MACHINE DESIGN DATA BOOK Final Year

DESIGN OF SHAFT
SYMBOLS
b width of keyway, m (in)
c machine cost,
D diameter of shaft (also with subscripts), mm
Di inside diameter of hollow shaft, mm
Do outside diameter of hollow shaft, mm)
E modulus of elasticity, GPa
F axial load (tensile or compressive), kN
G modulus of rigidity, GPa
h depth of keyway, mm
k radius of gyration, mm
k = Di/Do ratio of inner to outer diameter of hollow shaft
Kb numerical combined shock and fatigue factor to be applied to computed bending
moment
Kt numerical combined shock and fatigue factor to be applied to computed twisting
moment
Mb bending moment, Nmm
Mt twisting moment, Nmm
Mbm static equivalent of cyclic bending moment
T Twisting moment (or torque) acting upon the shaft
J Polar moment of inertia of the shaft about the axis of rotation
r Distance from neutral axis to the outer most fibre
P power, kW (hp)
n speed, rpm;
safety factor
n’ speed, rps
ρ specific weight of material, kN/mm3
σ stress (tensile or compressive) also with subscripts, MPa (psi)
τ shear stress (also with subscripts), MPa (psi)
α ratio of maximum intensity of stress to the average value from compressive stress only

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 MACHINE DESIGN DATA BOOK Final Year

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 MACHINE DESIGN DATA BOOK Final Year

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 MACHINE DESIGN DATA BOOK Final Year

Shafts Subjected to Twisting

Moment Only
Torque equations ,

𝜋
Torque transmitted by hallow TH= 𝜏 (do)3(1-k4)
shaft 16

Power Transmitted(watt)

In case of belt drives T = (T1 – T2 ) R

T1 and T2 = Tensions in the tight side and slack side of the belt resp.
R = Radius of the pulley.
Shafts Subjected to Bending
Moment Only:
M = Bending moment,
I = Moment of inertia of cross-
sectional area of the shaft about
the axis of rotation,
σb = Bending stress, and
y = Distance from neutral axis to
the outer-most fibre.
Combined Twisting Moment Max Shear Stress in shaft
and Bending Moment:

Design of shaft on the basis 𝑇 𝐺.𝜃

=
𝐽 𝐿
of Rigidity:
𝜃 = Torsional deflection or 𝜋
angle of twist in radians. = d4
32
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 MACHINE DESIGN DATA BOOK Final Year

T= Twisting moment or
𝜋
torque on shaft = [(d0)4 – (di)4]
32
J= Polar moment of inertia of
cross sectional area about the
axis of rotation

DESIGN OF KEYS

W= d / 4 t = 2w / 3 = d / 6
T = Torque transmitted by the
shaft,
F = Tangential force acting at
the circumference of the shaft,
d = Diameter of shaft,
l = Length of key,
w = Width of key.
t = Thickness of key, and
τ and σc = Shear and crushing
stresses for the material of key.

Strength of a Sunk key:

Considering shearing of the
key,

1.Tangential force acting at the F= l×w×τ

circumference of the shaft
2.Torque transmitted by the
shaft
Considering crushing of the key
1) Tangential force acting at
the circumference of the shaft
2) Torque transmitted by the
shaft
3) The key is equally strong in
shearing and crushing

w = width of the key and t= thickness of the key

𝜏1
l = 1.571d x ………..(material of shaft and key are different)
Length of the key to transmit 𝜏
full power of the shaft l = 1.571d……( material of shaft and key are same then 𝜏 = 𝜏1 )
Effect of keyways: w h
e = 1 - 0.2( ) – 1.1( )
By H.F.Moore d d
e= Shaft strength factor. It is the ratio of the strength of the shaft with
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 MACHINE DESIGN DATA BOOK Final Year

keyway to the strength of same shaft without keyway

w= Width of keyway, d= Diameter of the shaft

Thickness of key (t)

h= Depth of keyway =
2
keyway is too long and the key
is of sliding type

DESIGN OF COUPLING

Sleeve or Muff-coupling:

d = diameter of the shaft.

T = Torque to be transmitted
by the coupling
τc = Permissible shear stress
for the material of the sleeve
which is cast iron.
 Outer diameter of the D= 2d+13 mm
sleeve
 Length of sleeve L = 3.5d
𝜋
 Torque transmitted by T= 𝜏 D3 (1-k4)…………(k = 𝑑 𝐷 )
16 𝑐
hollow section
 Length of the key l=
3.5𝑑
2

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 MACHINE DESIGN DATA BOOK Final Year

 Torque transmitted T= l w 𝜏
𝑑
………….(Considering shearing of the key)
2

𝑡 𝑑
 Torque transmitted T = l 𝜍𝑐 …………(considering crushing of the key)
2 2

Clamp or Compression D = 2d + 13 mm
coupling: L = 3.5 d
Let Force exerted by each bolt,
T = Torque transmitted by the
shaft. Force exerted by the bolts on each
D = Diameter of the muff or side of the shaft,
sleeve
L = Length of the muff or sleeve
d = Diameter of the shaft.
db = Root or effective diameter of
the bolt.
n = Number of bolt.
σt = Permissible tensile stress for
bolt material .
μ=Coefficient of friction between
muff and shaft.(may be taken as
0.3)
L = Length of muff.
p = pressure on the shaft and the
muff surface F
F= Frictional force between each
shaft and muff
Root diameter of the bolt (db) may be evaluated
𝜋2
T= μ (db)2 σt n d
16
Flange Coupling
Unprotected type:

Let
d = Diameter of shaft or inner
diameter of hub
D = Outer diameter of the hub
d1 = Nominal or outside diameter
of the bolt
D1 = Pitch circle diameter of bolt
circle.
D2 = Outside diameter of flange
n = number of bolts
tf = Thickness of flange
𝜏𝑠 ,𝜏𝑏 and 𝜏𝑘 = Allowable shear
stress for shaft, bolt and key
material Tf = 0.5d
𝜏𝑐 = Allowable shear stress for
flange material
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 MACHINE DESIGN DATA BOOK Final Year

𝜍𝑐𝑏 and 𝜍𝑐𝑘 = allowable

crushing stress for bolt and key
material

= 3 for d up to 40 mm
Number of bolts = 4 for d up to 100 mm
= 6 for d up to 180 mm
Design for Hub,
Design of Flange Coupling

Length of Hub = 1.5d

Design for Flange,

Design for Bolt,

𝜋
= (d1)2 𝜏𝑏
 Load on each bolt 4

𝜋
 Total load on all the = (d1)2 𝜏𝑏 n
4
bolts
𝜋 𝐷1
T= (d1)2 𝜏𝑏 n
 Torque transmitted 4 2

= n d1 tf
 Area resisting crushing
of all the bolts
= n d1 tf 𝜍𝑐𝑏
 Crushing strength of all
the bolts
𝐷1
= n d1 tf 𝜍𝑐𝑏
 Torque 2

Flexible Coupling:

