑥 − 𝑀𝑡𝑚𝑖𝑛 175 − 60
𝑀𝑡𝑎 = = = 57.5 𝑁𝑚 = 57.5 × 103 𝑁 − 𝑚𝑚
2 2
Also Mean bending stress
32𝑀𝑏𝑚 32 × 150 × 103 1527.9 × 103
𝜎𝑚 = = = 𝑀𝑃𝑎
𝜋𝑑3 𝜋𝑑 3 𝑑3
Variable bending stress
32𝑀𝑏𝑎 32 × 350 × 103 3565.1 × 103
𝜎𝑎 = = = 𝑀𝑃𝑎
𝜋𝑑3 𝜋𝑑 3 𝑑3
Mean torsional stress
16𝑀𝑡𝑚 16 × 117.5 × 103 598.4 × 103
𝜏𝑚 = = = 𝑀𝑃𝑎
𝜋𝑑 3 𝜋𝑑 3 𝑑3
Variable torsional stress
16𝑀𝑡𝑚 16 × 57.5 × 103 292.8 × 103
𝜏𝑎 = = = 𝑀𝑃𝑎
𝜋𝑑3 𝜋𝑑 3 𝑑3
The endurance value is given by σ-1= 300 MPa
The design endurance limit
[𝜎−1 ] = 𝐾𝑙𝑏 . 𝐾𝑎 . 𝐾𝑏 . 𝜎−1 = 1 × 0.85 × 0.897 × 300 = 228.74 𝑀𝑃𝑎
The design torsional endurance limit
[𝜏−1 ] = 𝐾𝑙𝑡 . [𝜎−1 ] = 0.76 × 228.74 = 173.8 𝑀𝑃𝑎.
Also take
𝜎𝑦 = 0.6 × 𝜎𝑢 = 360 𝑀𝑃𝑎
𝜏𝑦 = 0.5 × 𝜎𝑦 = 180 𝑀𝑃𝑎
Fatigue Stress concentration factor
𝐾𝑓 = 𝑞 (𝐾𝑡 − 1) + 1 = 0.9(1.85 − 1) + 1 = 1.765
Therefore, equivalent bending stress (By Soderberg equation)
𝜎𝑎 . 𝜎𝑦
𝜎𝑒𝑞 = 𝜎𝑚 + 𝐾𝑓 ×
[𝜎−1 ]
3565.1 × 103
1527.9 × 10 3 ( ) × 360
𝑑3
𝜎𝑒𝑞 = ( ) + 1.765 ×
𝑑3 228.74
11431.1 × 103
= 𝑀𝑃𝑎 = 𝜎𝑥 .
𝑑3
Similarly, by equivalent torsional stress (By Soderberg equation)
 𝜏𝑎 . 𝜏𝑦
𝜏𝑒𝑞 = 𝜏𝑚 + 𝐾𝑓 ×
[𝜏−1 ]
292.8 × 103
598.4 × 103 ( ) × 180
𝑑3
𝜏𝑒𝑞 =( ) + 1.765 ×
𝑑3 173.8
1133.6 × 103
= 𝑀𝑃𝑎 = 𝜏𝑥𝑦
𝑑3
By Principal stresses
1
𝜎1,2 = [𝜎 ± √𝜎𝑥 2 + 4. 𝜏𝑥𝑦 2 ]
2 𝑥
2 2
1 11431.1 × 103 11431.1 × 103 1133.6 × 103
𝜎1,2 = [ ± √( ) + 4 ( ) ]
2 𝑑3 𝑑3 𝑑3

1 11431.1 × 103 11653765.2

𝜎1,2 =
[ ± ]
2 𝑑3 𝑑3
11542432.6 −111332.6
𝜎1 = [ ] , 𝜎 2 = [ ]
𝑑3 𝑑3
By Von-Mises Hencky Theory (PSGDB
7.3)
𝜎𝑦 2
𝜎1 2 + 𝜎2 2 − 𝜎1 𝜎2 = ( )
𝑛
2 2
11542432.6 −111332.6 11542432.6 −111332.6 360 2
=> [ ] + [ ] − [ ] [ ] = ( )
𝑑3 𝑑3 𝑑3 𝑑3 1.5
By solving d6 = 2335506845.6 mm6
d = 36.4 mm ~ 40 mm. (by R20 series)

PART C
6. A pulley is keyed to a shaft midway between two bearings. The shaft is made of
cold drawn steel for which the ultimate strength is 550 MPa and the yield
strength is 400 MPa. The bending moment at the pulley varies from -150 N-m to
+ 400 N-m as the torque on the shaft varies from -50 N-m to + 150 N-m. Obtain
the diameter of the shaft for an indefinite life. The stress concentration factors
for the keyway at the pulley in bending and in torsion are 1.6 and 1.3
respectively. Take the following values: Factor of safety = 1.5; Load correction
factors = 1.0 in bending, and 0.6 in torsion; Size effect factor =0.85; Surface effect
factor =0.88.
Solution:
Given: Mbmax = 400 N-m = 400 × 103 N-mm; Mbmin = -150 N-m = −150 × 103 N-mm; Mtmax
= 150 N-m = 150 × 103 N-mm; Mtmin = -50 N-m = −50 × 103 N-mm; σu = 550 MPa; σy= 400
MPa; Kfb = 1.6; Kft = 1.3; (FS) = n = 1.5; Load factor Klb = 1 for bending; Klt = 0.6 for torsion;
Ka = 0.88, Kb = 0.85
Mean Bending Moment
𝑀𝑏𝑚𝑎𝑥 + 𝑀𝑏𝑚𝑖𝑛 400 + (−150)
𝑀𝑏𝑚 = = = 125 𝑁𝑚 = 125 × 103 N − mm
2 2
Variable Bending Moment
𝑀𝑏𝑚𝑎𝑥 − 𝑀𝑏𝑚𝑖𝑛 400 − (−150)
𝑀𝑏𝑎 = = = 275 𝑁𝑚 = 275 × 103 N − mm
2 2
Mean twisting Moment
𝑀𝑡𝑚𝑎𝑥 + 𝑀𝑡𝑚𝑖𝑛 150 + (−50)
𝑀𝑡𝑚 = = = 50 𝑁𝑚 = 50 × 103 N − mm
2 2
Variable twisting Moment
𝑀𝑡𝑚𝑎𝑥 − 𝑀𝑡𝑚𝑖𝑛 150 − (−50)
𝑀𝑡𝑎 = = = 100 𝑁𝑚 = 100 × 103 N − mm
2 2
Also mean bending stress
32𝑀𝑏𝑚 32 × 125 × 103 1273.2 × 103
𝜎𝑚 = = = 𝑁/𝑚𝑚2
𝜋𝑑 3 𝜋𝑑 3 𝑑3
Variable bending stress
32𝑀𝑏𝑎 32 × 275 × 103 2801.2 × 103
𝜎𝑎 = = = 𝑁/𝑚𝑚2
𝜋𝑑 3 𝜋𝑑 3 𝑑3
Mean torsional stress
16𝑀𝑡𝑚 16 × 50 × 103 254.6 × 103
𝜏𝑚 = = = 𝑁/𝑚𝑚2
𝜋𝑑 3 𝜋𝑑 3 𝑑3
Variable torsional stress
16𝑀𝑡𝑚 16 × 100 × 103 509.3 × 103
𝜏𝑎 = = = 𝑁/𝑚𝑚2
𝜋𝑑 3 𝜋𝑑 3 𝑑3
The endurance value is given by
σu = 550 MPa,
𝜎−1 = 0.5 × 𝜎𝑢 = 0.5 × 550 = 275𝑀𝑃𝑎
The design endurance limit
[𝜎−1 ] = 𝐾𝑙𝑏 . 𝐾𝑎 . 𝐾𝑏 . 𝜎−1
= 1 × 0.88 × 0.85 × 275 = 205.7 𝑀𝑃𝑎
Yield stress in tension σy = 400 MPa,
Yield stress in shear
𝜏𝑦 = 0.5 × 𝜎𝑦 = 0.5 × 400 = 200 𝑀𝑃𝑎
The design torsional endurance limit
[𝜏−1 ] = 𝐾𝑙𝑡 . [𝜎−1 ] = 0.6 × 205.7 = 123.4 𝑀𝑃𝑎.
Therefore, by equivalent bending stress (By Soderberg equation)
𝜎𝑎 . 𝜎𝑦
𝜎𝑒𝑞 = 𝜎𝑚 + 𝐾𝑓𝑏 ×
[𝜎−1 ]
2801.2 × 103
1273.2 × 10 3 ( ) × 400 9988.7 × 103
𝑑3
=( ) + 1.6 × = 𝑀𝑃𝑎.
𝑑3 205.7 𝑑3
Similarly, by equivalent torsional stress (By Soderberg equation)
𝜏𝑎 . 𝜏𝑦
𝜏𝑒𝑞 = 𝜏𝑚 + 𝐾𝑓𝑏 ×
[𝜏−1 ]
 509.3 × 103
254.6 × 10 3 ( ) × 200 1327.7 × 103
𝑑3
=( ) + 1.3 × = 𝑀𝑃𝑎.
𝑑3 123.4 𝑑3
By combining the stress by Maximum Shear Stress Theory
2 2
1 𝜎𝑒𝑞 𝜏𝑒𝑞
= √( ) + ( )
𝑛 𝜎𝑦 𝜏𝑦
2 2
9988.7 × 103 1327.7 × 103
1 𝑑3 𝑑3
= √( ) +( )
1.5 400 200

By solving the equation we get d = 33.84 ~ 35.5 mm by R20 series.

UNIT II : SHAFTS AND COUPLINGS

PART A
1. What is key? What are the types of keys?
A key is device, which is used for connecting two machine parts for preventing relative
motion of rotation with respect to each other.
Types of keys:
Saddle key, Tangent key, Sunk key, Round key and taper pins
2. Discuss forces on keys.
When a key is used in transmitting torque from a shaft to a rotor or hub, the following
two types of forces act on the key:
1. Forces (F1) due to fit of the key in its keyway, as in a tight fitting straight key or in
a tapered key driven in place. These forces produce compressive stresses in the key
which are difficult to determine in magnitude.
2. Forces (F) due to the torque transmitted by the shaft. These forces produce
shearing and compressive (or crushing) stresses in the key.
The distribution of the forces along the length of the key is not uniform because the
forces are concentrated near the torque-input end. The non-uniformity of distribution
is caused by the twisting of the shaft within the hub.
3. Where are splines used?
Sometimes, keys are made integral with the shaft which fits in the keyways broached
in the hub. Such shafts are known as splined shafts. These shafts usually have four,
six, ten or sixteen splines. The splined shafts are relatively stronger than shafts having
a single keyway. The splined shafts are used when the force to be transmitted is large
in proportion to the size of the shaft as in automobile transmission and sliding gear
transmissions. By using splined shafts, axial movement as well as positive drive is
obtained.
4. Under what circumstances flexible couplings are used?
A flexible coupling is used to join the abutting ends of shafts when they are not in exact
alignment. In the case of a direct coupled drive from a prime mover to an electric
generator, we should have four bearings at a comparatively close distance. In such a
case and in many others, as in a direct electric drive from an electric motor to a
 machine tool, a flexible coupling is used so as to permit an axial misalignment of the
shaft without undue absorption of the power which the shaft is transmitting.
5. Name the stresses induced in the shaft.
The following stresses are induced in the shafts :1. Shear stresses due to the
transmission of torque (i.e. due to torsional load).2. Bending stresses (tensile or
compressive) due to the forces acting upon machine elements like gears, pulleys etc.
as well as due to the weight of the shaft itself.3. Stresses due to combined torsional
and bending loads.
PART B
1. A hollow shaft is required to transmit 600 kW at 110 r.p.m.; the maximum
torque being 20% greater than the mean. The shear stress is not to exceed 63
MPa and twist in a length of 3 meters not to exceed 1.4 degrees. Find the
external diameter of the shaft; if the ratio internal diameter to the external
diameter is 3/8. Take modulus of rigidity as 84 GPa.
Solution:
Given: P = 600 x 103 W; N=110 rpm; [Mt]=1.2Mt;
[τ]=63 MPa; θ=1.4°=1.4xπ/180=0.0244 rad;
l = 3000 mm; di/do=3/8. G = 84000 MPa
The torque transmitted by the shaft
𝑃 × 60 600 × 103 × 60
𝑀𝑡 = = = 52087𝑁 − 𝑚 = 52087 × 103 𝑁 − 𝑚𝑚
2𝜋𝑁 2 × 𝜋 × 110
Maximum torque
[Mt]=1.2Mt
[Mt]=1.2 × 52087 × 103 = 62504.5× 103 𝑁 − 𝑚𝑚
Design based on Strength
16[𝑀𝑡 ]
[𝜏] =
3 𝑑𝑖 4
𝜋𝑑𝑜 {1 − ( ) }
𝑑0
16 × 62504.5 × 103
63 =
3 3 4
𝜋𝑑𝑜 {1 − (8) }
d0=172.7 mm
Design based on rigidity
𝐺𝜃 [𝑀𝑡 ]
=
𝑙 𝜋 4 𝑑𝑖 4
𝑑 {1 − ( ) }
32 𝑜 𝑑0
84000 × 0.0244 62504.5 × 103
=
3000 𝜋 4 3 4
𝑑 {1 − (
32 𝑜 8) }
62504.5 × 103 × 3000 × 32
𝑑𝑜 4 =
3 4
𝜋 {1 − (8) } × 84000 × 0.0244
 d0=175.6 mm
Taking larger size d0=175.6 mm ≃ 180 mm (By R20 series)
The inner diameter di=(3/8)x180=67.5mm

