UNIT I A

Introduction to Mechanical Engineering

Mechanical Elements
Power transmission shafts, Axles, Keys, Bush and Ball
Bearings, Flywheels and Governors
Introduction
Machine element is an individual component or a group of
components of a machine which performs a specific function.

Its function may be of holding the components together, to
transmit power or to give supports.

Depending upon these functions only, the machine elements are
following types.
1) Machine elements used for holding the components.
2) for transmitting the power.
3) for support of other components.
Machine Elements
Machine elements used for holding the components :-
These type of machine elements include nuts and
bolts, screw, cotters, keys, couplings, pins, revettes.
Machine elements used for transmitting the power :-
Machine elements like gears, shafts, clutches and
brakes, pulleys, belts, chain, sprocket, are used to
transmit power from one place to another.
Machine elements used for support of other
components:-
Machine elements like bearings, axles, brackets,
hangers etc. are used to give support to rotating or
stationary members.

Basic Requirements
Safety
Reliability
Minimum Weight
Manufacturability
Machinability
Durability
Efficiency
Shaft
Introduction
A shaft is a rotating member/machine element, which is used to transmit
power from one place to another. In order to transfer the power from one shaft to
another the various members such as pulleys, gears, crank etc. are mounted on it.
These members are mounted on the shaft by means of keys or splines.
Types of Shaft
The following two types of shafts are important from subject point of view.
1) Machine shaft:
2) Transmission shaft:
Machine shaft:
These shafts form an integral part of the machine itself.
e.g. crank shaft of an I.C. engine.
Transmission shaft:
These shafts transmit power from the source of power to the machine which
absorbs that power.
e.g. the power is transmitted from motor to compressor by means of a
transmission shaft.
The transmission shaft is usually circular in cross section. The shaft is always
stepped (having different cross sections of shafts) for positioning transmission
elements like gears, pulleys and bearings. Transmission shafts may be solid or
hollow.

Types of Shaft
A shaft which is used to
transmit the power
between the source and
the machine absorbing
the power is called
transmission shaft

The transmission shaft
supports transmission
elements like : gears,
pulleys, sprockets, etc

The transmission shafts
are subjected to torque,
bending moment, and
axial force.
Main shaft between air
compressor and gas
turbine in air craft engine.
Transmission Shaft


AXLE
An axle is a non-rotating machine
element which is used to support
rotating machine elements like
wheels, pulleys, etc. In
appearance, an axle looks like a
shaft.
An axle does not transmit torque.
It is subjected to a bending
moment and / or axial force.
e.g. Rear axle of railway wagon,
Axle of motor car, Supporting
wheels.
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JNK
JNK
JNK
JNK
Keys
Introduction
Key is defined as a demountable machine element
which, when assembled into key seats, provides a
positive means for transmitting torque between the
shaft arid hub.
It is used to transmit torque from shaft to pulleys,
gears, sprockets, fly wheel etc.

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A key performs following two basic functions.
1) The primary function of key is to transmit the torque
from the shaft to the hub of machine element and vice-
versa.

2) The second function of the key is to prevent relative
rotational motion between the shaft and mounted machine
element like gear or pulley.

A keyed joint consisting of shaft, hub and key
A recess or slot machined on the shaft and or in the hub to
accommodate the key is called as key way.
Keys are designed in order to withstand shear and
compressive stresses resulting from transmission of torque.
Generally, material of the key is selected, which has less
strength than the shaft material.

Types of Keys
Keys are broadly classified as
a) Saddle keys
b) Sunk keys
c) Round key
d) Splines


Saddle Keys
Saddle keys are fitted only in the key way of one
member of the mating surface i.e. either shaft or hub.
Saddle keys are only of uniform width, and tapered in
thickness along the length.
Power transmission of the saddle key is due to the
frictional forces set up between the keys and the shaft.
Saddle keys are of two types -
i) Flat saddle key
ii) Hollow saddle key

Flat Saddle Key
The flat saddle key is a taper key which fits in a key
way in the hub and is flat on the shaft as shown in Fig.

Hollow Saddle Key

A hollow saddle key is a taper key which fits in a key
way in the hub and its lower surface of the key is
hollow or curved to fit on the curved surface of the
shaft as shown in Fig.
Advantages of Saddle Keys
1) Construction is simple.
2) Mounting cost is less as compared to other keys as
there is key way on the hub only.
3) No weakening of shaft as there is no key way.

Disadvantages of Saddle Keys
1) Used for transmission of lighter loads only.
2) No positive transmission of power as means of
power transmission in friction.

Applications
Used for light loads only like temporary fastening in
fixing and setting of eccentric cams etc.

