Machine Design-1 Manual

Laboratory Man
FACULTY OF ENGINEERING AND

TECHNOLOGY
BACHELOR OF TECHNOLOGY
MACHINE DESIGN-I
(03109351)
SEMESTER: 6th
Laboratory Manual
PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
VADODARA
PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design-I (03109351) B. Tech. 3RD year
PREFACE
It gives us immense pleasure to present the first edition of Machine Drawing

Practical Book for the B.Tech. 3rd year students for PARUL UNIVERSITY.
Machine Design-I laboratory courses at PARUL UNIVERSITY,
WAGHODIA, VADODARA are designed in such a way that students develop the
basic understanding of the subject in the laboratories and then try their hands on the
experiments/tutorials to realize the various physical phenomena learnt. The main
objective of the Machine Design-I laboratory course is: Learning mechanical
components and their practical problems. All the experiments are designed to serve
above objective and also to expose the students to various practical applications.
The objective of this Machine Design-I Practical Book is to provide a

comprehensive source for all the experiments included in the Machine Design-I
laboratory course. It explains all the aspects related to every experiment such as: basic
understanding of loads, stresses, components, Production Drawing, how to read
drawing and learn software to create such drawing.
We acknowledge the authors and publishers of all the books which we have
consulted while developing this Practical book. Hopefully this Machine Design-I
Practical Book will serve the purpose for which it has been developed.
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Instructions to students
1. The main objective of the Machine drawing laboratory is: Learning about design of
various components & drawings & their failure criteria.
2. Be prompt in arriving to the laboratory and always come well prepared for the
experiment..
3. Work quietly on computers. Give equal opportunity to all your fellow students to
work.
4. Every student should have his/her individual copy of the Machine Design-I Practical
Book.
5. Every student have to prepare the notebooks specifically reserved for the Machine
drawing practical work:” Machine Design-I Practical Book”
6. Every student has to necessarily bring his/her Machine Design-I Practical Book,
Machine Design-I Practical notes and Machine Design-I Practical Final Notebook,
when he/she comes to the Computer centre..
7. Prepare your drawing honestly. Never makeup drawing or doctor them either to get a
better view & detail in drawing. Display all on print out of drawing (if applicable)
8. All the calculations have to be neatly recorded in the Machine Design-I Practical
Notebook and verified by the instructor before leaving the Computer center.
9. If some of the drawing doesn’t show appropriate detail then prepare drawing again or
modify it.
10. Do not share your drawings & calculations with your fellow student. Every student
has to produce his/her own set of drawings & calculations by performing exercise
separately.
11. After verification of the drawings & calculations, do the calculation in the Machine
Design-I Practical Notebooks and get them verified by the instructor.
12. Never forget to mention the units of the observed quantities in the calculation. After
calculations, represent the results with appropriate units.
13. Calculate the percentage error in the results obtained by you if the standard results are
available and also try to point out the sources of errors in the experiment.
14. Find the answers of all the questions mentioned under the section ‘Exercise’ at the end
of each experiment in the Machine Design-I Practical Book.
15. Finally record the verified observations along with the calculation and results in the
Machine Design-I Practical Notebook.
16. Do not forget to get the information of your next allotment (the experiment which is
to be performed by you in the next laboratory session) before leaving the laboratory
from the Technical Assistant.
17. Finally record the verified drawings & calculations along with all necessary details in
the Machine Design-1 Practical Final Notebook.
18. The grades for the Machine Design-1 practical course work will be awarded based on
your performance in the laboratory, regularity, recording of calculations in the
Machine drawing Practical Final Notebook, lab quiz, regular viva and end-term
examination.
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CERTIFICATE
This is to certify that
Mr./Ms.......................................................................
................................................with enrolment
no. .........................................................................
has successfully completed his/her laboratory
experiments in the Machine Design-I
(03109351) from the department
of ................................................................. during
the academic year........................
Date of Submission:......................... Staff In charge:...........................

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Head of Department:...........................................
INDEX
Sr. Hours Starting Completed Page
Experiment Name Marks Sign
No. date Date no.
1 Exercise based on design 1
considerations and material selection.
2 Exercise to design helical spring and 2

leaf spring.
3 Exercise to design belt drive and chain 2

drive.
4 Exercise to design pulley and wire 2

rope.
5 Exercise to design roller bearings. 2
6 Exercise to design journal bearing. 2
7 Exercise to design thin and thick 2

pressure vessels.
8 Prepare drawing or model of designed 2

pressure vessel and bearing.
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EXPERIMENT NO.: 1
AIM: Study on material selection for given application.
OBJECTIVES:
1) Understand different material properties of material
2) Learn material selection on basis of material properties
OUTCOMES:
As an outcome of this study, students will be able to,
1) Understand material requirement for particular service condition and application.
2) Select material for any application.
1. THEORY
For many years Wood was the most favorable choice for construction of Vehicle-bodies in
the transportation sector.
Let us look at the reasons behind this choice:

 Traditionally wood was used in the transportation sector for building Chariots,
Animal drawn Carts, Palanquins etc – hence it became the natural choice for
building bodies of the automobiles, omnibuses etc. at the first phase of industrial
revolution.
 Wood has impressive mechanical properties. The elastic modulus of wood is in the
range of 8-20 GPa which is as good as materials like PMMA and GFRP. The
density of wood is about 0.6-75 Mg/m3 – lighter than most of the polymers except
polymeric foams. The strength of the wood is about 30 MPa which is again
comparable to high-performance polymers.
 Other advantages of wood are recyclability, ease of machining and aesthetically

pleasing quality.
With the advent of mass-scale production and automation in car-industry, it became

necessary to replace wood by metals and metallic alloys. Typical metal shaping
technologies like sheet forming which can handle large batch size (105 to 106 units per
batch) became very much suitable for the mass scale production of vehicles.
There were two-choices in terms of use of metals and metallic alloys: Steel and Aluminium
Alloys. Why these materials became so popular for Car-design? Let us find the material
indices most relevant from car-body construction point of view. It is observed that three
most significant issues in car-body design are:
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i. Stiffness of the sheets which is expressed as an objective to minimize mass against a

