DR.

JIVRAJ MEHTA INSTITUTE OF TECHNOLOGY, ANAND

MECHANICAL ENGINEERING DEPARTMENT
B.E. MECHANICAL ENGINEERING

DESIGN OF MACHINE ELEMENTS

Code: 3171917)
Laboratory Manual

th
Semester: 7
Course: B. E. Mech.

MECHANICAL ENGINEERING DEPARTMENT

Dr. JIVRAJ MEHTA INSTITUTE OF TECHNOLOGY
MOGAR – ANAND
 DR. JIVRAJ MEHTA INSTITUTE OF TECHNOLOGY, ANAND
MECHANICAL ENGINEERING DEPARTMENT
B.E. MECHANICAL ENGINEERING

CERTIFICATE
This is certify that Mr/Ms.__________________________________ of

class _____________ of Mechanical Engineering having Enrollment

No.________________________ and Batch________ has satisfactorily

completed his/ her termwork in the Subject Code 3171917 Subject

Name DESIGN OF MACHINE ELEMENTS at Dr. Jivraj Mehta

Institute of Technology, Mogar, Anand for the term ending in

_______ 2021-22.

Date: _____________

Sign of Teacher: ____________ Sign of H.O.D.: ___________

 DR. JIVRAJ MEHTA INSTITUTE OF TECHNOLOGY, ANAND
MECHANICAL ENGINEERING DEPARTMENT
B.E. MECHANICAL ENGINEERING

DESIGN OF MACHINE ELEMENTS (3171917)

Semester / Year : _________ / __________ Batch : _ __

Name of Faculty : ____________________Academic Year:_______ T / P : _T_

INDEX
No. of Date of Sign of
No. Date Title Marks
Pages Assessment Faculty

1
Design of rigid and flexible
couplings.
2
Design of helical and leaf
springs.
Design of two stage gear
3 box including gear design,
bearing selection.
4 Design of pressure vessels.

In-Charge Head of the

Department
 DR. JIVRAJ MEHTA INSTITUTE OF TECHNOLOGY, ANAND
MECHANICAL ENGINEERING DEPARTMENT
B.E. MECHANICAL ENGINEERING

TUTORIAL NO. 1:- DESIGN OF RIGID AND FLEXIBLE

COUPLINGS.

1. Draw and write design procedure for bushed pin type flexible
coupling.
2. What is a coupling? Classify the couplings.
3. Design of Couplings: Concept of rigid and flexible couplings.
4. Design of: Clamp, Rigid flange and Flexible couplings.
5. Design muff coupling to connect two steel shafts transmitting 40
kW at 350 rpm. The material for shafts and key is plain carbon steel
for which allowable shear and crushing stresses are 40 MPa and 80
MPa respectively. The material for muff is cast iron for which
allowable shear stress is 15 MPa.
6. 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 shaft, bolt and key are
made from steel having yield point stress and crushing stress of 160
N/mm2. The ultimate tensile strength of cast iron is 32 N/mm2.
Assume the shear stress is half of the normal stress and factor of
safety of 2.
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TUTORIAL NO. 2:- DESIGN OF HELICAL AND LEAF SPRINGS

1. Define spring. Explain important functions and applications of

springs.
2. Classify and explain springs according to their shapes with neat
sketches.
3. Briefly explain the spring materials. State and explain the
factors affecting selection of spring materials.
4. Explain the terms related to helical spring:
(i) Spring rate (ii) Free length (iii) Spring index (iv) Pitch (v) Solid
Length
5. What is A.M. Wahl’s factor in spring? Explain the importance of
Wahl’s stress factor in
spring design.
6. Explain the following and state how can they be prevented?
(i) Buckling of spring (ii) Surge in springs
7. Write a detailed note on disc (bellievele) springs.

EXAMPLES
1. Design a helical compression spring for maximum load of 1200
N for a deflection of 20 mm using the value of spring index as
5. Permissible shear stress for spring wire is 420 MPa. Modulus
of rigidity 80 KN/ mm2.
2. Design a helical compression spring for maximum load of 2400
N for a deflection of 15 mm using the value of spring index as
8. Permissible shear stress for spring wire is 417 MPa. Modulus
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of rigidity 81.4 KN/ mm2.

