A Tutorial Manual for

Design of Machine Elements &

Transmission System
(3144101)

B.E. Semester 4 ( RA )

Directorate of Technical Education, Gandhinagar,

Gujarat
GOVERNMENT ENGINEERING COLLEGE,GANDHINAGAR

Certificate

This is to certify that Mr./Ms. ___________________________________

Enrollment No. _______________ of B.E. Semester _____ ____________
Engineering of this Institute (GTU Code:013) has satisfactorily completed the
Tutorial work for the subject Design of Machine Elements & Transmission
system (3144101) for the academic year 20___-___

Place: __________
Date: __________

Name and Sign of Faculty member

Head of the Department

Design of Machine Elements & Transmission system (3144101)

Preface

Main motto of any laboratory/practical/field work is for enhancing required skills as well as
creating ability amongst students to solve real time problem by developing relevant
competencies in psychomotor domain. By keeping in view, GTU has designed competency
focused outcome-based curriculum for engineering degree programs where sufficient weightage
is given to practical work and tutorial. It shows importance of enhancement of skills amongst
the students and it pays attention to utilize every second of time allotted for practical amongst
students, instructors and faculty members to achieve relevant outcomes by solving the problems
as tutorial rather than having merely study type tutorials. It is must for effective implementation
of competency focused outcome-based curriculum that every tutorial is keenly designed to
serve as a tool to develop and enhance relevant competency required by the various industry
among every student. These psychomotor skills are very difficult to develop through traditional
chalk and board content delivery method in the classroom. Accordingly, this manual is designed
to focus on the industry defined relevant outcomes.

By using this manual/tutorial student can go through the relevant important theory which
creates an interest and students can have basic idea prior to solve the problems as tutorials. This
in turn enhances pre-determined outcomes amongst students. Each tutorial in this manual
begins with competency, course outcomes as well as practical outcomes (objectives).

This manual/tutorial also provides guidelines to faculty members to facilitate student centric
activities through each tutorials by arranging and managing necessary resources in order that the
students follow the procedures with required knowledge and necessary competency to achieve
the outcomes. It also gives an idea that how students will be assessed by providing rubrics.

The subject design of machine elements and transmission system requires a deep understanding
of the underlying physics and engineering principles, as well as an awareness of the latest
developments in materials and manufacturing technologies. In this subject, we will explore into
the design of various machine elements, including bolt/riveted/welded joints, key, shaft,
couplings, springs, gears, belt drive and bearings. By mastering the skills and techniques
covered in this subject, you will be able to create innovative and effective machine elements
that can withstand the stresses and demands of real-world applications.

Utmost care has been taken while preparing this manual/tutorials, however always there is
chances of improvement. Therefore, we welcome constructive suggestions for improvement and
removal of errors if any.
Design of Machine Elements & Transmission system (3144101)

Vision of the DTE

1. To provide globally competitive technical education.

2. Remove geographical imbalances and inconsistencies.
3. Develop student friendly resources with a special focus on girls’ education and support
to weaker sections.
4. Develop programs relevant to industry and create a vibrant pool of technical
professionals.

Vision of the Institute

To be a premier engineering institution, imparting quality education for innovative solutions

relevant to society and environment.

Mission of the Institute

 To develop human potential to its fullest extent so that intellectual and innovative
engineers can emerge in a wide range of professions.
 To advance knowledge and educate students in engineering and other areas of scholarship
that will best serve the nation and the world in future.
 To produce quality engineers, entrepreneurs and leaders to meet the present and future
needs of society as well as environment.
Design of Machine Elements & Transmission system (3144101)

Tutorial – Course Outcome matrix

Course Outcomes (COs):

CO1: To formulate and analyze stresses and strains in machine elements subjected to various loads.
CO2: To analyze and design structural joints such as Riveted joints, welded joints and Bolts
CO3: To analyze and design the components for power transmission like shaft and couplings.
CO4: To analyze and design different types of gears and belts for engineering applications
CO5: To analyze and design different types of springs and bearings for engineering applications

Sr. CO CO CO CO CO
Tutorials on
No. 1 2 3 4 5
Fundamentals of machine design and design considerations
1. √
in machine elements subjected to various loads.

2. Design of Bolts and Keys. √

3. Design of Riveted Joints and Welded Joints. √

4. Design of Shaft, Rigid and Flexible couplings. √ √

5. Design of Spur Gear and Helical Gear √

6. Design of Flat and V Belt drives √

7. Design of helical and leaf springs. √

8. Design of Sliding and Rolling Contact bearings √

Design of Machine Elements & Transmission system (3144101)

Industry Relevant Skills

The following industry relevant competency are expected to be developed in the student by
undertaking the tutorial work of this course.
1. Design skills: Students will develop skills in designing and selecting machine
elements based on the specific requirements of a given application. This involves
understanding the principles of material selection, manufacturing processes, and
mechanical analysis techniques.
2. Analysis skills: Students will learn how to analyze the mechanical behavior of
machine elements using both analytical and numerical methods. This includes
calculating stresses and strains, performing fatigue and fracture analysis, and
predicting component life.
3. Testing and validation skills: Students will learn how to test and validate machine
elements using experimental methods. This includes performing mechanical tests
such as tension, compression, and torsion, and using data acquisition and analysis
tools to evaluate component performance.
4. Technical communication skills: Students will develop skills in communicating
technical information to others through written reports, presentations, and drawings.
This involves effectively conveying complex information and analysis results to
stakeholders, such as colleagues, clients, and supervisors.
5. Teamwork and collaboration skills: Students will learn how to work effectively in
teams to solve complex engineering problems. This involves collaborating with
others, delegating tasks, and contributing to group discussions to achieve a common
goal.

