DESIGN OF MACHINE

ELEMENTS-II
Course Code:1003203203
III YEAR II SEMESTER
PREPARED BY Mr.S.SANYASIRAO
ASSISTANT PROFESSOR
9292556602,ssraome.1@gmail.com
 Course Overview
The course covers the design of various mechanical machine
elements like bearings, IC Engine parts, gears and power
transmission systems. It also develops the design aspects of
curved beams and mechanics of machine tool elements
Course Objectives

1. This course gives the insight of slider and roller bearings and
the life prediction.
2. Learn to design I.C engine parts
3. Design the mechanical systems for power transmission
elements such as gears, belts, ropes, chains and levers.
 Course Outcomes

COs Course outcomes

 

CO1 Select the suitable bearing based on the application of the loads
and predict the life of the bearing

CO2 Design of beams with various cross sections

 

CO3 Design of power transmission elements such as gears, belts,

chains, pulleys, ropes, levers and power screws

CO4 Design of IC Engines parts.

 COURSE CONTENT
UNIT-I:
 
Bearings: Classification of bearings- applications, types of journal bearings – lubrication
– bearing modulus –full and partial bearings – clearance ratio – heat dissipation of bearings,
bearing materials – journal bearing design – ball and roller bearings – static loading of ball & roller
bearings, bearing life.
 

UNIT-II:
 
Engine parts: Pistons, Forces acting on Various Parts of piston – construction design and
proportions of piston, Design of cylinder, cylinder liners. Connecting Rod: Forces Acting on the
Connecting Rod– Design Procedure for Connecting rod – Crank shafts- Design Procedure for
Crankshaft
 COURSE CONTENT
UNIT-III:
Power transmissions systems, pulleys: Transmission of power by belt and rope drives,
transmission efficiencies, belts – flat and v types - fibre ropes, pulleys for belt drive, Chain drives-
Design procedure of chain Drive.
 
Design of power screws- Types of Screw Threads , Stresses in Power Screws , Design of screw
Jack, square ACME, buttress screws, design of nut, , differential and compound screws, ball screw-
possible failures.
 
UNIT-IV:
 
Spur & helical gear drives: Spur gears- helical gears – load concentration factor – dynamic load
factor, surface compressive strength – bending strength – design analysis of spur gears – estimation
of centre distance, module and face width, check for plastic deformation, check for dynamic and
wear considerations
 COURSE CONTENT
UNIT-V:
 
Machine tool elements: Levers: design of levers – hand levers-foot lever –
cranked lever– lever of a lever loaded safety valve- rocker arm straight – angular-
design of a crank pin– brackets- hangers wall boxes.
 
Wire ropes: Construction, Designation, Stresses in wire ropes, rope sheaves and
drums.
 
Design of curved beams: Introduction, stresses in curved beams, expression for
radius of neutral axis for rectangular, circular, trapezoidal and t-section, design of
crane hooks, c – clamps
 Text Books/Reference Books
Text Books
1. Machine Design/V.Bandari/TMH Publishers
2. Machine Design/ NC Pandya & CS Shaw/ Charotar publishers
3.Design data Hand book by K.Mahadevan and K.BalaveeraReddy
4.Design Data book for Engineers by PSG College of Technology
 
References:
1. Machine Design: An integrated Approach / R.L. Norton / Pearson Education
2. Mech. Engg. Design / JE Shigley/Tata McGraw Hill education
3. Design of machine elements/Spotts/Pearson Publications
4. Machine Design/Norton/Pearson Publications
5.A Textbook of Machine Design/R.S.Khurmi and J.K.Gupta/ S.Chand
Publications
 Academic Calendar III B.Tech
Academic Year-2022-23
II – SEMESTER

Description From To Weeks

1 Unit of Instructions 09-01-2023 04-03-2023 8W

1 Mid Examinations 06-03-2023 11-03-2023 1W

II Unit of Instructions 13-03-2023 29-04-2023 7W

II Mid Examinations 01-05-2023 06-05-2023 1W

Preparation,Practicals & End

Examinations 08-05-2023 25-05-2023 3W

Industrial/Research Internship 29-05-2023 24-06-2023 4W

Summer Vacation 26-06-2023 01-07-2023 1W

Commencement of next year
Class work 03-07-2023
COURSE CONTENT
UNIT-I:
Bearings: Classification of bearings- applications, types of journal
bearings – lubrication– bearing modulus –full and partial bearings –
clearance ratio – heat dissipation of bearings, bearing materials –
journal bearing design – ball and roller bearings – static loading of ball
& roller bearings, bearing life.
How does a Cycle wheel Rotate? How does a Crank Shaft Rotate in IC ENGINE?