Let
l = Length of bush in the flange
d2 = Diameter of bush
Pb = Bearing pressure on the
bush or pin
D1 = Diameter of pitch circle
of pins

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 MACHINE DESIGN DATA BOOK Final Year

 Bearing load acting on W= pb × d2 × l

each pin
 Total Bearing load on = W × n = pb × d2 × l × n
the bush or pins
 Torque transmitted by T =w × n × ( 1 )
𝐷
= Pb × d2 × l × n × (
𝐷1
)
2 2
the coupling
 Direct shear stress due 𝜏= π
W
to pure torsion in the (d )2
4 1
coupling halves
 Maximum bending 𝑙
M = W × ( + 5 𝑚𝑚)
2
moment on the pin
 Bending stress 𝑙
W × (2 + 5 mm )
𝑀
𝜍= = π
𝑍 (d )3
32 1
 Maximum principle 1
= [ 𝜍 + 𝜍 2 + 4𝜏 2 ]
2
stress
 Maximum shear stress 1
= × 𝜍 2 + 4𝜏 2
2
on the pin

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 MACHINE DESIGN DATA BOOK Final Year

Oldham Coupling:

 Total pressure on each 1

F= × p × D × h
4
side of the coupling Where
P= allowable pressure 0.81 kgf/mm2
D = Diameter of flange
 Torque transmitted by 1
both sides of tongue T = × p × D2 × h
6

 Diameter of the disc D = 3d + c

Where c = distance between axis of shafts
 Diameter of boss D2 = 1.3d + 20 mm

 Hub length 0.75d+12.5

t = 0.4d + 0.15c
 Thickness of tongue
w= 0.25d + 0.1c
 Width of tongue
tf = 0.6d + 0.25c
 Thickness of flange

Universal coupling (hook’s

Joint) :
d = Diameter of shaft,
dp = Diameter of pin, and
τ and τ1 = Allowable shear stress
for the material of the shaft and
pin respectively
N = Speed of driving shaft in rpm
N1 = Speed of driven shaft in rpm
𝛼 = Angle of inclination of the
shaft
 = Angle of the driving shaft
from the position

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 MACHINE DESIGN DATA BOOK Final Year

𝜋
 Torque transmitted by T= × d3 × 𝜏 Pin is in Double shear
16
the shaft
2𝑇
 Diameter of the pin dp =
𝜋𝜏 𝑝 𝑑

𝑁 1−co 𝑠 2 θ.si 𝑛 2 α
 Ratio of speed of 𝑁1
=
cos α
driving shaft to driven
shaft

Design of Flywheel

A = Cross-sectional area of rim = b × t,

D = Mean diameter of flywheel
R = Mean radius of flywheel,
ρ = Density of flywheel material, kg/m3
ω = Angular speed of flywheel,
v = Linear velocity of flywheel, m/s
σt = Tensile or hoop stress, N/m2 or Pa
N1= Maximum speed in r.p.m during the
cycle
N2 = Minimum speed in r.p.m during the
cycle

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 MACHINE DESIGN DATA BOOK Final Year

 Coefficient of Cs =
𝑁1 − 𝑁2
=
𝜔1− 𝜔2
=
𝑣1 − 𝑣2
fluctuation of speed 𝑁 𝜔 𝑣
(Angular) (Linear)
1
m=
 Coefficient of steadiness 𝐶𝑠

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑐𝑡𝑢𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑒𝑛𝑒𝑟𝑔𝑦

 Coefficient of CE =
𝑊𝑜𝑟𝑘 𝑑𝑜𝑛𝑒 𝑝𝑒𝑟 𝑐𝑦𝑐𝑙𝑒
fluctuation of energy
Stresses in the flywheel rim: t = Thickness of the rim, and b = Width of the rim = 2 t

 Tensile stress due to 𝜍𝑡 = 𝜌R2𝜔2 = 𝜌.v2…… ...( v = 𝜔 R)

centrifugal force
𝑀 𝑏.𝑡.𝜌.𝜔 2 .𝑅 2𝜋𝑅 2 6
𝜍𝑏 = = ( ) ×
 Tensile bending stress 𝑍 12 𝑛 𝑏 × 𝑡2
caused by restraint of the
arms. 19.74 × 𝜌 × 𝜔 2 × 𝑅 2 19.74 × 𝜌 × 𝑣 2 × 𝑅
= =
𝑛2 × 𝑡 𝑛2 × 𝑡

 Total stress in the rim 3

𝜍 = 𝜍𝑡 + 𝜍𝑏
1
4 4
3 1 19.74 × 𝜌 × 𝑣 2 × 𝑅
= × 𝜌.v2 + ×
4 4 𝑛2 × 𝑡

Stresses in the Flywheel Arm:

 Tensile stress due to 3
𝜍𝑡1 = 𝜍𝑡 = 𝜌 × 𝑣 2
3
4 4
centrifugal force
𝑀 𝑇
𝜍𝑏1 = = (R- r)
 Bending stress due to 𝑍 𝑅.𝑛.𝑍
R= Mean radius of the rim,
torque transmitted
r = Radius of the hub,
n = Number of arms,
Z = section modulus for the cross- section of arms

 Total tensile stress in the

arms at the hub end 𝜍= 𝜍𝑡1 + 𝜍𝑏1

If the flywheel is used as a belt

pulley
 Bending stress due to the 𝑇1 −𝑇2 (𝑅−𝑟)
𝜍𝑏2 = 𝑛
belt tensions 2
∗𝑍

 Total bending stress in the 𝜍𝑏 = 𝜍𝑏1 + 𝜍𝑏2

arms ate the hub end

 Total tensile stress in the 𝜍 = 𝜍𝑡1 + 𝜍𝑏1 + 𝜍𝑏2

arms at the hub end
Design of Flywheel Arms: a1 = Major axis
b1 = Minor axis
Assume a1 = 2 b1

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 MACHINE DESIGN DATA BOOK Final Year

𝜋
 Section modulus Z= b1(a1)2
32

 Maximum bending 𝑇
M= (R-r)
moment 𝑅.𝑛.

