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Unit 4 Problems (Springs)

The document contains a series of examples related to the design of machine elements, specifically focusing on various types of springs including compression and helical springs. Each example provides specific parameters such as load, diameter, shear stress, and modulus of rigidity, along with calculations to determine maximum shear stress, deflection, and other relevant spring characteristics. The document serves as a practical guide for mechanical engineering students in understanding spring design principles and calculations.

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Ryan Ahmed
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0% found this document useful (0 votes)
1K views28 pages

Unit 4 Problems (Springs)

The document contains a series of examples related to the design of machine elements, specifically focusing on various types of springs including compression and helical springs. Each example provides specific parameters such as load, diameter, shear stress, and modulus of rigidity, along with calculations to determine maximum shear stress, deflection, and other relevant spring characteristics. The document serves as a practical guide for mechanical engineering students in understanding spring design principles and calculations.

Uploaded by

Ryan Ahmed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069

DEPARTMENT OF MECHANICAL ENGINEERING


ME 8593- DESIGN OF MACHINE ELEMENTS

Example 1. A compression coil spring made of an alloy steel is having the following specifications:
Mean diameter of coil = 50 mm; Wire diameter = 5 mm; Number of active coils = 20. If this spring is
subjected to an axial load of 500 N; calculate the maximum shear stress (neglect the curvature effect) to
which the spring material is subjected.
Solution. Given: D = 50 mm; d = 5 mm; n = 20; W = 500 N

Example 2. A helical spring is made from a wire of 6 mm diameter and has outside diameter of 75 mm.
If the permissible shear stress is 350 MPa and modulus of rigidity 84 kN/mm2, find the axial load which
the spring can carry and the deflection per active turn.
Solution. Given: d = 6 mm Do = 75 mm τ = 350 MPa = 350 N/mm2 G =84 kN/mm2 = 84 × 103 N/mm2

Dr.RGM/V-SEM/ME8593-DME/UNIT – III PROBLEMS Page 1


CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

Example 3. Design a spring for a balance to measure 0 to 1000 N over a scale of length 80 mm. The
spring is to be enclosed in a casing of 25 mm diameter. The approximate number of turns is 30. The
modulus of rigidity is 85 kN/mm2. Also calculate the maximum shear stress induced.
Solution. Given : W = 1000 N ; δ = 80 mm ; n = 30 ; G = 85 kN/mm2 = 85 × 103 N/mm2

Dr.RGM/V-SEM/ME8593-DME/UNIT – III PROBLEMS Page 2


CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Example 4. A mechanism used in printing machinery consists of a tension spring assembled with a
preload of 30 N. The wire diameter of spring is 2 mm with a spring index of 6. The spring has 18 active
coils. The spring wire is hard drawn and oil tempered having following material properties:Design
shear stress = 680 MPa Modulus of rigidity = 80 kN/mm2 Determine : 1. the initial torsional shear
stress in the wire; 2. spring rate; and 3. the force to cause the body of the spring to its yield strength.
Solution. Given : Wi = 30 N ;d = 2 mm ; C = D/d = 6 ; n = 18 ; τ = 680 MPa = 680 N/mm2 ;
G = 80 kN/mm2 = 80 × 103 N/mm2

Example 5. Design a helical compression spring for a maximum load of 1000 N for a deflection of 25
mm using the value of spring index as 5. The maximum permissible shear stress for spring wire is 420
MPa and modulus of rigidity is 84 kN/mm2.
Take Wahl’s factor,
K={[(4C-1)/(4C-4)]+[0.615/C]} where C = Spring index.
Solution. Given : W = 1000 N ; δ = 25 mm ; C = D/d = 5 ; τ = 420 MPa = 420 N/mm2 ;
G = 84 kN/mm2 = 84 × 103 N/mm2
1. Mean diameter of the spring coil
Let D = Mean diameter of the spring coil, and
d = Diameter of the spring wire.

