Basics in Mechanical Engineering

Unit 1: Introduction to Mechanical Elements,

Mechanism and Engineering Materials

Dr. Pritam Saha

Assistant Professor
Department of Engineering Science
(Mechanical Engineering)

November 22, 2022

April, 2023
Contents
1. Mechanical Elements:
❏ Function, Sketch, Description, Uses of -
Shaft, Axle, Key (Parallel key), Coupling (Rigid flanged-coupling), Bearing (Ball bearing),
Clutch (Single plate clutch), Brake (Disc brake).
2. Power Transmission Devices:
❏ Belt, chain and gear drive,
❏ Mechanism -
Introduction of Kinematic link and Kinematic chain, Four bar and slider crank mechanism
and its inversions.
3. Engineering Materials:
Selection of material, Advance materials for different applications, Composite and Nano
materials with applications, Applications of Engineering Materials - metals and non-metals
in the field of electronics, electrical, computer, instrumentation and artificial intelligence
etc.

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November 2
Mechanical Elements
Shaft
❏ Usually refers to a mechanical component of circular cross section that
- Rotates and,
- Transmits power from a driving device, such as a motor or engine,
through a machine.
❏ Can carry gears, pulleys, flywheels, and sprockets to transmit rotary motion
and power via mating gears, belts, and chains.
❏ May simply connect to another via a mechanical or magnetic flux coupling.

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November 3
Mechanical Elements (Cont…)
Shaft (Cont…)

Fig. 1: Transmission shaft, Input shaft, Line shaft, Machine shaft, Spindle shaft, Crank
shaft, Counter shaft, Output shaft, Camshaft (from left to right)

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November 4
Mechanical Elements (Cont…)
Shaft Loading and Deflection

Fig. 2: Typical machine shaft loading and deflection

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November 5
Mechanical Elements (Cont…)
Shaft Classification
1. Transmission Shafts
Are used to transmit power from the power source to the absorbing unit.
Such as
a) Axle
b) Spindle
c) Countershaft
d) Jackshaft
e) Line Shaft

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November 6
Mechanical Elements (Cont…)
Shaft Classification (Cont…)
2. Machine Shafts
Are integral parts of a machine itself. Such as
a) Crankshaft
b) Camshaft
c) Gear shaft

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November 7
Mechanical Elements (Cont…)
Axle
❏ Is a shaft that supports rotating elements like wheels, hoisting drums or
rope sheaves which is fitted to the housing by means of bearings.
❏ Is subjected to bending moment due to transverse loads like bearing
reactions.
❏ May or may not transmit useful torque.
❏ May therefore rotate with the wheel or simply support a rotating wheel.

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November 8
Mechanical Elements (Cont…)
Axle (Cont…)

Fig. 3: Axle in railway bogie Fig. 4: Axle in rear wheel assembly of

automobile
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November 9
Mechanical Elements (Cont…)
Flexible Shaft
❏ Are used to transmit torque between machine units, which may change
their relative positions during operation.
❏ Have two important properties
1. They have low rigidity in bending, making them flexible.
2. They have high rigidity in torsion, making them capable to transmit torque.
❏ Are mainly used in low power drive such as portable power driven tools,
speedometer drives, portable grinders, concrete vibrators, servo drives etc.

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November 10
Mechanical Elements (Cont…)
Shaft Keys
❏ Can be defined as a machine element which is used to connect the
transmission shaft to rotating machine elements like pulleys, gears,
sprockets or flywheels.
❏ Along with shaft and hub constitutes keyed joint.

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November 11
Mechanical Elements (Cont…)
Shaft Keys (Cont…)

Fig. 5: Keyed Joint

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November 12
Mechanical Elements (Cont…)
Shaft Keys (Cont…)
Functions are
❏ To transmit the torque from the shaft to the hub of the mating element
and vice versa.
❏ To prevent relative rotational motion between the shaft and the joined
machine element like gear or pulley.
❏ To prevent the axial motion between two elements (In most of the cases).