3. Design a helical compression spring from
the following data: Minimum load = 100N
Maximum load=225.6N
Compression of
spring=10 mm
Spring index = 8
Permissible shear stress for spring material
= 440 MPa Modulus of rigidity for spring
material = 0.80 x 105 MPa
Spring end – square and ground ends
4. Calculate the dimensions of a helical spring for a safety valve
from the following data: Valve diameter = 65 mm
Operating pressure = 0.7 N/mm2
Maximum pressure when the valve blows off
freely = 0.73 N/mm2 Valve lift when pressure
rises from 0.7 to 0.73 N/mm2 = 3.5 mm
Maximum allowable stress = 550 N/mm2
Spring index = 6
Modulus of rigidity = 8.3 × 104 N/mm2
5. A semi-elliptic leaf spring used for automobile suspension
consists of three extra full – length leaves and 15 graduated-
length leaves, including master leaf. The center-to- center
distance between two eyes of the spring is 1 m. The maximum
force that can act on the spring is 75 KN. For each leaf, the
ratio of width to thickness is 9:1. The modulus of elasticity of
the leaf material is 207000 N/mm2. The leaves are pre-stressed
in such a way that when the force is maximum, the stresses
induced in all leaves are same and equal to 450 N/mm2.
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Determine:
(i) The width and thickness of the leaves;
(ii) The initial nip; and
(iii) The initial pre-load required to close the gap C between
extra full-length leaves and graduated-length leaves.
6. A semi-elliptic leaf spring consists of two extra full length
leaves and eight graduated length leaves, including the master
leaf. The center to center distance between the two eyes of the
spring is 1 m. The maximum force acting on the spring is 10
kN and the width of the leaf is 50 mm. The spring is initially
preloaded in such a way that when the load is maximum, the
stresses induced in all the leaves are equal to 350 N/mm2. The
modulus of elasticity of the leaf material is 2.07 x 105 N/mm2.
Determine:
(i) The thickness of leaves
(ii) The deflection of the spring at maximum load
7. A semi-elliptic multi-leaf spring is used for the suspension of
the rear axle of a truck. It consists of two extra full length
leaves and ten graduated length leaves including the master
leaf. The center to center distance between the two eyes of the
spring is 1.2 m and the width of the leaf is 60 mm. The leaves
are made of steel 55Si2Mo90 (Syt = 1500 N/mm2 and E =
207000 N/mm2) and the factor of safety is 2.5. The spring is
to be designed for a maximum force of 30 kN. The leaves are
pre-stressed so as to equalize stresses in all the leaves.
Determine:
(1) The thickness of the leaves; and
(2) The deflection at the end of the spring
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TUTORIAL NO. 3: DESIGN OF TWO STAGE GEAR BOX

INCLUDING GEAR DESIGN, BEARING SELECTION.

INTRODUCTION :-
1.1 GEARBOX
A Gearbox is a device that used for transmitting power from the
Power source to the output shaft. A gearbox has a set of gears that
are enclosed in a casing. The gears are mounted on shafts which
rotate freely about their axis. The gears are fixed on the shafts by
Fits or by a key. These shafts are made to rotate freely on a support
called casing. Bearings are tightly fit between the shafts and the
casing. Today’s cars have various sets of gears which give different
speeds and torque on different Gears. A Gearbox is necessary
because it is impractical to directly connect the input source to the
output shaft. The power source may not have enough torque to bear
the whole load at once. This will put a load on the power source
which may cause overheating, more fuel consumption or even
failure of the components. Gearbox gives leverage to the power
source by enhancing the torque at initial gears and then delivering
high speeds at final stages. This reduces the capacity of the power
source required and hence less fuel consumption. Each Gearbox
has its own set of Gear ratios that can be selected by the driver or
just one set of universal Gear Ratio that will work with the help of
a Torque converter or a Continuously Variable Transmission Major
components include gears, Casing, Shafts, and Bearing.
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Figure 1.1: A Gearbox contain various Gear Ratios.