Guidelines for Faculty members

1. Teacher should provide the guideline with demonstration of practical to the students
with all features.
2. Teacher shall explain basic concepts/theory related to the tutorial to the students before
starting of each practical
3. Involve all the students in performance of each tutorial.
4. Teacher is expected to share the skills and competencies to be developed in the
students and ensure that the respective skills and competencies are developed in the
students after the completion of the tutorial.
5. Teacher may provide additional knowledge and skills to the students even though not
covered in the manual but are expected from the students by concerned industry.
6. Give practical assignment and assess the performance of students based on task
assigned to check whether it is as per the instructions or not.
7. Teacher is expected to refer complete curriculum of the course and follow the
guidelines for implementation.
Design of Machine Elements & Transmission system (3144101)

Instructions for Students

1. Students are expected to carefully listen to all the theory classes delivered by the faculty
members and understand the COs, content of the course, teaching and examination
scheme, skill set to be developed etc.
2. Students shall organize the work in the group and make record.
3. Students shall develop maintenance skill as expected by industries.
4. Student shall attempt to develop related hand-on skills and build confidence.
5. Student shall develop the habits of evolving more ideas, innovations, skills etc. apart from
those included in scope of manual.
6. Student shall refer technical magazines and data books.
7. Student should develop a habit of submitting the tutorial work as per the schedule
 Design of Machine Elements & Transmission system (3144101)

Index
(Progressive Assessment Sheet)

Assess Sign. of
Sr. Page Date of
Objective(s) of Tutorial Date ment Teacher Remarks
No. No. submission
Marks with date
Fundamentals of machine design and design
1. considerations in machine elements subjected
to various loads.
2. Design of Bolts and Keys.

3. Design of Riveted Joints and Welded Joints.

Design of Shaft, Rigid and Flexible
4.
couplings.
5. Design of Spur Gear and Helical Gear

6. Design of Flat and V Belts drives.

7. Design of helical and leaf springs.

Design of Sliding and Rolling Contact
8.
bearings.
Total
 Tutorial No: 01

Fundamentals of machine design and design considerations in machine

elements subjected to various loads.

Date:

Relevant CO: CO1

Objectives:
(a) Students can learn several important concepts and skills like engineering design process,
materials science and engineering, safety engineering, reliability engineering from
studying the general design considerations in machine design.
(b) Students can learn about the Modes of Failure, Factor of Safety, Principal Stresses,
Theories of Failure and Stress Concentration.
(c) Students can learn about Design against Static and Dynamic Load, Design for Finite and
Infinite Life, Soderberg and Goodman Criteria.

Theory:
Design considerations are critical in the field of machine design as they ensure that the
final product is reliable, efficient, and safe to use. Here are some more details on the design
considerations mentioned:

1. Standardization: Standardization is a critical aspect of the design of machine elements.

Standardization involves the use of commonly accepted standards, specifications, and
guidelines to ensure that the components of a machine are interchangeable and can be
produced efficiently and cost-effectively.
There are several organizations that establish standards for the design of machine elements,
such as the International Organization for Standardization (ISO), the American National
Standards Institute (ANSI), and the Society of Automotive Engineers (SAE). These
organizations publish standards and guidelines related to tolerances, fits, materials, and
dimensions for various machine components such as bolts, gears, bearings, and shafts.
Designers can use these standards as a starting point when designing machine elements,
which can help to ensure that the components they produce are compatible with other
machines and can be produced efficiently. Designers can also use software tools and
libraries that are based on these standards to help them design machine components quickly
and accurately. Standardization ensures that components are interchangeable, production is
efficient, and costs are reduced. Standardization reduces the need for manufacturers to create
unique parts for every product, which lowers production costs, minimizes inventory, and
streamlines the supply chain.

2. Preferred numbers: Preferred numbers in design of machine elements refer to a series of

standardized sizes for various components such as bolts, screws, bearings, gears, etc. These
standardized sizes make it easier for manufacturers to design, produce, and maintain
machinery, as well as for users to replace and interchange parts. The use of preferred
 numbers also reduces the number of unique sizes required and minimizes the inventory of
parts. Preferred numbers, are a series of numbers that facilitate easy selection of machine
components. These numbers allow designers to quickly determine the appropriate size of a
component by using a logarithmic scale. Using preferred numbers also helps to minimize
waste, reduce manufacturing costs, and simplify assembly.

3. Tolerances and fits: Tolerances and fits ensure that machine components work together as
intended. Tolerances and fits refer to the degree of permissible variation in the dimensions of
a part and the degree of interference or clearance between two mating parts, respectively.
Tolerances and fits are critical considerations in the design of machine elements to ensure
proper functioning, assembly, and interchangeability of parts. Tolerance is the allowable
limit of variation in a dimension of a part, while fit is the degree of tightness or looseness
between two mating parts.
Some of the common types of fits in the ISO system are:

Clearance fit: This fit allows for a clearance or gap between the two mating parts, such
as a shaft and a hole. It is typically used for applications where ease of assembly and
disassembly is important.
Interference fit: This fit requires a force or pressure to assemble the two mating parts
due to their tightness. It is commonly used in applications where high precision and
rigidity are required, such as in bearings and gears.
Transition fit: This fit falls between the clearance and interference fits and is used when
both clearance and interference fits are required, depending on the specific parts and their
tolerances.

The selection of appropriate tolerances and fits depends on the application requirements,
materials, manufacturing processes, and environmental conditions.

4. System design: System design considers how all the components of a machine work
together to achieve a specific function or goal. System design ensures that all the
components are compatible and function together seamlessly. It also considers factors such
as control systems, feedback mechanisms, and power sources to optimize the overall
performance of the machine.

