1 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 .

D ATA B A N K- S O U R C E O F
D ATA .

SCHOOL OF MECHANICAL SCIENCES

DESIGN DATA BANK

12ME233 DESIGN LAB

CREDIT 0:0:1

2 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D ATA B A N K- S O U R C E O F
D ATA .

TABLE OF CONTENTS
Exercis

Name of the Exercise

e No.

Page
No.

DESIGN OF A CLOSED COIL HELICAL

1.

2.
3.
4.
5.
6.

COMPRESSION SPRING USING C/C++

PROGRAM
DESIGN OF A SINGLE DRY PLATE CLUTCH
USING C/C PROGRAM
DESIGN OF A BRAKE DRUM USING C/C++
++

PROGRAM
DESIGN OF A JOURNAL BEARING USING
C/C++ PROGRAM
DESIGN OF A GEAR DRIVE USING C/C++
PROGRAM
DESIGN OF A HELICAL GEAR USING C/C+
+

PROGRAM

5
9
11
14
19

3 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D ATA B A N K- S O U R C E O F
D ATA .

DESIGN OF A CLOSED COIL HELICAL COMPRISSION SPRING

PARAMETERS:
Wmax Maximum service load, N (Newton)
Wmin Minimum service load, N (Newton)
range Axial deflection for the given range of load, mm (millimeters)
max Maximum deflection of the spring, mm (millimeters)
C Spring index (

), dimensionless

max Permissible shear stress intensity, N/mm2 (Newton per millimeters

squared)
G Modulus of Rigidity, N/mm2 (Newton per millimeters squared)
Ks Wahl stress factor, dimensionless
Wrange The load for which the spring deflects to the given magnitude (W max
Wmin), N (Newton)
d Diameter of the spring wire, mm (millimeters)
D Mean diameter of the spring, mm (millimeters)
Di Inner diameter of the spring, mm (millimeters)
Do Outer diameter of the spring, mm (millimeters)
n Number of turns of the spring wire, turns
nf - Number of turns of the spring wire with squared and ground ends,
turns
Lf Free length of the spring, mm (millimeters)
p Pitch of the coils, mm (millimeters)
ALGORITHM:

4 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D ATA B A N K- S O U R C E O F
D ATA .

5 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D ATA B A N K- S O U R C E O F
D ATA .

DESIGN OF A SINGLE PLATE FRICTION CLUTCH

PARAMETERS:
P Power to be transmitted, kW (kilo Watts)
N Speed of rotation of the clutch plate, rpm (revolutions per minute)
Dshaft Diameter of the shaft onto which the clutch plate is coupled, mm
(millimeters)
R Mean radius of the clutch plate

, mm

(millimeters)
b Face width of the clutch plate

, mm (millimeters)

r Ratio between mean radius and face width respectively

dimensionless
Ri - Inner radius of the clutch plate, mm (millimeters)
Ro - Outer radius of the clutch plate, mm (millimeters)
nsprings Number of helical compression springs, numbers
C Spring index (

), dimensionless

T Torque, N-m (Newton meter)

shaft Permissible shear stress intensity of the shaft, N/mm 2 (Newton per
millimeters squared)
spring Permissible shear stress intensity of the spring, N/mm 2 (Newton per
millimeters squared)

6 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D ATA B A N K- S O U R C E O F
D ATA .
pdisc Permissible pressure intensity on the friction disc, N/mm 2 (Newton
per millimeters squared)
- Coefficient of friction of the friction disc, dimensionless
ncontact Number of pairs of friction or contact surfaces, numbers
Waxial Axial load acting on the faces of the friction disc (clutch plate), N
(Newton)
Wtotal Axial load acting on the faces of the friction disc (clutch plate) by
considering 25% overload for the transmission of maximum engine torque,
N (Newton)
Wspring Load acting on each spring, N (Newton)
max Maximum deflection of the spring, mm (millimeters)
G Modulus of Rigidity, N/mm2 (Newton per millimeters squared)
Ks Wahl stress factor, dimensionless
Wrange The load for which the spring deflects to the given magnitude (W max
Wmin), N (Newton)
d Diameter of the spring wire, mm (millimeters)
D Mean diameter of the spring, mm (millimeters)
Di Inner diameter of the spring, mm (millimeters)
Do Outer diameter of the spring, mm (millimeters)
n Number of turns of the spring wire, turns
nf - Number of turns of the spring wire with squared and ground ends,
turns
Lf Free length of the spring, mm (millimeters)
p Pitch of the coils, mm (millimeters)
ALGORITHM:

7 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D ATA B A N K- S O U R C E O F
D ATA .

