Module IV MD
Module IV MD
ME - 211
E-mail: [email protected]
Mob: 9431927250
SYLLABUS (ME – 211 Machine Design)
Module –I
Failure of materials: Principles of Machine Design, standardization, Tolerances, Design against static and fluctuating loads, Theories of failures,
Design of cotter joint and knuckle joint, Fatigue failure, Endurance limit, Notch Sensitivity, Gerber, Soderberg, Goodman, and Modified
Goodman criteria, Design against combined loads.. (8L)
Module –II
Design of threaded, welded, and riveted joints: Threaded joints: Basic types of screw fastening, Bolt of uniform strength, Terminology of screw
threads, Bolt under tension, Welded joints: Butt joints, Fillet joints, Strength of butt and fillet welds. Riveted joints: Types of rivet heads, types of
rivet joints, Strength equations, Efficiency of joint, Caulking and fullering, Eccentrically loaded bolted, riveted and welded joints. (8L)
Module – III
Design of brakes and clutches: Types of Brakes and Clutches, Clutch/Brake selection and specification, Clutch and Brake materials, Disc
Clutches, Shoe, Band and Disk Brakes. (8L)
Module – IV
Design of springs and bearing: Spring configuration, Spring materials, Design of helical compression/extension springs. Bearings, Types of sliding
contact bearings, Bearing materials, Lubricating oils, Petroff’s equation, Mckee’s Investigation, Hydrostatic bearing, Rolling contact bearings .
(8L)
Module –V
Design of Gears: Types of gear, Terminology of gear, standard systems of gear tooth, Force analysis of spur, helical, bevel, and worm gears, Beam
and wear strength of gears, Lewis and Buckingham’s equation, Effective load on spur gear tooth. (8L)
Text Books:
1. Shigley’s Mechanical Engineering Design, by Richard Budynas (Author), Keith Nisbett (Author)
2. Introduction to Machine Design by V. B. Bhandari
3. Machine Design by Khurmi
Reference Books:
1. Machine Design, An Integrated Approach by Robert L. Norton, Second Edition.
2. Machine Design Data Handbook by K. Lingaiah
3. Mechanical Design of Machine Components by Ansel C. Ugural
Springs
Spring is an elastic machine element which deflects under the action of the load & returns to its
original shape when the load is removed
There are three objectives for the design of the helical spring
i) It should posses sufficient strength to withstand the external load.
ii) It should have the required load deflection characteristics.
iii) It should not buckle under the external load.
ATERIALS
four basic varieties of steel wire which are used in springs in the majority of ap
d and cold-drawn steel wires(unalloyed);
dened and tempered spring steel wires and valve spring wires;
rdened and tempered steel wires (alloyed); and
ess steel spring wires.
TERMINOLOGY OF HELICAL SPRINGS
d = wire diameter of spring (mm)
Di = inside diameter of spring coil (mm)
Do = outside diameter of spring coil (mm)
D = mean coil diameter (mm) , Therefore D =(Di +Do)/2
Spring index is the ratio of mean coil diameter to wire diameter , C=D/d
The pitch of the coil is the axial distance between adjacent coils in
uncompressed state of spring. It is denoted by p. It is given by, p = free
length/(Nt -1)
Design of Helical Springs
i) Estimate the maximum spring force (P) and the corresponding required deflection (δ)
of the spring. In some cases, maximum spring force (P) and stiffness k, which is
(P/ δ), are specified.
ii) Select a suitable spring material and find out ultimate tensile strength (S ut) from the
data. Calculate the permissible shear stress for the spring wire by following
relationship
Ʈ = 0.3 Sut or 0.5 Sut
iii) Assume a suitable spring index (C). For industrial applications, the spring index varies
from 8 to 10. The spring index should never be less than 3.
iv) Calculate the Wahl factor by
(4C – 1/ 4C – 4) + 0.651/ C
v) Determine wire diameter (d)
Ʈ = K (8 P C / π d2)
vi) Determine mean coil diameter (D) by D = C d
vii) Determine the number of active coils (N) by
δ = (8 P D3 N / G d4) The modulus of rigidity (G) for steel wires is 81
viii) Determine the number of inactive coils. Adding active & inactive coils, find out the
total number of coils (Nt)
(i)Wire diameter
(ii) mean coil diameter
(iii) number of active coils
(iv) total number of coils
(v) solid length of the spring
(vi) free length of the spring
(vii) required spring rate
(viii) actual spring rate
Design of Leaf springs
Multi-leaf springs are widely used for the suspension of cars, trucks and railway wagons.