2. A shaft is supported by two bearings placed 1 m apart. A 600 mm diameter

pulley is mounted at a distance of 300 mm to the right of left hand bearing and
this drives a pulley directly below it with the help of belt having maximum
tension of 2.25 kN. Another pulley 400 mm diameter is placed 200 mm to the
left of right hand bearing and is driven with the help of electric motor and belt,
which is placed horizontally, to the right. The angle of contact for both the
pulleys is 180o and µ=0.24. Determine the suitable diameter for a solid shaft,
allowing working stress of 60 MPa in tension and 40 MPa in shear for the
material of shaft. Assume that the torque on one pulley is equal to that on the
other pulley.
Solution:
Given: Dc = 600 mm; Tc1 = 2250 N; DD = 400 mm; θ = 180°=π radians; μ = 0.24; [τ] =
40 MPa; [σ] = 60 MPa
Pulley C:
We know the belt tension
𝑇𝐶1
= 𝑒 𝜇𝜃 = 𝑒 0.24×𝜋 = 2.126
𝑇𝐶2
Maximum Bending Moment:
Consider VLD (Vertical Load Diagram)
∑𝑉 = 0.
R VA + R VB − 3308.3 = 0
R VA + R VB = 3308.3 N
∑ 𝑀𝐴 = 0 (↻ −; ↺ +)
R VB × 1000 − 3308.3 × 300 = 0
R VB = 992.5 N
R VA = 3308.3 − R VB = 2315.8 N
Vertical Bending Moments:
𝑉𝐵𝑀𝐵 = 0 𝑁 − 𝑚𝑚
Therefore Tension in slack side
𝑇𝐶1
𝑇𝐶2 = = 1058.3 𝑁
2.126
And the torque transmitted by the pulley C
600
𝑀𝑡𝐶 = (𝑇𝐶1 − 𝑇𝐶2 )𝑅𝐶 = (2250 − 1058.3) × = 357510 𝑁𝑚𝑚
2
Total Load on Pulley C
𝑇𝐶 = 𝑇𝐶1 + 𝑇𝐶2 = 3308.3 𝑁(↓)
Pulley D:
The torque transmitted by pulley D = The torque transmitted by Pulley C
𝑀𝑡𝐷 = 𝑀𝑡𝐶 = 357510 𝑁𝑚𝑚
But
𝑀𝑡𝐷 = (𝑇𝐷1 − 𝑇𝐷2 )𝑅𝐷
400
=> (2.126 𝑇𝐷2 − 𝑇𝐷2 ) × = 357510 𝑁𝑚𝑚
2
𝑇𝐷2 = 1587.5 𝑁 and 𝑇𝐷1 = 3375 𝑁
Total Load on Pulley D
𝑇𝐷 = 𝑇𝐷1 + 𝑇𝐷2 = 4962.5 𝑁(→)

𝑉𝐵𝑀𝐷 = R VB × 200 = 992.5 × 200 = 198500 𝑁 − 𝑚𝑚

𝑉𝐵𝑀𝐶 = R VB × 700 = 992.5 × 700 = 694750 𝑁 − 𝑚𝑚
𝑉𝐵𝑀𝐴 = 0 𝑁 − 𝑚𝑚
Consider HLD (Horizontal Load Diagram)
∑𝐻 = 0.
R HA − 4962.5 + R HB = 0
R HA + R HB = 4962.5 N
∑ 𝑀𝐴 = 0 (↻ −; ↺ +)
−4962.5 × 800 + R HB × 1000 = 0
R HB = 3970 N
R HA = 4962.5 − R HB = 992.5 N
Horizontal Bending Moments:
𝐻𝐵𝑀𝐵 = 0 𝑁 − 𝑚𝑚
𝐻𝐵𝑀𝐷 = R HB × 200 = 3970 × 200 = 794000 𝑁 − 𝑚𝑚
𝐻𝐵𝑀𝐶 = R HB × 700 = 3970 × 700 − 4962.5 × 500 = 297750 𝑁 − 𝑚𝑚
𝐻𝐵𝑀𝐴 = 0 𝑁 − 𝑚𝑚
Resultant Bending Moment:
𝑅𝐵𝑀𝐵 = √(𝑉𝐵𝑀𝐵 )2 + (𝐻𝐵𝑀𝐵 )2 = 0 𝑁 − 𝑚𝑚
𝑅𝐵𝑀𝐷 = √(𝑉𝐵𝑀𝐷 )2 + (𝐻𝐵𝑀𝐷 )2 = √(198500)2 + (794000)2 = 818436.5 𝑁 − 𝑚𝑚
𝑅𝐵𝑀𝐶 = √(𝑉𝐵𝑀𝐶 )2 + (𝐻𝐵𝑀𝐶 )2 = √(694750)2 + (297750)2 = 755865.5 𝑁 − 𝑚𝑚
𝑅𝐵𝑀𝐴 = √(𝑉𝐵𝑀𝐴 )2 + (𝐻𝐵𝑀𝐴 )2 = 0 𝑁 − 𝑚𝑚
Therefore the maximum bending moment occurs at Support D
Mb=818436.5 N-mm
Maximum Twisting Moment
Mt=357510 N-mm
The equivalent twisting moment: Assume Shock and fatigue factors Kb=1.5 and Kt = 1
𝑀𝑡𝑒𝑞 = √[𝐾𝑏 𝑀𝑏 ]2 + (𝐾𝑡 𝑀𝑡 )2
𝑀𝑡𝑒𝑞 = √[1.5 × 818436.5]2 + (1 × 357510)2
𝑀𝑡𝑒𝑞 = 1278651.5 𝑁 − 𝑚𝑚
The equivalent bending moment: Assume Shock and fatigue factors Kb=1.5 and Kt = 1
1
𝑀𝑏𝑒𝑞 = [(𝐾𝑏 𝑀𝑏 ) + √[𝐾𝑏 𝑀𝑏 ]2 + (𝐾𝑡 𝑀𝑡 )2 ]
2
1
𝑀𝑏𝑒𝑞 = [(1.5 × 818436.5) + √[1.5 × 818436.5]2 + (1 × 357510)2 ]
2
𝑀𝑏𝑒𝑞 = 1253153.125 𝑁 − 𝑚𝑚
By Maximum shear stress theory; design shear stress in the shaft
16𝑀𝑡𝑒𝑞
[𝜏] =
𝜋𝑑3
16 × 1278651.5
40 =
𝜋𝑑 3
=> d=54.6 mm ≃ 50 mm (By R20).
By Maximum normal stress theory; design bending stress in the shaft
32𝑀𝑏𝑒𝑞
[𝜎] =
𝜋𝑑3
32 × 1253153.125
60 =
𝜋𝑑 3
=> d=59.7 mm
Taking larger size of above two values
D = 59.7 ≃ 64 mm (By R20).

3. A transmission shaft supporting a spur gear B and pulley D is shown in Fig. 2.1.
The shaft is mounted on two bearings A and C. The diameters of pulley and the
gear are 450 and 350 mm respectively. A 20 kW power at 500 rpm is
transmitted from the pulley to the gear. P1 and P2 are the belt tensions in the
tight and loose sides, while Pt and Pr are tangential and radial Components of
the gear tooth force. Assume P1 =3 P2 and Pr =Pt tan (20˚). The Gear and pulley
are keyed to the shaft. The material for the shaft is steel C 60 (ultimate strength
= 700 N/mm2, yield strength = 460 N/mm2). Determine the diameter of shaft.
 Figure 2.1
Solution:
Given: Power P=20x103 W; N=500 rpm; DB=350mm; DD=450mm; P1 = 3P2; Pr =Pt tan 20˚;
Keyed shaft;
Design Stress:
As per ASME code
[𝜏] = 0.3𝜎𝑦 (𝑜𝑟)0.18𝜎𝑢
whichever is minimum.
[𝜏] = 0.3𝜎𝑦 = 0.3 × 460 = 138 𝑀𝑃𝑎
[𝜏] = 0.18𝜎𝑢 = 0.18 × 700 = 126𝑀𝑃𝑎
Taking the minimum of above
[𝜏] = 126 𝑀𝑃𝑎.
But the pulley and gear are keyed on the shaft. Therefore 25% of stress value should be
reduced.
Modified design shear stress
[𝜏] = 0.75 × 126 = 94.5𝑀𝑃𝑎.
The torque transmitted by the shaft
𝑃 × 60 20 × 103 × 60
𝑀𝑡 = = = 382 𝑁 − 𝑚 = 382 × 103 𝑁 − 𝑚𝑚
2𝜋𝑁 2 × 𝜋 × 500
But the torque transmitted by the belt drive
𝑀𝑡 = (𝑃1 − 𝑃2 )𝑅𝐷
Substituting 𝑃1 = 3𝑃2 in torque equation; then
450
382 × 103 = (3𝑃2 − 𝑃2 ) ×
2
𝑃2 = 849𝑁 and 𝑃1 = 3 × 849 = 2547𝑁
Total Vertical load acting at the end of the shaft Pv = P1+P2 = 849+2547 = 3396 N
Tangential force acting on the gear B
2𝑀𝑡 2 × 382 × 103
𝑃𝑡 = = = 2183 𝑁
𝐷𝐵 350
Radial force acting on the gear B
𝑃𝑟 = 𝑃𝑡 × tan 20 = 795 𝑁
Maximum Bending Moment:
Consider VLD (Vertical Load Diagram)
∑𝑉 = 0.
R VA − 795 + R VC − 3396 = 0
R VA + R VC = 4191 N
∑ 𝑀𝐴 = 0 (↻ −; ↺ +)
−795 × 400 + R VC × 800 − 3396 × 1200 = 0
R VC = 5491.5 N
R VA = 4191 − R VC = −1300.5 N

VLD

HLD
Vertical Bending Moments:
𝑉𝐵𝑀𝐷 = 0 𝑁 − 𝑚𝑚
𝑉𝐵𝑀𝐶 = −3396 × 400 = −1358400 𝑁 − 𝑚𝑚
𝑉𝐵𝑀𝐵 = −3396 × 800 + R VC × 400 = −520200 𝑁 − 𝑚𝑚
𝑉𝐵𝑀𝐴 = 0 𝑁 − 𝑚𝑚

Consider HLD (Horizontal Load Diagram)

∑𝐻 = 0.
R HA − 2183 + R HC = 0
R HA + R HC = 2183 N
∑ 𝑀𝐴 = 0 (↻ −; ↺ +)
−2183 × 400 + R HC × 800 = 0Design a hollow shaft to transmit 25kW at 300 rpm.
R HC = 1091.5 N
R HA = 2183 − R HC = 1091.5 N
Horizontal Bending Moments:
𝐻𝐵𝑀𝐷 = 0 𝑁 − 𝑚𝑚
𝐻𝐵𝑀𝐶 = 0 𝑁 − 𝑚𝑚
𝐻𝐵𝑀𝐵 = R HC × 400 = 436600 𝑁 − 𝑚𝑚
𝐻𝐵𝑀𝐴 = 0 𝑁 − 𝑚𝑚

Resultant Bending Moment:

𝑅𝐵𝑀𝐷 = √(𝑉𝐵𝑀𝐷 )2 + (𝐻𝐵𝑀𝐷 )2 = 0 𝑁 − 𝑚𝑚
𝑅𝐵𝑀𝐶 = √(𝑉𝐵𝑀𝐶 )2 + (𝐻𝐵𝑀𝐶 )2 = √(−1358400)2 + (0)2 = 13; 58; 400 𝑁 − 𝑚𝑚
𝑅𝐵𝑀𝐵 = √(𝑉𝐵𝑀𝐵 )2 + (𝐻𝐵𝑀𝐵 )2 = √(−520200)2 + (436600)2 = 6; 79; 138 𝑁 − 𝑚𝑚
𝑅𝐵𝑀𝐴 = √(𝑉𝐵𝑀𝐴 )2 + (𝐻𝐵𝑀𝐴 )2 = 0 𝑁 − 𝑚𝑚
Therefore the maximum bending moment occurs at Support C Mb=1358400 N-mm
Maximum Twisting Moment Mt=382x103 N-mm
The equivalent twisting moment
𝑀𝑡𝑒𝑞 = √[𝐾𝑏 𝑀𝑏 ]2 + (𝐾𝑡 𝑀𝑡 )2
𝑀𝑡𝑒𝑞 = √[1.5 × 1358400]2 + (1 × 382000)2
𝑀𝑡𝑒𝑞 = 2073098.6 𝑁 − 𝑚𝑚
But the design stress in the shaft
16𝑀𝑡𝑒𝑞
[𝜏] =
𝜋𝑑 3
16 × 2073098.6
94.5 =
𝜋𝑑3
=> d=48.1 mm ≃ 50 mm (By R20).

4. A 600 mm diameter pulley driven by a horizontal belt transmits power through

a solid shaft to a 262 mm diameter pinion which drives a mating gear. The
pulley weighs 1200 N to provide some flywheel effect. The arrangement of
elements, the belt tensions and the components of the gear reactions of the
pinion are as indicated in Fig. 2.2. Determine necessary shaft diameter using a
suitable value for commercial shafting and shock fatigue factors of K b=2 and Kt
=1.5.
 Figure 2.2
Solution:
Assume the shaft is made up of low carbon steel C45 with factor of safety 3.
For C45 σy(Yield strength of material)= 360 MPa; then the design tensile stress
𝜎𝑦 360
[𝜎] = = = 120 𝑀𝑝𝑎
𝑛 3
Design shear stress
[𝜎] 120
[𝜏] = = = 60 𝑀𝑝𝑎
2 2
The load diagram of the shaft:

Maximum Bending Moment:

Consider VLD (Vertical Load Diagram)
∑𝑉 = 0.
R VA + R VB = −8000 + 1200 = −6800 N
∑ 𝑀𝐴 = 0 (↻ −; ↺ +)
R VB × 850 − 1200 × 600 + 8000 × 225 = 0
R VB = −1270.6 N (↓)
R VA = −6800 − R VB = −6800— 1270.6 = −5529.4 N(↓)
Vertical Bending Moments:
𝑉𝐵𝑀𝐵 = 0 𝑁 − 𝑚𝑚
𝑉𝐵𝑀𝐷 = R VB × 250 = −1270.6 × 200 = 317650 𝑁𝑚𝑚
𝑉𝐵𝑀𝐶 = R VA × 225 = −5529.4 × 225 = 1244115 𝑁𝑚𝑚
𝑉𝐵𝑀𝐴 = 0 𝑁𝑚𝑚

Consider HLD (Horizontal Load Diagram)

∑𝐻 = 0.
R HA + R HB = 3000 + 6500 = 9500 N
∑ 𝑀𝐴 = 0 (↻ −; ↺ +)
−3000 × 225 − 6500 × 600 + R HB × 850 = 0
R HB = 5382.4 N
R HA = 9500 − R HB = 4117.6 N
Horizontal Bending Moments:
𝐻𝐵𝑀𝐵 = 0 𝑁 − 𝑚𝑚
𝐻𝐵𝑀𝐷 = R HB × 250 = 5382.4 × 250 = 1345600 𝑁 − 𝑚𝑚
𝐻𝐵𝑀𝐶 = R HA × 225 = 4117.6 × 225 = 926460 𝑁𝑚𝑚
𝐻𝐵𝑀𝐴 = 0 𝑁𝑚𝑚

Resultant Bending Moment:

𝑅𝐵𝑀𝐴 = √(𝑉𝐵𝑀𝐴 )2 + (𝐻𝐵𝑀𝐴 )2 = 0 𝑁𝑚𝑚
𝑅𝐵𝑀𝐶 = √(𝑉𝐵𝑀𝐶 )2 + (𝐻𝐵𝑀𝐶 )2 = 1551177 𝑁𝑚𝑚
𝑅𝐵𝑀𝐷 == √(𝑉𝐵𝑀𝐷 )2 + (𝐻𝐵𝑀𝐷 )2 = 1382585 𝑁𝑚𝑚
𝑅𝐵𝑀𝐵 = √(𝑉𝐵𝑀𝐵 )2 + (𝐻𝐵𝑀𝐵 )2 = 0 𝑁𝑚𝑚
Therefore the maximum bending moment occurs at Support C Mb=1551177 N-mm
Maximum Twisting Moment
Maximum Torque at pinion C
262
𝑀𝑡𝐶 = 𝐹𝑡 × 𝑅𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑃𝑖𝑛𝑖𝑜𝑛 = 8000 × = 1048000 𝑁𝑚𝑚
2
Maximum Torque at Pulley D
 600
𝑀𝑡𝐷 = (5000 − 1500) × = 1050000 𝑁𝑚𝑚
2
Taking the larger value Mt=1050000 N-mm
The equivalent twisting moment: Assume Shock and fatigue factors Kb=2 and Kt = 1.5
𝑀𝑡𝑒𝑞 = √[𝐾𝑏 𝑀𝑏 ]2 + (𝐾𝑡 𝑀𝑡 )2
𝑀𝑡𝑒𝑞 = √[2 × 1551177]2 + (1.5 × 1050000)2
𝑀𝑡𝑒𝑞 = 3479256.4 𝑁𝑚𝑚
By Maximum shear stress theory; design shear stress in the shaft
16𝑀𝑡𝑒𝑞
[𝜏] =
𝜋𝑑3
16 × 3479256.4
60 =
𝜋𝑑 3
=> d=66.5 mm ≃ 71 mm (By R20).

