Find the main dimensions of a cost iron pipe drum from the following data for winding rope

Maximum load to be lifted = 40KN

Diameter of wire rope= 14mm

Lifting height = 10m

Drum diameter= 30 rope diameter

Allowable stress for cast iron = 25Mpa

Number of falls= 4

Use true movable sleaves.

Given data:-

Wt 3 3
= 40 X 10 H = 10 X 10
t
d = 14mm = 25 N/mm
hf
D = 30d =4

1) Diameter of rope drum (D) :-

D = 30d = 30 X 14 = 420mm

Fd
2) Total load on rope drum ( ) :-

WT 40 X 10
3
3
W= hf = 4 = 10 X 10 N

3
W 10 X 10
M= g = 9.8 T = 1019.37 Kg

According force = Mf = 1019.37 X 12 = 1223.24 N

Total load or nopes or rope drum,

Fd Wt Mf 3
= = 10 X 10 + 1223.24 = 11223.24 N
 3) Torque acting on rope drum (T) :-
Fd D 11223.24 X 420 6
T= 2 = 2 = 2.34688 X 10 N/mm

4) Dimensions of rope drum:-

Wall thickness of rope drum

T = 0.02 D + 8 = 0.02 x 420 +8 = 17mm

Or t = 17mm

Inner Diameter of rope drum,

Di
= D 2T = 420 2 X 17 = 386mm

Flange diameter of rope drum,

Df
= D + 6D = 420 + 6 X 14

Df
Or = 504mm

Ratio of pully systems ; I = 4

Hi 10 X 103 X 4
Zg
= D +2= X 420 + 2 = 32.31

Zg
Or = 33

Diameter of groove on the rope drum :-

dg
= d + 1.6 = 1.4 +1.6

dg
= 15.6 mm

Minimum clearance between ropes,

Cr
= 2.5 mm

Pitch of the groove on the rope drum,

Rg dg Cr
= + =15.6 + 2.5 = 18.1mm
Depth of the grooves on the rope drum,

bg
= 0.1 d = 0.1 X 1.4

L1
Let assume distance between grooves of two ropes as = 85mm

2 H1
+12 pg t1
L=[ tD +

3
2 X 10 X 10 X 4
X 420 L1
= + 12 ] X 18.1 +

= 1400 mm

5) Stress in rope drum :-

b
Bending stress ( ) :-
8Td LD 8 X 11223.24 X 1400 X 800 X 420
b
= ( D D ) 4 4 = 4 4
[ ( 420 ) ( 386 ) ]
T

b
= 1.885 N/mm

c
Crushing stress ( ) :-

Fd
Load on each rope = Nr

Fd
11223.24 /2
c Nr
= = 17 X 18.1 = 18.23 N/ mm
T pg

Torsional shear stress ( ) :-

 6
bT D 16 X 2.356 X 10 X 420
= ( D4D i4 ) = 4
[ ( 420 ) (386)4 ] = 0.565 N/mm

Maximum principle stress ( compressive) :-

b + c b c
max [ ]+ 2
=[ 2 ]+ 2

=[
1.885+18.23
2

+ [
1.88518.23 2
2
] + (0.565)
2

max
Or = 18.25 N/mm < 120 N/mm

Maximum shear stress

all 120
all
= 2 = 2 = 60 N/mm

max
= [
1.88518.23 2
2
] + (0.565)
2

max
Or = 8.192 N/mm < 60 N/mm

max all max all

Safety of brake drum < & <

Hence rope is safe.

Determine the dimensionof I section connecting rod for a petrol engine for a petrol engine from
the following data.

Diameter of the piston=110mm.

Mass of the reciprocating parts=2kg.

Length of the connecting rod =325mm

Stroke length=150mm

RPM=1500 with possible overload of 2500

Compression ratio=4:1

Max expansion pressure=205 N/mm2

Given data,

mr=2 kg
D=110,

L=325 mm

Stroke=150mm

So length of cranck=stroke/2

R=75mm

Speed(rpm)=1500

Compression ratio=4:1

P=2.5N/mm2

Take numerator constant(vc)=320N/mm2

Denominator constant(d)=1/7500

Dimension of the I section connecting rod

Flange and web thickness of secton=4

Height of the section =54

We know that in order to load have a connecting rod equally strong about both the axis

I xx =4 I yy

I xx
=4
I yy

I xx Moment of inertia of the section about xaxis

 I yy=Moment of inertia of the section about yaxis

Area of the section

A=2*(4t*t+3t*t)=11t2

I xx =1/12 {(4t*5t3)+3t*(3t)3}=11t2

=419/12*t4

I xx
I yy =(419/12* 12/131)