The flat plates are called leaves of the spring. The leaves have graduated lengths. The leaf at the
top has maximum length. The length gradually decreases from the top leaf to the bottom leaf. The
longest leaf at the top is called master leaf. It is bent at both ends to from the spring eyes. Two
bolts are inserted through these eyes to fix the leaf spring to the automobile body. The leaves are
held together by means of two U-bolts and a centre clip. Rebound clips are provided to keep the
leaves in alignment and prevent lateral shifting of the leaves during operation. At the centre, the
leaf spring is supported on the axle. Multi-leaf springs are provided with one or two extra full length
leaves in addition to master leaf. The extra full-length leaves are stacked between the master leaf
and the graduated length leaves. The extra full-length leaves are provided to support the
transverse shear force.
Bearin
Bearing is a mechanical element that permits relative motion between two
gs
parts, such as the shaft and the housing, with minimum friction. The
functions of the bearing are as follows:
(i) The bearing ensures free rotation of the shaft or the axle with minimum
friction.
(ii) The bearing supports the shaft or the axle and holds it in the correct
position.
(iii) The bearing takes up the forces that act on the shaft or the axle and
transmits them to the frame or the foundation.
Sliding contact bearings are also called plain bearings, journal bearings or
sleeve
bearings. In this case, the surface of the shaft slides over the surface
of the bush resulting in friction and wear. In order to reduce the
friction, these two surfaces are separated by a film of lubricating oil.
The bush is made of special bearing material like white metal or
bronze.
Sliding contact bearings are used in the following applications:
(i) crankshaft bearings in petrol and diesel engines;
(ii) centrifugal pumps;
(iii) large size electric motors;
(iv) steam and gas turbines; and
(v) concrete mixers, rope conveyors and marine installations.
Depending upon the direction of force that acts on them, bearings are
classified into two categories -radial and thrust bearings, as shown in Fig.
below.
(ii) Self-aligning ball bearings and spherical roller bearings are used in
applications where a misalignment between the axes of the shaft and housing
is likely to exist.
(iii) Thrust ball bearings are used for medium thrust loads whereas for heavy
thrust loads, cylindrical roller thrust bearings are recommended. Double
acting thrust bearings can carry the thrust load in either direction.
(iv) Deep groove ball bearings, angular contact bearings and spherical roller
bearings are suitable in applications where the load acting on the bearing
consists of two components— radial and thrust.
(v) The maximum permissible speed of the shaft depends upon the
temperature rise in the bearing. For high speed applications, deep groove
ball bearings, angular contact bearings and cylindrical roller bearings are
recommended.
From past experience, it has been found that a total permanent deformation
of 0.0001 of the ball or roller diameter occurring at the most heavily
stressed ball and race contact, can be tolerated in practice, without any
disturbance like noise or vibrations.
The static load carrying capacity of a bearing is defined as the static load
which corresponds to a total permanent deformation of balls and races, at
the most heavily stressed point of contact, equal to 0.0001 of the ball
diameter.
STRIBECK’S EQUATION
Stribeck’s equation gives the static load capacity of bearing.
It is based on the following assumptions:
(i) The races are rigid and retain their circular shape.
(ii) The balls are equally spaced.
(iii) The balls in the upper half do not support any load.
Figure (a) shows the forces acting on the inner race through the rolling
elements, which support the static load C0. It is assumed that there is a
single row of balls. Considering
the equilibrium of forces in the vertical direction,
The values of M for different values
of z are tabulated as follows:
DYNAMIC LOAD CARRYING CAPACITY
The life of a ball bearing is limited by the fatigue failure at the surfaces of
balls and races. The dynamic load carrying capacity of the bearing is,
therefore, based on the fatigue life of the bearing.
The dynamic load carrying capacity of a bearing is defined as the radial load
in radial bearings (or thrust load in thrust bearings) that can be carried for a
minimum life of one million revolutions.
The minimum life in this definition is the L10 life, which 90% of the bearings
will reach or exceed before fatigue failure.
EQUIVALENT BEARING LOAD
In actual applications, the force acting on the bearing has two components -
radial and thrust. It is therefore necessary to convert the two components
acting on the bearing into a single hypothetical load, fulfilling the conditions
applied to the dynamic load carrying capacity. Then the hypothetical load
can be compared with the dynamic load capacity.