5. Design a cast iron flange coupling for a mild steel shaft transmitting 90 kW at
[Link]; the allowable shear stress in the shaft is 40 MPa and the angle of twist is
not to exceed l˚ in a length of 20 diameters. The allowable shear stress in the
coupling bolts is 30 MPa. Take G = 84 kN/mm2
Given: P = 90×103 W; N = 250 rpm; [τs]= [τk]= [τb]= 40 MPa; θ = 1×π/180 = 0.0175 rad; l
= 20d
Assume for Cast Iron [σc]=30 MPa; [τc]=15 MPa
Design Torque:
Mean Torque
𝑃 × 60 90 × 103 × 60
𝑀𝑡 = = = 3437.75 𝑁𝑚 = 3437.75 × 103 𝑁 − 𝑚𝑚
2𝜋𝑁 2 × 𝜋 × 250
Design Torque
Assume Service Factor for the coupling Ks= 1.5
[𝑀𝑡 ] = 𝐾𝑠 . 𝑀𝑡 = 1.5 × 3437.75 × 103 = 5156.6 × 103 𝑁 − 𝑚𝑚
Design of Shaft:
Torque Transmitted by the shaft
𝜋
[𝑀𝑡 ] = × 𝑑 3 × [𝜏𝑠 ]
16
𝜋
5156.6 × 103 = × 𝑑 3 × 40
16
d = 86.92 mm ≃ 90 mm (By R20 series)
Torque Transmitted by the shaft
𝐺𝜃
[𝑀𝑡 ] = 𝐽
𝑙
Modulus of rigidity of the steel material G = 84 ×103 N/mm2
84 × 103 × 0.0175 𝜋 4
5156.6 × 103 = × 𝑑
20𝑑 32
d = 89.40 mm ≃ 90 mm (By R20 series)
Fix the dimensions of the coupling:
Flange Hub outer diameter D = 2d = 180 mm
Pitch Circle diameter of bolts D1= 3d = 270 mm
Length of the flange Hub L = 1.5d = 135 mm
Outer diameter of the flange D2 = 4d = 360 mm
Thickness of the flange tf = 0.5d = 45 mm
Thickness of protective flange tp = 0.25d = 22.5  24 mm
No. of bolts n = 4 for ‘d’ up to 100 mm.
Design of Flange Hub:
Torque Transmitted by the hub
𝜋 𝐷4 − 𝑑4
[𝑀𝑡 ] = × 𝜏𝑐 × [ ]
16 𝐷
3
𝜋 1804 − 904
5156.6 × 10 = × 𝜏𝑐 × [ ]
16 180
τc = 4.80 MPa < [τc]=15 MPa
Design is safe.
Design of Flange:
Torque Transmitted by the flange
𝜋
[𝑀𝑡 ] = × 𝜏𝑐 × 𝐷2 × 𝑡𝑓
2
𝜋
5156.6 × 10 = × 𝜏𝑐 × 1802 × 45
3
2
τc = 2.25 MPa < [τc]=15 MPa
Design is safe.
Design of Bolts: The bolts are subjected to shear stress due to the torque transmitted.
Torque Transmitted by the bolts
𝜋 𝐷1
[𝑀𝑡 ] = × [𝜏𝑏 ] × 𝑑1 2 × 𝑛 ×
4 2
𝜋 270
5156.6 × 103 = × 40 × 𝑑1 2 × 4 ×
4 2
Nominal diameter d1= 17.4 mm; M20 bolts
Checking bolts for crushing:
Torque Transmitted by the bolts
𝐷1
[𝑀𝑡 ] = 𝑛 × 𝑑1 × 𝑡𝑓 × 𝜎𝑐𝑏 ×
2
3
270
5156.6 × 10 = 4 × 20 × 45 × 𝜎𝑐𝑏 ×
2
σcb = 47.05 MPa < [σcb]=80 MPa (∵[σcb]= 2×[τb])
Design is safe.
Design for Key:
For shaft diameter 90mm; the key dimensions are b = 25 mm and h = 14 mm and take
length of key l = L = 135 mm
Check for shear:
Torque transmitted by the key
 𝑑
[𝑀𝑡 ] = 𝑙 × 𝑏 × 𝜏 ×
2
90
5156.6 × 103 = 135 × 25 × 𝜏 ×
2
τ = 33.96 MPa <[τk]=40 MPa
Design is safe
Check for crushing:
Torque transmitted by the key
ℎ 𝑑
[𝑀𝑡 ] = 𝑙 × × 𝜎𝑐𝑘 ×
2 2
14 90
5156.6 × 103 = 135 × × 𝜎𝑐𝑘 ×
2 2
σck =121.3 MPa >[σck]=80 MPa
Design is not safe. Therefore the length of the key should be modified
14 90
5156.6 × 103 = 𝑙 × × 80 ×
2 2
l = 204.6 mm  205 mm
Therefore the size of the key 14×9×205 mm

PART C
1. Design a cast iron protective type flange coupling to transmit 15 kW at 900 rpm
from an electric motor to a compressor-The service factor may be-assumed as 1.35.
The following permissible stress may be used: Shear stress for the shaft; bolt and
key material = 40 MPa; Crushing stress for bolt and key =80 MPa; Shear stress for
cast iron =8 MPa.
Solution:
Given: P = 15×103 W; N = 900 rpm; Ks = 1.35 [τs]= [τk]= [τb]= 40 MPa; For Cast Iron [τc] =
8 MPa
Design Torque:
Mean Torque
𝑃 × 60 15 × 103 × 60
𝑀𝑡 = = = 159.2 𝑁𝑚 = 159.2 × 103 𝑁 − 𝑚𝑚
2𝜋𝑁 2 × 𝜋 × 900
Design Torque
Service Factor for the coupling Ks= 1.35
[𝑀𝑡 ] = 𝐾𝑠 . 𝑀𝑡 = 1.35 × 159.2 × 103 = 215 × 103 𝑁 − 𝑚𝑚
Design of Shaft:
Torque Transmitted by the shaft
𝜋
[𝑀𝑡 ] = × 𝑑 3 × [𝜏𝑠 ]
16
𝜋
215 × 103 = × 𝑑 3 × 40
16
d = 30.14 mm ≃ 32 mm (By R20 series)
Fix the dimensions of the coupling:
Flange Hub outer diameter D = 2d = 64 mm
Pitch Circle diameter of bolts D1= 3d = 96 mm
Length of the flange Hub L = 1.5d = 48 mm
Outer diameter of the flange D2 = 4d = 128 mm
Thickness of the flange tf = 0.5d = 16 mm
Thickness of protective flange tp = 0.25d = 8 mm
No. of bolts n = 3 for ‘d’ up to 40 mm.
Design of Flange Hub:
Torque Transmitted by the hub
𝜋 𝐷4 − 𝑑4
[𝑀𝑡 ] = × 𝜏𝑐 × [ ]
16 𝐷
3
𝜋 644 − 324
215 × 10 = × 𝜏𝑐 × [ ]
16 64
τc = 4.67 MPa < [τc] = 8 MPa
Design is safe.
Design of Flange:
Torque Transmitted by the flange
𝜋
[𝑀𝑡 ] = × 𝜏𝑐 × 𝐷2 × 𝑡𝑓
2
𝜋
215 × 103 = × 𝜏𝑐 × 642 × 16
2
τc = 2.16 MPa < [τc] = 8 MPa
Design is safe.
Design of Bolts:
The bolts are subjected to shear stress due to the torque transmitted.
Torque Transmitted by the bolts
𝜋 𝐷1
[𝑀𝑡 ] = × [𝜏𝑏 ] × 𝑑1 2 × 𝑛 ×
4 2
𝜋 96
215 × 103 = × 40 × 𝑑1 2 × 3 ×
4 2
Nominal diameter d1= 6.93 mm; M8 bolts
Checking bolts for crushing:
Torque Transmitted by the bolts
𝐷1
[𝑀𝑡 ] = 𝑛 × 𝑑1 × 𝑡𝑓 × 𝜎𝑐𝑏 ×
2
96
215 × 103 = 3 × 8 × 16 × 𝜎𝑐𝑏 ×
2
σcb = 11.6 MPa < [σcb]=80 MPa (∵[σcb]= 2×[τb])
Design is safe.
Design for Key:
For shaft diameter 32 mm; the key dimensions are b = 10 mm and h = 8 mm and take
length of key l = L = 48 mm
Check for shear:
Torque transmitted by the key
𝑑
[𝑀𝑡 ] = 𝑙 × 𝑏 × 𝜏 ×
2
32
215 × 103 = 48 × 10 × 𝜏 ×
2
τ = 28.4 MPa <[τk]=40 MPa
Design is safe
Check for crushing:
Torque transmitted by the key
ℎ 𝑑
[𝑀𝑡 ] = 𝑙 ×× 𝜎𝑐𝑘 ×
2 2
8 32
215 × 103 = 48 × × 𝜎𝑐𝑘 ×
2 2
σck =71.09 MPa <[σck]=80 MPa
Design is safe.

UNIT III: TEMPORARY AND PERMANENT JOINTS

PART A
1. What are the advantages of screwed fasteners?
The advantages of screwed fasteners are
 They are highly reliable in operation
 They are convenient to assemble & disassemble
 A wide range of screws can be used for various operating conditions
 They are relatively cheap to produce.
2. Why are welded joints preferred over riveted joints?
Following are the advantages and disadvantages of welded joints over riveted joints.
Advantages
 The welded structures are usually lighter than riveted structures. This is due to
the reason, that in welding, gussets or other connecting components are not used.
 The welded joints provide maximum efficiency (may be 100%) which is not
possible in case of riveted joints.
 Alterations and additions can be easily made in the existing structures.
 As the welded structure is smooth in appearance, therefore it looks pleasing.
 In welded connections, the tension members are not weakened as in the case of
riveted joints.
 A welded joint has a great strength. Often a welded joint has the strength of the
parent metal itself.
 Sometimes, the members are of such a shape (i.e. circular steel pipes) that they
afford difficulty for riveting. But they can be easily welded.
 The welding provides very rigid joints. This is in line with the modern trend of
providing rigid frames.
  It is possible to weld any part of a structure at any point. But riveting requires
enough clearance.
 The process of welding takes less time than the riveting.
Disadvantages
 Since there is an uneven heating and cooling during fabrication, therefore the
members may get distorted or additional stresses may develop.
 It requires a highly skilled labour and supervision.
 Since no provision is kept for expansion and contraction in the frame, therefore
there is a possibility of cracks developing in it.
 The inspection of welding work is more difficult than riveting work.
3. How is a bolt designated? Give examples.
According to Indian standards, IS : 4218 (Part IV) 1976 (Reaffirmed 1996), the
complete designation of the screw thread shall include
1. Size designation: The size of the screw thread is designated by the letter `M'
followed by the diameter and pitch, the two being separated by the sign ×. When there
is no indication of the pitch, it shall mean that a coarse pitch is implied. For example,
A bolt thread of 10 mm size of fine pitch 1 mm is designated as M10 x 1 mm.
2. Tolerance designation: This shall include
(a) A figure designating tolerance grade as indicated below: ‘7’ for fine grade, ‘8’ for
normal (medium) grade, and ‘9’ for coarse grade.
(b) A letter designating the tolerance position as indicated below: ‘H’ for unit thread,
‘d’ for bolt thread with allowance, and ‘h’ for bolt thread without allowance.
For example, A bolt thread of 6 mm size of coarse pitch and with allowance on the
threads and normal (medium) tolerance grade is designated as M6-8d.
4. Name the possible modes of failure of 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.
5. What do you mean by bolt of uniform strength?
Bolts of Uniform Strength: When a bolt is subjected to shock loading, as in case of a
cylinder head bolt of an internal combustion engine, the resilience of the bolt should
be considered in order to prevent breakage at the thread. In an ordinary bolt shown
in Fig. (a), the effect of the impulsive loads applied axially is concentrated on the
weakest part of the bolt i.e. the cross-sectional area at the root of the threads.

In other words, the stress in the threaded part of the bolt will be higher than that in
the shank. Hence a great portion of the energy will be absorbed at the region of the
threaded part which may fracture the threaded portion because of its small length.
 If the shank of the bolt is turned down to a diameter equal or even slightly less than
the core diameter of the thread (Dc) as shown in Fig. (b), then shank of the bolt will
undergo a higher stress. This means that a shank will absorb a large portion of the
energy, thus relieving the material at the sections near the thread. The bolt, in this
way, becomes stronger and lighter and it increases the shock absorbing capacity of
the bolt because of an increased modulus of resilience. This gives us bolts of uniform
strength. The resilience of a bolt may also be increased by increasing its length.
A second alternative method of obtaining the bolts of uniform strength is shown in
Fig. (c). In this method, an axial hole is drilled through the head as far as the thread
portion such that the area of the shank becomes equal to the root area of the thread.
PART B
1. Design a knuckle joint to connect two circular rods subjected to an axial tensile
force of 50 kN. The rods are co-axial and a small amount of angular movements
between their axes is permissible. Design the joint and specify the dimensions of
its components. Select suitable materials for the parts.