specified deflection limit. Minimization mass directly implies the use of less amount of
material and hence less cost per unit. Also, mass minimization would increase fuel
efficiency of the vehicle. For a flat panel of size (L x B), thickness t, modulus of elasticity
E and density ρ, this would involve the search for a material having maximum value of an
index (E1/3/ρ).
ii. Another important consideration is dent resistance. A similar study would indicate
that this requires the maximization of an index (σ y), where σy is the yield strength and k
is the stiffness of the panel.
The third important issue is the resistance against crack propagation. This is indicated by
the parameter called ‘fracture toughness’ or KIC (MPa-m1/2 )
Now, let us look at the values of these parameters for four materials: Carbon Steel,
Stainless Steel, Aluminium Alloy, PMMA and GRFP (Glass Fiber Reinforced Plastic).
Material E1/3/ρ Σy KIC

(E – GPa, ρ-Mg/M3) (MPa) (MPa-m1/2)
Carbon Steel
(0.4 $/Kg) 0.75 250 12
Stainless steel
(1.2$/Kg) 0.77 170 12
Aluminium alloy
1.63 30 18
(1.3$/Kg)
PMMA
1.34 72 (max) 1.6 (max)
(2.4$/Kg)
GFRP
1.55 150 20
(9$/Kg)
The Table above explains why Carbon steel was tolerated for long time in Car-body
construction. It was cheapest among available materials having reasonably good material
indices. However, massive growth of automobile use in the Europe and USA caused
tremendous environmental problems. As a result in 1975 a rule was established by CAFE
(Corporate Average Fuel Economy) regulations, which set target of fuel economy up to
27.5 miles per Gallon of fuel). The average fuel efficiency of steel based Cars at that time
was only 14 mpg. New rules have shifted the favor towards Aluminium. In terms of specific
stiffness it is even placed better than steel. Table shows that from all round consideration
GFRP is even better than Aluminium. However, the cost of GFRP is still much higher than
Aluminum prohibiting its use in mass-scale manufacturing of automobiles.
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Advantages of using Aluminium in automobiles

 There is a marked increase in the use of aluminum in automobiles over the years.
Following the report of the Aluminum Association in the 2002 North American
Light Vehicle Aluminum Content Study, for 2002, the average aluminum content
for passenger cars and light trucks combined is about 125 Kg while the average
for all vehicles sold in 1999 was about 113 Kg.
 It is also noted that lower energy consumption and gas emissions is possible
through reduced weight, for example, extensive use of aluminum can result in up
to 300 kg weight reduction in a medium size vehicle (1400kg). For every 100 kg
reduction in the automotive sector, there is a cut of 20% lower exhaust gas
emissions and proportionally reduced operating costs.
 Major challenges in Aluminium industry is to machine complex components out

of thick plate replacing parts previously machined from die forgings/fabricated
from sheet & extrusions. It will reduce manufacturing cost & enhance application
of complex shapes.
 Picture shows Car which is having almost complete body & frame of Aluminium.
In this class, an overview of a group of material properties important for the designer. The
following properties are considered for this purpose:
1. Relative Prices, Aesthetic Properties: Appearance, Texture, Feel
2. Mechanical Properties: Density, Modulus, Damping, Yield & Tensile Strength,

Hardness, Fracture Toughness, Fatigue Strength, Thermal Fatigue Resistance,
Creep Strength
3. Surface Properties: Oxidation, Corrosion, Friction, Abrasion & Wear Thermal
4. Ease of Manufacture, Joining

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Exercise:
1. Use Google to research the history and uses of one of the following materials:
1. Tin 2. Glass 3. Cement 4. Titanium 5. Carbon fiber.

Present the result as a short report of about 100–200 words (roughly half a page).
2. What is meant by the design-limiting properties of a material in a given application?
3. There have been many attempts to manufacture and market plastic bicycles. All have
been too flexible. Which design-limiting property is insufficiently large?
4. What in your judgment are the design-limiting properties for the material for the
blade of a knife that will be used to cut fish?
5. What in your judgment are the design-limiting properties for the material of an oven
glove?
6. What in your judgment are the design-limiting properties for the material of an
electric lamp filament?
7. A material is needed for a flexible tube to carry fuel from the fuel tank to the
carburetor of a motor mower. The design requires that the tube be flexible and
transparent. List what you would think to be the design-limiting properties.
8. A material is required as the magnet for a magnetic soap holder. Soap is mildly
alkaline. List what you would judge to be the design-limiting properties.
9. The cases in which most CDs are sold have an irritating way of cracking and
breaking. Which design-limiting property has been neglected in selecting the material
of which they are made?
10. List three applications that, in your judgment, need high stiffness and low weight.
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EXPERIMENT NO.: 2
AIM: Study on design parameters of spring & design of spring
OBJECTIVES:
1) Understand spring and its types along with spring terminology
2) Learn design of various type of spring.
OUTCOMES:
1) Select appropriate type of spring for particular application
2) Design spring for all its parameters and for applicable load
2. THEORY:
2.1: Definition of spring & applications:

