2 πNTmean

Flywheel-1:- Step1)To det. T mean, P= ; T mean=__Nm ; Step2) To det. W.d./cycle,

60
W=T mean*θ=_Nm --- θ=4π ; Step3) Max W.D., W max =1.3*W ; Step4) To det. T max,
π
W max =area under T-θ diag. =∫ T max∗sin θ T max= ❑ =__Nm
;
0
❑
Eqn of Power Stroke,T=T max*sin θ ;Step5) To det. θ B & θ D, ; at B & D, T=T mean=__
θD
θ B=_rad & θ D=_rad ; Step6) To det. ΔE(area under curve bcd) ; ΔE=∫ (T −¿ T mean ) dθ ¿
θB
2 πN
ΔE=__Nm ; Step1)To det I(psg7.120), ΔE=I* K s *ω 2 ; ω= = _. Therefore, I=_
60
Step2) To det. Mean dia D, ; V= πDN V=3000to4000M/min(psg) ;Let us select V=3500m/min; D=_.
D² I
Step3) To det. Mass, I=mk² ; k²= =_ ; m= =_ ; weight, w=mg=__.N ; w=(πDbh)r …(psg7.120)
4 k²
r= sp wt = __N/cm³ (psg1.1) =__N/m³ ; b/h=0.65 to 2, say b/h = 2 ; b=2h ; w=(πD2h*h)r ; h=_m
r∗v ² πDN
h=_mm ; b=2h=_mm ; Checking ind stress,σ t = ; V= = _m/s. σ t=_N/m²=N/mm²
g 60
π ² v ² Dr 3 1
Bend. Stress, σ b= ; Assuming no of arms, n=6 ; σ b=¿_ ; , σ total= σ t + σ b = _N/mm²
n ² gh 4 4
, σ total=___<200N/mm². so safe ; allowble total stress, σ tot=200 to 300
Check , σ t=__ <28N/mm². so safe
M t ( D−d)
Step1)To det , z yy , [σ ¿¿ bt ]¿= --eq.1 ; assuming,σ t = 100 to 150 N/mm²
n∗z yy∗D
16 M t
M t =__Nm=_*10³Nmm ; D=_m=_mm, d=dia of hub= 2d s ; d s =dia of shaft= 3

Assuming allowable [τ]=40 ; d s =_mm to take care of ben & other stress
√ π (τ )

64∗z yy
d=2*d s =_mm; z yy = __mm³. ; major axis of elliptical arm, a= 3
√ π
=_mm

minor axis, c=a/2 = _mm ; d 0 =D+h = __mm ; Draw diag. with dimension,; Note: if mtrl not
Mention, assume C.I. & V=1500m/min.
Flywheel-2
Fs τ∗u∗πdx
Step1:to det energy req to punch 1 hole, ; E1=[ *x] = [ ]*x = __Nm.
2 2
Step2:to det fluctuation of energy, ; ΔE= E1 [1 – 1/5] = __Nm
H
To det or select electrical motor, ; Theo. Power, Motor power= E1* =_W =_KW
60
Theo Power
The actual power of motor, P= =_KW ; Selecting steel motor ---(psg5.124)
η
Selecting motor with power=_KW – from psg ; Selection of speed of electrical motor,
Speed of Flywheel, N=i*H = __rpm ; Thereforre speed of elec. Motor=1000rpm
Sel. min speed ; Let us select 3ф induc.Motor of _KW from psg
2 πN ΔE
Step3:to det I, ΔE= I* K s *ω 2 from psg 7.120 ; ω= = _. Therefore, I= = __kg-m²
60 K s∗ω2
D² I
I=mk², k²= =_ ; m= =_Kg. ; Weight of the flywheel = __mg
4 k²

DESIGN DATA---PSG TECH 7.115

 πDN
To det. b & h, selec. of mtrl., V= = _m/s. ; V=_*60 = __rpm < 1500rpm
60
C.I. Flywheel can be used. ---(psg7.120) ; Now, w=(πDbh)r ; b=2h; w=(πD2h*h)r ;
r∗v ²
h=_m; h=_mm ; b=2h=_mm ; Checking ind stress,σ t =
g
π ² v ² Dr 3 1
Bend. Stress, σ b= ; σ total= σ t + σ b = _N/mm²
n ² gh 4 4
M t ( D−d)
Check , σ t=__ <35N/mm². so safe ; Step1)To det , z yy , [σ ¿¿ bt ]¿=
n∗z yy∗D
D∗60 3 16 M t
M t=
2 πN
= _Nmm ; d s =
√π (τ )
, Asume allwable[τ]=40 ; d s =_mm, d=2*d s =_mm

64 z yy

a=_mm; c=a/2=_mm; d 0 =D+h = _mm ;