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

Example 6. Design a close coiled helical compression spring for a service load ranging from 2250 N to
2750 N. The axial deflection of the spring for the load range is 6 mm. Assume a spring index of 5. The
permissible shear stress intensity is 420 MPa and modulus of rigidity, G = 84 kN/mm2.
Neglect the effect of stress concentration. Draw a fully dimensioned sketch of the spring, showing details
of the finish of the end coils.
Solution. Given : W1 = 2250 N ; W2 = 2750 N ; δ = 6 mm ; C = D/d = 5 ; τ = 420 MPa = 420 N/mm2 ; G
= 84 kN/mm2 = 84 × 103 N/mm2
1. Mean diameter of the spring coil

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Let D = Mean diameter of the spring coil for a maximum load of
W2 = 2750 N, and d = Diameter of the spring wire.

Example 7. Design and draw a valve spring of a petrol engine for the following operating conditions :
Spring load when the valve is open = 400 N Spring load when the valve is closed = 250 N

Dr.RGM/V-SEM/ME8593-DME/UNIT – III PROBLEMS Page 5


CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Maximum inside diameter of spring = 25 mm Length of the spring when the valve is open = 40 mm
Length of the spring when the valve is closed = 50 mm Maximum permissible shear stress = 400 MPa
Solution. Given: W1 = 400 N; W2 = 250 N; Di = 25 mm; l1 = 40 mm; l2 = 50 mm;
τ = 400 MPa = 400 N/mm2
1. Mean diameter of the spring coil
Let d = Diameter of the spring wire in mm, and
D = Mean diameter of the spring coil = Inside dia. of spring + Dia. of spring wire = (25 + d) mm
Since the diameter of the spring wire is obtained for the maximum spring load (W1), therefore maximum
twisting moment on the spring,

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

Example 8. Design a helical spring for a spring loaded safety valve ( Rams bottom safety valve) for the
following conditions: Diameter of valve seat = 65 mm ; Operating pressure = 0.7 N/mm2; Maximum
pressure when the valve blows off freely = 0.75N/mm2; Maximum lift of the valve when the pressure
rises from 0.7 to 0.75 N/mm2 = 3.5 mm ; Maximum allowable stress = 550 MPa ;Modulus of rigidity =
84 kN/mm2; Spring index = 6. Draw a neat sketch of the free spring showing the main dimensions.
Solution. Given: D1 = 65 mm ; p1 = 0.7 N/mm2 ; p2 = 0.75 N/mm2 ; δ = 3.5 mm ; τ = 550 MPa = 550
N/mm2 ; G = 84 kN/mm2 = 84 × 103 N/mm2 ; C = 6
1. Mean diameter of the spring coil
Let D = Mean diameter of the spring coil, and d = Diameter of the spring wire.
Since the safety valve is a Rams bottom safety valve, therefore the spring will be under tension. We
know that initial tensile force acting on the spring (i.e. before the valve lifts),

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

Example 9. A safety valve of 60 mm diameter is to blow off at a pressure of 1.2 N/mm2. It is held on its
seat by a close coiled helical spring. The maximum lift of the valve is 10 mm. Design a suitable
compression spring of spring index 5 and providing an initial compression of 35 mm. The maximum
shear stress in the material of the wire is limited to 500 MPa. The modulus of rigidity for he spring
material is 80 kN/mm2. Calculate : 1. Diameter of the spring wire, 2. Mean coil diameter, 3. Number of
active turns, and 4. Pitch of the coil.
Take Wahl’s factor,
K={[(4C-1)/(4C-4)]+[0.615/C]} where C = Spring index.
Solution. Given : Valve dia. = 60 mm ; Max. pressure = 1.2 N/mm2 ; δ2 = 10 mm ; C = 5 ; δ1 = 35 mm ;
τ = 500 MPa = 500 N/mm2 ; G = 80 kN/mm2 = 80 × 103 N/mm2

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Example 10. Find the maximum shear stress and deflection induced in a helical spring of the following
specifications, if it has to absorb 1000 N-m of energy. Mean diameter of spring = 100 mm ; Diameter of
steel wire, used for making the spring = 20 mm; Number of coils = 30 ; Modulus of rigidity of steel = 85
kN/mm2.
Solution. Given : U = 1000 N-m ; D = 100 mm = 0.1 m ; d = 20 mm = 0.02 m ; n = 30 ;
G = 85 kN/mm2 = 85 × 109 N/m2