5. Manufacturing considerations: Manufacturing considerations take into account the

availability of materials, the cost of production, and the manufacturing process itself. By
considering these factors, designers can optimize the design of the product for efficient and
cost-effective manufacturing. This includes the use of appropriate materials, selecting
appropriate manufacturing processes, and minimizing the complexity of the design.
Quiz:
1. List and explain the different types of stresses considered in machine design.
2. What are the principles for the design of machine components?
3. Define the factor of safety. State and explain the factors affecting its selection.
4. Explain various aspects of materials selection in Machine Design.
5. What do you mean by standardization? Explain the use of standardization in design.
6. A bar of circular cross-section is subjected to alternating tensile forces varying from a
minimum of 200 kN to a maximum of 500 kN. It is to be manufactured of a material with an
ultimate tensile strength of 900 MPa and an endurance limit of 700 MPa. Determine the
diameter of bar using safety factors of 3.5 related to ultimate tensile strength and 4 related to
endurance limit and a stress concentration factor of 1.65 for fatigue load. Use Goodman
straight line as basis for design.
7. A steel rod is subjected to a reversed axial load of 180 kN. Find the diameter of the rod for a
factor of safety of 2. Neglect column action. The material has an ultimate tensile strength of
1070 MPa and yield strength of 910 MPa. The endurance limit in reversed bending may be
assumed to be one half of the ultimate tensile strength. Other correction factors may be taken
as follows: For axial loading = 0.7; for machined surface = 0.8; for size = 0.85; for stress
concentration = 1.0.
8. A machine component is subjected to fluctuating stress that varies from 40 to 100 N/mm2.
The corrected endurance limit stress for the machine component is 270 N/mm2. The
ultimate tensile strength and yield strength of the material are 600 and 450 N/mm2
respectively. Find the factor of safety using: (i) Gerber theory; (ii) Soderberg line; (iii)
Goodman line; and (iv) Also, find the factor of safety against static failure.

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks
 Tutorial No: 02
Design of bolts and keys
Date:
Relevant CO: CO2

Objectives:
(a) As per application students can design bolts as per industry standards and codes.
(b) Students can identify the industrial application of different keys.

Quiz:
1. How are keys classified?
2. Where are a square and rectangular key used?
3. Why in a rectangular key the width is always more than depth of key?
4. 45 mm diameter shaft is made of steel with a yield strength of 400 MPa. A parallel key of
size 14 mm wide and 9 mm thick made of steel with a yield strength of 340 Mpa is to be
used. Find the required length of key, if the shaft is loaded to transmit the maximum
permissible torque. Use maximum shear stress theory and assume a factor of safety of 2.
5. A steel plate subjected to a force of 5 kN and fixed to a channel by means of three identical
bolts is shown in Fig. The bolts are made from plain carbon steel 45C8 (Syt = 380 N/mm2)
and the factor of safety is 3. Specify the size of bolts.

6. Determine the diameter of the bolts and bracket thickness. Take allowable tensile stress=70MPa
and shear stress=50 MPa.

+
Rubric wise marks obtained:
Rubrics 1 2 3 4 5 Total
Marks
 Tutorial No: 03
Design of Riveted Joints and Welded Joints.
Date:
Relevant CO: CO2

Objectives:
(a) As per application students can design riveted and welded joints.

Quiz:
1. Draw a sketch of triple riveted lap joint. Show on its important terms used in riveted
joints.
2. How will you design riveted joints subjected to eccentric loading?
3. A steam boiler 2.25 meters in diameters is to work at a pressure of 0.84 MPa. Design a
double riveted butt joint with two unequal cover plates for a longitudinal joint. The
efficiency of the joint be not less than 70 %. The working stresses for the plates and rivets
are, 6t = 84 MPa, τ = 63 MPa, 6cr = 126 MPa. Check the efficiency of the joint.
4. A double riveted double cover butt joint in 20 mm plates is made with 25 mm diameter
rivets at 100 mm pitch. Find the efficiency of the joint. The design stresses for plate and
rivet material are 6t = 100 MPa, τ= 80MPa and 6c = [Link] by neat sketch the
various ways of in which a riveted joint may fail.
5. A brake band attached to the hinge by means of a riveted joint is shown. Determine the
size of the rivets needed for the load of 10 kN. Also, determine the width of the band. The
permissible stresses for the band and rivets in tension, shear and compression are 80, 60
and 120 N/mm2 respectively. Assume, margin (m) = 1.5d transverse pitch (pt ) = p Find
the pitch of the rivets.

6. A plate, 75 mm wide and 10 mm thick, is joined with another steel plate by means of
single transverse and double parallel fillet welds. The joint is subjected to a maximum
tensile force of 55 kN. The permissible tensile and shear stresses in the weld material are
 70 and 50 N/mm2 respectively. Determine the required length of each parallel fillet weld.

7. A welded connection, as shown is subjected to an eccentric force of 7.5 kN. Determine

the size of welds if the permissible shear stress for the weld is 100 N/mm2. Assume static
conditions. (example of Eccentric loading of weld)

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks
 Tutorial No: 04

Problems on design of shaft, rigid and flexible couplings.

Date:
Relevant CO: CO1, CO3

Objectives:
(a) Students can learn several important concepts and skills like engineering design process,
materials science and engineering, mechanical design from studying the design of shaft.
rigid and flexible couplings.
(b) Students can design and identify the industrial purpose of different couplings.

Theory:
Couplings are mechanical devices used to connect two shafts together to transmit torque
and rotation. The design of couplings can be classified into two main categories: rigid couplings
and flexible couplings.

(a) Rigid Couplings:

Rigid couplings are designed to provide a solid, permanent connection between two
shafts. They are generally used in applications where shaft misalignment is not a concern.

Fig.1 Rigid coupling

Rigid couplings are designed to transmit high levels of torque and are typically made
from materials such as steel or aluminum.
Design Considerations:
1. The bore size of the coupling must match the shaft diameter of the equipment
being connected.
2. The coupling must be designed to withstand the torque and horsepower of the
application.
 3. The length of the coupling must be sufficient to accommodate any axial
movement of the shafts.
4. The coupling should be balanced to minimize vibration and wear.