Spring is defined as elastic body, whose function is to distort when loaded and to recover its
original shape when the load is removed. Applications of springs are as follows:
1. To cushion, absorb or control energy due to either shock or vibration as in car springs,
railway Buffers, air-craft landing gears, shock absorbers and vibration dampers.
2. To apply forces, as in brakes, clutches and spring loaded valves.
3. To control motion by maintaining contact between two elements as in cams and followers.
4. To measure forces, as in spring balances and engine indicators.
5. To store energy, as in watches, toys, etc.
2.2. Types of springs:
According to their shape, springs are classified as follows:
A. Helical springs: A helical spring is made up of a wire coiled in the form of a helix and is
primarily intended for compressive or tensile loads. Cross-section of the wire from which the
spring is made may be circular, square or rectangular. The two forms of helical springs are
compression helical spring as shown in Fig. and tension helical spring as shown in Fig.
The helical springs are said to be closely coiled when the spring wire is coiled so close that
the plane containing each turn is nearly at right angles to the axis of the helix and the wire is
subjected to torsion. In a closely coiled helical spring, the helix angle is very small, it is
usually less than 10°. The major stresses produced in helical springs are shear stresses due to
twisting. The load applied is parallel to or along the axis of the spring. In open coiled helical
springs, the spring wire is coiled in such a way that there is a gap between the two
consecutive turns, as a result of which the helix angle is large.
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(a) Compression Helical spring (b) Tension Helical spring
B. Conical and volute springs: The conical and volute springs are used in special
applications where telescoping spring or spring with a spring rate that increases with the load
is desired. The conical spring, as shown is wound with uniform pitch whereas the volute
springs are wound in the form of parabolic with constant pitchand lead angles.
a) Conical Spring (b) Volute Spring

Springs may be made either partially or completely telescoping. In either case, the number of
active coils gradually decreases. The decreasing number of coils results in an increasing
spring rate. This characteristic is sometimes utilized in vibration problems where springs are
used to support a body that has a varying mass. The major stresses produced in conical and
volute springs are also shear stresses due to twisting.
C. Disc or bellevile springs: These springs consist of a number of conical discs held
together against slipping by a central bolt or tube as shown in Fig.(a). These springs are used
in applications where high spring rates and compact spring units are required. The major
stresses produced in disc or bellevile springs are tensile and compressive stresses.
Fig.(a) Disc or bellevile springs

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D. Special purpose springs: These springs are air or liquid springs, rubber springs, ring
springs etc. The fluids (air or liquid) can behave as a compression spring. These springs are
used for special types of application only.
1. Helical spring is made from a wire of 6 mm diameter and has outside diameter of 75 mm.
If the permissible shear stress is 350 MPa and modulus of rigidity 84 kN/ mm 2, find the axial
load which the spring can carry and the deflection per active turn
E. Torsion springs: These springs may be of helical or spiral type. Helical type may be
used in applications where load tends to wind up spring & in electrical mechanisms. Spiral
type is also used where the load tends to increase the number of coils & when made of flat
strip are used in watches & clocks. Stresses produced in it are tensile-compressive due to
bending
(a) Helical Torsion spring (b) Spiral Torsion spring
F. Laminated or leaf springs: Laminated or leaf spring (also known as flat spring or
carriage spring) consists of a number of flat plates (known as leaves) of varying lengths held
together by means of clamps and bolts, as shown in Fig. 23.4. These are mostly used in
automobiles. The major stresses produced in leaf springs are tensile and compressive
stresses.
Fig.(a) Laminated or leaf springs

2.3 Spring Terminology:
The following terms used in connection with compression springs are important from the
subject point of view.
1. Solid length: When the compression spring is compressed until the coils come in contact
with each other, then the spring is said to be solid. The solid length of a spring is the product
of total number of coils and the diameter of the wire.
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2. Free length: The free length of a compression spring, as shown in Fig. 23.6, is the length
of the spring in the free or unloaded condition. It is equal to the solid length plus the
maximum deflection or compression of the spring and the clearance between the adjacent
coils (when fully compressed).
Fig.Spring Nomenclature
3. Spring index: The spring index is defined as the ratio of the mean diameter of the coil to
the diameter of the wire.
4. Spring rate: The spring rate (or stiffness or spring constant) is defined as the load required
per unit deflection of the spring.
5. Pitch: It is defined as the axial distance between adjacent coils in uncompressed state.
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Exercise:
1. State Material used for spring along with their specification.
2. What is Surge in spring & nipping of spring?
3. Helical spring is made from a wire of 6 mm diameter and has outside diameter of 75 mm.
If the permissible shear stress is 350 Mpa and modulus of rigidity 84 KN/ mm 2, find the axial
load which the spring can carry and the deflection per active turn
4. Design a helical compression spring for a maximum load of 1000 N for a deflection of 25
mm using the value of spring index as 5. The maximum permissible shear stress for spring
wire is 420 Mpa and modulus of rigidity is 84 KN/mm2
5. A semi elliptic leaf spring consists of two extra full length leaves and eight graduated
length leaves, including the master leaf. The center to centre distance between the two eyes
of the spring is 1 m. The maximum force acting on the spring is 10 KN and the width of the
leaf is 50 mm. The spring is initially preloaded in such a way that when the load is
maximum, the stresses induced in all the leaves are equal to 350 N/mm2. The modulus of
elasticity of the leaf material is 2.07×105 N/ mm2. Determine:
(i) The thickness of leaves.
(ii) The deflection of the spring at maximum load.
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EXPERIMENT NO: 3
AIM: Study Design of belt drives.
OBJECTIVES:
1) Understand scope and difference and application of belt drive and chain drive
2) Learn Design of belt and chain drive for particular power transmitting capacity.
OUTCOMES:
1) Understand material of belt, belt drive types and use of belt & chain drive.
2) Select material for belt and design of belt & chain drive.
3. THEORY
3.1 Introduction to belt drive:

The belts or ropes are used to transmit power from one shaft to another by means of pulleys
which rotate at the same speed or at different speeds. The amount of power transmitted
depends upon the following factors:
1. The velocity of the belt.
2. The tension under which the belt is placed on the pulleys.
3. The arc of contact between the belt and the smaller pulley.
4. The conditions under which the belt is used.
It may be noted that