𝑀 𝑇
 Maximum bending 𝜍𝑏 =
𝑍
=
𝑅.𝑛.𝑍
(R-r)
stress
Note: The taper is about 20 mm per meter length
The number of arms are usually 6.Sometimes the
arms may be
8,10.12 for very large size flywheel

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 2A] Bearings

Sliding contact Bearing

 Coefficient of friction for 33 𝑍𝑁 𝑑
μ = 10 8 ( 𝑃 )( 𝑐 )+k ……(When Z is in kg/m-s and p is in
journal bearing
N/mm2)(k=0.002)
 Critical pressure or
minimum operating 𝑍𝑁 𝑑 𝑙
p = 4.75∗10 6 . ( 𝑐 )2. (𝑑+𝑙 ) N/mm2…….(when Z is in kg/m-s)
pressure of journal bearing

 Sommerfeld Number =
𝑍𝑁 𝑑 2
( )
𝑃 𝑐
For design purpose, its value is taken as follows
𝑍𝑁 𝑑 2
( ) = 14.3*106
𝑃 𝑐
 Heat generated in a journal Qg = μ.W.V N-m/s or J/s or watts
bearing Where
μ = Coefficient of friction
W= Load on the bearing in N
𝜋𝑑𝑁
V = Rubbing velocity in m/s = 60 ….d is in meters
N = Speed of journal in r.p.m

 Heat dissipated by bearing Qd = C.A.(𝑡𝑏 − 𝑡𝑎 )…….J/s or W

1
= 𝑡𝑏 − 𝑡𝑎 = 2 (to - ta)
Where
To = Temperature of oil film
C= Heat dissipation coefficient in W/m2/◦C
A= Projected area of the bearing in m2 = l*d
𝑡𝑏 = Temperature of bearing surface in ◦C
𝑡𝑎 = Temperature of the surrounding air in ◦C

 Heat taken away by the oil Qt= m.S.t ………J/s or watts

Design of bearing cap and Bolt
Where
m = mass of the oil in kg/s
S = Specific heat of oil. its value is taken as 1840 to 2100 J/kg/◦c
t = Difference between outlet and inlet temperature of the oil in ◦c
Let
W = Load supported at the centre
𝛼 = Distance between centre’s of holding down bolt
l = Length of bearing
t = Thickness of the cap

 Bending stress 3𝑊𝑎

𝜎𝑏 = 2𝑙𝑡 2

3𝑊𝑎
t= 2𝜎 𝑏 𝑙
 Deflection of cap 𝑊.𝑎 3 𝑊.𝑎 3
𝛿 = 48.𝐸.𝐼 = 4.𝐸.𝑙.𝑡 3 …………………(I=
𝑙.𝑡 3
)
12

 Core diameter (dc) may be 𝜋

*(dc)2𝜎𝑡 = 3 * 𝑛
4 𝑊

calculated by 4

 Power lost in friction P=

2𝜋𝑁𝑇
watts
60

 Bearing pressure 𝑊
P = 𝜋.(𝑅 2 −𝑟 2 )……….where r = Radius of counter bore
R = Radius of bearing surface or shaft
 Total frictional torque 2
T= 3 𝜇.W (𝑅 2 −𝑟 2 )
𝑅 3 −𝑟 3
 ROLLING CONTACT BEARING

Table 27.1. Principal dimensions for radial ball bearings.

Bearing No. Bore (mm) Outside diameter Width (mm)

213 65 120 23
313 140 33
413 160 37
214 70 125 24
314 150 35
414 180 42
Bearing No. Bore
75(mm) Outside
130diameter Width
25 (mm)
160 37
200 10 30
190 9
45
300
216 80 35
140 11
26
215
316
315
201 12 170
32 39
10
416
301
415 200
37 48
12
217 85 150 28
202 15 35 11
317 180 41
302 42 13
417 210 52
203
218 17
90 40
160 12
30
303
318 47
190 14
43
403 62 17
418 225 54
204 20 47 14
304 52 14
404 72 19
205 25 52 15
305 62 17
405 80 21
206 30 62 16
306 72 19
406 90 23
207 35 72 17
307 80 21
407 100 25
208 40 80 18
308 90 23
408 110 27
 Basic Static Load Rating of Rolling Contact Bearings

1. For radial ball bearings, the basic static radial load rating (C0) is
given by
C0 = f0.i.Z.D2 cos α
where i = Number of rows of balls in any one bearing,
Z = Number of ball per row,
D = Diameter of balls, in
mm,
α = Nominal angle of contact i.e. the nominal angle between the line of
action of the ball load and a plane perpendicular to the axis of
bearing,
and
f0 = A factor depending upon the type of bearing.
The value of factor ( f0 ) for bearings made of hardened steel are taken as
follows :
f0 = 3.33, for self-aligning ball bearings
= 12.3, for radial contact and angular contact groove ball bearings.
2. For radial roller bearings, the basic static radial load rating is
given by
C0 = f0.i.Z.le.D cos α
where i = Number of rows of rollers in the bearing,
Z = Number of rollers per row,
le = Effective length of contact between one roller and that ring (or washer)
where the contact is the shortest (in mm). It is equal to the overall
length of roller minus roller chamfers or grinding undercuts,

D = Diameter of roller in mm. It is the mean diameter in case of

tapered
rollers,
α = Nominal angle of contact. It is the angle between the line of
action of
the roller resultant load and a plane perpendicular to the axis of
the
bearing, and
f0 = 21.6, for bearings made of hardened steel.
3. For thrust ball bearings, the basic static axial load rating is
given by
C0 = f0.Z.D2 sin α
where Z = Number of balls carrying thrust in one direction, and
f0 = 49, for bearings made of hardened steel.
4. For thrust roller bearings, the basic static axial load rating is
given by
C0 = f0.Z.le.D.sin α
where Z = Number of rollers carrying thrust in one direction, and
f0 = 98.1, for bearings made of hardened steel.

Static Equivalent Load for Rolling Contact Bearings

The static equivalent radial load (W0R) for radial or roller bearings under combined radial and
axial or thrust loads is given by the greater magnitude of those obtained by the following two
equations, i.e.
1. W0R = X0.WR + Y0.WA ; and 2. W0R = WR
Axial or thrust load,
where WR = Radial load, WA =
X0 = Radial load factor, and Y0 = Axial or thrust load factor.
S.No Type of bearing Single row bearing Double row bearing
.
X0 Y0 X0 Y0
1. Radial contact groove ball bearings 0.60 0.50 0.60 0.50
2. Self aligning ball or roller bearings 0.50 0.22 cot θ 1 0.44 cot θ
and tapered roller bearing
3. Angular contact
T groove bearings :
a α = 15° 0.50 0.46 1 0.92
b α = 20° 0.50 0.42 1 0.84
l
e α = 25° 0.50 0.38 1 0.76
α = 30° 0.50 0.33 1 0.66
2 α = 35° 0.50 0.29 1 0.58
7
. α = 40° 0.50 0.26 1 0.52
2 α = 45° 0.50 0.22 1 0.44
.
Values of X0 and Y0 for radial bearings.
Notes : 1. The static equivalent radial load (W0R) is always greater than or equal to the radial load (WR).
2. For two similar single row angular contact ball bearings, mounted ‘face-to-face’ or ‘back-to-
back’, use the values of X0 and Y0 which apply to a double row angular contact ball bearings. For two
or more similar single row angular contact ball bearings mounted ‘in tandem’, use the values of X0
and Y0 which apply to a single row angular contact ball bearings.
3. The static equivalent radial load (W0R) for all cylindrical roller bearings is equal to the radial load
(WR).
4. The static equivalent axial or thrust load (W0A) for thrust ball or roller bearings with angle of
contact α ≠ 90º, under combined radial and axial loads is given by
W0A = 2.3 WR.tan α + WA
This formula is valid for all ratios of radial to axial load in the case of direction bearings. For
single direction bearings, it is valid where WR / WA ≤ 0.44 cot α.
5. The thrust ball or roller bearings with α = 90º can support axial loads only. The static
equivalent axial load for this type of bearing is given by
W0A = WA
S. No. Application of bearing Life of bearing, in hours
1. Instruments and apparatus that are rarely used
(a) Demonstration apparatus, mechanism for operating 500
sliding doors
(b) Aircraft engines 1000 - 2000
2. Machines used for short periods or intermittently and whose 4000 - 8000
breakdown would not have serious consequences e.g. hand
tools, lifting tackle in workshops, and operated machines,
agricultural machines, cranes in erecting shops, domestic
machines.
3. Machines working intermittently whose breakdown would 8000 - 12 000
have
serious consequences e.g. auxillary machinery in power
stations, conveyor plant for flow production, lifts, cranes for
4. piece goods, machine tools used frequently. 12 000 - 20 000
Machines working 8 hours per day and not always fully
utilised
5. 20 000 - 30 000
e.g. stationary electric motors, general purpose gear units.
Machines working 8 hours per day and fully utilised e.g.
machines for the engineering industry, cranes for bulk goods,
6. 40 000 - 60 000
ventilating fans, counter shafts.
Machines working 24 hours per day e.g. separators,
7. compressors, 100 000 - 200 000
pumps, mine hoists, naval vessels.
Machines required to work with high degree of reliability
24 hours per day e.g. pulp and paper making machinery, public
Table 27.3. Life of bearings for various types of machines
power plants, mine-pumps, water works.

