Course Number: MEM601, Course Title: MECHANICAL ENGINEERING DESIGN I

Class: B.Tech., Status of Course: MAJOR COURSE, Approved since session-2013-14

Total Credits:4, Periods(55 mts. each)/week: 4(L:4+T:0+P:0+S:0), Min.pds./sem.: 52

UNIT 1: DESIGN FUNDAMENTALS

Selection of Materials - Existing materials including advanced materials like composites, etc., their
properties, some case studies in material selection, material selection based on job requirements.
General considerations in design. Axial retainment of rotating parts.
UNIT 2: JOINTS, SHAFTS, KEYS & COUPLINGS
Joints for axial loads: Cotter joints. Knuckle joints. Adjustable screw joint (turnbuckle). Riveted joints.
Screwed connections. Eccentrically loaded bolted, riveted and welded joints.
Shafts, Keys and Couplings: Shaft, key Design. Rigid couplings, Flexible (compliant) couplings.
UNIT 3: STRESS CONCENTRATION AND FATIGUE
Stress concentration, Geometric stress concentration factors, Methods of reducing stress
concentration. Fatigue. Endurance limit, fatigue strength. S-N diagrams. Notch sensitivity. Life estima-
tion. Modified Goodman diagrams. Design aspects.
UNIT 4: LEVERS & BELT DRIVES
Levers: Hand lever, foot lever, cranked lever. Bell crank lever. Rocker arm. Lever of a lever safety
valve.
Belt drives: Belt, rope and chain drives. Hoisting machine elements. Pulleys, Flywheels.
UNIT 5: BRAKES AND CLUTCHES
Introduction, Types, Materials. External shoe brakes. Block brakes. Double shoe block brakes. Internal
shoe brakes. Band brake. Band and block brake. Single and multiple disk clutches. Cone clutch.
Centrifugal clutch.

SUGGESTED READING:
Lewis: SELECTION OF ENGINEERING MATERIALS
Sadhu Singh: Machine Design
Bhandari: DESIGN OF MACHINE ELEMENTS
Sharma & Agarwal: MACHINE DESIGN
Budynas, Nisbett: SHIGLEY'S MECHANICAL ENGINEERING DESIGN
Pandya & Shah: MACHINE DESIGN
RL Norton: MACHINE DESIGN: AN INTEGRATED APPROACH
 MEM601 - MECHANICAL ENGINEERING DESIGN-1

1 UNIT I – Design Fundamentals

1.1 a. What are the important considerations that govern the choice of a material for a
component to be designed.
b. What useful information is derived from a tensile test?
c. What are the advantages of forged components?
d. What advantages does cast iron have as a construction material?
1.2 a. Discuss the basic requirements for machine elements and machines.
b. Write a tentative design procedure.
1.3 State the fundamental requirements for proper support and retainment of rotating machine
parts.
1.4 What factors should be taken into consideration when mounting shafts on angular contact
bearings?
1.5 What precautions should be taken while mounting bevel gears and worm gears?
1.6 Explain the use of shims in various types of machine constructions with examples.
1.7 Write a note on the support and retainment of rotating parts. Give examples with figures.
1.8 Make a sketch of a cycle pedal showing in detail the axial retainment of various parts.
1.9 Sketch the elevation (front view) and plan (top view) of a single stage spur gear box showing
clearly the axial retainment of the various parts and the design of the housing.
1.10 What are performance indices? How are they used for material selection?
1.11 Select material for designing a light and stiff cantilever beam of circular cross section using
Ashby Charts.
1.12 Discuss the Weighted Property Index method of material selection.