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November 13
Mechanical Elements (Cont…)
Shaft Keys (Cont…)
Are categorized as
❏ Saddle key and sunk key
❏ Square key and flat key
❏ Taper key and parallel key
❏ Key with and without Gib-head
❏ Woodruff key
❏ Kennedy key
❏ Feather key

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November 14
Mechanical Elements (Cont…)
Shaft Keys (Cont…)

Fig. 6: Hollow Saddle Key and Flat Saddle Fig. 7: (a) Square Sunk Key and(b) Flat
Key Sunk Key

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November 15
Mechanical Elements (Cont…)
Shaft Keys (Cont…)

Fig. 8: Gib-headed key Fig. 9: Taper Key

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November 16
Mechanical Elements (Cont…)
Shaft Keys (Cont…)

Fig. 10: Feather Key Fig. 11: Woodruff Key Fig. 12: Kennedy Key

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November 17
Mechanical Elements (Cont…)
Couplings
❏ Is defined as a mechanical device that permanently joins two rotating
shafts to each other.
❏ Commonly used to join two separately built or purchased shafts so that a
new machine can be formed.
❏ Is a permanent connection or joint.

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November 18
Mechanical Elements (Cont…)
Couplings (Cont…)

Fig. 13: Shaft Coupling Fig. 14: Shaft Coupling

in a motor drive

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November 19
Mechanical Elements (Cont…)
Couplings (Cont…)
Couplings can be classified as
❏ Rigid Couplings
● Muff Coupling
● Split Muff Coupling or Clamp Coupling
● Marine or Solid Flange Coupling
● Flange Coupling
❏ Flexible Couplings
● Oldham Coupling
● Bushed Pin Flexible Coupling

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November 20
Mechanical Elements (Cont…)
Couplings (Cont…)

Fig. 15: Muff Coupling

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November 21
Mechanical Elements (Cont…)
Couplings (Cont…)

Fig. 16: Split Muff Coupling or Clamp

Coupling

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November 22
Mechanical Elements (Cont…)
Couplings (Cont…)

Fig. 17: Unprotected Type Flange Fig. 18: Protected Type Rigid Coupling
Coupling

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November 23
Mechanical Elements (Cont…)
Couplings (Cont…)

Fig. 19: Unprotected, Protected and Marine Type

Flange Coupling

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November 24
Mechanical Elements (Cont…)
Couplings (Cont…)

Fig. 20: Oldham Coupling

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November 25
Mechanical Elements (Cont…)
Couplings (Cont…)

Fig. 21: Bushed Pin Flexible Coupling

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November 26
Mechanical Elements (Cont…)
Bearings
❏ Are mechanical elements which support the shafts against the load on it and
provides relative motion between two elements of a machine.
❏ Have following functions:
a) The bearing ensures free rotation of the shaft or the axle with minimum friction.
b) The bearing supports the shaft or the axle and holds it in the correct position.
c) The bearing takes up the forces that act on the shaft or the axle and transmits
them to the frame or the foundation.

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November 27
Mechanical Elements (Cont…)
Bearings (Cont…)

Fig. 22: Bearings

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November 28
Mechanical Elements (Cont…)
Bearing Classifications
❏ Based upon the direction of load
a) Radial bearings - Supports the load, which is perpendicular to the axis of
the shaft.
b) Thrust bearings - supports the load, which acts along the axis of the shaft.

Fig. 23: Radial Bearings Fig. 24: Thrust Bearings

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November 29
Mechanical Elements (Cont…)
Bearing Classifications (Cont…)
❏ Based upon the nature of contact
a) Sliding contact bearings - Sliding friction between the members. Shaft slides over the
surface of the bush.
b) Rolling contact bearings - Rolling contact friction between the members. Rolling
elements, such as balls or rollers, are used.

Fig. 25: Sliding contact bearings Fig. 26: Rolling contact bearings
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November 30
Mechanical Elements (Cont…)
Bearing Applications
Sliding contact bearings are used in
a) Crankshaft bearings in petrol and diesel engines.
b) Centrifugal pumps.
c) Large size electric motors.
d) Steam and gas turbines.
e) Concrete mixers, rope conveyors and marine installations.

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November 31
Mechanical Elements (Cont…)
Bearing Applications (Cont…)
Rolling contact bearings are used in
a) Machine tool spindles
b) Automobile front and rear axles
c) Gear boxes
d) Small size electric motors
e) Rope sheaves, crane hooks and hoisting drums.

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November 32
Mechanical Elements (Cont…)
Rolling Contact Bearings

Fig. 27: Ball Bearing, Roller Bearing (left to right)

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November 33
Mechanical Elements (Cont…)
Ball Bearings
Are classified as
a) Deep groove ball bearing.
b) Self-aligning ball bearing.
c) Angular contact ball bearing.
d) Thrust ball bearing.