(a) The shafts should be properly in line to insure uniform tension across the belt section.
(b) The pulleys should not be too close together, in order that the arc of contact on the
smaller pulley may be as large as possible.
(c) The pulleys should not be so far apart as to cause the belt to weigh heavily on the shafts,
thus increasing the friction load on the bearings.
(d) A long belt tends to swing from side to side, causing the belt to run out of the pulleys,
which in turn develops crooked spots in the belt.
(e) The tight side of the belt should be at the bottom, so that whatever sag is present on the
loose side will increase the arc of contact at the pulleys.
(f) In order to get good results with flat belts, maximum distance between shafts shouldn’t
exceed 10 meters & minimum should not be less than 3.5 times the diameter of larger pulley.
3.2 Introduction to chain drives:
In belt and rope drives that slipping may occur. In order to avoid slipping, steel chains are
used. The chains are made up of number of rigid links which are hinged together by pin
joints in order to provide the necessary flexibility for wrapping round the driving and driven
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wheels. These wheels have projecting teeth of special profile and fit into the corresponding
recesses in the links of the chain as shown in Fig.. The toothed wheels are known as sprocket
wheels or simply sprockets. The sprockets and the chain are thus constrained to move
together without slipping and ensures perfect velocity ratio.
Fig. Sprocket & Chain
3.3 Advantages and Disadvantages of Chain Drive over Belt or Rope Drive
Advantages
1. As no slip takes place during chain drive, hence perfect velocity ratio is obtained.
2. Since the chains are made of metal, therefore they occupy less space in width than a belt or
rope drive.
3. It may be used for both long as well as short distances.
4. It gives high transmission efficiency (upto 98 percent).
5. It gives fewer loads on the shafts.
6. It has the ability to transmit motion to several shafts by one chain only.
7. It transmits more power than belts.
8. It permits high speed ratio of 8 to 10 in one step.
9. It can be operated under adverse temperature and atmospheric conditions.
Disadvantages
1. The production cost of chains is relatively high.

2. The chain drive needs accurate mounting and careful maintenance, particularly lubrication
and slack adjustment.
3. The chain drive has velocity fluctuations especially when unduly stretched.
3.4 Selection of a Belt Drive:

Following are the various important factors upon which the selection of a belt drive depends:
1. Speed of the driving and driven shafts, 2. Speed reduction ratio,
3. Power to be transmitted, 4. Centre distance between the shafts,
5. Positive drive requirements, 6. Shafts layout,
7. Space available, 8. Service condition.
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3.5 Types of Belt Drives

The belt drives are usually classified into the following three groups:
1. Light drives: These are used to transmit small powers at belt speeds upto about 10 m/s as
in agricultural machines and small machine tools.
2. Medium drives: These are used to transmit medium powers at belt speeds over 10 m/s but
up to 22 m/s, as in machine tools.
3. Heavy drives: These are used to transmit large powers at belt speeds above 22 m/s as in
compressors and generators.
3.6 Types of Belts:

Though there are many types of belts used these days, yet the following are important from
the subject point of view:
1. Flat belt. The flat belt as shown in Fig. 18.1 (a), is mostly used in the factories and
workshops, where a moderate amount of power is to be transmitted, from one pulley to
another when the two pulleys are not more than 8 meters apart.
2. V- belt. The V-belt as shown in Fig. 18.1 (b), is mostly used in the factories and
workshops, where a great amount of power is to be transmitted, from one pulley to
another, when the two pulleys are very near to each other.
3. Circular belt or rope. The circular belt or rope as shown in Fig. 18.1 (c) is mostly used in
the factories and workshops, where a great amount of power is to be transmitted, from one
pulley to another, when the two pulleys are more than 8 meters apart. If a huge amount of
power is to be transmitted, then a single belt may not be sufficient. In such a case, wide
pulleys (for V-belts or circular belts) with a number of grooves are used. Then a belt in
each groove is provided to transmit the required amount of power from one pulley to
another.
3.7 Material used for Belts:

The material used for belts and ropes must be strong, flexible, and durable. It must have a
high coefficient of friction. Various materials are Leather belts, Cotton or fabric belts,
Rubber belt, Balata belt.
3.8 Types of Flat Belt Drives

The power from one pulley to another may be transmitted by any of the following types of
belt drives.
1. Open belt drive. The open belt drive, as shown in fig is used with shafts arranged parallel
and rotating in the same direction. In this case, the driver A pulls the belt from one side (i.e.
lower side RQ) and delivers it to the other side (i.e. upper side LM). Thus the tension in the
lower side belt will be more than that in the upper side belt. The lower side belt (because of
more tension) is known as tight side whereas the upper side belt (because of less tension) is
known as slack side, as shown in Fig.
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Fig. Open belt Drive

2. Crossed or twist belt drive. The crossed or twist belt drive, as shown in Fig. 18.5, is used
with shafts arranged parallel and rotating in the opposite directions. In this case, the driver
pulls the belt from one side (i.e. RQ) and delivers it to the other side (i.e. LM). Thus, the
tension in the belt RQ will be more than that in the belt LM. The belt RQ (because of more
tension) is known as tight side, whereas the belt LM (because of less tension) is known as
slack side, as shown in Fig
At a point where the belt crosses, it rubs against each other and there will be excessive wear
and tear. In order to avoid this, the shafts should be placed at a Crossed or twist belt drive.
maximum distance of 20 b, where b is the width of belt and the speed of the belt should be
less than 15 m/s.
Fig. Cross or twist belt drive

