DESIGN OF MACHINE

ELEMENTS
PSG DESIGN DATA BOOK

(USEFUL CONTENTS)
 Module: 1&2
(Design against
Static and Fluctuating
Stresses)
 FACTORS OF SAFETY

Steel I Ductile Material

Type of load
Cl
Based on au Baaed on oY
Static load 3 •4 1.5 - 2 S-6
Repeated, mlld shock 6 3 7-8
Reversed mild shock 8 4 JO - 12
Heavy shock 10 - 15
I 5-7 15 - 20

VARIABLE LOADING

Equation Nomenclature

A = load factor
= I for reversed bending
= 0. 7 for reversed axial load
= 0.6 for reversed torsion
Endurance limit of the machine member
B = Size Factor
( with factors considered ) If D < 10mm then ·B = I
If IO mm < D <·50 mm then B = 0.9
If50 mm< D < 100 mm then B = 0.8
cr_ 1 ABC
Ifl00mm<D < l50mm thenB=0.7
Kr
C = Surface finish factor
= 0.9 for ground or cold rolled surface
= 0.7 for machined surface
= 0.6 for cold rolled surface

RELATIONSHIP BETWEEN ENDURANCE LIMIT AND

ULTIMATE STRENGTH

Steel cr - I = 0.5 cr u

Cast Steel
CJ - I = 0.4 cr u
CJ - I = 0.35 CJ u
Cast Iron
CJ = 0.3 CJ u
Non Ferrous metals and alloys -I
:
 Equation Nomeoclaturt
\.
Basquin equation

B
A = cr r L
A constant
3
cr r = 0.9 O' u for L = 10 cycles
B constant I
6
cr • I = 0.5 cr 0 for L = 10 cycles
(J' - I endurance limit

Miner's equation Le expected life

I =
(~:)+(~) + ····· N Number of actual cycles

or L
Life at that particular part of the load

(t ) (t)
I
r= + + ····· cr a variable stress for any part of the
C

loading cycle

Endurance strength for loading with cr m mean stress for any part of the
different values and parts loading cycle

cr rn ·== Kt cr acr u n = I, 2, 3 ................ n

(cr u- cr m)

RELIABILITY FACTORS
DESIGNATION OF PLAIN
Reliability ¾
Kr CARBON STEELS
50 IS Designation
I
90
Old Designation
0.897 C IO New Designation
95
0.868 C3o IO C 4
99 C40 30 C 8
0.814
99.9 40 C 8
0.753 C 35 Mn 75
C 45 35 C 8
99.99 0.702
C 50 45 C 8
50 C4
C60
.44 60 C4 ---
--.
DESIGN DATA - Psn "l ' r ,
 Module: 3
(Design of spring)
 Module: 4
(Riveted Joint)
 Module: 4
(Welded Joint)
 Module: 6
(Keys and Couplings)
 DIMENSIONS OF PARALLEL KEYS AND KEYWAYS

45

b
CHAMFER OR RADIUS KEYWAY RADIUSs
OF KEY IN SHAFT AND HUB

All dimensions in millimeters

For shaft Above |8 10 12 17 22 30 38 44 50 58 65 75 85 95 110 130 150 170 200 230 260 290 330 380 440
Diameters Upto 8 10 12 17 22 30 38 44 50 58 65 7585 95 110 130 150 170 200 230 260 290 330 380 440 500
Key cross Width b 2 4
-
6 8 10 12 14|16 18 20 22 25 28 32 36 40 45 50 56 63 70 80 90 100
Section Height h 2 3 4 5 67 8 8 9 10 11 12 14 14 16
18 20 22 25 28 3232 36 40 45 50
Key way In Shaft
Depth 1.2 1.8 2.5 3
3.5 4
555 5.56 7 7.5 8.5 9
10
20 22 25 28 31 11
12 13 15 17 19
(nominal) In hub t 1
1.4 1.82.3 2.8 3.3 3.3 3.3 3.8 4.3 4.4 4.9 5.9 5.4 6.4 7.4 84 9.4
Tolerance on +0.1 +0.2
10.411.4|13.4|12.4|14.4|15.4|17.4 19.5
+0.3
Keywaydepth| t +0.1 +0.2 +0.3
Chamfer or Max 0.25 0.35 0.55 0.8 1.3 2 2.95
Raidus of key r1 Min. 0.16 0.25 0.4 0.6
Key way 1.6 2.5
radius T2 Max 0.16 0.25 0.4 0.6
1.6 2.5
Length Min 668 1014 18 22 28 36 45 | 50 56 63 70
80 90 100 110|125
of Key
Max 20 36 45 56 70 140|16o/180 200/220/250/280
90110 140 160 180 200 220250 280 320 360|400 400|400|400
Designation: AParaliel Key of width 10mm
height Smm and length 50mm shall be
designated
400/400 40o 40040040o
as
: Parallel Key IO * S * 50 S : 204s - 1962
 PREFERRED LENGTHS OF PARALLEL KEYS