√
Assume σ bt=150 ; z yy = __mm³. ; Major axis of ellipticalar, a= 3
π

DESIGN DATA---PSG TECH 7.115

Multi-plate clutch:psg7.89,
[ M ¿¿ t] P∗60
i min= ¿ --eqn-1 ; a.Torque, M t = *106
2 π Pa b∗r∗r m ² 2 πN
r max +r min
Step2) Design Torque,[ M ¿¿ t ]¿= K w ∗M t=_. ; b=r max -r min =__; r m= =__
2
sub in eqn-1, i min=__ ; select i min net highest even no.
i i
psg7.90 ; m 1=no of driver plates(steel) ; m1= = __ m 2= +1= __
2 2
Total no. of plates=m 1+m 2=__ ; Step1)To det dia of i/p shaft,
P∗60
i> M t= *106 =_(rated torque) ; ii>To det K w =service factor (7.90)
2 πN
K w = K 1+ K 2+ K 3+ K 4 (psg7.89) ; K 1=driver dynamic characteristics
factor=0.5 ; K 2=driven shaft dy ch fac=1.25
K 3=wear factor=0.32 ; K 4 =frequency of operation fact=0.75
Therefore, K w = ___ ; iii>Design Torque, [ M ¿¿ t ]¿= K w ∗M t=_.
iv>selection of mtrl & stress, ; let us assume c-45 steel as mtrl.
Then from psg1.9, σ y=__ ; Let us assume FOS=4
σy [M ¿¿ t ] =_
Design shear stress, [τ]=
2∗FOS
D
√
=_. ; v>dia of the shaft, d s = 3 16
πτ
¿

Design of friction plates, ; r max = -thickness of housing(t)-radial clearance

2
r r
Assume t=5mm & c =1mm ; max =__mm ; Note:if space restriction is not given,
First find r min =2d (psg7.90) ; d=dia of shaft, r=__ ; r max =1.25 to 1.8 r min (psg7.90)
r max =1.5r min ; r min =__ ; Step3> Thickness of plate(c)=1 to 3mm
Let us take c=3mm ; Specifications:- r max =__ ; r min =__;c=_
[ M ¿¿ t]
ii>to det no of plates; i min= ¿ ; eqn-1; psg7.89 ; pa=k* pb
2 π Pa b∗r∗r m ²
pb=2.5 to 3kg/cm = 0.25 to 0.3N/mm ; r max =__ ;Therfore d max =__
π∗d max∗n r max +r min
Vel at max rad, v= = __m/s ; pa =_ ; b=r max -r min =__; r m = =__
60000 2
Μ=0.2 to 0.3 for dry[new unground] =0.0 to 0.07 for wet[ground plate]
Method-II to find r, r=0.2 [for dry plates] ; i min=__ ; from psg7.90
i i
m 1= = __ m 2= +1= __(driven plates)
2 2
Total no of plates = 1+m 2=__ (psg5.30) ; For dia 35mm, std spline, 8*36*40 can be selec.
m
d s=36=inner dia ; 40= outer dia ; Step4>design of spring: Actual press betwn plate(7.90)
[M ¿¿ t ]
σ= ¿ =__; ; Axial force,Q=π*σ*(r max ²-r min ²) = __N.
2 πi∗b∗r∗r m ²
Let us assume no of springs=6 ; Approx axial force per spring = 300N.
Q
The total force on each spring = = __N
no of spring
4
Gd
Force req during engagement, Pmin= __N ; Stiffness of spring, q = G d = (psg-7.100)
8 D³n 8C³n

DESIGN DATA---PSG TECH 7.115

Let us assume C=6 ; G=__; Let d=__mm ; N= no of active coil = _ ; q=_N/mm
Pmax = Pmin+qy. Let us assume axial motion of ; Plate=3mm [2to 5mm] ;y=3mm [comp of sprng]
Max force, Pmax = __N ; checking for induced stress, ;
no of ×used shift no of day
To det no of cycle= * * ; *no of years =__. Psg7.102 as 104 <N<1*16
shift day year
4 c−1 0.615
7.105psg d=_ gr34mat ; σ u =__ ; [τ]=0.344*σ u ; Psg7.100 ; K s = + =1.2525.
4 c−4 c
K ∗8∗P c
τ= s = __< [τ] check ; Heat balance---if asked in as in problem
π∗d ²
Step1>heat generated per cycle, ;Heat generated/cycle=[ M t ¿ avg∗θ =[
[ M t ] + D ]θ = [ M t ] * wt J/cycle
2 2
2 πN
ω= = _. [Note:if t is not given t=o.1 sec] ; H g =__ ; heat generated/hour=Hg/cycle cycle/hr=_
60
Step2>Heat dissipated, overall dimensions of housing c shell ;
π∗D∗n
B=(m 1+m 2)C +20= __. {Housing} Area=πD*B=_ ; Peripheral vel of housings, π= =__
60000
H d =6.14*A v 0.78*Δt= __ ---9.15psg ; H d = H g ; Δt=__ ; ΔT=T h*T atm
T h=housing surface ; T h= __ºc ; T h>75 increase r max or provide external looks

