MECHANICAL PART

2.1 WORKING PRINCIPLE:

Whenever the vehicle is allowed to pass over the dome, it gets pressed downwards. As the springs are attached to the dome, they get compressed and the rack, which is attached to, the bottom of the dome moves down in reciprocating motion. Since rack has teeth connected to gear there is conversion of reciprocating motion of rack in to rotary motion of gears, but the two gears rotate in opposite direction. So that shafts will rotate with certain RPM these shafts are connected through a chain drive to the dynamos, which converts the mechanical energy into electrical energy. ow made to rotate a wheel in one direction by supplying power to shaft, while other made to rotate freely on the shaft, as the free wheel is inserted in the gears. We can insert a flywheel is mounted on the shaft when the main function is to avoid energy fluctuation.

LINE DIGRAM

2.2 CONSTRUCTION DETAILS:

!he following theoretical data abstracted from the "A #A$%R&, where in which the system is still utili'ing. !he various machine elements in P%W&R #& &RA!(% )R%M SP&&* "R&A+&RS are ,. Rack -. Spur gear .. )ly wheel /. "earings 0. Shaft 1. Springs

2. &lectric dynamo A dome is mounted on four springs, to bottom of this dome a rack is clamped. !he rack has contact teeth on both the faces. (t has connected to two gear wheels. !o rotate the gear wheels only in one direction and making them free in other direction. We have inserted a free wheel in each gear. !his free wheel and gear assembly is mounted centrally. !he fly wheel is also mounted on the same shaft. !he shaft is simply supported at both ends by providing ball bearings. in concrete pit. ow a dynamo is connected to each shaft by chain drive. !his total assembly is arranged

1.2.1 RACK;
Material 3 Mild steel )unction 3 !o change the translator motion in to rotary motion Properties 3Strength, Rigidity ,Resistance to shock loads ,$ess wear and tear.

MANUFRACTURING PROCESS:
Re4uired s4uare rod is cut from the bar fit in the vice of milling machine id to cut on teeth according to dimensions of the drawing. #ears at infinite no. of. !eeth are called RA5+. With the help of rack and pinion, we can convert reciprocating motion in to rotary motion and vice versa. VELOCITY RATIO: $inear motion 67,8 $ength of handle Pitch of teeth on pinion o.of. teeth on pinion VELOCITY RATIO : 9 9 9 9 r, $ p

V.R

= *istance moved by the effort : *istance Moved by load. 9!P:-;$.

DESIGN OF RACK:
o. of teeth Si'e of rack Module Addendum *edendum !ooth load 6Wt8 9 9 9 9 9 9 ,/ <= > <= > 10=mm < ,-.01 ,-.01 2,./.?/

Rack and pinion in mesh Line diagram:

* Module M 9 3333333333 ! 9 d9m>t 9 < > -= 9 ,1= mm

,1= R 9 333333 9 <= mm

Ra

9 r @ addendum 9 <= @ 6=.<? > <8 9 <1./ mm

%uter diameter of gear wheel 9 -> Ra %.*. 9 ,2-.< mm

$et us assume o. of teeth on rack t )rom the fig $ength of path of contact +$9%+-3%$9 6P%@$A8 -36%P5%S B8 9

9 ,/

6<=91./8 -36<=5%S-==8 -

$A9addendum 9=.< > < 91./mm

9/-.0<1mm

$ength of arc of contact9 $ength of path of contact: cos B 9/-.0<1:cos -== 9/0..,?mm Minimum no.of teeth contact9 $ength of arc of contact:circular pitch 9/0..,?:6 C<8 9,.< teeth 9- teeth 9 one pair Angle turned by the pinion D wheel. When one pair of teeth is in contact

Angle turned by the gear wheel

$ength of are of contact > .1= 9 33333333333333333333333333333333333333333333333333 5ircumference of gear

/0..,< > .1= 9 333333333333333333333333333333 - Ra

/0..,< > .1= 9 333333333333333333333333333333 9 -> > <1./ .=.=0

$ength of rack 5ircumference of gear 9 9 9 -R - >n > <= 0=-.10/ mm

$ength of rack 9 0=-@,/<910=mm

1.2.2. SPUR GEAR:

(n precision machines, in which a definite velocity ratio is of importance, the only positive drive is by gears or toothed wheels. A gear drive is also provided, when the distance between the driver and follower is very small. CLASSIFICATION OF GEARS: ,. According to the position of a>is of shaft. a8 Parallel b8 (ntersecting c8 on intersecting

-. According to peripheral velocity of gears. a8 $ow velocity .. According to type of gearing. a8 &>ternal gearing a8 Straight TERMINOLOGY: b8 (nternal gearing b8 (nclined c8 Rack and pinion c8 5urved /. According to position of teeth b8 Medium velocity c8 Aigh velocity