Permissible shear stress intensity of the shaft, shaft = 40 N/mm2

(assume)

Permissible pressure intensity on the friction disc, p disc = 0.07 N/mm2

(assume)
Coefficient of friction of the friction disc, = 0.25 (assume)
Number of pairs of friction or contact surfaces, ncontact = 2 (for single
plate clutch)

8 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D ATA B A N K- S O U R C E O F
D ATA .

Number of turns of the spring wire, n = 4 (assume)

Modulus of Rigidity, G = 84000 N/mm2 (assume)

9 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D ATA B A N K- S O U R C E O F
D ATA .

DESIGN OF A BRAKE DRUM

PARAMETERS:
Drd Diameter of the rope drum, mm (millimeters)
Rrd Radius of the rope drum

, mm (millimeters)

Dbd Diameter of the brake drum, mm (millimeters)

Rbd Radius of the brake drum

, mm (millimeters)

10 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .
n - Number of brake shoes, numbers
2 Angle subtended by each of the brake shoes, (degrees)
m Mass of the elevator when loaded, kg (kilograms)
v Linear velocity of the elevator when loaded, m/s (meters per second)
u Initial velocity of the elevator when it starts from rest, m/s (meters per
second)
a Acceleration of the elevation, m/s2 (meters per second squared)
h Linear distance moved by the elevator after the application of the
brake, m (meters)
- Coefficient of friction between the brake drum and brake shoes,
dimensionless
pb Allowable pressure on brake shoes, N/mm2 (Newton per millimeters
squared)
Q Heat generated in stopping the elevator, J (Joules)
Fa Accelerating Force, N (Newton)
F Total load acting on the rope while moving, N (Newton)
T Torque acting on the rope drum (shaft), N-mm (Newton millimeters)
Ftb Tangential force acting on the brake drum, N (Newton)
Ft Tangential force acting on each brake shoe, N (Newton)
RN Normal load on each shoe, N (Newton)
Ab Projected area of the bearing on each brake shoe, mm2 (millimeters
squared)
w Width of the brake shoe, mm (millimeters)
g Acceleration due to gravity (9.80665 m/s2), m/s2 (meters per second
squared)

ALGORITHM:
From the third equation of motion, we have

11 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .

Total load acting on the rope while moving = Load on the elevator in
Newton + Accelerating force

The brake drum is provided with four number of cast iron shoes, therefore
the tangential force acting on each shoe is,

(If the angle of contact () of each shoe is 45, the equivalent

coefficient of friction () need not be calculated.

We know that,
The heat generated in stopping the elevator = Total energy absorbed by
the brake
= kinetic energy +
potential energy

12 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .
DESIGN OF A JOURNAL BEARING
PARAMETERS:
W Load on the journal, N (Newton)
N Speed of rotation of the clutch plate, rpm (revolutions per minute)
Z Absolute viscosity of SAE 10 oil, kg/m-s (kilograms per meter second)
toilFilm Oil film temperature i.e. the temperature at which viscosity of the
oil is considered, C (degree Celsius)
tambient Ambient temperature, C (degree Celsius)
pmax Maximum bearing pressure for pump, N/mm2 (Newton per
millimeters squared)
toil Maximum rise in temperature of oil, C (degree Celsius)
h Heat dissipation coefficient, W/m2-C (Watts per meter squared degree
Celsius)
l Length of the journal bearing, mm (millimeters)
d Diameter of the journal bearing, mm (millimeters)
p Pressure acting on the journal bearing as per the load acting on it,
N/mm2 (Newton per millimeters squared)
- Coefficient of friction between the journal and the journal bearing,
dimensionless
v Linear velocity of the journal, m/s (meters per second)
Qgenerated Heat generated per second, W (Watts)
Qdissipated Heat dissipated per second, W (Watts)
Qremoved Amount of heat that must be removed per second, W (Watts)
- Mass flow rate of the oil, kg/s (kilograms per second)
Cp Specific heat capacity of the oil at constant pressure, J/kg-C (Joules
per kilogram degree Celsius)
l/d Length to the diameter ratio of journal bearing, dimensionless

