Assignment No-2

Subject: Machine Design-I July, 2023 to Nov. 2023

Unit II: Design of Shafts & Couplings Date of Submission: 24-08-2023

1. a) Which theory is commonly used for design of a shaft? Explain why?

b) Enumerate the causes of shaft failures.
c) What effect has a keyway on the torsional rigidity of a shaft?
d) Name various materials and processes used for manufacturing shafts.

2. A rotating shaft of mean diameter 40 mm and thickness 4 mm is made of cold drawn C-20 steel
tubing and has a 6 mm diameter hole drilled transversely through it. Estimate the F.O.S. for fatigue
and static failures. The shaft is subjected to a pulsating torque from 20 Nm to 160 Nm and a steady
bending moment of 150 Nm.

3. A steel shaft transmitting 20 KW at 210 rpm is supported on two bearings 750 mm apart and has two
gears keyed to it. The pinion having 24 teeth of 16 DP is located 100 mm to the left of the right hand
bearing and delivers the power horizontally to the right. The gear having 80 teeth of 16 DP is located
150 mm to the right of the left hand bearing and receives power in vertical direction from below.
Using an allowable shear stress of 54 MPa, determine the size of the shaft.

4. A shaft 2 m long is supported at the ends by simple bearings. A vertical load of 2 KN is applied 0.5 m
from the left end, a load of 1.5 KN acting upward is applied at an angle of 60 o with the horizontal and
0.1 m from the left end and a load of 1.25 KN acting down and forward at an angle of 45 o with the
vertical is applied 1.5 m from the left end. A torque of 300 Nm is applied at the first load, and a torque
of 180 Nm is taken off at the third load. Determine the required shaft diameter if the allowable stress
is 70 MPa in tension and 40 MPa in shear. Assume Kb=2, Kt=1.5.

5. A hot rolled steel shaft is subjected to a torsional load that varies from 330 Nm CW to 110 Nm CCW
as an applied B.M. at a critical section varies from + 440 Nm to – 220 Nm. The shaft is of uniform
cross-section and no keyway is present at the critical section. The material has an ultimate strength of
550 N/mm2 and a yield strength of 410 N/mm 2. Design F.O.S. = 1.5. Take the endurance limit as half
the ultimate strength.

6. A solid circular shaft 300 mm diameter is made of alloy steel having ultimate tensile and shear
strengths of 644 N/mm2 and 530 N/mm2. A hollow shaft is to replace the above shaft and is made of
alloy steel having ultimate tensile and shear strength of 735 N/mm 2 and 695 N/mm2. Determine the
size of hollow shaft if a saving of 1/3 of the solid shaft is desired.

7. A ship requires 225 KW to drive it at a forward speed of 5 m/s and at this speed the propeller rotates
at 180 rpm. The horizontal propeller shaft is not liable to buckle. Find the diameter of the shaft. If the
maximum allowable shear stress is 45 MPa and the twist in degrees per meter. Take G= 0.08X10 6
MPa.

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8. Design a rigid sleeve coupling to connect two shafts, transmitting 18.75 KW at 1000 rpm. The
allowable shear stress in the material of the shaft is 55 N/mm 2. The material of the key and shaft is
same and the coupling is required to transmit 20 % overload. The material od sleeve is cast iron, the
allowable shear stress for which is 16 N/mm 2. Make a neat sketch of the designed sleeve coupling
showing side view and sectional elevation.

9. Two 40 mm shafts are connected by a flange coupling. The flanges are fitted with six bolts of carbon
steel on a 125 mm bolt circle. The shafts are run at 340 rpm and transmit a torsional moment of 1000
Nm. Assume a F.O.S. of 5. a) What diameter bolts should be used? b) How thick the flanges should
be? c) Determine the key dimensions. d) Determine the hub length. e) What power can be transmitted
by this coupling?

10. Design a flexible coupling of pin-bush type construction for connecting a reduction gear shaft to a
stone crusher shaft. The unit is driven by 30 KW, 720 rpm motor through 1: 5 reduction. Choose
suitable materials and their design stresses for the parts of the coupling.

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