The equivalent dynamic load is the constant radial load in radial bearings
(or thrust load in thrust bearings), which if applied to the bearing would
give same life as that which the bearing will attain under actual condition of
forces. The race-rotation factor depends upon
whether the inner race is rotating or the
The expression for the equivalent dynamic load is
outer race. written
The value as,
of V is 1 when the
inner race rotates while the outer race
is held stationary in the housing. The
value of V is 1.2 when the outer race
rotates with respect to the load, while
the inner race remains stationary. In
Assuming V as unity, the general equation
most offor equivalent
the dynamic
applications, load israce
the inner
given by, rotates and the outer race is fixed in the
housing.
LOAD-LIFE RELATIONSHIP
The relationship between the dynamic load carrying capacity, the equivalent
dynamic load, and the bearing life is given by,
Q1 A taper roller bearing has a dynamic load capacity of 26 kN. The
desired life for 90% of the bearings is 8000 h and the speed is 300
rpm. Calculate the equivalent radial load that the bearing can carry.
SELECTION OF BEARING LIFE
SELECTION OF BEARING FROM MANUFACTURER’S CATALOGUE
Table 15.5 Dimensions and static and dynamic load capacities of single-row deep
groove ball bearings
Sliding Contact Bearings
• Thick film lubrication describes a condition of lubrication, where two
surfaces of the bearing in relative motion are completely separated by a
film of fluid.
• Since there is no contact between the surfaces, the properties of surface,
like surface finish, have little or no influence on the performance of the
bearing.
• The resistance to relative motion arises from the viscous resistance of the
fluid. Therefore, the viscosity of the lubricant affects the performance of
the bearing.
• Hydrodynamic lubrication is a system of lubrication in which the load-
Thick film lubrication
• supporting fluid film isiscreated
furtherby
divided into two
the shape and groups:
relative hydrodynamic
motion of the
and hydrostatic
sliding surfaces.lubrication.
The principle
Initially, of hydrostatic
the shaft lubrication
rests on the in journal
bearing surface bearing is As
[Fig.16.5(a)]. illustrated
the pumpin
Fig. 16.5.
starts, high pressure fluid is admitted in the clearance space, forcing the
surfaces of the bearing and journal to separate out [Fig.16.5(b)]. Hydrostatic
bearings are used on vertical turbo generators, centrifuges and ball mills.
Hydrostatic bearings, although costly, offer
the following advantages:
(i)high load carrying capacity even at low
speeds;
(ii)no starting friction; and
(iii)no rubbing action at any operating speed
or load.
(i) In order to avoid seizure, the operating value of the bearing characteristic
number (μN/p) should be at least 5 to 6 times that when the coefficient of
friction is minimum. (5 K to 6 K or 5 to 6 times the bearing modulus).
(ii) If the bearing is subjected to fluctuating loads or impact conditions, the
operating value of the bearing characteristic number (μN/p) should be at
least 15 times that when the coefficient of friction is minimum. (15 K or 15
times the bearing modulus).
•It is observed from the (μN/p) curve that when viscosity of the lubricant is
very low, the value of (μN/p) parameter will be low and boundary lubrication
will result.
•Therefore, if the viscosity of the lubricant is very low then the lubricant will
not separate the surfaces of the journal and the bearing and metal to metal
contact will occur resulting in excessive wear at the contacting surfaces.
journal diameter = 75 mm
radial load = 10 kN
journal speed = 1440 rpm
minimum oil fi lm thickness = 22.5 microns
inlet temperature = 40°C
bearing material = babbitt
Determine the length of the bearing and select a
suitable oil for this application.
P.3 The following data is given for a
hydrostatic thrust bearing:
thrust load = 500 kN
shaft speed = 720 rpm
shaft diameter = 500 mm
recess diameter = 300 mm
film thickness = 0.15 mm
viscosity of lubricant = 160 SUS
specific gravity = 0.86
Calculate
(i) supply pressure;
(ii) flow requirement in litres/min;
(iii) power loss in pumping; and
(iv) frictional power loss.
P.4 The following data is given for the hydrostatic step bearing of a vertical
turbo generator:
thrust load = 450 kN shaft diameter = 400 mm recess diameter = 250 mm
shaft speed = 750 rpm viscosity of lubricant = 30 cP
Draw a neat sketch showing the effect of film thickness on energy losses.
Calculate the optimum film thickness for minimum power loss.
P.6 A hydrostatic spherical step bearing is shown in Fig. 16.37. Show that
the load carrying capacity of the bearing is given by