1.2 REDUCTION GEARBOX:

A reduction gearbox is a device by which an input speed can be
lowered for a requirement of slower output speed, with same or
more output torque. Reduction gear assembly consists of a set of
rotating gears connected to an output shaft. The high speed
incoming motion from the wheel work is transmitted to the set of
rotating gears, where in the motion or torque is changed. The
number of gears used in the reduction gear assembly depends on
the output speed requirement of the application. The reduction gear
assembly is usually known as reduction gear box. Depending on
the Output speed required, the reduction may have single stage or
two stage reduction.
1.2.1 TYPES OF REDUCTION GEARBOX
There are mainly two types of reduction gears:
Single reduction gear
Double reduction gear
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Single Reduction Gear:-

This arrangement consists of only one pair of gears. The reduction
gear box consists of ports through which the propeller shaft and
engine shaft enters the assembly. A small gear known as a pinion is
driven by the incoming engine shaft. The pinion directly drives a
large gear mounted on the propeller shaft. The speed is adjusted by
making the ratio of the speed reduction to the diameter of pinion
and gear proportional. Generally, a single gear assembly has a gear
double the size of a pinion.

Figure 1.2: A single Reduction has one set of gears.

Double Reduction gear:-
Double reduction gears are generally used in applications involving
very high speeds. In this arrangement the pinion is connected to the
input shaft using a flexible coupling. The pinion is connected to an
intermediate gear known as the first reduction gear. The first
reduction gear is then connected to a low speed pinion with the
help of one more shaft. This pinion is connected to the second
reduction gear mounted directly on the propeller shaft. Such
arrangement facilitates the reduction of speed to a ratio as high as
20:1.
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Figure 1.3: A Double Reduction has two set of gears.

1.3 COMPONENTS OF A GEARBOX:

A Gearbox comprises of major components namely:1.

Casing
Gears
Shafts
Bearings

1.3.1 CASING:
Casing is a fixture that fixes all the shafts and assembles all gears
into an assembly without any interference. Casing also contains the
mounting points to mount it in a power train Assembly. The Casing
takes the load imposed by the power source. Vibrations are also
transmitted in case the power source is an Engine. Intricate shape
are drawn on the casing to keep it from yielding. There are bearing
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sockets on the casing where the bearings are fit into the casing.
Then the shafts are placed in the bearing. An inlet is created in
casing to pour gear oil. The casing should be air tight as it
accommodates space for the gear oil for cooling. The casing is
usually a symmetric two piece setup that is used to open or close
the gearbox for maintenance or repairs. The casing should be
manufactured with utmost precision to avoid misalignment. Over
the years, Cast Iron is being used for manufacturing casing.
Nowadays, casings are coming in Steels or oven Aluminum Alloys.
1.3.2 Gears
A gear is a rotating machine part having cut teeth, which mesh with
another toothed part to transmit torque. Geared devices can change
the speed, torque, and direction of a power source. Gears almost
always produce a change in torque, creating a mechanical
advantage, through their ratio. The teeth on the two meshing gears
all have the same shape. Two or more meshing gears, working in a
sequence, are called a gear train or a
Transmission.

Advantages:-
1. It transmits exact velocity ratio.2. It may be used to transmit
large power.3. It may be used for small center distances of
shafts.4. It has high efficiency.5. It has reliable service.6. It has
compact layout.
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Figure 1.4: Terms used in Gears

Gear Ratio

It is the ratio between the Input and the output gear. From gear
ratio, we can calculate the speed, Diameter and number of teeth of
the gears
GEAR TYPES: SPUR GEAR AND HELICAL GEAR
SPUR GEAR:
Spur gears are mounted in series on parallel shafts to achieve large
gear reductions. The most common gears are spur gears and are
used in series for large gear reductions. The teeth on spur gears are
straight and are mounted in parallel on different shafts. Spur gears
are used in washing machines, screwdrivers, windup alarm clocks,
and other devices. These are particularly loud, due to the gear tooth
engaging and colliding. Each impact makes loud noises and causes
vibration, which is why spur gears are not used in machinery like
cars. A normal gear ratio range is 1:1 to 6:1
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FIGURE 1.5: SPUR GEAR HAS FLAT TEETH

HELICAL GEAR:
Helical gears operate more smoothly and quietly compared to spur
gears due to the way the teeth interact. The teeth on a helical gear
cut at an angle to the face of the gear. When two of the teeth start to
engage, the contact is gradual--starting a tone end of the tooth and
maintaining contact as the gear rotates into full engagement. The
typical range of the helix angle is about 15 to 30 deg. The thrust
load varies directly with the magnitude of tangent of helix angle.
Helical is the most commonly used gear in transmissions. They also
generate large amounts of thrust and use bearings to help support
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the thrust load. Helical gears can be used to adjust the rotation
angle by 90 deg. when mounted on perpendicular shafts. Its normal
gear ratio range is 3:2 to 10:1.