Example 11. A closely coiled helical spring is made of 10 mm diameter steel wire, the coil consisting of
10 complete turns with a mean diameter of 120 mm. The spring carries an axial pull of 200 N.
Determine the shear stress induced in the spring neglecting the effect of stress concentration. Determine
also the deflection in the spring, its stiffness and strain energy stored by it if the modulus of rigidity of
the material is 80 kN/mm2.
Solution. Given : d = 10 mm ; n = 10 ; D = 120 mm ; W = 200 N ; G = 80 kN/mm2 = 80 × 103 N/mm2
Shear stress induced in the spring neglecting the effect of stress concentration
We know that shear stress induced in the spring neglecting the effect of stress concentration is,

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

Example 12. At the bottom of a mine shaft, a group of 10 identical close coiled helical springs are set in
parallel to absorb the shock caused by the falling of the cage in case of a failure. The loaded cage
weighs 75 kN, while the counter weight has a weight of 15 kN. If the loaded cage falls through a height
of 50 metres from rest, find the maximum stress induced in each spring if it is made of 50 mm diameter
steel rod. The spring index is 6 and the number of active turns in each spring is 20. Modulus of rigidity,
G = 80 kN/mm2.
Solution. Given : No. of springs = 10 ; W1 = 75 kN = 75 000 N ; W2 = 15 kN = 15 000 N ;
h = 50 m = 50 000 mm ; d = 50 mm ; C = 6 ; n = 20 ; G = 80 kN/mm2 = 80 × 103 N/mm2
We know that net weight of the falling load,
P = W1 – W2 = 75 000 – 15 000 = 60 000 N
Let W = The equivalent static (or gradually applied) load on each spring which can produce the same
effect as by the falling load P.

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

Example 13. A rail wagon of mass 20 tonnes is moving with a velocity of 2 m/s. It is brought to rest by
two buffers with springs of 300 mm diameter. The maximum deflection of springs is 250 mm. The
allowable shear stress in the spring material is 600 MPa. Design the spring for the buffers.
Solution. Given : m = 20 t = 20 000 kg ; v = 2 m/s ; D = 300 mm ; δ = 250 mm ;
τ = 600 MPa = 600 N/mm2
1. Diameter of the spring wire
Let d =Diameter of the spring wire.
We know that kinetic energy of the wagon

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Example 14. A loaded narrow-gauge car of mass 1800 kg and moving at a velocity 72 m/min., is
brought to rest by a bumper consisting of two helical steel springs of square section. The mean diameter
of the coil is six times the side of the square section. In bringing the car to rest, the springs are to be
compressed 200 mm. Assuming the allowable shear stress as 365 MPa and spring index of 6, find :
1. Maximum load on each spring, 2. Side of the square section of the wire, 3. Mean diameter of coils,
and 4. Number of active coils. Take modulus of rigidity as 80 kN/mm2.
Solution. Given : m = 1800 kg ; ν = 72 m/min = 1.2 m/s ; δ = 200 mm ;τ = 365 MPa = 365 N/mm2 ;
C = 6 ; G = 80 kN/mm2 = 80 × 103 N/mm2
1. Maximum load on each spring,
Let W = Maximum load on each spring.
We know that kinetic energy of the car

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Example 15. A helical compression spring made of oil tempered carbon steel, is subjected to a load
which varies from 400 N to 1000 N. The spring index is 6 and the design factor of safety is 1.25. If the
yield stress in shear is 770 MPa and endurance stress in shear is 350 MPa, find : 1. Size of the spring
wire, 2. Diameters of the spring, 3. Number of turns of the spring, and 4. Free length of the spring.
The compression of the spring at the maximum load is 30 mm. The modulus of rigidity for the spring
material may be taken as 80 kN/mm2.
Solution. Given : Wmin = 400 N ; Wmax = 1000 N ; C = 6 ; F.S. = 1.25 ; τy = 770 MPa = 770 N/mm2 ;
τe = 350 MPa = 350 N/mm2 ; δ = 30 mm ; G = 80 kN/mm2 = 80 × 103 N/mm2
1. Size of the spring wire
Let d = Diameter of the spring wire, and
D = Mean diameter of the spring = C.d = 6 d ... (Q D/d = C = 6)
We know that the mean load,

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

Example 16. A concentric spring for an aircraft engine valve is to exert a maximum force of 5000 N
under an axial deflection of 40 mm. Both the springs have same free length, same solid length and are
subjected to equal maximum shear stress of 850 MPa. If the spring index for both the springs is 6, find
(a) the load shared by each spring, (b) the main dimensions of both the springs, and (c) the number of
active coils in each spring. Assume G = 80 kN/mm2 and diametral clearance to be equal to the
difference between the wire diameters.
Solution. Given : W = 5000 N ; δ = 40 mm ; τ1 = τ2 = 850 MPa = 850 N/mm2 ; C = 6 ;
G = 80 kN/mm2 = 80 × 103 N/mm2
The concentric spring is shown in Fig. (a).