Given: P = 50 x 103 N
Step 0: Selection of Material:
Assume C45 Steel with σy=360 N/mm2. (PSGDB 1.9) and assume a Factor of Safety = 3
∴Design Stress
𝜎𝑦 360
[σt ] = = = 120 𝑁/𝑚𝑚2
𝐹𝑂𝑆 3
and
[τ] = 0.5 [σt] = 60 N/mm2 and
[σc]= 2 [σt]=240 N/mm2
Step 1: Failure of the solid rod in tension
Load transmitted by the joint
𝜋
𝑃 = (𝑑)2 [𝜎𝑡 ]
4
𝜋
50 × 103 = (𝑑)2 × 120
4
⇒ d = 23.02 mm ≃25 mm (by R20 series PSGDB 7.20)
Step 2: Now the various dimensions are fixed as follows:
Diameter of pin; d1 = d = 25mm
Outer diameter of eye; d2 = 2 d1= 50mm
Diameter of knuckle pin head and collar;
d3 = 1.5d1= 37.5mm ≃ 38 mm
Thickness of single eye or rod end;
t = 1.25d1= 31.25mm ≃ 32 mm
Thickness of fork;
t1 = 0.75 d1= 18.75mm ≃20mm
Thickness of pin head;
t2 = 0.5 d1= 12.5mm ≃ 14mm
Step3: Failure of the knuckle pin in shear
Load transmitted by the joint
 𝝅
𝑷=𝟐× (𝒅𝟏 )𝟐 𝝉
𝟒
𝟓𝟎 × 𝟏𝟎𝟑 × 𝟒
𝛕 = = 𝟓𝟎. 𝟗 𝑴𝑷𝒂 < [𝛕] = 𝟔𝟎 𝐌𝐏𝐚
𝟐 × 𝝅 × 𝟐𝟓𝟐
Design is safe.
Since a small amount of angular movements between the rod axes is permissible; then
the pin should be checked for bending also. Therefore the bending stress
𝑷 𝒕𝟏 𝒕 𝟓𝟎 × 𝟏𝟎𝟑 𝟐𝟎 𝟑𝟐
𝑴𝒃 𝟐 ( 𝟑 + 𝟒) 𝟐 (𝟑 + 𝟒)
𝝈𝒕 = = 𝝅 = 𝝅 = 𝟐𝟑𝟗 𝐌𝐏𝐚 > [𝛔𝐭 ] = 𝟏𝟐𝟎 𝐌𝐏𝐚
𝒁 (𝒅𝟏 )𝟑 (𝟐𝟓)𝟑
𝟑𝟐 𝟑𝟐
Design is not safe.
Therefore modify the design for the design stress = 120 N/mm2.
𝟓𝟎 × 𝟏𝟎𝟑 𝟎. 𝟕𝟓𝒅𝟏 𝟏. 𝟐𝟓𝒅𝟏
( 𝟑 +
𝟏𝟐𝟎 = 𝟐 𝟒 )
𝝅
(𝒅 )𝟑
𝟑𝟐 𝟏
d1= 34.5 mm ≃ 35 mm
Then the other dimensions of the joint may be
Outer diameter of eye; d2 = 2 d1= 70mm
Diameter of knuckle pin head and collar;
d3 = 1.5 d1= 52.5mm ≃54mm
Thickness of single eye or rod end;
t = 1.25 d1= 43.75mm ≃ 44mm
Thickness of fork;
t1 = 0.75 d1= 26.25mm ≃28mm
Thickness of pin head;
t2 = 0.5 d1= 17.5mm ≃18mm
4. Failure of the single eye or rod end in tension
Load transmitted by the joint P = (d2 – d1) t × σt
50 × 103
𝜎𝑡 = = 32.4𝑀𝑃𝑎 < [σt ]
(70 − 35) × 44
Design is Safe.
5. Failure of the single eye or rod end in shearing
Load transmitted by the joint P = (d2 – d1) t × τ
50 × 103
τ = = 32.4𝑀𝑃𝑎 < [τ] = 60𝑀𝑃𝑎
(70 − 35) × 44
Design is Safe.
6. Failure of the single eye or rod end in crushing
Load transmitted by the joint P = d1 × t × σc
50 × 103
𝜎𝑐 = = 32.5 𝑀𝑃𝑎 < [σc ] = 240𝑀𝑃𝑎
35 × 44
Design is safe.
7. Failure of the forked end in tension
Load transmitted by the joint
 P = (d2 – d1) × 2t1 × σt
3
50 × 10
𝜎𝑐 = = 25.5𝑀𝑃𝑎 < [σt ]
(70 − 35) × 2 × 28
Design is safe.
8. Failure of the forked end in shear
Load transmitted by the joint
P = (d2 – d1) × 2t1 × τ
50 × 103
τ = = 25.5𝑀𝑃𝑎 < [τ]
(70 − 35) × 2 × 28
Design is safe.
9. Failure of the forked end in crushing
Load transmitted by the joint P = d1 × 2 t1 × σc
50 × 103
σc = = 25.5 𝑀𝑃𝑎 < [σc ]
35 × 2 × 28
Design is safe.
10. Draw the knuckle joint and show all the dimensions in the drawing.

2. Design and draw a cotter joint to support a load varying from 30 kN in

compression to 30 kN in tension; The material used is carbon steel for which the
following allowable stresses may be used. The load is applied statically. Tensile
stress = Compressive Stress = 50 MPa; Shear stress = 35 MPa and Crushing Stress =
90 MPa;
Solution:
Given: P = Load carried by the rods = 30 × 103 N
d = Diameter of the rods;
d1 = Outside diameter of socket;
d2 = Diameter of spigot or inside diameter of socket;
d3 = Outside diameter of spigot collar;
t1 = Thickness of spigot collar;
d4 = Diameter of socket collar;
c = Thickness of socket collar;
b = Mean width of cotter;
t = Thickness of cotter;
l = Length of cotter;
a = Distance from the end of the slot to the end of rod;
σt = Permissible tensile stress for the rods material = 50 MPa
τ = Permissible shear stress for the cotter material; = 35 MPa
σc = Permissible crushing stress for the cotter material = 90 MPa
1. Failure of the rods in tension
Tensile Load acting on the rod
𝜋 𝜋
𝑃 = × 𝑑 2 × 𝜎𝑡 ⇒ 30 × 103 = × 𝑑 2 × 50
4 4
d = 27.63 mm ≃ 28 mm
2. Failure of spigot in tension across the weakest section (or slot)
Tensile Load acting on the rod
𝜋
𝑃 = [ × 𝑑22 − 𝑑2 × 𝑡] 𝜎𝑡
4
𝜋 𝑑2
30 × 103 = [ × 𝑑22 − 𝑑2 × ] × 50
4 4
[∵ t = d2 /4]
⇒ d2 = 33.5 mm ≃ 34 mm and t = d2/4 = 8.5 mm ≃ 9 mm.
3. Failure of the rod or cotter in crushing
Crushing Load acting on the rod P =d2 × t × σc ⇒ 30×103 =34×9× σc
⇒σc = 98.04 MPa > [σc] = 90 MPa.
Design is not safe.
Therefore modify the design by taking
[σc] = 70 MPa and determine d2 and t.
d2
30 × 103 = d2 × × 70
4
⇒ d2 = 41.4 mm ≃ 42 mm and
t = d2/4 = 10.5 ≃ 12 mm
4. Failure of the socket in tension across the slot
Tensile Load acting on the rod
π
P = { [d12 − d22 ] − (d1 − d2 )t} σt
4
π
30 × 103 = { [d12 − 422 ] − (d1 − 42) × 12} × 50
4
⇒ 600 = 0.7854 d12 -1134.2 - 10d1+380
⇒ 0.7854 d12 - 10d1 – 1354.2 = 0
⇒ d1 = 48.4 mm ≃ 50 mm
5. Failure of cotter in shear
Shear Load acting on the rod P =2 b × t × τ
⇒ 30×103 = 2 b ×10×35
⇒ b = 42.9 mm ≃ 44 mm
6. Failure of the socket collar in crushing
Crushing Load acting on the rod
P = (d4 – d2) t × σc
⇒ 30×103 = (d4 – 34) × 10 × 90
⇒ d4 = 67.3 mm ≃ 68 mm
7. Failure of socket end in shearing
Shear Load acting on the rod
P =2 (d4 – d2) c × τ
⇒ 30×103 = 2 (68 – 34) × c × 35
⇒ c = 12.6 mm ≃ 14 mm
8. Failure of rod end in shear
Shear Load acting on the rod P = 2 a × d2 × τ
⇒ 30×103 = 2 a ×34× 35
⇒ a = 12.60 mm ≃ 14 mm
9. Failure of spigot collar in crushing
Crushing Load acting on the rod
π
P = { [d23 − d22 ]} σc
4
π
30 × 103 = [d23 − 342 ] × 70
4
⇒ d3 = 41.2 mm ≃ 42 mm
10. Failure of the spigot collar in shearing
Shear Load acting on the rod P = π d2 × t1 × τ ⇒32×103 = π×44× t1 ×39
⇒ t1 = 5.93 mm ≃ 6 mm
11. The length of cotter: l = 4 d = 4×28 = 112 mm
12. The taper in cotter should not exceed 1 in 24. In case the greater taper is required;
then a locking device must be provided.
13. The draw of cotter is generally taken as 2 to 3 mm.
14. Draw the cotter joint and show all the dimensions in the drawing.
3. A 125 × 95 × 10 mm angle is joined to a frame by two parallel fillet welds along
the edges of 15 mm leg. The angle is subjected to a tensile load of 180 kN. Find the
lengths of weld if the permissible static load per mm weld length is 430 N.

Solution:
Given: a + b = 125 mm ;
P = 180 kN = 180 × 103 N ; h = 15 mm
Allowable shear load per mm weld length
= 430 N/mm
Let la = Length of weld at the top,
lb = Length of weld at the bottom, and
l = Total length of the weld = la + lb
But total length of the weld
𝑇𝑜𝑡𝑎𝑙 𝑙𝑜𝑎𝑑 𝑃 180 × 103
𝑙= = = 418.6 𝑚𝑚 ≃ 420 𝑚𝑚
𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑙𝑜𝑎𝑑 𝑝𝑒𝑟 𝑚𝑚 430
la + lb = 420 mm
Now let us find out the position of the centroidal axis.
Let y = b = Distance of centroidal axis from the bottom of the angle.
𝐴1 𝑦1 + 𝐴2 𝑦2
𝑦=𝑏=
𝐴1 +𝐴2
 10 115
95 × 10 × ( 2 ) + 10 × 115 × (10 + 2 )
𝑏= = 39.23 𝑚𝑚
95 × 10 + 10 × 115
And a = 125 – 39.23 = 85.77 mm
We know that
𝑙𝑏 × 𝑏 𝑙𝑏 × 39.23
𝑙𝑎 = = = 0.46 𝑙𝑏
𝑎 85.77
But la + lb = 420 mm
0.46 lb + lb = 420 mm
lb =287.7 ≃ 288 mm
and la = 420 – 288 = 132 mm

4. A solid circular shaft; 26mm in diameter; is welded to a support by means of a

fillet weld as shown in Fig. Determine the leg dimension of the weld if the
permissible shear stress is 95 MPa.

Solution:
Given: P = 10 kN = 10 x 103 N; d = 45 mm.
h = Size of the fillet weld.
For fillet weld & static loading the design shear stress of the weld
[τ] = 95 MPa.
- Introduce two equal and opposite forces at the Centre of Gravity of weld P1 = P2 = P
- P1 induces a direct shear stress
𝑃1 10 × 103 10 × 103 90
𝜏𝑑 = = = = 𝑀𝑃𝑎
𝐴 𝜋 × 𝑑 × 0.707 ℎ 𝜋 × 50 × 0.707 ℎ ℎ
- P2 and P induces a bending moment in the weld and the bending stress
𝑀𝑏
𝜎𝑏 =
𝑍
Where Mb = Bending Moment
= 10 × 103 × 200 = 2000 × 103 𝑁 − 𝑚𝑚
Z = Section modulus of weld = 0.707 × ℎ × 𝑍𝑤
Zw = Section modulus of weld line from PSGDB 11.6.
𝜋𝑑2 𝜋 × 502
𝑍𝑤 = = = 1963.5 𝑚𝑚2
4 4
Therefore Z = 0.707 × ℎ × 𝑍𝑤 =1388.2 h mm3.
 2000 × 103 1.441 × 103
𝜎𝑏 = = 𝑀𝑃𝑎
1388.2 ℎ ℎ
- By Maximum shear stress theory
𝜎𝑏 2
[𝜏] = √( ) + 𝜏𝑑 2
2
2
1.441 × 103
ℎ 90 2 726
√
95 = ( ) +( ) =
2 ℎ ℎ

h =7.64 mm∼ 8 mm.

5. A rectangular steel plate is welded as a cantilever to a vertical column and
supports a single concentrated load P; as shown in Fig. Determine the weld size if
shear stress in the same is not to exceed 140MPa.