 P(!5A 5(R5$& 3 (t is an imaginary circle, which by pure rolling action would give the same motion as the actual gear. P(!5A 5(R5$& *(AM&!&R 3 it is the diameter of the pitch circle. !he si'e of gear is specified by the pitch circle diameter. A**& *EMF (t is the radial distance of a tooth from the pitch circle to the top of the tooth. *&*& *EMF (t is the radial distance of a tooth from the pitch circle to the top of the tooth. PR&SSER& A #$&F (t is the angle between the common normal to two gears teeth at the point of contact and the common tangent at the pitch point the standard pressure angles are ,/ D,:- 0 and -= 0 5(R5E$AR P(!5AF (t is the distance measured on the circumference of the pitch circle from a point of one tooth to the corresponding point on the ne>t tooth. Pc usually denotes it. Pc * ! = 9 9
D/T

*iameter of pitch circle o. of teeth on the wheel

 *(AM&!RA$ P(!5A F (t is the ratio of no. of teeth of the pitch circle diameter in millimeter. GPdG denotes its. Pd9!:;*9:Pc HPc9;*:!I ! 9 o. of teeth * 9 Pitch circle diameter. M%*E$& F (t is the ratio of the pitch circle diameter in mm to the o.of teeth. (t is usually denoted by GmG. m9*:!.

NOTE: !he recommended series of modules in (ndian standards are ,, ,.-0, ,.0, -, -.0, .,/, 0, 1, 2, <, ,=, ,-, ,1, -=, -0, .-, /= and 0=.

CONDITION FOR CONSTANT VELOCITY RATION OF GEARS -LAW OF GEARING: (f * D *- are pitch circle diameter of wheel , and - having teeth !i and ! respectively. !hen 7elocity ratio 9 *,: *- 9 !- : !, STANDARD PROPORTIONS OF GEAR SYSTEM: S.NO. ,. -. .. /. 0. FARTICULARS A**& *EM *&*& *EM W%R+( # *&P!A M( (MEM !%! A( *&P!A !%%!A !A(5+ &SS 20 STU INVOLUTE SYSTEM =.< m ,m ,.1=m ,.<=m ,.02=<m

1. 2.

M( (MEM 5$&AR& 5& )($$&! RA*(ES

=.-m =./m

STANDARD MINIMUM NUM ER OF TEETH ON THE PINION IN ORDER TO AVOID INTERFERENCE

SYSTEM OF GEAR TEETH -=JS!E" ( 7%$E!& from the relationF -Aw !p
9
KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK

MINIMUM NUM ER ON PINION. ,/

!he no. of teeth on the pinion 6!p8 in order to avoid interference may be obtained

# H, @ l:#6l:# @ -8sin-3l

# 9 !#:!p 9 *#:*P 9 Pressure angle GEAR MATERIALS: !he material used for the manufacture of gears depend up on the strength and service conditions like wear, noise etc. !he gears may be manufacture from metallic or non metallic materials. !he metallic gears with cut teeth are commercially obtained by cast iron, steel and bron'e. !he nonmetallic materials like wood etc cue used for reducing noise. 5ast iron widely used for gears to its good wearing properties, e>cellent machinabitly and easy of producing complicated shapes by casting method.

PERMISSI LE WORKING STRESS FOR GEAR IN THE LEWIS E!UATION: !he permissible working stress 6fw8 in the lewis e4uation depends upon the material for which as allowable static stress 6f=8 may be determined. !he allowable static stresses is the stress at the elastic limit of the material. (t is also called the basic stress. (n order to accounts for the dynamic effects which becomes more severe as the pitch line velocity increases the value of working stress is reduce. According to the "arth formula, !he permissible working stress 6fw 9 f= > 5v8 Where f= 9 Allowable static stress Allowable static stress for ordinary cast iron is 01 Allowable static stress for medium grade cast iron is 2= Allowable static stress for highest grade cast iron is ,=0 5v 5v 9 9 9 velocity factor !he valueGs of the 5v are given as follows. . : . @ 7, for ordinary cut gears operating at velocities up to ,-.0m:s /.0 : /.0 @ 7, for care fully cut gears operating at velocities up to ,-.0 m:s 9 1:1 @ 7, for very accurately cut and ground metallic gears operating at velocities up to -= m:s 9 =.20 : =.20 @ 7, for precession gears cut with high accuracy and operating velocities up to -= m:s. H=.20 ,, @ 7I @ =.-0, for non3 metallic gears. (n the above e>pression, 7 is the pitch line velocity in m:s.

DESIGN OF SPUR GEARS:

Material used for gear $et us consider the module of gear GmG Pressure angle for heavy duty shock loads We consider the teeth on pinion G!G Pitch circle diameter of pinion Gm>!G Radius !ooth thickness

9 9 9 9 9 9 9

5ast (ron < mm -== Stub involute -= <>-=9 ,1= mm 6<>-=8:- 9 <=mm ,.02=< > <9 ,-.011 mm

!he minimum number of teeth for this pressure angle 9 ,/

)ace width of teeth for general purpose rough cut gears 9 -P5 to .P5 Where Pc 9 circular pitch 9 ; m 9 -0.,- mm 5onsidering only statiscal tooth load, !angential load on teeth, Wt 9 f > b > n > m > y Where, M 9 9 9 9 f Where f= 5v 9 9 9 9 9 f 9 Stress developed in teeth b 9 )ace width module $ewiGs form factor =.,20 3 6=.</,8 :-= =.,.-?0 fo > 5v Statical working stress carried by material 0= :mm- for ordinary grade cast iron 1:61@v8 for ordinary cut gears having peripheral velocity below -= m:sec. 1 1 for -=J stub involute

coefficient of velocity.