(a) Load shared by each spring


Let W1 and W2 = Load shared by outer and inner
spring respectively,
d1 and d2 = Diameter of spring wires for outer and
inner springs respectively, and
D1 and D2 = Mean diameter of the outer and inner
springs respectively.

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

Example 17. A composite spring has two closed coil helical springs as shown in Fig. The outer spring is
15 mm larger than the inner spring. The outer spring has 10 coils of mean diameter 40 mm and wire
diameter 5mm. The inner spring has 8 coils of mean diameter 30 mm and wire diameter 4 mm. When the
spring is subjected to an axial load of 400 N, find 1. compression of each spring, 2. load shared by each
spring, and 3. Shear stress induced in each spring. The modulus of rigidity may be taken as 84 kN/mm2.
Solution. Given : δ1 = l1 – l2 = 15 mm ; n1 = 10 ; D1 = 40 mm ; d1 = 5 mm ; n2 = 8 ;D2 = 30 mm ;
d2 = 4 mm ; W = 400 N ; G = 84 kN/mm2 = 84 × 103 N/mm2
1. Compression of each spring
Since the outer spring is 15 mm larger than the inner spring, therefore the inner spring will not take any
load till the outer spring is compressed by 15 mm. After this, both the springs are compressed together.
Let P1 be the load on the outer spring to compress it by 15 mm.
We know that compression of the spring (δ),

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Example 18. A helical torsion spring of mean diameter 60 mm is made of a round wire of 6 mm
diameter. If a torque of 6 N-m is applied on the spring, find the bending stress induced and the angular
deflection of the spring in degrees. The spring index is 10 and modulus of elasticity for the spring
material is 200 kN/mm2. The number of effective turns may be taken as 5.5.
Solution. Given : D = 60 mm ; d = 6 mm ; M = 6 N-m = 6000 N-mm ; C = 10 ; E = 200 kN/mm2
= 200 × 103 N/mm2 ; n = 5.5
Bending stress induced
We know that Wahl’s stress factor for a spring made of round wire,

Example 19. Design a leaf spring for the following specifications : Total load = 140 kN ; Number of
springs supporting the load = 4 ; Maximum number of leaves = 10; Span of the spring = 1000 mm ;
Permissible deflection = 80 mm.Take Young’s modulus, E = 200 kN/mm2 and allowable stress in spring
material as 600 MPa.
Solution. Given : Total load = 140 kN ; No. of springs = 4; n = 10 ; 2L = 1000 mm or L = 500 mm ;
δ = 80 mm ; E = 200 kN/mm2 = 200 × 103 N/mm2 ; σ = 600 MPa = 600 N/mm2
We know that load on each spring,

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

Example 20. A truck spring has 12 numbers of leaves, two of which are full length leaves. The spring
supports are 1.05 m apart and the central band is 85 mm wide. The central load is to be 5.4 kN with a
permissible stress of 280 MPa. Determine the thickness and width of the steel spring leaves. The ratio of
the total depth to the width of the spring is 3. Also determine the deflection of the spring.
Solution. Given: n = 12 ; nF = 2 ; 2L1 = 1.05 m = 1050 mm ; l = 85 mm ; 2W = 5.4 kN = 5400 N or
W = 2700 N ; σF = 280 MPa = 280 N/mm2
Thickness and width of the spring leaves
Let t = Thickness of the leaves, and b = Width of the leaves.
Since it is given that the ratio of the total depth of the spring (n × t) and width of the spring (b) is 3,
therefore

