Amrutvahini Polytechnic, Sangamner

Experiment No. 06
Aim: Design and prepare the manual drawing / CAD drawing of power
transmission system elements like shaft, keys, coupling, bearing, pulley and
belt drive used in various machine like lathe machine, flour mills, sewing
machine and transmission system in different machines and justify the
dimensions.

Introduction:
There are many ways to generate power but sometimes it’s impossible to
generate power where it’s needed or in the right form or direction or magnitude.
Hence electrical & mechanical power transmissions are vital for any
engineering product design.

Mechanical power transmission and its elements are used for the following
reasons;
1. Generated power or energy can be converted into a useful form
2. Physical constraints limit the power generation at the place where its
used hence it can be transferred from source to a place where it is
needed
3. It can be used to change direction and magnitude such as speed or
torque
4. It can be used to change the type of energy i.e. rotational to linear and
vice versa
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Types of connections and components required to be used along the shaft axis
are dictated by the functional requirements of the product and depends on the
following factors
 Magnitude of Torque
 Shaft size
 Rotation speed
 Direction of rotation
Shafts and couplings are an integral part of the power transmission for modern
age engineering product designs such as machinery.
Sub-components such as couplings, gears, pulleys, sprockets etc are mounted on
to a shaft to transmit power or rotation via the central portion of the component
called hub along with retention devices such as keys and splines. The
connection should ensure the connection transmits the load, power & rotation
without slipping and within the accuracy requirement of the design.
Types of Mechanical power transmission elements
 Shafts & Couplings
 Power screws
 Gears & Gear trains
 Brakes & Clutches
 Belts, Ropes & Pulleys
 Chains & sprockets

Shafts and Key:

A shaft is a rotating machine element which is used to transmit power from one
place to another.
Key is used to transmit torque between shaft and the component mounted on the
shaft.
Couplings:
Couplings also known as shaft couplings are used to connect two shaft ends
together to transmit both angular rotation and torque. The main design
requirement for couplings and its retention devices are that the rated torque
must be transmitted without slip, premature failure or in some cases it needs to
withstand misalignment.
Mechanical power transmission couplings are typically divided into two broad
categories
 Rigid coupling
 Flexible coupling
Rigid couplings are simple, easy to design and comparatively cheap though
require precise alignment of the shafts, whereas the flexible couplings can
accommodate shaft misalignment.
Power Screws:
A Power screw also known as Leadscrew (or lead screw) and translation screw,
is a screw used as a power transmission linkage element in an engineering
product such as machine to translate rotational motion into linear motion. The
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large area of sliding contact between the male and female part of the screw
threads provides large mechanical advantage via the small wedge angle.
Gears and gear trains:
Gear trains are multiple sets of gears that transmit power. A gear train is a
mechanical power transmission system where gears are installed on shafts so
the teeth of the mating gears engage and each roll on each other on its pitch
circle diameter.
Speed ratio and mechanical advantage of mating gears are defined by the pitch
circle diameter ratio.
Brakes and Clutches:
Theoretically, brakes and clutches are nearly indistinguishable, though
functionally clutches are couplings that are used to engage and disengage the
transmitted power between two connecting shafts rotating at different speeds on
a common axis. The main function of a clutch is to bring both elements to a
common angular velocity.
A brake function in a similar manner, except that one of the elements, is fixed,
so when actuated the common angular velocity is zero.
Although brakes and clutches are known for its automotive application, it’s also
widely used in winches, mowers, hoists, washing machines, tractors, mills,
elevators and excavators.
Belts, Ropes & Pulleys:
Belts and pulleys are used when the distance between the shafts too far apart to
use gears.
Chain& Sprockets:
Chains are used for lower speed applications where distance between the shafts
is too far apart to use gear trains and belts are going to support the torque that
needs transmitting. They are also a good way of transmitting power when exact
speed ratios are needed

Equation used for design of Shaft:

Type of load Solid Shaft Hollow shaft (k = di/do)
Torsional load 𝜋 𝜋
𝑇= 𝜏 𝑑3 𝑇= 𝜏 𝑑03 (1 − 𝑘 4 )
16 16
Bending Load 𝜋 𝜋
𝑀= 𝜎𝑏 𝑑 3 𝑀= 𝜎𝑏 𝑑03 (1 − 𝑘 4 )
32 32
Combine bending Replace 𝑑 3 by 𝑑03 (1 −
and torsional loads 𝑘4)

Equation used for design of Key:

Width of key (W) = d/4
Thickness of key (t) = 2w/3 = d/6
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Length of key l = L (Length of coupling hub)

Check key for shear
𝑑 𝑑
𝑇 =𝐹𝑥 = 𝑙𝑥𝑤𝑥𝜏𝑥
2 2
Check key for Crushing
𝑑 𝑡 𝑑
𝑇 = 𝐹 𝑥 = 𝑙 𝑥 𝑥 𝜎𝑐𝑘 𝑥
2 2 2

Equation used for design of Muff/sleeve coupling:

Inner diameter of the sleeve = Diameter of shaft = d
Outer diameter of the sleeve, D = (2d + 13) mm and
Length of the sleeve, L = 3.5 d mm
Check sleeve for shear
𝜋
𝑇= 𝑥 𝜏 𝑥 𝑥𝐷3 𝑥 (1 − 𝐾 4 )
16

Equation used for design of Protected/unprotected Flange Coupling:

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Selection of Bearing:

The first step in sizing a suitable ball bearing for a given application is the
determination of the loads which support. In this section we list some of the
most frequently occurring mechanical configurations and the bearing loads
imposed by them.
The calculation of the radial bearing load in the case of shafts with two bearings
can be obtained from Cases (a) and (b).
Rating life: Rating life is defined as the life of a group of apparently identical
ball or roller bearings, in number of revolutions or hours, rotating at a given
speed, so that 90% of the bearings will complete or exceed before any
indication of failure occur. Suppose we consider 100 apparently identical
bearings. All the 100 bearings are put onto a shaft rotating at a given speed
while it is also acted upon by a load. After some time, one after another, failure
of bearings will be observed. When in this process, the tenth bearing fails, then
the number of revolutions or hours lapsed is recorded. These figures recorded
give the rating life of the bearings or simply L10 life (10 % failure). Similarly,
L50 means, 50 % of the bearings are operational. It is known as median life.
Bearing load: If two groups of identical bearings are tested under loads P1 and
P2 for respective lives of L1 and L2, then,
𝐿1 𝑃2
= ( )𝑎
𝐿2 𝑃1
Where, L: life in millions of revolution or life in hours
a : constant which is 3 for ball bearings and 10/3 for roller bearings
Basic load rating: It is that load which a group of apparently identical bearings
can withstand for a rating life of one million revolutions.
If say, L1 is taken as one million then the corresponding load is,
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1
𝐶 = 𝑃(𝐿)𝑎
Where, C is the basic or dynamic load rating
Therefore, for a given load and a given life the value of C represents the load
carrying capacity of the bearing for one million revolutions. This value of C, for
the purpose of bearing selection, should be lower than that given in the
manufacturer’s catalogue. Normally the basic or the dynamic load rating as
prescribed in the manufacturer’s catalogue is a conservative value, therefore the
chances of failure of bearing is very less.
Equivalent radial load The load rating of a bearing is given for radial loads only.
Therefore, if a bearing is subjected to both axial and radial load, then an
equivalent radial load is estimated as,)
Pe = VPr or
Pe = XVPr + YPa
Where, Pe : Equivalent radial load
Pr : Given radial load
Pa : Given axial load
V : Rotation factor (1.0, inner race rotating; 1.2, outer race rotating)
X : A radial factor
Y : An axial factor
The values of X and Y are found from the chart whose typical format and few
representative values are given below.
The factor, Co is obtained from the bearing catalogue.

Depending on the shaft diameter and magnitude of radial and axial load a
suitable type of bearing is to be chosen from the manufacturer’s catalogue. The
value of dynamic load rating C is calculated for the given bearing life and
equivalent radial load. From the known value of C, a suitable bearing of size
that conforms to the shaft is to be chosen.

Stepwise Procedure:
1. Observed different mechanical elements used in various machine like
lathe machine, flour mills, sewing machine and transmission system in
different machines.
2. Learn the concept and application of shaft, key, coupling pulley and
bearing.
3. Learn design procedure of shaft, key, coupling pulley and bearing.
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4. Collect information of power transmission (output power of motor)

5. By selecting suitable material design shaft, key and coupling.
6. Select suitable ball bearing from manufacturing catalogue
7. Prepare detail and assembly drawing indicating overall dimensions,
tolerances, fits and surface finish.

Observation:

Design Shaft, key coupling and bearing (select bearing from manufacturing
catalogue) used in above power transmission system
Take following data (Pulley radius 250mm and Weight is 300 N)
Batc Mot Motor Material of Material of ratio of Distanc Type of
h or speed key and shaft flange coupling belt e a and couplin
pow in rpm c-40 is CI tension b in g
er in s (mm)
KW T2/T1
A1, 20 700 σt = 110 σt = 28 N/mm 0.5 2
a = 300 Unprote
B1, N/mm 2
σc = 60 N/mm 2
and B cted
I1 σc = 110 τ = 10 N/mm 2
= 700 Flange
A2, 40 1000 N/mm 2
τ 0.5 a = 500 Protecte
2
B2, = 40 N/mm and b = d
I2 Pb = 25 500 Flange
2
A2, 10 800 N/mm 0.5 a = 700 Muff
B2, and b = /sleeve
I2 300
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Outer
Inner diameter d Width B
Designation Diameter D
(mm) (mm)
(mm)
Bearing at
C
Bearing at
D

Conclusion:
Machine parts fail when the stresses induced by external forces exceed their
strength. The external loads cause internal stresses in the elements and the
component size depends on the stresses developed. If the induced stress is less
than or equal to the limiting material strength then the designed component may
be considered to be safe and an indication about the size of the component is
obtained.