Machine Design
ME - 211
Dr. Sujeet Kumar Mishra
Department of Mechanical Engineering
Birla Institute of Technology
(In the service of the Nation since 1955)
(A Deemed University)
Mesra, Ranchi – 835 215 India
E-mail: sujeetmishra@[Link]
Mob: 9431927250
SYLLABUS (ME – 211 Machine Design)
Module –I
Failure of materials: Principles of Machine Design, standardization, Tolerances, Design against static and fluctuating loads, Theories of failures,
Design of cotter joint and knuckle joint, Fatigue failure, Endurance limit, Notch Sensitivity, Gerber, Soderberg, Goodman, and Modified
Goodman criteria, Design against combined loads.. (8L)
Module –II
Design of threaded, welded, and riveted joints: Threaded joints: Basic types of screw fastening, Bolt of uniform strength, Terminology of screw
threads, Bolt under tension, Welded joints: Butt joints, Fillet joints, Strength of butt and fillet welds. Riveted joints: Types of rivet heads, types of
rivet joints, Strength equations, Efficiency of joint, Caulking and fullering, Eccentrically loaded bolted, riveted and welded joints. (8L)
Module – III
Design of brakes and clutches: Types of Brakes and Clutches, Clutch/Brake selection and specification, Clutch and Brake materials, Disc
Clutches, Shoe, Band and Disk Brakes. (8L)
Module – IV
Design of springs and bearing: Spring configuration, Spring materials, Design of helical compression/extension springs. Bearings, Types of sliding
contact bearings, Bearing materials, Lubricating oils, Petroff’s equation, Mckee’s Investigation, Hydrostatic bearing, Rolling contact bearings .
(8L)
Module –V
Design of Gears: Types of gear, Terminology of gear, standard systems of gear tooth, Force analysis of spur, helical, bevel, and worm gears, Beam
and wear strength of gears, Lewis and Buckingham’s equation, Effective load on spur gear tooth. (8L)
Text Books:
1. Shigley’s Mechanical Engineering Design, by Richard Budynas (Author), Keith Nisbett (Author)
2. Introduction to Machine Design by V. B. Bhandari
3. Machine Design by Khurmi
Reference Books:
1. Machine Design, An Integrated Approach by Robert L. Norton, Second Edition.
2. Machine Design Data Handbook by K. Lingaiah
3. Mechanical Design of Machine Components by Ansel C. Ugural
Clutch
A clutch is a mechanical device which is used to connect or disconnect the source of
power from the remaining parts of the power transmission system at the will of the
operator.
In the operation of brake, the conditions are as follows:
i) Initial condition – The driving member is rotating and the driven member is at rest.
ii) Final condition – Both members rotate at the same speed and have no relative
motion.
Classification of Clutch
i) Positive contact Clutches: In these clutches power transmission achieved by means
of interlocking of jaws or teeth. Advantage is positive engagement & once coupled
transmit large torque no slip
ii) Friction Clutches: Power transmission is achieved by means friction between
contacting surfaces
iii) Electromagnetic Clutches: Power transmission is achieved by means of magnetic
field
iv) Fluid Clutches & Coupling: Power transmission is achieved by means of hydraulic
pressure. Fluid coupling provides extremely smooth start & absorbs shock
Advantages of Jaw clutches:
(a) They do not slip and engagement is positive.
(b) No heat is generated during engagement or disengagement.
Disadvantages of Jaw clutches:
(a)Jaw clutches can be engaged only when both shafts are stationary or rotate with very small
speed difference.
(b) They cannot be engaged at high speeds because engagement of jaws and sockets results in
shock.
Advantages of friction clutch:
(i) The engagement is smooth.
(ii) Slip occurs only during engaging operation and once the clutch is engaged, there is no slip
between the contacting surfaces. Therefore, power loss and consequent heat generation do not
create problems, unless the operation requires frequent starts and stops.
(iii) In certain cases, the friction clutch serves as a safety device. It slips when the torque
transmitted
through it exceeds a safe value.
Following factors should be considered while designing friction clutches:
(i) Selection of a proper type of clutch that is suitable for the given application
(ii) Selection of suitable friction material at the contacting surfaces
(iii) Designing the clutch for sufficient torque capacity
(iv) Engagement and disengagement should be without shock or jerk
(v) Provision for holding the contacting surfaces together by the clutch itself and without any
external assistance
TORQUE TRANSMITTING CAPACITY
A friction disk of a single plate clutch is shown in Fig. 11.3. The following notations are used in
the derivation:
D = outer diameter of friction disk (mm)
d = inner diameter of friction disk (mm)
p = intensity of pressure at radius r (N/mm 2)
P = total operating force (N)
Mt = torque transmitted by the clutch (N-mm)
The intensity of pressure p at radius r may be
constant or may be variable.
Two theories are used to obtain the torque capacity of the
clutch
(i) Uniform Pressure Theory: In case of new clutches employing a number of springs, the
pressure remains constant over the entire surface area of the friction disk.
With this assumption, p is assumed to be constant.
This constant pressure distribution is illustrated in
Fig. 11.5(a).
From Eq. (11.1)
The above equations have been derived for a single pair
of contacting surfaces. When there are a number of
friction surfaces in contact, as in the case of the multi-
disk clutch, Eq. (11.5) should be multiplied by the
number of pairs of contacting surfaces to obtain the
resultant torque transmitting capacity.
