Designoflever-Design of Machines

LEVER
Definition:
A lever is a rigid rod or bar capable of turning about
a fixed point called as a lever.
It is used as a mechanism to lift a load by the

application of small effort.
The ratio of load lifted to effort applied is called as

mechanical advantage
The ratio of effort arm to the load arm is called as

leverage.
Mr. V. R. Muttagi, Solapur, Maharashtra

(India)
Applications of Lever in Engineering
First Type of Lever:
The first type of lever, the fulcrum is in between the
load and effort.
The effort arm is greater than load arm, therefore
mechanical advantage obtained is more than one.

(India)
Second Type of Lever:
The second type of lever, the load is in between the
fulcrum and effort.
The effort arm is greater than load arm, therefore
mechanical advantage obtained is more than one.

(India)
Third Type of Lever:
The second type of lever, the effort is in between the
fulcrum and load.
The effort arm is less than load arm, therefore
mechanical advantage obtained is less than one.

(India)
Reactive Forces at Fulcrum Pin
First Type of Lever: Second Type of Lever:
Third Type of Lever: Lever with Inclined

Forces:
Bell Crank Lever:

(India)
Design of Hand Lever

(India)
Design of Shaft Under Torsion:
The shaft can be transmit the torque as,
But, the torque which is transmitted by the lever of length ‘L’ is,
Hence the torque developed by applied effort and length of lever that has to
be transmitted by the shaft of lever. Therefore equating both equation, we
can determine the diameter of shaft ‘d’

(India)
Design of Boss Under Tearing or Tension:
We know that the torque transmitted by the lever, the same torque will be
transmitted by the shaft through the boss attached with lever.
The torque produced a tangential force on the thickness of boss and hence,
area of thickness of boss is subjected to tensile stress. Because of this
tensile force, the boss may fails or tears along the length of boss.
The torque will be transmitted by the boss is,
Where, F is tensile load acting on thickness of boss, which is developed by

torque.

(India)
Design of Shaft in Bearing Under Equivalent Torque:
The shaft of diameter ‘d1’ is supported in the bearing and transmitting the
torque. This shaft support is eccentric at eccentricity of ‘l’ from the centre of
lever, hence bending moment is also developed by the applied force.
Therefore the shaft in bearing is subjected to the combined stresses of
bending and torsion, hence the design of shaft is done by considering the
equivalent torque. Torque transmitted,
Bending Moment on shaft,
Equivalent torque is,

(India)
Design of Kay Under Torsional Shear:
While transmitting the torque from boss to shaft a key is acting
perpendicular twisting forces, hence it is subjected to the shear stress,
Torque transmitted is,
Torque transmitted by key is,

(India)
Design of Lever Under Bending Stress:
We know that the bending stress is,
Bending moment acting on the lever is,
Section modulus of the lever is,

(India)
Empirical Equations:
P = Applied force on the handle of lever
L = Effective length of lever
d = Diameter of shaft in boss
d1 = Diameter of shaft in bearing
d2 = Diameter of boss
t = Thickness of lever near boss
t1 = Thickness of key = (2/3) w or d/6
t2 = Thickness of boss = 0.3 d
l = Length of bearing from centre of lever arm
l1 = Length of key = l
l2 = Length of boss = d to 1.25 d
B = Breadth of lever = 4t to 5t
w = Width of key = (d/4) (India)
Design of Foot Lever
The design procedure of Hand lever and Foot Lever is same except the
magnitude of load applied on the lever. Mr. V. R. Muttagi, Solapur, Maharashtra
(India)
Design of Bell Crank Lever