Width 2 10 12 14 16 18 20 2225 28 32 36 40 45 50 56 63
70 80 90 100
(b), mm
Height
h), mm 67 889 10 11 12 14 14 16 18 20 22 25 28 3232 36 40 45 50

10 10 10 10
1 2 12

28 2828 28 28 28
32 32 32 32 32 32
36 36 36 36 36 362
40 40 40 40 40 404
45 4545 45 454
50 0 50 5050 50
56 5656 56 56 566 56
63 6363 6363 6363 63 63
70 70 70 70 70 7070 70 70 70
80 8080 8080 80 80 80 80 80
90 90 90 9090 90 90 90 90 90 90
100 100100 100 100 100100 100 100 100 100
110 110 10 10 110 110 110 110 110110 110 110
125 125 125 125 125 125 125 125 125125 125 125
140 140140 140 140 140 140 140 140 140 140140 140
160 160 160 160160 160160 160160 160160 160 160|
180 180180 180 180 180180 |180180 |180180 180180
200 200 200 200|200 200 |200 200 |200 200 200 200|200
220 220 220 220 220 220 220 220 220 220 220 220 220
250 250 250 1250 250 250250 250250 250 250 250250
280 280 280 280280 12802801280 280 280280 |280 1280
320 1320 1320 320 |320 1320320 320 320 13201320 320
360 360 1360 1360 360 360 360 360 [360 1360 1360
400 400 400 400 400 400 400 400 400 400
 COUPLINGS

Equation Nomenelature
F tangential force, N
RIGID COUPLING
M torque transmitted, N mm

F,
F - nd,1T, 1 [T] allowable shear stress, N/ mm 2
D2
number of bolts

F,ndb [ o,] [o ] allowable bearing stress, N / mm

2
P bearing pressure on pin, N /mm
FLEXIBLE COUPLING M bending moment on pin, N/ mm
b

P F Forproportions ofcouplings, see tables 1&2,

d, (G- F)n p.7.107, 108.
Forservice factors seetablep.7.109
M,-Ft+%(G-F
M

M,sWLA[T,]
2
FORCED END TYPE RIGID COUPLINGS
s TLA[,]

F 2 M IA

-2/3 F
W
-RUBBER
E

Z
LG G
E
BUSH TYPE FLEXIBLE
COUPLING COUPLIN
DISC TYPE FLEXIBLE

7.106 - PSG
TECH
DESIGN DATA
DESIGN DATA PSG 7.107
-

TECH
 8

&

7.108
TECH
DESIGN DATA PSG
-
 i
M

VI

7.109
DESIGN DATA - PSG TECH
 Module: 7
(Design of Engine
Components)
 PISTON ASSEMBLY

CYLINDER

Apparent longitudinal stress in the cylinder

Dp/[D,- D D
Outside diameter of the cylinder in mm
Inside diameter of the cylinder in mm
Oc Dp/2t
Maximum pressure in engine in N/mm
Onf -[o,/m] Thickness of the cylinder wall in mm
1/m Poisson ratio - usually taken as 0.25
nc- [ o-[o/m]
Apparent circumferential stress in cylinder
(pD /12 o,) +C
Length of the cylinder
nf Net longitudinal stress

nc
Net Circumferential stress
C Allowance for reboring

D, mm 75 100 150 200 250 300 350 400 450 500

C mm 5244.0 6.3 8.0 9.5 12.5 12.5 12.5

= 0.045 D+1.6 mm
t Thickness of dry liner
t = 0.03 D to 0.035 D

wt 0.032 D + 1.6 Water space between the outer cylinder wall and inner jacket
wall 10 mm for 75 mm cylinder to 75 mm for 750 mm
or
cylinder or 0.08 D+6.5 mm
t/3 for bigger cylinder
3t/4 for smaller cylinder Length ofthe stroke () is generally 1.25 D to 2D
Length of the Cylinderis 15% greater than the length of the
stroke i.e. 1.151

