EXPERIMENT1

AIMDesignanddrawingofCotterJoint

FUNCTIONAcotterjointisusedtoconnectoneendofarodisprovidedwitha
sockettypeofendandtheotherendoftherodisinsertedtoasocket.Theendof
therodwhichgoesintoasocketisalsocalledSpigot.

APPLICATIONS

1. Jointsbetweenthepistonrodandthecrossneedofthesteamengine.
2. Jointsbetweenthesidespindleandtheforkofthevalvemechanism.
3. Jointbetweenthepistonrodandthetailorpumpfoundationbolts.

ASSUMPTIONS

1. Therodsaresubjectedtoaxialtensileforcetheeffectofsteels
concentrationduetoshaftisneglected.

NOTATION

F=Axialloadcarriedbytherod

d=Diameteroftherod

d1=diameterofspigot

d2=diameterofcollar

d3=outsidediameterofsleeve

d4=diameterofsleeveorsocket

a=widthatrodend

b=widthofcollar

c=widthofsocketend

e=Thicknessofcollar

t=thicknessofcotter
=allowableshearstress

c=allowablecrushingstress

PROCEDURE:

STEP1:Designofrods

Fortherodsunderaxialload,

Axialstressintherods,=4F

d2

STEP2:DesignofthespigotandtheCotter

a.) Crushingstrengthofthecotter,F=d1tc
b.) Axialstressacrosstheslotoftherod
=4F
(d1)24d1t

STEP3:Designofthecotter

StrengthofthecotterindoubleshearF=2bt

STEP4:Designofthecollar

a.) Bearingstressinthecollar,c=4F
{(d2)2(4d1)2}
b.) Shearstressinthecollar,=F
d1e





STEP5:Designofthesleeve

a.) Axialstressacrosstheslotofthesleeve
=4F
[(d3)2(d1)2]4t(d3d1)

b.) Crushingstrengthofthesocket
F=(d4d1)txc

STEP6:Designoftherodend

a.) Shearstressattherodendduetodoubleshear
=F
2ad1

STEP7:Designofthesocketend

Shearstressatthesocketend,=F
2c(d4d1)

EXPERIMENT2

AIMDesignofshaftssubjectedtoTorsion,BendingMomentandCombined
Bending&Torsion

INTRODUCTIONShaftusuallyaroundmember,solidorhollowcrosssectionthat
rotatesandtransmitspower.Itcarriesmachineelementslikegears,pulleys,
cams,sprockets,couplingsetc.Itsdesignprimarilyconsistsoffindingthesizein
ordertosatisfythestrengthandrigidity,whiletransmittingpower.Shaftsare
usuallysubjectedtotorsion,bendingetc.

NOTATIONS

P=PowerinkW

n=speedinrpm

Mb=Maximumbendingmomentonshaft

Mt=Maximumtorqueonshaft

D=Diameterofshaft
F=axialorthrustload

Kb=CombinedshockandEndurancefactorinBending

Kt=CombinedshockandEndurancefactorintorsion

Forrotatingshaftswithgraduallyappliedloads

Kb=1.5andKt=1.0

Suddenly,appliedloadswithminorshocks,Kb=1.5to2.0andKt=1to1.5

Suddenly,appliedloadswithheavyshocks,Kb=2.0to3.0andKt=1.5to3.0

=allowabletensilestressforshaftmaterial

=allowableshearstressforshaftmaterial

SHAFTSSUBJECTEDTOPURETORSION

SolidShaft:Diameterofshaft,D=16KtMt1/3

SHAFTSSUBJECTEDTOPUREBENDING

SolidShaft:Diameterofshaft,D=32KbMb1/3

SHAFTSSUBJECTEDTOCOMBINEDBENDINGANDTORSION

SolidShaft:

i. Accordingtomaximumnormalstresstheory
DiameterofShaft,D=16KbMb+(KbMb)2+(KtMt)21/3



ii. Accordingtomaximumshearstresstheory
DiameterofShaft,D=16(KbMb)2+(KtMt)21/3




EXPERIMENT3

AIMDesignofFlatandSquareKeys

INTRODUCTION

Keysareusedtopreventrelativemotionbetweenashaftandtheconnected
memberthroughwhichtorqueisbeingtransmitted.CommontypesofKeysare:
Squarekey,Rectangularkey,Featherkey,Roundkey,Gibkey,Headkey,Taper
key,Barthkey,Kennedykey,SaddlekeyandWoodruffkeyetc.