Figure 1.6: Helical Gears have inclined teeth.

1.3.3 SHAFTS
A shaft is a rotating machine element which is used to transmit
power from one place to another. The power is delivered to the
shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft permits the power to be transferred
to various machines linked up to the shaft. In order to transfer the
power from one shaft to another, the various members such as
pulleys, gears etc., are mounted on it. These members along with
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the forces exerted upon them causes the shaft to bending. In other
words, we may say that a shaft is used for the transmission of
torque and bending moment. The various members are mounted on
the shaft by means of keys or splines.
1.3.4 BEARINGS
Bearing is a component that ensures smooth rotation between the
fixed support and the rotating shafts. These components are made
of high carbon alloy steels that can bear huge amount of loads and
rotate at high RPMs/There are two types of bearing---Sliding
contact bearing and rolling contact bearings. Sliding contact have a
fluid between the inner and outer race that ensures smooth rotation.
Rolling contact bearings also known as ball bearings have a
handful of tiny hardened steel balls or rollers between the inner and
outer race, these balls are super finished and have less friction
compared to the sliding contact bearings.
These bearing have two types of loads acting on them namely
Radial and Axialloads. These loads are calculated while making the
gearbox. The outer race of the bearingare fitted into the casing and
the inner race to the shaft.
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1. List the major advantages of using geometric progression of for

speed regulation in a gear box.
2. Classify different types of bearings.
3. Explain the significance of L/D ratio and minimum oil-film
thickness in hydrodynamic bearings.
4. Differentiate between Hydrodynamic and Hydrostatic bearings.
5. How the bevel gears are classified ? Explain with neat sketches.
6. What is structure diagram ? Explain the method of drawing
structure diagram of gearbox.
7. Explain the types of gear tooth failure.
8. Write notes on : selection of gear materials.
9. Advantages and limitations of Helical gears.
10. Advantages and limitations of worm gears.
11. Discuss advantages of rolling contact bearings over sliding
contact bearings.

NUMERICALS
(1) Design a suitable nine speed gear box for a head stock of a lathe
that has a variation pf speeds from 105 r.p.m to 690 r.p.m. The
power is supplied by an electric motor of 10Kw capacity
running at 1000 r.p.m. and driving the input shaft through a V-
belt drive having speed ratio of 2:1 . Draw the structure
diagram, speed chartand determine the number of teeth on each
gears.
(2) Design a pair of straight teeth spur gears to transmit 20 kW when
the pinion rotates at 300 r.p.m. The velocity ratio is 1 : 3. The
allowable static stresses for the pinion and gear materials are 120
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MPa and 100 MPa respectively. The pinion has 15 teeth and its
face width is 14 times the module. Assume steady load condition
and 8-10 hours of service per day. Take, the tooth form factor, y
= 0.154 − ( 0.912 / No. of teeth ); and the velocity factor, Cv = 3
/ ( 3 + v ).
(3) Find the range ratio, geometric progression ratio and spindle
speeds for the following data: Nmin = 100 r.p.m., Nmax = 1800
r.p.m. and number of speed steps = 8.Also, draw all possible
structure diagrams.
(4) A full journal bearing of 50 mm diameter and 100 mm long has
a bearing pressure of 1.4 N/mm2. The speed of the journal is 900
r.p.m. and the ratio of journal diameter to the diametral clearance
is 1000. The bearing is lubricated with oil whose absolute
viscosity at the operating temperature of 75 °C may be taken as
0.011 kg/m-s. The room temperature is 35 °C. Find : 1. The
amount of artificial cooling required, and 2. The mass of the
lubricating oil required, if the difference between the outlet and
inlet temperature of the oil is 10°C. Take specific heat of the oil
as 1850 J / kg / °C.
(5) A pair of helical gears with pinions 26 teeth and gear 100 teeth
supplies power 5KW
at 2000 rpm of pinion. Normal pressure angle is 20o and helix
angle of teeth is 15o. Both the gears are made of hardened
steel with Sut = 660 N/mm2. Gears are finished to accuracy of
grade 8. Assume service factor =1.5, factor of safety = 1.8 and
pitch line velocity of gears as 10 m/s, determine normal
module of gear teeth as per beam strength. Specify the
hardness of the surface of gears if Sw = Sb.b =12mn.Where b
is face width.
(6) A pair of bevel gears is required to transmit 10 KW power at 500
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rpm from motor