=3.2

Therefore the section chosen is quite satisfractry

FC the equal the maximum force on the piston Ft

Taking the force on thrR( ( all to gas
pressure therefore

2
D P
( FC =(F t ) = 4

100 2 .5
= 4

FC =19634.95 N

Buckling load

b= F C F t
w

b= 19634656
w

=117809.72N

Rdious of gyration about the x axis

 I XX 2
K xx =( )
A

1
419 t 4
K xx ={ ( A 12 ) 1
1
11 t
4
}

=1.78t

Length of crank

R=stroke of piston/2

R=150/2

=75

Length of the connecting rod =l=325mm

wb
Now according to rankineformate buckling load (

c A
2
117809.72= 11 Ta ( K )
K XX

3520 T 2
117809.72= 1+ 4.45
2
T

T4
33.45= T 2 +4.48

33.46T2+148.89=T4

Hence by solving this we get,

T=6mm

So B=4T

=4*6

=24mm
H=30mm

Depth of the big end

H1=1.2H

=1.2*30

=26mm

Dimension of the section near big end

=H1*B

36*24mm

Dimension of the section near the small end

H1*B

26mm*24mm

Design a plain carbon steel center steel crankshaftfor the single acting four stroke cylinder
engine for the following data,

Piston dai. =250mm

Stroke =400mm

Max bearing pressure=2.5N/mm2

Weight of the flywheel=16KN

Total belt pull=3KN

Length of connecting rod =950mm

When the crank has connected through the 30 from top dead center, the pressure on the piston is
1N/mm2 and the torque in the crank is max.

Any data required in the this problem can be assumed.

GIVEN DATA,

Piston dia. =250mm

Stroke(L)= 400mm

Max bearing pressure(P)= 2.5n/mm2

Weight of the flywheel=16KN

Total belt pull(t1+t2)=3KN

Length of connecting rod(l1)=450mm

=30 TDC

Let the radius be r=200mm

Design of crank shaft when the crank is at the dead center,

The piston gas load,

2
RP = D P
4

RP = 25022.5
4

=122718.463KN

Let dia. Between the bearing center is,

B=2D

2*250=500mm

B1=b2=b/2 =500/2mm

The horizontal section H1 and H2 at the bearing load 2 respectively,

F pb
H1= b =122.718*250/500

=61.359KN

F pb
H2= b = 122.718*250/500

=6.359KN
Let two vertical reaction V2 and V3 at 2 and 3 respectively,

C1 C
w = w 2 = w/2 =16/2= 8KN
V2= C C

C1 C2
w w
V2= C = C = w/2 =16/2 =8KN

Due to resultant belt tension acting horizontal these will be two horizontal , there will be two
horizontal section 2,3 respectively such that,

T 1+ T T 1+ T
H 2= C1 =
2
H 2= 2
C1
C C

=T1+ T2/2=3/2

=1.5kn

T 1 +T
H 3= 2

=1.5KN

Design of cranckpin,

Let the dc = dia. Of crankpin

Lc= length of cranckpin

b = 75N/mm2 (crank)

Bending moment at center,

MC=H1*b2 =61.359*250

=15339.75KN.mm

3
d
Also MC 32 c b
 3
=7.364* d c Nmm

By equating (1) and (2)

d c 3 =15539/7.364

=2.083*106

(dc= 128mm)

Lc= fp/ dcpb

=122.718*103/128*106

=95.87mm

Design of left crank,

Thickness t= .65dc+6.35

.65*128*6.35

=89.35mm

Width of crank web w= 1.125*dc+12.7

=1.125*128+12.7

=156.7mm

Max bending moment of crank web

M= H1(B1- LC/2-T/2)

=610359(250-95.87/2-90/2)

=9637.35KN

Section module= z= 1/16t2

1/16*157*902

=211950 mm3

Bending stress

b = M/Z
= 9637.35/211950

=45.47* 10-3KN/mm2

Compressive stress,

c = H /wt
l

=61.359/(157*90)

=4.34N/mm2

Design of shaft under flywheel,

L1= l2=l3= (b/2-lc/2-t/2 )

=(500/2 95.87/2 90/2)

=157.06mm

Assuming width of flywheel as 300mm

C=300+ 157.06

=457.06mm

Take c=800mm

C1 = c2 =c/2= 400mm

Bending moment due to width of flywheel,

MW = V3 * C1= 1.5*400

=1.5*400

=600KN

Let Ms = (mw2 + mt2)^(.5)=

={(3.2*106)2 + (0.6*106)2}^(.5)

=10.6*106^(.5)

=3.225*106 Nmm

3
d = d S342
3.225*106 = MS = 32 S b 32
 3
3.789*106 = d S

DS = 92.4 mm

Design of the crank shaft when the crank is at an angle of maximum twisting moment.

We know that
2
F P= D P
4

F P= 250211
4

=49087.38KN

sin
sin =
Let L
2

sin 30
sin =
950
200

=6.044

+ 6.049+ 30
FA= FQ = = (49.36
sin sin

=24.04KN

6.049

FR = =49.36 30

cos cos

=39.65KN

There will be two reaction at bearing lands.