7elocity factor 5v

33333333333333333

333333333333333333333333

=.-0/.

1@v

1@,2.0/

=.</, !ooth form factor L 9 .,20 3 333333333333333 ! =.</, 9=.,20 3 33333333333 -= 9 =.,.-? Service factor cs ,.-0 6light shock <3,= hours per day8 Apply lewiMs e4n T"#$%#&'"( ()"* "+&'#$ )# &,% &))&, WT = -0 . C/ 0 . 1 . 2 . 3 9 ,=0 > =.-0/.> 6,=><8 > ; > < > =.,.-? 9 D3#"2'+ ()"* WD= WT 4W1 P !angential load W! 9 333333333> 5s 7 0== 9 3333333333333> ,.-0 ,2.0? 9 .0.-0 2,./.?/

And W, 9increment load due to dynamic action

-, v6b.c@ W!8 9 3333333333333 -, v 6b.c@ W!8

-,>,2.0?6<=>/,.@ -<./,-8 9 3333333333333 -,> ,2.0? 6<=>/,.@ -<./,-8 9--.,0?+ ow *L AM(5 $%A*96--.,0?N,===8@.0.-0 9--.,<2 + S&"&'+ ()"* W5 = -% 0 1 2 3 9</><=>O><>=.,.-? 9--.//0+ W5 6WD 5) *%5'$# '5 5"-% F7)2 *%5'$# "5 $%"7 +"# &"8% 2)7% &,"# &,'5 '& '5 5"-%: P%W&R #& &RA!(% )R%M SP&&* "R&A+&RS designed for )our wheeler SPECIFICATION OF GEAR: Material Module !ooth thickness Addendum *edendum Pitch circle diameter 9 9 9 9 9 9 5ast (ron < ,-.01 mm 1./ < ,1= mm

umber of teeth )ace width "ore diameter umber of pinions

9 9 9 9

-= <= mm 0= mm - nos.

DESIGN OF SHAFT FOR SPUR GEAR

Wt ormal load Wn 9 33333333333 5osB 2,./.?/ 9 3333333333333 5os-== 9 20?-.<//

Weight of the gear W#

=.==,,<C!CbCmCm

9=.==,,<C-=C<=C<C< 9,-=.<.-

Resultant load wR

9 wn- @ wg- @ - wn wg 5os B 9 620?-.<//8- @ 6,-=8- @ 6->20?-.</ > ,-=8 cos -== 9 22=1./<

(f the gear is overhung on the shaft, then the bending moment on the shaft due to resultant load.

9 9 9

wR > N 22=1./< > ,== 22=1/<.11? *# P mm

tor4ue

! 9 W! > 33333333333333 ,2-.< 9 2,./.?/ > 333333333333 9 1,1/0<.<,1 P mm

Since the shaft is under the combined effect of both torsion and bending, therefore we shall determine e4uivalent tor4ue

&4uivalent twisting moment !e 9 9 9 M- @ ! 622=1/<.11?8- @ 61,1/0<.<,18 ?<1<2/.-2 P mm

ow diameter of the gear shaft is determined by using following relation. !e 9 33333333333 > > dg. ,1

,1>?<1<2/.-2 *g 9 3333333333333333333 > /= *g 9 0= mm

*iameter of shaft for spur gear 9 0= mm

DESIGN OF KEYWAY
d,

Ma>

$ > w > > 3333333333333 -

Standard dimension for the shaft diameter d, 9 0= mm Width Aeight +ey way in shaft t, 6nominal8 in hub tb h 9 9 w t 9 9 ,/mm ? mm

9 0.0 mm6 *epth8 9 ..< mm

man 9 33333 d,. ,1 9 33333 > /= > 60=8. ,1 9 ?<,2/2.2= 3mm

d, man 9 33333 $ > w > > 3333 ?<,2/2.2= > 333333333333333333333 9 ,/ > /= > 0= $ $ Parallel key 9 9 2=.,- mm 2=mm Q ,1= mm 6ma>8 $

,/>?>2= (S F -=/< P ,?1-

1.2.9 FLY WHEEL:

!he primary function of a fly wheel is to act as energy RAccumulatorG Simply it reduces the GfluctuationG of speed. LOCATION: (t is interposed between the source of energy and the place where it is needed. DESCRIPTION: When the supply of energy does not vary and continuous in the same manner, (t does not demand for energy. (t will absorb energy when demand is less than the supply of energy and will give out energy when the demand is more than the energy being supplied. RE!UIREMENT OF FLY WHEEL IN OUR DESIGN: (n our design we are not getting the continuous energy from the rack and we are applying shock loads to the pinion and this energy is not constant throughout the cycle.