Solution:
Given: P = 60 kN; [τ] = 140 MPa; b=50mm; d=100mm
- Introduce two equal and opposite forces at the Centre of Gravity of weld P1 = P2 = P =
60 kN
- P1 induces a direct shear stress
𝑃1 60 × 103
𝜏𝑑 = =
𝐴 (2𝑏 + 𝑑) × 0.707 ℎ
60 × 103 424.3
= = 𝑀𝑃𝑎
(2 × 50 + 100) × 0.707 ℎ ℎ
- P2 and P induces a torsional moment in the weld and the torsional shear stress
𝑀𝑡 𝑅
𝜏𝑠 =
𝐽
Where Mt = Twisting Moment
= 60 × 103 × (150 + (50 − 𝑁𝑦 ))𝑁 − 𝑚𝑚
J= Polar modulus of weld = 0.707 × ℎ × 𝐽𝑤
Jw = Polar modulus of weld line from PSGDB 11.6.
(2𝑏 + 𝑑)3 𝑏 2 (𝑏 + 𝑑)2 (2 × 50 + 100)3 502 (50 + 100)2
𝐽𝑤 = − = − = 385416.7 𝑚𝑚2
12 (2𝑏 + 𝑑) 12 (2 × 50 + 100)
Therefore J = 272489.6 h mm3.
Also
𝑏2 502
𝑁𝑦 = = = 12.5 𝑚𝑚
2𝑏 + 𝑑 2 × 50 + 100
𝑀𝑡 = 60 × 103 × (150 + (50 − 12.5))
= 11250 × 103 𝑁 − 𝑚𝑚
Also maximum radius of weld
𝑅 = √(50 − 12.5)2 + 502 = 62.5 mm
(50 − 12.5)
cos 𝜃 = = 0.6
62.5

The torsional shear stress

𝑀𝑡 × 𝑅 11250 × 103 × 62.5 2580.4
𝜏𝑠 = = = 𝑁/𝑚𝑚2
𝐽 272489.6 ℎ ℎ
Resultant shear stress
[𝜏] = √𝜏𝑑 2 + 𝜏𝑠 2 + 2𝜏𝑑 𝜏𝑠 𝑐𝑜𝑠𝜃

424.3 2 2580.4 2 424.3 2580.4

140 = √( ) +( ) +2×( )×( ) × 0.6
ℎ ℎ ℎ ℎ
2855.2
140 = => ℎ = 20.4 𝑚𝑚 ≅ 22𝑚𝑚
ℎ
6. The structural connection shown in fig. is subjected to an eccentric force P of 10
kN with an eccentricity of 500 mm. The centre distance between bolts 1 and 2 is
200 mm and 1 and 3 is 150 mm. All the bolts are identical. Assume τ =80 MPa for
bolt material. Design the size of the bolts.
P = 10000N; e = 500mm; [τ] = 80MPa; n = 4
- Introduce two equal and opposite forces at the Centre of Gravity of weld P1 = P2 = P =
10 kN
- P1 induces a direct shear load
𝑃 10 × 103
𝑃𝑑 = = = 2.5 × 103 𝑁
𝑛𝑏 4
- P2 and P induces a torsional moment in the weld and the torsional shear stress
- Due to P & P2; the bolts are subjected to secondary shear stress and the bolts near to
the load are heavily loaded with respect to the centre of gravity CG.
- From the geometry of figure we can conclude Bolt No. 2 & 4 are heavily loaded
- The radius of rotation of the bolts from the centre of gravity are
𝑟1 = 𝑟2 = 𝑟3 = 𝑟4 = √752 + 1002 = 125 𝑚𝑚
and
100
𝑐𝑜𝑠𝜃 = = 0.8
125
Therefore the secondary torsional shear load acting on each bolt
𝑃 × 𝑒 × 𝑟2 10000 × 500 × 125
𝑃𝑠2 = 𝑃𝑠4 = 2 2 2 2
= = 10000 𝑁 = 𝑃𝑠
𝑟1 + 𝑟2 + 𝑟3 + 𝑟4 4 × 1252
Resultant shear load

𝑃𝑅 = √𝑃𝑑 2 + 𝑃𝑠 2 + 2𝑃𝑑 𝑃𝑠 𝑐𝑜𝑠𝜃

𝑃𝑅 = √(2.5 × 103 )2 + (10 × 103 )2 + 2 × 2.5 × 103 × 10 × 103 × 0.8

PR = 12093.4 N
Then the resultant shear stress
𝑃𝑅 4 × 12093.4
[𝜏] = 𝜋 => 80 =
2 𝜋 × 𝑑𝑐 2
4 × 𝑑𝑐
Core diameter of the thread 𝑑𝑐 = 13.87 mm
Major diameter of the thread
𝑑𝑐 13.87
𝑑= = = 16.52𝑚𝑚 ≈ 𝑀18 𝑚𝑚
0.84 0.84
PART C
1. Two flat plates subjected to a tensile force F are connected together by means of
double-strap butt joint as shown in Fig. The force F is 250 kN and the width of the
plate b is 200 mm. The rivets and plates are made of the same steel and the
permissible stresses in tension, compression and shear are 70, 100 and 60 N/mm2
respectively. Calculate:
(i) The diameter of the rivets;
(ii) The thickness of the plates;
(iii) The dimensions of the seam, viz., p, pt and m; and
(iv) The efficiency of the joint

Solution:
Given P = 250 kN; b = 200 mm; [σt] = 70 N/mm2; [τ] = 60 N/mm2; σc = 100 N/mm2.
Step I Diameter of rivets
There are five rivets subjected to double shear
𝜋
𝐹𝑠 = 2 [ 𝑑2 [𝜏]. 𝑖]
4

d = 23.03 or 25 mm (i)
Step II Thickness of the plates
 In case of tension in the plate, the first thought is to investigate the section-XX passing
through the centres of the three holes as shown in Fig.
 This section has minimum cross-sectional area.
 However, if the main plate is to break at this section, the two-hole section, denoted by
YY, must also fail before the joint will break.
 This failure at the section-YY may be due to shear failure in two rivets or crushing
failure in the plate at two holes.
 On the other hand, the plate might fail in tension at the two-hole section without
affecting the three hole section.
 Therefore, strength equations are written for two-hole sections rather than three-
hole sections. Or,
(b – 2d).t.[σt] = F
(200 – 2 × 25) t (70) = 250 × 103
t = 23.81 or 25 mm
Step III Pitch of rivets
The pitch of the rivets is given by,

p = 66.67 or p = 65 mm
The dimensions of the seam are as follows:
e = 1.5 d = 1.5(25) = 37.5 or 40 mm
pt = 0.6.p = 0.6 (65) = 39 or 40 mm
Step IV Efficiency of joint:
𝜋 𝜋
𝐹𝑠 = 2 [ 𝑑2 [𝜏]. 𝑖] = 2 [ (25)2 [60](5)]
4 4
= 294524.31 N (a)
Ft = (b – 2d)t.[σt] = (200 – 2 × 25)(25)(70)
= 262 500 N (b)
Fc =i. d. t. [σc] = (5) 25 (25)(100)
= 312 500 N (c)
From (a), (b) and (c), the lowest strength is
262500 N.
The strength of the solid plate is given by,
F = b.t. [σt] = 200 (25) (70) = 350 000 N
Therefore, the efficiency of the joint is given by,

UNIT IV: ENERGY STORING ELEMENTS AND ENGINE COMPONENTS

PART A
1. Distinguish between close coiled and open coiled springs.
The helical springs are said to be closely coiled when the spring wire is coiled so close
that the plane containing each turn is nearly at right angles to the axis of the helix and
the wire is subjected to torsion. In other words, in a closely coiled helical spring, the
helix angle is very small, it is usually less than 10°.
In open coiled helical springs, the spring wire is coiled in such a way that there is a
gap between the two consecutive turns, as a result of which the helix angle is large.
2. Explain about surge in springs?
When one end of the spring is resting on a rigid support and the other end is loaded
suddenly, all the coils of spring does not deflect equally, because some time is required
for the propagation of stress along the wire. Thus a wave of compression propagates
to the fixed end from where it is reflected back to the deflected end this wave passes
through the spring indefinitely. If the time interval between the load application and
that of the wave to propagate are equal, then resonance will occur. This will result in
very high stresses and cause failure. This phenomenon is called surge.
3. Why Wahl's factor is to be considered in the design of helical compression
springs?
The curvature of the wire increases the stress on the inside of the spring but decreases
it only slightly on the outside. This curvature stress is primarily important in fatigue
because the loads are lower and there is no opportunity for localized yielding.
For static loading, these stresses can normally be neglected because of strain-
strengthening with the first application of load. It is necessary to find the curvature
factor in a roundabout way.
 The Ks factor, which corrects for both curvature and direct shear. Then this factor is
given by either of the equations
4𝐶 − 1 0.615
𝐾𝑠 = +
4𝐶 − 4 𝐶
This is called as the Wahl factor.
(or)
The effect of direct shear is appreciable for springs of small spring index C. It may be
noted that when the springs are subjected to static loads, the effect of wire curvature
may be neglected, because yielding of the material will relieve the stresses. In order
to consider the effects of both direct shear as well as curvature of the wire, a Wahl’s
stress factor (K) introduced by A.M. Wahl may be used. The resultant diagram of
torsional shear, direct shear and curvature shear stress is shown in Fig

4. How does the function of flywheel differ from that of governor?

The function of a governor in engine is entirely different from that of a flywheel. It
regulates the mean speed of an engine when there are variations in the load, e.g. when
the load on the engine increases, it becomes necessary to increase the supply of
working fluid. On the other hand, when the load decreases, less working fluid is
required. The governor automatically controls the supply of working fluid to the
engine with the varying load condition and keeps the mean speed within certain
limits.
The flywheel does not maintain a constant speed, it simply reduces the fluctuation of
speed. In other words, a flywheel controls the speed variations caused by the
fluctuation of the engine turning moment during each cycle of operation. It does not
control the speed variations caused by the varying load.
5. What types of stresses are produced in a disc flywheel?
A flywheel consists of a rim at which the major portion of the mass or weight of
flywheel is concentrated, a boss or hub for fixing the flywheel on to the shaft and a
number of arms for supporting the rim on the hub.
The following types of stresses are induced in the rim of a flywheel:
 Tensile stress due to centrifugal force,
 Tensile bending stress caused by the restraint of the arms, and
 The shrinkage stresses due to unequal rate of cooling of casting. These stresses
may be very high but there is no easy method of determining. This stress is taken
care of by a factor of safety.
6. Why is I-section preferred for connecting rod?
I section is preferred for connecting rod because it has less weight so inertia force will
be less and consequently greater bending strength. Also twice every revolution, the
connecting rod comes to a stop. This exerts a massive pressure on the big-end bearing
and on the little-end bearing. By reducing the mass of the rod, this pressure is reduced.
The typical "I" section reduces the mass without weakening the rod.
PART B
1. A relief valve must blow off at a pressure of 1.5Mpa and should lift by 5mm for a
7% increase in pressure. The valve diameter is 60mm. Take the spring index as 6.
Maximum allowable shear stress of the spring material is 650 MPa. The diameters
of the available spring wires in mm are 13, 14, 15, 16 and 18. Modulus of rigidity is
81,370 MPa. Consider Wahl’s correction factor. Take inactive number of turns as 1.
Design the valve spring.
Solution:
Given: Pressure pmin = 1.5 MPa; pmax = 1.07× pmin =1.605 MPa; y = 5 mm; DV = 60 mm; C =
6; [τ] = 650 MPa; G = 81370 MPa,
Minimum load acting on the valve spring
𝝅 𝝅
𝑷𝒎𝒊𝒏 = 𝑫𝑽 𝟐 𝒑𝒎𝒊𝒏 = × 𝟔𝟎𝟐 × 𝟏. 𝟓 = 𝟒𝟐𝟒𝟏. 𝟐 𝑵
𝟒 𝟒
Maximum load acting on the valve spring
𝝅 𝝅
𝑷𝒎𝒂𝒙 = 𝑫𝑽 𝟐 𝒑𝒎𝒂𝒙 = × 𝟔𝟎𝟐 × 𝟏. 𝟔𝟎𝟓 = 𝟒𝟓𝟑𝟖. 𝟏 𝑵
𝟒 𝟒
The maximum shear stress induced in the spring wire (PSGDB 7.100)
𝟖𝑷𝒎𝒂𝒙 𝑪
[𝝉] = 𝑲𝒔
𝝅𝒅𝟐
For C = 6, the Wahl’s stress factor
𝟒𝑪 − 𝟏 𝟎. 𝟔𝟏𝟓 𝟒 × 𝟔 − 𝟏 𝟎. 𝟔𝟏𝟓
𝑲𝒔 = + = + = 𝟏. 𝟐𝟓𝟐𝟓
𝟒𝑪 − 𝟒 𝑪 𝟒×𝟔−𝟒 𝟔
The maximum shear stress
𝟖 × 𝟒𝟓𝟑𝟖. 𝟏 × 𝟔
𝟔𝟓𝟎 = 𝟏. 𝟐𝟓𝟐𝟓 ×
𝝅𝒅𝟐
Wire diameter d = 11.6 mm  13 mm (Given standard wire diameter)
Mean coil Diameter D = C.d = 6×13 = 78 mm
The deflection of the spring (PSGDB 7.100)
𝟖𝑷𝑪𝟑 𝒏
𝒚=
𝑮𝒅
Load for deflection y,
P = Pmax - Pmin = 4538.1 – 4241.2 = 269.9N
The deflection of the spring
𝟖 × 𝟐𝟔𝟗. 𝟗 × 𝟔𝟑 × 𝒏
𝟓=
𝟖𝟏𝟑𝟕𝟎 × 𝟏𝟑
No. of coils n = 11.4 coils  12 coils
Total No. of coils 𝑛′ = 𝑛 + 1 = 12 + 1 = 13 𝑐𝑜𝑖𝑙𝑠
Free length of the spring
𝐿𝑓 = 𝑛′ 𝑑 + 𝑦𝑚𝑎𝑥 + (𝑛′ − 1) × 1
Maximum deflection
𝟖𝑷𝒎𝒂𝒙 𝑪𝟑 𝒏 𝟖 × 𝟒𝟓𝟑𝟖. 𝟏 × 𝟔𝟑 × 𝟏𝟐
𝒚𝒎𝒂𝒙 = = = 𝟖𝟖. 𝟗𝟔 𝒎𝒎
𝑮𝒅 𝟖𝟏𝟑𝟕𝟎 × 𝟏𝟑
Free length of the spring
𝑳𝒇 = 𝟏𝟑 × 𝟏𝟑 + 𝟖𝟖. 𝟗𝟔 + (𝟏𝟑 − 𝟏) × 𝟏 = 𝟐𝟔𝟗. 𝟗𝟔 𝒎𝒎

Solid length of the spring

𝑳𝒔 = 𝒏′ 𝒅 = 𝟏𝟑 × 𝟏𝟑 = 𝟏𝟔𝟗 𝒎𝒎
Pitch of the spring for squared and ground end (PSGDB 7.100)
𝑳𝒇 − 𝟐𝒅 𝟐𝟔𝟗. 𝟗𝟔 − 𝟐 × 𝟏𝟏𝟑
𝒑= = = 𝟑. 𝟕 𝒎𝒎
𝒏 𝟏𝟐

2. A truck spring has 12 numbers of leaves, two of which are full length leaves. The
spring supports are 1.05 m apart and the central band is 85 mm wide. The central
load is to be 54 kN with a permissible stress of 280 MPa. Determine the thickness
and width of the steel spring leaves. The ratio of the total depth to the width of-the
spring is 3. Also determine the deflection of the spring.
Solution:
Given: n = 12, ne = 2, ng = n – ne = 10, 2L1 = 1050 mm, l = 85 mm, 2P = 54000 N,
[σb]=280 MPa, (nt/b) = 3
The effective length of the spring 2L = 2L1 – I = 1050-85 = 965 mm
Then L = 482.5 mm
Load on spring 2P = 54 × 103 N
Then P = 27 × 103 N
We know the extra full length leaves are highly stressed
18𝑃𝐿
[𝜎𝑏𝑒 ] =
𝑏𝑡 2 (3𝑛𝑒 + 2𝑛𝑔 )
𝑛𝑡 12𝑡
𝐺𝑖𝑣𝑒𝑛 = =3
𝑏 𝑏
Then b = 4t
3
18 × 27 × 10 × 482.5 2254759.6
280 = 2
= 𝑀𝑃𝑎
4𝑡 × 𝑡 (3 × 2 + 2 × 10) 𝑡3
Therefore thickness of leaves t = 20.04 mm ≃ 21 mm
Then the width of the leaves b = 4t = 4×21=84 mm
Deflection of the spring
12𝑃𝐿3
𝑦=
𝐸𝑏𝑡 3 (3𝑛𝑒 + 2𝑛𝑔 )
Assume Young’s Modulus for Steel E = 210 GPa = 210 × 103 MPa
 12 × 27000 × 482.53
𝑦= = 8.57 𝑚𝑚
210 × 103 × 84 × 213 (3 × 2 + 2 × 10)