Basic Dynamic Load Rating of Rolling Contact Bearings

1. According to IS: 3824 (Part 1)- 1983, the basic dynamic radial load rating for
radial and
angular contact ball bearings, except the filling slot type, with balls not larger than 25.4 mm in
diameter,
is given by
C = fc (i cos α)0.7 Z2/3 . D1.8
and for balls larger than 25.4 mm in diameter,
C = 3.647 fc (i cos α)0.7 Z2/3 . D1
where fc = A factor, depending upon the geometry of the bearing
components, the
accuracy of manufacture and the material used.
and i, Z, D and α have usual meanings as discussed in Art. 27.8.

2. According to IS: 3824 (Part 2)-1983, the basic dynamic radial load rating for radial
roller bearings is given by
C = fc (i.le cos α)7/9 Z3/4. D29/27
3. According to IS: 3824 (Part 3)-1983, the basic dynamic axial load rating for
single row, single or double direction thrust ball bearings is given as follows :
(a) For balls not larger than 25.4 mm in diameter and α =
90º,
 C = fc . Z2/3 . D1.8
(b) For balls not larger than 25.4 mm in diameter and α ≠
90º, C = fc (cos α)0.7 tan α. Z2/3 . D1.8
(c) For balls larger than 25.4 mm in diameter and α =
90º
C = 3.647 fc . Z2/3 . D1.4
(d) For balls larger than 25.4 mm in diameter and α ≠
90º,
C = 3.647 fc (cos α)0.7 tan α . Z2/3 .D1.4
4. According to IS: 3824 (Part 4)-1983, the basic dynamic axial load rating for
single row, single or double direction thrust roller bearings is given by
C = fc . le7/9 . Z3/4 . D29/27 ... (when α = 90º)
= fc (le cos α)7/9 tan α.Z3/4. D29/27 ... (when α ≠ 90º)

Dynamic Equivalent Load for Rolling Contact Bearings

The dynamic equivalent radial load (W ) for radial and angular contact bearings,
except the filling slot types, under combined constant radial load (WR) and constant axial or
thrust load (WA) is given by
W = X . V. WR + Y . WA
where V = A rotation factor,
= 1, for all types of bearings when the inner race is rotating,
= 1, for self-aligning bearings when inner race is stationary,
= 1.2, for all types of bearings except self-aligning, when inner
race is
stationary.
The values of radial load factor (X ) and axial or thrust load factor (Y ) for the
dynamically loaded bearings may be taken from the following table:

Dynamic Load Rating for Rolling Contact Bearings under Variable

Loads
The approximate rating (or service) life of ball or roller bearings is based on the
fundamental
equation,

𝐶
𝐿 = ( )𝐾 𝑋 106
𝑊
𝐿
C = W* 6
10
where L = Rating life,
C = Basic dynamic load rating,
W = Equivalent dynamic load, and
k = 3, for ball bearings,
= 10/3, for roller bearings.
The relationship between the life in revolutions (L) and
 the life in working hours (LH) is given by
L = 60 N . LH revolutions
where N is the speed in r.p.m.
Total load ,

L1 W13 + L2 W23 + L3 W33

W=
L1 + L2 + L3

2B] Belts
Velocity Ratio
of belt drives

Speed of the
belt 𝜋𝑑𝑁
v = 60
Centrifugal tension TC = m.v²
Max.Tension T = σ× A
Tension in T1 = T – TC
tight side 2.3 log (T1 / T2) = μ θ
Creep in the belt

𝜋𝑑𝑁 𝑆1
Slip in the belt v= 60
(1- 100 )
S1& s2 – slip in tight & slack side resp.
Length of an open Belt drive
Length of a Cross belt drive

Power transmitted by the per belt P = (T1 – T2)*v watt

For V - belt Drive
Centrifugal tension TC = m.v²
Max.Tension T = σ× A
Tension in tight side T1 = T – TC
2.3 log (T1 / T2) = μ θ cosec β
θ= 180° – 2α
Number of V-belts =
Total power transmitted /Power transmitted per belt

For Rope Drive

𝜋𝑑𝑁
Speed of the v= 60
pulley
𝑇
For max. power speed is 𝑣= Where T = Max. Tension
3𝑚
For max. power Centrifugal tension TC = T / 3
2.3 log (T1 / T2) = μ θ cosec β
 Design of Gears
3A Spur Gears
Spur gear
2𝐴𝑤
The number of teeth on the pinion Tp= where
1 1
(Tp) in order to avoid interference 𝐺[ 1+ ( +2)si𝑛 2 𝜑 − 1]
𝐺 𝐺
may be obtained from: Aw= Fraction by which the standard addendum for the wheel
should be multiplied,
𝑇 𝐷
G= Gear ratio or velocity ratio = 𝑇𝐺 = 𝐷𝐺
𝑃 𝑃
Φ =Pressure angle or angle of obliquity.

The maximum value of bending 𝑀.𝑦

stress or the permissible working
stress
𝜎𝑤 = 𝐼 where
M= Maximum bending moment at the critical section BC= WT.h
WT = Tangential load acting at the tooth,
h= Length of tooth
𝑡
y= Half the thickness of tooth (t) at critical section BC = 2
𝑏.𝑡 3
I= Moment of inertia about the centre line of the tooth=
12
b= Width of gear face.