So as to eliminate or overcome this shock loads we are using the flywheel to supply constant energy to the dynamo. ADVANTAGES: ,. (t is a device, which acts as energy redistributors. -. !his will result in a great reduction in the si'e and cost of power source. .. !he action is continuous from cycle to cycle. APPLICATIONS OF FLY WHEEL: )lywheels are used in (5 engines, punching presses, steering machines, riveting machine, crushers, hammering machines. MATERIAL USED: Material used for manufacturing of flywheel is cast iron.

COEFFICIENT OF FLUCTUATION OF SPEED: !he difference between tile ma>imum and minimum speeds during a cycle is called the Rma>imum fluctuation of speedR. !he ratio of a ma>imum fluctuation of speed to the mean speed is called Rco3efficient of fluctuation of speedR. (t is denoted by 5s. 5s 9 -6
, -

8:6

8 (n terms of speed

ENERGY STORED IN FLY WHEEL:

+inetic energy of fly wheel, & 9 S ( Since ( 9 m k-, & 9 ( k- 2 As speed of flywheel changes from <ox to a>2 the ma>imum fluctuation of energy. TE 9 9 9 9 Where ( M + 9 9 9 9 ma>imum +& 3 minimum +& ( - 5s m k- - 5s -&5S moment of inertia of fly wheel about the a>is mass of fly wheel in +g radius of gyration of fly wheel in meters mean angular speed in rad:sec. co3efficient of fluctuation of speed.

5s 9

STERSS IN FLY WHEEL RIM: !he maUor portion of the mass or weight of flywheel of flywheel is concentrated at the R(M. !he following stresses are induced in the rim of flywheel. ,. !ensile stress due to centrifugal force -. !ensile bending stress caused by the restraint of the arms .. Shrinkage stress due to une4ual rate of cooling of casting. TENSILE STRESS DUE TO CENTRIFUGAL FORCE:

f,

9 9

V R- V7- 6Where 7 9 R8 density of fly wheel material tensile or hoop stress mean radius of fly wheel angular speed of fly wheel linear velocity of fly wheel

V fr R

9 9 9 9 9

TENSILE EINGING STRESS CAUSED Y RESTRAINT OF THE ARMS: fb Where n t fb 9 9 9 9 6,?.2/ > V > 7- > R8 : n- > t number of arms thickness of rim bending stress

STRESS IN FLY WHEEL ARMS: ,. -. !ensile stress due to centrifugal force ft9 y/ > P > 7"ending stress due to the tor4ue transmitted f" 9 M:W 9 !:RXW 6R3r8

M W ! R n

9 9 9 9 9

ma>imum bending moment section modulus mum tor4ue transmitted mean radius number of arms

radius of the hub

DESIGN OF FLY WHEEL ARMS:

!he cross section of the arms is usually elliptical with maUor a>is as twice the minor a>is. (t is design for ma>imum bending moment. !herefore W 9 Where a, b, M 9 9 9 9 (( : .- > b, > a, maUor a>is minor a>is !:r n6R3r8 M:W 9 !:R n W 6R3r8

Ma>imum bending moment Ma>imum bending stress

"

"y assuming a, 9 - > b, the dimensions of arms may be obtain by above e4uation. T,% 52"((%7 -(3:,%%(5 ;(%55 &,"# <0022 *'"2%&%7= "7% #)& >7)/'*%* :'&, "725. T,%3 "7% 2"*% :'&, :%0 &3>% :'&, ,)(%5 '# &,% :%0 &) -"+'('&"&% ,"#*('#$

DESIGN PROCEDURE FOR FLY WHEEL:

!he material used is cast iron. We know the fluctuation of energy of the fly wheel 9 T&9l:- -.

Where,

9 9

number revolutions per minute. 0== rpm. 0-..0 rad : sec.

)luctuation of energy of the fly wheel 9 T& 9,:- (T& 9 9 9 mv- 5s ,<.-/1 > 6,2.0?8 - > =.=-= ,,-.?, Pm 9 2-1=>6,2.0?8 f, V Pv 7 * 9 9 9 9 9 -.-/1Mpa density of material in kg : m

!he stress developed in fly wheel f, 9 V7 -

Ft/p
* :1= 6v > 1=8 6n > 8

As our diameter below this the design of fly wheel rim diameter is safe.

DESIGN OF FLY WHEEL RIM: Assuming the flywheel having as cross section of rectangle with breadth twice that of thickness.

" m m t-

9 9 9

-t - R > b > t > p - R > -t- > p

9 6m:/RnP8

1.2.? EARINGS
A bearing is a machine element, which supports another machine element. (t permits a relative motion between the contact surface, while carrying the load. (n this automobile gearbo> roller bearings are adopted. !he ball or roller bearings consists of an inner race, which is mounted on the shaft or Uournal, and the outer race, which is carried by the housing or casing. (n between the inner and outer race there are balls or rollers. A o. of balls or rollers are used and these are helped at proper distance by retainers so that they do not touch each other. !he retainers are this strip and usually in two parts, which are assembled after the ball bearings are used for light loads and roller bearings are used for heavier loads.