HT1 = FT + b1/2
=29.07+250/2

15Kn

HT2 = FT + b2/2

= 15kn

Due to radial force (FR)

HR2 = FR + b1/2=FB*2 = 39.91/2

Limiting of crank pin,

Dc = dia. Of crank pin

Bending of moment at center

MC = HR1 + b2

= 20*50

=500 KNMM

LET TWISTING MOMENT

2
m c + m c
2

TC =

51000
2 +(30000) 2

=5.83*103 KNMM

We know that the

3
b = d
64 c

(dc)3 = .848 * 106

Dc = 94.65 mm
Design of shaft under the flywheel,

Let ds of shaft

Ms = 3.255 * 106 NMM

=FT * R
S

Equvuvalent twisting moment,

2
mc + m c
2

TC =

3.251000
2
+(5.0810000) 2

=6.66 * 106 NMM

3
ds
Let c = 16

933
6.66 *106 = 16

= 35 N/MM2

3
6 d 35
6.66 *10 = 16 s

d s3 = .989 *102

d s = 98.9 mm

Design of shaft at the uniform of right,

Let ds of shaft
 Design a four stork diesel engine consuming 0.3 kg of fuel per Kw of power per
N
hour and produce break mean pressure of the 0.7 mm2 the pressure inside

N
cylinder is 5 mm2 at a speed of 3500 rpm the cylinder diameter is 300 with

stoke 1.5 times the diameter of pinion may have 4 compression ring and an oil
ring the following can be data used four design
3
Higher calorific value of fuel=46 10 kJ/kg
Temp. Of piston center=700 k
Temp. Of pinion edge=475k
N
Permissible tensile stress strength of the pinion = 27 mm2

N
Pressure between rings pinion=0.04 mm
2

N
Permissible pressure on pinion pin=15 mm2

N
Permissible stress in piston pin=85 mm2
Solution
(1) Piston head
th
=
3 p D2
16 t = 3 5 (300)2
16 27 =55.90

t h =56mm

N 3500
n = = =1750
2 2

D2 (300)2
A= = =70585.83 mm
4 4
P m LAn
T.P = 60
 0.7 0.45 70685.83 1750
= 60 =650 Kw

nm
Let =80%
B p = J p nm = 650 0.5 = 520 Kw

Hlv m B P
H= C
3
= 0.05 46 10 8.33 10 520
5
=9962.68 W
9962.68
tH
= 12.5 (46.6)(700475) =75.651 mm

(2) Radial ribs

tH tH
tR
= 2 To 3

75.65 75.62
= 2 to 3

= 37.825 to 25.21

tR
Let a take = 31

(3) Piston rings

t1
=P 3 Pw
t = 300 3(0.04)
80 =11.618 mm

t 2 = 0.7 t 1 to t 3
=8.132 to 11.618
t
Let us take 2 =10 mm
P 300
t2
= 10+nr = 10+ 4 = 7.5 mm

The distance from the top of the piston to the first ring grove i.e the width of the
top land

th th
b= to 1.2 = 75.65 to 90.78

Width of other rings lands

b2 = 0.75 b2 to t 2 = 7.5 to 10

b1 b2
Let us take = 8.5 mm =9 mm

Gap between face ends of the ring

G1 = 3.5 t 1 to 4 t 1 = 40.635 to 46.44

G2 =0.6 to 1.2

Let us take

G1 = 44mm and G2 = 0.9mm

(4) Piston barrel

Since the radial depth of the piston rings grove is about 0.4mm more than the
radial thickness of the piston rings therefore

B= radial thickness+ 0.4

= 11.61+0.4 =12.01mm
We know that maximum thickness of barrel
t 3 =0.03D+b+4.5

=0.03(300)+12.01+4.5 =25.51mm

And piston wall thickness towards the open end

t 4 =0.25 t 3 to 0.35 t3

=6.377 to 8.925

t4
Let us take =7.5 mm

Piston skit

L=length of the skit in mm

DP 2 P
R= 4
 Let us take =0.1

2
300 5
= 0.1 4 =35342.917 N

Pb D l
R= =0.45(300)(l) =135l

From above we find that

135l=35342.917 so l = 261.8 mm

Total length of piston

L = length of skit + length of rings + rings top land

t2 b2 b1
= l + (4 +3 )+

= 261.8+{4(10)+3(9)}+85

=441 mm

(5) Piston pin

Let do= Outside dia. Of pin

Pl 1 = bearing pressure at the small end of the connecting rod

N
Pl 1
=15 mm2

N
jt
= 85 mm2

We know that land on the bearing pressure

=bearing pressure bearing area

d 0 l 1 d0
= 15 = 2025 N

We know that maximum load on the piston due to gas pressure on main gas bed

d0 P
2025 = 4d 2 = 4(300)2 (5)=353429.17

d 0 =175 mm

di
Inside dia. Of pin ( ) is taken as

d i = 0.6(175)=105 mm

Let the piston pin be made of heat treated alloy steel for which the bending stress may be taken
as 84 mpa

PD
M= 8

39275 300
= 8

N
=1472.812 mm
2

[ ]
4 4
d0 di
1472.812 = 32 d 0 b

[ ]
4 4
(175) 105
1472.812 = 32 b
175

N
b 103
=3.2154 mm2

Since the induced bending stress is less than the permissible stress the dimensions

d 0 =175 mm and d i =105 mm are satisfactory