Tangential load acting at the tooth 𝜎𝑤 .b.𝑡 2

WT= 6ℎ
= 𝜎𝑤 .b.Pc.y = 𝜎𝑤 .b.π.m.y ……………. Pc= π.m

Lewis form factor or tooth form 0.684 1

y = 0.124 – for 14 ° composite and full depth involute
𝑇 2
factor system.
0.684
= 0.154 – 𝑇 , for 20° full depth involute system
0.841
= 0.175 – 𝑇 ,for 20° stub system
The permissible working stress 𝜎𝑤 = 𝜎0 .Cv where
𝜎0 = Allowable static stress, and
Cv = Velocity factor
The values of velocity factors are given as follows
3
Cv= 3+𝑣 for ordinary cut gears operating at velocities up to 12.5
m/s
4.5
= 4.5+𝑣 for carefully cut gears operating at velocities up to
12.5 m/s
6
= 6+𝑣 for very accurately cut and ground metallic gears
operating at velocities up to 20 m/s
0.75
= 0.75+ 𝑣 for precision gears cut with high accuracy and
operating at velocities up to 20 m/s
0.75
=( 1+𝑣 )+0.25 for non-metallic gears
Dynamic tooth load 21.𝑣.(𝑏.𝐶+𝑊𝑇 )
WD= WT + WI = WT+ 21.𝑣. 𝑏.𝐶+𝑊𝑇
where
WD= Total dynamic load in Newton
WT= Steady transmitted load in Newton,
v = Pitch line velocity in m/s
b= Face width of gears in mm, and
C= A deformation or Dynamic factor in N/mm

Deformation or Dynamic factor 𝐾.𝑒

C= 1 1
+
may be determined by using the 𝐸𝑝 𝐸𝐺

relation where
K = A factor depending upon the form of the teeth
1
= 0.107 for 142 ° composite and full depth involute system.
= o.111 for 20° full depth involute system
= 0.115 for 20° stub system
𝐸𝑝 = Young’s modulus for material of pinion in N/mm2
𝐸𝐺 = Young’s modulus for material of gear in N/mm2
e= Tooth error action in mm

Static tooth load Ws= 𝜎𝑒 .b.Pc.y = 𝜎𝑒 .b.π.m.y

For steady loads Ws ≥ 1.25 WD
For pulsating load Ws ≥ 1.35 WD
For shock load Ws ≥ 1.5 WD
Wear tooth factor Ww= Dp.b.Q.K
where
Ww= Maximum or limiting load for wear in newtons,
Dp= Pitch circle diameter of the pinion in mm
b= Face width of the pinion in mm
Q= Ratio factor
2∗𝑉.𝑅 2𝑇𝐺
= 𝑉.𝑅+1= 𝑇 +𝑇 …….. for external gears
𝐺 𝑃

2∗𝑉.𝑅 2𝑇𝐺
= 𝑉.𝑅−1= 𝑇 …….. for internal gears
𝐺 −𝑇𝑃
𝑇𝐺
V.R = Velocity ratio =
𝑇𝑃
K = Load-stress factor (also known as material combination
factor)in N/mm2
(𝜎𝑒𝑠 )2 .𝑠𝑖𝑛𝜑 1 1
= 1.4
(𝐸 +𝐸 )
𝑝 𝐺
where
𝜎𝑒𝑠 = Surface endurance limit in Mpa or N/mm2
Φ = Pressure angle
𝐸𝑝 = Young’s modulus for material of pinion in N/mm2
𝐸𝐺 = Young’s modulus for material of gear in N/mm2
Note: The values of surface endurance limit (𝜎𝑒𝑠 ) are given in
the table
 3B Helical Gear
Overlap = Pc= b. tanα = 1.15Pc
1.15𝑃 1.15∗ 𝜋∗𝑚
∴ b = 𝑡𝑎𝑛𝛼 𝑐 = 𝑡𝑎𝑛𝛼 …….. (∵ 𝑃𝑐 = 𝜋. 𝑚)

Formative or equivalent number of 𝑇

TE= 3
𝑐𝑜 𝑠 𝛼
teeth on a helical gear where
T= Actual number of teeth on a helical gear
𝛼 = Helix angle
Lewis Equation WT= 𝜎𝑜 . 𝐶𝑣 .b.π.m.y’
Where
WT = Tangential tooth load
𝜎𝑜 = Allowable static stress
Cv = Velocity factor
b= Face width
m = Module
y’ = Tooth form factor or Lewis factor corresponding to the
formative or virtual or equivalent number of teeth
The value of velocity factor (Cv) 6
Cv= For peripheral velocities from 5 m/s to 10 m/s
6+𝑣
may be taken
15
= 15+𝑣 For peripheral velocities from 10 m/s to 20 m/s

0.75
= For peripheral velocities greater then 20 m/s
0.75+ 𝑣

0.75
=( )+0.25 for non-metallic gears
1+𝑣
The dynamic tooth load on the 21.𝑣.(𝑏.𝐶.𝑐𝑜 𝑠 2 𝛼+𝑊𝑇 .)𝑐𝑜𝑠𝛼
WD = WT +
helical gears 21.𝑣+ 𝑏.𝐶.𝑐𝑜 𝑠 2 𝛼 +𝑊𝑇

Static tooth load or endurance Ws= 𝜎𝑒 .b.π.m.y’

strength of the tooth
The maximum or limiting wear 𝐷𝑝 .𝑏.𝑄.𝐾
Ww= 𝑐𝑜 𝑠 2 𝛼
tooth load for helical gears is given
by
(𝜎𝑒𝑠 )2 .𝑠𝑖𝑛 𝜑 𝑁 1 1
K= 1.4
(𝐸 +𝐸 )
𝑝 𝐺
Where
𝜑𝑁 = Normal pressure angle

Properties of Helical gear
Pressure angle in the plane of rotation = Φ= 15° to 25°
Helix angle= 𝛼= 20° to 45°
Addendum = 0.8 m(maximum)
Dedendum =1m(minimum)
Minimum total depth = 0.2m
Thickness of tooth = 1.5708m
 3C Bevel Gears
Properties of Bevel gears
Addendum = a= 1 m
Dedendum =d= 1.2m
Clearance = 0.2m
Working depth = 2m
Thickness of tooth = 1.5708m
Where
m is the module

Cone distance or pitch cone radius 𝑝𝑖𝑡𝑐 ℎ 𝑟𝑎𝑑𝑖𝑢𝑠 𝐷 /2 𝐷 /2

OP= 𝑠𝑖𝑛 𝜃𝑝
= 𝑠𝑖𝑛𝑝𝜃 = 𝑠𝑖𝑛𝐺𝜃
𝑝1 𝑝2
Outside or addendum cone D0 = DP+2acos𝜃𝑃
diameter where
DP= Pitch circle diameter
a= Addendum
𝜃𝑃 = Pitch angle
Inside or dedendum cone diameter Di = DP-2dcos𝜃𝑃
where
DP= Inside diameter
d= dedendum
𝜃𝑃 = Pitch angle
Pitch angle for bevel gears 𝑆𝑖𝑛 𝜃
𝜃𝑃1 = ta𝑛−1 (𝑉.𝑅+cos𝑠 𝜃 ) &
𝑠
−1 𝑆𝑖𝑛 𝜃𝑠
𝜃𝑃2 = ta𝑛 ( 1 )
+cos 𝜃𝑠
𝑉.𝑅
When the angle between the shaft 1 𝐷 𝑁
𝜃𝑃1 = ta𝑛−1 (𝑉.𝑅 ) = ta𝑛−1 (𝐷𝑃 ) = ta𝑛−1 (𝑁𝐺 )
𝐺 𝑃
axes is 90° i.e 𝜃𝑠 =90°
𝐷 𝑇 𝑁
𝜃𝑃2 = ta𝑛−1 (V.R)= ta𝑛−1 (𝐷𝐺 ) = ta𝑛−1 (𝑇𝐺 ) = ta𝑛−1 (𝑁𝑃 )
𝑃 𝑃 𝐺