DESIGNOFSQUAREANDFLATKEY

Thekeysaresubjectedtoshearandcrushingorbearingstresswhiletransmitting
torque.

NOTATIONS

b=widthofkey

h=thickness

l=lengthofkey

Consideringtheshearingofkey

Shearstress,=F=F
Areaofshearbl
a.) WhereF=Force=Torque=Mt=Mt=2Mt
Radiusofshaftr(d/2)d

=2Mt=>widthofthekeyb=2Mt

dlb dl

Consideringcrushingofkey

Crushingstress,c=F=F

Areaofcrushing(h/2)l

c=2Mt=4Mt=>thicknessofkeyh=4Mt

d(h/2)ldhldlc

ForSquarekeyb=h

b=2Mtandh=b=4Mt

dhdlc

Mt=bdlinshearandMt=bdlcincrushing

4 4


ProcedureType1:LengthofKey

STEP1:FindTorque,Mt=9.55x106xPP=PowerinkW,n=speed,rpm

STEP2:Diameterofshaft,d=316Mt

s=allowableshearstressforshaftmaterial

STEP3:Findlengthofkeyfrom

a.) Widthofkey,b=2Mt
dlk

k=allowableshearstressforkey

b.) Thicknessofkey,h=4Mt
dlb'

Recommendthebiggeroneaslength.

b'=allowablecrushingstressorbearingstressforkey.

ProcedureType2:Lengthofkey

STEP1:Torque,Mt=9.55x106xP

STEP2:Diameterofshaft,d=316Mt

STEP3:DesignofKey

a.) Lengthofkey=lengthofhub=l
b.) Widthofkey,b=2Mt
dlk
c.) Thicknessofkey,h=4Mt
dlb'

 EXPERIMENT4

AIMDesignanddrawingofScrewJack

INTRODUCTION

Screwsusedforpowertransmissionareknownaspowerscrews.Theyprovidea
meansforobtainingalargemechanicaladvantage,insuchapplicationsasscrew
jacks,clamps,handpresseslandscrewonlathemachines,hoistingmachinesetc.

SCREWJACK

NOTATIONS

W=loadtobelifted

d=outsidediameterornominaldiameterofscrew

p=pitch

dh=diameterofhandle

lh=lengthofhandle

D=outsidediameterofnut

Di,Do=insideandoutsidethediameterofthrustcollar

dc=meandiameterofthethrustcollar=Di+Do

ln=nutlength

t=thicknessofbody

max=allowablenormalstressinthescrew

max=allowableshearstressinthescrew

b=allowablebendingstressinthescrew

b=allowablebearingpressureinthethreads

n=allowableshearstressinthenut

=coefficientofthreadfriction

c=coefficientofcollarfriction

DesignProcedure

STEP1:Designofscrew

a.) Consideringthescrewunderaxialcompression
c=W=>corearea,Ac=W
Acc
c=allowablecompressivestressinscrew=max

b.) Consideringthescrewasacolumnloadedinaxialcompression,whenfully
extended,Rankineequationforcolumns
=W1+ale2
Ack

=allowablestressinthescrew=max

Ac=d12/4

a=RankinesConstant=1/7500forsteels

le=equivalentlengthofthecolumn

ScrewJackisacolumnwithoneendfixedatnutandotherendisfreewherethe
loadissitting.

So,Equivalentlength,le=2x(liftorextension)

K=radiusofgyration=I=d14=d1

A644

d12

STEP2:Checkforprincipalstressesinthescrew

a.) Compressivestressinthescrew,c=W

Ac

b.) Shearstressinthescrew,s=Mtsr1
J
WhereMts=frictionaltorqueinthescrewonly
=Wd2tan+
21tan
d2=d1p,tan=l
2d2
(l=lead=1xpassumingsinglestart)
r1=d1
2
J=d14
32
c.) Combinedorprincipalstresses
i. Maximumnormalstress
max=1c+c2+4s2
2
ii. Maximumshearstress,max=1(c2+4s2)

2

STEP3:Designofscrewheadandcollar

Assumepinheaddiameter,Do=1.6d=outsidethediameterofthecollar

Pindiameter,Di=0.5d=Insidethediameterofthecollar

So,MeanDiameterofthecollar,dc=Di+Do

STEP4:Designofnut:

Assumingbronzefornut,

a.) Lengthofnut,ln=4Wp
b(d2d12)
b.) Tensilestressinthenut=nut=W
/4(D2d2)
Assume,b=15MPaand
nut=40to50MPa

STEP5:Frictionaltorque

TotalfrictionaltorqueincludingthecollarfrictionMt=Wd2tan++cdc

21tan2

STEP6:Designofhandle

a.) Lengthofhandle,lh=Mt
F
b.) Tofindthediameterofhandle,thehandleissubjectedtobendingmoment
WKTMb=b
Ic

WhereMb=bendingmoment=Flh=Mt

I=momentofinertiaforhandle,I=dh4

64

C=dh,b=allowablebendingstress

STEP7:Efficiency, =d2tan

tan+d2+cdc

1 tan

STEP8:Selflockingcondition

Thescrewjacktobeofselflockingtype,

Hencecheckforselflocking.

tan<d2+cdc

d2cdc

 EXPERIMENT5

AIMDesignanddrawingofRivetedJoints

INTRODUCTION

Twoormoreplatesarejoinedbymeansofrivetsandsuchjointsarecalled
rivetedjoints.Thesejointsarepermanentinnatureunlikeboltedjoints.Theseare
usedinbridges,ships,boilers,tanks,etc.

RivetedJointsareclassifiedintotwotypesviz,lapjointandbuttjoint.

NOTATIONS

Pitch,p=Itisthedistancebetweencentresoftwoconsecutiverivetsinarow

Margin,m=Itisthedistancefromendofplatetofirstlowofrivets.

Transversepitch,pt=Distancebetweentwoconsecutiverowsofrivets.

Diagonalpitch,pd=Inzigzagriveting,thedistancebetweencentresofadjacent
rivetsinsidebysiderows

F=tensileorcompressiveloadonplates

d=diameteroftherivet

dh=diameterofrivethole

h=thicknessofmainplate

h1,h2=thicknessofcoverplates

i1=numberofrivetsinsingleshearinonepitchlengthorrepetitivelengthofjoint

i2=numberofrivetsindoubleshearinonepitchlength

C=Corrosionallowance1to3mm

K=factorasperboilercode

=efficiency

b=widthofplate

t==allowabletensilestressforplates

=allowableshearstressforrivets

c=allowablecrushingstressforrivets

RIVETEDJOINTSFORBOILERS

D1=Insidediameteroftheboiler

Pf=Fluidpressureorsteampressure

DESIGNPROCEDUREFORBOILERJOINTS

PartILongitudinaljoint

Step1:Thicknessofplateh=PfDi+C

=Efficiencyofjoint=0.7to0.8

C=Corrosionallowance=1to3mm

Step2:Diameteroftherivet,d=6h

Step3:Pitchoftherivets:

a.) p=(i1+1.875i2)d2+dhand
4ph
b.) p=Kh+40

Step4:Transversepitchpt=2.25d

Step5:Marginm=1.5d

Step6:Thicknessofcoverplates:

Forequalcoversh1=h2=0.625h
Forunequalcoversh1=0.625handh2=0.625h

Step7:Efficiency

a.) Efficiencyofplate,p=pd
P
b.) Efficiencyofrivetsinshear,=i1+1.875i2d2
4ph
 c.) Efficiencyofrivetsincrushing,c=i2+i1h2c
h
i2+i1h2c+
h

PARTIICircumferentialjoints

Theplatestoberivetedbeingsameinbothlongitudinalandcircumferentialjoints
(hbeingsame),thediameterofrivets,transversepitchandmarginaresame.

h,d,ptandmaresameasabove.

Step1:TotalsteamloadF=Di2

STEP2:Strengthofeachrivet

a.) InshearF=d2
4
b.) IncrushingFc=dhc

STEP3:Numberofrivetsrequired=SteamLoad

Minimumstrengthofrivet

i=F

F1

Step4:Rivets/Rows=i/row=Totalnumberofrivets

Numberofrowsofrivets

Numberofrows=1forsinglerivetedjoint

=2fordoublerivetedjoint

Step5:Pitchforcircumferentialjoint

Pc=Circumference=Di

Rivets/Rowi/row

Step6:Efficiency

a.) Efficiencyofplate,p=pcdh
Pc
b.) Forrivetsinshear,=(i1+1.875i2)d2

4ph

 c.) Forrivetsincrushing,c=i2+i1h2c
h
i2+i1h2c+
h