3. A multi-cylinder engine is to run at a constant load at a speed of 600 rpm. On

drawing the crank effort diagram to a scale of 1 mm=250 N- m and 1 mm = 3
degrees, the areas in sq mm above and below the mean torque line are as follows:
+ 160, -172, + 168, -191, +197, -162 sq. mm. The speed is to be kept within ± 1% of
the mean speed of the engine. Calculate the necessary moment of the flywheel.
Determine suitable dimensions for cast iron flywheel with a rim whose breadth is
twice its radial thickness. The density of cast iron is 7250 kg/cu.m, and its working
stress in tension is 6 MPa. Assume that the rim contributes 92% of the flywheel
effect.
Solution:
Given: N = 600 rpm; 1 mm = 250 N-m; I mm = 3°= 0.524 rad; Ks = ±1% of mean speed =
0.02; b = 2h (Given); ρ = 7250 kg/m3, γ = 7.25×10-5 N/mm3,
[σt] = 6 MPa; K = 92% = 0.92,

Angular velocity of the flywheel

2𝜋𝑁 2 × 𝜋 × 600
𝜔= = = 62.83 𝑟𝑎𝑑/𝑠𝑒𝑐
60 60
Area of the crank angle and torque diagram
𝜋
1 𝑚𝑚2 = 250 × 3 × ( ) = 13.09 𝑁 − 𝑚
180
Let the total energy at A = E.
Therefore from Fig., we find that
Energy at B = E + 160
Energy at C = E + 160 – 172 = E – 12
Energy at D = E – 12 + 168 = E + 156
Energy at E = E + 156 – 191= E – 35
Energy at F = E – 35 + 197 = E + 162
Energy at G = E + 162 – 162 = E = Energy at A
From above, we find that the energy is maximum at F and minimum at E.
∴ Maximum energy = E + 162
And minimum energy = E – 35
We know that the maximum fluctuation of energy,
Δ E = Maximum energy – Minimum energy
Δ E = (E + 162) – (E – 35) = 197 mm2
= 197 × 13.09 = 2578.73 N-m
Since the fluctuation of speed is ± 1% of the mean speed (ω), therefore total fluctuation
of speed,
ω1 – ω2 = 2% ω = 0.02 ω
and coefficient of fluctuation of speed,
𝜔1 − 𝜔2
𝐾𝑠 = = 0.02
𝜔
Also maximum fluctuation of energy stored in the rim is 92%,
Therefore Energy stored in the flywheel
0.92 × ∆𝐸 = 𝐼. 𝐾𝑠 . 𝜔2
∴ 0.92 × 2578.73 = 𝐼 × 0.02 × (62.83)2
Mass moment of inertia of the flywheel
I = 30.1 N-m2.
The centrifugal stress acting on the flywheel
[σt ] = ρ × V 2
6 × 106 = 7250 × V 2
Then the velocity of the flywheel rim
V = 28.77 m/sec
Also the radius of the flywheel
𝑉 28.77
𝑅= = = 0.458 𝑚 = 458 𝑚𝑚
𝜔 62.83
The mass of the flywheel can be calculated from the moment of inertia taking radius of
gyration k = R
𝐼 = 𝑚𝑘 2 = 𝑚𝑅 2
30.1 = 𝑚 × 0.4582
Then m = 143.5 kg, then Weight W = 10 m = 1435 N
But the weight of the flywheel 𝑊 = 𝜋. 𝐷. 𝑏. ℎ. 𝛾
Substituting the values,
D = 2×0.458=0.916m = 916 mm
Given b/h =2, then b=2h
Then
1435 = 𝜋 × (916) × 2ℎ × ℎ × 7.25 × 10−5
The width of the flywheel rim
h = 58.7 mm 60 mm
Rim thickness b = 120 mm.
The No. of arms of the flywheel may be taken as
n = 4 when D< 1000 mm
Check the stresses in the Rim (PSGDB 7.120)
Bending Stress in the rim
𝜋2 × 𝑉2 × 𝐷 × 𝛾
𝜎𝑏 =
𝑛2 × 𝑔 × ℎ
𝜋2 × 𝑉2 × 𝐷 × 𝜌
= [∵ 𝛾 = 𝜌. 𝑔]
𝑛2 × ℎ
𝜋 2 × 287702 × 916 × 7.25 × 10−5
𝜎𝑏 = = 57.6 𝑁/𝑚𝑚2
42 × 9810 × 60
The resultant stress (PSGDB 7.120)
3 1 3 1
𝜎𝑇𝑜𝑡𝑎𝑙 = 𝜎𝑡 + 𝜎𝑏 = × 6 + × 57.6 = 18.9 𝑀𝑃𝑎 < [𝜎𝑡 ] = 35 𝑀𝑃𝑎
4 4 4 4
Design is safe.

4. Design a cast iron flywheel for a four-stroke IC engine developing 60 kW at 150

rpm with 75 explosions per minute. The total fluctuation of speed is limited to 0.5%
of the mean on either side. The work done during the working stroke is 1.4. times
the work clone during the cycle. Assume that the flywheel stores 16/15 times the
energy stored by the rim and the rim section having width four times the depth 80
that the hoop stress does not exceed 4 N/mm2.
Solution:
Given: P = 60×103 W; N = 150 rpm; WDP = 1.4×WDcycle; b/h = 4; 𝜎t = 4 MPa=4×106
Pa, 𝜌 = 7200 kg/m3
Since the speed variation is 0.5% either way from the mean, therefore the total
fluctuation of speed,
N1 – N2 = 1% of mean speed = 0.01 N
and coefficient of fluctuation of speed,
𝑁1 − 𝑁2
𝐾𝑠 = = 0.01
𝑁
Angular velocity
2𝜋𝑁 2 × 𝜋 × 150
𝜔= = = 15.7 𝑟𝑎𝑑/𝑠𝑒𝑐
60 60
Mean torque
𝑃 × 60 60 × 103 × 60
𝑀𝑡𝑚𝑒𝑎𝑛 = = = 3819.7 𝑁 − 𝑚
2𝜋𝑁 2𝜋 × 150
From the crank angle – torque diagram,
Workdone per cycle = Mtmean × θ = 3819.7 × 4π = 48000 N − m
Let WDP = Work done during Power stroke
WDCycle = Average Work done
Given
WDP = 1.4 × WDCycle = 1.4 × 48000 = 67200 N − m
Therefore work done during expansion or power stroke WDP = 67200 N-m
From the figure, the work done during expansion
stroke is shown in Δ ABC
1
∴ Δ ABC = × AC × BF
2
1
∴ WDP = × π × Mtmax
2
1
67200 = × 𝜋 × 𝑀𝑡𝑚𝑎𝑥
2
BF = Mtmax = 42781 N − m
The height above the mean torque line
BG = BF − GF = Mtmax − Mtmean = 42780.9 − 3819.7 = 38961.2 N − m
Since the area BDE (shown shaded in Fig.) above the mean torque line represents the
maximum fluctuation of energy (ΔE)
By similar triangles ΔABC and ΔDBE
Area of ∆DBE ∆E BG2
= = 2
Area of ∆ABC WDP BF
BG2 38961.22
∆𝐸 = WDP × 2 = 67200 × = 55736 𝑁 − 𝑚
BF 42780.92
The flywheel stores 16/15 times the energy stored by the rim of the flywheel
16
× ∆𝐸 = 𝐼. 𝐾𝑠 . 𝜔2
15
14
∴ × 55736 = 𝐼 × 0.01 × (15.7)2
15
Mass moment of inertia of the flywheel
I = 21104.4 kg-m2.
The centrifugal stress acting on the flywheel
σt = ρ × V 2
4 × 106 = 7200 × V 2
Then the velocity of the flywheel rim V = 23.6 m/sec
Also the radius of the flywheel
𝑉 23.6
𝑅= = = 1.5032 𝑚 = 1504 𝑚𝑚 = 1.504 𝑚
𝜔 15.7
The mass of the flywheel can be calculated from the moment of inertia taking radius of
gyration k = R
𝐼 = 𝑚𝑘 2 = 𝑚𝑅 2
21104.4 = 𝑚 × 1.5042
Then m = 9330 kg.
But the mass of the flywheel 𝑚 = 𝜋. 𝐷. 𝑏. ℎ. 𝜌
Substituting the values, D = 2×1.504=3.008 m,
Given b/h =4, then b = 4h
Then
9330 = 𝜋 × (2 × 1.504) × ℎ × 4ℎ × 7200
The width of the flywheel rim
h = 0.1852 m=185.2 mm ≃ 186 mm
Rim thickness b = 744 mm.
Check the stresses in the Rim (PSGDB 7.120) Take No. of arms n = 6 for D > 1000 mm
Bending stress in the rim
𝜋2 × 𝑉2 × 𝐷 × 𝛾 𝜋2 × 𝑉2 × 𝐷 × 𝜌
𝜎𝑏 = = [∵ 𝛾 = 𝜌. 𝑔]
𝑛2 × 𝑔 × ℎ 𝑛2 × ℎ
𝜋 2 × 23.62 × 3.008 × 7200
𝜎𝑏 = = 17.8 × 106 𝑁/𝑚2 = 17.8 𝑁/𝑚𝑚2
62 × 0.186
The resultant stress (PSGDB 7.120)
3 1 3 1
𝜎𝑇𝑜𝑡𝑎𝑙 = 𝜎𝑡 + 𝜎𝑏 = × 4 + × 17.8 = 7.45 𝑀𝑃𝑎 < [𝜎𝑡 ] = 35 𝑀𝑃𝑎
4 4 4 4
Design is safe.
The shaft diameter can be found out by using Torque equation
Given
𝑀𝑡𝑚𝑎𝑥 = 2 × 𝑀𝑡𝑚𝑒𝑎𝑛 = 2 × 3819.7 = 7639.4 𝑁 − 𝑚 = 7639.4 × 103 𝑁 − 𝑚𝑚
Assume the design shear stress for the shaft material as [τ] = 50 MPa
Therefore
16𝑀𝑡𝑚𝑎𝑥
[𝜏] =
𝜋𝑑𝑠3
16 × 7639.4 × 103
50 =
𝜋𝑑𝑠3
By solving ds = 91.9 mm = 100 mm by R20 series
Hub of the flywheel d = 2× ds = 2×100=200 mm
Length of the Hub Lh = 2× ds = 200 mm
For Diameter ds = 100 mm, the key size from PSGDB 5.16
Width of the key w = 28 mm
Thickness of key t = 16 mm
To find the cross section of the arm of flywheel from PSGDB 7.120
Assume the design bending stress for the arm 𝜎𝑏1 = 6.5 𝑀𝑃𝑎
𝑀𝑡𝑚𝑎𝑥 (𝐷 − 𝑑)
𝜎𝑏1 =
𝑛. 𝑍𝑦𝑦 . 𝐷
By substituting the values
7639.4 × 103 (3008 − 200)
6.5 =
6 × 𝑍𝑦𝑦 × 3008
Then Zyy = 182858 mm3
But the major axis of the elliptical cross section from PSGDB 7.120
3 64 × 𝑍𝑦𝑦 3 64 × 182858
𝑎=√ =√ = 155.01 156 𝑚𝑚
𝜋 𝜋
Then the minor axis c = a/2 = 156/2 = 78 mm
Flywheel effect
= 𝑚𝑅 2 = 9330 × (1.504)2 = 21104.6 𝑘𝑔 − 𝑚2

5. A punching machine makes 25 working strokes per minute and is capable of

punching 25 mm diameter holes in 18 mm thick steel plates having ultimate shear
strength of 300 MPa. The punching operation takes place during 1/l0th of a
revolution of the crank shaft. Estimate the power needed for the driving motor,
assuming mechanical efficiency of 95%. Determine suitable dimensions for the rim
cross-section of the flywheel, which is to revolve at 9 times the speed of the crank
shaft. The permissible coefficient of fluctuation of speed is 0.1. The diameter of the
flywheel must not exceed 1.4 m owing to space restrictions. Check for the
centrifugal stress induced in the rim.
Solution:
Given: n = 25; d1 = 25 mm ; t1 = 18 mm ; τu = 300 MPa = 300 N/mm2 ; ηm = 95% = 0.95 ;
KS = 0.1 ; σt = 6 MPa = 6 N/mm2 ; ρ = 7250 kg/m3 ; D = 1.4 m or R = 0.7m
Power needed for the driving motor
 We know that the area of plate sheared,
AS = πd1 × t1 = π× 25 × 18 = 1414 mm2
 ∴Maximum shearing force required for punching,
FS = AS × τu = 1414 × 300 = 424 200 N
 As the hole is punched, it is assumed that the shearing force decreases uniformly from
maximum value to zero.
 Energy required per stroke
= Average shear force × Thickness of plate
1 1
= 𝐹𝑆 × 𝑡1 = × 424200 × 18 = 3817.8 × 103 𝑁 − 𝑚𝑚
2 2
 ∴ Energy required per min
= Energy / stroke × No. of working strokes / min
= 3817.8 × 103 × 25 = 95.45 × 106 N-mm
= 95 450 N-m
 We know that the power needed for the driving motor
𝐸𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑝𝑒𝑟 𝑚𝑖𝑛 95450
= = = 1675 𝑊 = 1.675 𝑘𝑊
60 × 𝜂𝑚 60 × 0.95
Dimensions for the rim cross-section
 Considering the cross-section of the rim as rectangular and assuming the width of rim
equal to twice the thickness of rim.
 Let h = Thickness of rim in metres, and b = Width of rim in metres = 2h.
 ∴ Cross-sectional area of rim,
A = b ×h= 2h ×h = 2h2
 Since the punching operation takes place (i.e. energy is consumed) during 1/10th of a
revolution of the crank shaft, therefore during 9/10th of the revolution of a crank
shaft, the energy is stored in the flywheel.
 ∴ Maximum fluctuation of energy,
9 Energy 9
Δ𝐸 = × = × 3817.8 × 103 = 3436 × 103 N − mm = 3436 N − m
10 stroke 10
 Let m = Mass of the flywheel.
 Since the hub and the spokes provide 5% of the rotational inertia of the wheel,
therefore the maximum fluctuation of energy provided by the flywheel rim will be
95%.
 ∴ Maximum fluctuation of energy provided by the rim,
(Δ E)rim = 0.95 × Δ E = 0.95 × 3436 = 3264 N-m
 Since the flywheel is to revolve at 9 times the speed of the crankshaft and there are
25 working strokes per minute, therefore
 Mean speed of the flywheel,
N = 9 × 25 = 225 r.p.m. and
 mean angular speed,
ω = 2 π × 225 / 60 = 23.56 rad/s
 We know that maximum fluctuation of energy (ΔE),
3264 = m.R2.ω[Link] = m (0.7)2 (23.56)2 ×0.1 = 27.2 m
∴ m = 3264 / 27.2 = 120 kg
 We also know that mass of the flywheel (m),
120 = A × π D × ρ = 2 h2 × π × 1.4 × 7250
= 63 782 h2
∴ h2 = 120 / 63782 = 0.001 88 or
h = 0.044 m = 44 mm.
and b = 2h = 2 × 44 = 88 mm.
Check the stresses in the Rim (PSGDB 7.120)
 The No. of arms of the flywheel may be taken as
n = 4 when D< 1000 mm
 Bending Stress in the rim
𝜋2 × 𝑉2 × 𝐷 × 𝛾 𝜋2 × 𝑉2 × 𝐷 × 𝜌
𝜎𝑏 = = [∵ 𝛾 = 𝜌. 𝑔]
𝑛2 × 𝑔 × ℎ 𝑛2 × ℎ
 the velocity of the flywheel rim
𝜋𝐷𝑁 𝜋 × 1.4 × 225
𝑉= = = 16.5 𝑚/𝑠𝑒𝑐
60 60
 Bending Stress in the rim
𝜋 2 × 16.52 × 1.4 × 7250
𝜎𝑏 = = 38740124.9 𝑁/𝑚2 = 38.7 × 106 𝑁/𝑚2
42 × 0.044
= 38.7 𝑁/𝑚𝑚2
 The centrifugal stress acting on the flywheel
 [σt ] = ρ × V 2 = 7250 × (16.5)2 = 1973812 𝑁⁄𝑚2 = 1.97 × 106 𝑁⁄𝑚2
= 1.97 𝑁⁄𝑚𝑚2
 The resultant stress (PSGDB 7.120)
3 1 3 1
𝜎𝑇𝑜𝑡𝑎𝑙 = 𝜎𝑡 + 𝜎𝑏 = × 1.97 + × 38.7 = 11.2 𝑀𝑃𝑎 < [𝜎𝑡 ] = 35 𝑀𝑃𝑎
4 4 4 4
 Design is safe.
PART C
1. Design a connecting rod for a petrol engine for the following data: Diameter of
the piston = 68 mm, Stroke length = 80 mm, Length of connecting rod = 160 mm,
Maximum explosion pressure = 3.5 MPa, Mass of reciprocating parts = 2.5 kg, Speed
= 4000 rpm, Compression ratio = 8:1.
d = 68 mm, R/g = 2.5 kg, l = 160 mm, p = 3.5 MPa, Stroke length = 80 mm, N = 4000 rpm.
1) Select Material: Assume 35Mn2Mo28 for Connecting rod. The yield Stress 𝝈y = 540
MPa.
Assume 40Ni2Cr1Mo28 for bolts. The yield Stress 𝝈y = 600 MPa.
2) Force on connecting rod :
𝜋 𝜋
𝐹𝐺 = × 𝑑 2 × 𝑝 = × 682 × 3.5 = 12711 𝑁
4 4
3) Assume I – cross section for the Connecting rod
419 4
𝑎 = 11𝑡 2 , 𝐼𝑥𝑥 = 𝑡 , 𝑘𝑥𝑥 2 = 3.18 𝑡 2
12