shaft to a machine shaft. The speed reduction is 3:1 and the
shafts are inclined at 60o. the pinion is to have 24 teeth with
pressure angle 20o and is to be made of cast steel having
strength 75 N/ mm2. The gear is to be made of cast iron with
static stress of 55 N/ mm2. Design the gear pair.
(7) A 360o hydrodynamic bearing has 50 mm diameter and 50 mm
length. The journal is carrying a load of 15 KN and rotates at 1450
rpm. The eccentricity ratio is 0.8.
The radial clearance is 20 μm. Calculate
Probable coefficient of friction. b) Viscosity of oil.
c) Minimum film thickness. d) Quantity of oil in
circulation.
e) Oil leakages through sides.
If the oil is supplied at 28oc, find the oil temperature. The specific
gravity of oil is
0.86 and the specific heat can be taken as 2.09 KJ/Kg oc.
(8) A ball bearing is subjected to purely radial force. The
magnitude of radial force acting on the bearing varies in a
sinusoidal manner from 0 to 1500 N in first half revolution and
1500 N to 0 in second half revolution. The cycle then repeats. The
direction force remains fixed. The speed of rotation is 720 rpm.
Determine the dynamic load carrying capacity of the bearing for
a life of 8000 hours.
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TUTORIAL NO. 4: DESIGN OF PRESSURE VESSELS

1. List and explain the important pressure vessels materials. Also
explain the factors affecting selection of pressure vessels
materials.
2. When do you use Lame’s equation for cylinder wall thickness?
Derive Lame’s equation.
3. State the different equations used for thick cylinder design
with their conditions and limitations.
4. What is thick cylinder? Explain the auto frettage for pressure
vessels (or explain pre- stressing of thick cylinders).
5. What is compounding of cylinder? Why it is required?
6. Sketch and explain the different types of end closures used for
pressure vessels.
7. Classify pressure vessels. Derive equations for hoop stress and
longitudinal stress.

EXAMPLES
1. The piston rod of a hydraulic cylinder exerts an operating
force of 10 kN. The friction due to piston packing and stuffing
box is 10 % of the operating force. The pressure in the cylinder
is 10 N/mm2. The cylinder is made of C.I. having allowing
tensile stress of 40 N/mm2. Determine the diameter and
thickness of the cylinder.
2. The inner diameter of a cylinder tank for liquefied gas is 250
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mm. The gas pressure is limited to 15 MPa. The tank is made of

plain carbon steel 10C4 (Sut = 340 N/mm2 and μ
= 0.27) and the factor of safety is 5. Calculate the cylinder
wall thickness.

3. A high-pressure cylinder consists of a steel tube with inner and

outer diameters of 20 and 40 mm respectively. It is jacketed by
an outer steel tube, having an outer diameter of 60 mm. The
tubes are assembled by a shrinking process in such a way that
maximum principal stress induced in any tube is limited to 100
N/mm2. Calculate the shrinkage pressure and original
dimensions of the tubes (E = 207 kN/mm2).
4. A high pressure cylinder consists of a steel tube with 20 mm
and 35 mm as inner and outer diameters respectively. It is
jacketed by outer steel tube with 50 mm outer diameter. The
tubes are assembled by shrinking process in such a way that
the maximum tensile stress induced in any tube is limited to
100 N/mm2. Calculate the shrinking pressure and original
dimensions of the tubes. E = 2.0 x 105 N/mm2.

5. A hydraulic press has the

following specifications: Capacity
= 80 kN
Fluid pressure = 16 MPa
Stroke = 80 mm
Permissible tensile stress for pillar and ram =
75 MPa Permissible stress for C.I. cylinder =
30 MPa
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Distance between the center line of pillars = 800 mm

Distance between top supporting platform and bottom of top
plate when the ram is in the down most position = 800 mm
Design the ram, cylinder and pillars.