%"7'#$5 "7% +("55'-'%* "5:

,. *epending upon the direction of load to be supported Radial bearingF3 !he loads act perpendicular to the direction of the motion of the moving elements. !hrust bearingF3 !he load acts along the a>is of rotation

-. *epending upon the nature of contact. Sliding contact bearingF3 !he sliding takes place along the surface of contact between the moving elements and fi>ed elements. !he sliding contact bearings are also know as plain bearings. Rolling contact bearingsF3 !he steel balls or rollers are interposed between the moving and fi>ed elements the balls offer rolling friction at two points for each ball or roller. S&"#*"7* *'2%#5')#5 "#* *%5'$#"&')# )- 0"(( 0%"7'#$: !he dimensions that have been standardi'ed on an international basis. !hese dimensions are functions of the bearing bore and the series of bearing. !he standard dimensions are given in millimeters. !here is no standard for the si'e and the o. of balls. !he bearings are designated by a number. (n general the number consists of at least three digits additional digits or letters are used to indicate special feature. E@AMPLE:- *eep groove, filling notch etc. !he last three digits give the series and the bore of the bearing. !he last two digits from =/ onwards. When multiplied by =0, give the bore diameter in millimeters. !he third form of the last digit designates the series of the bearings. !he most common ball bearings are available in four series as followsF ,. &>tra light 6,==8 -. $ight 6-==8 .. Medium 6.==8 /. Aeavy 6/==8

E@AMPLE: (f the bearing is designated by a number .=0, it means that the bearing is of medium series whose bore is =0 > 0 i.e. -0mm MATERIALS: Since the rolling elements and the races are subUected to high local stresses of varying magnitude with revolution of the bearing. !herefore the material of the rolling element should be of high carbon 4uantity. !he balls are generally made of high carbon chromium steel. !he material of both the balls and races are Aeat !reated to give e>tra hardness and toughness. !he balls are made by hot forging on hammers from steel rods, they are then heat treated, ground and polished. !he races are also formed by forging and then heat treated, #round and polished..

DESIGN PROCEDURE: !hey should have to bear radial as well as lateral load. "all bearings are used. As the load is medium and diameter of the bore is .<. !he ball bearings are specified by 9 .=2 When . represents medium series =2 N 0 gives the bore diameter )or our proUect pillow block bearings are used and bearing number is 1.,= !hese are brought from the out side according to our re4uirements

.2.A SHAFT:
A shaft is a rotating element, which is used to transmit power from one place to another. !he power is delivered to the shaft by some tangential force and the

resultant tor4ue or tensional moment set up within the shaft permits the power to be transferred to various machines linked up to the shaft, in order to transfer the power from one shaft to another the various members such as pulleys, gears etc, are installed on it. !hese members causes the shaft to bending. (n other words we may say that a shaft is used for the transmission of tor4ue and bending. !he various members are mounted on the shaft by means of keys or splines. MATERIALS USED: !he material used for ordinary shafts is mild steel where high strength is re4uired. An alloy steel such as nickel, nickel chromium or chrome vanadium steel is used. MANUFACTUREING TECHNI!UE: Shafts are generally formed by hot rolling and finished to si'e by cold awing or turning. !here are two types of shaftsF a. !ransmission shaft b. Machine shaft. TANDARD SIBE OF SHAFT: -0 mm to 1= mm with 0 mm step 1= mm to ,,= mm with ,= mm step ,,= mm to ,/= mm with ,0 mm step ,/= mm to 0== mm with -= mm step STANDARD LENGTH OF THE SHAFT: 0 meters

1 meters 2 meters STRESS IN SHAFT: Shear stress due to transmission of tor4ue. 5ombined torsion and bending. "ending stress due to the force acting up on the machine element like gears, pulleys etc. As well as due to the weight of the shaft itself.

DESIGN OF SHAFTS:
!he shaft may be designed on the basis of strength D rigidity S,"-& 5C0D%+&%* &) &:'5&'#$ 2)2%#& )7 &)7EC% )#(3: Where the shaft is subUected to poor twisting moment then diameter of shaft. !:Y ! Y fs R 9 9 9 9 9 fs:R !wisting moment or tor4ue acting upon the shaft. Polar moment of inertia of cross sectional area about the access of rotation in mm/ !orsion shear stress ( mm- or + ( mm*istance from neutral a>is to the outer most layer mm or M

S) -)7 5)('* 5,"-& 7%EC'7%* &)7EC%: ! * 9 9 :,1 fs d. diameter of the shaft

)or hollow shaft ! 9 :,1fs 6d/= 3 d/i8 : d=

do di

9 9

outer diameter (nner diameter

S,"-& SC0D%+&%* &) %#*'#$ M)2%#&: When the shaft is subUected to a beading moment then the Ma>imum stress is given in bending e4uation M:( 9 fb : L M ! f bZ 9 9 9 "ending moment in 3M or 3mm Moment of inertia of cross sectional area about itGs a>is of rotation in mm "ending stress in :mm- or + :mm- L 9 *istance from neutral a>is to the outer most layer )or solid shaft 6M8 9 : .- > fb > d. d 9 diameter of the shaft )or hollow shaft 6M8 9 : .- > fb > 6,3k/8 > do + 9 9 outer diameter ratio of diameter 9 d,9:d=

Shaft subUected to combined twisting moment and bending moment. When the shaft is subUected to combine twisting moment and bending moment then the shaft must be designed on the basis of two moments simultaneously various theories have been they are subUected to various types of combined materials. !he following two theories are important from the subUect point of view. ,. Ma>imum hear stress theory or #uest theory is used for ductile materials. -. Ma>imum normal stress theory or Rankines theory is used for brittle materials.