2 UNIT III - Fastenings, Shafts, Keys and Couplings

Fastenings
2.1 Discuss the design procedure of a spigot and socket cotter joint.
2.2 Discuss the design procedure of a knuckle joint.
2.3 Two rod ends of a reciprocating pump are joined by means of a cotter, spigot and socket at
the ends. Design the joint for an axial load of 100 kN which alternately changes from tensile
to compressive. The allowable stresses for the material used are ft=50 MPa, fs=40 MPa and
fc=100 MPa.
2.4 Two mild steel rods 40 mm diameter are to be connected by a cotter joint. Calculate the
dimensions of the joint if the maximum permissible stresses are 46 MPa in tension, 35 MPa
in shear and 70 MPa in crushing.
2.5 A knuckle joint is required to withstand a tensile load of 25 kN. Design the joint if the
permissible stresses are : ft=56 MPa, fs=40 MPa and fc=70 MPa.
2.6 Discuss the design procedure of an adjustable screw joint (turn buckle) for round rods.
2.7 Design a knuckle joint for a tie rod of a circular section to sustain a maximum pull of 70 kN.
The ultimate strength of the material of the rod against tearing is 420 MPa. The ultimate
tensile and shearing strength of the pin material are 500 MPa and 380 MPa respectively.
Determine the tie rod section and pin section and all other dimensions of the knuckle joint.
Take factor of safety = 6.

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2.8 Discuss the design procedure of the big end of a connecting rod for a steam engine when
only one gib is used.
2.9 The pull in the tie rod of an iron roof truss is 50 kN. Design a suitable adjustable screwed
joint. The permissible stresses are ft=75 MPa, fs=37.5 MPa and fc=90 MPa.
2.10 a. How are rivets manufactured? What is the material used?
b. Describe common types of riveted joints. Illustrate your answer with neat sketches.
c. Describe briefly the various ways in which a riveted joint can fail.
2.11 What is an eccentric riveted joint? Describe the design of such a joint.
2.12 A double riveted lap joint with chain riveting is to be made for joining two plates 10 mm thick.
The allowable stresses are ft=60 MPa, fs=50 MPa and fc=80 MPa. Find the rivet diameter,
pitch of rivets and distance between rows of rivets. Also find the efficiency of the joint.
2.13 A triple riveted lap joint with zigzag riveting is to be designed to connect two plates of 6 mm
thickness. Determine the diameter of the rivet, 100kN
pitch of rivets and distance between the rows 250 mm
of rivets. Indicate how the joint will fail.
Assume ft=120 MPa, fs=100 MPa, fc=150
MPa. 75

2.14 A bracket is riveted to a column by six rivets of 75

equal size as shown in figure 1. It carries a Figure 1
load of 100 kN at a distance of 250 mm from
the centre of the column. If the maximum
shear stress in the rivet is limited to 63 MPa,
find the diameter of the rivet.
2.15 Design a double riveted double strap butt 120kN
75 mm
joint for the longitudinal seam of a boiler
shell, 750 mm diameter, to carry a maximum
steam pressure of 1 MPa gauge. The
25

allowable stresses are ft=35 MPa, fs=28 MPa

and fc=52 MPa. Assume the efficiency of
the joint as 75%.
2.16 A bracket is supported by means of four
rivets of the equal size as shown in figure 2.
Determine the diameter of the rivet if the Figure 2
maximum permissible stress is 140 MPa.
2.17 What is an eccentrically loaded welded joint? Discuss the procedure for designing such a
joint.
2.18 Write a short note on methods of welding.
2.19 A bracket carrying a load of 15 kN is to welded as 125mm 15kN
shown in figure 3. Find the size of the weld
required if the allowable shear stress is not to
exceed 80 MPa.
+G 80

50 Figure 3

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2.20 a. A plate 100 mm wide and 12.5 mm thick is to be welded to another plate by means of
parallel fillet welds. The plates are
la
subjected to a load of 50 kN. Find the
length of the weld so that the maximum
stress does not exceed 56 MPa. a
Consider the joint first under static 200
P
loading and then under fatigue loading.
b. A 200 x 150 x 10 mm angle is to be b
welded to a steel plate by fillet welds as 150 lb
shown in figure 4. If the angle is Figure 4
subjected to a static load of 200 kN, find
the length of weld at the top and bottom. The allowable shear stress for static loading may
be taken as 75 MPa. 40kN
400mm
2.21 The bracket shown in figure 5 carries a load of
40 kN. Calculate the size of weld if the allowable
shear stress is not to exceed 80 MPa. 200
2.22 a. Explain the methods of obtaining bolts of uniform
strength.
b. How is the core diameter of a bolt determined
when a bracket having a rectangular base is 150 Figure 5
bolted to a wall by four bolts and carries an
eccentric load parallel to the axis of the bolt?
c. Explain the method of determining the size of the bolt when the bracket carries an
eccentric load perpendicular to the axis of the bolt.
500mm
400mm