The Max. gas Pressure (p ) may be taken as 9 to 10 times the

mean effective pressure (Pm)

The flange thickness shouldbe taken as 1.2t to 1.4 t wheret

is the wall thickness of cylinder.

The nominal or major diameter ofthe stud or bolt ( d) usually

lies between 0.75 t , to t where t is the thickness of flange.
A stud or bolt in no case should be less than 16 mm diameter

The pitch of the stud or bolt should be between 19

Vd to 28.5 Vd.

DESIGN DATA - PSG TECH 5.137

 Cylinder head thickness

Cylinder bore in
mm
D

Div (cp/d.] P
Maximum pressure
inside the cylinder in N/mm

stress in MPa
a Allowablecircumferential
0.1
D D+3 d a constant value,
circle diameter
D, Thepitch

PISTON HEAD OR CROWN

tH Thickness of piston head (Based on strain)

Maximum gas pressure or explosion pressure in N/mm

D Cylinder Bore or outside diameter ofthe piston in mm

Permissible bending (tensile) stress of piston material in
tH3pD /16 G, mm MPa

For Grey CI =35 to 40 MPa

For Nickel CI & Aluminum alloy = 50 to 90 MPa

For forged steel 60 to 100 MPa

H Thickness of piston head (Based on heat transfer)

H Heat flowing through the

piston head in watts or kJ/s
K
Heat conductivity factor in W/m/°C
For Grey CI = 46.6 W/m/°C
tH H/12.56 K( Tc-TE) mm
For Steel = 51.25 W/m/°C

ForAluminum alloys = 174.75 W/m/°C

Tc Temperature at the center
of piston in °C
TE Temperature at the
edges of the piston head"C

The temperature difference (Tc-Tg)

may be taken as 220° C for Cl, 75° C for
aluminun

5.138
DESIGN DATA - PSG TEC
 H Heat flowing through the piston head

Constant representing the portion of the heat

Supplied to the engine. The value can be taken
as 0.05

H-CHCV m Bp HCV
(n &W) Higher calorific value offuel in kJ/kg

45x 10 kJ/kg for diesel

47x 10 kJ/kg for petrol
m mass ofthe fiuel used ing. brake power/Sec
B.p Brake power ofthe enginepereylinder

1The langer of two values oft is taken into account

When t y is ómm or less no ribs need to be provided. When t is greater than 6mm ribs should be
provided for a thickness oft y/3 to tp/2.
For engines having length of stroke to cylinder bore (LD) ratio Upto 1.5 a cup is provided in the top
ofthe piston having a radius equal to 0.71 D

D
Piston head
or crown

Ribs Grooves for

compression rings
Grooves for
oil control ring
Piston
boss

Piston
Circlip
pin

Piston for 1.C. engines

5.139
DESIGN DATA - PSG TECH
 PISTON RINGS

Radial thickness of the ring

PPressure of gas on the cylinder wall in N / mm
t D3P,/o
Value limited from 0.025 N/mm to 0.042 N/mm
t, D/10n R o, Allowable bending (tensile) stress in Mpa
Value may be 85 Mpa to 110 Mpa for Cl rings
b t to 1.2 t 2 The maximum axial thickness

DR No. of rings
b2 0.75t, to t b Width of the top land
b Width of the other lands