A++)7*'#$ &,% &) 2".'2C2 5,%"7 5&7%55 &,%)73 &,% 2".'2C2 5,%"7 5&7%55: fs 6ma>8 9 6fh- @/fs-8 &>pression 6M- @!-8 known as e4uivalent twisting moment denoted by !e !he e4uivalent twisting moment may be defined on that twisting moment which when acting alone produces tile same shear stress 6fs8 as the actual twisting moment by limiting the ma>imum shear stress Hfs 6ma>8I e4ual to the allowable shear stress 6fs8 for the material. != 9 M-@!-9:,1>fsd. ACCORDING TO MA@IMUM NOR MAL STRESS - THEORY: S 6m @ M-@!- 8 !he e>pression H,:- 6M@7M-@!- 8I is known as e4uivalent bending moment and is denoted by Me the e4uivalent bending moment may be defined as that moment which when acting alone produces the same tensile or compressive stress 6f=8 as the actual bending moment by limiting the ma>imum normal stress Hfo6ma>8I e4ual to Me9l:-6M @ 7M-@!-8 Me 9n:.->fb>d. S,"-& 5C0D%+&%* &) ".'"( ()"* '# "**'&')# &) +)20'#%* &) &)75')# "#* 0%#*'#$ ()"*5:

When the shaft is subUected to an a>ial load 6f8 in addition to torsion and bending loads as in propeller shafts and shafts for driving worm gears then the stress due to a>ial load must be added to bending stress 6fb8 Me 9;:.- > fb > 6l3k/8 > do. DESIGN OF SHAFTS ON THE ASIS OF RIGIDITY: Some times the shafts are to be designed on the basis of rigidity. We shall considered the following two types of rigidity. ,. !orsional rigidity -. $ateral rigidity TORSIONAL RIGIDITY: !he tensional rigidity is important in the case of transmission shafts deflection -.0J to .J:m. length may be used as limiting value they widely used deflection for the shaft is limited to , degree in length e4ual to -= times the diameter of the shaft. !he torsional deflection may be obtained by using the !:Y 9 # ? :$. B B ! Y 9 9 9 9 9 9 # 9 !$:Y# !orsional deflection or angle of twist in radians twisting moment or tor4ue on the shaft polar moment of inertia of the cross sectional area about the a>is of rotation. :.-d/ for solid shaft. :.-6d/= 3d/8 for hollow shaft. Modulus of rigidity for the shaft material.

LATERAL RIGIDITY:

(t is important in case of transmission, shaftening and running at high speed where small lateral rigidity is also important for maintaining proper bearing and clearances an for correct gear teeth alignment if the shaft is of uniform cross3 section then the lateral deflection of a shaft may be obtained by using the deflection formulae as in strength of materials. "ut when the shaft is of variable cross3section then the lateral deflection may be determined from the fundamental e4uation for the elastic curve of a beam. (,e. d-y:d>- 9 M: &(.

DESIGN PROCEDURE FOR SHAFT:

Shaft is always designed based on both strength and rigidity. We assume that length of the shaft necessary 9 -==mm !he shaft is loaded in a simply supported position. Aere the bending is due to the load of gear, flywheel and the twisting is due to tor4ue produced when the vehicle passes over the dome. !he material selected for shaft is milk steel Shaft used for gears. a8 ormal load due to gear acting on shaft W 9W! : 5os B 9 2,./.?/ : 5os -= 9 20?-.<// b8 Weight of the gear 9 =.==,,< > !# > b > m- . Where !c 9 b 9 m 9 We 9 umber of teeth on gear )ace width Module ,-= .

Weight or the gear 9 =.==,,< > -= > <= > <-

!he resultant load acting on shaft 9 WR 9 9 9 WW @ W# @- > W > W# > cos B 620?-8- @6,-=8- @->20?->,-=>cos-= 22=1./< .

(f the gear is overhung on the shaft, then the bending moment on the shaft due to resonant load.

9 9 9

we N > 22=1./< > ,== 22=1/<.11? *# P mm

9 W! > 33333333333333 ,2-.< 9 2,./.?/ > 333333333333 9 1,1/0<.<,1 P mm

&4uivalent twisting moment !e 9 9 9 M- @ ! 622=1/<.11?8- @ 61,1/0<.<,18 ?<1<2/.-2 P mm

!e 9 33333333333 > > dg.