(b) Flexible Couplings:

Flexible couplings are designed to accommodate shaft misalignment and reduce shock
and vibration.

Fig. 2 Flexible coupling

They are used in applications where the shafts are not perfectly aligned, such as those
with parallel, angular, or axial misalignment. Flexible couplings can be further classified
into three types: elastomeric, metallic, and universal.

Design Considerations:
1. The coupling must be designed to accommodate the level and type of
misalignment present in the application.
2. The bore size of the coupling must match the shaft diameter of the equipment
being connected.
3. The coupling must be designed to withstand the torque and horsepower of the
application.
4. The coupling should be balanced to minimize vibration and wear.
5. The material used for the coupling must be selected based on the environmental
conditions and type of application.
Quiz:

1. Discuss the function of a coupling. Give at least three practical applications.

2. What are flexible couplings and what are their applications? Illustrate your answer with
suitable examples and sketches.
3. Design a cast iron protective flange coupling to connect two shafts in order to transmit
7.5 kW at 720 r.p.m. The following permissible stresses may be used:
Permissible shear stress for shaft, bolt and key material = 33 MPa
Permissible crushing stress for bolt and key material = 60 MPa
Permissible shear stress for the cast iron = 15 MPa
4. Design a muff coupling to connect two steel shafts transmitting 25 kW power at 360 rpm.
The shafts and key are made of plain carbon steel 30C8 (S yt = Syc = 400 N/mm2). The
sleeve is made of grey cast iron FG 200 (Sut = 200 N/mm2). The factor of safety for the
shafts and key is 4. For the sleeve, the factor of safety is 6 based on ultimate strength.
5. A rigid coupling is used to transmit 50 kW power at 300 rpm. There are six bolts. The
outer diameter of the flanges is 200 mm, while the recess diameter is 150 mm. The
coefficient of friction between the flanges is 0.15. The bolts are made of steel 45C8 (Syt =
380 N/mm2) and the factor of safety is 3. Determine the diameter of the bolts. Assume
that the bolts are fitted in large clearance holes.
6. Design a bushed-pin type of flexible coupling to connect a pump shaft to a motor shaft
transmitting 32 kW at 960 rpm. The overall torque is 20 percent more than mean torque.
The material properties are as follows:
(a) The allowable shear and crushing stress for shaft and key material is 40 MPa and 80
MPa respectively.
(b) The allowable shear stress for cast iron is 15 MPa.
(c) The allowable bearing pressure for rubber bush is 0.8 N/mm2.
(d) The material of the pin is same as that of shaft and key.
Draw neat sketch of the coupling.

7. The layout of a shaft carrying two pulleys 1 and 2, and supported on two bearings A and
B is shown in Fig. The shaft transmits 7.5 kW power at 360 rpm from the pulley 1 to the
pulley 2. The diameters of pulleys 1 and 2 are 250 mm and 500 mm respectively. The
masses of pulleys 1 and 2 are 10 kg and 30 kg respectively. The belt tensions act
vertically downward and the ratio of belt tensions on the tight side to slack side for each
pulley is 2.5:1. The shaft is made of plain carbon steel 40C8 (Syt = 380 N/mm2) and the
factor of safety is 3. Estimate suitable diameter of shaft. If the permissible angle of twist
is 0.5° per meter length, calculate the shaft diameter on the basis of torsional rigidity.
Assume G = 79300 N/mm2.
 8. Below Fig. shows a hollow transmission shaft, having inside diameter 0.6 times the
outside diameter, is made of plain carbon steel 40C8 (Syt = 380 N/mm2) and the factor of
safety is 3. A belt pulley, 1000 mm in diameter, is mounted on the shaft, which overhangs
the left hand bearing by 250 mm. The belts are vertical and transmit power to the machine
shaft below the pulley. The tension on the tight and slack sides of the belt are 3 kN and 1
kN respectively, while the weight of the pulley is 500 N. The angle of wrap of the belt on
the pulley is 180°. Calculate the outside and inside diameters of the shaft.

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks
 Tutorial No: 05

Problems on design of Spur Gear and Helical Gear

Date:

Relevant CO: CO4

Objectives:
(a) Students can design spur gear and helical gear as per industry standards and codes.
(b) Students can identify the materials industrial application of spur gears and helical gears.

Theory:
Spur Gear
Spur gears are one of the most commonly used types of gears in mechanical systems. They are
cylindrical in shape and have teeth that are straight and parallel to the axis of rotation.

Fig. 1 Spur gear

Here are some key concepts and examples related to spur gears:

Gear Ratio: The gear ratio is the ratio of the number of teeth on the driving gear (or the input
gear) to the number of teeth on the driven gear (or the output gear). It determines how much the
output gear will rotate compared to the input gear.

Pitch Circle: The pitch circle is the imaginary circle on which the teeth of a gear are located. The
diameter of the pitch circle is called the pitch diameter.

Module: The module is a measure of the size of a gear. It is defined as the ratio of the pitch
diameter to the number of teeth.
 Fig. 1 gear nomenclature

Pressure Angle: The pressure angle is the angle between the direction of the force exerted by
one gear tooth on another gear tooth and the line perpendicular to the pitch circle.

Spur gear design:

Determine the gear ratio: It can be calculated by dividing the number of teeth on the driven gear
by the number of teeth on the driving gear.

Determine the pitch diameter: It can be calculated by multiplying the number of teeth by the
module.

Determine the number of teeth: The number of teeth is determined by the desired gear ratio
and pitch diameter.

Determine the pressure angle: It is typically set at 20 degrees or 14.5 degrees, depending on the
application.

