DME BOOK

UNIT-1
STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS
1.1 Introduction
The subject Machine Design is the creation of new and better machines and
improving the existing ones. A new or better machine is one which is more
economical in the overall cost of production and operation. The process of design is a
long and time consuming one. From the study of existing ideas, a new idea has to be
conceived. The idea is then studied keeping in mind its commercial success and given
shape and form in the form of drawings. In the preparation of these drawings, care
must be taken of the availability of resources in money, in men and in materials
required for the successful completion of the new idea into an actual reality. In
designing a machine component, it is necessary to have a good knowledge of many
subjects such as Mathematics, Engineering Mechanics, Strength of Materials, Theory
of Machines, Workshop Processes and Engineering Drawing.
Classifications of Machine Design The machine design may be classified as follows:
1. Adaptive design.
In most cases, the designer’s work is concerned with adaptation of existing

designs. This type of design needs no special knowledge or skill and can be attempted
by designers of ordinary technical training. The designer only makes minor alternation
or modification in the existing designs of the product.
2. Development design.
This type of design needs considerable scientific training and design ability in
order to modify the existing designs into a new idea by adopting a new material or
different method of manufacture. In this case, though the designer starts from the
existing design, but the final product may differ quite markedly from the original
product.
3. New design.
This type of design needs lot of research, technical ability and creative
thinking. Only those designers who have personal qualities of a sufficiently high order
can take up the work of a new design. The designs, depending upon the methods used,
may be classified as follows:
1
(a) Rational design.
This type of design depends upon mathematical formulae of principle of

mechanics.
(b) Empirical design.
This type of design depends upon empirical formulae based on the practice and
past experience.
(c) Industrial design.
This type of design depends upon the production aspects to manufacture any
machine component in the industry.
(d) Optimum design.
It is the best design for the given objective function under the specified
constraints. It may be achieved by minimising the undesirable effects.
(e) System design.
It is the design of any complex mechanical system like a motor car.
(f) Element design.
It is the design of any element of the mechanical system like piston, crankshaft,
connecting rod, etc.
(g) Computer aided design.
This type of design depends upon the use of computer systems to assist in the
creation, modification, analysis and optimisation of a design.
General Considerations in Machine Design
Following are the general considerations in designing a machine component:
1. Type of load and stresses caused by the load. The load, on a machine
component, may act in several ways due to which the internal stresses are set up. The
various types of load and stresses are discussed later.
2. Motion of the parts or kinematics of the machine. The successful operation

of any machine depends largely upon the simplest arrangement of the parts which will
give the motion required. The motion of the parts may be:
2
(a) Rectilinear motion which includes unidirectional and reciprocating motions.
(b) Curvilinear motion which includes rotary, oscillatory and simple harmonic.
(c) Constant velocity.
(d) Constant or variable acceleration.
3. Selection of materials. It is essential that a designer should have a thorough

knowledge of the properties of the materials and their behaviour under working
conditions. Some of the important characteristics of materials are: strength, durability,
flexibility, weight, resistance to heat and corrosion, ability to cast, welded or
hardened, machinability, electrical conductivity, etc. The various types of engineering
materials and their properties are discussed later.
4. Form and size of the parts. The form and size are based on judgment. The smallest
practicable cross-section may be used, but it may be checked that the stresses induced
in the designed cross-section are reasonably safe.
1.2 Impact & shock loading problem:
1).An unknown weight falls from a distance of 15mmm on to a collar rigidly

attached to the lower end of a vertical bar 2.5mm long and 500mm² cross section the
maximum instantaneous extension is 2mm find the corresponding stress and the
value of the weight falling Take E= 2x10⁵N/mm²?
Given:-
h = 15mm
l = 2.5 m= 2500mm
A = 500mm²
𝑠𝑙 =2mm
E = 2x10⁵N/mm²
To Find:-
Stress (σ)
Weight (w)
Solution:-
Strain (e) = 𝑠𝑙/𝑙
3
e =2/250
e =0.0008
Strain (e) = stress (σ)/young’s modulus (E)
σ = Exe
σ = 2x10⁵ x 0.0008
σ = 160/Nmm²
To find out the unknown weight, equating the strain energy and the loss in
potential energy.
½ P*(𝑠𝑙) = W*(h+ 𝑠𝑙)
P = stress+ Area
P = 160x500
P = 8x10⁴ N
P = ½ (8x10⁴) x2 = W*(15+2)
W = 4705.8N
Result:-
σ = 160N/mm²
W = 4705.8N
1.3 Variable loading problem:
2).A circular bar is simply supported with a span of 0.5mand is subjected to a

concentrated cyclic load at its mid span .The load varies from a minimum valve
of 20KN to maximum value of 45KN .The load direction is transverse to the
shaft anis decide upon the diameter of the bar for a factor of safety of 1.5 and
factors of 0.85 and 0.89 respectively for size and surface finish taken often the
following values for material properties ① ultimate strength =650N/mm²(②yield
strength = 450 N/mm²③ Endurance Strength =350N/mm² ?
Given:-
L = 0.5m = 500mm
𝑊𝑚𝑖𝑛 = 20KN = 20x10³ N
4
𝑊𝑚𝑎𝑥 = 45 KN = 45x10³ N
Factor of safety n = 1.5
Size factor K sz = 0.85
Surface factor K sf = 0.89
Ultimate strength σ u = 650N/mm²
Yield strength σ y = 450N/mm²
Endurance strength σ-1 = 350N/mm²
To find:-
Diameter of shaft ‘d’
Solution:-
(maximum bending moment ) 𝑀𝑏𝑚𝑎𝑥 =𝑊𝑚𝑎𝑥 xl/4 = 45x10³x500/4
𝑀𝑏𝑚𝑎𝑥 = 5625x10³ N.mm
(minimum bending moment) 𝑀𝑏𝑚𝑖𝑛 = xl /4 =20x10³x500/4
𝑀𝑏𝑚𝑖𝑛 = 2500x10³ N.mm
(Average bending moment)
Mbm = Mbmax + Mbmin/2
=(5625x10³)+(2500x10³)/2
Variable bending moment) 𝑀𝑎 = 𝑀𝑏𝑚𝑎𝑥 –𝑀𝑏𝑚𝑖𝑛 /2
= 5625x10³-2500x10³/2
Z = 0.0981xd³ mm³
(mean (or) average bending Stress) 𝜎𝑚 = Mbm/z
= 4062X10³/0.0981d³
𝜎𝑚 = 41.4x10⁶/d³ N/mm²
Variable bending stress) 𝜎𝑎 = Mba/z
= 1562x10³/0.0981d³
𝜎𝑎 = 15.9x10⁶/d³N/mm²\
5
Soderberg formula
1/n = 𝜎𝑚/ 𝜎𝑦 +𝑘𝑓. 𝜎𝑎 /𝜎−1 (𝑘𝑙 .𝑘𝑠𝑓 .𝑘𝑠𝑧 )
𝑘𝑓 = 𝑘𝑙 = 1
1/1.5 = 41.4x10⁶ /450d³ + 15.91x10⁶ x1/350x0.89x0.85xd³
1/1.5 = 92000/d³ + 6008875/d³
1/1.5 = 15208875/d³
D = 61.109 mm
From P.S.G 7.20
D = 63 mm
Result :-
Diameter of shaft d =63mm
3.A.shaft of diameter ‘d’ is subjected to a torque varying between 900Nm

to1800Nm .Assuming a factor of safety 2 and a stress concentration factor of
1.5find the diameter of the shaft . Take 𝜎𝑢 = 650N/mm², 𝜎𝑦 =480N/mm², size factor
B= 0.85and surface finish factor C =0.5
Given :-
𝑀𝑡𝑚𝑖𝑛 = 900 N.m = 900x10³ N.mm
𝑀𝑡𝑚𝑎𝑥 = 1800N.m = 1800x10³ N.mm
n = 2
𝐾𝑓 = 1.5
𝜎𝑢 = 650N/mm²
𝜎𝑦 = 480N/mm²
𝐾𝑠𝑧 = 0.85
𝐾𝑠𝑓 = 0.5
To find:-
Shaft diameter
6
Solution:-
For given 𝜎𝑢 =650N/mm², 𝜎𝑦 = 480N/mm²
Assume C45 material is used,
For C45 from P.S.G1.9
Ʈ𝑦 = 𝜎𝑦 /2 = 480/2
Ʈ𝑦 = 240N/mm²
From P.S.G 1.42 for reversed torsion, endurance shear stress
Ʈ−1 = 0.22 𝜎𝑢
= 0.22(650)
Ʈ−1 = 142N/mm²
Mean torque 𝑀𝑡𝑚 = 𝑀𝑡𝑚𝑎𝑥 + 𝑀𝑡𝑚𝑖𝑛 /2
= (1800+900)x10³/2
𝑀𝑡𝑚 = 1350x10³N.mm
Amplitude torque 𝑀𝑡𝑎 = 𝑀𝑡𝑚𝑎𝑥 - 𝑀𝑡𝑚𝑖𝑛 /2
= (1800-900)x10³/2
𝑀𝑡𝑎 = 450x10³ N.mm
Mean shear stress Ʈ𝑚 = 16 x 𝑀𝑡𝑚 /𝜋 𝑑³
= 16 x1350x10³/𝜋 x d³
Ʈ𝑚 = 6875.49 x10³/d³ N/mm²
Amplitude shear stress Ʈ𝑎 = 16 x 𝑀𝑡𝑎 / 𝜋 𝑑³
= 16x450 x10³/ 𝜋 x d³
Ʈ𝑎 = 2291.83 x10³ /d³N/mm²
From PSG 7.6 Ʈ𝑒𝑞 = Ʈ𝑦 /n = Ʈ𝑚 + 𝐾𝑓 . Ʈ𝑎 Ʈ𝑦 /Ʈ−1 . 𝐾𝑠𝑧 . 𝐾𝑠𝑓
240/2 = 6875.49 x10³/d³ + 1.5x(2291.83x10³)/d³ x240/143x0.85 x0.5
240/2 = 20451.12x10³/d³
7
d = 55.4 mm
d = 56 mm from PSG 7.20
Result :-
d = 56mm
1.4 Torsional shear stress problem
4. A shaft is transmitting 97.5 Kw at 180 rpm . If the allowable shear stress in

the material is 60Mpa find the suitable diameter for the shaft. The shaft is not
to twist more than 1° in a length of 3 meters Take C =80Gpa?
Given:-
P = 97.5Kw = 97.5 x10³ w
N = 180 rpm
Ʈ = 60Mpa = 60N/mm²
L=3m
Ø = 1°
C = 80 GPa
To find :-
Diameter of shaft
Solution :-
Step 1 Determination of torque
T = Px60/2𝜋N
T = 97.5 x60 x10³/2𝜋x180
T = 5172x10³ N.mm
Step 2 Determination of Diameter of shaft
Case 1 considering strength of the shaft

𝜋
T = (Ʈ ) d³
16
𝜋
5172x 10³ = (60) x d³
16
8
D = 76 mm
Case 2 considering stiffness of the shaft
T /J = CQ/ l
𝜋
5172x10³/𝜋/32x d⁴ = 80 x x10³/3000
180
d = 103.16 mm
Result :-
Taking larger of the two values d= 105 mm
1.5 Bending stress in straight beams:
5.An axle 1 meter long supported in bearings at its ends carries a flywheel
weighing 30 KN at the centre .If the stress is not to exceed 60Mpa.Find the
diameter of the axle ?
Given:-
Length of beam l = 1 m
Weight of flywheel = 30 K
To find:-
Diameter of shaft
Solution:-
𝜋
D.B 6.1 Z= xd³
32
M = wl /4
M = 30x10³x10³/4
9
M = 7.5x10⁶ N.mm
W.K.T M/I = σ/y

𝜋
7.5x10⁶/60 = xd³
32
D = 108.3 mm
Result :-
Diameter of the shaft d = 110mm
1.6 Bending stress in curved beams:
6.The frame of a punish press is shown in figure find the stress at the inner and
outer surface at section X-X of the frame if W = 5000N?
Given:-
W =5000 N
𝑏𝑖 =18 mm
𝑏𝑜 = 6mm
h = 40 mm
𝑅𝑖 = 25mm
𝑅𝑂 = 𝑅𝑖 + ℎ = 65𝑚𝑚
To find:-
Stress in Inner & Outer
10
Solution:-
W.K.T Area of cross section at X-X
A = 1/2x18+6)x40
A = 480mm²
W.K.L Radius of curvature of the neutral axis
𝑅𝑛 = (𝑏𝑖 +𝑏𝑜 /2)h / (𝑏𝑖 𝑅𝑂 − 𝑏𝑜 𝑅𝑖 /ℎ)𝑙𝑜𝑔𝑒 (𝑅𝑂 /𝑅𝑖 )- (𝑏𝑖 -𝑏𝑜 )
𝑅𝑛 = (18+6/2)x40/(18x65-6x25/40) 𝑙𝑜𝑔𝑒 (65/25) – (18-6)
𝑅𝑛 = 38.83mm
11
Radius of curvature of the centroidal axis
R = 𝑅𝑖 + h(𝑏𝑖 +2𝑏𝑜 )/3(𝑏𝑖 +𝑏𝑜 )
R = 25 + 40(18+2x6)/3(18+6)
R = 41.67mm
Distance b/w the centroidal axis and neutral axis
e = R-𝑅𝑛 =41.67- 38.83 = 2.84mm
Distance b/w the load and centroidal axis
x=100+ R =100+41.67= 141.67mm
Bending moment about the centroidal axis
M = w.x=5000x41.67 =708350mm
W.K.T
Direct tensile stress at section X-X
𝜎𝑡 = w/A = 5000/480 = 10.42N/mm²
Distance from the neutral axis to the Inner Surface 𝑦𝑖 = 𝑅𝑛 - 𝑅𝑖
𝑦𝑖 = 38.83-25 = 13.83mm
Distance from the neutral axis to the Outer Surface 𝑦𝑜 = 𝑅𝑂 - 𝑅𝑛
𝑦𝑜 = 65-38.83=26.17 mm
W.K.T Maximum bending stress at the inner surface
𝜎𝑏𝑖 = M. . 𝑦𝑖 / Ae 𝑅𝑖
𝜎𝑏𝑖 = 708350 x13.83/480 x2.84x25
= 26.17mm
Maximum bending stress at the outer surface
𝜎𝑏𝑜 = M . 𝑦𝑜 / Ae𝑅𝑂
𝜎𝑏𝑜 = 708350 x13.83/480x2.84x65
𝜎𝑏𝑜 = 209.2Mpa (Compressive)
12
Result stress at the inner surface
= 𝜎𝑡 + 𝜎𝑏𝑖
= 10.42-287.4
𝜎𝑖 = 297.82Mpa (tensile)
Result stress at the outer surface
= 𝜎𝑡 - 𝜎𝑏𝑜
= 10.42 -209.2
σo = -198.78Mpa (compressive)
Result :-
Stress at Inner = 297.82Mpa (tensile)
Stress at Outer = 198.78Mpa (compressive)
7.A shaft as show in figure is subject to a bending load of 3KN . Pure torque
of 1000x10³N.m and axial pulling force of 15KN . Calculate the stresses at A and
B?
Given :-
W =3KN
T = 1000x10³N.m
P = 15KN
d = 50mm
x =250mm
To find :-
Stresses at A & B
13
Solution :-
Tensile stress due to axial pulling at points A & B = 𝜎𝑜 = P/A

𝜋
𝜎𝑜 = 15x10³/ x50²
4
𝜎𝑜 = 7.64Mpa
Bending Moment at points A & B

𝜋
𝜎𝑏 = M/Z = M/ .d³
32
𝜋
𝜎𝑏 = 750x10³/ x50³
32
𝜎𝑏 = 61.1Mpa
The bending stress is tensile at points A and Compressive at Point B
Resultant tensile stress at point ‘A’
𝜎𝐴 = 𝜎𝑏 + 𝜎𝑜
= 61.1+7.64
𝜎𝐴 = 68.71Mpa
Resultant compressive stress at point ‘B’
𝜎𝐵 = -𝜎𝑏 +𝜎𝑜
= -61.1+7.64
𝜎𝐵 = -53.64Mpa
14
𝜎𝐵 =53.64Mpa (- sing indicates compressive)
Stress at Point ‘A’
𝜎𝐴(max) = 𝜎𝐴 /2+1/2√𝜎𝐴 ² + 4Ʈ²
68.742 + (4𝑥40.74)2
= 68.74/2+1/2√
𝜎𝐴(max) = 87.67Mpa (tensile)
W.K.T
The shear stresses at points A & B due to the torque transmitted
Ʈ = 16xT /𝜋d³
= 16x1x10⁶/𝜋x50³
Ʈ = 40.74Mpa
Min Principal stresses at point A
𝜎𝐴(min) = 𝜎𝐴 /2 -1/2√𝜎𝐴 ² + 4Ʈ²
= -18.93Mpa
𝜎𝐴(min) = 18.93Mpa (compressive)
Stress at point ‘B’
Max Principal stress 𝜎𝐵(max) = 𝜎𝐵 /2+1/2√𝜎𝐵 ² + 4Ʈ²
𝜎𝐵(max) = 53.46/2+1/2√53.46² + 4(40.74)²
𝜎𝐵(max) = 75.46Mpa (compressive)
Min Principal Stress
𝜎𝐵(min) = 𝜎𝐵 /2 – 1/2√𝜎𝐵 ² + 4Ʈ²
𝜎𝐵(min) = - 22Mpas
Max shear stress at point’B’
Ʈ𝐵(max) = 1/2√𝜎𝐵 ² + 4Ʈ²
15
53.462 + 4(40.74)2
= 1/2√
Ʈ𝐵(max) = 48.73Mpa
Max shear stress at point ‘A’
Ʈ𝐴(max) = 1/2√𝜎𝐴 ² + 4Ʈ²
= 1/2√68.74² + 4(40.74)²
Ʈ𝐴(max) = 53.3Mpa
Result :-
𝜎𝐴(max) , 𝜎𝐴(min) , Ʈ𝐴(max) , 𝜎𝐵(max) , 𝜎𝐵(min) , Ʈ𝐵(max)
8. An overhang crank with pin and shaft is shown in figure . A tangential load
of 15KN. Acts on the crank Pin. Determine the maximum principal stress and
the maximum shear stress at the centre of the crankshaft bearing?
Given:-
W = 15KN = 15x10³N
d= 80mm
y=140mm
x=120mm
To find:-
𝜎𝑡(max)
Ʈ𝑚𝑎𝑥
Solution:-
Bending moment at the centre of the crankshaft bearing M=wx
= 15x10³x120
M = 1.8x10⁶ N.mm
Torque transmitted at the axis of the shaft
T = w.y
16
= 15x10³ x140
T = 2.1x10⁶N.mm
W.K.T
Bending stress due to the bending moment

𝜋
𝜎𝑏 = M/z =M/ .d³
32
𝜎𝑏 = 32x1.8x10⁶/𝜋x80³
𝜎𝑏 = 35.8Mpa
Shear stress due to the torque transmitted
Ʈ = 16T/𝜋d³
Ʈ = 20.9Mpa
Maximum principal stress
𝜎𝑡(max) = 𝜎𝑡 /2+1/2√ 𝜎𝑡 ² + 4Ʈ²
= 35.8/2+1/2√35.8² + 4(20.9)²
𝜎𝑡(max) = 45.4Mpa
Maximum shear stress Ʈ𝑚𝑎𝑥 = 1/2√ 𝜎𝑡 ² + 4Ʈ²
17
= 1/2√35.8² + 4(20.9)²
Ʈ𝑚𝑎𝑥 =27.5Mpa
Result :-
𝜎𝑡(max) =45.4Mpa
Ʈ𝑚𝑎𝑥 = 27.5Mpa
9.A cylindrical shaft made of steel yield strength of 700Mpa is subject to static
loads consisting of bending moment 10KN.m and a torsional moment 30KN.m
.Determine the diameter of the shaft using two different theories of failure and
assuming a fos 2 , E =210Gpa , PR =0.25
Given :-
𝜎𝑦𝑡 = 700Mpa =700N/mm²
M = 10KN.m =10x10⁶ N.mm
T = 30KN.m =30x10⁶ N.mm
Fos =2
E = 210x10⁹ N/m² = 210x10³ N/mm²
(1/m)P.R = 0.25
To find:-
Diameter ‘d’
Solution:-
Let us find max and min principal stress bending (tensile) stress due to Bending
moment
𝜋
𝜎1 = M/z =10x10⁶/ xd³
32
𝜎1 = 101.8x10⁶/d³N/mm²
Shear stress due to torsional moment
Ʈ = 16T/𝜋d³
Ʈ = 152.8x10⁶/d³N/mm²
18
W.K.T Max principal stress
𝜎𝑡1 = 𝜎1 + 𝜎2 /2+1/2√(𝜎1 − 𝜎2 )2 + 4Ʈ²
𝜎𝑡1 = 𝜎1 /2+1/2√𝜎1 ² + 4Ʈ²
D.B7.2
106
= 101.8x10⁶/2d³+1/2√(101.8 × 106 /𝑑)² + 4(152.8 × )²
𝑑3
𝜎𝑡1 = 211.9x10⁶/d³ N/mm²
And min principal stress
𝜎𝑡2 = 𝜎1 /2-1/2√𝜎1 ² + 4Ʈ²
𝜎𝑡2 𝜎𝑡1 = 50.9x10⁶ /d³ − 161x10⁶/d
𝜎𝑡2 = -110.1x10⁶/d³ N/mm²
1. According to max shear stress theory
Ʈ𝑚𝑎𝑥 = 𝜎𝑡1 − 𝜎𝑡2 /2 =161x10³/d³
Max shear stress theory
Ʈ𝑚𝑎𝑥 = 𝜎𝑦𝑡 /2 x Fos
700/2x2= 161x10⁶/d³
d= 97.2mm
2.According to max strain energy theory
(𝜎𝑡1 )² + (𝜎𝑡2 )² − 2 𝜎𝑡1 x 𝜎𝑡2 /m = (𝜎𝑦𝑡 /𝐹𝑜𝑠)²
(211.9x10⁶/d³)² +(-110.1x10⁶/d³)² − 2(211.9x10⁶(-110.1x10⁶)/d⁶) x0.25
= (700/2)²
d= 90.8mm
Result :-
d=97.2mm
d=90.8mm
19
10. A wall bracket with a rectangular cross section is shown in figure the depth
of the cross section is twist of the width. The force P acting on the bracket at 60° to
the vertical is 5KN .The material of the bracket is grey cast iron SG200 and the
factor of safety is 3.5 .Determine the dimensions of the cross section of the bracket
.Assume maximum normal stress theory of failure ?
Given:-
P = 5KN
P.S.G .D B1.4 𝜎𝑡 = 200N/mm²
Fos = 3.5
d/w= 2
To find:-
Cross section of rectangular bracket
Solution:-
Step 1 : Calculate of permissible stresses
𝜎𝑚𝑎𝑥 = 𝜎𝑡 /Fos = 200/3.2 = 57.14N/mm² → ①
Step 2 : Calculate of direct and bending tensile at the point A in the

cross section xx. The point is subject to combined bending and direct
20
tensile stresses. The force P is resolved into two components horizontal
component 𝑃ℎ and vertical component 𝑃𝑣
𝑃ℎ = P sin 60° = 5x10³ x sin60° = 4330.13N
𝑃𝑣 = P cos 60° = 5x10³ xcos60° = 2500N
Bending moment 𝑀𝑏 = (𝑃ℎ x150) + (𝑃𝑣 x300)
𝑀𝑏 = 1399.52X10³N.mm
PSGD B 6.1 𝜎𝑏 = 𝑀𝑏 .y/I
𝜎𝑏 = 1399.52x10³x t/1/2xtx2t³
𝜎𝑏 = 2099.28x10³/t³ N/mm²
𝑃𝑣 induces shear stress at xx it is however small and neglected
Step 3 : Calculation of dimensions of cross section the resultant tensile

stress 𝜎𝑚𝑎𝑥 at the point A is given by
𝜎𝑚𝑎𝑥 = 𝜎𝑏 − 𝜎𝑡
𝜎𝑚𝑎𝑥 = 2099.28x10³ /t³ + 2165.07/t² → ②
Equating ① & ②
2099.28x10³ /t³+2165.07/t² = 57.14
t³ −37.89t−36739.24 =0
t=33.65mm
t≅35mm
Result:-
The dimensions of the cross section are 35x70mm
11. A ‘C’ clamp is to bear the force ‘F’ applied onto it .It has a ‘T’ section shown
in figure .If the maximum tensile stress in the clamp is limited to 130Mpa then find
‘F’ ?
Given :-
𝜎𝑚𝑎𝑥 = 130 Mpa
21
To find:-
Maximum force ‘F’
Solution:-
From the geometry, we can say that the maximum tensile stress will occur at
point ‘P’
On the inner fibre because of the following versions
i) Bending moment is maximum there

ii) It has curvature iii) A direct tensile stress (due to F)
also Acts
22
D.B 6.3 𝑟𝑛 = (𝑏𝑖 −t) 𝑡𝑖 +(r xn)/( 𝑏𝑖 −t)/ n ( 𝑟𝑖 +𝑡𝑖 )/𝑟𝑖 +t/n(𝑟𝑜 /𝑟𝑖 )
From figure ②
𝑏𝑖 =20, t =3 , 𝑡𝑖 = 3
h =22, 𝑟𝑖 = 25, 𝑟𝑜 =47 mm
𝑟𝑛 = (20-3) 3 + (3x22)/(20-3)/n(25+3/25) +3/n(47/25)
𝑟𝑛 = 30.5mm
Also for a ‘T’ section
R = 𝑟𝑖 + 1/2h² t +1/2 𝑡𝑖 ²(𝑏𝑖 -t)/ht +(𝑏𝑖 -t) 𝑡𝑖
R = 25 +(1/2x22² x3)+1/2x3²x(20-3)/(22x3)+(20-3)x3
R = 31.85 mm
C = R- 𝑟𝑛 = 31.85-30.5 = 1.35 mm
ℎ𝑖 = 𝑟𝑛 − 𝑟𝑖 = 30.5 -2.5 =5.5 mm
Area of the section = (20x3) +(22x3)
a=126mm²
Bending moment about the centroidial axis,
𝑀𝑏 = Fx(50+31.85)
23
𝑀𝑏 = 81.85F N.mm
Bending stress 𝜎𝑏 = 𝑀𝑏 . ℎ𝑖 /a.e. 𝑟𝑖
𝜎𝑏 = 81.85F x55/126x1.35x25
𝜎𝑏 = 0.105F N/mm²
Direct stress 𝜎𝑑 = F/Area
𝜎𝑑 = F/126 N/mm²
Maximum (total) stress
𝜎𝑚𝑎𝑥 = 𝜎𝑏 +𝜎𝑑
𝜎𝑚𝑎𝑥 = 0.105F+F/126
𝜎𝑚𝑎𝑥 = 0.1129 F N/mm²
Equating this to the maximum permissible tensile stress we have, 0.0129F = 130
F = 1151 N
Result:-
F = 1151N
12. A machine component is subjected to fluctuating stress that varies from 40 to 100
N/mm2 the corrected endurance limit stress for the component is 270N/mm2 the
ultimate tensile strength and yield strength material are 600 and 450 N/mm2
respectively find the factor of safety using 1) Gerber theory 2) soderberg line 3)
Goodman line 4) find factor of safety against static failure?
Given:-
𝜎𝑚𝑖𝑛 = 40N/mm²
𝜎𝑚𝑎𝑥 =100N/mm²
𝜎−1 = 270N/mm²
𝜎𝑢 = 600N/mm²
𝜎𝑦 = 450N/mm²
24
To find:-
Fos using 1)Gerber theory
2) Soderberg line
3) Goodman line
4) Against static failure
Solution:-
Mean Stress 𝜎𝑚 = 𝜎𝑚𝑎𝑥 + 𝜎𝑚𝑖𝑛 /2
𝜎𝑚 = 100+40/2
𝜎𝑚 = 70N/mm²
𝜎𝑎 = 𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛 /2
𝜎𝑎 = 30N/mm²
1) Fos using Gerber theory
𝜎𝑎 𝑥𝑛 / 𝜎−1 + ( 𝜎𝑚 𝑥𝑛 / 𝜎𝑢 )² =1
30 n/270 +(70n/600)² = 1
0.111x n +0.0136xn² -1 =0
Solving the equation n = 5.41
2) Fos using soderberg theory

PSG 7.4
1/n = 𝜎𝑎 / 𝜎−1 + 𝜎𝑚 /𝜎𝑦
1/n = 30/270 + 70/450
n= 3.75
3) Fos using Goodman theory

1/n = 𝜎𝑚 / 𝜎𝑢 +𝜎𝑎 / 𝜎−1
1/n = 70/600+30/270
n= 4.39
4) Fos against static failure

n= 𝜎𝑦 / 𝜎𝑚𝑎𝑥
n=450/100 n=4.5
25
Result:-
n = 5.41
n=3.75
n= 4.39
n=4.5
13)A pulley is keyed to a shaft midway b/w two antifriction bearings the bending
moment at the pulley varies from -170Nm and 510Nm as the torsional moment in
the shaft varies from 55Nm to165Nm the frequency of the variation of the loads
is the same as the shaft speed. The shaft is made of cold drawn steel having an
ultimate strength of 538Mpa and yield strength of 400Mpa .Determine the
required diameter for an indefinite life. The stress concentration factors the
keyway in bending and torsion may be taken as 1.6 and 1.3 respectively correction
factors A=1(for bending )A=0.6(for torsion) B=0.85 and C=0.88and Fos 1.5?
Given:-
𝑀𝑚𝑖𝑛 = -170Nm 𝐾𝑓𝑏 = 1.6
𝑀𝑚𝑎𝑥 = 510Nm 𝐾𝑓𝑡 = 1.3
𝑇𝑚𝑖𝑛 = 55Nm 𝐴𝑏 = 1, 𝐴𝑡 = 0.6
𝑇𝑚𝑎𝑥 = 165Nm B =0.85
𝜎𝑢 = 538Mpa C = 0.88
𝜎𝑦 = 400Mpa n = 1.5
To find:-
Diamete of the shaft
Solution:-
(a) To determine the equivalent normal stress (𝜎𝑒𝑞 )
𝜎𝑚𝑎𝑥 = 32 𝑀𝑏𝑚𝑎𝑥 /𝜋𝑑 3
D.B 7.21 𝜎𝑚𝑎𝑥 = 32x510x10³/ 𝜋𝑑 3
𝜎𝑚𝑎𝑥 = 5195x10³/d³
D.B 7.21 𝜎𝑚𝑖𝑛 = 32x(-170)x10³/ 𝜋𝑑 3
𝜎𝑚𝑖𝑛 = -1732x10³/d³
26
𝜎𝑚 = 𝜎𝑚𝑎𝑥 +𝜎𝑚𝑖𝑛 /2 = (5195/d³+(-1732/d³)/2)x10³
D.B 7.6
𝜎𝑚 = 1732/d³ x10³
𝜎𝑎 = 𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛 /2
𝜎𝑎 = ½(5195/d³ - (-1732)/d³)x10³
𝜎𝑎 = 3464/d³ x10³
𝜎𝑢
Assume that 𝜎−1 = = 538/2 =269Mpa
2
𝜎𝑎
D.B 7.6 𝜎𝑒𝑞 = 𝜎𝑚 + 𝐾𝑓𝑏 . 𝐴𝑏 . 𝐵. 𝐶(𝜎𝑦 / 𝜎−1 )
𝜎𝑒𝑞 = 1732/d³ +1.6x3464x10³/d³
(b) To determine the equivalent shear stress (Ʈ𝑒𝑞 )

(i) Due to torque
Ʈ𝑚𝑎𝑥 = 16x𝑀𝑡𝑚𝑎𝑥 /𝜋𝑑 3
Ʈ𝑚𝑎𝑥 = 16x165x10³/ 𝜋𝑑 3
Ʈ𝑚𝑎𝑥 = 840x10³/d³
Ʈ𝑚𝑖𝑛 = 16x𝑀𝑡𝑚𝑖𝑛 / 𝜋𝑑 3
Ʈ𝑚𝑖𝑛 = 16x55x10³/ 𝜋𝑑 3
Ʈ𝑚𝑖𝑛 = 280x10³/d³
Mean shear stress due to torque
Ʈ𝑚 = Ʈ𝑚𝑎𝑥 +Ʈ𝑚𝑖𝑛 /2
Ʈ𝑚 = 840+280/2d³
Ʈ𝑚 = 560/d³ x10³
Amplitude shear stress due to torque
D.B 7.6 Ʈ𝑎 = Ʈ𝑚𝑎𝑥 -Ʈ𝑚𝑎𝑥 /2
= 840-280/2d³
Ʈ𝑎 = 280/d³ x10³
27
D.B 7.6 Ʈ𝑒𝑞 = Ʈ𝑚 + 𝐾𝑓𝑡 . Ʈ𝑎 /𝐴𝑡 .B.C (Ʈ𝑦 /𝜎−1 )
Ʈ𝑦 = 𝜎𝑦 /2 =400/2=200Mpa
Ʈ𝑒𝑞 = 560/d³ x10³ + 1.3x280x10³ /0.6x0.85x0.88d³(280/269)
Ʈ𝑒𝑞 = 560/d³ x10³ +560/d³ x10³
Ʈ𝑒𝑞 = 1163.01x10³/d³
Maximum shear stress
Ʈ𝑚𝑎𝑥 = 1/2√𝜎𝑒𝑞²+4Ʈ𝑒𝑞 ²
=
1/2d³√1.275 × 10⁴ × 103 /𝑑³)² + (1163.01 × 103 /𝑑³)²
Ʈ𝑚𝑎𝑥 = 1/2d³√1.625 × 10ˡ4 + 5.410 × 10ˡ²
Ʈ𝑚𝑎𝑥 = 1.29x107/2d3
For designing equating this
Ʈ𝑚𝑎𝑥 = Ʈ𝑦 /n =200 / 1.5
Result:-
d= 36.49mm
14)What maximum Axial forces can be applied on a plate of width 50mm and
thickness 10mm with a central holeof10mm diameter without exceeding the yield
point stress of 62.5Mpa across its width?
Given:-
Width (w) = 50mm
Thickness (h) = 10mm
Central hole dia(a) = 10mm
Stress 𝜎2 = 62.5Mpa =62.5N/mm²
To find:-
Load P =?
28
Solution:-
To find 𝐾𝑡 = 𝜎𝑚𝑎𝑥 /𝜎𝑜 𝜎𝑜 (nominal stress in N/mm²)
𝜎𝑚𝑎𝑥 = 62.5 N/mm²
𝜎𝑜 = P/(w-a)h
𝜎𝑜 = P/(50-10)10 D.B (7.10)
𝜎𝑜 = P/400 N/mm²
𝐾𝑡 = 62.5/P/400
2.5 = 62.5x400/P
P = 10,000N
Result:-
P = 10KN
15)Taking stress concentration into account find the maximum stress induced when
a tensile load of 20KN is applied (a) a rectangular place of 80mm wide and 12mm
thick with a transverse hole of 16mm diameter(b) a stepped shaft if dia 60mm
and 30mm with a fillet radius of 6mm?
29
Given:-
P =20KN
W = 80mm
h =12mm
a =16mm
To find:-
Maximum stress
Solution:-
(a) For a rectangular plate

𝐾𝑡 = 𝜎𝑚𝑎𝑥 /𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙
𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙 = P/(w-a)h (D.B 7.10)
a/w =16/80 =0.2
𝐾𝑡 = 2.5
𝐾𝑡 =𝜎𝑚𝑎𝑥 /20x10³/(80-16)12
𝜎𝑚𝑎𝑥 = 65.104 N/mm²

(b) For a stepped shaft
D = 60mm
d = 30mm
r =6 mm
D/d = 60/30 = 2 (D.B 7.11)
𝐾𝑡 = 1.5
𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙 = P/A = 20000/706.5
𝜎𝑛𝑜𝑚𝑖𝑛𝑎𝑙 = 2829 N/mm²
𝜋 𝜋
A = d² = (30)² =706.5 mm²
4 4
𝐾𝑡 = 𝜎𝑚𝑎𝑥 /𝜎𝑛𝑜𝑛 = 1.5 = 𝜎𝑚𝑎𝑥 /28.29
𝜎𝑚𝑎𝑥 = 42.44N/mm²
30
Result:-
𝜎𝑚𝑎𝑥 = 65.104 N/mm² & 𝜎𝑚𝑎𝑥 = 42.44 N/mm²
16)A simply supported beam has a concentrated load at the centre which
fluctuates from a value of P to 4P .The span of the beam is 500mm and its cross
section circular with a diameter of 60mm . Taking for a beam material on
ultimate stress of 700Mpa stress of 500Mpa ,endurance limit ,Fos 1.3 calculate
the max value of P .Take size factor of 0.85, surface finish factor 0.9?
Given:-
Max load 𝑃𝑚𝑎𝑥 = 4P n = 1.3
Min load 𝑃𝑚𝑖𝑛 =P 𝐾𝑠𝑧 = 0.85
Length l = 500mm 𝐾𝑠𝑓 = 0.9
Diameter d = 60mm
Ultimate stress 𝜎𝑢 = 700Mpa = 700N/mm²
Endurance limit 𝜎−1 = 330N/mm²
Yield stress 𝜎𝑦 = 500N/mm²
To find:-
Maximum value of P
Solution:-
(1) Max. bending moment 𝑀𝑏(max) = 𝑃𝑚𝑎𝑥 /2 x ɩ/2

= 4P/2x500/2
𝑀𝑏(max) = 500P
𝜋
(2) Section modulus Z = d³
32
𝜋
= (60)³
32
Z = 21205.77mm³
𝑀𝑏(max)
(3) 𝜎𝑚𝑎𝑥 =
2
= 500P/2
𝜎𝑚𝑎𝑥 = 0.0235 P N/mm²
Mean stress 𝜎𝑚 = 𝜎𝑚𝑎𝑥 + 𝜎𝑚𝑖𝑛 /2
31
(4)Minimum bending moment 𝑀𝑏(min) = 𝑃𝑚𝑖𝑛 /2 xɩ/2
= P/2 x 500/2
𝑀𝑏(min) = 125P
(5)Min, bending stress 𝜎𝑚𝑖𝑛 = 𝑀𝑏(max) /Z
= 125P/21205.75
𝜎𝑚𝑖𝑛 = 0.00589 P N/mm²
𝜎𝑚 = 0.0235 P +0.00589 P/2
𝜎𝑚 = 0.0147P N/mm²
Amplitude stress
𝜎𝑎 =𝜎𝑚𝑎𝑥 -𝜎𝑚𝑖𝑛 /2
𝜎𝑎 = 0.0235P – 0.00589P/2
𝜎𝑎 = 0.008805 P N/mm²
i)Using soderberg e equation (D.B. 7.6)
1/n = 𝜎𝑚 /𝜎𝑦 + 𝐾𝑓 . 𝜎𝑎 / 𝜎−1 ( 𝐾𝑐 .𝐾𝑠𝑓 .𝐾𝑠𝑧 )

1/1.3=0.0147P/500 +1x0.008805 P/ 1x330x0.85x0.9
1/1.3 = 6.428x10−5 P
P = 1197.2N
ii) Using goodman equation
1/n =𝜎𝑚 /𝜎𝑢 + 𝐾𝑓 . 𝜎𝑎 / 𝜎−1 ( 𝐾𝑐 .𝐾𝑠𝑓 .𝐾𝑠𝑧 )
1/n = 0.0147P/700+ 1x0.008805P/1x330x0.85x0.9
1/1.3 = 5.388x10−5 𝑃
P =13766.2N
Result:-
Hence choose the maximum value P= 13766.2N
17)A pump lever rotating shaft is shown figure .The pump lever exerts forces
of 25KN and 35KN concentration at 150mm and 200mm from the left and right
hand bearing respectively .Find the diameter of the central portion of the shaft, If
the stress is not to exceed 100Mpa?
32
Given:-
𝜎𝑏 = 100Mpa
To Find:-
Diameter‘d’
Solution:-
Taking moment about ‘A’
𝜀𝑀𝐴 = 0
𝑅𝐵 x950 = (35x750)+(25x150)
𝐶 = 3000/950
𝑅𝐵 = 31.58KN → ①
Єv = 0
𝑅𝐴 + 𝑅𝐵 = (35+25) x10³
𝑅𝐴 = 60x10³ - 31.85x10³
𝑅𝐴 = 28.42x10³N
Bending moment at ‘C’
= 𝑅𝐴 x 150
= 28.42x10³x150
= 4.263x10⁶N.mm
33
Bending moment at ‘D’
=𝑅𝐵 x200
= 31.58x10³x200
=6.316x10⁶ N.mm
The maximum bending moment
M = 6.316x10⁶ N.mm
𝜋
Section modules Z = d³
32
Z = 0.0982d³
W.K.T that bending stress 𝜎𝑏
100 = M/Z = 6.316x10⁶/0.0982d³
d= 86.3mm
Result:-
d=90mm (D.B 7.20)
34
UNIT-2
SHAFTS AND COUPLINGS
2.1 Design of shaft:
1)In a axial flow compressor the shaft is subjected to a max. Torque of

1500x10³ N.mm and a max bending moment of 3000x10³N.mm the shear stress
is limited to 50N/mm². Assume a shock factor 1.5 in bending and shock factor
in twisting as 2 Design in the diameter of the shaft?
Given:-
𝑀𝑡𝑚𝑎𝑥 =1500x10³ N.mm
𝑀𝑏𝑚𝑎𝑥 = 3000x10³N.mm
Ʈ𝑚𝑎𝑥 = 50N/mm²
𝐾𝑏 = 1.5
𝐾𝑡 =2
To Find:-
Shaft diameter
Solution:-
D.B.7.21 d³ = 16/Ʈ.𝜋 √ (𝐾𝑏 𝑀𝑏 )² + ( 𝐾𝑡 𝑀𝑡 )²
d³ =
16/50𝜋 √(1.5 × 3000 × 10³)² + (2 × 1500𝑥103 )²
d³ = 550887.65
d= 81.97 mm
Result:-
d=90mm D.B.7.20
2)A shaft is to transmit 50Kw at 1200rpm .It is also subjected to a bending

moment of 275N.m .Allowable shear stress is 60N/mm² the shaft is not to twist
more more than 2° in a length of 2meter .Take G=80x10³N/mm² design the shaft ?
35
Given:-
P = 50Kw = 50x10³w
N = 1200rpm
𝑀𝑏 = 275N.m = 275x10³ N.mm
Ʈ = 60N/mm²
𝜋
Q =2° = 2x = 0.0349 rad
180
L = 2m
G = 80x10³ N/mm²
To find:-
Diameter ‘d’
Solution:-
(a) Calculation of dia of shaft based on strength
P = 2𝜋N𝑀𝑡 /60
𝑀𝑡 = 50x10³x60/2𝜋𝑥1200
𝑀𝑡 = 397.887
𝑀𝑡 = 397.887x10³N.mm
𝛼𝑃𝑑𝑜
𝑑𝑜 ³ = 16/ x 𝐾𝑏 𝑀𝑏 + 2 + (𝐾𝑡 𝑀𝑡 )²/𝜋xƮ(1-(𝑑𝑖 /𝑑𝑜 )⁴
√ 𝑑2
8(1+ 2𝑖 )
𝑑𝑜
𝑑𝑜 = d, 𝑑𝑖 = 0, P = 0
Assume 𝐾𝑏 = 𝐾𝑡 = 1
d³ = 16/𝜋Ʈ√(𝐾𝑏 𝑀𝑏 )² + (𝐾𝑡 𝑀𝑡 )²
d³ = 16/𝜋x60√(275 × 103 )2 + (397.88 × 103 )²
d= 34.49mm
36
d=35mm (R20 series)
(b) Calculation of dia of shaft based on angle of twist :-
D.B.7.1
𝑀𝑡
= GQ/l
𝐽
𝜋
397.88X10³/ d⁴ = 80x10³x0.0349/2x10³
32
d=41.27 mm
d=45mm (R20 series)
Result:-
d=35mm (based on strength)
d=45mm (based on angle of twist)
3)Design a shaft to transmit 2Kw at 150rpm from an electric motor lath head
stock through a pulley using a flat belt drive. The pulley is located at 140mm
from the centre of the bearing diameter of the pulley is 200mm.The pulley
weights 250N angle of lap of the belt is 180° and the coefficient of friction
b/w belt and pulley is 0.3 shock factor in bending is 1.5 and in twisting 1
Take allowable shear stress for the shaft material as 44 N/mm²?
Given:-
P = 2Kw = 2x10³watts
N=150rpm l=140mm
D=200mm, w=250N
Q=180° =𝜋 radians
𝜇 = 0.3
𝐾𝑡 =1.5
𝐾𝑏 =1
Ʈ =44N/mm²
37
To find:-
Diameter ‘d’
Solution:-
1. Belt tension 𝑇1 /𝑇2 = 𝑒 𝜇𝑄
𝑇1 /𝑇2 = 𝑒 0.3×𝜋
𝑇1 = 2.565𝑇2
𝑇1 & 𝑇2 Tight and slack side tensions respectively
P = (𝑇1 - 𝑇2 )V
V= 𝜋DN/60
V=𝜋 x 150x0.2/60
V = 1.571m/s
2x10³ = (𝑇1 - 𝑇2 )x1.571
𝑇1 - 𝑇2 = 1273N
𝑇1 = 2.565𝑇2
2.565𝑇2 -𝑇2 = 1273
𝑇2 = 813.5N
𝑇1 = 2086.5N
2. Bending moment due to three toads 𝑇1 & 𝑇2 & w
M = ( 𝑇1 +𝑇2 +w) x over hang
M =(2086.5+813.5+250)x140
M = 441000N.mm
3. Twisting moment (T)
T = (𝑇1 - 𝑇2 )xD/2
T = 127.3N.mm
4. Equivalent torque 𝐾𝑏
38
𝑇𝑒 = √(𝐾𝑏 M)² + (𝐾𝑡 𝑇)²
𝑇𝑒 = √(1 × 441000)² + (1.5 × 127300)²
𝑇𝑒 = 708804N.mm
5. Diameter of shaft
16𝑇𝑒 /𝜋d³ = Ʈ Ʈ = 44/n
Ʈ = 44x0.75 Ʈ = 44/1.3
Ʈ = 33N/mm² Ʈ = 33N/mm²
16x708804/𝜋d³ = 33
d³ = 16x708804/𝜋x33
d = 47.82mm
d = 50mm (standard)
Result:-
d=50mm (standard)
4)Power is transmitted to a shaft support on bearing 900mm apart by a belt

drive running on a 450 mm pulley, which overhangs the right bearing by
200mm.Power is transmitted from the shaft through a belt drive, running on a
250mm pulley, located mid way b/w the bearings. The belt drive are parallel
to each other and the ratio of belt tensions is 3, with the maximum tension in
both the belts being limited to 2KN.Determine the diameter of shaft assuming
permissible tensile & shear stresses are 100Mpa and 60Mpa?
Given:-
D = 250mm
r = 125mm
Ratio of belt tension = 3
Max. Tension in both belts = 2KN = 2x10³N
𝜎𝑡 = 100Mpa = 100N/mm²
Ʈ = 600Mpa = 60N/mm²
39
To find:-
Diameter ‘d’
Solution:-
Let 𝑇1 & 𝑇2 are tensions on hght side and slack side on pulley ‘c’
𝑇1 /𝑇2 = 3
𝑇1 = 2x10³N
40
𝑇2 = 2x10³/3
𝑇2 = 666.67N
𝑇3 /𝑇4 = 3
𝑇3 = 2x10³N
𝑇4 = 2x10³/3
𝑇4 = 666.67N
Let 𝑅𝐴 + 𝑅𝐵 = 2666.67+2666.67
(𝑇1 +𝑇2 ) (𝑇3 + 𝑇4 )
𝑅𝐴 + 𝑅𝐵 = 5333.34N
𝑅𝐵 ×900 = (2666.67×1100) + (2666.67× 450)
𝑅𝐵 = 4592.59N
Calculation of bending moment A, B, C, D
𝑀𝐴 = 0, 𝑀𝐷 = 0
Bending moment at C = 740.75 x 450
𝑀𝐶 = 333.33x10³N.mm
Bending moment at 𝑀𝐵 = 2666.67x200
𝑀𝐵 = 533.33x10³N.mm
From the above maximum bending moment is ‘B’
The shaft is also subject to twisting moment 𝑀𝑡 =(𝑇1 -𝑇2 )× R Pulley C
𝑀𝑡 = (2000 – 666.67)× 125
𝑀𝑡 = 166.66 x10³ N.m
To find the shaft diameter
d³ = 16/𝜋Ʈ√( 𝐾𝑏 𝑀𝑏 )2 + (𝐾𝑡 𝑀𝑡 )²
(533.33 × 103 )2 + (166.66 × 103 )2

d³ = 16/𝜋 × 60√
41
d = 36.19mm
d = 40mm (7.20 D.B)
Result:-
d = 40mm
5)Compare mass, strength , stiffness of a hollow shaft of the internal diameter

as that of a solid shaft the inside diameter of the hollow shaft is being 0.6
times the external diameter both the shaft have same material and length .
Given:-
Inner dia of hollow 𝑑𝑖 = 0.6 𝑑𝑜
d = dia of solid shaft
To find:-
Mass, strength, stiffness comparison
Solution:-
Hollow shaft subjected to torsion only
PSG D.B 7.21
Ʈ𝑚𝑎𝑥 = 16(𝑀𝑡 )hollow 𝑑𝑜 /𝜋( 𝑑𝑜 ⁴ − 𝑑𝑜 ⁴)
𝑀𝑡 (hollow) = Ʈ𝑚𝑎𝑥 × 𝜋( 𝑑𝑜 ⁴ −0.6 𝑑𝑜 ⁴)/16𝑑𝑜
𝑀𝑡 (hollow) = Ʈ𝑚𝑎𝑥 × 𝜋 (0.870+𝑑𝑜 ⁴/16𝑑𝑜
𝑀𝑡 (hollow) = Ʈ𝑚𝑎𝑥 0.1703𝑑𝑜 ³ → ①
Consider solid shaft
𝑑𝑖 = 0, 𝑑𝑜 = d, d =0.6
Ʈ𝑚𝑎𝑥 = 16(𝑀𝑡 ) solid × (0.6𝑑𝑜 )/((0.6𝑑𝑜 )⁴−0)
𝑀𝑡 (soild) = Ʈ𝑚𝑎𝑥 × 𝜋 ×(0.6𝑑𝑜 )⁴/16×0.6𝑑𝑜
𝑀𝑡 (soild) = Ʈ𝑚𝑎𝑥 ×0.0424𝑑𝑜 ³ → ②
①/② 𝑀𝑡 (hollow) / 𝑀𝑡 (soild) = Ʈ𝑚𝑎𝑥 ×0.1709𝑑𝑜 ³ /

Ʈ𝑚𝑎𝑥 × 0.0424𝑑𝑜 ³
42
𝑀𝑡 (hollow) = 4.0306 ( 𝑀𝑡 )solid
Comparison of weight :-
Mass = density × volume
Mass = density ×area ×length
𝑀𝐻 = p xA xl
𝑀𝐻 = 𝑝𝐻 × 𝜋/4(𝑑𝑜 ² - 𝑑𝑖 ²)× 𝑙𝐻
𝑀𝐻 = 𝑝𝐻 × 𝑙𝐻 × 𝜋/4 ×((𝑑𝑜 ²) –
(0.6𝑑𝑜 )²
𝑀𝐻 = 𝑝𝐻 × 𝑙𝐻 ×(0.5026) 𝑑𝑜 ² → ③
𝑀𝑆 = 𝑝𝑠 × 𝐴𝑆 × 𝑙𝑆
𝑀𝑆 = 𝑝𝑠 × 𝜋/4d² × 𝑙𝑆
𝑀𝑆 = 𝑝𝑠 × 𝑙𝑆 × (0.2827) 𝑑𝑜 ² → ④
③/④
𝑀𝐻 / 𝑀𝑆 =𝑝𝐻 𝑙𝐻 ×(0.5026) 𝑑𝑜 ² / 𝑝𝑠 𝑙𝑆 × (0.2827)

𝑑𝑜 ²
𝑀𝐻 / 𝑀𝑆 = 1.777
𝑀𝐻 = 1.777 𝑀𝑆
\\\𝑙𝑦 𝑤𝐻 = 1.777𝑤𝑠
Comparison of stiffness:-
G → constant
J as stiffness
𝜋
𝐽𝐻 = (𝑑𝑜 ⁴ - 𝑑𝑖 ⁴)
32
𝜋
𝐽𝐻 = (((𝑑𝑜 ⁴- (0.6𝑑𝑜 )⁴)
32
𝐽𝐻 = 0.08545 𝑑𝑜 ⁴
𝜋
𝐽𝑆 = 𝑑𝑜 ⁴
32
43
𝜋
𝐽𝑆 = 0.6𝑑𝑜 ⁴
32
𝐽𝑆 = 0.01272𝑑𝑜 ⁴
𝐽𝐻 / 𝐽𝑆 = 0.8545 𝑑𝑜 ⁴/0.01272𝑑𝑜 ⁴
𝐽𝐻 / 𝐽𝑆 = 6.715
𝐽𝐻 = 6.715𝐽𝑆
Result:-
(𝑀𝑡 )𝐻 = 4.03 (𝑀𝑡 )𝐻
𝑤𝐻 = 1.777 𝑤𝑠
𝐽𝐻 = 6.715 𝐽𝑆
6).Determine the requirement standard diameter of an uniform circular

shaft carrying 2 pulleys of weight 2KN each .The shaft is 750mm long
simply supported at the ends and carries two pulleys at 250mm and
500mm from the left end, Belt pulley is 10KN horizontal on the left
pulley and pulley on. The right pulley is 10KN vertically downwards. The
shaft transmit a torque of 3KN.m b/w the pulleys. Assume 𝐾𝑏 = 𝐾𝑡 = 1.5
and allowable shear stress of 70N/mm²?
Given:-
Weight each pulley = 2KN =2x10³N
Torque 𝑀𝑡 = 3KN.m = 3x10⁶N.m
𝐾𝑏 = 𝐾𝑡 = 1.5
Ʈ = 70 N/mm²
To find:-
Diameter‘d’
Solution:-
Load Pulley C Pulley D

Horizontal load 10*103N -
Vertical load 2*103N (10*103)+(2*103)=12*103N
44
T1&T2 are the belt tensions on pulley ’C’
ie T1+T2=10KN(H)
T3+T4=10KN(V)
Consider Horizontal loading:-
Let (RA)H and (RB)H are the support sections at A&B respectively
(RA)H +(RB)H =10*103 --------------------------- (1)
(RB)H*750=10*103*250
45
(RB)H=3.33*103N----------------------------- (2)
Substitute equation(2) value in equation (1)
(RA)H=10*103-3.33*103
(RA)H=6.67*103N
Calculation of bending moment (M)RAH=0
(M)RBH=0
MCH=Bending moment at ‘C’
=(RA)H*250
=6.67*103*250
MCH=1.6675*106 N.mm
MDH = Bending moment at ‘D’
=(RB)H*250
=3.38*103*250
MDH =0.845*106 N.mm
Consider Vertical loading:-
Let (RA)V &(RB)V are the support reactions at A&B
(RA)V+(RB)V = (12*103)+(2*103)
(RA)V + (RB)V = 14*103 N --------------- (3)
Taking moment about ‘B’
(RB)V*750 = (12*103*500) + (2*103*250)
(RB)V =6.6*106/750
(RB)V = 8.66*103N -----------------------(4)
Substitute equation(4) value in (3)
(RA)V=14*103-8.66*103
(RA)V = 5.34*103 N
Calculation of bending moment
46
(M)RAV=0, (M)RBV=0
MCV=Bending moment at C = (RAV*250)
=5.34*103*250
MCV = 1.335*106 N.mm
Resolution Bending moment At ‘C’
(M)Resultant at C = √(MCH)2 + (MCV)2
Mbc =√ (1.6675*106)2 + (1.335*106)2
Mbc = 2.1360*106 N.mm
At ‘D’ the bending moment is maximum.
Max. bending moment =Mmax = Mb = 2.139*106 N.mm
Max. Twisting moment =Mt =3*106 N.mm
d3 = 16/𝜋(𝑡) √(KbMb)2+(ktMt)2
d3=16/𝜋 ∗ 70 ∗ √(1.5*2.319*106)2 + (1.5*3*106)2
d3 = 0.4138*106
d=74.518mm
R20 Series
d=80mm
Result:-
d=80mm
7) A C45 steel transmits 10 Kw at 750 rpm it is supported on two bearings

800mm apart and it is has two gears keyed on it. The pinion having 30 teeth of
5mm module is located 120 mm to the left of the right hand bearing and
delivers power horizontally to the right. the gear having 100 teeth of 5mm
module is located 150mm to the right of the left hand bearing and receives
power ( ccw viewed from the left end ) from below. Determine the diameter of
the shaft?
47
Given:-
P =10kw =10*103 W
N = 750rpm
L =800 mm
𝑇𝐷 = 30
𝑀𝐷 = 5 mm
𝑇𝑐 = 100
𝑀𝑐 = 5 mm
To find:-
Diameter‘d’
48
Solution:-
Torque 𝑀𝑡 = Px60/2𝜋N
= 10x10³x60/2𝜋 x750
𝑀𝑡 = 127.32 N.m
𝑀𝑡 = 127.32 x10³ N.mm
Diameter of gear , C
𝐷𝑐 = 𝑇𝑐 x 𝑀𝑐
𝐷𝑐 = 100 x5
𝐷𝑐 = 500 mm
Radius of 𝑅𝑐 = 𝐷𝑐 /2 = 500/2 = 250 mm
Radius of 𝑅𝐷 = 𝑇𝐷 x 𝑀𝐷 /2 = 30x5/2 = 75 mm
𝐹𝑡𝑐 = 2𝑀𝑡 /𝐷𝑐

49
𝐹𝑡𝑐 = 2x127.32x10³
𝐹𝑡𝑐 = 509.28N
𝐹𝑡𝑐 = 2𝑀𝑡 /𝐷𝐷
𝐹𝑡𝑐 = 2X127.32X10³/150
𝐹𝑡𝑐 = 1697.6N
i)consider vertical loading only:-

𝑅𝐴𝑉 + 𝑅𝐵𝑉 = 509.28N
(moment about ‘A’) 𝑅𝐵𝑉 x800 = 509.28 x150
𝑅𝐵𝑉 = 95.49N
𝑅𝐴𝑉 = 509.28 – 95.49
𝑅𝐴𝑉 = 413.79 N
W.K.T
B.M at 𝑀𝑐𝑣 = 𝑅𝐴𝑉 x150
= 413.79x150
𝑀𝑐𝑣 = 62068.5N.mm
B.M at 𝑀𝐷𝑉 = 𝑅𝐵𝑉 x120
= 95.49 x120
𝑀𝐷𝑉 = 11458.8N.mm
ii)Consider horizontal loading only:-
𝑅𝐴𝐻 + 𝑅𝐵𝐻 = 1697.6N
Taking Moment about ‘A’
𝑅𝐵𝐻 x800 = 1697.6x(800-120)
𝑅𝐵𝐻 = 1442.96N
𝑅𝐴𝐻 = 1697.6 -1442.96 = 254.64 N
W.K.T Bending moment at 𝑀𝐴𝐻 = 𝑀𝐵𝐻 = 0
B.M at ‘c’ 𝑀𝐶𝐻 = 𝑅𝐴𝐻 x150 = 38196N.mm
50
B.M at ‘D’ 𝑀𝐷𝐻 =𝑅𝐵𝐻 x120 = 1442.46x120 =173155N.mm
W.K.T Resultant B.M at ‘C’
𝑀𝐶 = √(𝑀𝑐𝑣 )2 + (𝑀𝐶𝐻 )²
𝑀𝐶 = √(62068.5)2 + (38196)²
𝑀𝐶 = 72879 N.mm
𝑀𝐷 = √(𝑀𝐷𝑉 )2 + (𝑀𝐷𝐻 )²
𝑀𝐷 = 173533N.mm
Maximum bending moment
𝑀𝑏 = 𝑀𝐷 =173533N.mm
𝑀𝑡𝑒 = √𝑀𝑏 ² + 𝑀𝑡 ²
= √173533² + (127.3 × 103 )²
𝑀𝑡𝑒 = 215219.2N.mm
𝜋
𝑀𝑡𝑒 = xƮxd³
16
D.B.1.12 C45 steel 𝜎𝑦 = 380 N/mm²

𝜎𝑦
Ʈ = = 380/2 = 190N/mm²
2
F.O.S = 3.5
Ʈ = 190/3.5 = 54N/mm²
𝜋
215x10³ = x54xd³
16
d= 27.26 mm
d= 30mm
Result:-
Shaft diameter ‘d’ = 30 mm
51
2.2 Design of key:
8)Design a keyway and a key in motor shaft extension for a 20Kw , 1000
rpm motor having a mild steel shaft 50mm diameter , the extension of
80mm, the shear & crushing stresses mild steel are 60Mpa & 120Mpa,
check for the shear strength of the key against the normal strength of the
shaft ?
Given:-
P = 20Kw = 20x10³ w
N = 1000 rpm
d = 50 mm
Ʈ = 60Mpa = 60 N/mm²
𝜎𝑒 = 120 Mpa =120 N/mm²
l= 80 mm
To find :-
Design a key
Solution :-
(i)To find torque
T = P x60/2𝜋N
T = 20 x10³ x60/2𝜋 x1000
T = 190.98 x10³ N.mm
(ii) Width of key

T = lxbxƮxd/2
191x10³ = 80 x b x60 x50/2
b = 1.59mm
b= d/4 = 50/4
b= 12.5 mm
𝜎𝑐 = 2Ʈ
52
b= 13 mm & t= 13mm = h
(iii) Check for shear strength

Strength factor e = 1- 0.2 (b/d) -1.1(h/2d)
e= 1-0.2(13/50) – 1.1x(13/2x50)
(iv) Strength of shaft with keyway
𝜋
= xƮxd³xe
16
𝜋
= x60x50³x0.805
16
= 1185460 N
Shear strength of the key = l x w x Ʈ x d/2
= 80x13x60x50/2
= 1560000N
Shear strength of the key/Normal strength of shaft = 1560000/1185460
= 1.316
Result:-
b=13 mm
t= 13mm
2.3 Design of coupling:
9)Muff coupling is to be designed for a shaft which transmit 56.25Kw at

120rpm.the following are the permissible stresses Ʈ𝑠ℎ𝑎𝑓𝑡 = 60 N/mm²,
Ʈ𝑚𝑢𝑓𝑓 =10N/mm² ,Ʈ𝑘𝑒𝑦 =40N/mm² , 𝜎𝑘𝑒𝑦 =100N/mm²?
Given:-
P = 56.25 Kw = 56.25x10³ w
N = 120 rpm
Ʈ𝑠ℎ𝑎𝑓𝑡 =60N/mm²
Ʈ𝑚𝑢𝑓𝑓 =10N/mm²
Ʈ𝑘𝑒𝑦 =40N/mm²
53
𝜎𝑘𝑒𝑦 =100N/mm²
To find :-
Design of muff coupling
Solution:-
(i) Design of the shaft
𝑀𝑡 = 𝜋(Ʈ𝑠ℎ𝑎𝑓𝑡 )d³/16
P = 2𝜋N𝑀𝑡 /60
𝑀𝑡 = Px60/2𝜋N
𝑀𝑡 = 4476.23x10³N.mm
d³ = 16x4476.23x10³/𝜋x60
d= 72.423mm
d=80 mm
(ii) Design of sleeve
D → Outside Diameter
d → Inside Diameter
D → 2d+13
D → 2 x80+13
Outside diameter of sleeve
L = 3.5 d
L = 3.8 x8
L = 280 mm
Check the shear stress in the sleeve

𝜋
𝑀𝑡 = (Ʈ(𝑠𝑙𝑒𝑒𝑣𝑒) D³ (1-K⁴)
16
K = d/D = 80/173 = 0.4624
54
Ʈ(𝑠𝑙𝑒𝑒𝑣𝑒) = 16x4476.23x10³ /𝜋 x173³ x(1-0.4624⁴)
Ʈ𝑠 =4.61N/mm² <10N/mm²
iii)Design of key :-
for shaft dia = 80mm
b=22 mm, h = 14 mm
l=sleeve length/2 = 280/2
l=140 mm
(a) Checking of shear stress (Ʈ)
𝑀𝑡 = bxlxƮxd/2
Induced shear strees
Ʈ = 4476.23 x10³ x2/22x140x80
Ʈ = 36.3N/mm²< 40 N/mm²
The design is satisfactory
(b) Checking of crushing stress (𝜎𝑐 )
𝑀𝑡 = h/2 . l. 𝜎𝑐 .d/2
Induced crushing stress
𝜎𝑐 = 𝑀𝑡 x2 x2/hxlx d
𝜎𝑐 = 4476.23x10³x2x2/14x140x80
𝜎𝑐 = 119.18 N/mm² > 100 N/mm²
The design is not satisfactory
Therefore, change the length of the key at b= 22mm, h = 14 mm,
l =160mm
Recalculate, 𝜎𝑐
55
Ʈ = 𝑀𝑡 x2/b.l.d = 4467.23 x10³ x2 /14 x160 x80
Ʈ = 31.79 N/mm² < 40 N/mm²
𝜎𝑐 = 𝑀𝑡 x 2x2/bxlxd
𝜎𝑐 = 4467.23x10³x2x2/14x160x80
𝜎𝑐 = 99.91 N/mm² < 100N/mm²
Key length taken as = 180 mm
Result:-
D= 173mm b=22mm
d= 80 mm h = 14 mm
L =280mm l= 180 mm
10)Design a taper key for a shaft of diameter 100 mm transmitting 60 kw

at 300rpm .The allowable compressive stress may be taken as 175 N/mm²?
Given :-
d= 180mm
P = 60 kw
N = 300 rpm
𝜎𝑐 = 172 N/mm²
To find :-
Dimensions of taper key
Solution:-
For the shaft diameter of 100 mm
D.B.5.21 width of b = 28 mm
h= 16 mm
p= 2𝜋N𝑀𝑡 /60
60x10³ = 2𝜋x300x𝑀𝑡 /60
𝑀𝑡 = 1909.85 N.m
𝑀𝑡 = 0.5 𝜇1 b l d 𝜎𝑐
56
Assume 𝜇1 = 0.25
1909.85 x10³ = 0.5 x0.25x28x2xlx100x175
L = 31.18mm
D.B.5.21
L = 1.25d
L =1.25 x100
L = 125 mm
Taper key has a standard slope of 1:100
Result:-
b=28mm
h= 13 mm
l= 125mm
Taper = 1 : 100
11) Design a protected type flange coupling for the following

requirement power to be transmitted 10 kw, speed of the shafts 960rpm,
select the suitable material?
Given:-
P = 10 kw
N = 960 rpm
To find:-
Design of protected type flange coupling
Solution:-
(i) Design of shaft :- 𝑀𝑡 = Px60/2𝜋N

𝑀𝑡 = 10x10³x60/2𝜋 x960
𝑀𝑡 = 99.47 N.m
𝑀𝑡 = 99.47x10³ N.mm
Assume (shaft, key , bolt, as mild steel with shear strength 50 N/mm² ,
crushing strength 90 N/mm² )
𝜋
99471.8 = x50xd³
16
d= 21.638 mm
57
d=25mm
(ii)Dimensions of flange coupling :-
Hub outside D = 2d = 2 (25) = 50mm
Length of hub L= 1.5 d = 1.5(25) 37.5 mm
Pitch circle diameter of the bolts 𝐷1 = 3d =75 mm
Thickness of flange 𝑡𝑓 = 0.5 d = 0.5(25) = 12.5 mm
Outside dia of the flange 𝐷2 4d = 4(25) = 100mm
Thickness of protective circumferential flange 𝑡𝑝 = 0.25d = 0.25(25) =

6.25 mm
(iii) Design of hub

𝜋
𝑀𝑡 = Ʈℎ (D⁴ - d⁴)/D
16
𝜋
999471.8 = xƮℎ (50⁴ - 25⁴)/50
16
Ʈ𝑠ℎ = 4.325 N/mm² < 50 N/mm² Design is safe
(iv)Design of key :-
d=25mm
D.B 5.16 l=L = 37.5 mm
b=9mm
h=7.5mm
(a) Check for shearing :-

𝑀𝑡 = lxbxƮ𝑘 xd/2
99471.8 = 37.5 x9x Ʈ𝑘 xd/2
Ʈ𝑘 = 23.57 N/mm² < 50N/mm²
Design is safe
(b) Design of flange :-
𝑀𝑡 = lx h/2 x 𝜎𝑐𝑘 xd/2
99471.8 = 37.5 x7.5/2 x 𝜎𝑐𝑘 x25/2
𝜎𝑐𝑘 = 57 N/mm² <90 N/mm²

58
Design is safe
(v)Design of flange :-
𝜋𝐷 2
𝑀𝑡 = xƮℎ x𝑡𝑓
2
99471.8 = 𝜋x50²/2 xƮℎ x12.5
Ʈℎ = 2.02 N/mm² < 50 N/mm²
(iv)Design of bolts :-
𝜋
𝑀𝑡 = 𝑑𝑏 ²xƮ𝑏 xhx𝐷1 /2 (h=3 for D up to 50mm)
4
𝜋
99471.8 = x𝑑𝑏 ² x50x3x75/2
4
𝑑𝑏 = 4.74 mm
𝑑𝑏 = 6 mm
Check for crushing
𝑀𝑡 = nx 𝑑𝑏 x𝑡𝑓 x 𝜎𝑐𝑏 x𝐷1 /2
99471.8 = 3x6x12.5x𝜎𝑐𝑏 x75/2
𝜎𝑐𝑏 = 11.78 N/mm² < 90 N/mm² Design is safe
Result:-
d. D . L ,D, 𝑡𝑓 , 𝐷2 , 𝑡𝑝 (flange)
l. b, h (key)
𝑑𝑏 (bolt)
n(no of bolt)
12)Two 35mm shafts are connected by a flanged coupling .The flanges

are fitted with 6 bolts on 25mm bolt circle. The shaft transmits a torque of
800 Nm at 350rpm for the safe stresses mentioned below calculate
(i)diameter of bolts (ii) Thickness of flanges (iii) Key safe stress for shaft
material 63 Mpa , safe stress for cast iron coupling 10Mpa and safe stress
for key material 46 Mpa?
59
Given:-
d= 35 mm Ʈ𝑠 = 63 N/mm²
n= 6 Ʈ𝑏 = 56 N/mm²
𝐷1 /2= 25 mm Ʈℎ = 10 N/mm²
𝑀𝑡 =800 N.m Ʈ𝑘 = 46 N/mm²
To find:-
Design a flange coupling
Solution :-
(i)Diameter of the bolt (𝑑𝑏 )

𝐷1
𝑀𝑡 = 𝜋𝑋𝑑𝑏 ²/4 X Ʈ𝑏 𝑋n x
2
800 000 = 𝜋𝑋𝑑𝑏 ²/4 x56x6x25
𝑑𝑏 = 11.01 mm
𝑑𝑏 =12 mm
(ii)Thickness of flange (𝑡𝑓 )
D= 2d = 2x35=70 mm
𝑡𝑓 = 0.5 d =0.5x35 = 17.5 mm
𝑀𝑡 = 𝜋xD²/2 xƮℎ x𝑡𝑓
800000 = 𝜋 x70²/2 xƮℎ x17.5
Ʈℎ = 5.94 N/mm² < 10 N/mm²
Design is safe
(iii)Key dimensions
From PSGD.B.5.16 corresponding to
d=35mm
Width b = 10 mm
Height h = 8 mm
60
Length L = L = 1.5 d= 1.5(35) =52.5mm
𝑀𝑡 = lxbxƮ𝑘 xd/2
800000 = 52.5 x10 xƮ𝑘 x 35/2
Ʈ𝑘 = 87.07 N/mm² > 46N/mm²
So, change the key dimensions
b= 20 mm, h = 11 mm
800000 = 52.5 x20xƮ𝑘 x 35/2
Ʈ𝑘 = 43.53 N/mm² < 46 N/mm²
Width b=20 mm , h = 52.5mm
(iv)Hub length (L)
L = 1.5 d = 1.5 (35) =52.5mm
(v)Power transmitted
P = 2𝜋 N 𝑀𝑡 /60
P = 2𝜋x600 x800000/60
P = 50.26 x10⁶N.mm/s
P = 50.26 x10³N.m/s
P = 50.26 kw
Result :-
𝑑𝑏 , 𝑡𝑓 , key dimesions (hub length) L, Power
13)Design a bushed pin type of flexible coupling to connect a pump shaft

transmitting 30KW at 900rpm.The overall torque is 15% more than mean torque
.The material available properties are as follows
σ ) in crushing for shaft & key material) = 80Mpa
Ʈ(in shear for shaft & key material ) = 40Mpa
Ʈ(in shear for cast iron ) = 15Mpa
Bearing pressure for rubber bush =0.8Mpa
61
Material of the pin is as same as that of shaft and key, Draw the sketch
of the following coupling?
Solution :-
𝑀𝑡 = Px60/2𝜋N
𝑀𝑡 = 60x10³ x60 /2𝜋x900
𝑀𝑡 = 3183 x10³N.mm
d= (16 x 𝑀𝑡𝑚𝑎𝑥 /𝜋 x Ʈ)⅓
= (16 x 366.05 x10³/𝜋 x40)⅓
d= 36 mm
D.B. 7.108 F= 12 mm D = 90 mm
n= 4 C = 55 mm
G = 30 mm E = 40 mm
t=4 mm H = 15 mm
𝑑𝑏 = 25 mm B = 132 mm
Max shear stress = 1/2 √𝜎𝑏 ² + 4Ʈ²
= ½ √28.48² + 4(17.99)²
= 22.94 N/mm²
Design of key
d= 36 mm
D.B. 5.19 b=10 mm
h=8 mm
l=E/2 = 40/2 = 20 mm
𝑇𝑚𝑎𝑥 = 1.15 𝑇𝑚𝑒𝑎𝑛
= 1.15 (318.3)
𝑇𝑚𝑎𝑥 = 366.05 x10³ N.mm
Check for shearing :-

62
𝑀𝑡𝑚𝑎𝑥 = lxbxƮ𝑘𝑖 xd/2
366.05x10³ = 20x10xƮ𝑘𝑖 x36/2
Ʈ𝑘𝑖 = 101.67 N/mm²
Ʈ𝑘 < Ʈ𝑘𝑖
b= 366.05 x10³x2/20x36x40
b= 25mm
Check for bolt :-
𝑀𝑡 = W xn x D/2
366.05 x10³= Wx 4 x90/2
W = 2033.6 N
𝜋
Ʈ =w/ xF²
4
Ʈ = 2033.6/𝜋/4 x12²
Ʈ = 17.99 N/mm²
𝑀𝑏 = W(G/2+t)
= 2033.6 (30/2+4)
𝑀𝑏 = 38638 N.mm
𝑀𝑏
𝜎𝑏 =
𝑍
𝜋
= 38638/ (12)³
4
𝜎𝑏 = 28.48N/mm²
𝜎𝑏
Maximum Principal stress = +1/2√𝜎𝑏 ² + 4Ʈ²
2
= 28.48/2+1/2√28.98² + 4(17.99)²
= 37.2N/mm²
Since the max. Principal stress l max.shear within limit ,Design is safe
Check for crushing
63
𝑀𝑡 = lxh/2x𝜎𝑐𝑘𝑖 xd/2
366.05x10³ = 20x8/2 x𝜎𝑐𝑘𝑖 x36/2
𝜎𝑐𝑘𝑖 =254.16N/mm² > 80N/mm²
Design is not safe
h= 2x366.05x10³ x2/20 x36x80
h= 25mm
\ Design of Bush :-
L = G+t – 2/3 xF
= 30+4-2/3x12
L = 26 mm
0.8 = 2033.6/𝑑𝑏 x26
𝑑𝑏 = 97.76 mm
Design of Hub :-
𝜋
𝑀𝑡 = x Ʈℎ x(𝐶 4 - A⁴)/C
16
366.05x10³ = 𝜋/16x Ʈℎ x(55⁴ -36⁴)/55
Ʈℎ = 13.72 N/mm²
Design of flange :-
𝑀𝑡 = 𝜋c²/2xƮℎ xG
366.05 = 𝜋(55)²/2 xƮℎ x30
Result:-
d, F, n, G , t, 𝑑𝑏 , D, C, E, H
64
UNIT-3
TEMPORARY AND PERMANENT JOINTS
3.1 Design of welding:
1)A plate 100mm wide and 12.5 mm thick is to be welded to another

plate by means of single transverse and double parallel fillet welds,
Determine the length of weld run in each case if the joint is subjected to
varying loads. The recommended design stress in tension is not to exceed
70N/mm² and in shear 56N/mm² for static loaded ?
Given:-
b=100mm
t=12.5mm
𝜎𝑡 = 70 N/mm²
Ʈ = 56 N/mm²
To find:-
Single transverse ( 𝑙1 )
Double parallel (𝑙2 )
Solution:-
𝑙1 = d-t
65
𝑙1 = 100 -12.5
𝑙1 = 87.5 mm
P = Area x tensile stress (𝜎𝑡 )
P = b x t x 𝜎𝑡
P = 100 x12.5 x70
P = 87500 N
In case of varying load, the stress concentration factor for
Transverse weld = 1.5
Parallel fillet weld = 2.7
𝜎𝑡 = 70/1.5 = 46.7 N/mm²
Ʈ = 56/2.7 =20.74 N/mm²
Single transverse weld
𝑃1 = 0.707 x h x 𝑙1 x 𝜎𝑡
𝑃1 = 0.707 x 12.5 x 87.5 x46.7
𝑃1 = 36112.23N
Double parallel fillet weld
𝑃2 = 2 x0.707xh x 𝑙2 x Ʈ
𝑃2 = 2 x0.707 x12.5x 𝑙2 x20.74
𝑃2 = 366.5 𝑙2 N
P = 𝑃1 + 𝑃2
87500 = 36112.23 + 366.57 𝑙2
𝑙2 = 140.18mm
Length of the weld in parallel fillet (𝑙2 ) =𝑙2 +12.5
= 140.18 +12.5
= 152.68 mm
66
𝑙2 = 153 mm
Result:-
𝑙1 = 87.5 mm
𝑙1 = 153mm
2) A circular shaft 60mmin diameter is welded to a support plate by

means of a fillet weld shown in figure determine the size of weld the
permissible shear stress in the weld is limited to 85Mpa?
Given:-
D= 60 mm
P = 7 KN = 7000 N
Ʈ = 85N/mm²
To find:-
Weld size ‘h’
67
Solution:-
𝜎𝑏 = 5.66 𝑀𝑏 /𝜋D²h
𝑀𝑏 = P x e
𝑀𝑏 = 7000x 150
𝑀𝑏 = 1050000 N.mm
𝜎𝑏 = 2 xƮ = 2 x 85 = 170 N.mm
170 = 5.66 x1050000 / 𝜋 x 60 ² x h
h= 3.09 mm
Result:-
h= 3.09 mm
3)A shaft of rectangular cross section is welded to a support plate by

means of a fillet weld its one end shown in figure the other end is
loaded by 2 kN. If the size of weld is 6mm, find the maximum normal
and shear stress in the weld?
Given:-
P = 25 KN
e = 500mm
Cross section = 100 x 150 mm
h= 6 mm
To find:-
Maximum normal stress

Maximum shear stress
68
Solution :-
A = t (2b + 2d)
A = 0.707 x6 x (2 (150) +2 (100))
(Area ) A = 2121 mm²
(shear stress) Ʈ = P/A
Ʈ = 25000/2121
Ʈ = 11.78 N/mm²
(Bending moment ) 𝑀𝑏 = P xe
𝑀𝑏 = 25000 x 500
𝑀𝑏 = 12.5 x 10 ⁶ N.mm
(Section Modulus) 𝑍𝑤 = t (bd + d²/3)
𝑍𝑤 = 0.707 x 6x (100 x 150 + 150²/3)
𝑍𝑤 = 95445 mm³
(Bending 𝜎𝑏 = 𝑀𝑏 /Z = 12.5 x10⁶ /95445 = 130.96 N/mm²
(Maximum normal stress )

𝜎𝑚𝑎𝑥 = 𝜎𝑏 /2 +1/2 √𝜎𝑏 ² + 4Ʈ²
𝜎𝑚𝑎𝑥 = 130.96/2+1/2
√130.96² + 4(11.78)²
𝜎𝑚𝑎𝑥 = 132 N/mm²
69
(maximum shear stress)
Ʈ𝑚𝑎𝑥 = ½ √𝜎𝑏 ² + 4Ʈ²
Ʈ𝑚𝑎𝑥 = ½ √130.96² + 4(11.78)²
Ʈ𝑚𝑎𝑥 = 66.53 N/mm²
Result:-
𝜎𝑚𝑎𝑥 = 132 N/mm²

Ʈ𝑚𝑎𝑥 = 66.53 N/mm²
4)A plate of 200mm width and 600mm long is welded to a vertical plate
by placing it on the vertical plate to from a cantilever with projecting
length of 480mm and overlap b/w plates as 120 mm fillet weld is done
on all three sides. A vertical load 30KN is applied at the free end of the
cantilever plate parallel to its width of 200 mm . If the allowable weld
stress is 95Mpa, determine weld size ?
Given:-
d= 200 mm
L= 600 mm\
Projecting length = 480 mm
Overlap b/w the plate = 120 mm
P = 30 kN = 30 x10³ N
σ = 95 Mpa = 95x10⁶ N/m² = 95 N/mm²
To find:-
Weld size ‘h’
70
Solution :-
Primary shear stress (Ʈ1 )

Secondary shear stress (Ʈ2 )
A = 0.707 h (2b+d)
A = 0.707 x h x (2(120)+200)
A = 311 h mm²
Ʈ1 = P/A = 30 x10³/311h = 96.4/h N/mm²
D.B. 11.5 𝑁𝑦 = b²/2b+d = 120² /(2x120)+200 = 32.72 mm

𝑁𝑦 = 33 m
Eccentricity e = 480+ (120 -𝑁𝑦 )

e= 480 +(120-33)
e= 567 mm
Twisting moment 𝑀𝑡 = P xe
𝑀𝑡 = 30 x10³ x567
𝑀𝑡 = 17010000 N.mm
r= √𝐺𝐵 2 + 𝐴𝐵2
71
200
r=√(120 − 𝑁𝑦 )² + ( )²
2
r= √(120 − 33)2 + 100²

r= 132.54 mm
cosQ = GB/r = 87/132.54

D.B. 11.75 𝐽𝑤 = ((2b+d)³/12 - b²(b+d)²/2b+d) x t
𝐽𝑤 = ((2x120+200)³/12 - 120²(120+200)²/2x120+200)
0.707 h
𝐽𝑤 = 2649407.5 h
Ʈ2 = 𝑀𝑡 x r/𝐽𝑤
Ʈ2 = 17010000 x 132.54/2649407.5h
Ʈ2 = 851/h N/mm² Ʈ1 Ʈ2
Resultant stress Ʈ = √Ʈ1 ² + Ʈ2 ² + 2Ʈ1 Ʈ2 cosQ
Ʈ
=√(964/ℎ)² + (851/ℎ)² + 2(96.4/ℎ)(851/ℎ)0.656
95 = 917.16 /h
h= 917.16/95
h = 9.65 mm
h= 10 mm
Result:-
h=10mm
5)The bracket arrangement is shown in figure the protruding portion of

this bracket consists of a ‘T’ cross section with the dimensions indicated
and it is welded to a support plate .The load to be supported is
40kN.Find the necessary weld size for the connection b/w the protruding
portion and the support plate. The maximum shear stress in the weld
should not exceed 100N/mm²?
72
Given:-
P = 40 KN
e= 300 mm
Ʈ = 100N/mm²
To find:-
Weld size h
Solution:-
Area A = ((100+80)+ (2x100)0.707 x h
Weld A = 268.66 h mm²
Ʈ = P/A = 40000/268.66 h
Ʈ = 148.8/h N/mm²
𝑀𝑏 = P x e
73
𝑀𝑏 = 40000 x300
𝑀𝑏 = 12 x10⁶ N.mm
D.B.11.6
𝑍𝑤 = 4bd +d²/3
If weld thickness is considered , then
𝑍𝑤 = (4bd+d²/3)x0.707 h
𝑍𝑤 = (4x100 x120 +120²/3) x0.707 xh
𝑍𝑤 = 14705.6 h mm³
𝜎𝑏 = 𝑀𝑏 /𝑍𝑤 = 12x10⁶/ 14705.6 h
𝜎𝑏 = 816/h N/mm²
D.B.7.2
Ʈ𝑚𝑎𝑥 = ½ √𝜎𝑏 ² + 4Ʈ²
816 2 1488
= 1/2√( ) +( )²
ℎ ℎ
Ʈ𝑚𝑎𝑥 = 434.3/h N/mm²
100 = 434.3 /h
h= 4.34 mm
Result:-
h=5mm
6)A shaft of rectangular cross section is welded to a support plate by

means of fillet welds shown in figure .Determine the size of the weld if
the permissible shear stress in the weld is limited to 75 N/mm² ?
74
Given:-
P = 25 kN
Ʈ = 75 N/mm²
To find:-
Weld size ‘h;
Solution:-
A = t (2b+2d)
A = 0.707x h x(2(150)+2x100)
A = 353.5 h mm²
Ʈ = P/A= 25000/353.5h
Ʈ = 70.72/h N/mm²
𝑀𝑏 = P xe
= 25000 x 500
𝑀𝑏 = 12.5x10⁶N.mm
𝑍𝑤 = t (bd + d²/3)
𝑍𝑤 = 0.707 xh (100 x150+150²/3)
𝑍𝑤 =15907.5h mm³
𝜎𝑏 = 𝑀𝑏 /𝑍𝑤
𝜎𝑏 = 12.5 x10⁶/15907.5h = 785.79/h

N/mm²
D.B.7.2 Ʈ𝑚𝑎𝑥 = ½ √𝜎𝑏 ² + 4Ʈ²
75
785.79 2 70.72 2
75 = ½√( ) +4×( )
ℎ ℎ
h= 5.32 mm
Result:-
h= 5.32mm
7)A weld joint shown in figure is subjected to an eccentrics load of

2KN.find the size of weld , if the maximum shear stress in the weld is
25Mpa?
Given:-
P = 2KN =2000 N
Ʈ = 25 N/mm²
To find:- Weld size ‘h’
Solution:-
A = 2x0.707 xh x s
A =2 x 0.707 x h x40
A = 56.56 h mm²
Ʈ = P/A = 2000/56.56(h)
Ʈ = 35.36/h N/mm²
e= 120 mm
D.B.16.3 𝜎𝑏 = 4. 24 Pe/hl²
𝜎𝑏 = 4.24 x2000x120/h x40²
𝜎𝑏 = 636/h N/mm²
Ʈ𝑚𝑎𝑥 = ½√𝜎𝑏2 + 4Ʈ2
636 2 35.36
= 1/2√( ) + 4( )²
ℎ ℎ
Ʈ𝑚𝑎𝑥 =320/h N/mm²
76
320/h = 25
h=12.8 mm
Result:-
Weld size h=12.8 mm
8)Find the minimum shear stress induced in the weld of 6mm size when
a channel shown in figure is weld to plate and loaded with 20KN
force at a distance of 200 mm?
Given:-
h= 6 mm
P = 20 KN = 20x10³ N
e= 200mm
To find:-
Ʈ𝑚𝑎𝑥
Solution:-
A = t(2b +d)
A = 0.707 x6 (2x40+90)
A = 721.14 mm²
Ʈ =P/A
Ʈ =20000/72.14N/mm²
77
𝑀𝑏 =Px e
𝑀𝑏 =20000 x200
𝑀𝑏 =4x10⁶ N.mm
D.B. 11.5 & 11.6 𝑍𝑤 = t (bd+d²/6)
𝑍𝑤 = 0.707 xh(40 x90 +90²/6)
𝑍𝑤 = 20997.9 mm³
𝜎𝑏 = 𝑀𝑏 /𝑍𝑤
= 4 x10⁶ /20997.9
𝜎𝑏 =190.49 N/mm²
Ʈ𝑚𝑎𝑥 = ½√𝜎𝑏 ² + 4Ʈ²

= ½ √190.49² + 4(27.73)²
Ʈ𝑚𝑎𝑥 = 99.2N/mm²
Result:-
Ʈ𝑚𝑎𝑥 = 99.2 N/mm²
9)A cylindrical beam of size 60mm is attached to support by a complex

circumferential fillet weld of 6 mm find (i) torque and (ii) bending moment
that can be applied if limiting shear stress is 140Mpa?
Given:-
D = 60mm
h= 6 mm
Ʈ = 140 N/mm²
To find:-
(i)Maximum torque (𝑀𝑡 )
(ii) Bending moment (𝑀𝑏 )
78
Solution:-
Ʈ = 2.83 𝑀𝑡 /𝜋hD²
140 = 2.83 𝑀𝑡 /𝜋 x6x60²
𝑀𝑡 = 3356.95 x10³N.mm
Result:-
𝑀𝑡 = 3356.95x10³ N.mm
𝑀𝑏 =3356.95x10³N.mm
10)An eccentrically loaded plate is welded to a frame shown in figure

design the welded joint if the tensile stresses not exceed 100 N/mm² and
that in weld is 80N/mm²?
Given:-
σ =100 N/mm²
P = 60 KN = 60 x10³ N
To find:-
(i) Size of weld’h’
79
(ii) Length of weld at the top 𝑙𝑎
(iii) Length of weld at the bottom 𝑙𝑏
Solution:-
Since the tensile stress σ = P/A = P/bxt
In the plate should not 100N/mm², 100 = 60x10³/130 xt
The maximum thickness of plate t = 4.6 mm
h=t = 5 mm ( The size of weld not exceed the thickness of the

plate)
D.B. 11.3
𝑙𝑎 = 1.414 P 𝑒2 /σhb
𝑙𝑎 = 1.414 x60x10³x80/100x5x130
𝑙𝑎 = 104.4mm
𝑙𝑎 = 104.4 +12.5 (adding 12.5 mm for stopping & starting of weld run)
𝑙𝑎 = 117 mm
D.B.11.3 𝑙𝑏 = 1.414 P 𝑒1 /σhb
𝑙𝑏 = 1.414x60x10³x50/100x5x130
𝑙𝑏 = 65.26 mm
80
𝑙𝑏 = 65.26+12.5
𝑙𝑏 = 77.76 mm
Result:-
h= 5 mm
𝑙𝑎 = 117 mm
𝑙𝑏 = 78 mm
3.2 Design of knuckle joint:
11) A knuckle joint is to transmit a force of 140KN, Allowable stresses in

tension , shear, and compression are 75 N/sqmm , 65 N/sqmm, 140N/sqmm
respectively design the joint?
Given:-
P =140KN
𝜎𝑡 = 75 N/mm²
Ʈ = 65N/mm²
𝜎𝑐 =140N/mm²
To find:-
Design knuckle joint
Solution:-
𝜋
P = d² 𝜎𝑡
4
𝜋
140 x10³ = x d² x 75
4
d=48.75 mm = 50mm
Dia of pin 𝑑1 = d =50mm
Outer dia of eye 𝑑2 = 2d = 100mm
Dia of pin head = 1.25 d=62.5 mm
Thickness of eye t 1.25 d = 62.5 mm
Thickness of fork 𝑡1 = 0.75 d = 62.5 mm
81
Thickness of pin head 𝑡2 = 0.5d = 25 mm
Check for shear:-
1. Failure of knuckle pin by double
𝜋
P = 2x 𝑑1 ² Ʈ
4
𝜋
140x10³= 2 x x50² x Ʈ
4
Ʈ = 35.65 N/mm² <65N/mm²

Design is safe
2. Failure of single eye or rod end in double shear
P = (𝑑2 - 𝑑1 )t xƮ
140 x10³ = (100-50)x 62.5 xƮ
Ʈ = 44.8 N/mm² < 65 N/mm²
Design is safe
3. Failure of forked ends in double shear

P = (𝑑2 - 𝑑1 )t x2 xƮ
140 x10³ = (100-50)x62.5 xƮ
Ʈ = 22.4 N/mm² < 65 N/mm²
Design is safe
Check for tensile stress:-
4. Faliure of the single eye or rod end in tension
P =(𝑑2 - 𝑑1 )t 𝜎𝑡
140x10³ = (100-50) x 62.5 x 𝜎𝑡
𝜎𝑡 = 44.8 N/mm² < 75 N/mm²
Design is safe
5.Faliure of forked end in tension :-
P = (𝑑2 - 𝑑1 ) 𝑡1 2𝜎𝑡
140 x10³ = (100-50) x 37.5 x 2 x𝜎𝑡
82
𝜎𝑡 = 37.33 N/mm² < 75 N/mm²
Design is safe
Checking for crushing stress :-
6.Faliure of single eye or rod end in crushing
P = 𝑑1 t 𝜎𝑡
140 x10³ = 50 (62 -5) 𝜎𝑐
𝜎𝑐 = 44.8 N/mm² < 140 N/mm²
Design is safe
7.Faliure of forked end in crushing
P = 𝑑1 𝑡1 2 𝜎𝑐
140 x10³ = 50x(37.5)x 2 x 𝜎𝑐
𝜎𝑐 = 37.33 N/mm² < 140 N/mm²
Design is safe
Result:-
d, 𝑑1 , 𝑑2 , 𝑑3 , t , 𝑡1 , 𝑡2
3.3 Design of cotter joint:
12)Design a cotter joint with one gib to transmit a force of 50KN along
a rod of square section .Assume that the gib, rod and cotter are made of
same material with the following available stresses?
Given:-
𝜎𝑡 = 20N/mm²
𝜎𝑐 = 50 N/mm²
Ʈ = 15 N/mm²
F = 50 KN
To find:-
Design a cotter joint with one gib
83
Solution:-
1.Faliure of rod in tension
F = h² (𝜎𝑡 )
50x10³ = h² x 20
h= 50 mm
w=h= 50mm
2. Shearing of gib and cotter
F = 2 B t Ʈ𝑎𝑙𝑙
50000 = 2B x 15 x15
B = 111.11 mm say B = 112 mm
Width of gib =0.55 B = 0.55 x112 = 61.6 mm
Width of cotter = 0.45 B = 0.45 x 112 = 50.4mm
3. Faliure of strap end in tension
F = 2 (w. 𝑡1 - t. 𝑡1 ) (𝜎𝑡 )
50000 = 2 (50 𝑡1 -15 𝑡1 )x20
𝑡1 = 35.7mm say 36 mm
4 . Crushing of gib or strap at the strap hole
F = 2 t 𝑡1 𝜎𝑐
50000 = 2 x36 x 15 x 𝜎𝑐
𝜎𝑐 = 46.29 N/mm²
Design is safe
5. Shearing of strap end

F = 2 x2 x𝑙3 x 𝑡1 xƮ
500000 = 4x𝑙3 x36x15
𝑙3 = 23.14 mm
6. Shearing of rod end
84
F = 2 x𝑙2 x hxƮ𝑎𝑙𝑙
50000 = 2 x𝑙2 x 50 x15
𝑙2 = 34 mm
7. Other Parameters
𝑙1 = t = 15 mm
𝑙4 = 2/3 h = 2/3 x50 = 33.3 mm
𝑡2 = 1.3 t = 1.3 x15 =19.5 mm
Overall gib length = h+ 2(𝑡1 + 𝑡2 )
= 50+2(36+20)
= 162 mm
Cotter length = 4 h = 4 x50 = 200 mm
Result :-
h, w , t width of gib , width of cotter , 𝑙1 , 𝑙2 , 𝑙3 , 𝑙4
3.4 Design of Bolt:
13)A cast iron cylinder head is fastened to cylinder of 500mm bone &stud
bolts .The maximum pressure inside the cylinder is 2Mpa. The stiffness of
part is thrice the stiffness of the bolt. What should be the initial tightening
load so that the point is leak proof at maximum pressure? Alse choose a
suitable bolt for the above application?
Given:-
D =500 mm
n=8
𝑃𝑚𝑎𝑥 = 2 N/mm²
𝑞𝑝 = 3𝑞𝑏
To find:-
Initial tightening load and suitable size of bolt
85
Solution:-
1)Total load at the pressure of 2Mpa

𝜋
P = 𝑃𝑚𝑎𝑥 x D²
4
𝜋
P = 2x x 500²
4
P = 392699.08 N
2) Load on each 𝑃𝑚𝑎𝑥 = P/n = 392699.08/8 = 49087.38 N
3) This force bolt, max be kept as in the force required to open

the joint (𝑃𝑜 )
4)If the force this force is not enough to maximum external load
𝑃𝑚𝑎𝑥 = 𝑃𝑗 (𝑞𝑏 +𝑞𝑝 /𝑞𝑝 )
Initial force 𝑃𝑖 = 49087.38 (3/3+1)
𝑃𝑗 = 36065.54 N
Slightly greater force might be applied ensue the leak

proof joint So , the Initial force is assumed to be 37000N
𝑃𝑏 = 𝑃𝑖 + ∆P
Where, ∆ P = 𝑃𝑜 (𝑞𝑏 /𝑞𝑏 +𝑞𝑝 )
𝑃𝑏 = 𝑃𝑖 +𝑃𝑜 (𝑞𝑏 /𝑞𝑏 +𝑞𝑝 )
𝑃𝑏 = 3700+ 49087.3 (1/1+3)
𝑃𝑏 = 49271.84 N
𝐴𝑐 = (60𝑞𝑝 /𝜎𝑦 )⅔ for < 45 mm
𝐴𝑐 = (60x49271.84/300)⅔
𝐴𝑐 = 459.56mm²
5.42D.B M30 x3.5 ISO METRIC
Result:-
M30x3.5 Bolt selected
86
14)A bracket is fitted to a channel with 4 bolts shown in figure ,distance
b/w bolts 1 and 3 is equal to the distance b/w bolts 2 and 4 which is
150 mm. Eccentricity is 300mm find a suitable bolts?
Given:-
P = 40000 N
e= 300mm
To find:-
Bolt diameter
Solution:-
CG of the bolt group is at (75, 75 ) with bolt 1 as
For bolt 1 , x=75 , y = 0 , r= 75
For bolt 2 , x =0, y =75 , r =75
For bolt 3 , x= 75 , y =0, r = 75
For bolt 4, x =0 , y =75, r =75
𝐹1 = P/n = 40000/4 = 10000 N
𝐹2 = Pe/nr = 40000x 300/ 4x75
= 40000 N
87
FR =√F1 ² + F2 ² + 2F1 F2 cosQ
FR =F1 + F2
= 10000+ 40000
FR = 50000 N
FR /Ac = σy /n
σy = 300 N/mm² and n = 3
50000/Ac =300/ 3
Ac = 500 mm²
D.B. 5.42 Bolt size M30 ×3.5
Result:-
Bolt Size M30 × 3.5
15)A bracket shown in figure is fitted to a wall with 5 bolts, three as

the top and two at the bottom with all the bolts, equally spaced.A load
of 20000 N is Acting at an eccentricity of 200 mm vertical distances of
first and second rows from the hinge point are 50 mm and 250 mm
respectively select a suitable bolt size for this application
Given:-
P =20000 N
e=200 mm
𝑙1 = 50 mm
𝑙2 = 250 mm
𝑛1 = 2
𝑛2 = 3
To find :-
Bolt Size ‘d’
88
Solution:-
Force on first row bolts F1 = P e l1 /n1 l1 ² +n2 l2 ²
F1 = 20000 ×200 ×50/(2× 50²) + (3 × 2502 )
F1 = 1038.96 N
Force on second row bolts F2 = Pe l2 /n1 l1 ² +n2 l2 ²
= 20000 × 200 × 250 /(2× 50²) + (3 × 2502 )
F2 = 5194.8N
F2 > F1
σ2 = F2 /Ac = 5194.8/ Ac
Ʈ = P/( n1 + n2 ) Ac = 20000/(2+3) Ac
= 4000 / 𝐴𝑐
Ʈ𝑚𝑎𝑥 = ½ √𝜎² + 4Ʈ²
= ½√(5194.8/ 𝐴𝑐 )² + 4(4000/ 𝐴𝑐 )²
Ʈ𝑚𝑎𝑥 = 4768.65/ 𝐴𝑐
But, Ʈ𝑚𝑎𝑥 = 𝜎𝑦 /n
89
𝜎𝑦 = 300 N/mm² and FOS = 3
4768.65/ Ac = 300/3
Ac = 47.68 mm²
D.B. 5.42 M10 ×1.5 bolt is selected
90
UNIT-4
ENERGY STORING ELEMENTS AND ENGINE COMPONENTS
4.1 Design of Helical spring:
1)A helical spring is made from a wine of 8mm diameter and outside
diameter of 75mm .The spring has 6 Numbers of active coils. If the
permissible stress in shear is 350 N/mm², and the modulus of rigidity is
84 KN/mm², Find the axial load which the spring can taken and the
deflection produced?
Given:-
Spring wine d = 8 mm
Outside spring diameter of Do = 75 mm
n= 6
Ʈ = 350N/mm²
G =84 KN/mm²
To find:-
(i)Axial load on the spring (P)
(ii) Deflection of the spring(y)
Solution:-
(i)Axial load on the spring (p)
(Mean coil diameter D = Do - d =75-8 = 67 mm
(spring index ) C = D/d = 67/ 8 = 8.375
(what stress factor ) K s = 4 C-1/4C-4 + 0.615/C
= 4(8.375)-1/4(8.375)-4+0.615/8.375
K s = 1.175
Ʈ = K s 8 P C/π d²
P = 893.9N
(ii)Deflection of the spring produced (y)
91
y= 8 P C³n/Gd
y= 8 ×893.9×8.375²×6/84 × 10³ × 8
y= 37.5 mm
Result:-
(i) P = 893.9 N
(ii) y= 37.5 mm
2)A helical value spring is to be designed for an operating load range of

90 N to 135N. The deflection of the spring index of 10 , a permissible
shear stress of 480 N/mm², for the material and the modulus of rigidity of
0.8 × 105 N/mm²c, determine the dimensions of the spring?
Given:-
Pmin = 90 N
Pmax = 135 N
Deflection y = 7.5 mm
Spring index C= 10
Ʈ = 480 N/mm²
G = 0.8 × 105 N/mm²
To find:-
Diameter of the spring
Solution :-
(i)Diameter of the spring wine (d)
7.100 Wahl stress factor K s = 4C-1 /4C-4+0.615/C
= 4(10) -1/4(10)-4 + 0.615/10
K s =1.1448
Ʈ = K s 8 P C/π d²
480 = 1.1448 ×8×135×10/π ×d²

92
d² = 8.199
d= 2.86 mm
d= 3 mm
(ii)Mean coil diameter (D)
Spring index C = D/d
D =c×d
D = 10×3
D = 30 mm
(iii)Outside diameter of the spring (Do )
Do = D +d = 30+3
Do = 33 mm
(iv)Number of Active turn (n)
An increase in load 135- 90 = 45 N cases deflection of 7.5 mm
y= 8 P C³ n/Gd
7.5 = 8 ×45 × 10³×n/ 0.8 × 105 × 3
Assume end of the spring coil is square and ground
Total number of coil nt = n +2
= 5+2
nt =7
(v)free length of the spring (Lf )
Solid length Ls = dn+2d = (3×5)+(2×3)= 21 mm
Free length Lf = Ls + y = 21 +7.5 = 28.5 mm
Result:-
d, Do , D , n , Lf
93
3) A helical spring is subjected to a load varying from 400N to 1000N
having the spring index of 6 and the design factor of safety is 1.25, the
compression of the spring at the maximum load is 30mm,Design the
helical compression spring take the yield stress in shear as 110N/mm²
endurance shear as 350 N/mm², and the modulus of rigidity for the spring
material as 80× 10³ N/mm²?
Given:-
Pmin = 400N
Pmax = 1000N
C =6
ns = 1.25
y=30 mm
Ʈy = 110 N/mm²
Ʈ−1 = 350 N/mm²
G = 80×10³N/mm²
To find:-
Design of helical spring
Solution:-
Mean load on the spring Pm = Pmax +Pmin /2
Pm = 1000+400/2
Pm = 700 N
Amplitude load on the spring Pa = Pmax -Pmin /2
= 1000-400/2
Pa = 300 N
Direct shear stress K sh = 1+0.615/C
= 1+ 0.615/6
K sh = 1.1025
94
Mean shear stress
D.B. 7.102 Ʈm = 8 K sh Pm C/πd²
Ʈm =8× 1.1025 × 700 × 6/ πd²
Ʈm =11791.47/d²
Amplitude shear stress
Ʈa = 8K s Pa C/ πd²
= 8×1.26× 300 × 6/ πd²
For repealed loading 1/n = Ʈm - Ʈa /Ʈy + 2Ʈa / Ʈ−1

5811.51
1/1.25 = 1179.14/d²-5811.51/d²+2× /350
d2
1/1.25 = 5879.96/d²/110+11623.02/d²
1/1.25 = 54.36/d² +33.2/d²
1/1.25=87.57/d²
d= 109.46
d= 10.46mm
Spring index C = D/d
D = C× d
D = 6 × 10.6 =63.6 mm
(iii)Number of Active turns (n)
7.100 y= 8 Pmax C³n/Gd
30 = 8× 1000 × 6³ × n/80 × 10³ × 10.6
n= 14.72
n=15
Assume end of the coil is squared and grand
7.101 nt = n+2
95
nt = 15+2 = 17
(iv)Solid length of the spring (Ls )
Ls = dn+2d
= (10.6× 15) + (2 × 10.6)
Ls = 180.2 mm
(v)free length of the spring (Lf )
Lf =Ls + y
= 180.2 +30
Lf = 210.2 mm
(vi)Pitch of the coil (p)
P = Lf -Ls /nt + d
P = 210.2 -180.2 /17+11
P = 12.76 mm
(vii)Helix angle of the coil (α )
α = tan−1 (P/πD)
= tan−1 (12.76/π × 63.6)
α = 3.65°
(viii)Spring rate(q)
q= Pmax /y
q= 1000/30
q= 33.33 N/mm
Result:-
d, D, n , nt , Ls , Lf , P, α , q
96
4)A relief value must blow off at a pressure of 1.25 Mpa and should lift
by 6mm for a 6% increase in pressure .The value diameter is 65mm .Take
the spring index as 8 maximum allowable shear stress of the spring
material is 600N/m² .The diameter of the available spring wires in mm
13.14.15.16 and 18. Modulus of rigidity is 81370N/mm consider Wahl’s
correction factor Take inactive numbers of turns as 1 design the value
spring?
Given:-
Pv = 1.25Mpa = 1.25N/mm²
y= 6 mm
Increase in Pv = 6%
dv = 65 mm
C =8
Ʈmax = 600 N/mm²
d= 13, 14, 15, 16, 18
G = 81370 N/mm²
In Active no of turns = 1
To find :-
Design the valve spring
Solution:-
(i)Diameter of the spring wire(d)
(Area of the value ) Av =π × dv ²/4
= π × 65²/4
Av = 3318.3 mm²
(load on the spring ) P1 = Pressure ×Area
= 1.25×3318.3
P1 = 4147.87 N
97
Pv max = Pv +increase in Pr
= 1.25+6/100 ×1.25
Pv max = 1.325 N/mm²
(maximum load on the value ) P2 = Pv max ×value Area
= 1.325 ×3318.3
P2 = 4396.75N
K s = 4C-1 /4C-4 +0.615/C
Ks = (4× 8)-1 /(4× 8) − 4 + .615/8
Ks = 1.184
Ʈmax = K s 8P2 C/πd2

8
600 = 1.184× 4396.75 ×
πd2
d² = 176.75
d = 13.29 mm
Choose d = 14 mm
Spring Index C =D/d
D = C× d
= 8× 4
D = 112 mm
(iii)Outer diameter of the coil (Do )
Do = D+d
= 112+14
Do = 126 mm
(iv)Number of active turns(n)
P = P2 -P1
98
= 4396.75 – 4147.87
P = 248.88 N
y= 8P C³n/G.d
n
6 = 8× 248.88 × 83 × × 14
81370
n= 6.7
Total no of coils nt =n+1 = 6.7+1 = 7.7 turns
(v)Free length and solid length of the coil (Lf +Ls )
Solid length = Ls
Assume end of the spring coil is squared and ground
Ls = dn + d
= 14× 6.7 × +14
Ls = 107.8 mm
Lf = Ls +deflection
= 107.8 +6
Lf = 113.8 mm
(vi)Pitch of the coil (p)
P = Lf - Ls / nt + d
= 113.8 -107.8 /7.7+ 14
P = 14.78 mm
(vii)Helix Angle of the coil (∝)
∝ =tan−1 (P/πD)
=tan−1 (14.78/π × 112)
∝ = 2.4°
(viii) Spring rate (or) stiffness of the spring (q)
q= Gd/8C³n
99
14
= 81370× × 83 × 6.7
8
q = 41.51 N/m
Result:-
d, D, Do , n , nt , Lf , Ls , P, ∝ , q
5)A close coiled helical compression spring has plain ends and is to fit
over a 2.5mm diameter rod When a compression force of 100N is applied
to the spring it compresses by 50mm.If the spring has a preferred wire
diameter 4 mm, and the spring material has a maximum allowable shear
stress of 180MN/m² and a modulus of rigidity of 81GN/m² Determine the
(i)Mean coil diameter of the spring
(ii) diameter material clearance b/w the spring and thread
(iii)Number of coil in the spring
(iv)Solid length of the spring
Given:-
End condition = plain end
Diameter of rod = 25 mm
Force P = 100 N
Deflection y = 50 mm
Wire diameter d = 4 mm
Ʈ = 180 MN/m² = 180N/mm²
G = 81 GN/m² = 81× 10³N/mm²
To find :-
(i)mean coil diameter ‘D’
(ii)Diametrical clearance
(iii)Number of coils n
(iv)Solid length Ls
100
Solution :-
(i)Wahl stress factors K s = 4C-1/4C-4 +0.615/C
= 4(D/d)-1/4(D/d)-4 +0.615/(D/d)
= 4D-d /4D-4d +0.615d/D

4
K s = 4D-4/4D-16 +0.615×
D
Allowable shear stress Ʈ = K s 8PD/πd3

100
180 = (4D-4/4D-16 +2.46/D)× 8 × × 43
π
180 = (4D-4 /4D-16+2.46/D) × 3.979D
180/3.979 = 4D²-4D/4D-16 +2.46
42.77 = 4D² -4D/4D-16
(4D-16) 42.77 =4D²-4D
171 D - 684.32 = 4D²- 4D
D = 39.44 mm
D = 40 mm
(ii)Diameter clearance
40-4- 25 = 11mm
(iii)Deflection
y= 8PD³ n/ Gd⁴
50 = 8× 100 × 403 × n/80× 103 × 44
n= 20.25 coils
(iv)For plain ends solid length
Ls = d(n+1)
= 4(20.25+1)
Ls = 85mm
101
Result:-
D = 40 mm
Clearance = 11 mm
n=20.25
Ls = 85 mm
4.2 Design of Leaf spring:
6)Design a leaf spring for a truck to the following specification

maximum load on the spring 140KN, Number of spring 4 , material for
spring chromium vanadium steel ,permissible tensile stress 600N/mm²
minimum number of leaves , span of spring 1000mm permissible
deflection 80 mm, young’s modulus of the spring 200KN/mm² ?
Given:-
Maximum load on the spring 2P = 140 KN
Number of spring ns = 4
σ= 600 N/mm²
No of leaves =10
Span of spring 2 L = 1000 mm, L = 500 mm
y= 80mm
E = 200 KN/mm² = 200× 10³ N/mm²
To find:-
(i)width of spring ‘b’
(ii)Thickness of leaf ‘t’
Solution:-
Load on the spring 2P = 140× 10³
2P = 140× 10³/4
P = 17500 N
D. B.7.104 Permissible stress σ = 6PL/nbt²
102
600 = 6× 17500 × 500/10× bt²
bt³ = 8750
D.B 7.104 y= 6PL³/ Enbt³
80=6× 17500 × 500³/200× 103 × 10 × bt 3
bt³ = 82031.25
bt² .t = 82031.25
8750 t = 82031.25
t= 82031.25/8750
t = 9.375 mm
t = 10 mm
b= 8750/t² = 8750/ 10² = 87.5 mm
b = 90 mm
Result:-
Width of leaf spring b = 90 mm
Thickness of the load t = 10 mm
7) Design a cantilever leaf spring to absorb 600N.m energy without

exceeding a deflection of 150mm, and a stress of 800N/mm².The material
of the spring is 600mm .The material of the spring is steel?
Given:-
Cantilever leaf spring energy absorbed E1 = 600N.m
Deflection y = 150 mm
σb = 800 N/mm²
L = 600mm
To find :-
(i)width of the leaf ‘b’
103
(ii)Thickness of the leaf t’
Solution :-
E1 = ½×P×y
600× 10³ = 1/2× P × 150
P = 8000N
σb = 6PL/nbt²
600
800= 6 × 8000 ×
nbt2
nbt² = 6× 8000 × 600/800
nbt² = 36000
Deflection of the spring
y=6PL³/Enbt³
E = 2× 105 N/mm²
150 = 6× 8000 × 600³/2 × 105 × nbt³
nbt³ = 345600
nbt².t = 345600
(36000) t = 345600
t=345600/36000
t= 9.6 mm
nb = 345600/t³
nb= 345600/9.6³
nb = 390.625
Standard width of size =80 mm
n= 390.625/80
n= 5
104
Result:-
Width of the leaf b = 80 mm
Thickness of the leaf t = 10 mm
Number of leaves n = 5
8)A shear elliptic leaf spring is of 1m long and is required to resist a

load of 50KN.The spring has 15 leaves, of which three are full length
leaves. The width of central band is 100mm All the leaves are to be
stressed to 420Mpa .The ratio of total depth to width is 3.Take E =
2.1× 105 Mpa. Determine the (i)Thickness and width of the leaves (ii)Initial
gap that should be provided between the fall length and graduated leaves
before assembly and (iii)load exerted on the band for the assembly ?
Given:-
Overall length of the spring 2L =1m = 1000 mm
Load on the spring 2P = 50 KN =P = 25 x10³ N
Number of full length leaves ne = 3
Number of graduated leaves ng = 12
Width of central band l = 100 mm
σb = 420N/mm²
Ratio of spring depth to width = n× t/b = 3
E = 2.1 × 105 N/mm²
To find:-
(i)Width of the leaves ‘b’
(ii)Thickness of the leaves ‘t’
(iii)Initial space ‘C’
(iv)load exerted on the band after the spring is

assembly Pb
105
Solution:-
(i)Total number of leaves ‘n’
n= ng +ne = 12+ 3 = 15
Total spring depth to width
n× t /b = 3
15t/b = 3
b=5t
Effective length of the leaves 2L
2L = 2L1 -l = 1000- 900 mm
2L = 900 mm
L =450 mm
Since all the leaves are stressed to the same stress when loaded
σb = 6PL/nbt²
420 =6× 25 × 10³ × 450/15 × 5t × t²
t³ = 2142.86
t = 12.89mm
t = 13 mm
b= 5 × 13
b= 65 mm
(ii)Initial space (x)
x = 6PL³/Enbt³
4503
= 6× 25 × 103 × × 105 × 15 × 65 × 13³
2.1
X = 30.38 mm
(ii)load exerted on the band after the space assembled (Pb )
Pb = 2ne × ng × P/n(2ng + 3ne )
106
= 2× 3 × 12 × 25 × 10³/15(2 × 12 + 3 × 3)
Pb = 3636.36 N
Result:-
b=65 mm
t = 13 mm
x= 30.38mm
Pb = 3636.36N
4.3 Design of Flywheel:
9)A multi cylinder engine is to run at a constant load at a speed of

500rpm on drawing the crank effort diagram to scale of 1 cm = 2500Nm
and 1cm = 60° the area above and below the mean torque line were
measured and found to be in order + 1.60 , -1.72, +1.68 . -1.91, +1.97, -
1.62.If the speed is to be kept within limits of +-1% of the mean speed
design the suitable type of flywheel?
Given:-
N =500rpm
w=2πN/60 = 2π × 500/60 = 52.35 rad/s
P = 7200 kg/m³
To find:-
Design the suitable type of flywheel
Solution :-
π π
1 cm = 60× = rad
180 3
I = moment of Inertia of flywheel
Turning moment 1 c.m = 2500Nm & crank angle 1 cm = 60°

π π
1 c.m = 60× = rad
180 3
π
1 c.m² on turning moment diagram = 2500 ×
3
= 2617.99 N.m
107
Total energy A = F
Energy at B = E+ 1.60
Energy at C = E +1.60 – 1.72 = E – 0.12
D = E -0.12 +1.68 = E +1.56
E = E+1.56 -1.91 = E-0.35
F = E-0.35 +1.97 =E +1.62
G = E+1.62-1.62 =Eenergy at A
We find that the energy is maximum at F and minimum at E
Maximum energy = E +1.62
Minimum energy = E -0.35
∆E = maximum energy – minimum energy
∆E = (E+1.62)- (E-0.35) = 1.97 cm²
∆E = 1.97× 2617.99
∆E = 5157.44 Nm
(fluctuation of speed +-1%) w1 -w2 = 2% w
(coefficient of fluctuation speed) K s = w1 -w2 /w =0.02 D.B.7.120
Maximum fluctuation of energy
∆E = Iw² Cs
5157.44 = I × (52.35)2 × 0.02

108
I = 94.09 kgm²
Dimensions of flywheel rim :-
t=thickness of the flywheel rim in meters and
b=width of flywheel rim in meters =2t
D.B. 7.120 σt =PV ²
6x10⁶=7200 x V²
V = 28.87 m/s
(peripheral velocity)
V = πDN/60
28.87 = π × D × 500/60
D =1m
Mass of the flywheel rim
∆E = Ex2 Cs
5157.44 = E x2 x0.02
E = 128936 N.m
E = ½ mv²
128936 =1/2mx (28.76)²
m= 311.76 kg
meters of the flywheel rim (m)
D.B. 7.120 m= bhπ D ρ
311.76 = 2h xh x π x 1 x 7200
h= 0.083 m = 83 mm
b=2h = 2 x 83 = 166 mm
Result :-
D = 1 m , m = 311.76 kg, h = 83 mm
b = 166 mm
109
UNIT-5
BEARINGS
5.1 Design of Journal Bearing :
1)Design a journal bearing for a centrifugal pump with the following

data, Diameter of the journal =150 mm, Load on bearing 40KN, speed
of the journal 900rpm?
Given:-
D = 150 mm
W = 40KN = 40x10³
n= 900 rpm
To find:-
Design a journal bearing
Solution:-
Step 1:-
D.B.7.31 L/ D = 1 to 2 =1.5
L = 1.5 x 150
L = 225 mm
Step 2 :-
P = W/LD
= 4000 /150 x225
P = 1.185 N/mm²
Step 3 :-
Selection of lubricating oil
The minimum value of Zn/P from D.B.7.31

𝑍𝑛
( )𝑚𝑖𝑛 = 2844.5
𝑃
P =1.185 N/mm
110
P = 11.85 kgf/cm²
𝑍𝑚𝑖𝑛 = 2844.5 x11.85/900
𝑍𝑚𝑖𝑛 = 37.45 centipoise
D.B.7.41 40 cp and 60° c the net standard higher value of SAE 40 oil
Z = 40 c.p
Step 4
D.B.7.34 𝜇 = 33.25/1010 (Zn/P) (D/C) + k
C- Diametrical clearance assumed 150 microns
D/C = 150/150 x10−3 = 1000
From graph K = 0.002 for 0.75 < L/D < 2.8
𝜇 = 33.25/1010 (40x900/11.85 ) x1000 +0.002
𝜇 = 0.0121
Step 5
D.B 7.34
Hg = 𝜇 . w.v
V = 𝜋DN/60
V =𝜋 x 0.15x900/60
V = 7.0686 m/s
Hg = 0.0121 x40000x7.0686
Hg = 3421.56 w
∆𝑡 = ½ (𝑡𝑜 - 𝑡𝑎 )
∆𝑡 = ½ (60 -28 )
∆𝑡 = 16° C
D.B 7.34 𝐻𝑑 = (∆𝑡+18 )² LD /K = (16+18)² x0.15 x0.225/ 0.484
𝐻𝑑 = 80.6 W
111
𝐷𝑏 = D +C
= 150 +0.15
𝐷𝑏 = 150.15 mm
D.B.7.30 Rubber or modulated plastic laminate
Result:-
D, L , 𝐷𝑏 , C , SAE 40, 𝑡𝑜 = 60° 𝐶, 𝑡𝑎 = 28 ° 𝐶
Artificial cooling, Rubber or modulated
2)Design a journal bearing of 12 Mw, 1000 rpm, Steam turbine which

is supported by two bearings. Take the atmospheric temperature as 16 °
C and operating temperature of oil as 60° C assume the viscosity of oil
as 23 centipose ?
Given:-
P = 12 Mw = 12 x10⁶ W
n= 1000 rpm
𝑇𝑎 = 16° C
𝑇𝑜 = 60 ° C
Z = 23 CP = 23 x10−3 N.S/m²
To find:-
Solution:-
D.B.7.31 P = 7 to 20 kgf/cm²
Zn/ P = 1422.3
23 x1000/P = 1422.3
P = 16.17 kgf/cm² = 1.617 N/mm²
L/D = 1 to 2
L/D = 1.5
112
P = 2𝜋N(𝑀𝑡 )/60
12 x10⁶ = 2𝜋 x 1000 (𝑀𝑡 ) /60
𝑀𝑡 = 114591.56 N.m
D.B.7.30 Heavy Babbitt liner on steel or cast iron
Tensile yield strength 70 kgf/cm²
FOS = 1.5
Ʈ = 0.55 𝜎𝑦 /FOS
Ʈ = 0.55 x 700 /1.5
Ʈ = 256.68 N/mm²
𝜋
W.K.T 𝑀𝑡 = Ʈ D³
16
114591.56x10³ = 𝜋 /16 x 256.67 xD ³
D = 131.5 mm
D = 132 mm
L/D = 1.5
L/D = 132 (1.5)
L = 198 mm
C = 150 microns = 150 x10−3 mm
𝜇 = 33.25 /150 x10−3 = 880
K = 0.002 for 0.75 < Z/D < 2.8
𝜇 = (33.25/1010) ) (23 x1000/16.17) x 880 +0.002
𝜇 = 0.00616
𝜋𝐷𝑁 1000
V = = 𝜋 × 0.132 × = 6.91 m/s
60 60
W = PDL = 1.617 x133 x 198 = 42261.9 N
Hg = 𝜇w v
Hg = 0.00616 x42261.9 x6.91
113
Hg = 1799.3 w
∆𝑡 = ½ (𝑡𝑜 - 𝑡𝑎 )
∆𝑡 =1/2(60 -16 )
∆𝑡 = 22 ° C
Hd= (∆𝑡 + 18)²𝐿𝐷/𝐾
= (22+18)² x 0.132 x0.198 /0.484
Hd = 86.4 w
Hg > Hd
Artificial cooling is Need
D.B.7.41 23 CP and 60° 𝐶 , SAE 30 oil Selected.
Result :-
D, L ,C, 𝐷𝑏 , SAE 30 oil, 𝑡𝑜 , 𝑡𝑎 Artificial cooling , Heavy Babbitt liner
3)Design a journal bearing for centrifugal pump for the following data,
Load on the journal 12 KN, Diameter of the journal 75 mm, Speed 1440
rpm, Atmosphere temp 16° C and operating temp 60° absolute viscosity
of oil at 60°𝐶 23 centipoise ?
Given:-
W = 12 KN
D = 75 mm
n= 1440 rpm
𝑡𝑎 =16 °𝐶
𝑡0 = 60°𝐶
Z = 23 centipoises
To find:-

114
Solution :-
Step 1 :
L/D = 1.5
L = 1.5 (75 )
L = 112.5 mm
Step 2:
P = W/LD
= 12000 / 112.5 x75
P = 1.4 N/mm² = 14 kgf/cm²
Pressure (0.7 to 1.4 N/mm² ) D.B.7.31
Step 3 :
D.B.7.41 Z = 23 CP and 60°𝐶
SAE 30 oil will be selected
Step 4:
D/C = 75/150x 10−3 =500
L/D = 112.5/75 = 1.5
K = 0.002 for 0.75 < L/D < 2.8
𝜇 = 33.25 /1010 (Zn/P) (D/C) +k
𝜇 = 33.25 /1010 (23 x1440/14) x 500 +0.002
𝜇 =0.005933
Step 5:
Hg = 𝜇 w v
V = 𝜋 D N/60 = 𝜋 x0.075 x1440/60
V = 5.66 m/s
Hg = 0.05933 x12000 x 5.66

115
Hg= 402.97 w
∆t = ½ (𝑡𝑜 - 𝑡𝑎 )
= ½ (60-16)
∆t = 22 °𝐶
Hd = (∆t+18)² 𝐿𝐷/𝐾
= (22 +18 )² x0.1125 x0.075 /0.484
Hd = 27.8 w
𝐷𝑏 = D+C
= 75 +0.15
𝐷𝑏 = 75.15 mm
Material PSG D.B. 7.30 Rubber (or)modulated plastic

laminate
Result:-
D, L , 𝐷𝑏 , C , SAE 30 , 𝑡𝑜 , Artificial cooling , Rubber (or)

modulated plastic
4)A 50mm diameter journal bearing rotates 1500 rpm , L/D =1 , radial
clearance is 0.05mm, minimum film thickness 0.01mm , calculate the
maximum radial load that the journal bearing can carry and this load
, calculate the power lost in friction and increase in the oil temperature
assumed Hg = Hd Absolute viscosity = 20 x10³ Pas , SP gravity of oil
0.88, SP. heat of oil 2.1 kJ/kg °𝐶 ?
Given:-
D = 50 mm = 0.05 m
n= 1500 rpm
L/D = 1
C /2 = 0.05 mm
ℎ𝑜 = 0.01 mm
116
L = 50 mm
Z = 20 x 10−3 pas = 0.02 N S/m²
S = 0.88
CP = 2.1 KJ/kg ‘c = 2.1 x10³ J/kg’c
To find :-
(i)Radial Load (w)
(ii)Operating temperature (∆𝑡)
(iii)Power lost (H)
Solution:-
D.B.7.60 B= 360° , L/D = 1
Minimum flim 2 ℎ𝑜 /C = 0.01/0.05 =0.2 S = 0.0446
S = 𝑍 ′ 𝑛′ /P (D/C)²
0.0446 = 0.002x(1500/60) /P x (50/0.1)²
P = 2802690.58 N/m²
P = W/LD
2802690.58 = W/0.05x 0.05
W = 7006.73 N
𝜋𝐷𝑁
V =
60
V = 𝜋 x0.05 x 1500 /60
V = 3.93 m/s
D.B.7.40
B = 360° , S = 0.0446
𝜇 (D/C) =1.7
𝜇 = 1.7 x 0.1 /50
𝜇 =3.4x 10−3
117
Hg = 𝜇 w v
= 3.4 x 10−3 x 7006.73 x3.93
Hg = 93.62 w
Heat generated = Heat dissipated
Hd = 93.62 w
D.B. 7.36
Q /r(C/2) NL = 4.62 4q/D C 𝑛′ L = 4.62
Q = 4.62 x r x(C/2) NL
Q = 4.62 x50/2 x0.05 x(1500/60) x50
Q = 7218.75 mm³/s
Q = 7218.75 x 10−9 m³/s
m= Density x discharge
m= 0.88 x1000 x7218.75 x 10−9
m= 6.3525 x110−3 kg/s
W.K.T
Hd = mCp∆t
93.62 = 6.3525 x10−3 x2.1x10³x∆𝑡
∆𝑡= 7.02°𝐶
Result:-
W = 7006.73 N, ∆𝑡 = 7.02°𝐶 , H = 93.62 W
5.2 Design of Ball Bearing :
5)Select a bearing for a 40 mm diameter shaft rotating at 400 rpm .Due

to a bevel gear mounted on the shaft , the bearing will have to withstand
a 5000 N radial load and a 3000 N thrust load. The life of the bearing is
expected to be at least 1000 hours ?
Given:-
D = 40 mm
118
N = 400 rpm
𝐹𝑟 = 5000 N
𝐹𝑎 = 3000 N
𝐿ℎ = 1000 hrs
To find:-
Bearing type
Solution :-
𝐹𝑎
= 3000/ 5000 = 0.6
𝐹𝑟
𝐹𝑎
< 0.7 , a single row deep grove ball bearing may be
𝐹𝑟
suitable
Shaft 40 mm , PSG D.B. 4.13 ,Select SKF 6208 bearing

,Static load rating
𝐶𝑜 = 1600 Kgf = 16000 N
Dynamic load rating C = 22800 N
𝐹𝑎 / 𝐶𝑜 = 3000/ 16000 = 0.1875
D.B. 4.4 𝐹𝑎 / 𝐶𝑜 = 0.1875 , e = 0.33875(interpolation)

𝐹𝑎
= 3000/5000 = 0.6 > e
𝐹𝑟
P.S.G. 4.4 radial load factor
X = 0.56 , Y = 1.23 (interpolation)
D.B. 4.2 Service factor 1.2
Equivalent load
P= ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
P = (0.56 x 5000 +1.23 x3000 ) x 1.2
P = 7788 N
D.B.9.6 Corresponding 400 rpm and 1000hrs of life loading ratios
119
C/P = 2.9
C = 2.9 x7788
C = 22588.2 N
Since, the dynamic load rating of SKF 6208 bearing , is more than the
required dynamic load capacity, the select bearing is suitable
Result :-
SKF 6208 bearing
6)Select a suitable deep groove ball bearing for supporting a radial

load of 10 KN and an axial load of 3KN for a life of 4000 hrs at 800
rpm. Select from series 63. Calculate the expected life of the select
bearing?
Given:-
𝐹𝑟 = 10 KN
𝐹𝑎 = 3 KN
n= 800 rpm
𝐿ℎ = 4000 hrs
Bearing series 63
To find :-
Bearing size, expected life
Solution:-
𝐹𝑎
= 3000 /10000 = 0.3 >e
𝐹𝑟
D.B.4.4 X = 0.56 , Y= 1.5
Assume service factor S= 1.2
Equivalent load
P = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
P = (0.56x1000 +1.5 x3000) x 1.2
P = 12120 N
120
D.B.4.6 800 rpm and 4000 hrs
C/P = 5.75
C = 5.75 x 12120 = 69690 N
D.B.4.6 Corresponding to C > 69690 N the bearing SKF

6313 is selected which has the load capacity of C = 72000 N
C/P = 72000/ 12120 = 5.95
D.B.4.6 Corresponding 800 rpm and C/P = 5.95
𝐿ℎ = 4300 hrs
Expected life of the selected bearing
L = 60 n 𝐿ℎ /10⁶
= 60 x800 x4300 /10⁶
L = 206.4 million revolutions
Result :-
SKF 6313 bearing is selected
L = 206. 4 million revolutions
7)Find the rated load of a deep groove ball bearing for the following
load cycle
S.No Radial load(N) Axial load (N) % of

time
1. 3000 1000 15
2. 3500 1000 20
3. 3500 100 30
4. 500 2000 35
Also find the 90% life of ball bearing used is 6207 with dynamic
capacity 19620N?
Given:-
121
Radial load 𝐹𝑟 = 3000 N , 𝐹𝑎 = 1000 N, 𝑡1 = 15 %
𝐹𝑟 = 3500 N, 𝐹𝑎 = 1000 N, 𝑡2 = 20%
𝐹𝑟 = 3500 N, 𝐹𝑎 = 100 N, 𝑡3 = 30%
𝐹𝑟 = 500 N, 𝐹𝑎 = 2000 N, 𝑡4 = 35%
C = 19620 N
To find:-
Rated load , 90% life of ball bearing
Solution:-
𝐹𝑎
= 1000 /3000 = 0.333 > e
𝐹𝑟
D.B.44 ( Radial load factor) X =0.56 , Y = 1.2
D.B. 4.2 S = 1.5 (Service factor )
Equivalent load 𝐹1 = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
= (0.56 x3000+ 1.2 x1000) x1.5
𝐹1 = 4320 N
𝐹2 = (X 𝐹𝑟 + Y 𝐹𝑎 ) S
= (0.56 x3500 + 1.2x1000) x1.5
𝐹2 = 4740 N
𝐹3 = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
= (0.56 x3500+ 1.2x100 )1.5
𝐹3 = 2940 N
𝐹4 = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
= (0.56 x 500+1.2 x2000 ) 1.5
𝐹4 = 4020
𝐹𝑚 = (𝐹1 ³𝑛1 𝑡1 +𝐹2 ³𝑛2 𝑡2 + 𝐹3 ³𝑛3 𝑡3 + 𝐹4 ³𝑛4 𝑡4 / Σ𝑛 )⅓
122
𝐹𝑚 = {(4320³𝑛1 0.15)+(472 0³𝑛2 0.2) + 2940³𝑛3 0.3) +
(4020³𝑛4 0.35))/n+n+n+n}⅓
𝐹𝑚 = 2513.07 N
Equivalent P = 𝐹𝑚 = 2513.07N
Loading ratio C / P = 19620/2513.07 = 7.81
Assuming the speed of bearing as 1000rpm
C/P = 7.81
𝐿ℎ = 7940hrs
Result :-
Equivalent load P = 2513.07N
Rated life 𝐿ℎ = 7940 ℎ𝑟𝑠
8)A single row deep groove ball bearing no 6002 is subjected to an

axial thrust load of 1000 N and a radial load of 2200 N, Find the
expected life that 50% of the bearings will complete under this condition?
Given:-
Bearing 6002
𝐹𝑎 = 1000 N
𝐹𝑟 = 2200 N
To find:-
Expected life 50% of the bearing
Solution:-
D.B.4.14 𝐶𝑜 = 28500N
C = 55900 N
𝐹𝑎 /𝐶𝑜 = 1000 /28500 = 0.035
D.B.4.4
𝐹𝑎 /𝐶𝑜 = 0.035
The value of e = 0.235 (by interpolation)

123
𝐹𝑎
= 1000 /2200 = 0.454 > e , from D.B.4.4
𝐹𝑟
X = 0.56 , Y = 1.83
D.B. 4.2 S = 1.1 to 1.5 say 1.3
Equivalent load P = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
= (0.56 x 2200 +1.83 x1000 ) 1.3
P = 39806 N
𝐶
L= ( )𝑏
𝑃
= (55900/ 39806 )³
L = 2.77 million rev
(b=3 for ball bearing)
Equivalent life at 50% reliability (𝐿50 ) is

obtained from
𝐿50 /𝐿90 = ln (1/𝑅50 )/ln (1/𝑅90 )1/𝑏
𝐿50 /2.77 = ln (1/0.5)/ln (1/0.90)1/1.17 = 5
𝐿50 = 5 x2.77
𝐿50 = 13.85 million revolutions
Result:-
𝐿50 = 13.85 million revolutions
9)A 30BCo3 deep groove ball bearing is to operate at 1600 rpm and
carries 8KN radial load and 6 KN thrust load. The bearing is subjected to
a light shock load. Determine the rating life of the bearing?
Given:-
Bearing type 30BCo3
N=1000 rpm
𝐹𝑟 = 8 KN = 8000 N
124
𝐹𝑎 = 6 KN = 6000 N
To find :-
Rating life of the bearing
Solution:-
From PSG D.B 4.14 (SKF 6306 ) bearing
𝐶𝑜 = 1460 kgf = 14600 N
C = 2200 kgf = 22000 N
𝐹𝑎 /𝐶𝑜 = 6000 /14600 = 0.411
From PSG D.B. 4.4
X = 0.411 y =?
𝑥1 = 0.25 𝑦1 = 0.37
𝑥2 =0.5 𝑦2 = 0.44
Y = 𝑦2 + (𝑦1 - 𝑦2 ) x (x- 𝑥2 )/( 𝑥1 − 𝑥2 )
= 0.44 +(0.37- 0.44) x (0.411 – 0.5)/ (0.25- 0.5)
Y = 0.415
𝐹𝑎
= 6000/8000 = 0.75
𝐹𝑟
0.75 > 0.415
X = 0.411 , y =?
𝑥1 = 0.25 , 𝑦1 = 1.2
𝑥2 =0.5 , 𝑦2 = 1
Y = 1 +( 1.2 -1 ) x (0.411 -0.5 )/ (0.25 -0.5 )
Y = 1.07
X = 0.56 , y = 1.07
From PSGD.B. 4.2 S = 1.5
125
P = ( X 𝐹𝑟 + Y 𝐹𝑎 ) S
= (0.56 x8000+ 1.07 x 6000 )x1.5
P =16350 N
From PSGD.B. 4.6 for 1600 rpm
C/P = 22000 / 16350 = 1.34 , 𝐿ℎ = 25 hrs
L= 60 n𝐿ℎ /10⁶
L = 60 x1600 x25 /10⁶
L= 2.4 million rev
Result :-
L = 2.4 million rev
126
TWO MARKS QUESTIONS AND ANSWERS
UNIT-1
1. What is adaptive design? Where it is used? Give example
It is a design process where a new product is developed just by

making small changes to the existing product. It is used where no or
limited scope is available to go for an entirely new design. Example
geared bicycle, die design for a small sized product which is similar to an
existing large sized product.
2. What are the various process of design process?
 Recognition of need
 Definition of problem
 Synthesis
 Analysis and optimization
 Evaluation
 Presentation
3. Write down the factors influencing machine design?

 Strength and stiffness
 Surface finish and tolerances
 Manufacturability
 Ergonomics and aesthetics
 Working atmosphere
 Wear and hardness requirement
 Cooling and lubrication
 Safety and reliability
 Noise requirement
 Cost
4. What you mean by optimum design?

Optimization is the process of maximizing a desired quantity or
minimizing an undesired one.
5. What are the various optimization methods available?

 Optimization by available
 Optimization by intuition
 Optimization by trail error
127
 Optimization by numerical algorithm
6. Which are the mechanical properties of the metals?
Strength, stiffness, toughness, ductility, malleability are the

mechanical properties of metals.
7. Describe material properties hardness, stiffness, and resilience?
 Hardness is the ability of material to resist scratching and

indentation.
 Stiffness is the ability of material to resist deformation under
loading.
 Resilience is the ability of material to resist absorb energy and to
resist shock and impact load.
8. Mention some standard codes of specification of steels?
 Designation of plain carbon steels

These are denoted like x.C.y
Where x – number 100 times the average percent of carbon
y- number 100 times the average percent of manganese
 Designation of alloy steel

Alloy steels are denoted by arranging the alloying elements in the
descending order of the proportion. and, the average % of each
element is shown with its chemical symbol before that number
.the letter C is vomited here, and just the number is written to
denote carbon percentage. When alloying element is less than %
,that element is denoted by an underline, after written to two
decimal places.
Illustration 40Cr14
It means average carbon content is (40/100)=0.4% it means , it
can vary from say , 0.3% to 0.5%
Chromium is the principle alloying element with (14/100)=0.14%
It means, it can vary from say, 0.13% to 0.15%
128
9. Define tolerance?
Tolerance is the amount of variation permitted to a basic size. (or) Difference

between maximum and minimum limits of sizes is called tolerance.
Tolerance refers to the band in which a particular dimension is allowed to vary.
10. What are unilateral and bilateral tolerances?
A unilateral tolerance is tolerance in which variation is permitted only in

one direction from the specified direction. Example 1800+0.000/-0.060
Bilateral tolerance is tolerance in which variation is permitted in both

directions from the specified direction. Example 1800+0.060/-0.060
11. Define fit?
Fit refers to the relative tightness or looseness between two mating parts.
12. Differentiate between hardness and toughness of materials?
S.No Hardness Toughness

1. It refers the energy required to It refers the total energy
deform a material. which can be used before
break the materials
breaks.
2. Hardness is the characteristic Toughness is the
of solid material expressing its resistance to fracture of
resistance to permanent a material when
deformation. stressed .
3. Hardness is the ability to Toughness is the

withstand localized deformation measure of a materials
at the surface. ability to absorb energy
without breaking or
fracture.
13. For ductile material, which of the strength is considered for

designing a
a) Component subjected to static loading
b) Component subjected to fatigue loading.
129
For component subjected to static loading Yield strength is
considered .
For Component subjected to fatigue loading Endurance strength is

considered.
14. List at least two methods to improve the fatigue strength .

(i) Annealing
(ii) Plastic coating
(iii) Cold straining
15. Determine the force required to punch a hole of 20 mm diameter

in a 5 mm thick plate with ultimate shear strength of 250 Mpa .
Given data:
Diameter , d = 20 mm
Thickness, t = 5mm
Shear strength , Ʈ = 250 Mpa = 250 N/mm²
Solution :
Force, F = 𝜋𝑑𝑡. Ʈ = 𝜋 x 20 x 5 x 250 = 78539.8N = 78.54 kN
16. What is neutral axis in bending?

Neutral axis refers to the beam cross section where the
bending stress is neither tensile nor compressive. In other words,
bending stress is zero in the neutral axis .
17.State the difference between straight beams and curved beams .
Feature Straight beam Curved beam

Centroidal Are coincident Are not
axis and coincident
neutral axis Neutral axis is
shifted towards
the centre of
curvature
Stress Same throughout Different at

developed the section inner and outer
radii of the
section.
130
18. What is meant by eccentric loading ?
Eccentric loading refers to loads applied away from the
centroidal axis of the member.
19.How is stress concentration factor minimized by generalized

design aspect ?
1. Avoiding sharp corners .
2. Providing fillets
3. Use of multiple holes instead of single hole.
4. Undercutting the shoulder parts.
20. Differentiate the stress distribution in a bar subjected to axial

force and beam subjected to bending .
In axial case, the stress is uniform across the section . In bending ,

the stress is tensile on one side of the neutral axis and compressive on
the other.
21. A flat bar 32 mm wide and 12 mm thick is loaded by a steady

tensile load of 85kN. The material is mild steel with yield point stress of
315N/mm² . Find the factor of safety based on the yield point .
Solution :
Stress induced , 𝜎𝑑 = Load / Area
= 85 x 10 ³ / (32 x12 ) = 221. 34 Mpa
Factor of safety = yield stress / Stress induced
= 315 /221.34 = 1.42
22. List the important factors that influence the magnitude of factor
of safety
(i) Material properties
(ii) Nature of load
(iii) Presence of localized stresses
(iv) Presence of initial stress
(iv) Mode of failure
131
23.What are the factors that govern selection of materials while
designing a machine component ?
(i) Required material properties
(ii) Manufacturing ease
(iii) Material availability
(iv) Cost
24.What are the various theories of failure?
1. maximum principal stress theory
2. Maximum shear stress theory
3. Maximum principal strain theory
4. Maximum strain energy theory
25. State rankine’s theory ?
Failure occurs when the maximum normal stress is equal to the

tensile yield strength.
26. State St.Venant theory of failure ?
According to this theory failure occurs when the maximum strain

in the member equals the tensile yield strength
𝜎1 – 𝛾(𝜎2 + 𝜎3 ) (or) 𝜎2 – 𝛾 (𝜎3 + 𝜎1 ) (or) 𝜎3 –𝛾 (𝜎1 +𝜎2 ) = 𝜎𝑦
Whichever is maximum
Where 𝛾 = Poisson’s ratio
27. What is Gerber theory ?
Gerber parabola joins endurance stress and ultimate stress (like

Good man line) .According to Gerber method, the relationship between 𝜎𝑚 ,
𝜎𝑎 , 𝜎𝑢 and 𝜎−1 is given by
𝜎𝑎 = 𝜎−1 (1- (𝜎𝑚 /𝜎𝑢 )²)
From the equation itself it is evident that the relationship is of parabolic

nature. Gerber parabola is shown in figure.
132
28.Define the terms “Equivalent torque and equivalent moment”
Let 𝑀𝑏 and 𝑀𝑡 be the bearing and twisting moments acting on a

shaft , Then,
Equivalent torque , 𝑀𝑡𝑒 = √𝑀𝑏 ² + 𝑀𝑡 ²
And
Equivalent moment, 𝑀𝑏𝑒 = ½ (𝑀𝑏 + √𝑀𝑏 ² + 𝑀𝑡 ² )
29.What is stress concentration factor?
Stress concentration is the increase in local stresses at points of

rapid change in cross section discontinuities.
Stress concentration factor 𝐾𝑡 is the ratio of maximum stress at

critical section to the nominal stress (i.e) 𝐾𝑡 = 𝜎𝑚𝑎𝑥 / 𝜎𝑜
30.What are the methods to reduce stress concentration ?
i) Avoiding sharp corners
ii) Providing sillets
iii) Use of multiple holes instead of single hole

iv) Undercutting the shoulder parts.
31.Write Soderberg equation for machine component subject to
a) Combination of mean and variable torques
b) Combination of mean and variable bending moments
Ʈ 𝑒𝑞 = Ʈ𝑦 /n = Ʈ𝑚 + 𝐾𝑓 . Ʈ𝑎 . Ʈ𝑦 / Ʈ−1
𝜎𝑒𝑞 = 𝜎𝑦 /n = 𝜎𝑚 + 𝐾𝑓 . 𝜎𝑎 . 𝜎𝑦 / 𝜎−1
Where
Ʈ 𝑒𝑞 = Equivalent twisting
133
32.What are the methods used to improve fatigue strength ?
i) Cold working like shot peening , burnishing
ii) Heat treatments such as induction hardening , case hardening,

nitrating
iii) Pre- stressing (or) auto fretting
Unit- 2
1. What is meant by equivalent bending moment?
When a shaft is subjected to combined bending and torsion

loading, the design is usually based on the maximum shear stress
theory since the shafts are usually made of ductile materials. The
expression ½ (𝑀𝑏 + √𝑀𝑏 ² + 𝑀𝑡 ² ) is called equivalent bending
moment and is denoted by , 𝑀𝑏𝑒
Equivalent bending moment, 𝑀𝑏𝑒 = ½ (𝑀𝑏 + √𝑀𝑏 ² + 𝑀𝑡 ² )
While calculating the diameter of shaft , 𝑀𝑏𝑒 is equated to the theory

𝜋
of bending equation of x 𝜎𝑏 x d³ .
32
2. What are the types of stresses acting on a shaft ?
i) Shear due to torsion

ii) Stress due to bending
iii) Axial stress if an axial load acts.
3. A shaft of 70 mm long is subjected to shear stress of 40 Mpa and

has an angle of twist equal to 0.017 radian. Determine the diameter
of the shaft . Take G = 80 Mpa.?
Given data:
Length of the shaft , l = 750 mm
Shear stress, Ʈ = 40 Mpa = 40 N/mm²
Angle of twist , 𝜃 = 0.017 radian
Modulus of rigidity , G =0.8 x10⁵
134
To find:
Diameter of shaft , d
Solution:
We know that the torsional moment of the shaft
𝜋
𝑀𝑡 = x Ʈ x d³ and
16
𝜋 𝜋𝑑4
Angle of twist , 𝜃 = 𝑀𝑡 x l /GJ = x Ʈ x d³ x l / G x( )
16 32
= 2Ʈl / Gd
0.017 = 2 x 40 x750 / 0.8 x 10⁵ xd
d= 44.11 mm.
The standard diameter , d = 45 mm
4. Shaft A has diameter which is double the diameter of shaft B of

same material and transmit 80 kW if both shafts rotate at same
speed, what is the power transmitted by shaft B ?
Power transmitted by shaft A , 𝑃𝐴 = 2 𝜋𝑁𝐴 𝑀𝐴𝑡 /60

Similarly , power transmitted by shaft B, 𝑃𝐵 =2𝜋𝑁𝐵 𝑀𝐵𝑡 /60
For the same speed of both shafts , 𝑁𝐴 = 𝑁𝐵
Power ratio , 𝑃𝐵 /𝑃𝐴 = 2𝜋𝑁𝐵 𝑀𝐵𝑡 /= 2 𝜋𝑁𝐴 𝑀𝐴𝑡 = 𝑀𝐵𝑡 /𝑀𝐴𝑡

𝜋 𝜋
We know that 𝑀𝐴𝑡 = xƮ𝐴 x 𝑑𝐴 ³ and 𝑀𝐵𝑡 = x Ʈ𝐵 x 𝑑𝐵 ³
16 16
𝜋 𝜋
Power ratio, 𝑃𝐵 /𝑃𝐴 = x Ʈ𝐵 x 𝑑𝐵 ³ / xƮ𝐴 x 𝑑𝐴 ³ = 𝑑𝐵 ³/ 𝑑𝐴 ³
16 16
For power , 𝑃𝐴 = 80kW and 𝑑𝐴 = 3𝑑𝐵
Power transmitted by shaft B , 𝑃𝐵 = 𝑃𝐴 (𝑑𝐵 /𝑑𝐴 )³
= 80 x (1/2)³ = 10kW
5. Why a hollow shaft has greater strength and stiffness than solid
shaft of equal weight ?
Stresses are maximum at the outer surface of a shaft. A

hollow shaft has almost all the material concentrated at the outer
circumference . So , it has a better strength and stiffness for equal
weight.
135
6. What do you mean by stiffness and rigidity with reference to
shafts?
Stiffness is the resistance offered by the shaft for twisting

and rigidity is resistance offered by the shaft for lateral bending.
7. Why is maximum shear stress theory used for shaft ?
Since, the shaft is made of ductile material, thus , the

,maximum shear stress is used.
8. What is the significance of slenderness ratio in shaft design?
If slenderness ratio (l/k) is increased , the shaft deviates

from its ‘stub ’ behaviour and it is essential to consider the
buckling while designing the shaft.
9. Indicate the effects of providing key ways in the shaft ?
i) It reduces strengths of the shaft because of material

removal
ii) It increase stress concentration.
10. What is the main use of woodruff keys ?

A woodruff key is used to transmit less torque in
automotive and machine tool industries . The keyway in the shaft
is milled in a curved shape whereas the key way in the hub is
usually straight .
11. What types of stresses are developed in the key ?
Shear stress and crushing stress
136
12. Difference between keys and splines?
S.NO Keys Splines

1. A shaft which is A shaft which is
having single having multiple
keyway keyways.
2. Keys are used in Splines are used in

couplings automobiles and
machine tools.
13. Discuss forces on keys ?
i) Shear force
ii) Bearing force
iii) Tensile force
14. What is coupling ?
The elements which join two shafts are called coupling .It is
used to connect sections of long transmission shafts to the shaft of
a driving machine . Couplings are used to connect sections of long
transmission shafts and connect the shaft of a driving machine to
the shaft of a driven machine .
15. What are the various factors Involved in good shaft coupling ?
i) It must be able to accommodate misalignment of

shafts.
ii) It is ease of assembly and dismantling
iii) Long life.
16. Under what circumstances flexible couplings are used ?
i) They are used to joint the abutting ends of shafts

when they are not in exact alignment
ii) They are used to permit an axial misalignment of the
shafts without under absorption of the power which
the shafts are transmitting.
17. How is flexibility achieved in flexible coupling?

137
i) Kinematic arrangement such as loosely fit members
ii) Using rubber such as materials
18. Name any two of the rigid and flexible couplings?
1) Rigid couplings
i) Sleeve couplings
ii) Flange couplings
iii) Clamp couplings
2) Flexible couplings
i) Universal couplings
ii) Oldham’s couplings
iii) Pushed pin couplings
19. What is advantage of gear coupling?
i) Gear coupling is a rigid coupling with some

flexibility because of using curved external teeth.
ii) Strength of gear coupling is very high
iii) Most compact coupling for high power transmission
20. Suggest suitable couplings for i) Shafts with parallel misalignment

ii) shafts with angular misalignment of 10° .iii)shafts in perfect
alignment?
Flexible coupling such as spring coupling can be used for

shafts with parallel misalignment .Universal coupling is suitable for shafts
with angular misalignment of 10°. Rigid coupling can be used for shafts
in a perfect alignment .
Unit-3
1. What is a stud?
A stud is a bold in which the head is replaced by a threaded end.

It passes through one of the parts to be connected and is crewed in to the
part.
2. What do you understand by the single start and double start threads?
138
Single starts means that there is only one ridge wrapped around
the cylinder of the screw’s body. Each time that the screw’s body
rotates one turn (360°) , it has advanced axially by the one pitch
distance. Double -start means that there are two ridges wrapped
around the cylinder of the screw’s body. Each time that the
screw’s body rotates one turn (360°), it has advanced axially by
the two pitch distance.
3. Why are ACME threads preferred over square thread for power
screw?
Acme thread is easier to machine and is stronger than the
square thread. Acme threads are thicker and wider and they operate
better in environments with dirt and debris .
4. How is a bolt designed ? Give examples ?
A thread is designed with

i) Letter ‘M’ followed by
ii) Nominal diameter in mm and
iii) Pitch in mm (for fine pitches only)
5. What is the meaning of bolt M24 x 2?

Bolt nominal diameter , d = 24 mm and bolt pitch ,P = 2 mm
6. State three conditions where tap bolts are used ?
a. One of the parts beings joined has enough thickness to

accommodate threaded hole.
b. Insufficient space for a nut.
c. Material is strong enough so that the threads have long
life .
7. What are the various initial stresses developed due to screwing up
in the bolted joints ?
When a nut is tightened over a screw following stresses are
induced .
i) Tensile stresses due to stretching of the bolt
ii) Torsional shear stress due to frictional resistance at
the threads .
iii) Shear stress across threads
iv) Compressive or crushing stress on the threads
139
v) Bending stress if the surfaces under the bolt head or
nut are not perfectly normal to the bolt axis.
8. Determine the safe tensile load for a bolt of M20, assuming a

safe tensile stress of 40Mpa ?
From PSGDB 5.42, for M20,

Stress area, 𝐴𝑐 = 245 mm²
σ = P/ 𝐴𝑐
P = σ x 𝐴𝑐 = 40 x 245 = 9800 N
9. Give two examples of bolted joints subjected to a fatigue load?
i) Bolts in a crankshaft
ii) Bolts used in the head of a cylindrical pressure vessel
with repeated filling and discharging.
10. Under what force, the big end bolts and caps are designed ?
The big end bolts and caps are designed for inertia (𝐹𝑖 )
force due to reciprocating parts.
11. State the advantages of the threaded joints ?
i) High clamping
ii) Small tightening force requirement
iii) Easy manufacture
iv) Simple design.
12. Write down the advantages and disadvantages of threaded

fasteners?
i) High clamping
ii) Small tightening force requirement
iii) Easy manufacture
iv) Simple design.
13. Define the term self – locking of power screws
140
If the friction angle (∅ ) is greater than helix angle (𝛼 ) of the
power screw, the torque required to lower the load will be
positive indicating that an effort is applied to lower the load. This
type is screw is known as self - locking screw. The efficiency of
the self - locking screw is less than 50 %.
14. What is a gib? Why is provided in a cotter joint ?
Gib is an element made of mild steel with thickness equal

to the cotter . A gib is used in combination with the cotter to
provide the following advantages.
i) Reduce bending of socked end.
ii) Increase the bearing area of contact between the
mating surfaces.
15. What are the different types of cotter joints?
1. Socket and spigot cotter joint

2. Sleeve and cotter joint
3. Gib and cotter joint
16. Why are welded joints preferred over riveted joints ?
Material is saved in welding joints and hence the machine

element will be light if welded joints are used instead of riveted
joints. Leak proof joints can be easily obtained by welded joints
compared riveted joints.
17. How is welding classified ?
i) Forge welding
ii) Electric resistance welding and
iii) Fusion welding
18. Write any two advantages of welded joints over riveted joints?
i) Welded joints are lighter in weight and have higher

joining efficiency.
ii) Welded joints are leak proof and economical from the
point of view of cost of material and labours.
141
iii) The design of welded assemblies can be easily and
economically modified to meet the changing product
requirement.
iv) The quality and strength of welded joints also depend
upon the skill of the labours.
19. What are the disadvantages of welding?
i) It has poor vibration damping characteristics.

ii) Welding result in a thermal distortion of the parts,
there by including residual stresses. Therefore, it needs
stress relieving heat treatment.
iii) The quality and strength of welded joints also depend
upon the skill of the labours.
20. What is heat affected zone in welded joint? List the effects due to
that?
Heat affected zone refers to the area of the base metal

whose microstructure and properties are changed due to the heat
produced by the welding process. Cracks are possible in the heat
affected zone and hence weld quality is affected.
21. How are welding process classified ?
i) Forge welding.
ii) Electric resistance welding and
iii) Fusion welding.
22. When will the edge preparation need ?
If the two plates to be welded have more than 6mm,

thickness , the edge preparation should be carried out.
23. What is the minimum size for fillet weld?
If the required weld size from strength consideration is too

small how will you fulfil the condition of minimum weld size?
142
It is defined as the minimum size of the weld for a a given
thickness of the thinner part joined or plate to avoid cold cracking
by escaping the rapid cooling.
24. State the two types of eccentric welded connections?
1. Welded connections subjected to moment in a plane of

the weld.
2. Welded connections subjected to moment in a plane
normal to the plane of the weld.
25. What are the reasons of replacing riveted joint by welded joint in
modern equipment ?
Material is saved in welding joints and hence the machine

element will be light if welded joints are used instead of riveted
joints. Leak proof joints can be easily obtained welded joints
compared riveted joints.
26. Classify the rivet heads according to IS specifications ?
According to Indian standard specifications, The rivet heads

are classified into the following three types:
a) Rivet heads for general purpose (below 12 mm diameter
)according to IS: 2155- 1982 (Reaffirmed 1996).
b) Rivet heads for general purpose (From 12 mm to 48 mm
diameter ), according to IS: 1929- 1982 (Reaffirmed 1996).
c) Rivet heads for boiler work (from 12mm to 48 mm
diameter), according IS : 1928 -1961 (Reaffirmed 1996).
27. Name the possible modes of failure of riveted joint?
1. Crushing of rivets
2. Shear of rivets
3. Tearing of the plate at the edge
4. Tearing of the plate between rivets
28. What is meant by the efficiency of the riveted joint?
The efficiency of the riveted joint is the ratio of strength of

the joint at the weakest made of failure to the strength of un
punched plate in one pitch length of the joint
143
Ŋ= least of 𝐹𝑡 , 𝐹𝑠 and 𝐹𝑐 / p x t x 𝜎𝑡
Unit-4
1. Why are springs used in the machines?
Springs are used in the machines to provide cushioning

effect or reduce the effect of shock or impact loading.
2. State any two functions of springs?
i) To measure forces in spring balance, meters and

engine indicators.
ii) To store energy
3. Mention any four types of springs?
i) Helical spring
ii) Spiral spring
iii) Leaf spring
iv) Conical spring
v) Disc spring or Belleville springs
4. A helical spring of rate 12 N/mm is mounded on the top of

another spring of rate 8 N/mm .Find the force required to give
a deflection of 50 mm ?
Given data :
Stiffness of first spring 𝑞1 = 12 N/mm
Stiffness of second spring , 𝑞2 = 8 N/mm
Deflection , y = 50 mm
To find:
Force, P
Solution :
When two springs are arranged in series ,
1/q = 1/𝑞1 + 1/𝑞2
= 1/12 +1/8
Total stiffness , q = 4.8 N/mm
Stiffness , q = Load / Deflection
4.8 = P/ 50
144
P = 240 N
5. How will you find whether the given helical spring is a

compression spring or tension spring?
Ends of compression springs are flat whereas for tension

springs, hooks will be provided at the ends.
Coils will be slightly opened to facilitate compression
springs whereas in tension springs. Coils are very close.
6. Why leaf springs are made in layers instead of single plate?
To have equal stress and to achieve economical design, leaf

springs are made in layers.
7. Under what circumstance Belleville springs are preferred?
i) When large force is applied and deflection must be

small
ii) When space availability is small.
8. What is spring index ? or Define the term spring rate?
The ratio of mean or pitch diameter to the diameter of wire

for the spring is called spring index.
9. Define (a) Spring index (b) Spring rate?
The ratio of mean or pitch diameter to the diameter of wire

for the spring is called spring index.
Stiffness is the ratio of load to deflection .
Stiffness , q = Load /Deflection = P/ y
10. What is the effect of increase in wire diameter on the

allowable stress value?
Increase in wire diameter will increase the spring rate but it
reduces the spring index.
145
11. What are the different styles of end for helical compression
spring?
Plain end, plain and ground, squared and ground .
12. Define surging of springs?
Consider a helical spring resting on a rigid support at one

end . When a compressive load is applied suddenly to a helical
spring, the coil at the contact end gets deflected and sends a
compression wave that travels along the spring up to the
supported end where it gets deflected and travels back to the
deflected end. If there is no damping present , this wave
travels along the spring indefinitely. The material is subjected
to higher stresses which may cause early fatigue failure. This
effect is called spring surge.
13. What is surge in springs?
The material is subjected to higher stresses, which may

cause early fatigue failure . This effect is called as spring surge
14. When two concentric springs of stiffness 100 N/mm and 50

N/mm respectively are subjected to an axial load of 750 N,
what will be the deflection of each spring?
Given data:
𝑞1 = 100 N/mm
𝑞2 = 50 N/mm
P = 750 N
To find:
Deflection
Solution :
Total stiffness , q = 𝑞1 +𝑞2 = 100+50 =150 N/mm
Deflection = Load / stiffness = P/q= 750 /150
146
= 5 mm
15. For springs in series , the spring rates (stiffness) and

reciprocally- prove
When the springs are connected in series then total

deflection produced by the spring is equal to the sum of the
deflections of the individual springs
𝑌𝑒𝑞𝑢 = 𝑦1 +𝑦2
P/𝑞𝑒𝑞𝑢 = P/𝑞1 + P/𝑞2
1/𝑞𝑒𝑞𝑢 = 1/𝑞1 +1/𝑞2
16. Give some of the materials used for springs?
Material Safe Shear Modulus of

Stress, rigidity ,
N/mm² N/mm²
High carbon steel 480 0.8 x10⁵
Oil tempered 400 0.8 x10⁵

carbon steels
Stainless steel 325 0.7 x10⁵
Music steel 460 0.8 x10⁵

Phosphor bronze 225 0.48 x10⁵
Monel 250 0.67 x10⁵
Brass spring 160 0.4 x10⁵
Chromium 405 0.8 x10⁵

vanadium alloy
steel
Nickel silver 250 0.39 x10⁵
17. Where are Belleville springs used?
i) Stiffness required is very large

ii) Space availability is limited.
147
18. State any two important applications of leaf spring?
1. Structural members
2. Energy absorbing devices.
19. What is meant by semi elliptical leaf spring ?
The spring consist of number of leaves , which are held

together by U- clips. The long leaf fastened to the supported is
called master leaf. Remaining leaves are called graduated leaves.
20. What is nipping of laminated leaf spring? Discuss its role in

spring design ?
For the economical use of materials , designing all leaves

should be equally stressed, otherwise the master leaf will fail.
This condition can be obtained if the full- length leaves are
given a greater radius of curvature than that used in the
graduated leaves before the leaves are assembled to from a
spring . It will create an initial gap (x) between the leaves
called the nip. When the central bolt is tightened, the full-
length leaf will bend back and have an initial stress in a
direction opposite to that of the normal load. When the load is
gradually applied to the spring, the full – length leaf is first
relieved of this initial stress and then stressed in opposite
direction. Such a pre- stressing obtained by a difference of radii
of curvature is known as nipping.
21. Why Wahl’s factor is to be considered in the design of

helical compression springs?
When a wire is would in the form of helix, the length of

inner fibre of wire is reduced in comparison to the length of
outer fibre. It results in stress concentration at the inner fibre.
Wahl’s factor takes into account the effect of curvature as well
as shear stress correction factor.
148
22. What is the purpose of flywheel that is used in an IC engine?
A flywheel is a heavy rotating mass which is placed

between the power source and the driven member to act as a
reservoir of energy. The primary function of flywheel is to act
as an “energy accumulator”. It will absorb energy when
demand is less than the supply of energy and will release it
when the demand is more than the energy being supplied.
23. What is the function of flywheel?
A flywheel used in machine serves as a reservoir which

stores energy during the period when the supply of energy is
more than the requirement and releases it dulling the period
when the requirement of energy is more than the supply.
24. How does the function of flywheel differ from that of

governor?
A governor regulates the mean speed of an engine when

there are variations in the mean loads. It automatically controls
the supply of working fluid to engine with the varying load
condition and keeps the mean speed within the limits. It does
not control the speed variation caused by the varying load. A
flywheel does not maintain constant speed.
25.Define the term “fluctuation of energy “ ?
The difference between maximum and minimum energy

during the cycle is called fluctuation of energy (∆E).
∆E = 𝐸𝑚𝑎𝑥 - 𝐸𝑚𝑖𝑛
26.Define coefficient of fluctuation of speed in case of flywheels?
Coefficient of fluctuation of speed is the ratio of the

maximum change of speed to mean speed of the flywheel.
𝐾𝑆 = 𝑤𝑚𝑎𝑥 - 𝑤𝑚𝑖𝑛 / 𝑤𝑚𝑒𝑎𝑛 or
149
= 2(𝑤𝑚𝑎𝑥 - 𝑤𝑚𝑖𝑛 )/𝑤𝑚𝑎𝑥 +𝑤𝑚𝑖𝑛
27. What type of stresses is produced in a disc flywheel?
1. Radial stress
2.Tangential stress
28. What are the type of external forces act on connecting rod?
The combined effect of a) load on the piston due to the gas

pressure and due to inertia of the reciprocating parts, and b) the friction of
piston rings, pistons, piston rod and cross head.
1. Inertia of the connecting rod

2. The friction force in the gudgeon and crank pin bearings.
29.Why is piston end of a connecting rod kept smaller than the crankpin
end ?
The piston end of the connecting rod experiences less bending

moment than the crank end. Hence on the basis of beam of uniform
strength , the piston end of the connecting rod is smaller.
30. Define mechanical advantage of the lever?
It is the ratio of load and effort.
31. At what angle of the crank the twisting moment is maximum in the
crankshaft?
The crank angle for maximum moment usually lies between 25°
and 35° from TDC for petrol engine and between 30° and 40° for diesel
engines.
32.Define coefficient of fluctuation of speed and energy?
The difference between maximum speed and minimum

speed during a cycle is called maximum fluctuation of speed. The
ratio of maximum fluctuation of speed to the mean speed is called
coefficient of fluctuation of speed 𝐾𝑠 .
The difference between maximum and minimum energy
during the cycle is called fluctuation of energy (∆E).
150
∆E = 𝐸𝑚𝑎𝑥 - 𝐸𝑚𝑖𝑛
The ratio of fluctuation of energy to the mean energy is called

coefficient of fluctuation of energy
𝐾𝐸 = 𝐸𝑚𝑎𝑥 - 𝐸𝑚𝑖𝑛 /E = ∆E/E.
33.Define coefficient of fluctuation of speed and coefficient of

steadiness?
Coefficient of fluctuation of speed is the ratio of the maximum

change of speed to mean speed of the flywheel.
𝐾𝑆 = 𝑤𝑚𝑎𝑥 - 𝑤𝑚𝑖𝑛 / 𝑤𝑚𝑒𝑎𝑛 or
= 2(𝑤𝑚𝑎𝑥 - 𝑤𝑚𝑖𝑛 )/𝑤𝑚𝑎𝑥 +𝑤𝑚𝑖𝑛
Coefficient of steadiness is the reciprocal of the coefficient of

fluctuation of energy.
Unit-5
1. How are bearings are classified?
 Depending upon the type of contact

a. Rolling element bearing
b. Sliding element bearing
 Depending upon the type of rolling element

a. Ball bearing
b. Roller bearing
 Depending upon the load to be carried
a. Radial
b. Angular contact
c. Thrust bearing
2. What is a journal bearing? List any two applications?
151
A journal bearing is a sliding contact bearing which gives lateral
support to the rotating shaft.
3. Classify the sliding contact bearings according to the thickness of

layer of the lubricant between the bearing and the journal?
a. Thin film layout

b. Thick film layout
c. Hydrostatic bearings
d. Hydrodynamic bearings
4. For a journal bearing , the maximum operating temperature must

be less than 80°c why?
Temperature rise will result in the reduction of the viscosity

of the oil used in the bearing it would lead to metal to metal
contact there by affecting the bearing performance and life.
5. What is known as self acting bearing?
The pressure is created with in the system due to rotation of

the shaft known as self acting bearing .
6. In hydrodynamic bearing , what are factors which influence the

formation of wedge fluid film ?
i) The contact surfaces must meet at a slight angle to

allow the formation of the lubricant wedge.
ii) The fluid viscosity must be high to maintain an
adequate film thickness to separate the contacting
surfaces at operating speeds.
iii) The fluid must be adhering to contact surfaces for
conveyance into the pressure area to support the load
iv) The fluid must be distributing it self completely with
in the bearing clearance area.
v) The operating speed must be sufficient to allow the
formation and maintenance of the fluid film.
vi) The contact surfaces of bearings and journals must be
smooth and free from sharp surfaces that will disrupt
the fluid film.
152
7. Explain the term dynamic load carrying capacities of rolling
contact bearing?
Dynamic load rating is defined as the radial load in radial

bearings (or thrust load in thrust bearings ) which can be
carried for a minimum life of one million revolutions .
8. What is the application of thrust bearing?
Thrust bearings are used to support axial loads imposed on

the rotating elements.
9. List any four advantages to rolling contact bearings over sliding

contact bearings ?
i) Starting friction is slow

ii) Lubrication is simple
iii) It requires less axial space and more diametral space
iv) Heavier loads and higher speeds are permissible .
10. State the disadvantages of thrust ball bearing?
i) High initial cost

ii) Less capacity to withstand shock.
iii) Noisy operation at very high speed .
iv) Life is finite.
v) Design of bearing housing is complicated .
11. Define static capacity of bearing?
It is defined as load acting on a non rotating bearing under

which permanent deformation is 0.0001 times the ball or roller
diameter.
12. What are the modes of failure of rolling contact bearing ?
i) Flaking or surface fatigue .

ii) Peeling.
iii) Scoring.
iv) Fretting.
153
v) Creep.
13. What are the materials commonly used for manufacturing

contact bearing?
i) Lead based babbit.
ii) Tin based babbit.
iii) Leaded bronze.
iv) Copper lead alloy.
v) Gun metal.
vi) Phosphor bronze.
14. What is the advantage of teflon which is used for bearings?
Teflon has high fatigue strength, hardness and more resistant

to abrasive.
15. What is meant by life of antifriction bearings?
For an individual rolling bearing the number of revolutions

which one of the bearing rings (or washers) makes in relation
to the other rings (or washers) under the prevailing working
condition before the first evidence of fatigue develops in the
material of one of the rings (or washers) or rolling elements.
154

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UNIT-1

STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS

Classifications of Machine Design The machine design may be classified as follows:

In most cases, the designer’s work is concerned with adaptation of existing

This type of design depends upon mathematical formulae of principle of

(b) Empirical design.

(c) Industrial design.

(d) Optimum design.

(e) System design.

It is the design of any complex mechanical system like a motor car.

(f) Element design.

(g) Computer aided design.

General Considerations in Machine Design

Following are the general considerations in designing a machine component:

2. Motion of the parts or kinematics of the machine. The successful operation

(c) Constant velocity.

(d) Constant or variable acceleration.

3. Selection of materials. It is essential that a designer should have a thorough

1.2 Impact & shock loading problem:

1).An unknown weight falls from a distance of 15mmm on to a collar rigidly

Strain (e) = 𝑠𝑙/𝑙

Strain (e) = stress (σ)/young’s modulus (E)

½ P*(𝑠𝑙) = W*(h+ 𝑠𝑙)

1.3 Variable loading problem:

2).A circular bar is simply supported with a span of 0.5mand is subjected to a

𝑊𝑚𝑖𝑛 = 20KN = 20x10³ N

Factor of safety n = 1.5

Size factor K sz = 0.85

Surface factor K sf = 0.89

Ultimate strength σ u = 650N/mm²

Yield strength σ y = 450N/mm²

Endurance strength σ-1 = 350N/mm²

Diameter of shaft ‘d’

(maximum bending moment ) 𝑀𝑏𝑚𝑎𝑥 =𝑊𝑚𝑎𝑥 xl/4 = 45x10³x500/4

𝑀𝑏𝑚𝑎𝑥 = 5625x10³ N.mm

(minimum bending moment) 𝑀𝑏𝑚𝑖𝑛 = xl /4 =20x10³x500/4

𝑀𝑏𝑚𝑖𝑛 = 2500x10³ N.mm

(Average bending moment)

Mbm = Mbmax + Mbmin/2

Variable bending moment) 𝑀𝑎 = 𝑀𝑏𝑚𝑎𝑥 –𝑀𝑏𝑚𝑖𝑛 /2

(mean (or) average bending Stress) 𝜎𝑚 = Mbm/z

Variable bending stress) 𝜎𝑎 = Mba/z

1/n = 𝜎𝑚/ 𝜎𝑦 +𝑘𝑓. 𝜎𝑎 /𝜎−1 (𝑘𝑙 .𝑘𝑠𝑓 .𝑘𝑠𝑧 )

1/1.5 = 41.4x10⁶ /450d³ + 15.91x10⁶ x1/350x0.89x0.85xd³

1/1.5 = 92000/d³ + 6008875/d³

From P.S.G 7.20

Diameter of shaft d =63mm

3.A.shaft of diameter ‘d’ is subjected to a torque varying between 900Nm

𝑀𝑡𝑚𝑖𝑛 = 900 N.m = 900x10³ N.mm

𝑀𝑡𝑚𝑎𝑥 = 1800N.m = 1800x10³ N.mm

For given 𝜎𝑢 =650N/mm², 𝜎𝑦 = 480N/mm²

Assume C45 material is used,

For C45 from P.S.G1.9

From P.S.G 1.42 for reversed torsion, endurance shear stress

Mean torque 𝑀𝑡𝑚 = 𝑀𝑡𝑚𝑎𝑥 + 𝑀𝑡𝑚𝑖𝑛 /2

Amplitude torque 𝑀𝑡𝑎 = 𝑀𝑡𝑚𝑎𝑥 - 𝑀𝑡𝑚𝑖𝑛 /2

𝑀𝑡𝑎 = 450x10³ N.mm

Mean shear stress Ʈ𝑚 = 16 x 𝑀𝑡𝑚 /𝜋 𝑑³

Ʈ𝑚 = 6875.49 x10³/d³ N/mm²

½ P(𝑠𝑙) = W(h+ 𝑠𝑙)