Dr.RGM/V-SEM/ME8593-DME/UNIT – III PROBLEMS Page 20


CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Example 21. A locomotive semi-elliptical laminated spring has an overall length of 1 m and sustains a
load of 70 kN at its centre. The spring has 3 full length leaves and 15 graduated leaves with a central
band of 100 mm width. All the leaves are to be stressed to 400 MPa, when fully loaded. The ratio of the
total spring depth to that of width is 2. E = 210 kN/mm2. Determine : 1. The thickness and width of the
leaves. 2. The initial gap that should be provided between the full length and graduated leaves before
the band load is applied. 3. The load exerted on the band after the spring is assembled.
Solution. Given : 2L1 = 1 m = 1000 mm ; 2W = 70 kN or W = 35 kN = 35 × 103 N ; nF = 3 ; nG = 15 ;
l = 100 mm ; σ = 400 MPa = 400 N/mm2 ; E = 210 kN/mm2 = 210 × 103 N/mm2
1. Thickness and width of leaves
Let t = Thickness of leaves, and b = Width of leaves.
We know that the total number of leaves, n = nF + nG = 3 + 15 = 18
Since it is given that ratio of the total spring depth (n × t) and width of leaves is 2, therefore

Example 22. A semi-elliptical laminated vehicle spring to carry a load of 6000 N is to consist of seven
leaves 65 mm wide, two of the leaves extending the full length of the spring. The spring is to be 1.1 m in
length and attached to the axle by two U-bolts 80 mm apart. The bolts hold the central portion of the

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
spring so rigidly that they may be considered equivalent to a band having a width equal to the distance
between the bolts. Assume a design stress for spring material as 350MPa. Determine :
1. Thickness of leaves, 2. Deflection of spring, 3. Diameter of eye, 4. Length of leaves, and 5. Radius to
which leaves should be initially bent. Sketch the semi-elliptical leaf-spring arrangement.
The standard thickness of leaves are : 5, 6, 6.5, 7, 7.5, 8, 9, 10, 11 etc. in mm.
Solution. Given : 2W = 6000 N or W = 3000 N ; n = 7 ; b = 65 mm ; nF = 2 ; 2L1 = 1.1 m = 1100 mm or
L1 = 550 mm ; l = 80 mm ; σ = 350 MPa = 350 N/mm2
1. Thickness of leaves
Let t = Thickness of leaves.
We know that the effective length of the spring, 2L = 2L1 – l = 1100 – 80 = 1020 mm
∴ L = 1020 / 2 = 510 mm
and number of graduated leaves, nG = n – nF = 7 – 2 = 5
Assuming that the leaves are not initially stressed, the maximum stress (σF),

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Example 1. Design a connecting rod for an I.C. engine running at 1800 r.p.m. and developing a
maximum pressure of 3.15 N/mm2. The diameter of the piston is 100 mm ; mass of the reciprocating
parts per cylinder 2.25 kg; length of connecting rod 380 mm; stroke of piston 190 mm and compression
ratio 6 : 1. Take a factor of safety of 6 for the design. Take length to diameter ratio for big end bearing
as 1.3 and small end bearing as 2 and the corresponding bearing pressures as 10 N/mm2 and 15 N/mm2.
The density of material of the rod may be taken as 8000 kg/m3 and the allowable stress in the bolts as 60
N/mm2 and in cap as 80 N/mm2. The rod is to be of I-section for which you can choose your own
proportions.
Draw a neat dimensioned sketch showing provision for lubrication. Use Rankine formula for which the
numerator constant may be taken as 320 N/mm2 and the denominator constant 1 / 7500.
Solution. Given : N = 1800 r.p.m. ; p = 3.15 N/mm2 ; D = 100 mm ; mR = 2.25 kg ; l = 380 mm
= 0.38 m ; Stroke = 190 mm ; *Compression ratio = 6 : 1 ; F. S. = 6.
The connecting rod is designed as discussed below:
1. Dimension of I- section of the connecting rod
Let us consider an I-section of the connecting rod, as shown in Fig. (a), with the following
proportions :
Flange and web thickness of the section = t Width of the section, B = 4t
and depth or height of the section, H = 5t
First of all, let us find whether the section chosen
is satisfactory or not.
We have already discussed that the connecting rod
is considered like both ends hinged for buckling
about X-axis and both ends fixed for buckling
about Y-axis. The connecting rod should be equally
strong in buckling about both the axes. We know
that in order to have a connecting rod equally
strong about both the axes,
Ixx = 4 Iyy
where Ixx = Moment of inertia of the section about X-axis, and
Iyy = Moment of inertia of the section about Y-axis.
In actual practice, Ixx is kept slightly less than 4 Iyy.
It is usually taken between 3 and 3.5 and the connecting rod is designed for buckling about X-axis.