200

2.23 A crane runway bracket is shown in figure 100

6. Determine the tensile and compressive
stresses produced in the section XX when 4 bolts M25
Figure 6
the magnitude of the wheel load is 15 kN.
25
Also find the maximum stress produced in
135
the bolts used for fastening the bracket to the
roof truss. 25
W
200

2.24 Determine the size

of the foundation
bolts for a 60 kN
pillar crane as
shown in figure 7,
e
from the following
data - Distance of W
the load from the
centre of pillar
flange = 6 m, Tilting A
Edge
Diameter of pillar A
flange = 1.8 metre,
Diameter of bolt Figure 7
circle = 1.6 metre, d
D
number of bolts,
equally spaced = 8, Allowable tensile stress for bolts = 70 MPa.

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2.25 For supporting a travelling crane in a workshop the brackets
are fixed on steel columns as shown in figure 8. The 400mm
maximum load that comes on the bracket is 15 kN, acting 15kN
vertically at a distance of 400 mm from the face of the
column. The vertical face of the bracket is secured to a
column by four bolts, in two rows (two in each row) at a 375
distance of 50 mm from the lower edge of the bracket.
Determine the size of the bolts if the permissible value of the
tensile stress for the bolt material is 84 MPa. Also find the cross 50
section of the arm of the bracket which is rectangular. ft for bracket Figure 8
material is the same as for the bolts.

R
2.26 A pillar crane having a circular base of 600 mm Fig 9a R Y Fig 9b
diameter is fixed to a concrete foundation by r r
means of four bolts. The bolts are of size 30 mm
and are equally spaced on a bolt circle diameter of 45o X
X
500 mm. Determine - (a) The distance of the load
from the centre of the pillar along a line XX as
shown in figure 9a. The load lifted by the pillar Y
crane is 60 kN and the allowable stress (tensile)
for the bolt material is 60 MPa, and (b) The maximum
200
stress induced in the bolts if the load is applied along
a line Y-Y of the foundation at the same distance as
in part (a), see figure 9b.
2.27 Figure 10 shows a solid forged bracket to carry a 200
vertical load of 13.5 kN applied along the axis of the
hole. The square flange is secured to the flat side
13.5kN
of a vertical stanchion by means of four bolts.
Calculate suitable diameters D and d for the arms of 275 sq.
the bracket, if the permissible stresses are 110 MPa in
tension and 65 MPa in shear. Estimate also the Figure 10
tensile load on each top bolt and the maximum
shearing force on each bolt. D

Shafts 300

2.28 A hollow steel shaft transmits 600 kW at 500 rpm. The

d
maximum shear stress is 64 MPa. Find the outside
and inside diameter of the shaft if the outer diameter is
250
twice the inside diameter, assuming that the maximum torque
is 20% greater than the mean torque.
2.29 A shaft is subjected to a twisting moment of 900 N-m and a bending moment of 500 N-m.
Assuming the shaft to be subjected to gradually applied loads find the diameter of the shaft.
2.30 A line shaft rotating at 200 rpm is to transmit 20 kW. The allowable shear stress for the
material of the shaft is 42 MPa. If the shaft carries a central load of 900 N and is simply
supported between bearings 3 meters apart, determine the diameter of the shaft. The
maximum tensile or compressive stress is not to exceed 56 MPa.
2.31 A centrifugal circulating pump for a steam turbine condenser is to be connected to a motor
through a short shaft and a pair of flexible couplings. The pump delivers 30000 litres per
minute at 900 rpm against a dynamic head of 8 metres. The pump efficiency is 80%.
Assuming a permissible shear stress of 56 MPa, determine the diameter of the shaft.

