DEPARTMENT OF MECHANICAL ENGINEERING

S7 ME
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MACHINE DESIGN - I

Assignment No. 3&4

To be submitted on 15-11-2013

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A laminated semi-elliptic leaf spring under a central load of 12 kN is to have an effective length of 1 m and is to deflect not more than 80 mm. The spring has 14 leaves, three of which are full length, and have been pre-stressed so that all leaves have the same stress after the full load has been applied. All leaves have the same width and thickness. The maximum stress in the leaves is not to exceed 350 MN/m2. Calculate the width and thickness of the leaves. Modulus of elasticity of the spring material is 210 GPa. Also, determine the width and thickness of the leaves if the leaves are not prestressed, the other parameters remaining the same. A semi-elliptic leaf spring has an effective length of 1.5m (figure-1). The spring seat, midway between the shackles, carries a helical spring upon which is imposed an impact equivalent to 1000 Nm of energy. The laminated spring is composed of 13 graduated leaves and 2 extra full length leaves, each 6.5 mm thick and 55 mm Figure-1 wide. The coil spring is composed of 6 effective turns of 50 mm wire. The mean coil diameter is 100 mm. Calculate the maximum stress induced in each spring. A shaft made of C-40 steel and 2.2m long, is supported by two bearings, one at the left end and another at 1.7m from the left. The shaft carries two pulleys keyed to it, one at mid-span and another at the right end. The pulleys are of diameter 0.6m and 0.5m respectively. Input power at the left pulley is 24 kW and the power output is from the right pulley. The input to the left pulley is horizontal and the drive from the right pulley is to a machine vertically below. Speed of the shaft is 600 r.p.m. and the coefficient of friction is 0.3. Combined shock and fatigue factors in bending and torsion may be taken as 2.0 and 1.5 respectively. Design the shaft assuming suitable stresses. Also, design suitable keys for connection between the shaft and the pulleys. Determine the diameter for a hollow shaft having inside diameter 0.6 times the outside diameter. The maximum allowable shear stress for the shaft is 80 MPa. The shaft is driven by a 750mm diameter overhung pulley placed vertically below it. The weight of the pulley is 600 N. The tensions on tight and slack sides of the belt are 3.2 kN and 1.2 kN respectively. The overhung is 250mm. Assume angle of lap of the belt on the pulley to be 180. A horizontal solid shaft is supported on two bearings 1.5 m apart. A helical gear (45 helix angle) of 20 involute teeth and 200 mm pitch diameter is located 400 mm to the right of the left bearing. The gear is driven by a mating gear directly behind it. A 600 mm diameter pulley is keyed to the shaft 600 mm to the left of the right bearing. The pulley drives another pulley with a horizontal belt directly behind it. The ratio of tensions of the belt is 2.8 with the slack side on top. The drive transmits 30 kW at 300 rpm. Design the shaft if the allowable shear stress for the shaft material is 40 N/mm2. Determine the inside and outside diameters of a hollow shaft which will replace a solid shaft of the same material. The hollow shaft should have the same strength as that of the solid shaft, but must weigh half the solid shaft per metre length. A 600mm pulley, P, driven by a horizontal belt transmits 20 kW of power at 300 r.p.m. through a solid steel shaft to a 20 spur gear, G, of diameter 250 mm, which drives a mating gear directly behind it (figure-2). The pulley weighs 1000 N and the ratio of tensions between the two sides of the belt is 3.2. The shaft is supported between narrow bearings B1 and B2 and both the pulley and the gear are keyed to the shaft. If commercial steel shafting is used and the shock and fatigue factors are chosen to be Kb = 2.0 and Kt = 1.5, determine the necessary diameter of the shaft. Figure-2

8. A shaft and a key are made of the same material and the key width is of the shaft diameter. Considering shear only, determine the minimum length of the key in terms of the shaft diameter. The shearing strength of the key material is 60% of its crushing strength. Determine the thickness of the key to make the key equally strong in shear and crushing. 9. Design and sketch a protected type of C.I. flange coupling for a mild steel shaft transmitting 18 kW at 200 r.p.m. Shaft and key are of the same material. Bolts are made of alloy steel for which the maximum shear stress should not exceed 30 MPa. The maximum torque may be taken as 25% greater than the full-load torque. 10. A flexible coupling (shown in figure-3) is used to transmit 15 kW of power at 100 r.p.m. There are six pins and their pitch circle diameter is 200 mm. The length of the pin in contact with the left hand flange, the gap between the two flanges and the length of bush in contact with the right hand flange are 23, 5 and 35 mm respectively. The permissible shear and bending stresses in the pin are 35 and 152 N/mm2 respectively. The permissible pressure for the rubber bush is 1 N/mm2. Calculate: (i) the pin diameter by shear consideration, (ii) the pin diameter by bending consideration and (iii) outer diameter of the rubber bush. 11. Design a cotter joint to connect two mild steel shafts transmitting an axial force of 28 kN which is subject to slow reversals of direction. The material of the cotter and rods will permit the following safe stresses: t = 55 MPa

= 45 MPa

and

c = 110 MPa

12. Design a knuckle joint to transmit a tensile load of 42 kN. 13. Design a double riveted, double cover butt joint for 18 mm thick plates, and find the efficiency of the joint. Allowable stresses for the plate and rivet materials may be taken as t = 55 MPa, c = 85 MPa and = 40 MPa. 14. Design a triple riveted double butt strap joint for the longitudinal seam of a boiler 2.2 m in diameter when the working pressure is 1.2 MPa. The plate material has an ultimate tensile strength of 440 MPa, crushing strength of 680 MPa and shearing strength of 310 MPa. Use a factor of safety of 2.5 and a minimum joint efficiency of 84%.

Figure -3