Formative or equivalent number of 2𝑅 2.𝑅.𝑠𝑒𝑐 𝜃

teeth for bevel gears(Tredgolds
approximation)
The modified form of Lewis
equation for the tangential tooth
load
TE= 𝑚𝐵 = 𝑚 𝑝 = T.secθP
where
T= Actual number of teeth on the gear.
𝐿−𝑏
WT = (σo*CV).b.π.m.y’( 𝐿 )
where
σo=allowable static stress
CV=Velocity factor
3
= 3+𝑣 for teeth cut by form cutters
6
= 6+𝑣 for teeth generated with precision machines
v = Peripheral speed in m/s
b=Face width
m= module
y’ = Tooth form factor or Lewis factor for the equivalent no. of
teeth
L= Slant height of pitch cone or cone distance
 𝐷𝐺 2 𝐷𝑃 2
L= ( 2
) +( 2
)

𝐿−𝑏
( 𝐿
) is called as bevel factor

Static tooth load or endurance 𝐿−𝑏

Ws = (σe*CV).b.π.m.y’( )
𝐿
strength of tooth for bevel gears Where
σe = Flexural endurance limit

The maximum or limiting load for 𝐷𝑝 .𝑏.𝑄.𝐾

WW = 𝑐𝑜𝑠 𝜃𝑝 1
wear for bevel gear
Note: 𝐷𝑝 , 𝑏 𝑎𝑛𝑑 𝐾 are same meaning as taken in spur gears
except that Q
2𝑇𝐸𝐺
Q= 𝑇 +𝑇
𝐸𝐺 𝐸𝑃

Forces acting on a bevel gear:

The magnitude of the tangential WT = WN.cos𝜑
component is
The magnitude of the radial WR = WN.sin𝜑 = WTtan𝜑
component
Mean radius (Rm) 𝑏 𝑏 𝐷
Rm= (L- 2 ).sinθp1 = (L- 2 ). 2𝐿𝑝
Axial force acting on the pinion WRH= WR. sinθp1 = WT.𝑡𝑎𝑛𝜑. sinθp1
shaft
Radial force acting on the pinion WRV= WR. cosθp1 = WT.𝑡𝑎𝑛𝜑. cosθp1
shaft
Torque acting on the pinion 𝑝.60
T = 2𝜋𝑁 …. N-m
𝑃
Tangential force 𝑇
WT= 𝑅
𝑚
Resultant bending moment on the
pinion shaft:
The bending moment due to WRH M1 = WRV*Overhang - WRH*Rm
and WRV is given by
The bending moment due to WT M2 = WT*Overhang
Resultant bending Moment
M = 𝑀1 2 + 𝑀2 2
 3D Worm Gears

Lead l = Pa.n
where
Pa= axial pitch
N= Number of
𝑚 .𝑛
Lead angle 𝜆 may be calculated as tan 𝜆= 𝐷
𝑤
where
m= module
Dw= Pitch circle diameter of worm
Note: For complete design
𝑁
tan 𝜆= (𝑁 𝐺 )∧ 13
𝑊
Normal pitch PN= Pa. 𝑐𝑜𝑠 𝜆
Helix angle 𝛼𝑤 +𝜆= 90°
Velocity ratio 𝑃𝑐. 𝑇𝐺 𝑃𝑎 . 𝑇𝐺 𝑇𝐺
𝑙
= 𝑃 .𝑛 = 𝑛
𝑎.
Efficiency of worm gearing 𝜂=
tan 𝜆(cos 𝜑 – 𝜇 .Tan 𝜆)
𝑐𝑜𝑠𝜑 .𝑡𝑎𝑛𝜆 +𝜇
where
𝜑= Normal pressure angle
𝜇 = Coefficient of friction
𝜆 = Lead angle
Maximum efficiency Tan𝜆= 1 + 𝜇2 – 𝜇
Efficiency for square thread 𝜂=
tan 𝜆(1 – 𝜇.Tan 𝜆)
=
(1 – 𝜇 .Tan 𝜆) .Tan 𝜆)
= tan ⁡(𝜆+𝜙
𝑡𝑎𝑛𝜆 +𝜇 𝜇
1+ 𝑡𝑎𝑛𝜆 1)
where
𝜙1 = Angle of friction, such that tan 𝜙1 = 𝜇

Strength of worm gear teeth WT =(𝜎𝑜 .Cv)b.π.m.y

where
WT=Permissible tangential tooth load or beam strength of
gear tooth
𝜎𝑜 = Allowable static stress
Cv = Velocity factor
6
= 6+𝑣 where v is peripheral velocity of worm gear
b= Face width
m= Module
y = Tooth form factor or Lewis factor
0.684 1
= 0.124 – for 14 ° involute teeth
𝑇𝐺 2
 0.912
= 0.154 – 𝑇𝐺
for 20° involute teeth

Dynamic tooth load on worm gear is 𝑊𝑇 6

WD = 𝐶𝑣
= WT (6+𝑣)
given by
where
WT = Actual tangential load on the teeth
The static tooth load or endurance WS = 𝜎𝑒 .b.π.m.y
strength of tooth (WS) where
𝜎𝑒 = Flexural endurance limit. its value may be taken as 84
Mpa for cast iron and 168 Mpa for phosphor bronze
gear.
Wear tooth load for Worm Gear:
Limiting or maximum load for wear WW= DG.b.K
(WW) where
DG = Pitch circle diameter of the worm gear,
b= Face width of the worm gear
K= Load stress factor
Thermal rating of worm gearing:
The quantity heat generated Qg= Power lost in friction in watts = P(1- 𝜂)
where
P= Power transmitted in watts
𝜂= efficiency of the worm gearing
The heat dissipating capacity Qd = A(t2 – t1)K
Where
A= Area of housing
(t2 – t1) = Temperature difference between the housing
surface and surrounding air
K= conductivity of the material
Design of worm gearing:

𝐷𝑤 +𝐷𝐺 𝑙 𝑙𝑁 1 𝑉.𝑅
x= = (cot𝜆 +V.R) = ( + )
2 2𝜋 2𝜋 𝑠𝑖𝑛𝜆 𝑐𝑜𝑠𝜆

note: The lowest point on the curve may be determined

𝑥
by differentiating 𝑙 w.r.to 𝜆 and equate to zero
𝑁
𝑉.𝑅 𝑠𝑖𝑛 3 𝜆−𝑐𝑜𝑠 3 𝜆
= 0 or V.R = 𝑐𝑜𝑡 3 𝜆
𝑠𝑖𝑛 2 𝜆.𝑐𝑜𝑠 2 𝜆
 TABLE (Load Factor KL) Ref: D.P.Mandal
Driver Driven machinery KL
Electric generator, Steady load 1.00
Steam engine Turbine blower, centrifugal pump 1.25
Induced draft fan; line shaft rolling mill 2.00
Turbine blower; metal working machinery 1.25
Centrifugal pump, wood working machinery 1.50
Line shaft; ship propeller; double acting pump 1.75
Electric motor
Triplex single acting pump; elevator crane 1.75
Air or ammonia compressor 1.75
Rolling mill; rubber mill 2.50
Steam engine Electric motor drive 1.2 to 1,5

TABLE : Service Factor for Worm Gear – KS Ref: D.P.Mandal

Sr.no Type of service Ks
1 Intermittent with light shock 1.0 – 1.5
2 Continuous with medium shock crushers etc 1.5 – 2.0
3 Continuous with heavy shock reciprocating pump and rubber mill 2.0 – 2.5
4 Continuous with heavy shock main line, steel mill 2.5 – 3.0

TABLE : Coefficient of friction 𝝁 Ref: D.P.Mandal

Sr.no Types of services 𝝁
1 Very careful machining 0.02
2 Ordinary industrial worm well lubricated 0.05
3 Low speed and Indifferent lubrication 0.15
 TABLE: Rubbing Velocity Ref: D.P.Mandal
Ordinary industrial worm 370 m/min
Well designed hardened and ground worm 900 m/min

TABLE: Velocity Ratio Ref: D.P.Mandal

Number of starts V.R
Single 20 and over
Double 12 -16
Triple 8 – 12
Quadruple 6 – 12

TABLE: Efficiency of Worm gear drive Ref: D.P.Mandal

Number of start on worm 𝜼
1 0.70 to 0.75
2 0.70 to 0.82
3 and 4 0.80 to 0.92
 MACHINE DESIGN DATA BOOK Final Year

4A IC Engine Parts

p = Maximum pressure inside the cylinder in N/mm2,

D = Inside diameter of the cylinder or cylinder bore in mm,
σc = Permissible circumferential or hoop stress for the cylinder material in MPa or N/mm2.
C = Allowance for re boring
pm = Indicated mean effective pressure in N/mm2,
A = Cross-sectional area of the cylinder in mm²,
l = Length of stroke in metres,
N = Speed of the engine in r.p.m., and
n = Number of working strokes per min
= N, for two stroke engine
= N/2, for four stroke engine.
L = Length of the cylinder
(B. P.) = brake power
ns = Number of studs. It may be taken as (0.01 D + 4 to 0.02 D + 4)
dc = Core or minor diameter, i.e. diameter at the root of the thread
σt = Allowable tensile stress for the material of studs or bolts in MPa
H = Heat flowing through the piston head in kJ/s or watts,
k =Heat conductivity factor in W/m/°C.
Grey Cast Iron = 46.6 W/m/°C
Steel = 51.25 W/m/°C
Aluminium Alloys = 174.75 W/m/°C for.
TC = Temperature at the centre of the piston head in °C,
TE = Temperature at the edges of the piston head in °C.
The temperature difference (TC – TE) may be taken as;
For cast iron = 220°C and
For aluminium= 75°C.
Where C = Constant representing that portion of the heat supplied to the engine which is absorbed by the piston.
Its value is usually taken as 0.05.
HCV = Higher calorific value of the fuel in kJ/kg.
For diesel = 45 × 103 kJ/kg
For petrol= 47 × 103 kJ/ kg
m = Mass of the fuel used in kg per brake power per second, and
B.P. = Brake power of the engine per cylinder
l1 = Length of the piston pin in the bush of the small end of the connecting rod in mm; (0.45 D).
d0 = Outside diameter of the piston pin in mm
pb1 = Bearing pressure at the small end of the connecting rod bushing in N/mm2 .For the bronze bushing may be taken
as 25 N/mm2.

G. H. Raisoni College of Engineering and Management, Amravati Page 1

 MACHINE DESIGN DATA BOOK Final Year

The thickness of the cylinder wall : t = 0.045 D + 1.6 mm

It varies from 4.5 mm to 25 mm
Thickness of the dry liner 0.03 D to 0.035 D
Thickness of the water jacket wall 0.032 D + 1.6 mm or t / 3 m for bigger cylinders
and
3t /4 for smaller cylinders
Water space between the outer cylinder wall and 10 mm for a 75 mm cylinder to 75 mm for a 750
inner jacket wall mm cylinder or
0.08 D + 6.5 mm
Indicated power
pm l A n BP
I P= =
60 ηm

The length of stroke (l) l = 1.25 D to 2D

Length of the cylinder L = 1.15 × Length of stroke = 1.15 l
π π
Cylinder flange and stud D2 = ns 4 dc 2 σt
4
the pitch of the studs or bolts between 19 d to 28.5 d
Thickness of cylinder Head C.p
σc = 30 to 50 MPa, th = D
σc
C = Constant = 0.1.
Dp = D + 3d.
The thickness of the piston head (tH ), 3pD 2
σt = 35 to 40 MPa for grey cast iron, tH =
16σt
in mm
50 to 90 MPa for nickel cast iron
60 to 100 MPa aluminium alloy
Treating the piston head as a flat circular plate, its H
thickness is given by (in mm) tH =
12.56 k(T C −T E )

The heat flowing through the piston head (H) H = C × HCV × m × B.P. (in kW)

Radial thickness of piston ring 3P w

t1= D σt
pw = 0.025 N/mm2 to 0.042 N/mm2
Minimum axial thickness t2 t2 = D/10 x nr
nr = Number of rings.
Width of top land b1 = tH to 1.2 tH
Width of other ring land b2 = 0.75 t2 to t2
The gap between the free ends of the ring. G1 = 3.5 t1 to 4 t1
G. H. Raisoni College of Engineering and Management, Amravati Page 2
 MACHINE DESIGN DATA BOOK Final Year

The gap, when the ring is in the cylinder

G2 = 0.002 D to 0.004 D
The maximum thickness (t3) of the piston barrel t3 = 0.03 D + b + 4.5 mm
b = t1 + 0.4 mm
Maximum gas load on the piston πD 2
P=p∗
4
Maximum side thrust on the cylinder πD 2
R =P/10 = 0.1 p *
p = Maximum gas pressure in N/mm2, and 4
D =Cylinder bore in mm.
The side thrust (R) is also given by
R =Bearing pressure × Projected bearing area of the
piston skirt, where l = Length of the piston skirt R = pb × D × l