Sunk Keys
Sunk keys are inserted half in the key way of hub and
half in the key way of the shaft. Sunk keys are of uniform
width and tapered in thickness along the length.
Power transmission of the sunk key is due to the
tangential force between key and mating surfaces.
No relative motion between the shaft and hub no slip
between them Hence it is a positive drive.

Sunk keys are of following types.
i) Parallel sunk key
ii) Taper sunk key
iii) Feather key
iv) Woodruff key

Parallel Sunk Key
A parallel key is square or rectangular in cross section and
of uniform thickness and width over its length.

Bearings
Introduction
Bearing is a mechanical element, which supports the
rotating element. Thus it permits the relative rotating
motion between two parts.
Due to relative motion, a moving part comes in contact
causing friction with the stationary part, resulting wear
of mating surface. To reduce the frictional resistance
and wear, a lubricant is provided between the mating
surface.
A lubricant is a substance placed between the two
surfaces which reduces friction, wear and takes away
heat.
Generally mineral oil, vegetable oil or grease are used as
lubricant in bearings.
Bearings
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29
Bearings
Sliding
contact
Journal
Thrust
Rolling
Contact
Ball B
Roller B
Classification of Bearings
Rolling contact bearings

Ball
bearings
Roller bearings
Single row deep groove
bearings
Double row deep groove
bearings
Angular contact bearings
Cylindrical Roller bearings
Needle Roller bearings
Taper Roller bearings
Taper roller thrust Roller
bearings

Sliding contact bearings
Guide
bearings
Journal bearings
Thrust bearings
Collar bearings
Footstep or pivot
bearings

Solid journal bearing
Bush bearing
Split bearing or plummer
block
Sliding Contact Bearings
The motion between the shaft and the bearing is
purely sliding.

Because of the surface contact, the friction between
the rotating shaft and bearing surface is high and
hence lubrication is necessary.

They are used for crankshaft in I.C. engine, ball mills,
centrifugal machines in sugar industry, turbo-
generators centrifugal pumps. etc.

Rolling Contact Bearing
Rolling motion takes place along the surfaces
of contact between the parts. Steel balls or
rollers are interposed between the moving
and fixed elements, which offer rolling
friction.
They are also known as antifriction bearings.
They have point or line contact with moving
element.
Rolling Contact Bearing (Antifriction Bearing)
This type of bearing have rolling
contact instead of sliding contact. This
results in low frictional resistance
than the sliding contact hence name
as antifriction bearings.
A rolling contact bearing, irrespective
of any type has four major parts.
1) Outer race
2) Inner race
3) Rolling elements like ball,
roller or needle
4) Cage which holds the rolling
elements together with equal space.
A rolling contact bearing is as shown
in Fig.
Classification of Rolling Contact Bearing
1) Depending upon the type of rolling element:
i) Ball bearing
ii) Roller bearing
2) Depending upon the direction of load:
i) Radial bearing
ii) Thrust bearing
iii) Combination of radial and thrust load Ball
bearing
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The Ball Bearing
It is as shown in Fig.
It also consists of four major
parts.
(i) Outer race
(ii) Inner race
(iii) Balls and
(iv) Cage
It consist of number of balls placed between the races. The balls are
placed properly by the cage, which acts like a separator. All balls are
free to rotate within the cage and are able to roll inside the outer
race and inner race.
A position clearance is kept between the races to accomplish slight
misalignment of balls due to load.
Ball bearings are able to take only radial loads. It is used in high speed
applications like grinders, cutters etc.
Deep groove ball bearings are able to sustain radial load as well as
axial (thrust) load.
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39
40
Difference between Rolling Contact and Sliding
Contact Bearing
Sr.
No
Factors Rolling Contact
Bearing
Sliding
Contact
Bearing
1
Starting Torque Low High
2
Running Friction Low High
3
Load Can carry
combined radial
and axial load
Can take load
only in one
direction
4
Axial Space required Less More
Difference between Rolling Contact and Sliding
Contact Bearing
Sr.
No
Factors Rolling
Contact
Bearing
Sliding
Contact
Bearing
5
Radial Space required More
Less
6
Lubrication Simple Continuous
and adequate
7
Initial Cost Low More
8
Maintenance Cost Low More
9
Noise at higher speeds More Less
Difference between Rolling Contact and Sliding
Contact Bearing
Sr.
No
Factors Rolling Contact Sliding Contact
10 Load carrying
capacity
Low More
11 Working Life Less More
12 Shock absorbing
capacity
Poor Good

13 Suitability For frequent starting
of machine
Continuous working
of machine.
UNIT I B
Power Transmission Devices
Belt and Belt derives, Chain drives, Types of Gears,
Types of Couplings, Friction Clutch (Cone and Single
Plate), Brakes

Drives
Drives are the mechanism used to transmit
power & speed from prime mover to machine.