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2.32 A line shaft is to transmit 32 kW at 160 rpm. It is driven by a motor placed directly under it by
means of a belt running on a 1 m diameter pulley keyed to the end of the shaft. The tension
on the tight side of the belt is 2.5 times that on the slack side and the centre of the pulley
overhangs 150 mm beyond the centre line of the end bearing. Determine the diameter of the
shaft if the allowable shear stress is 56 MPa and the pulley has a mass of 160 kg.
2.33 An overhung hollow shaft carries a 900 mm diameter pulley whose centre is 250 mm from
the centre of the nearest bearing. The mass of the pulley is 160 kg and the angle of lap is
180°. The pulley is driven by a motor placed at the same height. If the permissible tension in
the belt is 2.65 kN and if the coefficient of friction between the belt and the pulley surface is
0.3, estimate diameters of shaft, when the internal diameter is 0.6 of the external. Neglect
centrifugal tension and assume permissible tensile and shear stresses in the shaft as
75 MPa and 56 MPa respectively.
2.34 A mild steel shaft transmits 15 kW at 210 rpm. It is supported on two bearings 750 mm apart
and has two gears keyed to it. The pinion having 24 teeth of 6 mm module is located 100
mm to the left of the right hand bearing and delivers the power horizontally to the right. The
gear having 80 teeth of module 6 mm is located 150 mm to the right of the left hand bearing
and receives power in a vertical direction from below. Assuming the allowable working shear
stress as 53 MPa and a combined shock and fatigue factor of 1.5 in bending as well as in
torsion determine the diameter of the shaft.
2.35 A machine shaft, supported in bearings having their centres 750 mm apart, transmits 200 kW
at 600 rpm. A gear of 200 mm and 20° tooth profile is located 250 mm to the right of left
hand bearing and a 450 mm diameter pulley is mounted 200 mm to the right of right hand
bearing. The gear is driven by a pinion with a downward tangential force while the pulley
drives a horizontal belt having 180° angle of contact. The pulley mass is 100 kg and the
tension ratio is 3. Find the diameter of the shaft if the allowable shear stress of the material
is 63 MPa.
2.36 A shaft is required to transmit 1 MW power at 240 rpm. The shaft must not twist more than
10° on a length of 15 diameters. If the modulus of rigidity for the material of the shaft is
80 GPa, find the diameter of the shaft and shear stress induced.
2.37 The internal diameter of a hollow shaft is 2/3rd of its external diameter. Compare the
strength and stiffness of the shaft with that of a solid shaft of the same material and mass.
2.38 a. What is the difference between a shaft and an axle?
b. How the shafts are formed?
c. What type of stresses are induced in shafts.
d. Define equivalent twisting moment and equivalent bending moment. State when these
two terms are used in the design of shafts.
e. When the shaft is subjected to fluctuating loads, what will be the equivalent twisting
moment and equivalent bending moment?
f. What do you understand by torsional rigidity and lateral rigidity.
Keys and Couplings
2.39 a. Discuss the various types of keys with sketches.
b. What is the effect of a keyway cut into the shaft?
c. Give reasons for joining shafts with couplings.
d. In which situations are flexible couplings preferred over rigid couplings?
2.40 Explain the design procedure for clamp couplings.
2.41 Discuss the design procedure of a rigid flange coupling of the protected type.
2.42 Discuss the design procedure of bushed pin type flexible coupling.

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2.43 Design a cast iron protective flange coupling to connect two shafts in order to transmit
7.5 kW at 720 rpm. The following permissible stresses may be used: s for shaft, bolt and
key material=33 MPa, c for bolt and key material=60 MPa, s for cast iron=15 MPa.
2.44 Two 80 mm diameter shafts are connected by means of a flange coupling of protective type.
The flanges are connected by four bolts of 16 mm diameter, arranged symmetrically along a
pitch circle of 240 mm diameter. The shaft transmits 100 kW at 250 rpm. Design the
coupling with the following permissible stresses: fs for shaft, bolt and key material = 50 MPa;
fc for bolt and key material = 150 MPa; fs for cast iron = 8 MPa.
2.45 Design a bushed pin flexible coupling for connecting a motor shaft to a pump shaft for the
following service conditions – Power to be transmitted = 20 kW at 1000 rpm, Diameter of
motor shaft = 50 mm, Diameter of pump shaft=45 mm, Bearing pressure on rubber
bush = 0.35 MPa, Allowable shear stress in pins = 20 MPa.

3 UNIT III - Stress Concentration and Fatigue,

Stress Concentration and Fatigue
3.1 Explain the following terms in detail in connection with the design of machine members
subjected to variable loads:
a. Endurance limit b. Size factor c. Surface finish factor d. Notch sensitivity
3.2 a. Write a full note on stress concentration.
b. Write a short note on stress concentration factor and significant stress.
c. Discuss the methods of reducing stress concentration in machine members.
3.3 Explain the methods of solving problems on combined steady and variable stresses. Make
sketches of the modified Goodman diagrams for normal stresses and for shear stresses and
explain their usage.
3.4 A steady load of 10000 N is applied midway between the bearings of a simply supported
steel shaft. The shaft span is 450 mm. It is required to determine the minimum diameter of
the shaft assuming that no stress raiser is present. The shaft is ground finished and rotates
at 3000 rpm. Take ut  600MPa, Ksize = 0.85, Ksurface = 0.87, factor of safety = 1.6.
3.5 Using a factor of safety 1.5, find the diameter of shaft made of 37 Mn2 steel. The shaft is
subjected to completely reversed axial load of 250 kN. Value of surface factor for simple
turning is 0.8, ut = 600 MPa, yt = 440 MPa. Neglect stress concentration factor, if any.
Assume any other data required.
3.6 Figure 2 shows the dimensions of a 500 100
circular cantilever beam. The load at Figure 2
the end varies from -F to +3F. Find the
maximum load which it can sustain for
infinite life with a factor of safety of 1.8. 14  20
The values of the ultimate tensile
strength and yield strength of the
material are 700 MPa and 540 MPa
respectively. -F to +3F r=3

3.7 A stepped shaft is to be designed to transmit a torque varying from 100 to 3000 N-m. The
ratio of diameters is 1.5 and the material properties are en' = 290 MPa, yt = 540 MPa.
Assume Kf=1.2, Ksize=0.85, Ksurface=0.85 and design factor = 2.

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3.8 Figure 3 illustrates a rotating shaft loaded by a force F varying from 0 to 50 kN. The material
properties are ut  800MPa F 45
Figure 3
 yt  600 MPa and the shaft is machine
finished. For a factor of safety of 1.5,

D=2d
90% reliability and 80000 cycles of life, d
determine the required diameter of the
shaft. r=d/10
30
3.9 A beam is subjected to a fluctuating
bending stress varying between 300 MPa and 500 MPa. The beam is made of steel having
ut  600MPa, e  330 MPa at 106 cycles,  yt  450 MPa. The value of the theoretical stress
concentration factor corresponding to a discontinuity present is 1.4 for a notch radius of
1.5 mm. Find the expected number of stress cycles before failure occurs.
3.10 Determine the diameter of a shaft with the following data: Torque acting on the shaft varies
from 300 N-m clockwise to 100 N-m anticlockwise, bending moment varies from 500 N-m to
–250 N-m. Kfs=Kf=1.21, Life for shaft = 105 cycles, factor of safety on yield = 1.8,
ut  560MPa, yt  420MPa, Ksize=0.85, Ksurface=0.85.
3.11 A member has been subjected to the following stress spectrum:  1  800 MPa for n1=103
cycles,  2  740 MPa for n2=103 cycles,  3  600 MPa for n3=104 cycles,  4  540 MPa for
n4=5*104 cycles. Find the subsequent number of cycles (ni) to failure for stress level of
 i  670 MPa. The N relation is 6.4 * N = 7406.4 * 31000 where  is the stress in MPa.

4 UNIT IV - Levers, Belt Drives, Pulleys, Flywheels, Hoisting Machine Elements

Levers
4.1 a. What are the various types of levers? Discuss the application of each type in engineering
practice.
b. Explain the design procedure of a lever.
4.2 State the application of hand and foot levers. Discuss the design procedure for a hand lever
or a foot lever.
4.3 Explain the design procedure of a lever for a lever safety valve.
4.4 Discuss the design procedure of a rocker arm for operating an exhaust valve.
4.5 A lever safety valve, 65 mm diameter, is required to blow off at 1.4 MPa gauge. Design a
suitable lever of rectangular cross section from the following data:-
Distance between the fulcrum and the pin at the valve spindle link = 65 mm
Distance from the fulcrum to the dead load on the lever = 625 mm
Ratio of width to thickness of the lever = 3
Allowable bending stress for lever = 70 MPa
Allowable shear stress for pins = 56 MPa
Allowable bearing pressure at the fulcrum pin and the valve spindle link pin = 28 MPa
4.6 Design a right angled bell crank lever having one arm 500 mm and the other 150 mm long.
A load of 5 kN acting on a pin at the end of 500 mm arm is to be raised and the effort is
applied at the end of 150 mm arm. The lever consists of a steel forging, turning on a point at
the fulcrum. The permissible stresses for the pin and lever are 84 MPa in tension and
compression and 70 MPa in shear. The bearing pressure on the pin is not to exceed
10 MPa.
4.7 For operating the exhaust valve of a petrol engine the maximum load required on the valve is
5 kN. The rocker arm oscillates around a pin whose centre line is 250 mm away from the
valve axis. The two arms of the rocker are equal and make an included angle of 160°.
Design the rocker arm with the fulcrum if the limiting tensile stress and bearing pressure are
45 MPa and 7 MPa respectively. Assume the cross section of the rocker arm as rectangular.
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Belt Drives, Pulleys, Flywheels
4.8 Discuss the various types of belts and materials used for the transmission of power.
4.9 With the help of neat sketches, explain the types of various flat belt drives.
4.10 a. State reasons for V-belt drive being preferred to flat belt drive.
b. What are the various types of pulleys commonly used for the transmission of power.
4.11 Discuss the design procedure of a flat belt cast iron pulley.
4.12 A cranked lever as shown in figure 11 has the following
x=100mm
dimensions:- Length of handle = 300 mm, Length
of lever arm = 400 mm, Overhang of the
journal = 100 mm. If the lever is operated by a
single person exerting a maximum force of D/2
400 N at a distance of 1/3rd length of the handle
from its free end, find the diameter of the handle, journal
the cross section of the lever arm, and the t L=400
diameter of the journal. The lever
handle
permissible bending stress
for the lever material may l=300mm
Figure 11
be taken as 50 MPa
and the shear stress for
shaft material as 40 MPa.
4.13 An open belt, 100 mm wide, connects two pulleys mounted on parallel shafts with their
centres 2.4 metres apart. The diameter of the larger pulley is 450 mm and that of the smaller
pulley 300 mm. The coefficient of friction between the belt and the pulley is 0.3 and the
maximum tension in the belt is limited to 14 N/mm width. If the larger pulley rotates at 120
rpm, find the maximum power that can be transmitted.
4.14 A leather belt, 125 mm wide and 6 mm thick, transmits power from a 750 mm diameter pulley
which runs at 500 rpm. The angle of lap is 150° and =0.3. If the mass of 1 m3 of leather is
1 Mg and the stress in the belt is not to exceed 2.75 MN/m2 find the maximum power that can
be transmitted.
4.15 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 per meter 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 MPa, find – a. the maximum power transmitted,
and b. the initial tension in the belt.
4.16 A V-belt drive consists of three V-belts in parallel on grooved pulleys of the same size. The
angle of groove is 30° and the coefficient of friction 0.12. The cross sectional area of each
belt is 800 mm² and the permissible safe stress in the material is 3 MPa. Calculate the power
that can be transmitted between two pulleys of 400 mm diameter rotating at 960 rpm.
4.17 A rope drive is required to transmit 750 kW from a pulley of 1m diameter at 450 rpm. The
safe pull in each rope is 2.25 kN and the rope has a mass of 1 kg per meter length. The angle
of lap and the groove angle are 150° and 45° respectively. Find the number of ropes required
for the drive if the coefficient of friction between the rope and the pulley is 0.3.
4.18 An overhung pulley transmits 35 kW at 240 rpm. The belt drive is vertical and the angle of
wrap may be taken as 180. The distance of pulley centre line from the nearest bearing is 350
