Department of Mechanical Engineering

Design of Machine Members 1

1. A shaft supported at the ends in ball bearings carries a straight tooth spur gear at its mid span and
is to transmit 7.5 kW at 300 r.p.m. The pitch circle diameter of the gear is 150 mm. The distances
between the centre line of bearings and gear are 100 mm each. If the shaft is made of steel and the
allowable shear stress is 45 MPa, determine the diameter of the shaft. Show in a sketch how the
gear will be mounted on the shaft; also indicate the ends where the bearings will be mounted? The
pressure angle of the gear may be taken as 20°.
2. A shaft is supported by two bearings placed 1 m apart. A 600 mm diameter pulley is mounted at a
distance of 300 mm to the right of left hand bearing and this drives a pulley directly below it with
the help of belt having maximum tension of 2.25 KN. Another pulley 400 mm diameter is placed
200 mm to the left of right hand bearing and is driven with the help of electric motor and belt,
which is placed horizontally to the right. The angle of contact for both the pulleys is 180° and μ =
0.24. Determine the suitable diameter for a solid shaft, allowing working stress of 63 MPa in
tension and 42 MPa in shear for the material of shaft. Assume that the torque on one pulley is
equal to that on the other pulley
3. A shaft is supported on bearings A and B, 800 mm between centres. A 20° straight tooth spur gear
having 600 mm pitch diameter, is located 200 mm to the right of the left hand bearing A, and a
700 mm diameter pulley is mounted 250 mm towards the left of bearing B. The gear is driven by
a pinion with a downward tangential force while the pulley drives a horizontal belt having 180°
angle of wrap. The pulley also serves as a flywheel and weighs 2000 N. The maximum belt
tension is 3000 N and the tension ratio is 3 : 1. Determine the maximum bending moment and the
necessary shaft diameter if the allowable shear stress of the material is 40 MPa.
4. A solid steel shaft is supported on two bearings 1.8 m apart and rotates at 250 r.p.m. A 20°
involute gear D, 300 mm diameter is keyed to the shaft at a distance of 150 mm to the left on the
right hand bearing. Two pulleys B and C are located on the shaft at distances of 600 mm and 1350
mm respectively to the right of the left hand bearing. The diameters of the pulleys B and C are
750 mm and 600 mm respectively. 30 kW is supplied to the gear, out of which 18.75 kW is taken
off at the pulley C and 11.25 kW from pulley B. The drive from B is vertically downward while
from C the drive is downward at an angle of 60° to the horizontal. In both cases the belt tension
ratio is 2 and the angle of lap is 180°. The combined fatigue and shock factors for torsion and
 bending may be taken as 1.5 and 2 respectively. Design a suitable shaft taking working stress to
be 42 MPa in shear and 84 MPa in tension.
5. Define equivalent twisting moment and equivalent bending moment. State when these two terms
are used in design of shafts.
6. Design and make a neat, dimensioned sketch of a muff coupling which is used to connect two
steel shafts transmitting 40 kW at 350 r.p.m. The material for the shafts and key is plain carbon
steel for which allowable shear and crushing stresses may be taken as 40 MPa and 80 MPa
respectively. The material for the muff is cast iron for which the allowable shear stress may be
assumed as 15 MPa.
7. Design a clamp coupling to transmit 30 kW at 100 r.p.m. The allowable shear stress for the shaft
and key is 40 MPa and the number of bolts connecting the two halves are six. The permissible
tensile stress for the bolts is 70 MPa. The coefficient of friction between the muff and the shaft
surface may be taken as 0.3.
8. Design a clamp coupling for a mild steel shaft transmitting 40 kW at 100 rpm. Coefficient of the
friction between the muff and the shaft surface is 0.3 and number of bolts connecting two halves
are 6. The allowable shear stress in the shaft and coupling bolts are 40 MPa and 70 MPa
Respectively
9. Design a cast iron protective type flange coupling to transmit 15 kW at 900 r.p.m. from an electric
motor to a compressor. The service factor may be assumed as 1.35. The following permissible
stresses may be used : Shear stress for shaft, bolt and key material = 40 MPa Crushing stress for
bolt and key = 80 MPa Shear stress for cast iron = 8 MPa Draw a neat sketch of the coupling
10. . Design and draw a protective type of cast iron flange coupling for a steel shaft transmitting 15
kW at 200 r.p.m. and having an allowable shear stress of 40 MPa. The working stress in the bolts
should not exceed 30 MPa. Assume that the same material is used for shaft and key and that the
crushing stress is twice the value of its shear stress. The maximum torque is 25% greater than the
full load torque. The shear stress for cast iron is 14 MPa.
11. Design a rigid flange coupling to transmit a torque of 250 N-m between two co axial shafts. The
shaft is made of alloy steel, flanges out of cast iron and bolts out of steel. Four bolts are used to
couple the flanges. The shafts are keyed to the flange hub. The permissible stresses are given
below: Shear stress on shaft =100 MPa Bearing or crushing stress on shaft =250 MPa Shear stress
on keys =100 MPa Bearing stress on keys =250 MPa Shearing stress on cast iron =200 MPa Shear
stress on bolts =100 MPa After designing the various elements, make a neat sketch of the
assembly indicating the important dimensions. The stresses developed in the various members
may be checked if thumb rules are used for fixing the dimensions.
12. Two 35 mm shafts are connected by a flanged coupling. The flanges are fitted with 6 bolts on 125
mm bolt circle. The shafts transmit a torque of 800 N-m at 350 r.p.m. For the safe stresses
mentioned below, calculate 1. diameter of bolts ; 2. thickness of flanges ; 3. key dimensions ; 4.
hub length; and 5. power transmitted. Safe shear stress for shaft material = 63 MPa Safe stress for
bolt material = 56 MPa Safe stress for cast iron coupling = 10 MPa Safe stress for key material =
46 MPa