(ii) Uniform wear Theory: According to this theory, it is assumed that the wear is uniformly
distributed over the entire surface area of the friction disk. This assumption is used for worn out
clutches.
The axial wear of the friction disk is proportional to the frictional work.
The work done by the friction force at radius r is proportional to the frictional force (μp) and
rubbing velocity (2pr n) where n is speed in rev/min.
The above equation gives the torque transmitting capacity for
a single pair of contacting surfaces.
Q.1 A plate clutch consists of one pair of contacting surfaces. The inner and outer diameters of
the friction disk are 100 and 200 mm respectively. The coefficient of friction is 0.2 and the
permissible intensity of pressure is 1 N/mm2. Assuming uniform-wear theory, calculate the
power-transmitting capacity of the clutch at 750 rpm.
Q.2 Assume the data given in Q.1 calculate the power transmitting capacity of the clutch using
uniform pressure theory.
Q.3 A single plate clutch consists of one pair of contacting surfaces. The inner and outer
diameters of the friction disk are 125 and 250 mm respectively. The coefficient of friction is 0.25
and the total axial force is 15 kN. Calculate the power transmitting capacity of the clutch at 500
rpm using :
(i)uniform wear theory; and
(ii)uniform pressure theory
Q.4 An automotive single plate clutch consists of two pairs of contacting surfaces. The outer
diameter of the friction disk is 270 mm. The coefficient of friction is 0.3 and the maximum
intensity of pressure is 0.3 N/mm2. The clutch is transmitting a torque of 531 N-m. Assuming
uniform wear theory, calculate:
(i)the inner diameter of the friction disk; and
(ii)spring force required to keep the clutch engaged.
Brake
A brake is a mechanical device, which is used to absorb the energy possessed by a
moving system or mechanism by means of friction.
The primary purpose of the brake is to slow down or completely stop the motion of a moving system, such
as a rotating drum, machine or vehicle. It is also used to hold the parts of the system in position at rest.
An automobile brake is used either to reduce the speed of the car or to bring it to rest.
(i) Initial Condition One member such as the brake drum is rotating and the braking member
such as the brake shoe is at rest.
(ii) Final Condition Both members are at rest and have no relative motion.
Brakes are classified into the following three groups:
(i)Mechanical brakes, which are operated by mechanical means such as levers, springs and
pedals. Depending upon the shape of the friction material, the mechanical brakes are classified as
block brakes, internal or external shoes brakes, disk brakes and band brakes.
(ii) Hydraulic and pneumatic brakes, which are operated by fluid pressure such as oil pressure or
air
pressure.
(iii) Electrical brakes, which are operated by magnetic forces and which include magnetic
particle brakes,
hysteresis brakes and eddy current brakes.
Brake capacity depends upon the following factors:
(i) The unit pressure between braking surfaces
(ii) The contacting area of braking surface
(iii) The radius of the brake drum
ENERGY EQUATIONS
The first step in the design of a mechanical brake is to determine the braking-torque capacity for
the given application.
The braking-torque depends upon the amount of energy absorbed by the brake.
When a mechanical system of mass m moving with a velocity v1 is slowed down to the velocity
v2 during the period of braking, the kinetic energy absorbed by the brake is given by
Q.1 A solid cast iron disk, 1 m in diameter and 0.2 m thick, is used as a flywheel. It is rotating at
350 rpm. It is brought to rest in 1.5 s by means of a brake. Calculate
(i) the energy absorbed by the brake; and (ii) the torque capacity of the brake.
Q.2 A four-wheeled automobile car has a total mass of 1000 kg. The moment of inertia of each
wheel about a transverse axis through its centre of gravity is 0.5 kg-m2. The rolling radius of the
wheel is 0.35 m. The rotating and reciprocating parts of the engine and the transmission system
are equivalent to a moment of inertia of 2.5 kg-m 2, which rotates at five times the road-wheel
speed. The car is traveling at a speed of 100 km/h on a plane road. When the brakes are
applied, the car decelerates at 0.5 g. There are brakes on all four wheels. Calculate:
(i)the energy absorbed by each brake; and (ii) the torque capacity of each brake.
Q.3 A mass of 2500 kg is lowered at a velocity of 1.5 m/s from the drum as shown in Fig. The
mass of the drum is 50 kg and its radius of gyration can be taken as 0.7 m. On applying the
brake, the mass is brought to rest in a distance of 0.5 m. Calculate
(i)the energy absorbed by the brake; and
(ii)the torque capacity of the brake.
Solution Q.2
BLOCK BRAKE WITH SHORT SHOE
• A block brake consists of a simple block, which is pressed against the rotating drum by means
of a lever as shown in Fig. 12.2.
• The friction between the block and the brake drum causes the retardation of the drum. This
type of brake is commonly employed in railway trains.
• The block is either rigidly attached to the lever or, in some applications, pivoted to the lever.
• The angle of contact between the block and the brake drum is usually small.
• When it is less than 45°, the intensity of pressure between the block and brake drum is
Theuniform.
free-body diagram of forces acting on the drum and the
lever is shown in Fig. 12.3.
The analysis is based on the following assumptions: