2.

2 Design of Levers

Prepared By
Sunil Mandore
Department of Mechanical Engineering,
MET’s Institute of Polytechnic,
Bhujbal Knowledge City, Nasik.
 Design of Levers
A lever is defined as a mechanical device in the form of a rigid link
which is pivoted about a fulcrum to transfer or multiply the force.

where = leverage
 Type of Levers

Type I Lever
Mechanical Advantage > 1

Type II Lever
Mechanical Advantage > 1

Type III Lever

Mechanical Advantage < 1

 Design of Levers
The length of lever is decided on the basis of leverage ( .
The cross-section of lever is designed on basis of bending stresses

Step 1: Force Analysis :

The load or the force F to be exerted by the lever is given.
The effort required to produce this force is calculated by taking moments about the fulcrum.
𝐹 ×𝑙 2=𝑃 ×𝑙 1 𝑙1 Lever with arm inclinations
∴𝐹=𝑃×
𝑙2
For Type 1 lever For Type 2 lever

∑ 𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙𝐹𝑜𝑟𝑐𝑒𝑠=0
∴ 𝑅=𝑃 +𝐹
where R is reaction at pin

𝑅=√ 𝐹 +𝑃 −2 𝐹𝑃𝑐𝑜𝑠 𝜃
2 2

…if = 900
 Design of Levers
Step 2: Design of Lever Arm :
The cross-section at which the bending moment is maximum can be determined by
constructing a bending-moment diagram.
In Fig. (b), the bending moment is maximum
at section XX and it is given by,
𝑴 𝒃 =𝑷 ( 𝒍 𝟏 − 𝒅 𝟏 )
For a rectangular cross-section,
𝑑
∴ 𝑦=  
2

The dimension d is usually taken as twice of b. or, d = 2b.

For an elliptical cross-section

𝜋 𝑏 𝑎3 𝑎
𝐼=    and    𝑦=
64 2
Usually a = 2b
𝑴𝒃 𝒚
Dimensions of the cross-section of the lever can be determined by, 𝝈 𝒃 = 𝑰
 Design of Levers
Step 2: Design of Fulcrum Pin :
The fulcrum pin is subjected to reaction R as shown in Fig..
The dimensions of the pin, viz., diameter d1 and length l1 in
lever boss are determined by bearing consideration and then
checked for shear consideration.
R  = p  ( d1 × l1)
where p is the permissible bearing pressure,
The permissible bearing pressure for a phosphor bronze bush
is 5 to 10 N/mm2
𝑅
𝑅𝑒𝑎𝑟𝑟𝑎𝑛𝑔𝑖𝑛𝑔 𝑝=
( 𝑑 1 × 𝑙1 )
For the fulcrum pin, the ratio of length to diameter (l 1/d1) = 1 to 2.

The outside diameter of the boss in the lever is taken as twice of

the diameter of the pin, i.e., (2d1).
A phosphor bronze bush, usually 3 mm thick, is fitted inside the boss to reduce the friction.

𝑻𝒉𝒆𝒅𝒊𝒎𝒆𝒕𝒆𝒓 𝒐𝒇𝒑𝒊𝒏 𝒅𝟏 𝒊𝒔𝒄𝒉𝒆𝒄𝒌𝒆𝒅 𝒇𝒐𝒓 𝒅𝒐𝒖𝒃𝒍𝒆 𝒔𝒉𝒆𝒂𝒓 𝒇𝒂𝒊𝒍𝒖𝒓𝒆 𝒇𝒐𝒓 𝒎𝒂𝒙𝒊𝒎𝒖𝒎 𝒇𝒐𝒓𝒄𝒆
 Design of Levers
Problem 1: A lever-loaded safety valve is mounted on the boiler to blow off at a pressure of
1.5MPa gauge. The effective diameter of the opening of the valve is 50 mm. The distance
between the fulcrum and the dead weights on the lever is 1000mm. The distance between the
fulcrum and the pin connecting the valve spindle to the lever is 100 mm. The lever and the pin
are made of plain carbon steel 30C8 (Syt = 400 N/mm2) and the factor of safety is 5. The
permissible bearing pressure at the pins in the lever is 25 N/mm2. The lever has a rectangular
cross-section and ratio of width to thickness is3:1. Design a suitable lever for the safety valve.
 Design of Levers
Step II Calculation of forces:
Maximum steam load F at which the valve
blows

Taking moment of forces

2945.24 × 100= 𝑃 ×1000

P = 294.52 N

𝑅=𝐹 − 𝑃 =2650.72 𝑁
Step II Diameter and length of pin :
 Design of Levers
Step II Diameter and length of pin :

Step II Width and Thickness of lever:

 Design of Levers
Problem 2 :
A right angled bell-crank lever is to be designed to raise a load of 5 kN at the short arm end. The
lengths of short and long arms are 100 and 450 mm respectively. The lever and the pins are
made of steel 30C8 (Syt = 400 N/mm2) and the factor of safety is 5. The permissible bearing
pressure on the pin is 10 N/mm2 .The lever has a rectangular cross-section and the ratio of width
to thickness is 3:1. The length to diameter ratio of the fulcrum pin is 1.25:1. Calculate
(i) The diameter and the length of the fulcrum pin
(ii) The shear stress in the pin
(ii) The dimensions of the boss of the lever at the fulcrum
(iii) The dimensions of the cross-section of the lever
Assume that the arm of the bending moment on the lever extends up to the axis of the fulcrum.
Solution:
Given: F = 5 kN = 5000 N , Syt = 400 N/mm2 ,(fs) = 5, Long arm = 450 mm ,
Short arm = 100 mm , Bearing pressure = 10 N/mm2
Step I Calculation of Permissible stresses for pin and lever

𝑆 𝑦𝑡 400 2
σ 𝒕= = =80 N /mm
𝑓 .𝑠 5
0.5 𝑆 𝑦𝑡 0.5( 400) 2
𝝉= = =40 N /mm
𝑓 .𝑠 3
 Design of Levers
Step II Calculation of Forces acting on Lever
The forces acting on the lever are shown in Fig.
Taking moment of forces about the axis of the fulcrum,
P × 450 = F × 100 P × 450 = 5000 × 100 P = = 1111.11 N

𝑅=√ 𝐹 +𝑃 −2 𝐹𝑃𝑐𝑜𝑠 𝜃
Reaction force R is given by 2 2

…as = 900 = 5121.97 N

Step III Diameter and length of fulcrum pin

Considering bearing pressure on the fulcrum pin,
R 5121.97 5121.97
𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑝 𝑏= ≡10= ≡10=
𝑃𝑟𝑜𝑗𝑒𝑐𝑡𝑒𝑑 𝐴𝑟𝑒𝑎 𝑑 1 × 𝑙1   𝑑 1 × 1.25 𝑑 1
≡ 𝑑1 =2 0.24 𝑚𝑚 = 26 mm

Step IV Shear stress in pin

The pin is subjected to double shear. The shear stress in the pin is given by,
𝑅
𝝉= =¿ 2
𝝉=7.96 N /mm2 ¿ 40 N /mm
2[𝜋 2
4
𝑑1 ]
h𝑒𝑛𝑐𝑒𝑑𝑒𝑠𝑖𝑔𝑛𝑜𝑓𝑝𝑖𝑛𝑖𝑠 𝑠𝑎𝑓𝑒 𝑖𝑛 𝑠h𝑒𝑎𝑟
 Design of Levers
Step V Dimensions of the boss
The dimensions of the boss of the lever at the fulcrum are as follows:
inner diameter = 21 mm outer diameter = 42 mm length = 26 mm

Step VI Dimensions of cross-section of lever

For the lever, 𝑑=3 𝑏

𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑀𝑜𝑚𝑒𝑛𝑡 𝑀 𝑏=1111.11 × 450 = 500000  N.  mm

5 00000 (1.5 𝑏) 5 00000(1.5 𝑏) 3 5 00000(1.5)

𝑀𝑏. 𝑦 σ 𝒃= 80= 3 𝑏 =
σ 𝒃= 𝑏 . 𝑑3 𝑏 .( 3 𝑏) 27
𝐼  × 80
12   12   12  

mm 18 mm mm
 Components Subjected to Eccentric Loading
Mechanical components subjected to an external force, tensile or compressive, which does not
pass through the centroid of the cross-section
See the figure

Resultant stresses are obtained by the principle of superimposition of stresses.

Therefore resultant stresses are given by.
𝑃 𝑃 . 𝑒. 𝑦 𝑃 𝑀 𝑏. 𝑦
𝝈 =¿ 𝐴
+¿
𝐼 
𝝈=
𝐴
+
𝐼