4) Assume factor of safety = 5

5) Determine the web thickness by Johnson’s Formula
𝐹𝐺 𝜎𝑦 𝜎𝑦 𝐿0 2
= [1 − 2 ( ) ]
𝑎 𝑛 4𝜋 𝐸 𝑘
𝐹𝐺 𝜎𝑦 𝜎𝑦 𝐿0 2
= [1 − 2 ( 2 )]
𝑎 𝑛 4𝜋 𝐸 𝑘𝑥𝑥
Take L0 = l = 160 mm, E = 210×103 N/mm2
12711 540 540 1602
= [1 − ( )]
11𝑡 2 5 4𝜋 2 × 210 × 103 3.18 𝑡 2
10.7 0.524
2
= 1− 2
𝑡 𝑡
By solving t = 3.35 mm ≃ 4 mm
6) Permissible bending stress
 𝜎𝑦 440
[σb ] = = = 108 𝑀𝑃𝑎
𝑛 5
7) Whipping or bending stress due to the inertia force
𝛾. 𝑎. 𝑙 2 . 𝜔2 . 𝑟
𝜎𝑏𝑚𝑎𝑥 =
9√3. 𝑔. 𝑍𝑥𝑥
Where
𝜸=7.85×10-5 N/mm3
a = 11 ×42=176 mm2
2πN 2π × 4000
ω = = = 418.9 rad/sec
60 60
𝑆𝑡𝑟𝑜𝑘𝑒 80
𝑟= = = 40 𝑚𝑚
2 2
g = 9810 N-mm/s2
419 419
𝑍𝑥𝑥 = × 𝑡3 = × 43 = 893.9 𝑚𝑚3
30 30
Therefore the bending stress
7.85 × 10−5 × 176 × 1602 × 418.92 × 40
𝜎𝑏𝑚𝑎𝑥 = = 18.2 𝑀𝑃𝑎 < [𝜎𝑏 ] = 108 𝑀𝑃𝑎
9√3 × 9810 × 893.9
Design is Safe
8) Design of Bearings:
Big End: From PSGDB 7.31 for Petrol engine
Ratio LB/DB = 1.25 (Take)
∴ LB = 1. 25 DB
Bearing pressure [pb]B = 11 MPa (Take)
Also Gas Force
𝐹𝐺 = 𝐿𝐵 × 𝐷𝐵 × [𝑝𝑏 ]𝐵
12711 = 1.25𝐷𝐵 × 𝐷𝐵 × 11
DB = 30.4 ≃32 mm
LB = 1.25×32 = 40 mm
Small End: From PSGDB 7.31 for Petrol engine
Ratio LS/DS = 1.5 (Take)
∴ LS = 1.5 DS
Bearing pressure [pb]S = 13 MPa (Take)
Also Gas Force
𝐹𝐺 = 𝐿𝑆 × 𝐷𝑆 × [𝑝𝑏 ]𝑆
12711 = 1.5𝐷𝑆 × 𝐷𝑆 × 13
DS = 25.5 ≃ 26 mm
LS = 1.5×26 = 39 mm
9) Design of bolts: Inertia force
R 2 cos 2θ
Fi = ω r [cos θ + ]
g (l⁄r)
Put 𝜃 = 0⁰ where the inertia force will be maximum
40 40
Fi = 2.5 × (418.9)2 × ( ) [1 + ] = 21932.5 N
1000 160
Assume No. of bolts nb = 2
Then the inertia force acting on the bolts
𝜋
𝐹𝑖 = 𝑑𝑐 2 × [𝜎𝑡 ]𝑏𝑜𝑙𝑡 × 𝑛𝑏
4
𝜋 600
21932.5 = 𝑑𝑐 2 × ( )×2
4 5
The bolt core diameter dc = 10.79 mm
The bolt major diameter assuming coarse thread
𝑑𝑐 10.79
𝑑𝑏 = = = 12.25 𝑚𝑚 ≃ 14𝑚𝑚 = 𝑀14 𝑏𝑜𝑙𝑡𝑠
0.88 0.88
10) Determination of cap thickness
 The thickness of the big end cap (tc) may be determined by treating the cap as a beam
freely supported at the cap bolt centres and loaded by the inertia force at the top dead
centre on the exhaust stroke (i.e. Fi when θ = 0).
 This load is assumed to act in between the uniformly distributed load and the
centrally concentrated load.
 Therefore, the maximum bending moment acting on the cap will be taken as
Fi × lc
Mb =
6
Where lc = Distance between bolt centres
= Dia. of crankpin or big end bearing (DB) + 2 × Thickness of bearing liner (5 mm)
+ Bolt Diameter + Clearance (10 mm)
𝑙𝑐 = 32 + 2 × 5 + 14 + 10 = 66 𝑚𝑚
Therefore the bending moment
21932.5 × 66
𝑀𝑏 = = 241257.5 𝑁 − 𝑚𝑚
6
We know the bending stress
Mb
[σb ] =
Z
From the above equation the thickness of the cap may found.
Z = section modulus of the cap
1 2
Z= bt
6 c
b = Width of cap
= length of crank pin – 2 x flange thickness of bush (5mm assumed)
b = 40 - 2×5 = 30mm
Section modulus of the cap
1
𝑍= × 30 × 𝑡𝑐2 = 5𝑡𝑐2
6
the bending stress
241257.5
108 =
5𝑡𝑐2
Then the cap thickness tc = 21.13 ≃ 22 mm

UNIT V :: BEARINGS
PART A
1) What are the required properties of bearing materials?
Bearing material should have the following properties.
 High compressive strength
 Low coefficient of friction
 High thermal conductivity
 High resistance to corrosion
 Sufficient fatigue strength
 It should be soft with a low modulus of elasticity
 Bearing materials should not get weld easily to the journal material.
2. What is a 'bearing characteristic number'.
The factor (ZN/p) is termed as bearing characteristic number and is a
dimensionless number. The variation of coefficient of friction with the operating
values of bearing characteristic number (ZN/p) as obtained by McKee brothers
(S.A. McKee and T.R. McKee) in an actual test of friction.
The factor (ZN/p) helps to predict the performance of a bearing. When the value
of (ZN/p) is greater than bearing modulus K, then the bearing will operate with
thick film lubrication or under hydrodynamic conditions.
On the other hand, when the value of (ZN/p) is less than K, then the oil film will
rupture and there is a metal to metal contact
3. List any four advantages of rolling contact bearings over sliding contact bearing.
The following are some advantages and disadvantages of rolling contact bearings
over sliding contact bearings.
Advantages
1. Low starting and running friction except at very high speeds.
2. Ability to withstand momentary shock loads.
3. Accuracy of shaft alignment.
4. Low cost of maintenance, as no lubrication is required while in service.
5. Small overall dimensions.
6. Reliability of service.
7. Easy to mount and erect.
 8. Cleanliness.
Disadvantages
1. More noisy at very high speeds.
2. Low resistance to shock loading.
3. More initial cost.
4. Design of bearing housing complicated.
4) Classify the sliding contact bearings according to the thickness of layer of the
lubricant between the bearing and the journal,
The sliding contact bearings, according to the thickness of layer of the lubricant
between the bearing and the journal, may also be classified as follows:
1. Thick film bearings. The thick film bearings are those in which the working
surfaces are completely separated from each other by the lubricant. Such type of
bearings are also called as hydrodynamic lubricated bearings.
2. Thin film bearings. The thin film bearings are those in which, although lubricant
is present, the working surfaces partially contact each other at least part of the
time. Such type of bearings are also called boundary lubricated bearings.
3. Zero film bearings. The zero film bearings are those which operate without any
lubricant present.
4. Hydrostatic or externally pressurized lubricated bearings. The hydrostatic
bearings are those which can support steady loads without any relative motion
between the journal and the bearing. This is achieved by forcing externally
pressurized lubricant between the members.
5) Why are ball and roller bearings called anti-friction bearings?
For starting conditions and at moderate speeds, the frictional losses in rolling
contact bearings are lower than that of equivalent hydrodynamic journal bearing.
This is because the sliding contact is replaced by rolling contact resulting in low
co-efficient of friction. Therefore the rolling contact bearings are called as
antifriction bearings.
6) Name the materials used for sliding contact bearings.
The materials commonly used for sliding contact bearings are discussed below:
1) Babbit metal:
 Tin base babbits : Tin 90% ; Copper 4.5% ; Antimony 5% ; Lead 0.5%.
 Lead base babbits : Lead 84% ; Tin 6% ; Antimony 9.5% ; Copper 0.5%.
2) Bronzes
3) Cast iron.
4) Silver
5) Non-metallic bearings
PART B
1. Select a bearing for a 45mm diameter shaft rotates at 500rpm. Due to a bevel
gear mounted on the shaft, the bearing will have to withstand a 4500N radial load
and a 2500N thrust load. The life of the bearing expected to be least 6000hr.
Solution:
Given: d = 45 mm; n = 500 rpm; Fr = 4500 N; Fa = 2500 N; LH = 6000 hrs.

Bearing life in revolutions

 𝐿𝐻 × 𝑟𝑝𝑚 × 60 6000 × 500 × 60
𝐿= = = 180 𝑚𝑟
106 106
X and Y factors
When the bearing is subjected to radial as well as axial load, the values of X and Y factors
are obtained from Table in PSGDB 4.4 by trial and error procedure.
It is observed from table 4.4, that values of X are constant and the values of Y vary only in
case when,
𝐹𝑎
( )>𝑒
𝐹𝑟
In this case, the value of Y varies from 1.0 to 2.0.
Based on the ratio of axial force and static load capacity, the value of ‘e’ should be
calculated for assumed bearing.
Let us assume the bearing No. SKF 6209, which have C = 25500 N, C0 = 18300 N
𝐹𝑎 2500
= = 0.14
𝐶𝑜 18300
The corresponding value of e for the above ratio from table PSGDB 4.4
𝑭𝒂
𝑭𝒂 ( )>𝑒
( ) 𝑭𝒓 e
𝑪𝒐
X Y
0.13 1.4 0.31
0.56
0.25 1.2 0.37
0.14 0.56 1.383 0.315
By interpolation
(0.37 − 0.31)
𝑒 = 0.31 + × (0.14 − 0.13) = 0.315
(0.25 − 0.13)
Also
𝐹𝑎 2500
( )=( ) = 0.56 > 𝑒 = 0.315
𝐹𝑟 4500
Therefore X = 0.56 and the value of Y by interpolation
(1.2 − 1.4)
𝑌 = 1.4 + × (0.14 − 0.13) = 1.383
(0.25 − 0.13)
Equivalent radial load
𝑃 = (𝑋𝐹𝑟 + 𝑌𝐹𝑎 ). 𝑆
Also assume service factor S = 1.1
𝑃 = (0.56 × 4500 + 1.383 × 2500) × 1.1 = 2575.25 𝑁
Dynamic load capacity of the ball bearing
1
𝐿 𝑘
𝐶 =[ ] ×𝑃
𝐿10
For ball bearing k = 3 and rated life L10 = 1 mr, then
 1
180 3
𝐶=[ ] × 2575.25 = 14540.4 𝑁 < [𝐶] = 25500 𝑁
1
The Selection is safe.
We can select SKF 6209 for the given requirement.