Determine the tooth profile: The tooth profile is the shape of the teeth on the gear. It can be
calculated using specialized software or found in tables provided by gear manufacturers.

Choose the material: The material of the gear depends on the application, load, and operating
conditions. Common materials include steel, brass, and plastic.

Design the gear assembly: The gear assembly includes the gear, shaft, and bearings. The design
should ensure proper alignment, clearance, and lubrication.

Here are the equations for designing a spur gear:

Pitch Diameter (D):
D=N/m
where, N is the number of teeth and m is the module.

Module (m):
m=D/N

Gear Ratio (GR):

GR = N2 / N1
where, N1 is the number of teeth on the driving gear and N2 is the number of teeth on the
driven gear.

Center Distance (C):

C = (D1 + D2) / 2
where, D1 is the pitch diameter of the driving gear and D2 is the pitch diameter of the
driven gear.

Addendum (a):
a=m

Dedendum (b):
b = 1.25 × m

Tooth Thickness (t):

t = (π × m) / 2

Circular Pitch (p):

p=π×m

Outside Diameter (Do):

Do = D + 2 × a

Root Diameter (Dr):

Dr = D - 2 × b

Face Width (F):

F=b

Contact Ratio (CR):

CR = (L1 + L2) / (π × m)
Where, L1 and L2 are the arc of action for the driving and driven gears, respectively.

These equations can be used to design spur gears for various applications. It is important to note
that these equations provide a basic understanding of spur gear design, and more advanced
design considerations such as tooth form, gear strength, and meshing conditions must also be
taken into account.

Applications of spur gears:

Gearboxes: Spur gears are commonly used in gearboxes to transmit power from one rotating
shaft to another.

Clocks: Spur gears are used in clock mechanisms to control the motion of the clock's hands.

Robotics: Spur gears are used in robotics to control the movement of robot arms and other
components.

Automobiles: Spur gears are used in automobile transmissions to control the speed and torque of
the wheels.

Industrial machinery: Spur gears are used in many types of industrial machinery, such as
conveyor belts, printing presses, and machine tools.

Helical gear
Helical gears are a type of cylindrical gears that have teeth that are cut at an angle to the axis of
rotation. The teeth of a helical gear are shaped like a helix, which is a spiral curve.

Fig. Helical gear

Helix Angle: The helix angle is the angle between the helix of the gear teeth and the axis of
rotation. It determines the degree of overlap between the teeth of the driving and driven gears.

Design of a helical gear:

Pitch Diameter (D):

D = m × N / cos(α)
where, m is the module, N is the number of teeth, and α is the helix angle.
Module (m):
m = D / N / cos(α)

Gear Ratio (GR):

GR = N2 / N1
where, N1 is the number of teeth on the driving gear and N2 is the number of teeth on the
driven gear.

Center Distance (C):

C = (D1 + D2) / 2
where, D1 is the pitch diameter of the driving gear and D2 is the pitch diameter of the
driven gear.

Addendum (a):
a = m × (π / 2 + tan(α))

Dedendum (b):
b = 1.25 × m

Tooth Thickness (t):

t = (π × m) / 2

Circular Pitch (p):

p = π × m / cos(α)

Outside Diameter (Do):

Do = D + 2 × a

Root Diameter (Dr):

Dr = D - 2 × b

Face Width (F):

F = b × (2.5 + 0.02 × N)

Contact Ratio (CR):

CR = (L1 + L2) / (π × m × cos(α))
where, L1 and L2 are the arc of action for the driving and driven gears, respectively.

These equations can be used to design helical gears for various applications. It is important to
note that helical gears have more complex geometries than spur gears, and additional design
considerations such as helix angle, tooth form, gear strength, and meshing conditions must also
be taken into account.
Applications of helical gears can be found in many mechanical systems:

Gearboxes: Helical gears are commonly used in gearboxes to transmit power from one rotating
shaft to another. They are often used in high-speed applications, as they provide smoother and
quieter operation than spur gears.

Industrial machinery: Helical gears are used in many types of industrial machinery, such as
printing presses, machine tools, and conveyors. They can transmit high torque and are less prone
to wear than spur gears.

Vehicles: Helical gears are used in automotive transmissions to control the speed and torque of
the wheels. They provide smoother and more efficient operation than spur gears.

Robotics: Helical gears are used in robotics to control the movement of robot arms and other
components. They can transmit high torque and provide precise motion control.

Quiz:
1. Explain standard system of gear tooth and advantage and disadvantages of 14.50 and 200
involutes system.
2. What is formative number of teeth in helical gear? Derive the expression for formative
number of teeth in helical gears.
3. The following data refers to a spur gear pair:

Service factor = 1.5 Dynamic load factor = 230 N/mm

Lewis’s form factor Y = Π [0.154 – 0.912/Z]
Velocity factor = 3 / 3 + v
Wear factor = 0.156 [ BHN/ 100]2 MPa
Specify the kW capacity of the gear unit.
4. Design a spur gear pair from the following given data.
Power to be transmitted = 22.5 kW, Pinion speed = 1450 rpm, Speed reduction = 2.5, No.
of teeth on pinion = 20, Service factor = 1.5, b= 10m, Pitch line velocity = 5 m/sec (For
initial calculation of module), Maximum permissible error in gear tooth profile = 0.025
mm, k = A factor depending upon the form of teeth = 0.111, Velocity factor = 3/ (3 + V),
where V is the pitch line velocity in m/s. Take endurance surface hardness = 600 MPa.
Lewis form factor = 0.154 – 0.912/No. of teeth for 200 pressure angle involute tooth
system. The materials and stresses are as under:
 5. A stock helical gear has normal pressure angle of 20o, a helix angle of 25o, and a
transverse diametral pitch of 6 teeth / in, and has 18 teeth. find:
(a) The pitch diameter
(b) The transverse, the normal and axial pitches
(c) The normal diametral pitch
(d) The transverse pressure angle.
6. The following data is given for a pair of helical gears made of steel:
Normal module = 5 mm,
Face Width = 50 mm,
No. of Pinion Teeth = 30,
No. of Gear Teeth = 60,
Centre distance = 245 mm,
Normal Pressure angle =200,
Pinion speed = 1000 r.p.m,
Surface hardness = 300 BHN,
FOS = 2
Service Factor = 1.5,
Grade of Machining = 8,
Tooth form factor (Y) = 0.385
Permissible σb for pinion and gear material=150N / mm2.
Determine: (i) Helix angle (ii) Beam strength (iii) Max. static load that gear can transmit
(iv) Power transmitting capacity
7. A pair of parallel helical gears consists of a 20 teeth pinion meshing with a 100 teeth
gear. The pinion rotates at 720 rpm. The normal pressure angle is 200, while the helix
angle 250. The face width is 40 mm and the normal module is 40 mm. The pinion as well
as the gear are made of steel 40C8 having ultimate tensile strength of 600 N/mm2 and
heat treated to a surface hardness of 300 BHN. The service factor and the factor of safety
are 1.5 and 2 respectively. Assume that the velocity factor accounts for the dynamic load
and calculate the power transmitting capacity of gears.

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 Tutorial No: 06

Problems on design of flat and v belt drive.

Date:
Relevant CO: CO4

Objectives:
(a) Students can design different belt drives as per industry requirements.
(b) Students can identify the industrial application of different belt with its materials.

Quiz:

1. Discuss the different types of belts and their material used for power transmission.
2. Discuss the various important parameters necessary for the selection of a particular drive
for power transmission.
3. Derive the ratio of the driving tensions on the two sides of a pulley
4. Sketch the cross-section of a V-belt and label its important parts.
5. What are the advantages and disadvantages of V-belt drive over flat belt drive?
6. Power is transmitted between two shafts by a V-belt whose mass is 0.9 kg/m length. The
maximum permissible tension in the belt is limited to 2.2 kN. The angle of lap is 170° and
the groove angle 45°. If the coefficient of friction between the belt and pulleys is 0.17;
find 1. velocity of the belt for maximum power; and 2. power transmitted at this velocity.
7. A V-belt drive system transmits 100 kW at 475 r.p.m. The belt has a mass of 0.6 kg/m.
The maximum permissible tension in the belt is 900 N. The groove angle is 38° and the
angle of contact is 160°. Find minimum number of belts and pulley diameter. The
coefficient of friction between belt and pulley is 0.2.
8. A flat belt, 8 mm thick and 100 mm wide transmits power between two pulleys, running
at 1600 m/min. The mass of the belt is 0.9 kg/m length. The angle of lap in the smaller
pulley is 165° and the coefficient of friction between the belt and pulleys is 0.3. If the
maximum permissible stress in the belt is 2 MN/m2, find (i) Maximum power
transmitted, and (ii) Initial tension in the belt.

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 Tutorial No: 07

Problems on design of helical and leaf springs.

Date:
Relevant CO: CO5

Objectives:
(c) Students can design different springs like helical sprig and leaf spring as per industry
requirements.
(d) Students can identify the industrial application of different springs with its materials.

Theory:

1. Introduction
A spring is defined as an elastic body, whose function is to distort when loaded and to recover its
original shape when the load is removed. The various important applications of springs are as
follows:
1. To cushion, absorb or control energy due to either shock or vibration as in car springs,
railway buffers, air-craft landing gears, shock absorbers and vibration dampers.
2. To apply forces, as in brakes, clutches and spring-loaded valves.
3. To control motion by maintaining contact between two elements as in cams and
followers.
4. To measure forces, as in spring balances and engine indicators.
5. To store energy, as in watches, toys, etc.

2. Types of springs
Though there are many types of the springs, yet the following, according to their shape, are
important from the subject point of view.
1. Helical spring
2. Conical and volute springs
3. Torsion springs
4. Laminated or leaf spring
5. Disc or bellevile springs
6. Special purpose springs
 Fig. 1 Types of springs

3. Material for spring

The material of the spring should have high fatigue strength, high ductility, high resilience and it
should be creep resistant. It largely depends upon the service for which they are used i.e. severe
service, average service or light service.
Severe service means rapid continuous loading where the ratio of minimum to maximum load (or
stress) is one-half or less, as in automotive valve springs.
Average service includes the same stress range as in severe service but with only intermittent
operation, as in engine governor springs and automobile suspension springs.
Light service includes springs subjected to loads that are static or very infrequently varied, as in
safety valve springs.

Helical Spring:
A helical spring is made of a tightly wound coil of wire, which is typically made of steel or other
metals with high tensile strength. The wire is wound in a helical or spiral shape, with each coil
touching the adjacent coil.

Stress and Deflection Equations:

The stress and deflection equations for a helical spring can be calculated using the following
formulas:

Stress: σ = 8Wd / πd3n

where, σ = stress (N/mm2)