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Now, for the section as shown in Fig. (a), area of the section,
A = 2 (4 t × t ) + 3t × t = 11 t2

These dimensions are at the middle of the connecting rod. The width (B) is kept constant throughout
the length of the rod, but the depth (H) varies. The depth near the big end or crank end is kept as 1.1H
to 1.25H and the depth near the small end or piston end is kept as 0.75H to 0.9H. Let us take
Depth near the big end, H1 = 1.2H = 1.2 × 35 = 42 mm
and depth near the small end, H2 = 0.85H = 0.85 × 35 = 29.75 say 30 mm
∴ Dimensions of the section near the big end = 42 mm × 28 mm Ans.
and dimensions of the section near the small end = 30 mm × 28 mm Ans.
Since the connecting rod is manufactured by forging, therefore the sharp corners of I-section are
rounded off, as shown in Fig. (b), for easy removal of the section from the dies.
2. Dimensions of the crankpin or the big end bearing and piston pin or small end bearing
Let dc = Diameter of the crankpin or big end bearing,
lc = length of the crankpin or big end bearing = 1.3 dc ...(Given)
pbc = Bearing pressure = 10 N/mm2 ...(Given)
We know that load on the crankpin or big end bearing
= Projected area × Bearing pressure = dc .lc . pbc = dc × 1.3 dc × 10 = 13 (dc)2

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CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS
Since the crankpin or the big end bearing is designed for the maximum gas force (FL), therefore,
equating the load on the crankpin or big end bearing to the maximum gas force, i.e.
13 (dc)2 = FL = 24 740 N
∴ (dc )2 = 24 740 / 13 = 1903 or dc = 43.6 say 44 mm Ans.
and lc = 1.3 dc = 1.3 × 44 = 57.2 say 58 mm Ans.
The big end has removable precision bearing shells of brass or bronze or steel with a thin lining
(1mm or less) of bearing metal such as babbit.
Again, let dp = Diameter of the piston pin or small end bearing,
lp = Length of the piston pin or small end bearing = 2dp ...(Given)
pbp = Bearing pressure = 15 N/mm2 ..(Given)
We know that the load on the piston pin or small end bearing
= Project area × Bearing pressure = dp . lp . pbp = dp × 2 dp × 15 = 30 (dp)2
Since the piston pin or the small end bearing is designed for the maximum gas force (FL), therefore,
equating the load on the piston pin or the small end bearing to the maximum gas force, i.e.
30 (dp)2 = 24 740 N
∴ (dp)2 = 24 740 / 30 = 825 or dp = 28.7 say 29 mm Ans.
and lp = 2 dp = 2 × 29 = 58 mm Ans.
The small end bearing is usually a phosphor bronze bush of about 3 mm thickness.
3. Size of bolts for securing the big end cap
Let dcb = Core diameter of the bolts,
σt = Allowable tensile stress for the material of the bolts = 60 N/mm2 ...(Given)
nb = Number of bolts. Generally two bolts are used.
We know that force on the bolts

Dr.RGM/V-SEM/ME8593-DME/UNIT – III PROBLEMS Page 26


CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

4. Thickness of the big end cap


Let tc = Thickness of the big end cap,
bc = Width of the big end cap. It is taken equal to the length of the crankpin or big end bearing (lc) = 58
mm (calculated above)
σb = Allowable bending stress for the material of the cap = 80 N/mm2 ...(Given)
The big end cap is designed as a beam freely supported at the cap bolt centres and loaded by the inertia
force at the top dead centre on the exhaust stroke (i.e. FI when θ = 0). Since the load is assumed to act in
between the uniformly distributed load and the centrallyconcentrated load, therefore, maximum bending
moment is taken as

Dr.RGM/V-SEM/ME8593-DME/UNIT – III PROBLEMS Page 27


CHENNAI INSTITUTE OF TECHNOLOGY , CHENNAI – 600 069
DEPARTMENT OF MECHANICAL ENGINEERING
ME 8593- DESIGN OF MACHINE ELEMENTS

Dr.RGM/V-SEM/ME8593-DME/UNIT – III PROBLEMS Page 28

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