(India)
Reactive Force at Fulcrum Pin:
Design of Fulcrum Pin Under Bearing Pressure:
Where,
l = Length of Fulcrum Pin = 1.25 d
d = Diameter of Fulcrum Pin
RF = Reactive Force at Fulcrum Pin
Design of Fulcrum Pin Under Shear Stress:
Where,
Diameter of Hole in Lever = d+2t
t = Thickness of Brass Bush = 3mm Mr. V. R. Muttagi, Solapur, Maharashtra
(India)
Design of Pin at A Under Bearing Pressure:
The length of effort arm is too less than the load arm, hence the direction of reactive
force at fulcrum pin is nearly equal to the applied effort, therefore,
Where,
l1 = Length of Pin at A = 1.25 d1
d1 = Diameter of Pin at A
Design of Pin at A Under Shear Stress:
Where,
Diameter of Hole in Lever = d1+2t
t = Thickness of Brass Bush = 3mm
(India)
Design of Pin at B Under Bearing Pressure:
Where,
l2 = Length of Pin at B = 1.25 d2
d2 = Diameter of Pin at B
Design of Pin at B Under Shear Stress:
Where,
Diameter of Hole in Lever = d2+2t
(India)
Design of Forked Eye:
Forked eye is not playing an important role in the operations of lever, hence their
dimensions have to designed as per the empirical equations as below,
t1 = Thickness of each Forked Eye = (l2/2)

D = Outer Diameter of each Eye = 2d2
Design of Lever Arm Under Bending:

(India)
Design of Lever for Lever Safety Valve

(India)
Reactive Force at Fulcrum Pin F:
The reactive force at fulcrum pin is determined by,
………………(1)
The load at valve seat is due to the steam pressure acting on the valve seat, it is
determined as,
Effort P can be determined by taking moment of forces about fulcrum point F as below,
………………(2)
From equation 2 effort P can be determined, by putting the value of P and W in

equation 1 reactive force can be determined.
(India)
Design of Fulcrum Pin Under Bearing Pressure:
Where,
lF = Length of Fulcrum Pin = 1.25 dF
dF = Diameter of Fulcrum Pin
Design of Fulcrum Pin Under Shear Stress:
A gunmetal bush of 3mm thickness is provided inside the pinhole at F,
Diameter of hole for fulcrum pin = dF+(2X3)

Outside diameter of boss = 2dF
(India)
Design of Pin at A Under Bearing Pressure:
Since reactive force does not differ than load at A due to minimum length between A
and F,
Where,
lA = Length of Pin at A = 1.25 dA
dA = Diameter of Pin at A
Design of Pin at A Under Shear Stress:
A gunmetal bush of 3mm thickness is provided inside the pinhole at A,
Diameter of hole for pin at A = dA+(2X3)

Outside diameter of boss = 2dA
(India)
Design of Lever Under Bending:

(India)

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LEVER

It is used as a mechanism to lift a load by the

The ratio of load lifted to effort applied is called as

The ratio of effort arm to the load arm is called as

Mr. V. R. Muttagi, Solapur, Maharashtra

Mr. V. R. Muttagi, Solapur, Maharashtra

Mr. V. R. Muttagi, Solapur, Maharashtra

Mr. V. R. Muttagi, Solapur, Maharashtra

Third Type of Lever: Lever with Inclined

Bell Crank Lever:

Mr. V. R. Muttagi, Solapur, Maharashtra

Mr. V. R. Muttagi, Solapur, Maharashtra

The shaft can be transmit the torque as,

Mr. V. R. Muttagi, Solapur, Maharashtra

Where, F is tensile load acting on thickness of boss, which is developed by

Mr. V. R. Muttagi, Solapur, Maharashtra

Bending Moment on shaft,

Equivalent torque is,

Mr. V. R. Muttagi, Solapur, Maharashtra

Torque transmitted by key is,

Mr. V. R. Muttagi, Solapur, Maharashtra

Bending moment acting on the lever is,

Section modulus of the lever is,

Mr. V. R. Muttagi, Solapur, Maharashtra

Mr. V. R. Muttagi, Solapur, Maharashtra

Design of Fulcrum Pin Under Bearing Pressure:

Design of Pin at B Under Shear Stress:

t1 = Thickness of each Forked Eye = (l2/2)

Design of Lever Arm Under Bending:

Mr. V. R. Muttagi, Solapur, Maharashtra

Mr. V. R. Muttagi, Solapur, Maharashtra

From equation 2 effort P can be determined, by putting the value of P and W in

Design of Fulcrum Pin Under Shear Stress:

A gunmetal bush of 3mm thickness is provided inside the pinhole at F,

Diameter of hole for fulcrum pin = dF+(2X3)

Design of Pin at A Under Shear Stress:

A gunmetal bush of 3mm thickness is provided inside the pinhole at A,

Diameter of hole for pin at A = dA+(2X3)

Mr. V. R. Muttagi, Solapur, Maharashtra

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