How does a Shaft Rotate in a Centrifugal Pump?

Ball bearings are used between the hub the and axle of a ceiling fans as it reduces friction between the rotating
hub and the static axle of the fan to a greater extent as compare to direct contact, which could produce huge
amount of heat.
Propeller-shaft-bearings

Power transmission in industries

Wind turbine -bearings

  List the important physical characteristics of a
good bearing material.

 Bearing material should have high compressive

strength to withstand this maximum pressure so as
to prevent permanent deformation of the bearing
 Bearing material should have sufficient fatigue
strength so that it can withstand repeated loads
without developing surface fatigue cracks

 The bearing material should be of high thermal conductivity so as to permit

the rapid removal of the heat generated by friction
 The bearing material should be of low coefficient of thermal expansion
Properties Applications
Materials used
for Sliding
Contact Bearings

KMDB 364P or PSG DB 7.30P

 Distinguish between full and partial
journal bearings

Most of the bearings used in industrial applications are full journal bearings.
 Distinguish between full and partial
journal bearings

Partial bearing can take loads in only one radial direction. Partial bearings are used in railroad-cars.
The advantages of partial bearings compared to full journal bearing are as follows:
(i) Partial bearing is simple in construction.
(ii) It is easy to supply lubricating oil to the partial bearing.
(iii) The frictional loss in partial bearing is less. Therefore, temperature rise is low.
  Enumerate the factors that influence most the formation and
maintenance of the thick oil film in hydrodynamic bearings.
Important Factors for the Formation of Thick Oil
Film in Hydrodynamic Lubricated Bearings:
According to Reynolds, the following
factors are essential for the formation
of a thick film of oil in hydrodynamic
lubricated bearings :
1. A continuous supply of oil.
2. A relative motion between the two
surfaces in a direction approximately
tangential to the surfaces.
3. The ability of one of the surfaces to
 List  the  basic  assumptions  used  in  the  theory  of   hydrodynamic
take up a small inclination to the other
lubrication.
Assumptions in Hydrodynamic Lubricated Bearings: The following are the surface in the direction of the relative
basic assumptions used in the theory of hydrodynamic lubricated bearings: motion.
1. The lubricant obeys Newton's law of viscous flow. 4. The line of action of resultant oil
2. The pressure is assumed to be constant throughout the film thickness. pressure must coincide with the line of
3. The lubricant is assumed to be incompressible. action of the external load between
4. The viscosity is assumed to be constant throughout the film. the surfaces
5. The flow is one dimensional, i.e. the side leakage is neglected.
 Distinguish the “Hydrodynamic”
and “Hydrostatic Bearings” with
figures and suitable applications.
 Sketch the pressure distribution in a journal bearing with thick film lubrication in axial, and radial directions.
Pressure Distribution in Hydrodynamic Bearing
As the journal starts to rotate, it climbs the bearing surface and as the speed is further increased, it forces the fluid
into the wedge-shaped region. Since more and more fluid is forced into the wedge-shaped clearance space,
pressure is generated within the system. The pressure distribution around the periphery of the journal is shown in
Fig. Since the pressure is created within the system due to rotation of the shaft, this type of bearing is known as self-
acting bearing. The pressure generated in the clearance space supports the external load (W). In this case, it is not
necessary to supply the lubricant under pressure and the only requirement is sufficient and continuous supply of the
lubricant. This mode of lubrication is seen in bearings mounted on engines and centrifugal pumps.

Pressure Distribution in Hydrodynamic Bearing

 What are the various terms used in journal bearings analysis and design? Give their definitions in brief