,1 ,1>?<1<2/.-2 dg 9 3333333333333333333 > /= dg 9 0= mm

*iameter of shaft for spur gear 9 0= mm SPECIFICATION OF THE SHAFT: $ength of the shaft !he material used *iameter of the shaft o. of shafts 9 9 9 9 <==mm mild steel 0=mm /

1.2.< SPRINGS
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. PURPOSES F APPLICATIONS: !o cushion, absorb or control energy due to either shocks or vibration as in our spring railway buffers, air craft, landing gears, shock absorbers and vibration dampers. !o apply forces, as in brakes, clutches and spring loaded valves !o control motion by maintaining contact between two elements as in cams and followers. !o measure forces, as in spring balances and engine indicates. TYPES OF SPRINGS: !hese are mainlyF

,. Aelical springs -. !orsion springs .. (nvolute spring /. 5onical casting laminated or leaf spring We are using Aelical compression springs. HELICAL COMPRESSION SPRINGS: !hese are mainly intended for compressive or tensile loads. (n a closely coiled helical spring the Aeli> angle is very small 6Q,=J8. !he maUor stresses produced in helical springs are shear stresses due to twisting. !he load applied is parallel to 6or8 along the a>is. (n open coiled helical springs the heli> angle is large i.e., the spring wire coiled in such a way that there is no gap between two consecutive turns therefore application of these types is limited. MATERIALS FOR SPRINGS: !he material for spring should have high fatigue strength, high ductility, high resilience and it should be creep resistant. =.?[ 3 ,.=[ carbon is common material for springs. Steel with =.<0[ 3 =.?0[ carbon and =..[ 3 =./[ .. Manganese is used for longer si'ed springs. Alloy steels such as chrome 3 vanadium and silicon manganese steels are used for better grade springs. 5hrome steel, phosphorus bron'e and Monel metal 6nickel alloy8 can also be used in special cases, to increase corrosion resistance and temperature resistance.

P"7"2%&%75 "#* G%)2%&7'+ D'2%#5')#5 )- " C3('#*7'+"( S>7'#$

6wire dia.8, d 6outside dia.8, D2 6inside dia.8, D, 6mean dia.8, D 6pitch8, p 6pitch angle8, 6free length8, Lf

STRESS IN SPRINGS: 5onsider a helical spring made of circular wire diameter, GdG mm. Pitch of spring is very small. !he action of load RWR tends to twist the wire there by causing torsional shear stresses in the wire. Such springs are designed for torsion. eglecting effect of bending and direct shear. $et, W 9 a>ial load R 9 mean radius of coil d 9 diameter of coil wire Stress can be calculated by using torsion e4uation, . !:Y 9 fs:R )s 9 !R:Y 9 !:Wp :,1>d Where , Wp 9 section modulus 9

! 9 tor4ue transmitted by the spring 9 W>R Shear stress induced, fs 9 ,1 WR:nd.

COMPRESSION SPRINGS: !erms used in connection with springs are 1. S)('* L%#$&,: When compression spring is compresses until the coils come in contact with each other then the spring is solid. Solid length of spring, $s !otal number of coils, n *iameter of wire, d

2. S>7'#$ I#*%.: !he spring is defined as the ratio of mean diameter of the coil to diameter of wire. Spring (nde>, Where, .. P'&+,: Pitch at the coil is defined as the a>ial distance between adUacent coils in uncompressed state. Pitch at the coil, P 9 tree length : n, 3 , 6or8 P 9 $, 3 Wn, @ d Where $, $s
,

5 9*:d * 9 mean diameter or coil d 9 diameter of wire

9 9 9 9

tree length at spring solid length as spring total number of coils diameter of wire

A /"7'%&3 )- %#* &7%"&2%#&5 )7 T3>%5 )- %#*5

"oth ends plain

S4uare end ground ends

!he end turns are s4uared and then ground perpendicular to the heli> a>is.

5lose and ground ends

D%5'$# )- 5>7'#$ :'7% /5 P , =.1,0

WahlMs factor + 9 KKKKKKKKK >KKKKKKKK 9 ,.., /5 3/ 5

We know that <wc

+>

333333333333 d-

*-

,..,><>,.>,=.>0 KKKKKKKKKKKKKKKKKKKKKK N-<=

**

9 9

22/.0 -2.<-mm

9 -< mm

Mean diameter d 9 c>d 9 0>-< 9 ,/= mm $et us assume number of turns n92 )or s4uare and ground ends n, = n+2= 7+2=9

S4uare and ground ends

*eflection of spring
=
1/WR . n 1/ ,. ,= . .0. 0 = = ./ mm Gd / < ,= / 6,18 /

)ree length of the spring

l f = 6 n, d 8 + + 6=.,0 8 = 62 -<8 + -? + 6=.,0 -?8 = --?..0mm

Pitch of the coil

p= f!ee lengt n ,
,

--?..0 .<mm 2 ,

1.2.G. CHAIN DRIVES

Relation b:w pitch and pitch circle diameter

Pitch of chain p 9 d sin -

3333333

.1=o 9 333 333333 !

,<= P 9 * sin 333333333 !