3. Quarter turn belt drive. The quarter turn belt drive (also known as right angle belt drive) as
shown in Fig. 18.6 (a), is used with shafts arranged at right angles and rotating in one definite
direction. In order to prevent the belt from leaving the pulley, the width of the face of the
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pulley should be greater or equal to 1.4 b, where b is width of belt. In case the pulleys cannot
be arranged as shown in Fig. or when the reversible motion is desired, then a quarter turn
belt drive with a guide pulley, as shown in Fig. may be used.
Fig.(a) Quarter turn belt drive Fig.(b) Quarter turn belt drive with guide pulley
4. Belt drive with idler pulleys. Belt drive with an idler pulley (also known as jockey pulley
drive) as shown in Fig. is used with shafts arranged parallel & when open belt drive can’t be
used due to small angle of contact on the smaller pulley. This type of drive is provided to
obtain high velocity ratio & when required belt tension can not be obtained by other means.
Fig. Belt drive with an idler pulley Fig. Belt drive with many idler pulley
5. Fast and loose pulley drive. A fast and loose pulley drive, as shown in Fig. 18.11, is used
when the driven or machine shaft is to be started or stopped whenever desired without
interfering with the driving shaft. A pulley which is keyed to the machine shaft is called fast
pulley and runs at the same speed as that of machine shaft. A loose pulley runs freely over
the machine shaft and is incapable of transmitting any power. When the driven shaft is
required to be stopped, the belt is pushed on to the loose pulley by means of sliding bar
having belt forks
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5. Compound belt drive. A compound belt drive as shown in Fig., is used when power is
transmitted from one shaft to another through a number of pulleys.
Fig. Compound Belt drive
6. Stepped or cone pulley drive. Stepped or cone pulley drive, as shown in Fig is used for
changing the speed of the driven shaft while the main or driving shaft runs at constant speed.
This is accomplished by shifting the belt from one part of the steps to the other.
7. Fast and loose pulley drive. A fast and loose pulley drive, as shown in Fig is used
when the driven or machine shaft is to be started or stopped whenever desired without
interfering with the driving shaft. A pulley which is keyed to the machine shaft is called fast
pulley and runs at the same speed as that of machine shaft. A loose pulley runs freely over
the machine shaft and is incapable of transmitting any power. When the driven shaft is
required to be stopped, the belt is pushed on to the loose pulley by means of sliding bar
having belt forks
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Exercise:
1. Explain Slip & creep of belt.

2. Explain Belt materials in detail.
3. Write down procedure for selection of chain drive
4. Design a flat belt drive to transmit 110 kW at a belt speed of 25 m/s between two pulleys
of diameters 250 mm and 400 mm having a pulley centre distance of 1 meter. The allowable
belt stress is 8.5 Mpa and the belts are available having a thickness to width ratio of 0.1 and a
material density of 1100 kg/m3. Given that the coefficient of friction between the belt and
pulleys is 0.3, determine the minimum required belt width. What would be the necessary
installation force between the pulley bearings and what will be the force between the pulley
bearings when the full power is transmitted?
5. A 18 kW, 900 r.p.m. motor drives a centrifugal pump at 290 r.p.m. by means of a leather
belt. The pulleys are of cast iron and are 1.2 meter centre distance. The pulleys of diameter
less than 150 mm should not be used. The coefficient of friction between the leather belt and
the cast iron pulley is 0.35, and the mass of the belt is 9 kg/m width/m length. The maximum
permissible tension per mm width of the belt is 10 N. The drive is to be designed for 20%
overload. Determine the pulley diameters, the required width and length of the belt. Also find
the initial tension with which the belt is to be mounted on the pulleys.
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EXPERIMENT NO: 4
AIM: To Study design of pulley and wire rope.
OBJECTIVES:
1) Understand difference between various power transmission drives
2) Learn Pulley construction, manufacturing method & Design of pulley, wire rope.
OUTCOMES:
1) Select particular power transmission drive for various applications.
2) Select material for rope and pulley.
.
4. THEORY:
4.1 Introduction:
The pulleys are used to transmit power from one shaft to another by means of flat belts,
V-belts or ropes. Since the velocity ratio is the inverse ratio of the diameters of driving
and driven pulleys, therefore the pulley diameters should be carefully selected in order to
have a desired velocity ratio. The pulleys must be in perfect alignment in order to allow
the belt to travel in a line normal to the pulley faces.
The pulleys may be made of cast iron, cast steel or pressed steel, wood and paper. The
cast materials should have good friction and wear characteristics. The pulleys made of
pressed steel are lighter than cast pulleys, but in many cases they have lower friction and
may produce excessive wear
4.2 Types of Pulleys for Flat Belts

Following are the various types of pulleys for flat belts :
1. Cast iron pulleys, 2. Steel pulleys, 3. Wooden pulleys, 4. Paper pulleys, and 5. Fast and
loose Pulleys. The arms may be straight or curved as shown in Fig. (a) and (b) and the
cross-section is usually elliptical.
Fig. (a)- Straight arm pulley (b) Curved arm pulley

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4.3 Introduction to wire rope:
When a large amount of power is to be transmitted over long distances from one pulley to
another (i.e. when the pulleys are upto 150 metres apart), then wire ropes are used. The
wire ropes are widely used in elevators, mine hoists, cranes, conveyors, hauling devices
and suspension bridges.
The wire ropes run on grooved pulleys but they rest on the bottom of the *grooves and
are not wedged between the sides of the grooves. The wire ropes are made from cold
drawn wires in order to have increase in strength and durability. It may be noted that the
strength of the wire rope increases as its size decreases. The various materials used for
wire ropes in order of increasing strength are wrought iron, cast steel, extra strong cast
steel, plough steel and alloy steel. For certain purposes, the wire ropes may also be made
of copper, bronze, aluminium alloys and stainless steels
4.4 Advantages of Wire Ropes`
The wire ropes have the following advantages as compared to fibre ropes.
1. These are lighter in weight, 2. These offer silent operation,
3. These can withstand shock loads, 4. These are more reliable,
5. These are more durable, 6. They do not fail suddenly,
7. The efficiency is high, 8. The cost is low.
4.5 Designation of Wire Ropes

The wire ropes are designated by the number of strands and the number of wires in each
strand.
For example, a wire rope having six strands and seven wires in each strand is designated
by 6 × 7 rope. Following table shows the standard designation of ropes and their
applications
Standard designation Application