Bearing/Diametral Clearance
 Define the following terms as applied to
journal bearings :
(a) Bearing characteristic number ;
(b) Bearing pressure; and
(c) Diametral clearance ratio
KMDB 366P or PSG DB 7.33P
 What is the importance of McKee’s investigation?
MCKEE’S INVESTIGATION
In hydrodynamic bearings, initially the journal is at rest. There is no relative motion and no hydrodynamic film.
Therefore, there is metal to metal contact between the surfaces of the journal and the bearing. As the journal starts
to rotate, it takes some time for the hydrodynamic film to build sufficient pressure in the clearance space. During this
period, there is partial metal to metal contact and a partial lubricant film. This is thin film lubrication.
As the speed is increased, more and more lubricant is forced into the wedge-
shaped clearance space and sufficient pressure is built up, separating the
surfaces of the journal and the bearing. This is thick film lubrication. Therefore,
there is a transition from thin film lubrication to thick film lubrication as the
speed increases.
The transition from thin film lubrication to thick film hydrodynamic lubrication
can be better visualized by means of a curve called ZN/p curve. This curve is
shown in Fig. ZN/p Curve is an experimental curve developed by McKee
brothers.
 What is meant by bearing characteristic number?  
Bearing
  Characteristic Number and Bearing Modulus for Journal Bearings
The factor ZN / p is termed as bearing characteristic number and is a dimensionless number. The factor ZN/p helps
to predict the performance of a bearing.
The minimum amount of friction occurs at A and at this point the value of ZN / p is known as bearing modulus
which is denoted by K
Slight increase in pressure will break the oil film and make the journal to operate with metal to metal contact. This
will result in high friction, wear and heating. In order to prevent such conditions, the bearing should be designed for
a value of ZN / p at least three times the minimum value of bearing modulus (K).
Ta=Room temperature or Ambient temperature or Atmosphere Temperature

PSG DB 7.35P
 What procedure would you follow while designing Design Procedure for Journal Bearing
The following procedure may be adopted in designing journal bearings, when the bearing load, the diameter and the speed
of the shaft are known. KMDB 366P or PSG DB 7.31P
1. Determine the bearing length by choosing a ratio of l/d from Table in K.Mahadevan Design data book(KMDB) 366P

2. Check the bearing pressure, p = W / l.d from Table KMDB 366P for probable satisfactory value.

This Relation Available in KMDB 351P

3. Assume a lubricant from graph in PSG DB 7.41P and its operating temperature (to). This temperature should be between
a journal bearing? Explain

26.5°C and 60°C with 82°C as a maximum for high temperature installations such as steam turbines.

4. Determine the operating value of ZN / p for the assumed bearing temperature and check this value with corresponding
values in Table in the PSG DB 7.31P , to determine the possibility of maintaining fluid film operation.

5. Assume a clearance ratio c/d from Table in KMDB 366P

6. Determine the coefficient of friction by using the relation in PSG Design data book(PSG DB)7.34P

7. Determine the heat generated by using the relation in PSG DB 7.34P

8. Determine the heat dissipated by using the relation in PSG DB 7.34P

9. Determine the thermal equilibrium to see that the heat dissipated becomes at least equal to the heat generated. In case

the heat generated is more than the heat dissipated then either the bearing is redesigned or it is artificially cooled by water.
 What procedure would you follow while designing a journal bearing? Explain

 Define the
following terms
as applied to
journal bearings :
(a) Bearing
characteristic
number ;
(b) Bearing
pressure; and
(c) Diametral
clearance ratio

W= Permissible load on the bearing

This Relation Available in KMDB
351P
KMDB 353P
 KMDB 356P
KMDB 353P

KMDB 360P

KMDB 361P
1.Design a journal bearing for a centrifugal pump from the following data: Load on the
journal = 20000N; Speed of the journal = 900 r.p.m.; Type of oil is SAE 10, for which the absolute
viscosity at 55°C = 0.017 kg / m-s; Ambient temperature of oil = 15.5°C ; Maximum bearing
pressure for the pump = 1.5 N / mm2. Calculate also mass of the lubricating oil required for
artificial cooling, if rise of temperature of oil be limited to 10°C. Heat dissipation coefficient = 1232
W/m2/°C
This Relation(W/2lr) Available in KMDB 351P

KMDB 366P
KMDB 366P or PSG DB 7.31P
 c/r from KMDB 366P

KMDB 366P or PSG DB 7.31P

relation in PSG DB 7.34P

 Why ball and roller bearings are called anti
friction bearings?
LARGER BEARING CAPACITY
  Why taper
roller
bearings
are used in
pairs?

Taper roller bearing can carry both radial and axial loads. In other words, a taper roller bearing subjected to pure radial load induces a thrust
component and vice versa. Therefore, taper roller bearings are always used in pairs to balance the thrust component.
 Define the
following terms
as applied to
rolling contact
bearings:
(a) Static load rating
(b) Equivalent
bearing load
(c) Bearing Life
 Define the following terms
as applied to rolling contact
bearings:
(a) Static load rating
(b) Equivalent bearing load
(c) Bearing Life
 Define the following
terms as applied to
rolling contact
bearings:
(a) Static load rating
(b) Equivalent bearing
load
(c) Bearing Life
Selection of Radial Ball Bearing
 What are the advantages and disadvantages of rolling contact bearings over Sliding Contact Bearings?