DESIGN DATA---PSG TECH 7.115

Cone Clutch:
P∗60
Step1: to det dia of splinrd shaft ; Transmitted torque, M t = *106 = _Nmm
2 πN
Step2) Design Torque,[ M ¿¿ t ]¿= K w ∗M t=_.(7.89) ; (7.90) K 1=0.5, K 2=1.2, K 3=0.285, K 4 =0.75
K w = K 1+ K 2+ K 3+ K 4 (psg7.89) ; Selection of mtrl for shaft & design stress
σy
Let select C-30 as mtrl of shaft ; σ y=30kgf/mm², fos=4 ;Allowable Ten. Stress, σ y= =_
fos
[σ ¿¿ t ] 16 M t
Allowable Shear stress[τ]=
2 √
¿= _ ; To det dia of shaft, d s = 3
π (τ )
= _ (psg5.30)

Sel of std spline, 8*46*50 can be selec. ; d s=46=inner dia; 8=no of spline ; 50= outer dia
To design cone, design assumption, total cone ; Angle, 2α=23º . therefore, α = 12.5º
Coeff of friction, μ=0.2, normal axial pre, Pa =0.25 ; Mean dia,d m =368=8*d s ; Step1> to det face width,
dm r max −r min
[ M t ]=μ* Pa(πd m *b) r m ; b=_. Check =4.5to8 ; Step2>to det r max & r min ; = sin α --eqn1
b b
r max +r min d m
; = --eqn-2 ; Solv. r max =_ ; r min =_ ; Actual α from the diagram as per pythagoras rule
2 2
Design of cup, generates t=10 – 15, say t=10mm ; t’=t+5=_. Thickness of friction lining, D0= D 1+2t=_
len of cone, L’=bcos α =_. Len of cup,L=t’+gap+L’ ; Note:1>if pres is 1to1.25 given pres is normal
Press. & get Pa = Pnsinα. 2>if given pres is around ; 0.25 it is axial press even though it is mentioned
Normal press intensity. ; Design of spring: Stepi> to det max force on spring,
Pmax =(πd m*b). Pa(sinα+rcosα) = _N. ; Step2> min force on spring, Pmin=(πd m*b). Pa*sinα=_
P max
Step3>deciding no of springs, let us 4 springs, =_ ; force on each spring [note there are two approach for
n
design of spring] 1>static load method, 2>static approach to variable loading. Use 1st method when
no of operations per hour(or per shaft)and/or life reqd ; method-I: use second method when given, ; psg1.17
[σ ¿¿ y /2]
spring steel SS 5:2 m90 ; (1.15psg) σ y=150kgf/mm² ; fos=2 ; hence allowable shear stress[τ]= ¿= _
fos
D 4 c−1 0.615
spring index=C= =_. ; then wohls factor(psg7.100) ; K s = + =1.2525. ; (psg7.100) τ =
d 4 c−4 c
K s∗8∗P c
, d=_
π∗d ²
8 PC ³ n
Mean coil dia=D=C*d=_. ; Let us assume compr of spring, y=6mm ; y= =_
Gd
8 PC ³ n
No of active coil,n=_ ; actual compr, ; y= =_ ; Assuming square & ground end, n’=n+2=_
Gd
Free length of spring, Lf =n’d+1.5y ; Spring specifications: 1>wire dia, d=11mm
2>coil mean dia,D=66; 3> free len, Lf =75mm ; 3>no of coil,n’=6 ; no of springs = 4
Lf −1 P
Pitch,P= ' =_ ; helix angle,α= tan = _<10º ; Method-II: note spring force should be less than2000
n −1 πD
P max no of ×used shift no of day
Let take 5 spring,P= =_. To det no of cycles ; To det no of cycle= * *
5 shift day year
4 6
*no of years =__.; frm psg7.102 as 10 <N<1*1 ; 7.105psg. ; trial d=6mm & gr 3mtrl therf, u =_. σ

DESIGN DATA---PSG TECH 7.115

Τ=_. ; psg7.100, τ= K s *
8 PC
= _check for stress ; Step1)Heat generated/cycle=[ M t ¿ avg∗θ =[
[ M t ] + D ]θ
πd ² 2
[ M t] 2 πN
= * wt J/cycle ; ω= = _. [Note:if t is not given t=o.1 sec]
2 60
H g =__ ; heat generated/hour=Hg*(no of cycle/hr)=_ ; Det heat generated when MI of rotating part is
[ Mt]
known,, I=mk² ; [ M t ¿=Iα ; α= ; find slip time,t’, v=u+at ; t=w/α
I
heat generated=avg torque * wt ; heat generated/hour=Hg*(no of cycle/hr)=_

DESIGN DATA---PSG TECH 7.115