6 × 7 rope It is a standard coarse laid rope used as haulage rope in mines,
tramways, power transmission
6 × 19 rope It is a standard hoisting rope used for hoisting purposes in
mines, quarries, cranes, dredges, elevators, tramways, well
drilling
6 × 37 rope It is an extra flexible hoisting rope used in steel mill laddles,
cranes, high speed elevators
8 × 19 rope It is also an extra flexible hoisting rope
PARUL UNIVERSITY
Exercise:
1. Discuss the different types of pulleys used in belt drives.
2. Discuss the procedure used in designing a cast iron pulley.
3. Discuss the uses and construction of wire ropes. How are wire-rope ends fastened
4. A cast iron pulley transmits 20 kW at 300 r.p.m. The diameter of pulley is 550 mm and
has four straight arms of elliptical cross-section in which the major axis is twice the
minor axis. Find the dimensions of the arm if the allowable bending stress is 15 Mpa.
Mention the plane in which the major axis of the arm should lie.
5. A workshop crane is lifting a load of 25 KN through a wire rope and a hook. The
weight of the hook etc. is 15 KN. The rope drum diameter may be taken as 30 times the
diameter of the rope. The load is to be lifted with an acceleration of 1 m/s2. Calculate the
diameter of the wire rope. Take a factor of safety of 6 and Young’s modulus for the wire
rope 80 kN/mm2. The ultimate stress may be taken as 1800 Mpa. The cross-sectional
area of the wire rope may be taken as 0.38 times the square of the wire rope diameter
PARUL UNIVERSITY
EXPERIMENT NO: 5
AIM: To study Design roller bearings.
OBJECTIVES:
1) Understand difference between sliding & rolling contact bearings.
2) Learn different type of bearings & their applicability
3) Learn design of bearing for various design parameters.
OUTCOMES:
1) Select particular type of bearing based on application
2) Design bearing for available service condition for required life.
5. THEORY:
5.1 Introduction:
In rolling contact bearings, the contact between the bearing surfaces is rolling instead of
sliding as in sliding contact bearings. We have already discussed that the ordinary sliding
bearing starts from rest with practically metal-to-metal contact and has a high coefficient
of friction.
It is an outstanding advantage of a rolling contact bearing over a sliding bearing that it
has a low starting friction. Due to this low friction offered by rolling contact bearings,
these are called antifriction bearings.
5.2 Advantages and Disadvantages of Rolling Contact Bearings Over Sliding Contact
Bearings
Following are some advantages and disadvantages of rolling contact bearings over sliding
contact bearings.
Advantages
1. Low starting and running friction except at very high speeds.
2. Ability to withstand momentary shock loads & accuracy of shaft alignment.
3. Low cost of maintenance, as no lubrication is required while in service.
4. Small overall dimensions.
5. Reliability of service.
6. Easy to mount and erect & Cleanliness.
Disadvantages
1. More noisy at very high speeds.
2. Low resistance to shock loading.
3. More initial cost.
4. Design of bearing housing complicated.
5.3 Types of Rolling Contact Bearings

Following are the two types of rolling contact bearings:
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1. Ball bearings; and 2. Roller bearings.
The ball and roller bearings consist of an inner race which is mounted on the shaft or
journal and an outer race which is carried by the housing or casing. In between the inner
and outer race, there are balls or rollers. A number of balls or rollers are used and these
are held at proper distances by retainers so that they do not touch each other. The
retainers are thin strips and are usually in two parts which are assembled after the balls
have been properly spaced. The ball bearings are used for light loads and the roller
bearings are used for heavier loads.
(a) Ball bearing (b) Roller Bearing (c) Radial ball bearing (d) Thrust ball bearing
The rolling contact bearings, depending upon the load to be carried, are classified as :
(a) Radial bearings, and (b) Thrust bearings.
The radial and thrust ball bearings are shown in Fig. (c) and (d) respectively. When a ball
Bearing supports only a radial load (WR), the plane of rotation of the ball is normal to the
centre line of the bearing, as shown in Fig. (c). the action of thrust load (WA) is to shift
the plane of rotation of the balls, as shown in Fig. (d). the radial and thrust loads both
may be carried simultaneously.
Further radial bearing can be divided as single row deep groove ball bearing , Filling
notch bearing, Angular contact bearing, Double row bearing, Self-aligning bearing as
shown in figure.
(a)single row deep (b)Filling notch (c) Angular contact (d) Double row (e)Self- aligning
groove bearing bearing bearing bearing bearing
Static Equivalent Load for Rolling Contact Bearings The static equivalent load may be
defined as the static radial load (in case of radial ball or roller bearings) or axial load (in
case of thrust ball or roller bearings) which, if applied, would cause the same total
permanent deformation at the most heavily stressed ball (or roller) and race contact as
that which occurs under the actual conditions of loading.
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5.4 Life of a Bearing

Life of individual ball (or roller) bearing may be defined as the number of revolutions (or
hours at some given constant speed) which the bearing runs before the first evidence of
fatigue develops in the material of one of the rings or any of the rolling elements. The
rating life of a group of apparently identical ball or roller bearings is defined as the
number of revolutions (or hours at some given constant speed) that 90 per cent of a group
of bearings will complete or exceed before the first evidence of fatigue develops (i.e. only
10 per cent of a group of bearings fail due to fatigue). The term minimum life is also used
to denote the rating life.
5.5 Basic Dynamic Load Rating of Rolling Contact Bearings
The basic dynamic load rating is defined as the constant stationary radial load (in case of
radial ball or roller bearings) or constant axial load (in case of thrust ball or roller
bearings) which a group of apparently identical bearings with stationary outer ring can
endure for a rating life of one million revolutions (which is equivalent to 500 hours of
operation at 33.3 r.p.m.) with only 10 per cent failure.
Exercise:
1. Write short note on classifications and different types of antifriction bearings.
2. How do you express the life of a bearing? What is an average or median life?
3. Define the following terms as applied to rolling contact bearings:

(a) Basic static load rating (b) Static equivalent load
(c) Basic dynamic load rating (d) Dynamic equivalent load
3. A single row angular contact ball bearing number 310 is used for an axial flow
compressor. The bearing is to carry a radial load of 2500 N and an axial or thrust load
of 1500 N. Assuming light shock load, determine the rating life of the bearing
4. Design a self-aligning ball bearing for a radial load of 7000 N and a thrust load of 2100
N. The desired life of the bearing is 160 millions of revolutions at 300 r.p.m. Assume
uniform and steady load,
PARUL UNIVERSITY
EXPERIMENT NO: 6
AIM: To study Design of journal bearing
OBJECTIVES:
1) Understand concept of sliding contact bearings
2) Understand various design parameters related to hydrodynamic bearing.
OUTCOMES:
1) learn about Lubricants and their properties and design of hydrodynamic bearing.
6. THEORY:
6.1 Introduction:
A bearing is a machine element which supports another moving machine element (known as
journal). It permits a relative motion between the contact surfaces of the members, while
carrying the load. A little consideration will show that due to the relative motion between the
contact surfaces, a certain amount of power is wasted in overcoming frictional resistance and
if the rubbing surfaces are in direct contact, there will be rapid wear. In order to reduce
frictional resistance and wear and in some cases to carry away the heat generated, a layer of
fluid (known as lubricant) may be provided. The lubricant used to separate the journal and
bearing is usually a mineral oil refined from petroleum, but vegetable oils, silicon oils,
greases etc., may be used.
6.2 Classification of Bearings:

1. Depending on direction of load to be supported, bearings under this group are classified as:
(a) Radial bearings (b) Thrust bearings
2. Depending upon the nature of contact, bearings under this group are classified as:
(a) Sliding contact bearings (b) Rolling contact bearings.
6.3 Types of Sliding Contact Bearings
The sliding contact bearings in which the sliding action is guided in a straight line and
carrying radial loads, as shown in Fig. (a) may be called slipper or guide bearings. Such type
of bearings are usually found in cross-head of steam engines.
(a) Full journal bearing (b) Partial journal bearing (c) Fitted journal bearing
DEPARTMENT OF MECHANICAL ENGINEERINGPage 28

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6.4 Terms used in Hydrodynamic Journal Bearing:
If O is the centre of the journal of hydrodynamic bearing and O′is the centre of the bearing.
The following terms used in hydrodynamic journal
Bearing are important from the subject point of view:
1. Diametral clearance. It the difference between the diameters of the bearing and journal.
Mathematically, Diametral clearance, C = D – d
A commonly used clearance in industrial machines is 0.025 mm per cm of journal diameter.
2. Radial clearance. It is the difference between the radii of the bearing and the journal.
Mathematically, radial clearance,
3. Diametral clearance ratio. It is the ratio of the diametral clearance to the diameter of the
Journal. Mathematically, diametral clearance ratio
4. Eccentricity. It is the radial distance between the centre (O) of the bearing and the
displaced centre (O′) of the bearing under load. It is denoted by e.
5. Minimum oil film thickness. It is the minimum distance between the bearing and the
journal, under complete lubrication condition. It is denoted by h0 and occurs at the line of
centres. Its value may be assumed as c / 4.
6. Attitude or eccentricity ratio. It is the ratio of the eccentricity to the radial clearance.
7. Short and long bearing. If the ratio of the length to the diameter of the journal (i.e. l / d) is
less than 1, then the bearing is said to be short bearing. On the other hand, if l / d is greater
than 1, then the bearing is known as long bearing
26.11 Lubricants
The lubricants are used in bearings to reduce friction between the rubbing surfaces and to
carry away the heat generated by friction. It also protects the bearing against corrosion. All
lubricants are classified into the following three groups:
1. Liquid, 2. Semi-liquid 3. Solid.
The liquid lubricants usually used in bearings are mineral oils and synthetic oils. The mineral
oils are most commonly used because of their cheapness and stability. The liquid lubricants
are usually preferred where they may be retained.
Grease is semi-liquid lubricant having higher viscosity than oils. They are employed where
slow speed, heavy pressure exist and where oil drip from the bearing is undesirable. The solid
lubricants are useful in reducing friction where oil films cannot be maintained because of
pressures or temperatures. They should be softer than materials being lubricated. A graphite
is the most common of the solid lubricants either alone or mixed with oil or grease

PARUL UNIVERSITY
Exercise:
1. What are journal bearings? Give a classification of these bearings.
2. What is meant by hydrodynamic lubrication?
3. List the basic assumptions used in the theory of hydrodynamic lubrication
4. Design a journal bearing for a centrifugal pump from the following data :
Load on the journal = 20 000 N; Speed of the journal = 900 r.p.m.; Type of oil is SAE 10,
for which the absolute viscosity at 55°C = 0.017 kg / m-s; Ambient temperature of oil =
15.5°C; Maximum bearing pressure for the pump = 1.5 N / mm2.
Calculate also mass of the lubricating oil required for artificial cooling, if rise of
temperature of oil be limited to 10°C. Heat dissipation coefficient = 1232 W/m2/°C.
5. The load on the journal bearing is 150 kN due to turbine shaft of 300 mm diameter running
at 1800 r.p.m. Determine the following: (1) Length of the bearing if the allowable bearing
pressure is 1.6 N/mm2 (2) Amount of heat to be removed by the lubricant per minute if the
bearing temperature is 60°C and viscosity of the oil at 60°C is 0.02 kg/m-s and the bearing
clearance is 0.25 mm.

PARUL UNIVERSITY
EXPERIMENT NO: 7
AIM: To study design thin and thick pressure vessels.
OBJECTIVES:
1) Understand use and application and type of pressure vessel in industry
2) Learn Design of pressure vessel
OUTCOMES:
1) Understand stresses on pressure vessel
2) Design pressure vessel parts
7. THEORY:
7.1 Introduction to Pressure vessel
The pressure vessels (i.e. cylinders or tanks) are used to store fluids under pressure. The fluid
being stored may undergo a change of state inside the pressure vessel as in case of steam
boilers or it may combine with other reagents as in a chemical plant. The pressure vessels are
designed with great care because rupture of a pressure vessel means an explosion which may
cause loss of life and property. The material of pressure vessels may be brittle such as cast
iron, or ductile such as mild steel.
7.2 Classification of Pressure Vessels

The pressure vessels may be classified as follows:
7.2.1. According to the dimensions.