mm, the coefficient of friction is 0.25. Determine- a. the diameter of the pulley, b. width of the
belt assuming thickness of 10 mm, c. diameter of the shaft, d. dimensions of the key for
securing the pulley on to the shaft, e. size of arms, six in number. The section of the arm
may be taken as elliptical, the major axis being twice the minor axis. The following
permissible stresses may be assumed: Tensile stress 80 MPa in shaft key, 2.5 MPa in belt,
4.5 MPa in pulley rim and 15 MPa in pulley arms, Shear stress 50 MPa in shaft key.
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4.19 a. A shaft hub and key are to be designed for a flywheel. Discuss the design procedure.
b. Describe the construction of flywheels.
4.20 a. What do you understand by "fluctuation of energy" and maximum fluctuation of energy as
applied to the design of a flywheel.
b. Define "coefficient of fluctuation of energy".
c. Discuss the various types of stresses induced in flywheel rim.
d. Explain the procedure for determining the cross sectional dimensions of the arms of a
flywheel.
4.21 The intercepted areas between the output torque curve and the mean resistance line of a
turning moment diagram for a multi-cylinder engine, taken in order from one end are as
follows:-
-0.35, +4.10, -2.85, +3.25, -3.35, +2.60, -3.65, +2.85, -2.60 cm2.
The diagram has been drawn to a scale of 1 cm=700 N-m and 1 cm= 45°. The engine speed
is 900 rpm and the fluctuation in speed is not to exceed 2% of the mean speed. Find the
cross section of the flywheel rim having 650 mm mean diameter. The density of the material
of the flywheel may be taken as 7200 kg/m3. The rim is rectangular with the width 2 times the
thickness. Neglect effect of arms, etc.
4.22 A single cylinder double acting steam engine develops 150 kW at a mean speed of 80 rpm.
The coefficient of fluctuation of energy is 0.1 and the fluctuation of speed is +
_2% of the mean
speed. If the mean diameter of the flywheel rim is 2 metres and the hub and spokes provide
5% of the rotational inertia of the wheel, find the mass of the flywheel and the cross-sectional
area of the rim. Assume the density of the flywheel material (which is cast iron) as
7200 kg/m3.
Hoisting Machine Elements
4.23 A block and tackle, having two sheaves at the top block and two at the hook with the rope
anchored at the top block, is reefed with a manila rope. Suggest a suitable diameter for the
rope if the maximum load to be raised is 4000 N. Also calculate the efficiency of the hoist.
4.24 A hand operated winch has a drum 300 mm in diameter. Suggest a suitable wire rope for a
load of 7000 N. Suggest a suitable thickness for the drum, radius of the groove and the pitch
of grooves.
4.25 A hand operated wire rope hoist is to raise a load of 2000 N. The force on the operating
lever is limited to 200 N and the rope is being wound on a drum of 250 mm diameter. The
effective length of the lever is 350 mm. Determine the number of ropes leading to the hook
block, the efficiency of the hoist and the factor of safety of the hoist assuming that it is reefed
with 15 mm - 6 * 37 wire ropes.
4.26 A block and tackle has six sheaves on each block and is reefed with 25 mm diameter manila
rope for which the working load is given as P = 30 d2 kg. Determine the capacity of the block
and tackle and its efficiency.
4.27 A high speed mine hoist has a lift capacity of 20 kN and the hoist drum speed of 50 rpm.
The hoist drum is 900 mm in diameter. The hoist lift is 600 m and the hoist attains its full
speed in 30 sec. Select a suitable wire rope for the service.
4.28 A hoisting drum 500 mm in diameter is keyed to a shaft which is supported in two bearings
and driven through a 12:1 reduction gearing by an electric motor. Determine the power of
the driving motor if the maximum load of 8000 N is hoisted at a speed of 50 m/min and the
efficiency of the drive is 80%. Also determine the torque of the drum shaft and the speed of
the motor. Determine the diameter of the shaft made of machinery steel, the working
stresses for which are 115 MPa in tension and 56 MPa in shear. The drive gear, whose
diameter is 450 mm is mounted on the end of the shaft such that it overhangs the nearest
bearings by 150 mm. The combined shock and fatigue factors for bending and torsion may
be taken as 2 and 1.5 respectively.
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4.29 A hand operated wire rope hoist shaft has bearings 300 mm apart. The drum of 200 mm
diameter is keyed to the shaft. The tangential load on the drum at the rated capacity of the
hoist is 400 N. Assuming 100% overload capacity and allowable shear stress of 42 MPa,
calculate the dimensions for the shaft, key, drum and hand lever. The length of the lever is
250 mm and is made of steel for which the permissible bending stress may be taken as
105 MPa.