Sprocket outside diameter *o 9 * @ =.<d, *, 9 dia of chain roles

,

!9 33333333333

7.R. 9

33333333333

!,

, -

D !, for smalles sprocket D !- for large sprocket

* Avg velocity 7 9 33333333 1= !P 9 33333333333333 1=

"ush rolles chain )actor of safety for chain drives Wb ).S. 9 33333333 W

!angential driving force acting on the chain P )t 9 333333333333 7 5entrifugal tension fc 9 m7 -

!emion in the chain drive due to sagging fs m 9 9 kmg> mass of chain in kg : m length

9 9

- to -.1 , to ,.0

6or8 Q /=o \ /=o

Power transmitted by chains on the basis of bearing load

Wb>7 P 9 3333333333333333 > +s +s 9 +, N +- N +. n 9 factor of safety

%n the basis of bearing sticks fb > A > 7 P9 333333333333333333333333 +s

,. $oad factor +, 9 ,.0 for heavy shock loads -. $ubrication factor +- 9 ,.0 for periodic lubrication .. Rating factor +. 9 , for haves per day.

umber of teeth on the smaller 6or8 driving sprocket 6or8 pinion d 7 ma> 9 33333333333 m :s d 9 pitch circle dia for smaller

o. of teeth on sprocket !, 9 -? 7ariation of speed 9 ,.1 [. )or ,2 teeth 7.R 9 -./<

!7.R. 9 3333333333 9 !, -./<

!- 9 -./<> -? 9 2- teeths.

P7'#+'>"( *'2%#5')# )- &))&, >7)-'(% ,. !ooth flank radices re 9 9 *, ! 9 9 =.==< d, 6!- @ ,<=8 mar =.,- d, 6!@-8 min Roller dia o. of teeth

-. Roller seating radies 6R,8 R, 9 9 =.0=0 d, @ =.=1? . d, =.0=0 d,

.. Roller seating angle ?=o 9 ,/=o 3 333333333 !

?=o 9 ,-=o 3 333333333 ! /. !ooth height above pitch polygon 6ha8

?=o Aa 9 =.1-0 p P =.0d,@ 333333333 !

9 0. Pitch circle diameter P * 9 333333 9

=.0 6p P d,8

,<= p coses 333333333

Sing 6,<=8

L%#$&, )- +,"'# *7'/%

$9;6r, @ r-8@->@ 6r, 3 r-8- :> where > 9.= to 0= times pitch at (S% chain number =1" pitch9?.0-0mm >9 /=C?.0-09.<,mm

PRACTICAL APPLICATIONS OF CHAIN DRIVES

!he chains are mostly used to transmit motion and power from one shaft to another, when the centre distance between their shafts is short such as in bicycles, motor cycles, agricultural machinery, conveyors, rolling mills, road rollers etc.

 !he chains may also be used for long centre distance of upto < metres. the chains are used for velocities up to -0 m : s and for power upto ,,= kw. in some cases, higher power transmission is also possible

1.2.G ELECTRIC DYNAMO

(t is well known that whenever electric current flows through a conductor a magnetic flu> is immediately brought ,= e>istences in the space surrounding the conductor. We say that when the electrons are under motion they produce magnetic field. !he converse is also true, i.e., when a magnetic field embracing a conductor moves relative to the conductor, it produces a flow of electrons. !his the phenomenon used in the dynamo. !his &M) is produced is known as electro magnetically induced emf. !hese are based on RfaradayGs laws of electromagnetic inductionR. !hey are ,. )(RS! $AW F when ever a conductor cuts across magnetic lines of flu> an &.M.) is induced in it. -. S&5% * $AWF the magnitude of induced &.M.). is e4ual to the rate of change of flu>.

DYNAMO: (t is a device, which converts mechanical energy into power energy. !he dynamo mainly consists of the following partsF !hey are F ,. A magnets -. A conductor WORKING: (magine the coil is rotating in clockwise direction as the coil continues rotating further the rate of change of flu> linkage and hence &.M.). induced in it increases till position is reached. Where
1

9 ?=. Aere the coil plane is hori'ontal

i.e., parallel to the lines of flu> as seen the flu> linked with the coil is minimum, but rate of change of flu> linkages or rate of flu> cutting is ma>imum. Aere ma>imum &.M.). is induced in the coil when this position. (n the ne>t 4uarter revolution i.ei from ?=J 3 ,<=J. !he flu> linked with the coil gradually increases but the raise of change of flu> decreases. C Aence the induced e.m.f. decreases gradually till it in position half of the coil it is reduces to = values. So we find that in the final half revolution of the coil no e.m.f. is induces in it when in positional. Ma>imum e.m.f. is induced when in position . D no e.m.f. is induced when in positions. !he direction of this induced e.m.f. can be found buy applying )lemings right hand rule. Which give direction] Aence the direction of current flow is A"M$5*. !he current through the load resistance R flows from M to $ during the first revolution of the coil. (n the ne>t half revolution i.e., from ,<== to .1=J the variation in the magnitude is of e.m.f. are similar to those in the first half revolution. (ts value is ma>imum when coil is in position 2 and minimum when it is in position ,. "ut it

will be found that the direction of the induced current is from * to 5 D " to A. Aence the form of current flow is along *5$M"A which is Uust the reverse of the previous direction of the flow of the current.