Gap Between the free ends of the ring = 3.5 t to 4t

Gap when the rings in the cylinder 0.002D to 0.004 D

Piston
boss Connecting rod

Piston
pin

PISTON PIN

PISTON BARREL

t3 Thickness of Barrel
t30.03D+b+4.5 mm b Radial
b = t + 0.4
depth of piston ring
groove whichis taken as 0.4 mm
largerthan the radial thickness of piston ring (t)
t30.03 D+ti+4.9 mm The piston wall thickness t towards the open end is decreasc
from0.25t, to 0.35 t3
PISTON SKIRT
P -p[mD'/4] Maximum gas load on the
piston
R 1/10 of Max. gas load R Maximum side thrust on the
0.65 D to 0.8 D
cylinder
=
Length of the piston skirt
5.140
DESIGN DATA - PSG TECH
 FLY WHEELS

AE = IK, 0

D+(D-2h for rim fly wheel

8

D/4 when h is small

D 1 8 for disc flywheel
V TDN

For CIFlywheel
V < 1 5 0 0m/min for H. P < 100

<2000 m/ min for H. P> 100

For cast steel flywheel

=
3000- 4000 m/min
W
T Dbhy
b/h = 0.65 -2 AE Excess energy
For belt pulley flywheel b should be 3 to 5 Mass moment of inertia of the
cm wider than the belt
flywheel
Stresses in the rim coefficient of fluctuation of
Tensile stress due to speed (refer table)
centrifugal force o,=
-2
Bending stress, Ob TVD
ngh , 0 2 and are maximum, minimum
total4 o, + % b and mean angular velocities
respectively
S 350 kgf/ cm for C. I
k radius of gyration of flywheel
65 kgf/cm for C. I
D,D outside and mean diameters of
<280 kgf/ cm for cast steel the rim

Stresses in the
h thickness of the rim
arm (at the hub End)
mean rim speed
Bending stress b1 M,(D-d)
W weight oftherim ofthe flywheel
nZyD
For C.I o b1130 kgf/ cm 2 with ofthe flywhel

<65 kgf/ cm , for severe load Specific weight

Section of arm number ofarms 6,8 or 10
M transmitted torque
64 yy with C a/2
T1, T2 belt tensions
7.120 DATA - PSG
TECH
DESIGN
 Taperof ar 1 n 50
For belt
pulley flywheel

(T- T,) (D-d)

b2 2nz yy

2
8 bh y v
nc a S

total bI+b2 + Ot
200 kgf/cm for CI

Values of K ,

Driven Machinery Type of drive K

Hammers, Crushers, Punch Presses Belt 0.2

Excavators Belt 0.1 0.14

Compressors, Concrete mixers,
Belt or flexible 0.04 0.05
Pumps, Shears coupling

Belt 0.033
wood working machines
Metal working and
Belt 0.02 0.025
Flour, Paper and Textile mills

Gears 0.02
machines
Compressors, Pumps and Similar
Belt 0.016 0.02
Spinning machines, Coarse to fine

Belt 0.03

D. C. generators single or parallel

Direct coupled 0.014
D. C. generators single or parallel
Belt 0.016

A.C. generators single or parallel

Direct coupled 0.01

A.C. generators single or parallel

7.121
DESIGN DATA - PSG TECH
 CONNECTING ROD

AXIAL LOAD ON THE CONNECTING ROD or steam ssure

P as
gas
kgfl cm
Load due to gas or steam pressure diameter of piston, cm

Fo4 dp R weight of reciprocating parts, kgf

Inertia force due to reciprocating parts angular velocity, rad / sec

FFi R o cos 6+ cos2 0

length of connecting rod, cm
(1/r)J
radius of the crank, cm
Effective force on the piston
F =
Fg t F
Y specific weight, kgf/cm
Axial load on the connecting rod
F area of cross section at mid.
F 2
section of connecting rod, cm
Sin 9
3
By Johnson's Formula Zxmodulus of section, cm
KX

factor of safety, 3 to 6

L equivalent length, cm
INERTIA FORCE

Inertia force on the connecting rod k radius of gyration, cm

at 1/3 1 from the crank pin
E modulus of elasticity, kgf/ cm
P 2 alor(for a =90 )
P inertia force, kgf
Bending stress due to inertia force

=-
ya l aor angle between crank and
Ob max 9 3 g ZXx connecting rod, degrees

2alo'r At mid section

a 1lt*
419
12

.-.
2
3.18t
mn

Depth at big end 1.1 to 1.2 times the

depth at the mid section
7.122 TECH
DESIGN DATA -PSG