5 UNIT V - Brakes and Clutches

Brakes
5.1 Discuss various types of brakes.
5.2 Show that in a band and block brake, the ratio of the maximum and minimum tensions in the
T 1 tan  n
brake straps is: T o  , where To, Tn, ,  have their usual meanings.
n 1 tan 
5.3 Describe with the help of a neat sketch the principle of operation of an internal expanding
shoe brake. Derive the expression for the braking torque. 200 200

5.4 A single block brake as shown in figure 12 has the

diameter of its brake drum as 250 mm and the angle of
contact is 90°. An operating force of 700 N is applied at
the end of a lever and the coefficient of friction between
the drum and lining is 0.35. Determine the torque that 50 700N
may be transmitted by the block brake.
5.5 A band brake is operated by a lever of length 500 mm. The
brake drum has a diameter of 500 mm and the maximum
Figure 12
torque on the drum is 1000 N-m. The band brake embraces
2/3rd of circumference. One end of the band is attached to a pin
100 mm from the fulcrum of a lever and the other end to another pin 80
S S
mm from the fulcrum and on the other side of Figure 13
it when the operating force is also acting. If
the band brake is lined with asbestos fabric
having a coefficient of friction 0.3, find the F 250mm
2
operating force required. Design the steel
band, shaft, key and fulcrum pin. The
permissible stress may be taken as 70 MPa
in tension, 50 MPa in shear and 20 MPa in
bearing. The bearing pressure for the brake
lining should not exceed 0.2 MPa. F1
250mm
80 mm
5.6 A double shoe brake (Figure 13) is capable of O
absorbing torque of 1400 N-m. The diameter of 2
O1
brake drum is 350 mm and angle of contact for
each shoe is 100°. The coefficient of friction between the brake drum and lining is 0.4. Find
- the spring force necessary to set the brake, and the width of the brake shoes, if the bearing
pressure on the lining material is not to exceed 0.3 MPa. 30° 30°

5.7 Figure 14 shows the arrangement of two brake shoes acting on F1 F

the internal surface of a cylindrical brake drum. The braking 2

force F1 and F2 are applied as shown and each shoe pivots on 100
its fulcrum O1 and O2. The width of the brake lining is 35 100° R200
mm. The intensity of pressure at any point is 0.4sin
MPa, where  is measured as shown from either pivot. The 
100
coefficient of friction is 0.4. Determine the magnitude of
o
braking torque and the magnitude of forces of F1 and F2. O1 O2
o

25° Figure 14
25° 25°
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Clutches
5.8 Name different types of friction clutches. Why is it necessary to dissipate the heat generated
when brakes or clutches operate?
5.9 Describe with the help of neat sketches the working principle of two different types of friction
clutches. What materials are in common use as friction surfaces?
5.10 Establish a formula for the frictional torque transmitted by a cone clutch.
5.11 With the help of a neat sketch, describe a centrifugal clutch and deduce an expression for
the total frictional torque transmitted. How are the shoes and springs designed for such a
clutch?
5.12 A friction clutch is to transmit 12 kW at 3000 rpm. It is to be of single plate type with both
sides of the plate effective, the axial pressure being limited to 0.09 MPa. If the external
diameter of the friction lining is 1.4 times the internal diameter, find the required dimensions
of the friction lining. Assume uniform wear conditions. The coefficient of friction may be
taken as 0.3.
5.13 A single dry plate clutch is to be designed to transmit 8 kW at 900 rpm. Find - a. diameter of
the shaft, b. mean radius and face width of the friction lining assuming the ratio of the mean
radius to the face width as 4, c. outer and inner radii of clutch plate, and d. dimensions of
the springs, assuming the number of springs = 6. Assume spring index = 6. Allowable shear
stress for the material of the spring wire is 420 MPa.
5.14 A multi disc clutch has three discs on the driving shaft and two on the driven shaft. The inside
diameter of the contact surfaces is 120 mm. =0.3. Design the clutch to transmit 25 kW at
1600 rpm.
5.15 A cone clutch is to be designed to transmit 7.5 kW at 900 rpm. The cone has a face angle of
12°. The width of the face is half of the mean radius and the normal pressure between the
contact faces is not to exceed 0.09 MPa. Assuming uniform wear and the coefficient of
friction between contact faces as 0.2, find the main dimensions of the clutch and the axial
force required to engage the clutch.
5.16 A centrifugal clutch is to be designed to transmit 15 kW at 900 rpm. The shoes are four in
number. The speed at which the engagement begins is 3/4th of the running speed. The
inside radius of the pulley rim is 150 mm. The shoes are lined with Ferrodo for which the
coefficient of friction may be taken as 0.25. Determine the mass and size of each shoe.
–x–

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