13 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .
c/d Clearance to the diameter ratio of the journal bearing, dimensionless
K Bearing modulus (the point at which the coefficient of friction is
minimum and at which the bearing must not be operated because a slight
decrease in speed or increase in pressure might break the oil film and
make the journal operate with metal to metal contact), dimensionless
k Factor to correct for end leakage. It depends upon the ratio of length
to the diameter of the bearing (l/d) (k = 0.002, for l/d ratios of 0.75 to 2.8),
dimensionless
ALGORITHM:
Table: 1
Machinery

Generator
s,
motors ,
and
centrifuga
l pumps

Bearing

Rotor

Maximum
bearing
pressure,
N/mm2
0.7 1.4

Operating values
Absolute
viscosity
(Z), kg/ms
0.025

Z, kg/m-s
p, N/mm2
28

0.0013

1-2

First of all let us find the length of the journal bearing (l). Assume that the
diameter of the journal bearing (d) as 100 mm. From Table: 1 we find that
the ratio of l/d for centrifugal pumps is in the range between 1 and 2. Let
us take l/d = 1.6

If the pressure induced in the journal bearing by the load acting on the
journal is less than the maximum bearing pressure of the pump, then the
design is safe.
In other words, if p < pmax, then the design is safe.
Otherwise change the dimensions appropriately.

14 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .
From Table: 1 we find that the operating value of the bearing
characteristic number,

The value of bearing characteristic number

at which the friction is at

its minimum is called the bearing modulus, and is denoted by the letter
K. The bearing should not be operated at this value of bearing modulus
because it might break the oil film and cause metal to metal contact to
occur between the journal and the journal bearing, therefore the bearing
should be designed for a value of

at least three times the minimum

value of bearing modulus.

Therefore the minimum value of bearing modulus at which the oil film will
break can be represented mathematically as,
Substitute
Substitute the
the
value
value obtained
obtained
from
from Table:
Table: 11

Check whether

The
The
comput
comput
ed
ed
value
value

From Table: 1, we find that the clearance ratio

0.0013.

The
The
computed
computed
value
value

, assumed for
convenience

for centrifugal pumps is

15 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .

If

, cooling of the journal bearing must be facilitated

artificially.

(Assume)
(Assume)

DESIGN OF A GEAR DRIVE

PARAMETERS:
P Maximum power that can be transmitted, W (Watts)
i The gear ratio or velocity ratio

, dimensionless

NP Speed of the pinion, rpm (revolutions per minute)

NG Speed of the gear, rpm (revolutions per minute)
DG Pitch diameter of the gear, mm (millimeters)
DP Pitch diameter of the pinion, mm (millimeters)
TG Number of teeth on gear, numbers
TP Number of teeth on pinion, numbers
L the center distance between the shafts, mm (millimeters)

16 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .
og = op static stress of the material of which the gear and pinion is
made of , N/mm2 (Newton per millimeters squared)
yp Lewis form factor or tooth form factor for pinion, dimensionless
b Face width of gear or pinion, mm (millimeters)
m Module of the gear or pinion

, mm (millimeters)

C Deformation or dynamic factor in Buckingham equation (a factor

depending on machining error)
K Material combination factor for wear
Cv Velocity factor, dimensionless
v Linear velocity of the gears or pinions pitch circle, m/s (meters per
second)
WT Tangential tooth load (beam strength of the tooth), N (Newton)
WD Dynamic load on tooth, N (Newton)
WI Increment load due to machining error and the pitch line velocity