The total length of the piston (L) is given by L = Length of skirt + Length of ring section + Top
The length of the piston between D and 1.5 D. land
load on the piston pin due to bearing pressure or = Bearing pressure × Bearing area = pb1 × d0 × l1,
bearing load
Length between the support l2= D + l1/2
Maximum bending moment, for the piston pin M = P.D / 8
σb = Allowable bending stress for the material of
the piston pin π d04 − di 4
M=
32 d0
x σb
84 MPa for case hardened carbon steel and
140 MPa for heat treated alloy steel

Coneecting Rod,
p = Maximum pressure of gas,
D = Diameter of piston,
A = Cross-section area of piston
mR = Mass of reciprocating parts,
= Mass of piston, gudgeon pin etc. +1/3rd mass of connecting rod,
ω= Angular speed of crank,
ϕ= Angle of inclination of the connecting rod with the line of stroke,
θ= Angle of inclination of the crank from top dead centre,
r = Radius of crank,
l = Length of connecting rod, and
n = Ratio of length of connecting rod to radius of crank = l / r.
A = Cross-sectional area of the connecting rod,
l = Length of the connecting rod,
σc = Compressive yield stress, in MPa
σt = Allowable tensile stress for the material of the bolts, in MPa
σb = Allowable bending stress for the material of the cap in MPa
WB = Buckling load,
Ixx and Iyy = Moment of inertia of the section about X-axis and Y-axis resp.
kxx and kyy = Radius of gyration of the section about X-axis and Y-axis resp.
L = Equivalent length of the connecting rod, and
a = Constant
= 1 / 7500, for mild steel
= 1 / 9000, for wrought iron
= 1 / 1600, for cast iron
Thickness of the flange and web of the section = t
Width of the section, B = 4 t
Depth or height of the section, H = 5t
D = Cylinder bore or piston diameter in mm, and
p = Maximum gas pressure in N/mm2
dc = Diameter of the crank pin in mm,
lc = Length of the crank pin in mm,
pbc = Allowable bearing pressure in N/mm2, and

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 MACHINE DESIGN DATA BOOK Final Year

dp, lp and pbp = Corresponding values for the piston pin,

For bolts a factor of safety may be taken as 6.
Let dcb = Core diameter of the bolt in mm,
nb = Number of bolts. Generally two bolts are used.
x = Distance between the bolt centres
bc = Width of the cap in mm.

Force on the piston due to pressure of gas,

πD 2
FL = Pressure × Area = p . A = p ×
4
Inertia force of reciprocating parts,
cos 2θ
FI = Mass × *Acceleration = mR ω².r(cosθ + )
n

Net force acting on the piston or piston pin (or

gudgeon pin or wrist pin) FP = Force due to gas pressure + Inertia force
= FL + FI
Force on connecting rod = FC FC = Fp/cosϕ
Buckling load σc.A
WB = [ l ]
From Fig. we find that area of the section, 1+a(
2Kyy
)
A = 2 (4 t × t) + 3 t × t = 11 t2 kx2x 4ky2y or Ixx 4I yy ...(∵I = A · k2)
WB = Max. gas force × Factor of safety
The factor of safety may be taken as 5 to 6.
Moment of inertia of the section about X-axis,
1 419 4
Ixx = ( 4t. 5t 3 − 3t. (3t 3 )) = t
12 12
and moment of inertia of the section about Y-axis,
1 1 131 4
Iyy = (2 ∗ t. 4t 3 + (3t). t 3 ) = t
12 12 12
419 12
Ixx/Iyy = ∗ = 3.2
12 131

lies between 3 and 3.5, therefore, I-section chosen is

quite satisfactory.
H1 = 0.75 H to 0.9H and the depth near the big end
(or crank end) is taken
H2 = 1.1H to 1.25H.
Dimensions at big end and small end maximum gas force,
πD 2
FL = p ×
4
load on the crank pin
= Projected area × Bearing pressure
= dc . lc . pbc
Similarly, load on the piston pin
= dp . lp . pbp
FL = dc · lc · pbc
Taking lc = 1.25 dc to 1.5 dc, we have
FL = dp · lp · pbp
Taking lp = 1.5 dp to 2 dp, the value of dp and lp
Size of bolt securing big end, We know that inertia
force of the reciprocating parts,
cos 2θ
FI = mR* ω².r(cosθ + )
l/r
When θ = 0 ,
r
FI = mR* ω².r(1+ )
l

Force on the bolts π

(dcb)². σt. nb
4
Equating the inertia force to the force on the bolts, π
FI = (dcb)². σt. nb
4
From this expression, dcb is obtained. The nominal
or major diameter (db) of the bolt is given by

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 MACHINE DESIGN DATA BOOK Final Year

db = db/ 0.84
Thickness of big end cap MC = (FI* x )/6
where x = Distance between the bolt centres.
= Dia. of crankpin or big end bearing (dc) + 2 ×
Thickness of bearing
liner (3 mm) + Clearance (3 mm)
We know that section modulus for the cap Zc = (bc.(tc)²)/6
Bending stress σb = Mc/Zc

4B GOVERNORS

m = Mass of each ball in kg,

M = Mass of sleeve in kg,
r1 = Minimum radius of rotation in meters,
r2 = Maximum radius of rotation in meters,
ω1 = Angular speed of the governor at minimum radius in rad/s,
ω2 = Angular speed of the governor at maximum radius in rad/s,
S1 = Spring force exerted on the sleeve at ω1 in newtons,
S2 = Spring force exerted on the sleeve at ω2 in newtons,
FC1 = Centrifugal force at ω1 in newtons = m (ω1)2 r1,
FC2 = Centrifugal force at ω2 in newtons = m (ω2)2 r2,
s = Stiffness of the spring or the force required to compress the
spring by one mm,
x = Length of the vertical or ball arm of the lever in meters,
y = Length of the horizontal or sleeve arm of the lever in meters,
r = Distance of fulcrum O from the governor axis or the radius of
rotation when the governor is in mid-position, in meters.
h = compression of the spring when the radius of rotation changes from r1 to r2.

Minimum position i.e. when the radius of rotation h1 a1 r−r1

changes from r to r1, = = ….(1)
y x x
Maximum position i.e. when the radius of rotation h2 a2 r2−r
changes from r to r2, = = ….(2)
y x x

Compare 1&2
y
h = (r2-r1)
x

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 MACHINE DESIGN DATA BOOK Final Year

maximum position, taking moments about point O M.g+S2

x y2 = FC2 .x2 + mg a2
2
minimum position, taking moments about point O, M.g+S1
x y1 = FC1.x1 + mg a1
2
Stiffness of the spring S2−S1 S2−S1 x
s= =
h r2−r1 y
Neglecting the obliquity effect of the arms (i.e. x1 = x2 = Minimum position
x, and y1 = y2 = y) and the moment due to weight of the
balls (i.e. m.g),
M.g+S1
x y = FC1 .x
2
Maximum position

M.g+S2
x y = FC2 .x
2

S2−S1 FC 2−FC 1 x 2
s= =
h r2−r1 y

FC 2−FC 1 FC −FC 1 FC 2−FC

= =
r2−r1 r−r1 r2−r

G. H. Raisoni College of Engineering and Management, Amravati Page 6