The pressure vessels, according to their dimensions, may be classified as thin shell or thick
shell. If the wall thickness of the shell (t) is less than 1/10 of the diameter of the shell (d),
then it is called a thin shell. On the other hand, if the wall thickness of the shell is greater than
1/10 of the diameter of the shell, then it is said to be a thick shell. Thin shells are used in
boilers, tanks and pipes, whereas thick shells are used in high pressure cylinders, tanks, gun
barrels etc
7.2.2. According to the end construction.

The pressure vessels, according to the end construction, may be classified as open end or
closed end. A simple cylinder with a piston, such as cylinder of a press is an example of an
open end vessel, whereas a tank is an example of a closed end vessel. In case of vessels
having open ends, the circumferential or hoop stresses are induced by the fluid pressure,
whereas in case of closed ends, longitudinal stresses in addition to circumferential stresses are
induced.
7.3 Stresses in a Thin Cylindrical Shell due to an Internal Pressure

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7.3.1 Circumferential or Hoop Stress:

Consider thin cylindrical shell subjected to internal pressure as shown in Fig. (a),(b). Tensile
stress acting in direction tangential to the circumference is called circumferential or hoop
stress. In other words, it is a tensile stress on longitudinal section (or on the cylindrical walls).
Fig. (a) View of shell Fig. (b) Cross-section of shell
7.3.2 Longitudinal Stress:

Consider a closed thin cylindrical shell subjected to an internal pressure as shown in Fig.(a),
(b). Tensile stress acting in the direction of the axis is called longitudinal stress. In other
words, it is a tensile stress acting on the *transverse or circumferential section Y-Y (or on the
ends of the vessel).
Fig. (a) View of shell Fig. (b) Cross-section of shell

PARUL UNIVERSITY
Exercise:
1. What are the important points to be considered while designing a pressure vessel?
2. Compare the stress distribution in thin and thick walled pressure vessels
3. The piston rod of a hydraulic cylinder exerts an operating force of 10 KN. The friction due
to piston packing and stuffing box is 10 % of the operating force. The pressure in the
cylinder is 10 N/mm2. The cylinder is made of C.I. having allowing tensile stress of 40 N/
mm2. Determine the diameter and thickness of the cylinder.
4. A high pressure cylinder consists of a steel tube with 20 mm and 35 mm as inner and outer
diameters respectively. It is jacketed by outer steel tube with 50 mm outer diameter. The
tubes are assembled by shrinking process in such a way that the maximum tensile stress
induced in any tube is limited to 100 N/mm2. Calculate the shrinking pressure and original
dimensions of the tubes. E =2.0x105 N/mm2.
5. An air receiver consisting of a cylinder closed by hemispherical ends. Pressure not to

exceed 2 N/mm2 .If the material is steel having yield point 250 N/mm2 and F.O.S = 2.5.
Calculate the thickness of cylinder and thickness of hemispherical ends. Assume joint
efficiency of shell and ends are 0.8 and 0.9 respectively.

PARUL UNIVERSITY
EXPERIMENT NO: 8
AIM: Prepare drawing or model of designed pressure vessel and bearing.
OBJECTIVES:
1) After understanding pressure vessel design, student should be able to do drawing of design
OUTCOMES:
1) Student will be able to prepare and understand drawing.
Exercise:
 Prepare following drawing.

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Laboratory Man

FACULTY OF ENGINEERING AND

It gives us immense pleasure to present the first edition of Machine Drawing

The objective of this Machine Design-I Practical Book is to provide a

This is to certify that

has successfully completed his/her laboratory

experiments in the Machine Design-I

(03109351) from the department

the academic year........................

Date of Submission:......................... Staff In charge:...........................

2 Exercise to design helical spring and 2

3 Exercise to design belt drive and chain 2

4 Exercise to design pulley and wire 2

5 Exercise to design roller bearings. 2

6 Exercise to design journal bearing. 2

7 Exercise to design thin and thick 2

8 Prepare drawing or model of designed 2

AIM: Study on material selection for given application.

Let us look at the reasons behind this choice:

 Other advantages of wood are recyclability, ease of machining and aesthetically

With the advent of mass-scale production and automation in car-industry, it became

i. Stiffness of the sheets which is expressed as an objective to minimize mass against a

Material E1/3/ρ Σy KIC

Advantages of using Aluminium in automobiles

 Major challenges in Aluminium industry is to machine complex components out

1. Relative Prices, Aesthetic Properties: Appearance, Texture, Feel

2. Mechanical Properties: Density, Modulus, Damping, Yield & Tensile Strength,

3. Surface Properties: Oxidation, Corrosion, Friction, Abrasion & Wear Thermal

4. Ease of Manufacture, Joining

1. Tin 2. Glass 3. Cement 4. Titanium 5. Carbon fiber.

2. What is meant by the design-limiting properties of a material in a given application?

AIM: Study on design parameters of spring & design of spring

2.1: Definition of spring & applications:

2. To apply forces, as in brakes, clutches and spring loaded valves.

4. To measure forces, as in spring balances and engine indicators.

5. To store energy, as in watches, toys, etc.

2.2. Types of springs:

According to their shape, springs are classified as follows:

(a) Compression Helical spring (b) Tension Helical spring

a) Conical Spring (b) Volute Spring

Fig.(a) Disc or bellevile springs

(a) Helical Torsion spring (b) Spiral Torsion spring

Fig.(a) Laminated or leaf springs

2. What is Surge in spring & nipping of spring?

AIM: Study Design of belt drives.

3.1 Introduction to belt drive:

It may be noted that

3.2 Introduction to chain drives:

Fig. Sprocket & Chain

1. The production cost of chains is relatively high.

3.4 Selection of a Belt Drive:

3.5 Types of Belt Drives

3.6 Types of Belts:

3.7 Material used for Belts:

3.8 Types of Flat Belt Drives

Fig. Open belt Drive

Fig. Cross or twist belt drive

Fig. Compound Belt drive

1. Explain Slip & creep of belt.