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November 34
Mechanical Elements (Cont…)
Ball Bearings (Cont…)

Fig. 28: Deep groove ball bearing

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November 35
Mechanical Elements (Cont…)
Ball Bearings (Cont…)

Fig. 29: Angular contact ball bearing

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November 36
Mechanical Elements (Cont…)
Ball Bearings (Cont…)

Fig. 30: Self-aligning ball bearing

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November 37
Mechanical Elements (Cont…)
Ball Bearings (Cont…)

Fig. 30: Thrust ball bearing

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November 38
Mechanical Elements (Cont…)
Clutches
❏ Are mechanical device, which is used to connect or disconnect the source of
power from the remaining parts of the power transmission system at the will
of the operator.
❏ Can be used for any of the following functions -
a) To connect or disconnect the source power from the remaining parts of the power
transmission system.
b) To serve as a safety device by slipping when the torque transmitted through it
exceeds a safe value.
c) To reduce or to absorb the impact and shock load and to alter the vibrational
characteristics of two connecting shafts.

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November 39
Mechanical Elements (Cont…)
Clutches (Cont…)
Flywheel

Clutch Plate

Pressure Plate

Fig. 31: Clutch assembly

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November 40
Mechanical Elements (Cont…)
Clutches (Cont…)
❏ Clutches are classified into the following four groups
1) Positive contact Clutches - Square jaw clutches, spiral jaw clutches and
toothed clutches.
2) Friction Clutches - Single and multi-plate clutches, cone clutches and
centrifugal clutches.
3) Electromagnetic Clutches - Magnetic particle clutches, magnetic hysteresis
clutches and eddy current clutches.
4) Fluid Clutches - Power transmission is achieved by means of hydraulic
pressure

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November 41
Mechanical Elements (Cont…)
Single Plate Clutch

Fig. 32: Single plate clutch

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November 42
Mechanical Elements (Cont…)
Single Plate Clutch (Cont…)
The main advantages of friction clutch are as follows
1. The engagement is smooth.
2. Slip occurs only during engaging operation and once the clutch is engaged, there is no
slip between the contacting surfaces. Therefore, power loss and consequent heat
generation do not create problems, unless the operation requires frequent starts and
stops.
3. In certain cases, the friction clutch serves as a safety device. It slips when the torque
transmitted through it exceeds a safe value. This prevents the breakage of parts in the
transmission chain.

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November 43
Mechanical Elements (Cont…)
Brakes
❏ Is defined as a mechanical device, which is used to absorb the energy
possessed by a moving system or mechanism by means of friction.
❏ Absorb kinetic energy from moving element and dissipate it in the form of
heat.
❏ Are used to slow down or completely stop the motion of a moving system.

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November 44
Mechanical Elements (Cont…)
Brakes (Cont…)
Brakes are classified into the following three groups
1. Mechanical brakes: Works by means of mechanical elements such as levers,
springs and pedals. Block brakes, internal or external shoes brakes, disk
brakes and band brakes.
2. Hydraulic and pneumatic brakes: Operated by fluid pressure such as oil
pressure or air pressure.
3. Electrical brakes: Operated by magnetic forces. Magnetic particle brakes,
hysteresis brakes and eddy current brakes.

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November 45
Mechanical Elements (Cont…)
Disk Brakes

Fig. 33: Disk Brakes

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November 46
Mechanical Elements (Cont…)
Disk Brakes (Cont…)

Fig. 34: Components of Disk Brakes

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November 47
Mechanical Elements (Cont…)
Disk Brakes (Cont…)

Fig. 35: Working of Disk Brakes

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November 48
Mechanical Elements (Cont…)
Disk Brakes (Cont…)
Disk brakes have the following advantages
❏ Disk brake is simple to install and service.
❏ Disk brake has high torque transmitting capacity in small volume.
❏ Due to inherent ability of the disk brake to dissipate heat, it is insensitive to
changes in the coefficient of friction.
❏ There is no mechanical ‘fade’ of friction lining. Fading is the loss of
torque-transmitting capacity of friction lining at higher temperatures.
❏ The brake can never become self-locking.

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November 49
 Thank You

November 22, 2022