2. A single row deep groove ball bearing operating at 2000 rpm is acted by a 10 kN
radial load and 8 kN thrust load. The bearing is subjected to a moderate shock load
and the outer ring is rotating. Determine the rating life of the bearing.
Solution:
Given: n = 2000 rpm; Fr = 10000 N; Fa = 8000 N;
Outer ring rotating. Therefore Rotation factor V= 1.2
Moderate shock load S = 2
No diameter of the bearing is given.
Also, the Dynamic load capacity not given.
Therefore we can assume the diameter of the bearing as d = 50 mm
For d = 50 mm, we can take SKF 6310;
Static load capacity C0 = 35500 N;
Dynamic load capacity C =48000 N.
The ratio
𝐹𝑎 8000
= = 0.2254
𝐶𝑜 35500
Also the ratio
𝐹𝑎 8000
( )=( ) = 0.8
𝐹𝑟 10000
The corresponding value of e for the above ratio from table PSGDB 4.4
𝑭
𝑭 (𝑭𝒂) > 𝑒
(𝑪𝒂) 𝒓 e
𝒐
X Y
x1 0.13 1.4 y1 0.31
0.56
x2 0.25 1.2 y2 0.37
x 0.2254 0.56 1.241 Y 0.3577
By interpolation formula
(𝑦2 − 𝑦1 )
𝑦 = 𝑦1 + × (𝑥 − 𝑥1 )
(𝑥2 − 𝑥1 )
(0.37 − 0.31)
𝑒 = 0.31 + × (0.2254 − 0.13) = 0.3577
(0.25 − 0.13)
Also
 𝐹𝑎
( )>𝑒
𝐹𝑟
Therefore X = 0.56 and the value of Y by interpolation
(1.2 − 1.4)
𝑌 = 1.4 + × (0.2254 − 0.13) = 1.241
(0.25 − 0.13)
Equivalent radial load
𝑃 = (𝑉𝑋𝐹𝑟 + 𝑌𝐹𝑎 ). 𝑆
Also the service factor S = 2
𝑃 = (1.2 × 0.56 × 10000 + 1.241 × 8000) × 2 = 33296 𝑁
Dynamic load capacity of the ball bearing
1
𝐿 𝑘
𝐶 =[ ] ×𝑃
𝐿10
For ball bearing k = 3 and rated life L10 = 1 mr, then
1
𝐿 3
48000 = [ ] × 33296
1
By solving we find L = 2.996mr.
Therefore the rating life of the bearing in hours
𝐿 × 106 2.9967 × 106
𝐿𝐻 = = = 24.97 ℎ𝑟𝑠
𝑟𝑝𝑚 × 60 2000 × 60
The same problem can be solved for SKF 6210 bearing also.
3. A ball bearing is operated on work cycle consisting of three parts- a radial load
of 3000 N at 1440 rpm for one quarter cycle, a radial load of 5000 N at 720 rpm for
one half cycle, and radial load of 2500 Nat 1440 rpm for the remaining cycle. The
expected life of bearing is 10,000 hrs. Calculate the dynamic load capacity of the
bearing.
Solution:
Given: Fr1 = 3000 N; n1 = 1440 rpm; t1 = 1/4th total time
Fr2 = 3000 N; n2 = 720 rpm; t2 = 1/2th total time
Fr3 = 3000 N; n3 = 1440 rpm; t3 = 1/4th total time
LH = 10000 hrs
Bearing life in revolutions
𝐿𝐻 × 𝑟𝑝𝑚 × 60 10000 × 𝑛 × 60
𝐿= = = 0.6 𝑛 𝑚𝑟
106 106
1 1
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 𝑡ℎ 𝑜𝑓 𝑐𝑦𝑐𝑙𝑒 = × 0.6 𝑛 × 1440 = 216 𝑛 𝑚𝑟
4 4
1 1
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 𝑡ℎ 𝑜𝑓 𝑐𝑦𝑐𝑙𝑒 = × 0.6 𝑛 × 720 = 216 𝑛 𝑚𝑟
2 2
 1 1
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 𝑡ℎ 𝑜𝑓 𝑐𝑦𝑐𝑙𝑒 = × 0.6 𝑛 × 1440 = 216 𝑛 𝑚𝑟
4 4
From PSGDB 4.2 the cubic mean load
1⁄
𝐹1 3 × 𝑡1 + 𝐹2 3 × 𝑡2 + 𝐹3 3 × 𝑡3 3
𝐹𝑚 = [ ]
∑𝑡
1⁄
30003 × 216 𝑛 + 50003 × 216 𝑛 + 25003 × 216 𝑛 3
=[ ] = 3823.01 𝑁
∑(216 + 216 + 216)𝑛

Dynamic load capacity of the ball bearing

1
𝐿 𝑘
𝐶 = [ ] × 𝐹𝑚
𝐿10
L = 216+216+216 = 648 n mr
For ball bearing k = 3 and rated life L10 = 1 mr, then
1
648 3
𝐶=[ ] × 3823.01 = 33082.4 𝑁
1
4. Design a journal bearing for 12 MW, 1000 rpm steam turbine, which is supported
by two bearings, Take the atmospheric temperature as 16°C and operating
temperature of oil as 60°C. Assume viscosity of oil as 0.023 Ns/m2.
Solution:
Given: P =12×106 W; n = 1000 rpm, ta = 16⁰C; to = 60⁰C; Z = 0.023 Ns/m2 = 23 cP
Torque transmitted by the bearing
𝑃 × 60 12 × 106 × 60
𝑀𝑡 = = = 114592 𝑁 − 𝑚 = 114592 × 103 𝑁 − 𝑚𝑚
2𝜋𝑛 2 × 𝜋 × 1000
Let us assume the permissible shear stress for the shaft material as [𝜏] = 50 MPa.
We know
16𝑀𝑡 16 × 114592 × 103
[𝜏] = => 50 =
𝜋𝐷3 𝜋 × 𝐷3
By solving D = 226.8 mm ≃250 mm
From PSGDB 7.31, for turbine L/D = 1 to 2
We can take L/D = 2; L = 2D = 2×250=500 mm
Also minimum dimensionaless No.
𝑍𝑛
= 1422.3 × 10−8
𝑃
By substituting the values
0.023 × 1000
= 1422.3 × 10−8
𝑃
Then Pressure P = 1.67×106 N/m2 = 1.67 N/mm2.
But the Pressure
𝑊
𝑃=
𝐿×𝐷
𝑊
1.67 =
500 × 250
The radial load W = 208750 N
Let us assume (C/D) = 0.002
By Mc-Kees equation (PSGDB 7.34)
Zn D
μ = 0.326 ( )( ) + k
P C
And taking k = 0.002
0.023 × 1000 1
μ = 0.326 ( 6
)( ) + 0.002 = 0.00432
1.617 × 10 0.002
Heat generated Hg = μWv Watts or Nm/s
π × 0.25 × 1000
Hg = 0.00432 × 208750 × ( ) Watts
60
Hg = 11804.5 Watts = 11.81 kW
Heat dissipated
(∆t + 18)2 LD
Hd =
K
Where
(𝑡𝑜 − 𝑡𝑎 ) (60 − 16)
𝑡 = 𝑡𝑏 – 𝑡𝑎 = = = 22⁰𝐶
2 2
For bearing of heavy construction and well ventilated °Cm2/W
K = 437/1600 = 0.273125 ⁰Cm2/W
Therefore
(22 + 18)2 × 0.5 × 0.25
Hd = = 732.3 Watts
0.273125
Since Hg >> Hd artificial cooling is required.
The amount of oil required for cooling
𝐻𝑔 − 𝐻𝑑 = 𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 × 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 ℎ𝑒𝑎𝑡 𝑜𝑓 𝑜𝑖𝑙 × 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 𝑖𝑛 𝑜𝑖𝑙
Hg − Hd = mo × C′ × ∆t 0
Assume C’ = 1710 J/kg⁰C (PSGDB 7.36) and
Temperature rise in the oil ∆t0 can be calculated as follows: 10⁰C
We know coefficient of friction variable
𝐷 1
𝜇 = 0.00432 × = 2.16
𝐶 0.002
For full journal bearing the temperature rise variable (ρC’Δto/P) from table PSGDB 7.36

μD/C ρC’Δto/P
x1 3.22 y1 14.2
x2 1.7 y2 8
x 2.16 y 9.876
By interpolation
𝜌𝐶 ′ ∆𝑡0
= 9.876
𝑃
𝑃 1.67 × 106
∆𝑡0 = 9.876 × = 9.876 × = 11.62°𝐶
𝜌𝐶′ 14.2 × 105
Therefore the amount of oil required for cooling
11804.5 − 732.3 = mo × (1710) × 11.62
Mass of oil required mO = 0.56 kg/sec
5. Design a journal bearing for a centrifugal pump from the following data: Load on
the journal = 20000 N; Speed of the journal = 900 rpm.; Type of oil is SAE 10, for
which absolute viscosity at 55°C = 0.017 kg/m-s; Ambient temperature of oil =15.5°
C; Maximum bearing pressure for the pump =1.5 N/[Link], Calculate also mass of
the lubricating oil required for artificial cooling, if rise of temperature of oil be
limited to 10°C. Heat dissipation coefficient =1232 W/m2/°C.
Solution:
Given: W =20000 N; n = 900 rpm, n’ = 15 rps; SAE 10;
ta = 15.5⁰C; to = 55⁰C; Z = 0.017 Ns/m2 = 17 cP;
P = 1.5 MPa; Cd = 1232 N/m2°C;
For centrifugal pump take L/D = 2 from PSGDB 7.31, therefore L = 2D
We know the pressure on the bearing
𝑊 20000
𝑃= => 1.5 =
𝐿𝐷 2𝐷 × 𝐷
By solving D = 81.7 mm≃ 90 mm (By R20 series)
Therefore L = 2D = 180 mm
By Mc-Kees equation (PSGDB 7.34)
 Zn D
μ = 0.326 ( )( ) + k
P C
Taking the constant k = 0.002
Mean Velocity
Vm = πDn = π×0.09×900 = 254.5 m/min =4.24 m/s
For Vm = 254.5 m/min > 160 m/min, take
C = 100 µm = 0.1 mm
Also the corrected Pressure
𝑊 20000
𝑃= = = 1.235 𝑀𝑃𝑎 = 1.235 × 106 𝑃𝑎
𝐿𝐷 180 × 90
Therefore
0.017 × 900 90
μ = 0.326 ( ) ( ) + 0.002 = 0.00564
1.235 × 106 0.1
Heat generated Hg = μWv Watts or Nm/s

Hg = 0.00564 × 20000 × 4.24 Watts

Hg = 478.3 Watts = 0.48 kW

Heat dissipated
Hd = Cd × A × ∆t
Where
(𝑡𝑜 − 𝑡𝑎 ) (55 − 15.5)
𝑡 = 𝑡𝑏 – 𝑡𝑎 = = = 19.75⁰𝐶
2 2
Cd = 1232 W/ m2 ⁰C
Therefore
Hd = 1232 × 0.09 × 0.18 × 19.75 = 394.2 Watts
Since Hg > Hd artificial cooling is required.
The amount of oil required for cooling
𝐻𝑔 − 𝐻𝑑 = 𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 × 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 ℎ𝑒𝑎𝑡 𝑜𝑓 𝑜𝑖𝑙 × 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 𝑖𝑛 𝑜𝑖𝑙
Hg − Hd = mo × C′ × ∆t 0
Assume C’ = 1710 J/kg⁰C and temperature rise in the oil as ∆t0 = 10⁰C
478.3 − 394.2 = mo × (1710) × 10
Mass of oil required
m0 = 0.00492 kg/sec = 0.295 kg/min
 PART C
1. The following data is given for a 360° hydrodynamic bearing: radial load = 10 kN;
journal speed = 1440 rpm; unit bearing pressure = 1000 kPa; clearance ratio (r/c)
= 800; viscosity of lubricant = 30 mPa-s; Assuming that the total heat generated in
the bearing is carried by the total oil flow in the bearing, calculate: (i) dimensions
of bearing; (ii) coefficient of friction; (iii) power lost in friction; (iv) total flow of oil;
(v) side leakage; and (vi) temperature rise.
Solution:
Given: W = 10 kN = 10000 N; n = 1440 rpm;
n’ = n/60 = 24 rps; p = 1000 kPa = 1 MPa;
r/c = 800 = D/C; Z = 30 mPa s = 30 cP
Dimensions of bearing
Let us assume, L/D = 1, then L = D
The bearing pressure P = 1 MPa = 1 N/mm2
𝑊 10000
P = => 1 =
𝐿𝐷 (𝐷)(𝐷)
The diameter of the Journal 𝐷 = 100 𝑚𝑚
Then length of the bearing L = 100 mm
Performance parameters:
Z = 30 m Pa s = 30 milli Pascals s = 30 (10–3) Pa s
= 30 (10–9) MPa s = 30⨯10–3 N-s/m2
Sommerfeld Number
Zn′ D 2 (0.03)(24)
S = ( )( ) = ( ) (800)2 = 0.461
P C 1 × 106
The values of dimensionless performance parameters are obtained by linear
interpolation from Table PSGDB 7.36.
From table PSGDB 11.36, for L/D =1 and S = 0.121, the performance variables are
𝟐𝒉𝟎 𝑫 𝟒𝒒 𝒒𝒔 𝝆𝑪′∆𝒕𝟎 𝑷
S 𝝁
𝑪 𝑪 𝑫𝑪𝒏′ 𝑳 𝒒 𝑷 𝑷𝒎𝒂𝒙
0.631 0.800 12.800 3.590 0.280 52.100 0.529
0.264 0.600 5.790 3.990 0.497 24.300 0.484
0.461 0.707 9.553 3.775 0.381 39.223 0.508
From Coefficient of friction variable, the co-efficient of friction
𝐷
𝜇 = 9.553
𝐶
1
𝜇 = 9.553 × ( ) = 0.012
800
The power lost in friction = Heat generated during sliding
𝑄𝑓 = 𝐻𝑔 = 𝜇𝑊𝑣
𝜋(100 × 10−3 )(1440)
= 0.012 × 10000 × ( ) = 904.8 𝐽/𝑠𝑒𝑐
60
Flow requirement from the flow variable
𝐷𝐶𝑛′ 𝐿
𝑞 = 3.775 × ( )
4
 0.1
(0.1) ( (24)(0.1)
= 3.775 × 800)
4
−5
𝑚3 𝑙𝑖𝑡𝑟𝑒𝑠
𝑞 = 2.8335 × 10 = 2.8335 × 10−2
𝑠𝑒𝑐 𝑠𝑒𝑐
= 1.7 𝑙𝑖𝑡𝑟𝑒𝑠/𝑚𝑖𝑛
Side leakage from the flow ratio
𝑞𝑠 = 0.381 × 𝑞 = 0.381 × 2.8335 × 10−5
𝑚3 𝑙𝑡𝑟
= 1.08 × 10−5 = 0.65
𝑠𝑒𝑐 𝑚𝑖𝑛
The temperature rise from temperature variable (ρC’=14.2 X 105 N/m2°C)
𝜌𝐶 ′ ∆𝑡0
= 39.223
𝑃
𝑃 1 × 106
∆𝑡0 = 39.223 × = 39.223 × = 27.6° 𝐶
𝜌𝐶′ 14.2 × 105