The commonly used prime mover is an electric
motor. (I. C. engines, steam engines)
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Belt Drives
Introduction
Belts are used to transmit power between two parallel
shafts by means of friction using pulleys.
A belt drive consists of three elements viz, driving and
driven pulleys and a belt, which envelops them. The
power is transmitted from driving pulley to driven pulley
because of frictional grip between the belt and pulley
surface.

Speed ratio of Belt drive (Velocity ratio):

= [ speed of driver shaft ] / [ speed of driven shaft ]

= n / N = D / d

= n / N = (D+t) / (d+t) [ if belt thickness is considered]
Types of Belts (According to Material Used)
The material used for belts must be strong, flexible and
durable. It must have a high coefficient of friction. Belts are
classified according to material as.
1) Leather belt
2) Cotton or fabric belt

3) Rubber belt

4) Balata belt : layers of fabric impregnated with balata gun..
Types of Belts (According to Shape)
1) Flat belt
2) Vee belt
3) Circular or rope belt
4) Timing belt
Difference between Flat Belt and Vee Belt
FACTORS FLAT BELT V-BELT
1. Cost Less, easy to produce High, material is costly
2. Maintenance Low High
3. Simplicity of design Simple to design &
manuf.
Complex to design &
manuf.
4. Center distance Can be used for long
center distance shafts
Suitable for short to
medium center
distance shafts
5. Power transmitting
capacity
Less (less frictional
contact)
High (more frictional
contact)
6. Overall size of belt Bigger size Compact size
7. Operation Noisy Smooth & quiet
8. Speed ratio Up-to 4:1 Up-to 7:1
Types of Belt Drive (According to its
Arrangement)
The power from one shaft to another can be
transmitted by different arrangements of the
belts. According to its arrangement, Belt
drives are classified as
1) Open belt drive
2) Crossed belt drive
3) Drive with Idler Pulley
4) Drive with Jockey or Rider pulley.
Open belt drive
It is used, when shafts are
arranged parallel and rotating
in the same direction, as
shown in Fig. In this case, the
driver A pulls the belt from one
side (i.e. lower side) and
delivers it to the other side (i.e.
upper side).

Thus the tension in the lower
side belt will be more than that
in the upper side belt. Hence
lower side belt is known as
tight side, whereas the upper
side belt is known as slack
side.


Crossed belt drive
This belt drive is used when shaft are arranged parallel
and rotating in the opposite direction as shown in Fig. A
crossed belt drive can transmit more power than open
belt drive, as the angle of wrap is more. However, the
belt has to bend in two different planes and it wears out
more.

Drive with Idler Pulley
With constant use, the belt is permanently stretched a
little in length. This reduces the initial tension in the belt
leading to lower power transmission capacity. However,
the tension in the belt can be restored to the original
value, by using idler pulley as shown in above Fig.
Drive with Idler Pulley
A bell crank lever, hinged on the axis of the smaller
pulley, supports adjustable weights on its one arm and
the axis of a pulley on the other. The pulley is free to
rotate on its axis and is known as idler pulley. Owing
to the weights on one arm of the lever, the pulley
exerts pressure on the belt increasing the tension and
increasing angle of contact. Thus life of the belt is
increased and power capacity is restored to the
previous value.

Advantages of Belt drive:
Can be used for long distances.
Lubrication is not required.
Not affected by dust & dirt. (flat)
Cheap & easy to maintain.

Disadvantages:
Low power transmission capacity
Cant use for extremely high speeds
Life span is less as compared to gear drives.
Occupy more space as compared to gear drives.

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Chain Drive
Chain Drive
A belt or rope drive does not give
constant velocity ratio due to
slip, which may occur due to
overload or due to greasy
contact between belt and pulley.
A belt or rope can be replaced by
a chain, whenever there is a
need to have a constant velocity
ratio or a positive drive.
The chain drive is intermediate
between belt and gear drives. It
has some features of belt drives
and some of gear drives. Like
gears, chains are made up of
metal and therefore they are
stronger and occupy lesser space
and give constant velocity ratio.
Like belts, they are flexible and
are used for longer centre
distance.
The chains are made up of
number of rigid links, which
are hinged together by pin
joints in order to provide the
necessary flexibility to chain. It
is an endless chain. A wheel,
which has projected teeth to fit
into the recesses in the chain,
is known as sprocket wheel or
simply sprocket. The sprockets
and chain are thus constrained
to move together without
slipping and ensures perfect
velocity ratio