W = load (N)
d = wire diameter (mm)
D = mean coil diameter (mm)
n = number of coils
 Deflection: δ = (8Wd3n)/(Gd4N)
where,
δ = deflection (mm)
G = shear modulus of elasticity (N/mm2)
N = number of active coils
Leaf Spring:
A leaf spring is a type of suspension system commonly used in automobiles and other vehicles.
A leaf spring consists of several layers or leaves of spring steel, which are bound together with
clamps or bolts. The longest leaf, called the master leaf or main leaf, is attached to the vehicle
chassis, while the other leaves are attached to the axle. When the vehicle moves over a bump or
uneven terrain, the leaf spring deflects and absorbs the shock.
Quiz:
1. Explain the importance of Wahl’s stress factor in spring design.
2. What is nipping in a leaf spring? Discuss its role.
3. Calculate the dimensions of the helical spring for a rams bottom safety valve for the
following data.
Valve diameter = 65 mm,
Maximum blows off pressure = 0.8 N/mm2,
Valve lift for pressure rise from 0.75 to 0.80 N/mm2 = 3.5 mm
Maximum allowable stress = 550 N/mm2
Spring index = 6, Modulus of rigidity = 8.3×104 N/mm2
4. Design a helical compression spring from the following data:
Minimum load = 100 N,
Maximum load = 225.6 N,
Compression of spring = 10 mm,
Permissible shear stress for spring material = 440 MPa
Spring end – square and ground ends
Modulus of rigidity for spring material = 0.80 x 105 MPa
5. A semi-elliptic leaf spring consists of two extra full-length leaves and eight graduated length
leaves, including the master leaf. The center-to-center distance between the two eyes of the
spring is 1 m. The maximum force acting on the spring is 10 kN and the width of the leaf is
50 mm. The spring is initially preloaded in such a way that when the load is maximum, the
stresses induced in all the leaves are equal to 350 N/mm2. The modulus of elasticity of the
leaf material is 2.07x105 N/mm2. Determine: (i) The thickness of leaves. (ii) The deflection
of the spring at maximum load.
6. Design a leaf spring for the following specifications: Total load = 140 kN; Number of
springs supporting the load = 4; Maximum number of leaves = 10; Span of the spring = 1000
mm; Permissible deflection = 80 mm. Take Young’s modulus, E = 200 kN/mm 2 and
allowable stress in spring material as 600 MPa.

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 Tutorial No: 08

Problems on design of Sliding and Rolling Contact bearings

Date:
Relevant CO: CO5

Objectives:
(a) The design aims to minimize wear on the surfaces and to distribute the load evenly
across the bearing surface.
(b) Students can learn several important concepts such as materials science, tribology,
engineering design, applications in industry.

Theory:
(A) Sliding contact bearings
Sliding contact bearings, also known as plain bearings or journal bearings, are a type of
bearing that operates with sliding contact between the bearing surface and the shaft. The
primary function of these bearings is to support the radial load and axial load of rotating
machinery while reducing friction and wear.

Fig. 1 3D model of sliding contact bearing

There are several types of sliding contact bearings, some of which are:

Plain Bearings: A plain bearing is a simple type of bearing that consists of a shaft rotating
inside a hole or bore. The contact between the shaft and the bore is lubricated to reduce
friction and wear. Plain bearings are commonly used in engines, turbines, and other
machinery.

Journal Bearings: A journal bearing is a type of plain bearing that supports a shaft that
rotates inside the bearing. The bearing has a cylindrical shape, and the contact between the
shaft and the bearing is lubricated to reduce friction and wear. Journal bearings are
commonly used in engines, turbines, and other machinery.
Thrust Bearings: A thrust bearing is a type of bearing that is designed to support axial
loads, which are forces that act parallel to the axis of the shaft. Thrust bearings are often
used in applications where there is a need to support heavy loads, such as in gearboxes and
industrial equipment.

Spherical Bearings: A spherical bearing is a type of bearing that can support radial and
axial loads. The bearing has a spherical shape, and the contact between the bearing and the
shaft is lubricated to reduce friction and wear. Spherical bearings are commonly used in
applications where there is a need for flexibility and alignment, such as in automotive
suspensions and steering systems.

Linear Bearings: A linear bearing is a type of bearing that is designed to support linear
motion. The bearing consists of a shaft that moves along a track or guide. Linear bearings
are commonly used in applications such as robotics, machine tools, and automation
equipment.

Basic mode of lubrication:

The basic mode of lubrication in sliding contact bearings is hydrodynamic lubrication. In
this mode, a thin film of lubricant is created between the bearing surface and the shaft due to
the relative motion between them. This film of lubricant prevents direct metal-to-metal
contact and reduces friction and wear.

Measurement of viscosity:
Viscosity is a key property of lubricants that determines the ability of the lubricant to flow
and form a film between the bearing and the shaft. Viscosity can be measured using
viscometers such as the Saybolt viscometer, Redwood viscometer, and the Engler
viscometer. The unit of viscosity is typically expressed in centipoise (cP) or centistokes
(cSt).

Viscosity index:
Viscosity index is a measure of the change in viscosity of a lubricant with temperature. It is a
dimensionless number that indicates the rate of change of viscosity with temperature. A high
viscosity index indicates that the lubricant's viscosity changes minimally with temperature,
making it suitable for use in a wide range of operating conditions.

Petroff’s equation:
Petroff's equation is an analytical solution to the Reynolds equation, which governs the flow
of lubricant in journal bearings. The equation provides a mathematical model of the pressure
distribution in the lubricant film and helps in the design of journal bearings.

McKee’s equations:
McKee's equations are a set of equations that describe the pressure distribution in the
lubricant film in journal bearings. These equations consider the effects of shaft speed,
viscosity, bearing length, and bearing diameter on the pressure distribution.
 Reynold’s equation:
Reynolds equation is a partial differential equation that describes the flow of a thin film of
lubricant in journal bearings. The equation provides a mathematical model of the pressure
distribution in the lubricant film and helps in the design of journal bearings.

Difference between hydrodynamic and hydrostatic bearing:

In a hydrodynamic bearing, the bearing surface is separated from the shaft by a thin film of
lubricant generated by the relative motion between them. In a hydrostatic bearing, the
lubricant film is generated by an external source such as a pump, and the bearing surface is
separated from the shaft by a pressurized lubricant film.

Performance parameters for journal bearings:

The performance parameters for journal bearings include load capacity, coefficient of
friction, temperature rise, and oil flow rate. These parameters are important in the design and
selection of journal bearings for specific applications.