, N (Newton)
Ws Static tooth load or endurance strength of the tooth, N (Newton)
Q Ratio factor
e Flexural endurance limit, N/mm2 (Newton per millimeters squared)
wp Permissible working stress for pinion

N/mm2 (Newton per millimeters squared)

pcp Circular pitch for pinion

, mm (millimeters)

Ww Maximum or limiting load for wear, N (Newton)

17 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .
r Ratio between face width and module

(assumed for

convenience), dimensionless

ALGORITHM:

Since both the gear and pinion will be made of the same material, the
pinion that will be subject to much wear, tear, and rotations. Thus the
design will be based on pinion.

18 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .

19 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .

Table: 1 (Values of service factor (Cs))

Type of load
steady
Light shock
Medium shock
Heavy shock

Type of service
Intermittent or 3
hours per day
0.80
1.00
1.25
1.54

8-10 hours per

day
1.00
1.25
1.54
1.80

Continuous 24
hours per day
1.25
1.54
1.80
2.00

Assuming steady load conditions, and 8-10 hours of service per day, the
service factor (Cs) as given in Table: 1 be taken as 1.00.

Solve the equation obtained which of the third order, and compare the
value of the module (m) against the standard values given in Table: 2, and
then select the appropriate one.
Table: 2 (Standard module values in mm (millimeters))
Preferred values of module
(mm)
1
1.25
1.5
2
2.5
3
4
5
6
8
10
12
16
20

Option 1
(mm)
1.125
1.375
1.75
2.25
2.75
3.5
4.5
5.5
7
9
11
14
18

Option 2
(mm)

3.25
3.75
6.5

20 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .
Note: Choose the values of modules form the column that specifies the
preferred values

A check for dynamic and wear load.

Table: 3
Material of pinion and
gear
Grey cast iron

Brinell Hardness Number

(B.H.N)
160

Flexural endurance limit

(e) in Mpa (N/mm2)
84

Substitute the
value from Table:
3

If, Ws >WD, and Ww >WD then the design is safe.

21 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .
DESIGN OF HELICAL GEAR
PARAMETERS:
- Helix angle of the cast steel gear, (degrees)
P Power that has to be transmitted, W (Watts)
NG of the gear, rpm (revolutions per minute)
TG - Number of teeth on gear, numbers
TE Equivalent number of teeth on gear

, numbers

DG Pitch diameter of the gear, mm (millimeters)

b Face width of gear, mm (millimeters)
o static stress of the material of which the gear is made of , N/mm 2
(Newton per millimeters squared)
pN Normal pitch of the gear, mm (millimeters)
r Ratio between face width and normal pitch

(assumed

for convenience), dimensionless

y Lewis form factor or tooth form factor for gear, dimensionless
T Torque transmitted through the gear, N-mm (Newton millimeter)
v Linear velocity of the gears pitch circle, m/s (meters per second)
WT Tangential tooth load (beam strength of the tooth), N (Newton)
Cv Velocity factor, dimensionless
, N/mm2

w Permissible working stress for gear

(Newton per millimeters squared)
pc Circular pitch for gear

pN Normal pitch of the gear

, mm (millimeters)

, mm (millimeters)

22 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .
m Module of the gear

, mm (millimeters)

WA Tangential tooth load (beam strength of the tooth), N (Newton)

ALGORITHM:

23 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .

Assume that the peripheral velocity will be between 10 and 20 m/s.

Solve the equation obtained which of the third order, and compare the
value of the module (m) against the standard values given in Table: 1, and
then select the appropriate one.
Table: 1 (Standard module values in mm (millimeters))
Preferred values of module
(mm)
1
1.25
1.5
2
2.5
3

Option 1
(mm)

Option 2
(mm)

1.125
1.375
1.75
2.25
2.75

3.25

24 | P a g e D E S I G N L A B - 1 0 M E 2 0 9 . D A T A B A N K - S O U R C E O F
D ATA .
4
5
6
8
10
12
16
20

3.5
4.5
5.5
7
9
11
14
18

3.75
6.5