Selection of parameters for journal bearing design:

The selection of parameters for journal bearings depends on the operating conditions, such
as load, speed, and temperature. The key parameters to consider include bearing clearance,
bearing length, bearing diameter, lubricant viscosity, and lubricant flow rate. The design of
journal bearings involves a trade-off between load capacity, friction, and temperature rise.
The design must also consider factors such as ease of maintenance and durability.

(B) Rolling contact bearings:

Rolling contact bearings are used extensively in machinery to support rotating shafts with
minimum friction and maximum reliability. There are two main types of rolling contact
bearings: ball bearings and roller bearings. These bearings rely on rolling elements, such as
balls or rollers, to reduce friction between two surfaces that are in contact.

(a) (b)
Fig.2 Rolling contact bearing
There are several types of rolling contact bearings used in various applications. Here are
some of the most common types of rolling contact bearings with a neat sketch:
Ball bearings: Ball bearings are the most commonly used type of rolling contact bearings.
They are designed to support both radial and axial loads. A ball bearing consists of an outer
race, an inner race, and a cage that holds the balls in place.

Roller bearings: Roller bearings are used to support radial loads. They have a cylindrical
shape and are available in different designs, such as cylindrical, needle, and tapered. A roller
bearing consists of an outer race, an inner race, and a roller cage that holds the rollers in
place.

Thrust bearings: Thrust bearings are used to support axial loads. They are designed to
accommodate the axial load in one direction only. A thrust bearing consists of two races and
a set of rollers or balls between them.

Tapered roller bearings: Tapered roller bearings are designed to support both radial and
axial loads. They have a conical shape and can handle larger loads than ball bearings. A
tapered roller bearing consists of an outer race, an inner race, and tapered rollers.

Needle bearings: Needle bearings are used to support high radial loads in limited spaces.
They have a cylindrical shape and a small diameter. A needle bearing consists of an outer
race, an inner race, and needle rollers.

Selection of the appropriate type of bearing depends on the application, including factors
such as load capacity, operating speed, temperature, and environmental conditions.

Static load carrying capacity: Static load carrying capacity refers to the maximum load a
bearing can support without deformation or damage. Dynamic load carrying capacity, on the
other hand, refers to the maximum load a bearing can support over a certain period of time
while maintaining proper function.

Equivalent bearing load: Equivalent bearing load is a way to calculate the dynamic load
carrying capacity of a bearing, taking into account the magnitude, direction, and frequency
of the loads. Load-life relationship is used to determine the life of the bearing, given the
applied loads and operating conditions.

Bearing selecting from a manufacturer's catalogue: When selecting a bearing from a

manufacturer's catalogue, important parameters to consider include the type and size of the
bearing, load rating, and speed rating. It is also important to consider the probability of
survival, which is the likelihood that the bearing will last a given amount of time without
failing.

Design for cyclic load: Design for cyclic load involves selecting a bearing with adequate
dynamic load carrying capacity to withstand the cyclic loads that it will experience during
operation. This involves calculating the equivalent bearing load and selecting a bearing that
can withstand the expected cyclic loading conditions.
Quiz:

1. Explain the performance of a hydrodynamic bearing with the curve of μ versus ZN/p.
2. Explain Petroff’s equation for hydrodynamic journal bearings.
3. How do you express the life of a bearing? What is an average or median life?
4. Define the following terms as applied to rolling contact bearings:
(a) Basic static load rating (b) Static equivalent load
(c) Basic dynamic load rating (d) Dynamic equivalent load.
5. Design a journal bearing from the following data:
Radial load = 20 kN
Diameter of journal =100 mm
Speed of journal =900 r.p.m.
Oil SAE 10 with viscosity at 550 C = 0.017 kg/m-sec
Ambient temperature =15.50 C
Maximum bearing pressure = 1.5 Mpa
Permissible rise in oil temperature = 100 C
Heat dissipation coefficient = 1232 W/m2/0C
L/D ratio = 1.6
Design parameter ZN/p = 28
Clearance ratio = 0.0013
Specific heat of oil = 1900 J/kg/0C
6. A 75 mm diameter full journal bearing runs at 400 rpm. It is 75 mm long and is subjected
to a radial load of 2500 N. The bearing is lubricated with SAE 30 oil with the viscosity
16.5×10-3 kg/m-s flows into the bearing at a temperature of 75oC. The radial clearance is
0.03 mm. Determine:
(1) Summerfield number (2) Minimum film thickness (3) Attitude (4) Power loss in
friction (5) Heat loss (6) Side flow & Total flow of lubricants (7) Temperature rise
7. The ball bearings are to be selected for an application in which the radial load is 2000 N
during 90 per cent of the time and 8000 N during the remaining 10 per cent. The shaft is
to rotate at 150 rpm. Determine the minimum value of the basic dynamic load rating for
5000 hours of operation with not more than 10 per cent failures.
8. It is required to select a ball bearing suitable for a 50 mm diameter shaft rotating at 1500
rpm. The radial and thrust loads at the bearing are 4500 N and 1600 N respectively. The
value of X and Y factors are 0.56 and 1.2 respectively. Select a proper ball bearing from
the following table for the rating life of 22500 hr. the inner ring rotates and the service
factor is 1.
Bearing No. 6010 6210 6310 6410
C (N) 21600 35100 61800 87100

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Design of Machine Elements and
Transmission System
(3144101)
Lab Manuals are prepared by

Prof. S. D. Ambaliya
Asst. Prof. (Mechanical Engineering)
GEC, Surat

Prof. Mital D. Patel

Asst. Prof. (Mechanical Engineering)
LDCE, Ahmedabad

Branch Coordinator
Dr. Komal G. Dave
Professor of Mechanical Engineering
L. D. College of Engineering, A’bad

Committee Chairman
Dr N M Bhatt
Professor of Mechanical Engineering
L. E. College, Morbi